Neopost DS-90 User manual

DS-35
DS-90
USER’S GUIDE

Table of Contents
1 Read this First ...............................................................................................1
Warning............................................................................................................1
About this manual.............................................................................................1
Safety...............................................................................................................2
Country Specific Conditions.............................................................................4
End of Life........................................................................................................5
2 Meet your Document System ......................................................................6
Overview..........................................................................................................6
Operating Controls...........................................................................................9
Control Panel..................................................................................................10
Installing the Document Feed Trays...............................................................11
Power Up........................................................................................................12
Home Menu....................................................................................................13
Job Info...........................................................................................................14
Side Guides....................................................................................................16
Document Orientation....................................................................................17
Filling the Document Feeder Tray..................................................................18
Loading Envelopes.........................................................................................19
Filling the Sealing Liquid Reservoir................................................................20
Shut Down the System...................................................................................21
3 Options ........................................................................................................22
MaxiFeeder....................................................................................................22
Installing the MaxiFeeder...............................................................................22
Adjusting the MaxiFeeder Side Guides..........................................................23
Adjusting the MaxiFeeder Document Separation...........................................24
Feeding documents (MaxiFeeder).................................................................25
High Capacity Document Feeder (HCDF)......................................................25
Installing the HCDF........................................................................................26
| Page 1 | TOC | jun-13-2012 10:56 |

Adjusting the HCDF Side Guides...................................................................26
Document Separation for the HCDF..............................................................27
Feeding documents (HCDF)..........................................................................27
VersaFeeder (VF-3)........................................................................................28
Installing the VersaFeeder..............................................................................29
Operating controls (VersaFeeder)..................................................................30
Adjusting the Side Guides (VersaFeeder)......................................................30
Adjusting the Document Separation (VersaFeeder).......................................31
Hopper Capacity (VersaFeeder).....................................................................32
Support for Curved Reply Envelopes (option for VersaFeeder).....................33
Power Stacker Support..................................................................................34
High Capacity Envelope Hopper (EF-4).........................................................35
High Capacity Conveyor Belt (CS-2)..............................................................37
Installing the High Capacity Conveyor Belt....................................................37
Operating the High Capacity Conveyor Belt...................................................38
Catch Tray......................................................................................................38
Catch Tray on Left Hand Side........................................................................38
insert'n Frank / insert'n Mail ...........................................................................39
Mail Piece Production Control (MPPC)..........................................................39
4 Processing Mail Sets ..................................................................................41
Introduction.....................................................................................................41
Processing a Basic Mail Set...........................................................................42
Processing a mail set with BRE or inserts......................................................43
Document Separation.....................................................................................44
Adjustment of the Document Stoppers...........................................................45
Processing Daily Mail.....................................................................................46
Test Run.........................................................................................................47
Adjusting the Address Position.......................................................................47
Adjusting the Envelope Insert Fingers............................................................48
Verifying the Insert Position............................................................................49
5 Working with Jobs ......................................................................................50
What is a job...................................................................................................50
| Page 2 | TOC | jun-13-2012 10:56 |

Creating a new job.........................................................................................50
Performing a test run......................................................................................52
Adjusting the Envelope Position.....................................................................54
Using a job.....................................................................................................55
Editing a job....................................................................................................55
Copying a job.................................................................................................56
Deleting a job.................................................................................................58
Job settings....................................................................................................59
Envelope settings...........................................................................................60
Document settings..........................................................................................61
Reading settings (option)...............................................................................63
Double feed control settings...........................................................................66
Job name........................................................................................................67
Exit select settings..........................................................................................67
Mailing/Franking settings (option)..................................................................72
Mail Piece Production Control settings (option).............................................73
6 Advanced Settings .....................................................................................74
What are Advanced Setting?..........................................................................74
Opening the Advanced Settings.....................................................................75
Changing the Display Settings.......................................................................75
Viewing System info and Software versions..................................................77
What are licensed options?............................................................................78
Activating an option........................................................................................79
Test Menu.......................................................................................................80
Running diagnostics.......................................................................................80
Job Settings (Supervisor)...............................................................................81
Flap Closer Offset..........................................................................................82
Envelope Clearing..........................................................................................83
System Output................................................................................................83
Changing Document Offset............................................................................84
Changing BRE Offset.....................................................................................85
7 Reading .......................................................................................................87
| Page 3 | TOC | jun-13-2012 10:56 |

