KAS HS565 Mailmaster User manual

21/08/2007
HS565-NT21-Ops-V3.DOC3
KAS
HS565 Mailmaster
Small touch screen (NT21)
OPERATORS MANUAL

CONTENTS: Page
Introduction - 2
1 Important Notes - 2
2 Operator Guide
2.1 Power Up - 3
2.2 Selecting End Feeders - 4
2.3 OMR Enable Setup - 5
2.4 System Setup - 6
2.5 Post Batch Setup - 7
2.6 Overhead Feeder Folder - 8
2.7 Test Mode - 9
2.8 System Status - 12
2.9 Operators’ Screen - 13
2.10 Data Log Control - 14
2.11 Clearing Machine - 15
2.12 Operator Help Pages - 17
2.13 Warning Pages - 19
3 Operator Adjustments
3.1 Feed Gate Setting - 21
3.2 Side Feeder Operations - 22
3.3 End Feeder Operations - 24
4 HS565 Sealer
4.1 Description - 25
4.2 Operator Adjustments - 25
5 Specifications - 28
6 Fold Options - 29

2
INTRODUCTION
The HS565 will operate as a standalone unit being hand fed or part of an automated feed
system. Documents pass along the main table collecting items from feeders where installed. An
envelope is fed from a hopper, down onto the moving table where it is filled with the document
(set). Once filled, the envelopes are counted, sealed and stacked on a conveyor.
The HS565 can run at a maximum speed of 7000 envelopes/hour.
1. IMPORTANT NOTES:
1. For the machine to operate correctly, after power up, it must be cycled using the
'Clear' facility on the System Setup screen. See 2.4.
2. The 'CLEAR' switch will only operate if all feeders are deselected and the on line
sensor is uncovered. See 2.11.
3. Before switching off the machine, all feeders should be deselected (by selecting
'CANCEL' from the System Setup menu) and emptied of paper (using the
'CLEAR' facility). It is recommended that the machine be cleared after each job is
completed.
4. 'TEST' can only be selected when the machine is not running. ‘ONLINE’ can be
used in test mode but not ‘END FEEDER’.
5. When 'Re-booting’ the power must be switched off for at least 30 seconds to allow
processor to clear.
Clearing Document Jams on the Moving Table
It should be noted that the moving table is secured under spring pressure, and in the event of
documents jamming in this area under normal operating conditions, the table may come to
rest under spring tension.
WARNING:
Do not attempt to remove documents until you have cycled the machine to its normal rest
position using the inch button. Failure to do so may cause the table to spring back quickly
into its correct position, when removing a wreck by hand.
When a document jam occurs and the documents are firmly trapped by the moving table the
inch button should be held until the table has completely opened before removing the
documents.

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2. Operator Guide:
2.1 - Power Up:
Connect the IEC power lead to the switched inlet socket on the main connector panel. Switch
on and observe the KAS logo being displayed on the touch screen.
By touching the centre of the screen the System Setup menu will be displayed. See 2.4.
When installing a new End Feeder the switch should be used. This will display the
End Feeder Select screen (2.2), followed by the OMR Setup menus (2.3).

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2.2 – Selecting End Feeders:
This menu is used to install the selected end feeder by pressing the appropriate switch and
seeing it illuminate. Pressing will then take you to the OMR Enable Setup menu. (See
2.3). If using a series of end devices, the device feeding the HS565’s on line position should be
selected, except when using a Fast Sheet Feeder and folder, select Fast Sheet Feeder + Set
Collector.

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2.3 – OMR Enable Setup:
From this page, it is possible to enable or disable any of the request signals given by an
intelligent end feeder to feed documents from the side feeder stations. All signals are enabled
by default on power-up, apart from EOS (end of set), which remains in the last state set by the
user.
For example, if it is desired that Station 1 inserts requests should be ignored, the button
should be pressed to turn it off. All the buttons can be pressed or re-pressed to toggle the
status required. Black being ‘on’ white being ‘off’
Go to the System Setup menu. (See 2.4).
Go to the End Feeder Select menu. (See 2.2).

