Neopost Carat Prisma User manual

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TABLE OF CONTENTS
1 Health, Safety and Environment ...................................................... 3
1.1 Precautions and Safety Issues ................................................... 3
1.2 Country Specific Conditions ...................................................... 4
1.3 End of Life .............................................................................. 4
2 Functional Description ..................................................................... 6
2.1 Overview ................................................................................ 7
2.1.1 Feeder (1) .................................................................... 7
2.1.2 Collating Area (2) .......................................................... 8
2.1.3 Divert area(3) ............................................................... 8
2.1.4 Folder (4) ..................................................................... 8
2.1.5 Inserter (6) .................................................................. 8
2.2 Operating Controls .................................................................. 9
2.3 Display Buttons ...................................................................... 10
2.4 Software Description ............................................................... 10
2.4.1 Main Menu ................................................................... 10
2.4.2 Job Info ...................................................................... 12
2.4.3 Counters ..................................................................... 13
2.4.4 Display Settings ........................................................... 13
2.4.5 Job Menu ..................................................................... 14
2.4.6 Supervisor Menu .......................................................... 14
3 Operating Instructions .................................................................. 20
3.1 Installation ............................................................................ 20
3.2 Preparation ........................................................................... 20
3.2.1 Document Feed Trays ................................................... 20
3.2.2 Conveyor Stacker ......................................................... 21
3.3 Starting Up ............................................................................ 21
3.4 Loading Documents ................................................................ 22
3.4.1 Document Orientation ................................................... 22
3.4.2 Side Guides ................................................................. 23
3.4.3 Document Separation .................................................... 23
3.4.4 Filling the Document Feed Tray ...................................... 24
3.4.5 Adjustment of the Document Stoppers ............................ 24
3.5 Loading Envelopes .................................................................. 25
3.5.1 Adjusting Side Guides ................................................... 25
3.5.2 Envelope Separation ..................................................... 25
3.5.3 Feeding Envelopes ........................................................ 26
3.6 Sealing Envelopes .................................................................. 26
3.7 Job Selection or Fill & Start ...................................................... 27
3.7.1 Using Fill & Start .......................................................... 27
3.7.2 Select Another Job ........................................................ 29
3.8 Run the Daily Mail .................................................................. 30
3.9 Create a Job .......................................................................... 31
3.9.1 Job Settings ................................................................. 32
3.9.2 Envelope Settings ......................................................... 32
3.9.3 Document Settings ....................................................... 33
3.9.4 Fold Settings ................................................................ 34
3.9.5 Optical Mark Recognition Settings (Option) ...................... 36
3.9.6 Double Feed Control Settings ......................................... 37
3.9.7 Job Name .................................................................... 38

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3.9.8 Mailing (Franking) Settings (Option) ................................ 39
3.10 Edit a Job .............................................................................. 40
3.11 Copy a Job ............................................................................ 40
3.12 Delete a Job .......................................................................... 41
4 Options.......................................................................................... 42
4.1 Activate an Option .................................................................. 42
4.2 Optical Mark Recognition (OMR) ............................................... 42
4.2.1 General ....................................................................... 42
4.2.2 Alignment .................................................................... 43
4.2.3 Document Orientation ................................................... 44
4.2.4 OMR Codes .................................................................. 44
4.3 Online Services ...................................................................... 48
4.3.1 General ....................................................................... 48
4.3.2 Start-Up Online Services ............................................... 48
4.3.3 Connection .................................................................. 48
4.3.4 Messages ................................................................... 49
4.3.5 Configuration Menu ....................................................... 50
4.4 MaxiFeeder™ ......................................................................... 51
4.4.1 Function ...................................................................... 51
4.4.2 Preparations ................................................................ 51
4.4.3 Adjust Side Guides ....................................................... 52
4.4.4 Document Separation .................................................... 52
4.4.5 Feeding Documents ...................................................... 52
4.5 insert & Mail (insert’n Frank™) ................................................. 53
5 Maintenance .................................................................................. 54
5.1 Operator Maintenance ............................................................. 54
6 Fault Finding.................................................................................. 55
6.1 Error Messages ...................................................................... 55
6.2 Clearing Stoppages ................................................................ 56
6.2.1 Exit, Sealing and Inserting Area ..................................... 56
6.2.2 Envelope Hopper .......................................................... 57
6.2.3 Lower Envelope Track ................................................... 57
6.2.4 Folder ......................................................................... 58
6.2.5 Feeder ........................................................................ 58
6.2.6 Collating Area .............................................................. 58
6.3 Operator Troubleshooting ........................................................ 58
7 Specifications ................................................................................ 62
7.1 Technical Specifications ........................................................... 62
7.2 Configuration Dimensions ........................................................ 62
7.3 Other Specifications ................................................................ 62
7.4 Document Specifications ......................................................... 62
7.5 Envelope and Insert Specifications ............................................ 63
8 Terminology .................................................................................. 65
Index.............................................................................................. 72

