Neopost DS-600i User manual

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NEOPOST TECHNOLOGIES LTD
Dynamic Envelope Printer (DEP)
User Guide
DS-600i/200i/FFI
Issue 3.0
10/08/2017

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Revision Level
Version
Change description
Released
1.0
New document - DRAFT
14 Feb 2017
2.0
New document
13 March 2017
3.0
Update
10 August 2017

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CONTENTS
Revision Level .....................................................................................................2
1.0 Technical Specifications ..................................................................................5
1.1 Max Speed by Pack & Output Options ......................................................5
1.2 Pack thickness for printing .....................................................................6
1.3 Printer Specifications .............................................................................6
1.4 Mechanical & Electrical ..........................................................................7
1.0 System Description ........................................................................................8
2.0 System Identification Key Equipment ...............................................................8
3.0 Switch ON Sequence ......................................................................................8
4.0 Creating a Job in IMOS ...................................................................................9
4.1 Scripting Modes ..................................................................................10
5.0 Creating a Project in Flexmail ........................................................................11
5.1 Introduction ......................................................................................11
5.2 Projects and Templates........................................................................11
5.3 Creating a customer ‘Project’ from the NTL ‘Template’ .............................14
5.4 Designing the print layout for the customers project................................18
5.5 Page Setup ........................................................................................20
5.6 DEP Paper Offset Settings ....................................................................23
5.7 Offsets U1 and U2...............................................................................24
5.8 Fonts + Layouts..................................................................................26
5.9 Print Quality DPI and Transport Speed...................................................31
5.10 Script and Printer ..............................................................................32
5.11 Print Orientation ...............................................................................33
5.12 IMOS Scripting modes .......................................................................34
5.12.1 Matching /DB lookup scripting mode .................................................34
5.12.2 Mail shot / Sequential (Non-Reset) ...................................................40
5.12.3 Matching/ Dynamic DB Lookup using AIMS ........................................43
5.13 Flexmail Automatic Updates (version 4.2) ............................................50
6.0 Printer print quality ......................................................................................52
7.0 IMOS Job Instructions...................................................................................52
8.0 Troubleshooting Information..........................................................................58

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1.0 Technical Specifications
Refer to the Technical Specifications located within the User guides for the DS600i / 200i / Output devices.
These documents will highlight the envelope sizes and pack thickness that can be accepted into the Dynamic
Envelope Printer (DEP), see below extract
1.1 Max Speed by Pack & Output Options
DS-600i
DS-200i

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1.2 Pack thickness for printing
1.3 Printer Specifications
Printer Type –Inject fixed head with automatic head positioning
Print Area
2 banks of Print Heads = 6 Total
Each capable of 38mm band across envelope
Total print area 76mm x width of envelope
Cartridges
Each bank uses 3 = 6 per system
From 10k-100k envelopes per set of cartridges
DS-
200i
DS-
600i

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1.4 Mechanical & Electrical
Dimensions LxWxH (unboxed):
880mm x 740mm x 330mm (34.6” x 29.1” x 13.0”)
Weights (unboxed) :
92Kg / 202.8lbs
Electrical: Frequency:
100-240VAC 50-60Hz
Operating Temperature:
18 - 28 deg C (64 - 82 deg F)
Operating humidity:
30 - 80% RH

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1.0 System Description
The Dynamic Envelope Printer (DEP) option is now available online to the inserter which
allows you to print on the envelope after it has been enveloped.
It uses a Neopost AS3060A inject printing system along with Flexmail software to
control the printer.
Full user manuals for the DEP and Flexmail are available from the Neopost Web page
kb.neopost.com
2.0 System Identification Key Equipment
3.0 Switch ON Sequence
To ensure correct communications is established, all modules are correctly detected,
follow the following switch on sequence
First - Output devices (e.g. INF module or Sorters (if fitted)
Followed by - DEP and Flexmail PC
Last - Inserter then IMOS PC
In the event you have to switch off any part of the system, ensure the Inserter
and IMOS PC is always the last equipment to switch ON.

