Neopost DS-140 User manual

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140 Operator Manual
TABLE OF CONTENTS
1 Introduction ............................................................................... 3
1.1 Pictograms ........................................................................... 3
1.2 Notes on the Use of this Handbook .......................................... 4
2. Safety Notes ............................................................................... 4
2.1 General safety notes.............................................................. 5
2.2 End of Life............................................................................ 6
3. TECHNICAL SPECIFICATION ....................................................... 8
3.1 Machine rating sheet.............................................................. 8
4. Machine Layout Guide................................................................. 9
4.1 Description of machine........................................................... 9
4.2 Partsidentication................................................................10
5. Operating Instructions.............................................................. 11
5.1 What’s in this Document........................................................11
5.2 Starting the Operating Program..............................................12
5.3 The Run screen explained......................................................13
5.3.1 To change the User.......................................................14
5.3.2 To change the Job ........................................................14
5.3.3 To adjust the Envelope Inserter settings..........................15
5.3.4 To adjust the Document Inserter settings ........................17
5.4 The Setup screen .................................................................19
5.4.1 The Setup screen explained...........................................19
5.4.2 The List Box ................................................................20
5.5 The OMR Code screen ...........................................................21
5.6 The Barcode/Labels screen ....................................................23
5.7 The Documents screen..........................................................25
5.8 The Envelopes screen ...........................................................27
5.9 TheCongurationscreen.......................................................29
5.9.1 Conguringtheinserter. ............................................29
5.9.2 Setting the inserter options for the Inserter unit...............30
5.9.3 Setting the document options for the Feed unit ................31
5.9.4 Setting the feed options for the Feed unit ........................32
5.9.5 Setting the module options for a Folder...........................34
5.9.6 Setting the output options.............................................35
5.9.7 Setting the postage options ...........................................36
5.9.8 Setting the miscellaneous options...................................37
5.10 The Job screen.....................................................................38
5.11 The Users screen..................................................................39
5.12 The Statistics screen.............................................................40
5.12.1 Filter ........................................................................40
5.12.2 View Summary ..........................................................41
5.12.3 Current & Previous sessions.........................................41

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5.12.4 Data Logs..................................................................42
5.12.5 Open Archive .............................................................43
6. Running The Job ....................................................................... 44
7. Daily Post (Handfeed)............................................................... 45
8. Setting Up The Machine ............................................................ 46
8.1 Loading the paper hoppers Insert Feeder (Single, tower, OMR/
Barcode) .............................................................................46
8.2 Loading the envelope hopper .................................................47
8.3 Setting the separator gap......................................................48
8.4 Using the accumulator ..........................................................48
8.5 Operator settable separator (Optional) ....................................49
9. Operator Maintenance .............................................................. 50
9.1 Clearing paper crashes..........................................................50
9.2 Cleaning rollers and sensors ..................................................52
9.3 Maintaining the wetting system ..............................................56
10. Document Orientation Tables.................................................... 57

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140 Operator Manual
1 INTRODUCTION
With this inserter you have an advanced, medium-volume folding and inserting machine.
Itsmodularconstructionallowsupto8feedunitstobetted,withamaximumof17feed
trays.Itssophisticatedsoftwarecontroloptimisestheorderandowofdocumentsfor
collating at the insert head before insertion into the envelope. All fold and adjustments take
place automatically according to the requirements programmed in by the operator.
In order to ensure the long usage of this machine and its components, and above all the
safe use of the machine, you must read and adhere to the operating instructions and safety
notes. Always be aware of all warnings and notes that are mounted or noted on the machine
itself.
All persons entrusted with the handling of this machine must also be familiar with the
operating manual.
Save this handbook carefully, so that the information it contains may be available at all
times.
1.1 Pictograms
General Warnings
Warning of danger from electricity or electrical shock
Information / Note indicating important information regarding the handling of
the machine.

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1.2 Notes on the Use of this Handbook
This document contains all general information and explanatory text necessary in order to
be able to carry out the operation of the machine.
When some action is expected from the operator, this will always be explicitly stated, and
where relevant, accompanied by an illustration or graphic.
Always read through each step, so that you will obtain all of the necessary information. Do
not anticipate what you believe will follow in the handbook: It will prevent you from making
mistakes!
Chronology and Reference
This handbook is structured chronologically, and therefore ordered sequentially for the
operationally ready machine. It assumes that the machine has been installed in the
correct environment by an Authorised Service Engineer and that the operator or his or her
supervisor has had a degree of operator training.
When you are unfamiliar with the machine, it is best to read through the handbook from
beginning to end. You will be guided step by step, and in this way you can easily and quickly
have the machine in operation.
If you are already familiar with the machine, it will make thing easy if you use this
handbook as a reference work.
2. SAFETY NOTES
For your own safety and the operating safety of the machine, read the following notes
carefully before starting your machine. Always be aware of all warnings and notes that
are mounted or noted on the machine itself. Save this handbook carefully, so that the
information it contains may be available at all times.
The machine is of advanced construction and reliable in operation. Nevertheless, the device
does present hazards when operated by untrained personnel. The same applies to use that
is inappropriate and not in keeping with its intended purpose.
In not adhering to this handbook, there is the danger of
 • anelectricalshock,
 • injuriesfromtheintakeattherotatingrollers,
 • damagetothemachine.
IMPORTANT: To switch the machine off in an
emergency, open any cover.