Introduction.....................................................................................................87
Reverse reading.............................................................................................88
Document Orientation....................................................................................89
BCR Code Description...................................................................................90
Reading a configuration sheet (BCR only).....................................................92
Running a BCR test........................................................................................93
OMR Code Description..................................................................................95
Running an OMR test.....................................................................................99
2-track OMR.................................................................................................101
8 Online Services .........................................................................................102
Online Services............................................................................................102
Start-up Online Services..............................................................................103
Connecting to the server..............................................................................104
Viewing the history.......................................................................................104
Viewing messages.......................................................................................105
Installing a new job or new software............................................................106
Configuration Menu......................................................................................107
Setting the telephone number......................................................................108
Setting the prefix..........................................................................................108
Selecting the country....................................................................................109
Entering date and time.................................................................................109
Setting the dial tone detection......................................................................110
Setting the modem volume...........................................................................110
9 Operator Maintenance .............................................................................111
Maintenance Schedule.................................................................................111
Clean and replace brushes..........................................................................112
Replace or clean moistening cloth...............................................................112
Resetting Photocells.....................................................................................113
10 Fault Finding .............................................................................................114
Error Messages............................................................................................114
Clearing Stoppages......................................................................................115
Envelope Hopper..........................................................................................116
| Page 4 | TOC | jun-13-2012 10:56 |

Exit, Sealing and Inserting Area...................................................................117
Lower Envelope Track..................................................................................117
powerFold.....................................................................................................118
flexFeed........................................................................................................119
Collating Area...............................................................................................119
versaFeeder.................................................................................................120
Operator Troubleshooting.............................................................................121
Trouble Shooting Table.................................................................................121
11 Specifications ...........................................................................................125
Technical Specifications...............................................................................125
Hopper and feeder capacity.........................................................................126
Configuration Dimensions............................................................................126
Document and Insert Specifications.............................................................126
Envelope and Document Set Specifications................................................127
maxiFeeder Specifications...........................................................................128
versaFeeder Specifications..........................................................................129
High Capacity Envelope Hopper Specifications...........................................130
High Capacity Conveyor Belt Specifications................................................131
12 Terminology ..............................................................................................132
Terminology..................................................................................................132
13 EC Declaration of Conformity .................................................................138
EC Declaration of Conformity DS-90, M8800, FPi 6600, FD6604...............138
EC Declaration of Conformity MF-1.............................................................139
EC Declaration of Conformity VF-3..............................................................140
EC Declaration of Conformity EF-4..............................................................141
EC Declaration of Conformity CS-2..............................................................142
| Page 5 | TOC | jun-13-2012 10:56 |

| Page 6 | TOC | jun-13-2012 10:56 |

Read this First1
Warning
Ensure you have read and fully understood the safety requirements
in this section.
About this manual
Languages
According to the EC (European Commission) declaration following the Low Voltage Directive
(2006/95/EC), this operator manual must be available in the national language(s) of the
country where the system is delivered. Therefore, if you do not have an operator manual
in your country’s language(s), contact your authorized distributor.
Software
The software used for the reading option is based in part on the work of the Independent
JPEG Group.
Audience
This manual is meant for operators of the document system.
Trademarks
maxiFeeder™, insert'n Frank™, powerFold™, intelliDeck™, flexFeed™ and versaFeeder™
are trademarks of Neopost however the affix ™ will not be used further in this manual.
1
| Page 1 | jun-13-2012 10:56 |
1
English

Symbols
This manual uses the symbols listed below.
WARNING : Indicates a human safety hazard.
ATTENTION : A risk to the equipment or mail could result from an
action you may perform.
NOTE : A remark that explains different cases or specificities.
TIP : Advice to help save you time when processing your mail.
SUPERVISOR : Indicates that you have to use the supervisor
menu to perform the procedure.
Safety
Warnings
• Disconnect the power supply before performing any maintenance.
• Before connecting the system to the electrical supply, Ensure that the system is
suitable for the local mains voltage. Refer to the serial plate on your system for voltage
requirements.
2
| Page 2 | jun-13-2012 10:56 |
1
English