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1. HEALTH, SAFETY AND ENVIRONMENT
1.1 Precautions and Safety Issues
Thoroughly read this operator manual, before using this machine.
According to the European Guideline for machine safety (EC98-37), this operator manual
must be available in the national language(s) of the country where the machine is
delivered. Therefore, if you do not have an operator manual in your country’s language(s),
contact your authorized distributor.
Warnings
• If the feed/fold unit and inserter unit have to be physically separated, the operator
should pay attention to the heavy weight of the unit during separation.
• Before connecting check whether the system is suitable for the local mains voltage.
Refer to the type plate.
Safety Precautions
• Only competent personnel should operate this machine.
If incompetent personnel do operate this machine, the manufacturer does 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 machine 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 machine.
• For safety reasons, it is essential that the machine is connected to a socket outlet that
has a protective earth connection.
• Over-current 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
- 12-pole connector, located on the right-hand side

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Conventions
Note
A note gives additional relevant information.
1.2 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 connection when inserted into a Danish socket outlet.
Make sure the machine has a good functioning connection that has protective earthing
(the plug and socket outlet must match).
Japan
• Establish an earth connection before connecting the mains plug to the power supply.
• First disconnect the power supply before removing the earth connection.
Languages
This manual is also available in other languages. For more information, please contact
your local supplier.
1.3 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 rectified 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 electronical 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 electronical
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.
Warning
This symbol:
• Identifies situations where improper use of the machine can result in
personal injury or permanent/catastrophic damage to the machine.
• Indicates that the operator manual should be consulted.
Warning
This symbol indicates a danger caused by high voltage.

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In order to facilitate collection and treatment separated from normal domestic waste,
electrical and electronical 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
collection system dedicated to electrical
and electronical waste.
Please use the subjoined return or
Equipment produced after August 13,
2005.

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2. FUNCTIONAL DESCRIPTION
The system feeds, folds and inserts documents into envelopes and then seals and stacks
the envelopes. Automatic monitoring ensures the correct number of inserts per envelope.
The machine is a sophisticated folding and inserting system which can process large
quantities of mail rapidly and easily. 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 as document thickness
detection, programmable jobs, Fill & Start, Feeder, double feed control, hopper swap,
multifeed, daily mail, Divert area and Folder.

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2.1 Overview
The system consists of the following parts:
2.1.1 Feeder (1)
The Feeder is the feeding part of the system. There are two types of feeders available: the
automatic and the special feeder. The automatic feeder does not require any adjustments
for the separation. The Feeder is equipped with double feed control. In this way the
system can detect faulty sets of documents. The Feeder is equipped with hopper swap.
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 other empty feeder can be refilled
without stopping. It’s also possible to feed multiple documents from one feeder. In this
way more documents can be fed from one station, for example an original and a copy of a
document.
The upper automatic feeder is equipped with a “daily mail” function for processing
documents or sets of documents which cannot be processed automatically (e.g. stapled).
1
2
3
4
6
5
7
1. Feeder
2. Collating area
3. Divert area
4. Folder
5. Envelope feeder
6. Inserter
7. Envelope exit (including conveyor
stacker)

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2.1.2 Collating Area (2)
After feeding, the documents are gathered and aligned in the collating area.
2.1.3 Divert area(3)
The Divert area automatically throws out incorrect sets of documents. In this way the
system does not need to stop. Correct sets will be transported to the Folder unit.
2.1.4 Folder (4)
The Folder unit folds the documents. The following fold types are possible:
•Nofold
•Singlefold
• Letter fold
• Zig-zag fold
• Double parallel fold
2.1.5 Inserter (6)
After folding the documents are transported to the inserter unit where the documents are
inserted into a waiting envelope. The inserter then seals the envelope (or not) and stacks
them on the conveyor stacker. Automatic monitoring ensures the correct number of
inserts per envelope.

