Opex MPS 40 User manual

MPS 40
Operators Manual
©OPEX Corporation 1997
305 Commerce Drive • Moorestown, NJ 08057-4235 USA
Phone [phone] • Fax [phone]
P/N 3012900

Copyright 1998, Opex Corporation. All Rights Reserved.
Copyright
Information Copying, duplicating, selling or otherwise distributing any part of this manual or the
information contained herein without the express, prior written consent of an authorized
representative of Opex Corporation is strictly prohibited.

From the President of
OPEX Corporation
We’re excited about the possibilities to better serve our customers
with the MPS-40!
Welcome to the future of Mail-Sorting! For years now OPEX has streamlined the
sorting of mail. Our expertise led to industry changing technologies and provided
methods of sorting large amounts of incoming mail efficiently and accurately. Now the
next generation of mail sorting is here.
The MPS-40 is our latest advance. This new machine will continue to enable mail
rooms to sort based on thickness, length, the presence or absence of a check, metals
such as staples and paper clips, PostNet Barcodes and Custom Barcodes. Depending
on the needs of the process, selected envelopes can even be milled open on the fly. In
addition we have increased the speed to 40,000 per hour and added many new features.
These features include OCR and MLOCR, all of the usual Outgoing Mail types of pre-
sorts, the full range of Postnet barcode spraying and verification functions, and sort
groups and bins with up to 256 different combinations.
All of these capabilities are modular in nature. You need purchase only those modules
that your application requires. Some MPS-40’s may be specifically set up to sort
incoming mail, others may be prepared for outgoing mail or a combination of both.
Whatever the application the key to this fully automated process is the MPS-40
OPERATOR. We’ve gone to great lengths to design our equipment to be user
friendly, and I believe you’ll be pleased with the results we’ve achieved.
Thank-you for taking the time to familiarize yourself with the contents of this manual.
We recognize that you the operator are important to the overall performance of the
machine.
Sincerely,
OPEX Corporation
President
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Table of Contents
Introduction 5
Incoming Mail 5
Outgoing Mail 6
Before You Begin - Safety! 7
Machine Overview 7
The MPS-40 Main Controls 8
Before You Start 9
Loading the Mail 9
Loading the mail During Operation 10
Emptying the Sort Bins 10
Main Screen 12
Login Screen 13
Password Screen 13
Select Job Screen 14
Job Select Screen 14
Run Screen- (Idle) 15
Run Screen – (Running) 16
Loading the mail During Operation 16
Emptying the Sort Bins 16
Stacker Area 17
Overhead Mail Racks 17
Sort Bin Area 17
Emptying Sort Bins (cont.) 18
Machine Jams 18
Clearing a Jam 18
Clearing Jams (cont.) 19
Tips 19
ReRuns and Rejects 19
Sample Screen 20
Sample Statistic Screen 20
Completing the Job 21
Statistics 22
Access to Statistics 22
Summary 22
Summary Report (Sample) 23
Individual Report (sample) 23
Accessing Stats (cont.) 24
Statistics Report Criteria Screen 25
Appendix A – Error Messages 26
Jam information Basics 26

5
Overview of the MPS 40
Introduction
The MPS40 (Multi-Purpose Sorter) is just that - the most versatile sorter on the
market. The MPS-40 is a workflow tool that aids you and your shop in achieving
the utmost in productivity and accuracy. The MPS-40 is modular and customizable.
It can be used as both an incoming and outgoing sorter. The major modules
include:
Justifier Module – Corrects skew, justifying envelopes misaligned due to
damage or anomalies in feeding. This module can be configured with or
without an OPEX image camera.
Incoming Module – Provides thickness, length, MICR, and metal detection,
as well as check orientation.
Selective Cutting Module – Mills open selected sort groups, adjustable from
no cut to 1/8 of an inch.
OPEX Image Module – Allows for PostNet Barcode reads, mark detect, and
OCR reads.
Habitech Image Module – Allows for PostNet Barcode and multi-line OCR
reads.
Delay Module – Lengthens the paper path to allow enough time for proper
decision making.
Additional Output Bins – Allows for up to 256 sorts.
Overhead Mail Rack – Provides a place to rest standard mail trays for easy
clearing of the stacker bins.
Incoming Mail
When used to sort incoming mail, the MPS40 facilitates improved prioritization of
incoming mail. Even before the envelope is opened, the MPS40 can make
determinations about the contents.
The MPS40 can determine:
How many pieces of paper are in the envelope
Length of the envelope
Presence of a check in the envelope
Orientation of the check

