Neopost Automailer 5 User manual

InstallationGuide
Installation GuideIssue4 August 2008 Page 1
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INSTALLATION GUIDE
Contents
1. Safetynotes2
2. Mainsconnections 3
3. General specifications 5
4. Removal frompallet 7
5. Fittingtogether 8
6. Head&track sectionwiring 10
7. Divert, Collate, OMRFolder, Single
On-lineI/F&2-UpMerger 10
8. Folder&Feeders14
9. Hi-Cap/Lo-Cap 16
10. Finishing(monitorarm, coversetc.)17
11. Vertical stacker 21
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InstallationGuide
Installation GuideIssue 4 August 2008 Page 2
1. SAFETYNOTES
Thefollowingpointsmustbeobservedwheninstallingthemachine.
Failuretodo socouldresultinasafetyhazardtooperators.
• The machine isswitchedoff byturning the isolatorswitchonthe rearof
the inserthead covertothe ‘off’position. Turning the switchdoesnot
isolatethe PCfrommainssupply, whichislefton foraccess totechnical
documentation. Toswitchthisoff also, the powercablemust be isolated
fromthe incoming supplybyswitching off at supplysource.
• The machine must be installed insufficient spacetoallowaminimumof
1mof cleardistancefromanypoint ofthe machinetoawallorother
object.
• Donot fit anymachine coverifit damaged, distorted orinthecaseof an
opening cover, functioning incorrectly. Orderareplacement.
• Check that thesafetyinterlocks on allopeningcoversareworking
properly,and that themachine stopsifacoverisopened.
• Ensurethatthe electricalconnectorson bothpowercableand mains
conformtothe standarddescribed inthe specifications. Thepowercable
must be routed sothatitisnotavailabletoaccess ortopresent ahazard
tomachine users.
• Check that theblue indicatorlight on the topof the insert headand each
moduleisfunctioning.
• Instruct operatorsastothe location of the isolatorstopswitchat the rear
of the insert head, andhowtoswitchof thepowerat source.
• Instruct operatorsthatif anyfixed coverisdamaged orfound removed, a
PFEServiceEngineermust be contacted toreplaceit.
• Ensurethe safetylabelG3068Aisinplaceandnot obscured on all
opening covers.
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InstallationGuide
Installation GuideIssue 4 August 2008 Page 3
2. MAINSCONNECTIONS
Europe
MachinesforEuropean marketsarefitted withan IEC60309 powerconnector
and must be connected onlybyplugging intoamating wall socket. Noother
connection isrequired.
NorthAmerica
Therearetwopossiblemethodsof connection: eitherbyplug orpermanently
connected tothe mainssupply.
Plug: The machine must be fitted eitheraplug conforming to
NEMAL6-30, locking3-pindevice, wired toachieve230V(X
and Y, orLiveand Neutralpinsare'hot'withrespect to
ground). Observecorrectpolarityof wiresaccording tolocal
codesand regulations. Note: Changingthe suppliedplug
must be carriedout byaqualifiedelectrician.
Permanently The wiresmust be connected toan isolatorswitchwithover-
currentprotection rated at 30A, sited withineasy reachof
operatororincloseproximitytothe machine. Wiresare
colour-coded asfollows:
Live(L1): Black
Neutral(NorL2): White
Ground: Green
The mainssupplyisconnectedtotheswitchlocated atthe rearof the insert
head, abovethewetterfluidbottle. Togainaccess, removethe outercover,
then the plateholding theswitch. The incomingmainscablesconnect tothetop
of the switchand exit at the bottomtoconnecttothe DINrailfuses(see
followingpage)
Connected:
Protectivecoveroverfuses
andmainscables.
Warning:Highvoltage
PCalwaysliveunless
isolatedatwall.
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InstallationGuide
Installation GuideIssue 4 August 2008P age 4
EarthConnections
The earthwiresfromincoming mains, outgoingmainsand the connectiontoall
otherfusesterminateat themainearthpost. Thisislocatedat therearof the
insert headand isvisibleafterremoving the panelforthe mainsswitch, as
described on the previouspage.
Earthconnection
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InstallationGuide
Installation GuideIssue 4 August Page 5
3. GENERALSPECIFICATIONS
Voltage:
230V@50/60Hz(±10%maximum).
MaximumHeatOutput(BTU/hour):
Rated current xRated Voltsx3.412 (eg. 11,222 BTU/hourfor‘typical’
configuration).
MaximumHeatOutput(Watts):
Rated Current xRated Volts(eg. 3.289 kWfor‘typical’configuration).
OperatingTemperature:
18 -28 deg C(64 -82 degF)
Operatinghumidity:
30 -80%RH
Noise Level:
Without collator: less than 78dBA,measured at1.6mheight, 1mfromcover
wherenoiselevelisatitshighest.
Withcollator: less than 81dBA,measured at1.6mheight, 1mfromcover
wherenoiselevelisatitshighest.
Note:Measurementstaken using averaging of peaks.
Leq (8) 79dBA
Note: Leq (8)islowerthan thefirstaction levelrequired by:
Europe -PhysicalAgents(Noise)Directive2003/10/CUK
-Health&Safety.The Controlof NoiseatWork
Regulations2005 statutoryinstruments2005 No. 1643.