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2.2 Operating Controls
U TVWX OPQR
A B D
J
K
M
N
F
G
H
I
E
C
S
L
A conveyor stacker
Bloccover
C unlocking lever for loc
D power inlet, power switch
Einsertercover
F RS232 connector / USB / modem
G display (operator panel)
H OMR reading head cover
I hand grip vertical transport cover
J document feed tray
Kcollatorarm
L operator manual storage space
MFolder
N locking handle Folder
O air plugs for cleaning the sensors
P handle for manual envelope transport
Q unlocking handle for rollers envelope
track
R water reservoir
S bellows for cleaning sensors
T side cover (opened)
U thumb wheel for side guide adjustment
V side guides envelope feed tray
W lever for envelope separation
adjustment
X envelopes support

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2.3 Display Buttons
The machine has a graphical touch screen.
There are three buttons mounted at the display:
• A: the clear key
When the clear key is pressed during processing
documents, the system will stop feeding
documents after completing the set. The set will
be inserted resulting in a cleared system which
is ready to process a new job. The envelopes
have to be removed manually if necessary.
When the system is stopped already and the
clear key is pressed, it will process one set of
documents and the system will be cleared.
When a feeder runs empty after the clear key is pressed, an button will be
displayed together with the feeder empty message. By pressing the button
the clear process will be continued ignoring the empty feeder.
• B: the start key
When the start key is pressed the system starts processing.
•C:thestopkey
After pressing the stop key the system does not stop immediately, but on the first
opportunity while processing. Because of this there can be incomplete sets in some
parts of the system.
Caution
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.
2.4 Software Description
2.4.1 Main Menu
After starting up, the “main menu (1)” screen will
appear.
The screen shows the selected job number and the
total number of envelopes that have been processed
using this job.
The main menu consists of 2 menus, “main menu
(1)” and “main menu (2)”.
The “main menu (1)” shows 7 different functions:
• : job information (see 2.4.2 ”Job
Info” on page 12): shows job details.
A
B
C

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The job information function is available in all the menus where the button
is shown.
• : go to the “job selection” menu to select another job (see
3.7.2 ”Select Another Job” on page 29).
• : go to the “test run” menu to perform a test run (see ”Perform a Test
Run” on page 30).
• : go to the “counters” menu to reset the counter or to set a stop value
(see 2.4.3 ”Counters” on page 13).
• : go to the “Fill & Start” menu to start a Fill & Start job (see
3.7.1 ”Using Fill & Start” on page 27).
• : rotate display 180°.
• : go to the “main menu (2)”.
The “main menu (2)” shows 6 different functions:
• : job information (see 2.4.2 ”Job
Info” on page 12): shows job details.
• : change display and volume
settings (see 2.4.4 ”Display Settings” on page
13).
• : go to the “job menu” to create,
edit, copy or delete a job (see 2.4.5 ”Job Menu”
on page 14, only for authorized personnel).
• : go to the “supervisor menu” to change system settings (see
2.4.6 ”Supervisor Menu” on page 14, only for authorized personnel).
• : return to the “main menu (1)”.
• : rotate display 180°.

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2.4.2 Job Info
To enter the “job info” menu, press .
This menu displays all relevant information about
the selected job. If the optional insert‘n Frank™/
Insert & Mail is used the “insert‘n Frank™/Insert &
Mail info” menu is also available using the
button. If the optional OMR is used the “1 track OMR
info” menu is also available using the button.
To return to the “main menu (1/2)”, press .
The “job info” menu contains the following information:
Gives information about the envelope size (ISO format or height in mm).
Shows the type of fold.
Shows the feeders selected to pick documents from (black is selected).
The sign below this icon shows if the document double feed detection for the
relevant feeder is switched on - or off - .
The number under this icon indicates the number of sheets that must be
picked from the relevant feeder.
This sign indicates that the relevant feeder is set for daily mail.
Below this icon, the format of the document in the relevant feeder is
indicated (ISO standard or height in mm).
This sign indicates that the relevant feeders are linked. This means that
when one feeder is empty, the system automatically starts picking
documents from the other feeder.
The sign indicates that for the relevant feeder the Optical Mark Recognition
(OMR) is switched on (optional).
1
2
3
2
3