Safety Precautions
• Only competent, trained personnel should operate this system. If non-trained
personnel do operate this system, the manufacturer will not accept responsibility
for any resulting accidents or injuries.
• Only skilled persons, who are aware of the risks involved, may open the protective
covers.
For safety reasons, the system will not function when the covers are open.
• Keep long hair, fingers, jewelry, etc. away from rotating and moving parts.
• The power connection must be easily accessible, preferably close to the system.
For safety reasons, it is essential that the system is connected to a socket outlet that
has a protective earth (ground) connection.
• Overcurrent protection in the equipment also relies on the branch circuit protection
(max. 20 A).
• The following part(s) is (are) considered the equipment disconnect device(s):
- Power supply cord plug or appliance coupler.
- 12-pole connector, located on the right-hand side.
CAUTION: DOUBLE POLE / NEUTRAL FUSING
(this means that after operating of the fuse, parts of the equipment
that remain energized, might represent a hazard during servicing.)
Precaution
The general process of automated document handling can sometimes create a build up of
static electricity. Therefore we recommend that the following measures are taken to reduce
the side effects of any electrostatic charge.
• Make sure that you operate the system within the recommended temperature and
humidity conditions.
• Make use of antistatic mats where appropriate.
• If necessary, make use of an ionizer to reduce static charge build up in the room
where the system is located.
Please contact your supplier for further information.
1
English
3
| Page 3 | jun-13-2012 10:56 |

Country Specific Conditions
Denmark
In Denmark, certain types of Class 1 appliances may be provided with a plug that does not
provide an adequate earth (ground) connection when inserted into a Danish socket outlet.
Make sure the system has a good functioning connection that has protective earthing (the
plug and socket outlet must match).
Japan
•Establish an earth (ground) connection before connecting the mains plug to the power
supply.
• First disconnect the power supply before removing the earth (ground) connection.
4
| Page 4 | jun-13-2012 10:56 |
1
English

End of Life
The objectives of the European Community's environment policy are, in particular, to
preserve, protect and improve the quality of the environment, protect human health and
utilize natural resources prudently and rationally. That policy is based on the precautionary
principle and principles that preventive action should be taken, that environmental damage
should as a priority be rectified at source.
Separating waste during collection is the precondition to ensure reuse and recycling of waste.
The proper disposal of electrical or electronic equipment is necessary to achieve the chosen
level of protection of human health and the environment in the European Community.
More particularly, certain materials and components of waste electrical and electronic
equipment need special treatment as improper handling or disposal on or into land, water
or air would represent a major threat to the environment and human health.
In order to facilitate collection and treatment separated from normal domestic waste,
electrical and electronical equipment is marked with the following logo:
By law, not only are you not allowed to dispose of the waste equipment via other waste
channels, but we encourage you to actively contribute to the success of such collection
and to the common good and better quality of life of present and future generations. For
more information on the correct disposal of this product, please contact your local service
organization.
1
English
5
| Page 5 | jun-13-2012 10:56 |

Meet your Document
System
2
Overview
Introduction
The system is a folding and inserting system for processing mail easily. The system:
• feeds documents
• folds the documents
• inserts the documents into envelopes
• seals the envelopes
• stacks the envelopes
Automatic monitoring ensures the correct number of documents per envelope. The system
can be operated by means of a user friendly interface. The settings of the system (types
of documents, type of envelopes and the type of fold) is recorded in so called jobs. These
jobs can be programmed by an authorized user.
The system is equipped with a variety of special features, such as:
• document thickness detection
• programmable jobs
• automatic jobs
• flexFeed
• double feed control
• hopper swap
• multifeed
• daily mail
• intelliDeck
• powerFold.
6
| Page 6 | jun-13-2012 10:56 |
2
English

The figure shows an overview of the system.
Document Feeders (flexFeed) (1)
The flexFeed is the feeding part of the system. There are two types of feeders: the automatic
and the special feeder. The automatic feeder does not require any adjustments for the
separation. From a feeder you can feed one or more documents (multi feed). The feeders
have a double feed control (DFC). DFC detects if more documents are fed instead of one.
You can link feeders. This means that two feeders can be linked as pairs. When the first
feeder is empty, the system switches to the other feeder. Meanwhile the empty feeder can
be refilled without stopping the system.
The upper automatic feeder is equipped with a 'daily mail' function. You can use this feeder
to process sets of documents that you cannot process automatically (stapled documents
and sets with varying thickness).
Collating Area (2)
All documents of a document set are collated and aligned in the collating area.
2
English
7
| Page 7 | jun-13-2012 10:56 |