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2.4 - System Setup:
The System Setup menu is used to enable the required feeders or modes of operation. It is not
possible to select 'ENDFEEDER' and 'ONLINE' together as both devices share the same input
position (3.3)
END FEED. Enables the device specified in the End Feeder Select menu (2.2)
ONLINE. Indicates that the end feeder to be used does not need synchronisation.
Toggles each side station on and off respectively.
CANCEL. Deselects all feed options, including CLEAR if it has been selected.
CLEAR. Used to empty the machine at the end of a run. It can only be selected when all
feed stations are deselected and the ‘ON LINE’ sensor position is empty. (See 2.11).
TEST MODE. Used to set the machine and run a test envelope with documents. (See 2.7).
POST BATCH SETUP. Displays the Post Batch Setup screen. (See 2.5).
END FEED SETUP. Used to return to the End Feed Select menu (See 2.2). This can
only be achieved if the machine is cleared first.
Go to the System Status screen. (See 2.8).

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2.5 – Post Batch Setup:
The Post Batch Setup screen allows control over the exit conveyor.
Turns off all modes of conveyor batching.
Enables USER batch mode. This mode allows a batch count to be set via the batch
COUNT thumbwheel. When a batch is completed, the conveyor is indexed to separate the
completed batch from the following one.
Enables POST batch mode. This mode performs a batch operation according to
postcode signals received from and end feeder. At the appropriate time, the conveyor is
indexed to separate the completed postcode batch from the following one.
Enables BATCH STOP mode. This mode causes the machine to pause at the end of
each batch operation, requiring the start button to be pressed to restart the machine. This
mode can only be selected when either USER or POST batch mode is selected. When a batch
stop is in operation, the start button will flash.
Reset USER batch count. This can be used to reset the USER batch count at any time. It
will have no effect on POST batch operation. The current USER batch count can be seen below
the thumbwheel.
This thumbwheel allows adjustment of the conveyor index time for each individual
envelope, regardless of any batch mode in operation.
Go to the System Setup screen. (See 2.4).

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2.6 – Overhead Feeder Folder Setup:
When the button on the System Setup page is pressed the above screen is displayed.
(On machines fitted with an overhead feeder folder in station one only. Machines without
this facility will not display this screen.)
If is pressed, the overhead feeder folder will run in OMR mode where printed,
allowing inserts to be selected from the side stations. This capability is not fitted as standard.
If is pressed, the overhead feeder folder will run in BATCH mode. This means that
the feeder will feed and fold a number of sheets according to the setting of the adjacent
thumbwheel. The minimum batch setting is 1 and the maximum is 5.
NOTE:
If the batch setting is greater than one and BATCH mode is selected, or if OMR mode is
selected, then the station cannot be deselected immediately by pressing CANCEL or the
station select toggle button. By pressing either of these, the station will continue feeding until
the current batch is completed (BATCH mode) or the current set is completed (OMR mode).
If the station is required to be cancelled regardless of the state of the current batch or set,
then it can be by pressing and holding CANCEL or the station select toggle button for one
and a half seconds. This will then force the station to be deselected.

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2.7 - Test Mode:
Test mode is used to place one set of documents into an envelope, thus ensuring the machine is
set to produce correctly sealed envelopes. It can only be selected when the machine is not
running. The necessary side stations should be selected in the System Setup menu. ‘ONLINE’
should be selected in test mode if you require a document from the end feeder, not the end
feeder switch. After test mode has been completed the operator should then switch to end
feeder in order to run the machine.
In Test Mode Procedure the operator can choose whether to stop each document under its
double sensor or not.
Do not stop the machine to set the double switches.
Stop the machine at each selected side station to set its double switch.
Go to the Test Mode operation screen.
Go to the Test Mode End screen.

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2.7 - Test Mode continued:
This screen shows a representational layout of the system feeders for test mode operation.
Each symbol represents a sensor that will flash if that fault occurs. Selecting will move
back to the Test Mode Control screen. Press (start) and the machine will begin to feed
one set of documents. (If ‘On-Line’ has been selected, a set of documents must be placed on
the end feed delivery table.)
If has been selected in Test Mode Control, the feeders will stop with one document
under the feed roller allowing the double sensor to be set. The corresponding lamp on the
screen will flash, indicating the appropriate sensor for adjustment. When the sensor requires
adjustment, the sensor indicator will light. When correctly set it will be off. Turn the
thumbscrew on the particular feeder anticlockwise until the double sensor indicator lights
(switch clicks). Then turn clockwise until indicator turns off (switch clicks). Then turn
further clockwise ¼ turn for single sheet 80gsm paper, or 1 turn for documents greater than
3mm. Once that sensor has been set, press (reset) and then (start) to continue
the test. Repeat this for each side station selected.
Pressing will allow an envelope to be fed without any inserts. This can only be done if
all stations are turned off.
A flashing lamp indicates that a specific error has occurred and this has to be rectified by
removing or inching the document. (Reset) can then be pressed to cancel
the flashing lamp and the (start) switch pressed to restart the machine. Test Mode will
end when one envelope has been filled with a set of documents and passed to the conveyor.

