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
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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
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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
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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
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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
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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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Lock the boltsup tight ensuring that alignment and levelaremaintained. Ensurethat thelatchon the underside of the collatoris
working correctlyandthe collatorslideswithease.
IGUSChain
Ensurethe paperpathfromthe forms
divertertothe folderisat therightheight
and parallel. Thisiscontrolledbytheheight
of the chassisand divert stand, sovery
important at thisstage,and criticaltoensure
good folding.
Locatealltheunitsontheirrespective
stands(thecollatecomescompleteon
itsstand)and securetherunner
brackets.
Connect beltasshown,
then tension.
Fit4screws2eachside
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Pass allthesignal, 36-voltand OMRcables(2x4wayJSTleads)throughso
that theyarelayingon top of the stands, and intothe IGUSchain. Attachthem
tothe stand withcable. Ensurethat allthe cablesmovefreelyandallow
sufficient movement forthe unitstounlatchandslideback. Notethatitisthe
installation engineer’sresponsibilitytoensurethat cablesarenot snagging,
pullingorbeing trappedbyanyof the metalwork. Connectthemtotheir
respectivecircuit boards-notethat allcablesarenumbered fortheirspecific
connector.
Fitthe EMCcovertothe RH side of the collatorand check the EMCcoveron
the output of thecollatorinthephotoabove.
The SingleOnline and2-upMergersiton standssimilartothe divert and
collator.Theyalsorollandlatchinasimilarmanner. SoInstallation isexactly
the same. Pass allcablesthrowthe IGUSchaininthe collatorandconnect
themasmarked.
Latch
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8. FOLDERSAND FEEDERS
Foldersarealreadyfitted tothe machine using4xM5screwsat the baseand 2
xM5screwstothe shuttlebed.
Feeder
Long
Conveyor
2xM5screws
tothe shuttle
bed.
8xM5screw
holdthe
coverson.
Folder
Feeder/ standard&longConveyors.
Black communicationscable
(Dconnector) and black and red
36Vtomoduleboard.
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TwoM5screwseach
side holdtheconveyor
on.
TwoM5screwat
the top eachside.
TwoM5screwsattach
feedertothe feeder
supportlegs.
Showing belt andadjuster. Notethe
pulleyison theinside, being fittedto
an envelopefeeder(outside for
standardfeeder).
TwoM4countersunkscrewson
the top of conveyor.
Small
Conveyor
The feedersareusuallyfitted tothe
machine on delivery. Check belt
tension iscorrect. Ifit hasmoved in
transit andistoo tightit willsnap.
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9. HI-CAP/LO-CAPFEEDERS
Attachthe feedermounting bracket (B8481P)fittingthe locating bushes
(C2893A)atthe bottom, then feed the 36 voltand signalcablesthrough the
panels. Hookon the runnerbracket assembly(A3198A)andtemporarilyfit the
rampsprovidedforinstallation
RolltheHi-Cap/Lo-Cap feederup therampsontothe runnerbracket assembly.
usingthe adjustablefeetinthe runnerbracket, levelthe feedersothatthe front
faceisparallelwiththe folderand ensurethatthe track chassisandthe fixing
holesalign (2off M6abovethe electricalboxand 1offM5insidethe electrical
box). Notethat thisalignment isimportant toensurethat the trolleys willlocate
easilyintothe Hi-Cap Feeder.
A3198A C2893A B8481P
Adjust the
feet on the
trolleyup or
down tillthe
twoholes
areinline.
Screwlocation onHi-cap fitted toFolder.
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10. FINISHING (MONITORARM, COVERSETC.)
MonitorArm (earlymachines –see overleafforlaterversions)
Bolt thekeyboardendtothemonitorarm, attachthe monitorviafourscrewsat
the rearandplug inallPC&Powercables.
Fitthe monitorarmtothe headunit.
Feed thecableduct throughthe
chassisholethen through the large
black plasticgrommet and on tothe
PC. Guide the endof the steminto
the oiliteat the base. Clipthe white
monitorarmhousing C6-0418-A
overthe cableduct and fitit tothe
chassiswiththe twofixing screws.
Large black plasticgrommet toPC
Chassishole
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InstallationGuide
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MonitorArm (latermachines –see previouspageforearlyversions)
Onlatermachines(fromlateNovember2007), the pivotpostisattached tothe
baseunitratherthanthe monitorarm(see belowforcomponents).
Toassemblethearm, layit on the topof thebaseunit andfeedthe cable
through. Lift it overthepivot post andallowit toslidedown, ensuringthe vane
on the postlocatesinthe slotinthe arm.Wheninplace, securewith2off M6x
50 Cap Headscrewson the back of themonitorarm.
Bolt thekeyboardendtothemonitorarm, attachthe monitorviafourscrewsat
the rearandplug inallPC&Powercables.
Pivot postfixed tobase
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AdjustmentofTrack covers.
Adjustmentoftheheadtothefirsttrack pair
Thisiscriticaltoensurethatthe head coverdoesnot rub on the track cover
when itisopened.Thereneedstobe abouta5mm gap.
5mm gap on
covers Ensurecoverlinesareparallelwith approx5mm gap on shutlines.
Toachievethissee below.
Adjust the coversinthe
slotssothat theyline up
foreandaft.
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InstallationGuide
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If the instructionsinthe first partof theinstallationguide havebeen followed,
the covergapsshouldnotbe farout.Toachievethe finaladjustment loosenthe
4boltsthatscrewintothe tension barsdescribed insection2.
Check List
Someareasmaymoveintransit, socheck thefollowing:
• EnvelopeConveyor: Removethe 2screwssecuring theturnover
assemblyand slide it away. Usea1.5mm Allenkeytocheckthe gap at
the conveyorexit point. Adjust usingthe screwsbelowifitiswrong.
• InsertArea: Check thatthe pinchrollerpressuresareeven.
• Feeder: Check that the belt tensionisnot too tight.
Tension
Bars
Then adjust the feet toopenthe
gap orclosethe gap onthe
covers. Alsoadjust the head or
track fromback tofront toalign
the coversforeand aft.
Onlyafewturnsshouldbe
needed toadjust thisgap.
If itisout byalong way
then something hasbeen
assembled wrongly.
Acceptable
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11. VERTICALSTACKER
See VS set up docforfullinstallation savedunder.
C:\ProgramFiles\PFE\Automailer5\ Documentation\otherdocumentation\vertical stacker\VS set up.doc
Adjust the feet to
achievethisheight
Fortheenvelope.
2screwstofixthe VS
tothe AM5.
Pushthe conveyorandthe wheelendof
the stackertogetherasshown. Ensure
rollersonthe wheelpass smoothly
throughthe slotsinthe conveyor.
Clipcableinto
positionasshown.
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