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Presence of a credit card in the envelope
Presence of extraneous metal such as coins, paper clips or staples
Intended recipient if equipped with barcode read capability
The MPS40 then sends the mail based on these criteria to the proper pre-
programmed output pockets. The MPS40 can sort the mail in any combination of
the above criteria. The machine can selectively mill open any designated sort
group. Once the work is sorted into the correct groupings, each type of work can be
routed to the appropriate department for expedited handling.
Outgoing Mail
When used to sort outgoing mail, the MPS40 provides for improved accuracy and
throughput. The paper path of the machine and the Jam control features assure ease
in handling even the most difficult of Post Office acceptable first class mail.
The MPS40, equipped with the necessary modules and software, can:
Read fixed and/or wide area barcode
Single and/or multi-line OCR
Spray PostNet barcode
Support RVE
Verify barcode accuracy (ABE)
Utilize FASTforward change of address software
Reports are easily accessible and printed in formats required by the USPS.
Even with all of its advanced features, the MPS40 is operator friendly; the NT-
based software makes programming and running jobs very easy. And the
engineers’ attention to detail makes the MPS40 easy to service. The MPS40
incorporates the best in market-proven technology with new developments to
provide for state of the art performance.
We thank you for your trust in OPEX’s people and products.

Before You Begin - Safety!
The MPS-40 has
been designed
with safety in
mind. Our
engineers have
incorporated
specific safety
systems into the
machine. Do not
at any time
bypass, or
disable any
safety feature.
 Module Covers – Each module has been designed with a clear cover.
These covers allow the operator to see the paper path and important
hardware. If a cover is opened while the machine is running a safety
interlock will stop the machine. The safety interlock will need to be re-
set after the cover has been opened in order for the machine to re-start.
Press the “ON” button to re-set the interlocks.
 Panic Buttons – Red emergency buttons are designed into the machine
and located in several locations to enable a quick stop of the machine.
 Do Not Attempt to Disable Safety Features!
Machine Overview
Wear appropriate clothing. Neckties, scarves, and loose-fitting clothing are
potentially hazardous around any moving piece of equipment.
On/Off Buttons
Covers w/Interlocks
Panic Buttons
Long Hair – If you have long hair - tie back while you are working.
Listen to your machine – You will grow accustomed to the sound of the machine
when it is working properly. Report any unusual sounds to you supervisor.
7

The MPS-40 Main Controls
1. “ON” button. The on button begins the process of turning on the machine. You
must first press the “OFF” button to the recessed position.
2. “OFF” button. Pressing the “OFF” button at any time will turn off the machine.
Before you press the “OFF” button, make sure you have returned to the Main
“Sign-on” screen.
3. Monitor - The MPS-40 monitor displays important information to the operator.
4. Keyboard - The traditional keyboard enables the operator to enter his or her
password, choose a job, or access any menu item by using the “Function” keys
as needed.
5. Mouse - A common mouse allows the operator to click any on-screen command
as needed.
6. Optional Computer Select Module. This allows the operator to select an
optional computer to be displayed on the monitor.
Mouse
Keyboard
Computer Select
“OFF” button
“ON” button
Monitor
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Before You Start
The MPS-40 requires some simple cleaning in preparing to run your mail. Your
OPEX Sales Engineer, OPEX Service Technician, or your Supervisor will instruct
you in some basic cleaning. This is a simple, yet necessary part of the operator’s
job. It will directly affect the smooth operation of the machine.
These duties are:
1. Vacuuming, all areas of the paper path. This includes the feed area, modules, and
stackers.
2. Clean LVDT.(if present)
3. Clean all sensors by using by using compressed or forced air.
4. Blow any loose paper scraps away from sensors, belts, or other devices as needed.
5. Check the trash receptacle associated with the milling cutter. (if present)
In the event of a poor running machine stop the machine and perform routine
cleaning. This minimal investment of time will pay off in the long run.
Loading the Mail
Loading the machine is easy. Follow the simple steps outlined below and you will
find that the MPS-40 has been designed to make your job easy.
1. Position trays of mail in USPS mail trays near the feed or use the optional mail tray
holders.
2. Use two hands to grasp a section of mail from the mail tray. Remove any obviously
damaged or “extra thick” mail.
3. Load the mail on the feed conveyor with the address side of the envelopes facing away
from the feed. The first envelope and subsequent envelopes should stand vertically
parallel to the input area.
4. Load the entire feed with mail before starting the machine. The mail at the end of the
feed should lean towards the feed
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10
Loading the mail During Operation
Once you have chosen the Run Continuously option the MPS-40 will run until all
of the mail has been sorted, the machine jams, or until the Feed is out of mail. So
that the machine does not stop because of an empty feed, the operator will need to
pay attention to keeping the feed area loaded with mail. With practice, the operator
will grow accustomed to transferring mail from mail trays to the feed area.
The MPS-40 has been designed to run with one operator in its base configuration.
Emptying the Sort Bins
Plan ahead. Empty mail trays should be available to empty the sort bins. Make
sure that you place the sorted mail in the correct trays. Optional mail racks above
the sort bins may be used to place empty mail trays, or aisle racks may be used.
Whatever the method of emptying the bins, always keep a balance between the
feeding of unsorted mail and the emptying of sorted mail.