intelliDeck(3)
The intelliDeck automatically throws out incorrect sets of documents. In this way the system
does not need to stop. Correct sets will be transported to the powerFold unit.
powerFold (4)
The fold unit folds the documents. The following fold types are possible (see Terminology
on page 132):
• No fold
• V-fold
• C-fold
• Z-fold
• Double V-fold
Inserter (5)
After the documents are folded, the documents are transported to the inserter. The inserter
inserts the documents into a waiting envelope. The inserter seals the envelope or not,
depending on the settings. Automatic monitoring ensures the correct number of inserts per
envelope.
Present on Deck (6)
The documents inserted (or not) can leave the inserter from the upper unit (present on
deck). This can occur when:
• Clearing the machine;
• Making a test set;
• Depending on the reading code.
Stacker (7)
The documents inserted (or not) are transported to the stacker depending on the
programmed job. The stacker automatically stacks inserted documents.
Side exit (8)
The documents inserted are transported to the side exit depending on the programmed
job. The side exit can be used for sorting and stacking of documents into the catch tray as
well as transporting to the optional conveyor belt or franking/mailing machine.
Envelope Feeder (9)
Envelopes that are placed on a stack by the user, are fed one by one into the system by
the envelope feeder.
8
| Page 8 | jun-13-2012 10:56 |
2
English

Operating Controls
M- powerFold
N- locking handle powerFold
O- handle for manual transport of the envel-
ope
P- handle for manual transport of the mail
set
Q- unlocking handle for rollers envelope
track
R- sealing liquid reservoir
S- side cover (opened)
T- thumb wheel for side guide adjustment
U- side guides envelope feed tray
V- flap for envelope separation adjustment
W- envelope support
A- catch tray (optional)
B- side exit / stacker unit
C- side guides stacker
D- power inlet, power switch
E- RS232 connector / USB / modem
F- unlocking lever for upper unit
G- display (operator panel)
H- vertical transport
I- hand grip vertical transport cover
J- document feed tray
K- collator arm
L- intelliDeck (divert)
2
English
9
| Page 9 | jun-13-2012 10:56 |

Control Panel
The control panel consists of the touch screen and the following buttons:
A: On/Off ( ): Switches the system on or off. If the system is not used for one hour,
the system switches to the power save mode. Press the On/Off button to switch back to
the user mode.
B: Stop ( ): The system completes the current mail set and stops, leaving the system
empty and ready for a new set.
C: Start ( ): The system starts to process mail sets.
The display is covered with a thin pressure-sensitive layer. To avoid
permanent damage of the display, do not use sharp objects to press
on the display.
10
| Page 10 | jun-13-2012 10:56 |
2
English

Installing the Document Feed Trays
Place the document feed trays in position:
1. Hold the document feeder slightly inclined as shown in the figure.
2. Place the front end of the document feed tray underneath the two black rollers.
3. Move the document feed tray upwards (lifting the black rollers), until it is possible to
‘hook’ the feeder into place.
4. Move the document feed tray towards the machine and move the hooks over the
mounting points (on both sides).
5. Let the document feed tray rest on the machine.
2
English
11
| Page 11 | jun-13-2012 10:56 |

Power Up
To start up the system:
You can severely damage the machine if it is connected to the
incorrect power supply. Before plugging in the machine, check if
the local voltage is the same as the voltage mentioned on the type
plate.
1. Connect the system to the mains power supply.
2. Use the power switch to switch the system on. The power switch is located on the
back of the system.
3. Press the on/off button next to the display. (Only necessary when the system is
in standby mode.)
The touch screen shows the home menu.
12
| Page 12 | jun-13-2012 10:56 |
2
English

Home Menu
When you start up the system, the ‘home’ menu appears. With the arrows you can scroll
through the jobs. If you want more information on a job, select the job.
If you just want to start without job definition, press [New job] and select [Automatic] (see
Processing mail sets on page 41).
With the home button ( ) you get back to the home menu. The [Menu] button opens
the advanced settings menu (see Opening the Advanced Settings on page 75).
2
English
13
| Page 13 | jun-13-2012 10:56 |