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140 Operator Manual
Caution!
Please, read these notes with care.
Save these instructions for later use.
All notes and warnings found on the machine are to be followed.
Important! The machine must be installed only by an Authorised
Service Engineer. A safe, level position is necessary, when installing the
machine,withsufcientspaceallroundtooperateit.Themachineistobe
protected from moisture. If moving the machine, ensure that the castor
brakes are off, and push on the stand, not the machine.
Ensure there is at least 1 metre of free space between the operator side of
the machine and a wall or barrier. To provide access to the mains switch, the
opposite side of the machine must be at least 150mm from a wall or barrier.
Do not place surrounding furniture or other objects where your path may be
obstructed.
The machine may only be connected to a voltage of 230V/50Hz or 115V/60
Hz,depending upon model.
The mains plug may only be connected with a socket having an installed
protective contact! The protective effect will be compromised by the use of
an extension line without a protective grounding conductor. All interruptions
of the protective grounding conductor, within or outside of the machine,
are prohibited. The device is double pole fused! When fuse failure occurs,
electrical machine parts can still carry voltage. When making the connection
to the mains power, be aware of the connection values on the nameplate.
Inspect the voltage setting on the device’s power input module. Run the
supply lines in such a way, that no-one may trip over them. Do not place any
objects upon the supply line. When the machine is not in use over a long
period of time, it should be disconnected from the power supply. In this way,
damage would be prevented in the event of excess voltage. Protect the device
from moisture. When moisture enters the machine, there is the danger of
electrical shock. Never open the machine except the top cover. For reasons
of electrical safety, the machine may only be opened by authorized Service
Agents.
Never reach into the machine when it is running! This could only occur if a
safety interlock were to fail.
The danger of injuries exists, through pulling in and crushing on the rotating
rollers. In addition, keep long hair and parts of loose clothing far from the
machine in operation. If a safety interlock fails, your Service Agent must
be contacted immediately!
In order to prevent damage to the machine, only factory authorized accessory
parts should be used.
Prior to cleaning the exterior of the machine, it should be disconnected from
the power supply. When cleaning the machine, do not use liquid or spray
cleaners, but only a cloth dampened with water.
When cleaning sensors use onlynon-ammableairdusters,eg.partnumber
E0070A.Othertypesmayuseammablepropellants,whichcouldresultinre
or explosion.
Installing
the
machine
Electrical
danger
Operating
safety
Cleaning
the
machine
Cleaning
sensors
2.1 General safety notes

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In the following cases, the mains plug must be unplugged and the device
left for the authorized Service Agents:
 • Whenthemainscableorplugiswornordamaged.
 • Whenwaterorotherliquidhasenteredthedevice.
 • Whenthedevicedoesnotfunctionproperly,inspiteof
following the instructions provided.
 • Whenthedevicehasfallendownorthehousingis
damaged.
 • Whentherearenoticeabledifferencesinthenormal
operation of the machine.
When repair work is carried out, only original spare parts or spare parts
corresponding to the original parts may be used.
Do not disassemble the machine any further than is described in this
handbook. Other than the top cover, the opening of the machine by
unauthorized personnel is not permitted. Repairs may only be carried out
by an authorized Service Agent.
 Modicationisnotpermitted:
 Forsafetyreasons,yourownreworkingandmodicationsarenot
permitted.
Please contact your Service Agent, for all questions relating to service and
repair. In this way, you ensure the operational safety of your machine.
2.2 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
utilise 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rectiedatsource.
Separate collection of waste is the precondition to ensure reuse and recycling of waste that
is generated at the disposal of electrical or electronic equipment and 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 needs selective treatment as their injudicious handling or disposing of on or into
land, water or air would represent a major threat to the environment and human health.
Allow
machine to
be checked
by the
Service
Agent
Spare Parts
Repairs

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140 Operator Manual
In order to facilitate collection and treatment separated from normal domestic waste,
electrical and electronic equipment is marked with the following logo:
Not only are you by law not allowed to dispose of the waste equipment via other waste-
streams, 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 dealer.
Do not mix with normal domestic waste.
Please use the subjoined return or
collection system dedicated to electrical
and electronic waste.
Equipment produced after August 13
2005