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4.0 Creating a Job in IMOS
The job can be created in the usual way, refer to the DS-600i/200i user guides for
details.
The DEP can be enabled in the Output setting screen (section 6) of the Job
programming wizard
EXPLANATION
Flexmail
Master
Script
Name
Must match the script set in Flexmail
(case sensitive)
Scripting
Mode
Determines how the data base is
used for printing (see next table)
Lookup
Must match the heading of the
column in the database that contains
information that links to the
document
Head
heights
Must be set to the thickest pack fed
and current height of print heads at
beginning of job.
Dynamic
Head
mode
When this feature is active, operators
will be asked to adjust the printer
head height for the relevant pack
thickness. If a thicker pack is fed, the
machine will stop, holding the
envelope at the output rollers, give
instructions to position the height of
the head before continuing. (This
avoids printer heads from becoming
damaged).

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4.1 Scripting Modes
There are 5 scripting modes that can be selected in IMOS
Scripting Mode
Description
Pass through
No printing
Mail shot / Sequential
The printer works through and
prints the data held in Flexmail
onto the envelopes.
Matching /DB lookup
Matching Lookup
Printer matches contents of
barcode (data logging
characters) to Flexmail data
base. (See table)
Mail shot / Sequential
(Non-Reset)
Sequential (non reset)
Same as Mail shot / sequential
but data base does not reset
when changing jobs in IMOS.
Matching /Dynamic
DB lookup
Dynamic Lookup
Same as Matching /DB lookup
but database data is held in
AIMS. (only works with AIMS
500/1000 and when Flexmail is
networked to AIMS)Flexmail will
need a generic data base for
this scripting mode which will
be found in
C:\Users\Public\Documents\Flex
Systems\FlexMail 4.2\DEP
Dynamic\Example Databases,
and is called DEP Dynamic
Lookup

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5.0 Creating a Project in Flexmail
5.1 Introduction
This part of the document explains the setup procedure for using the Flexmail v4.2 (or
above) software with the DS-600i/200i for controlling the DEP
The DEP printer is controlled by a software application called Flexmail. This software
application sends commands to the printer as well as the data that needs to be printed
on the envelope. The DS-600i/200i communicates with the Flexmail software
application via a script file.
For more detailed information on using the Flexmail application see Flexmail ‘Getting
Started’document in the Flexmail application.
Flexmail requires a project to be setup for each printing application. The project
determines the Envelope size, the print head position, the data to be printed, where
the data is stored as well as many of customizable settings (DPI, orientation, etc.)
For a brief video introduction, Please follow this link http://www.flex-
systems.com/Help/HelpVideo.aspx
5.2 Projects and Templates
Important Note!
NTL provides both sample Flexmail ‘Projects’ and sample ‘Templates’, which include
databases, test documents, AIMS configurations and JAF files, etc. These projects and
templates ensure that ALL DEP settings are correct before starting to create customer
projects for the DEP
Testing during installation
It is recommended that:-
a) During installation and commissioning the sample NTL Flexmail Projects are
used. These can be found in:-
C:\Users\Public\PublicDocuments\FlexSystems\FlexMail 4.2\Projects\Neopost
Samples
Both US and European version are supplied
If you choose NOT to use the NTL templates then you must ensure that you set:-
Envelope size (go to File - Page Setup)
Position of the Print heads relative to the Envelope (select the rule on the left hand
side and drag the print heads to the desired location. Repeat for U1 and U2)