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2.4.3 Counters
To enter the “counters” menu, press
from the “main menu (1)”.
The “counters” menu shows the following functions:
• : press this button to reset the
daily job counter and stop counter to zero.
• : press this button to enter a
stop value.
The stop counter is switched off when it is set to
zero. The display will show “Stop at off”.
The stop counter can be set between 0 (switched off) and 9999. The system will continue
until the job counter reaches the stop counter value. The system stops and can be re-
started.
Note
The counter settings are job related.
2.4.4 Display Settings
To enter the “display settings” menu, press
from the “main menu (2)”.
The “display settings” menu shows the following
functions:
• : enables to change the contrast of the
display. The graphic shows the contrast setting.
• : enables to adjust the volume of the
acoustic signals. The graphic shows the volume setting.
• Rotate display: press the button to rotate the display 180 °.

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2.4.5 Job Menu
After pressing the button a login
menu opens.
To prevent jobs being edited or deleted without
informing the ‘job owner’, this menu is protected by
a PIN-code. The PIN-code is
2546 .
When a wrong pin code is entered, the cursor is set
to the first number to try again.
After 3 times entering a wrong pin code the display
shows the “main menu (1)” again.
After entering the correct pin code the “job menu”
appears.
This menu enables the creation, deletion and/or
editing of jobs.
The “job menu” shows the following functions:
• : job information (see 2.4.2 ”Job
Info” on page 12).
• : create a job (see 3.9 ”Create a
Job” on page 31.)
• : edit a job (see 3.10 ”Edit a Job” on page 40).
• : copy a job (see 3.11 ”Copy a Job” on page 40).
• : delete a job (see 3.12 ”Delete a Job” on page 41).
• : exit and return to the “main menu (1)”.
2.4.6 Supervisor Menu
After pressing the button a login
menu opens.
Enter the PIN-code 2546 to access the “supervisor
menu”.

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After entering the correct pin code the “supervisor
menu” appears.
This menu enables checking and configuring the
system.
The “supervisor menu” shows the following
functions:
• : shows system information,
like:
- The flex certificate, used for OMR
- The counter since last visit: the counter value since the last service visit
- The last error generated by the system
The screen shows a button : this shows the software versions that are
present in the total system.
• : shows option information and system information:
-ThechipID
-ThesystemID
- The installed options
For installing new options, see 4.1 ”Activate an Option” on page 42.
• : opens the “job settings” supervisor menu (see ”Job Settings
(Supervisor)” on page 16). From this menu system parameters can be set.
• : opens the “test menu” (see ”Test” on page 18). Use this menu to
test the system.
• : opens the “Online Services” menu (option, see 4.3 ”Online Services”
on page 48). This screen enables to connect the system to a server and receive
messages.

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Job Settings (Supervisor)
Caution
Job settings normally will be changed by a service engineer only. Therefore first consult
the supplier’s Helpdesk before changing any settings. Changes to the job settings can
result in malfunctioning of jobs.
The “job settings” menu (supervisor) can be opened
from the “supervisor menu”. From this menu system
parameters can be set. The “job settings” menu
shows the following functions:
• : opens the “mode menu” to set
the output mode for a job (see ”Mode Menu” on
page 16).
• : opens the “document offset”
menu to set the document offset in a set of
documents for a job (see ”Document Offset” on page 17).
• : opens the “BRE offset” menu to set the BRE offset on or off (see
”BRE Offset” on page 17).
• : opens the “flap closer” menu (see ”Flap Closer” on page 18). Use
this function to improve the envelope sealing process.
Mode Menu
When selecting from the “supervisor menu”
, , the “mode menu”
appears.
In this menu for each of the jobs 1 through 25 and
Fill & Start a choice can be made between output
Mode 1 and Mode 2 using the button. Mode 2 is
the default setting.
Mode 1 focuses on the versatility of paper
parameters (paper thickness; document length), i.e.
correct operation under even extreme paper conditions.
Mode 2 focuses on high speed and is achieved as follows:
• During multi feed (more than one page from one feeder) the movement on the
collator is minimal. In mode 1 the divert unit will be used for completing the collating
process (less paper on paper transport).
• During the transportation of a set from the collator into the Folder, the next set is
going into the collator already. This results in temporary overlapping sets with two
different transport directions. In mode 1 the set has left the collator completely before
the next set enters the collator.