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3. TECHNICAL SPECIFICATION
3.1 Machine rating sheet
1. CAUTION: In order to ensure correct safety and operation, this machine must
only be installed and maintained by an authorized Service Engineer.
2. CAUTION: Should any cover or safety interlock be damaged, the machine must
not be used until service repairs have been completed.
3. CAUTION: This machine must be earthed. The wire colours in the mains
power cord are:
(Green/Yellow 230v) (Green 115v) which must be connected to Earth (Ground).
(Blue 230v) (White 115v) which must be connected to Neutral.
(Brown 230v) (Black 115v) which must be connected to Live (Line).
4. CAUTION: This machine is supplied with an unterminated mains cable for hard
wiring or connection with a suitable 16A plug/socket conforming to
IEC 60309.
5. CAUTION: Forcontinuedprotectionagainstriskofre,replacewithsametype
and rating of fuse. The fuse rating/type for this machine is :
T 6.3 A Amps 230Volts (Part No. 135-106).
T 10 A Amps 115Volts (Part No. 135-110).
6. Model Details:
Model Name: 140 series
Model Number: 1430
Input Voltage: 230 Volts @ 50 Hz 115 Volts @ 60 Hz
Input current: 3.5 Amps 7 Amps
Sound Reading: 75dBA 75dBA
(measured at a distance of 1 meter from the nearest cover and a height of 1.6
metres from the ground).
7. The use for this machine is for collating, folding and inserting documents into an
envelope.
8. The weight of this machine is: 290 kgs (unpackaged)
400 kgs (packaged, with accessories)
Basedonaconguration3xFeedersand3-PlateFolder
Lifting or handling must only be carried out by competent persons using appropriate
means.

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140 Operator Manual
4. MACHINE LAYOUT GUIDE
4.1 Description of machine
The function of the machine is to feed forms from a number of hoppers, fold them in either
‘C’, ‘Z’, ‘V’ or double forward fold and insert them into an envelope which is then sealed and
ejected.Furtherform(s)mayoptionallybecollatedwiththerstform,eitherbyfolding
together or collating on the track. Inserts (cards, cheques etc.) may also be collated on the
track before inserting. The machine is OMR/Barcode compatible, allowing a group of forms
to be collated in the accumulator prior to folding. Forms may be inserted without sealing
the envelope for subsequent hand insertion of card, gift etc. Multiple insertions may also
be used, ie. a preset number of forms (or combination of forms) are separately inserted
into the collation pocket in the inserter head. There is a batch processing facility, allowing a
preset number of cycles to be completed before the machine automatically stops.
The machine consists of a number of modules, depending upon the build ordered - these
modulesarebrieydescribedbelow:
a) Inserter head - Collates all documents in a pocket before insertion, feeds
theenvelope,insertsthepackandsealstheap.
b) Insert Feeder - Feeds shortform inserts (cards, cheques, booklets etc.) onto
the track for subsequent insertion. Available as a single feeder with one feed
hopper or a tower feeder with two feed hoppers. An OMR/Barcode version (with
one feed hopper) is also available.
c) Feeder Folder - Mounts on the track, either in conjunction with a tower
folder (see below) or as the last station. Fitted with one feed hopper, and
folds the same size stationery as the tower folder, but uses a 2-plate folding
mechanism. An OMR/Barcode version (with one feed tray) is also available.
c) Tower Folder-Mountsinthelaststationpositionandttedwitheitherone
or three trays depending upon option. Includes a 3-plate folding mechanism,
handfeed tray and an optional accumulator and/or single divert bin.
The machine is equipped with PC controlled operating software from where jobs can be
programmed and run. Jobs can be quickly switched from the main screen, and can also be
‘ne-tuned’toaccommodateasmallchangeinjobrequirement.Thenumberofjobsthatcan
be programmed is limited only by the capacity of the PC. Input is via touch-screen monitor
or keyboard/mouse.
The machine is OMR and Barcode enabled, capable of reading a variety of different barcode
symbologies. Other symbologies can be accommodated at special request.
A daily post function can be used on the handfeed tray built into a tower folder as standard,
and is an otional feature on a feeder folder. This allows groups of documents, stapled or loose,
to be hand-fed; they will then be folded and inserted into an envelope. If other hoppers are
loaded, further forms can be collated. An optional daily post function is also available on the
feeder folder.
No manual setting of the fold plates or envelope closer is required, these being adjusted
automatically according to the settings in the selected program.
Anoptionaloutputconveyorcanbespecied,toreplacethestandardreceivingtray.Thisis
available in two lengths.

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4.2 Partsidentication
Envelope
hopper
Insert/collate
area
Filled
envelope tray
PC control panel Tower feeder
Tower folder
(see below)
Storage cupboards
(PC under insert head)
Tower Folder
Accumulator sideguide
Forms
diverter
(optional)
Accumulator (optional)
Daily post tray
Feed trays (either 3 or 1)
Note: Station 1 is the rst
feed unit after the insert/
collate area.
Standard feeder