Ambientlight:
Althoughthe machinemayoperateinsunlight, itisnot designed forusein
direct sunlight, orwheresunlightisexposed tothe machine throughwindowsor
skylights.The light-sensitivesensorscan be affected intheseconditions. It is
thereforerecommended to:
a)Locatethe machine out ofdirect sunlight
b)Protectthe machine fromdirect sunlight using blindsorsimilar
blockingdevices.
If the machine canonlybelocated whereit maybe exposed todirect sunlight,
then pleasecontactTechnicalSupport department, who maybe abletoadvise
on the useof blockingmaterialonthe insideof the Perspexcoverswhere
necessary.
ImportantNotes:
1. The machinewillfunction withhumiditylevelslowerthan30%RH, buthigh
levelsof staticmaybe generated,impairingmachineperformance.
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InstallationGuide
Installation GuideIssue3June 2008 Page 6
2. The machinewillfunction withhumiditylevelshigherthan 80%RH, but
moistureabsorption intothe materialmayimpairmachine performance.
3. Condensation must not be present underanycircumstances.
4. Toensuresafeoperationand provideformaintenanceaccess, aminimumof
1mof free spaceshouldbe availablebetweenanypart of the machine anda
wall orotherstructure.
5. The machinewillfunction temperaturelevelsabove28deg C(82 degF)and
below18 degC(64deg F).Temperaturelevelsoutside theselimitsmayimpair
the machine performance.
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InstallationGuide
Installation GuideIssue3June 2008 Page 7
4. REMOVALFROMPALLET
First removealloutercasing and
boxed parts, asshownabove. RemoveRearPanel
B2-1099-Wand Head
Undercover B1-0925-W
Removethe 4coach
bolts&Transport
Bracket B8470X.
Forklift theheadunit
fromthe pallet.
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InstallationGuide
Installation GuideIssue3June 2008 Page 8
Using pumptrucks located underthe chassisof the unitsmovethemtotheir
finallocation. NotethatPFEcan supplytrolleysforinstallation, whichlocate
underthe chassisbut do not protrude, minimising the sizeof the units-order
A0392Afor2off Installation Trolleys, thequantityrecommended forinstallation.
The minimumdooropeningis38" (965mm)forthe head unit.
5. FITTINGTOGETHER(HEIGHTMATCHING, LEVELLING &ALIGNMENT
Tomatch(align)themachine height, eachtrack section must be levelledas
well asmatchingthemat the top ofthe track chassis.Thisisanimportant step
of the installation andshouldbe carried out withcareasthe subsequent
machine performanceand alignment of coversmaybe affectedifitisnot
correct.
C7313X
E2748A C5978P C5978P
C5983P
Align bottomedgesof
track and head atrear.
Tension
Bars
B7296A
M5Nut
C7313X
BaseAdjustment Tool.
C9215A125mm
Donot attempt toinstallthemachine withoutaspiritlevel.
Tension
Bars B7218P
(see page6)
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InstallationGuide
Installation GuideIssue3June 2008 Page 9
Looselyjointhesecondtrack
sectiontothefirst track section
usingthe tensioning bars
(C5978PandC5983P)and
bolts(E2748A)at top &
bottom. Matchthe height at the
top of thetrack chassiswhere
theyjointogethersothat the
joinisperfectlysmooth.
Align bottomedgesof
track and head atthe front.
Align bottom
edgesof track
pairtothenext.
Levelthe second track sectioninbothdirections, making suretheystillmatchat the
join. Repeat thisprocess fortrack section 3and beyond. Thechassisisjoinedwith
the sametension barsasthe head except C7313Xisonlyused on thehead.
Afterinitiallevelling tighten allthe boltswhichsecurethechassissectionstogether.
Re-check that allthe chassisarelevelandsurfacesmatching.
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InstallationGuide
Installation GuideIssue3June 2008 Page 10
6. HEADAND TRACK SECTIONWIRING
7. DIVERT, COLLATE, OMRFOLDER, SINGLEONLINEINTERFACE&2-UP
MERGERUNITS
Regardless of combination being fittedtogetherthe principleisthe same. All
unitshaveastand withthe unitsfitted on top.Fromthe folderworking back, the
divertisalways first thenthe collatorfollowed byHi-cap/Lo-cap feeder, Single
on lineI/F, 2-up/Cutteretc.
First adjust the stand heightssothat allthestandsalign atthe top withthetop
of the track section.
Looselybolt the (first)stand tothe track sectionthen continue tolevelthestand
usingaspiritlevelsothatit alignsperfectlywiththe track.
Laythe mainscablesalong the rear
of the machine throughthe holes
provided inthe chassisand plug them
intothe IECconnectorblocks.
Removethe mainscablestraps
(B7218P), then replacethem
securing downthe mainscables. Do
not stress the cables-theyare
sufficientlylong toallowforplayat
bothends.
Pass the communicationscables(blue
coloured C.A.N. cable)along thefront of the
machine throughthe holesprovided inthe
chassis.
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