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• Anticipation call for the envelope is used. That means that a (folded) set is leaving the
Feeder already before the envelope is ready on the insert position. In mode 1 the
envelope is on the insert position already before the set leaves the Feeder.
It is advised to use Mode 1 with a paper thickness of 65 g/m
2
or less, a document length
of 12 inch (305 mm) or higher, and for situations where Mode 2 is not functioning
properly. In all other cases Mode 2 is advised.
If you select Mode 2, select if the reply envelope has a window or not.
Document Offset
When selecting from the “supervisor menu”
, , the “document
offset” menu appears.
The vertical transport of documents fed by the
various feeders is arranged in such a way that the
documents are partially overlapping each other. This
overlapping scheme ensures that the documents are
properly aligned in the collator area.
In the “document offset” menu you can set the
extend to which the documents are not overlapping
each other, i.e. the document offset value. The default value is 50 mm (2.0 inch). The
document offset can be varied between 20 mm (0.8 inch) and 75 mm (3.0 inch).
BRE Offset
When selecting from the “supervisor menu”
, , the “BRE offset”
menu appears.
If a document is longer than the set address fold but
shorter than the envelope height, this document
sometimes will be unnecessarily folded. Under
certain conditions this document can be prevented
from being folded. This can be implemented with the
menu “BRE offset” (BRE means Business Reply
Envelope).
For each of the jobs 1 through 25 and F&S (Fill & Start) an offset can be switched on or off
using the button.
In the case of offset “on” the last document that was added to the set will be shifted from
the rest of the set (offsetting). This document will be held back during a certain distance.
This means that the trailing edge of this upper document leaves the collator at last. This
document will not be folded. During the insertion into the envelope the documents of the
set will be realigned.
The conditions are:
• The feeder that supplies this upper document (BRE) is set to one document per set
(no multi feeding).

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• The document directly beneath this document must be at least 60 mm (2.4 inch)
longer than the BRE.
• The upper document must be longer than the set address fold.
• The folding mode is either single fold or letter fold (no Z-fold).
• The upper document must be shorter than the envelope height.
Note
It is possible to use the BRE offset for a BRE and an enclosure (card) in one set. The extra
condition is that this enclosure is equal to or smaller than the set address fold and should
be placed direct underneath the BRE in the set.
The whole BRE offset is based on friction between documents within a set. Therefore it is
necessary to make use of these conditions to reduce the risk of bad transporting, folding
and inserting.
Flap Closer
When selecting from the “supervisor menu”
, , the “flap closer”
menu appears. Use this function to improve the
envelope sealing process for a job. The offset can be
varied between -20 and 20. If for example the offset
is set to +10 the sealing process will be activated 10
pulses later than initially.
For each of the jobs 1 through 25 and F&S (Fill &
Start) an offset can be set.
Test
The “test menu” menu can be opened from the
“supervisor menu”. Use this menu to check the
system, reset all photocells and execute an OMR
test. The menu consists of the following functions:
• : use this function to check if all
motors, clutches and sensors are correctly
connected. This test derives the status of the
actuators and clutches by briefly activating the
actuators and then measuring the current.
Note
Remove all paper and close all covers before testing.
• : use this function to calibrate all photocells.

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ENGLISH
Note
Remove all paper and close all covers before calibration.
• : use this function to align and test the OMR reading head (see ”OMR
Test” on page 19).
OMR Test
The “OMR test” menu can be opened from the “test
menu”. Use this menu to align and test the OMR
reading head (see ”Reading Head Position” on page
43). The menu consists of the following functions:
• : align the OMR reading head.
Put a document with reading marks in the
feeder and press this button.
• : shows the mark quality and the
number of read marks from the last processed document. Also the gain of the OMR
amplifier is shown.

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3. OPERATING INSTRUCTIONS
3.1 Installation
Caution
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.
3.2 Preparation
3.2.1 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.