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2.7 - Test Mode continued:
At the end of a test run, a Test Mode Complete screen will be displayed, see below, informing
the operator that they have the option to exit test mode or run another test.
Note:
Test Mode can be used as many times as necessary. It is advised to use Test Mode to check all
of the machine settings, i.e. paper track alignment, outfeed wheel setting, sealer stop
adjustment, etc. before your main run is commenced.

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2.8 - System Status:
Flashes if a cover is lifted and the machine will stop if it is running.
SHEET STOP. This is used to send a signal to the end feeder to stop feeding.
SHEET START. This is used to send a signal to the end feeder to start feeding.
CYCLE START. This will start the machine.
CYCLE STOP. This will cause the machine to hold at the end of a cycle. It
will NOT stop the motor.
INCH. This will inch (jog) the machine.
Displays the Data Log Control screen. (See 2.10).
Displays the number of envelopes that have fed through the machine.
Displays the cycle speed of the machine.
Used to alter the speed of the machine. MIN – 0, MAX - 7.
Go to the System Setup screen. (See 2.4), or Operators screen (See 2.9)

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2.9 - Operators’ screen:
The Operators’ screen shows a representational layout of the system in normal operator’s mode.
Each symbol corresponds to a sensor and will flash or remain lit if that error occurs.
Flashes if a cover is lifted and the machine will stop.
Flashes to warn the operator that the envelope feed hopper needs refilling. If the
operator ignores this warning, as the envelope hopper gets even lower, the flashing
warning light will be constantly illuminated and the machine will stop.
and lamps will be lit when a side station or an end device has been selected.
SHEET STOP. This is used to send a signal to the end feeder to stop feeding.
SHEET START. This is used to send a signal to the end feeder to start
feeding.
CYCLE START. This will start the machine.
CYCLE STOP. This will cause the machine to hold at the end of a cycle. It
will NOT stop the motor.
INCH. This will inch (jog) the machine. It is used to inch the machine to
clear paper wrecks etc.
RESET. This will cancel any error symbol once the error has been rectified.
Go to the System Status screen. (See 2.8).
Displays the first page of a series of operator help pages. (See 2.12).

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2.10 – Data Log Control:
Reset the displayed envelope total count.
Displays the total envelopes that have run through the machine.
Enter the user data log pages that display runtime information.
Display a screen requiring the operator to confirm that he wishes to clear the
data log or not.
Go to the System Status screen. (See 2.8).
Data Log screens:

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2.11 - Clearing Machine:
From the System Setup screen the machine has the facility to be emptied or cleared.
The switch is used for this at the end of a job run. It can only be selected if all feed
stations have been deselected using the cancel switch and the on line sensor is empty.
In this condition, will change the screen to the Machine Clearing screen, as shown below:
CYCLE START. This can be used to start the machine if it is not running.
Flashes if a machine cover is open.
Go to the System Setup screen. (See 2.4).
If an error occurs during clearing the Operators’ screen will be displayed showing a
particular fault and the machine will stop as in normal run.

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2.11 - Clearing Machine continued:
At the end of the clear cycle, the screen will change to the Machine Empty screen:
Displays the ‘envelopes processed’ counter. (Also displayed on the ‘System
Status’ screen).
Purges the conveyor and then returns you to the System Setup menu screen. (See 2.4).

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2.12 - Operators Help pages:

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2.12 - Operators Help pages continued:

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2.13 - Warning pages:
If the above screen is displayed, the problem is likely to be the control cable to the feeder is
loose, damaged or not connected. Rectify as necessary and press the switch.
NOTE: If this screen should show (PLC battery low), please contact your KAS agent.