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Position of Variable data (picture) (double click the picture to select the source,
click and drag to re-position)
Fields to be used in the variable data (text) (dependent on the database mapping
field names) (Double click on the text box and select the required fields to be
printed) (click and drag to re-position) (Create new text boxes if required)
DPI required (400DPI (2x6) for DS-200i/600i
Recommended Transport Speed 1500 mm/s for DS-200i/600i
Position of fixed data (if any required)(click and drag to re-position)
Load the Flexmail application
Select File and then open a ‘Project’
Select the project ‘NTL Generic US (or European).fm4’
If Flexmail cannot find the database then in Flexmail browse to:-
C:\Users\Public\PublicDocuments\Flex Systems\FlexMail 4.2\Example Databases
See also Creating a Customer Project
And choose ‘DEP Test Generic 2.xls’
To obtain test stationery browse to the following directory:-
C:\Users\Public\PublicDocuments\Flex Systems\FlexMail 4.2\Test Documents

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Use the document ‘TEST Generic USA (or A4)’
If you want to work with AIMS browse to the following directory:-
C:\Users\Public\PublicDocuments\Flex Systems\FlexMail 4.2\AIMS
Use the AIMS configuration, NTLJ1.txt, and AIMS JAF, 95136547852196.NTLJ1,
specifically for use with this test document
For complete guide of printing with AIMS, see 5.13

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5.3 Creating a customer ‘Project’ from the NTL
‘Template’
Recommended method!
Begin by opening Flexmail
From here the default template will open and will look like below
For variable printing you will need to import a database.
This is what is used to determine which address is printed on which envelope. This
database also contains all of the variable data that is going to be printed on the
envelope.
A link in the project needs to be set to the required database.
Depending on scripting mode the database will need to contain a ‘Lookup’ field so the
correct address information can be looked up in the database and printed on the
correct envelope. All databases MUST have column headings in the database so that
they can be defined as an envelope Lookup field within the project

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To link a database to a project or change to a different database in the same
project proceed as follows:-
Select the Datasheet tab (A above), DEP Test Generic 2.xls in our example
Then select the Data Tab (B above)
Select the database file format (Access, Excel, Text, etc.) or press more for other types
(C above)
Select the desired database file from the saved location
Then follow the on screen wizard to select the required range (typically the correct
worksheet from a multiple worksheet Excel file).
A
B
C

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Also define that row 1 contains column headings
The database is now linked to the project and the column headings used in the design
of the envelope layout to determine what data is printed where
Enable the option: First row contains field names
Then select finish.

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The project will now open as shown below as ‘Project1’ –FlexMail 4’
Before making any changes save this project as your customer’s named project. To do
this, go to File, Save As, FlexMail Project
In this example we have called the customer’s project ‘Customer 1’

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Now you are ready to design the customer’s project
5.4 Designing the print layout for the customers
project
The ‘Designer’ tab can now be selected
Select the Designer tab (see A)
The designer part of the project sets up all physical aspects, rather than data, of the
item to be printed. This includes:
Envelope size.
Print Head Position.
Position of variable data.
Position of fixed data (if any).
Printer Settings (print quality etc)
There are two important areas of the screen to view while working on the design layout
as follows:-
a) On the left hand side is a pictorial view of the envelope and the print heads
A

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b) On the right hand side, under the ‘WORKSPACE’ tab is a table view of the fields
in the database followed by the construction in designer
The images below show the structure of the project derived from the sample
template ‘NTL Generic US (or European)’

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Begin changing the template by selecting the envelope size (as it enters the printer)
On the designer tab, select page size
Page type always Full page
Paper size selected from list or ‘User defined size’
Example shown is for a #10 envelope 4 1/8” (241mm) x 9 ½” (105mm)
This panel clearly shows:-
a) The datasheet in use (DEP Test Generic 2.xls)
b) The datasheet columns ([PieceID] through to [Match])
c) Designer tree with named layouts and their content
Before adding any new customer design to the project delete any unwanted images,
text fields, barcodes, etc.
5.5 Page Setup
NOTE
If you change the paper size from the NTL
Generic template to a new paper size, say 6”
x 9.5”, then you need to repeat the page
setup for each layout