11

Main Screen
Also known as the Home Screen, Sign-on or Sign-off Screen
Information
Screen – contains
Machine name
and Software
Version
Help Button
Click with the
Mouse or press
F1
Clicking with the
mouse or
pressing F3 will
go back one
screen
Clicking with the
mouse or
pressing F4 will
go forward one
screen
Clicking with the
mouse or
pressing F5 will
open the
Operator Login
Screen
OPEX-Pop Up
Menu Button
Click with the
Mouse or press
F2
From this Main Screen all other machine functions can be accessed. For security
purposes before you can run the machine you must LOGIN.
The LOGIN feature assures that statistics and other vital job information is
recorded accurately.
Simply click the LOGIN button or press F3.
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Login Screen
When the operator chooses the LOGIN button (see previous page) the LOGIN
screen appears as below.
Select the correct operator name using either the mouse (highlight and click), or the
up or down arrow keys and the Enter on the keyboard.
Password Screen
Using the keyboard – type in your password.
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After typing in your password click on the LOGIN bar just below the dialogue
window or press enter on the keyboard
Select Job Screen
The next window to appear will be the window that lists the jobs that have been pre
programmed into the MPS-40 by your OPEX service technician. Determine which
job needs to be run and select it by highlighting it with the mouse or arrow keys.
Simply double-click on the highlighted job or a single click on the Select toolbar just
below the job list or use the keyboard and press Enter.
Job Select Screen
By now you have figured out that the MPS-40 operator interface is very user
friendly. Most functions can be selected either by using the mouse or keyboard.
After choosing the job the Run Screen will appear.
14

Run Screen- (Idle)
Please take a moment to familiarize yourself with the Run Screen Below
15
Important
directions
for loading
the mail
Run Buttons – Allows the operator or technicians to
confirm job settings prior to continuous operation
Statistics
for job in
progress
Confirm the
correct job
and
operator
name
before
beginning
the job
Information TABS –Groups, Re-runs, StatRpt,
Feedinfo, Images. Each Tab will have detailed
information related to job performance.
The Run Buttons allow the operator to run a single envelope through the MPS-40.
 Run 1 - allows you to make sure that the envelopes are feeding properly, that the belts
and sensors are clear, and that the entire paper path is clear.
 Run 5 - allows you or the technician to gradually increase the number of envelopes
run to perform various diagnostic tests.
 Run 25 – allows a final test of the machine before running continuously.
 Run Continuously – When all preparations are made and you are ready to begin.

Run Screen – (Running)
While the
machine is
running
information
regarding the
performance
of the
machine is
displayed.
Note: Simply
click on
Cancel (F5)
or press
escape on the
keyboard to
stop the Feed.
Loading the mail During Operation
Once you have chosen the Run Continuously option the MPS-40 will run until all
of the mail has been sorted, the machine jams, or until the Feed is out of mail. So
that the machine does not stop because of an empty feed, the operator will need to
pay attention to keeping the feed area loaded with mail. With practice, the operator
will grow accustomed to transferring mail from mail trays to the feed area.
The MPS-40 has been designed to run with one operator in its base configuration.
Emptying the Sort Bins
Plan ahead. Empty mail trays should be available to empty the sort bins. Make
sure that you place the sorted mail in the correct trays. Optional mail racks above
the sort bins may be used to place empty mail trays, or aisle racks may be used.
Whatever the method of emptying the bins, always keep a balance between the
feeding of unsorted mail and the emptying of sorted mail.
16

Stacker Area
It is very convenient to use the optional over head mail rack for the placement of
mail trays. Note how easy it is to locate the proper mail tray above the sort bin for
easy unloading of the stacker bins.
Overhead Mail Racks
Sort Bin Area
As the individual bins fill the
mail will gently fall forward
outside of the wire bale.
Allow enough mail to fall and
then grasp a comfortable
handful to place in the correct
mail tray.
17

Emptying Sort Bins (cont.)
Near each sort bin is a red indicator light. The red light serves several purposes in
the regular operation of the machine.
1. Bin Full – The light comes on and stays on when a bin is full. If there are not other
bins assigned to the same sort group the machine will stop.
2. Bin Almost Full – The light will flash when the bin is nearly full. The operator will
still have a short time to empty the bin.
3. Bin Override – In the event of a problem in a particular sort bin, the red button can be
pushed taking the bin out of service. This should almost never be used but has been
included to give flexibility when more than one bin has been assigned to the same sort
group.
Machine Jams
Even though the machine has been correctly loaded with mail that is in good
condition with no visible damage or visibly ”thick” envelopes – there will be
conditions that cause the machine to stop due to Jams.
Jams can be cleared in an efficient and logical way and the machine can be re-
started easily without loss of productivity.
In the event of a machine stoppage due to a jam the operator is prompted as to
where the jam has occurred so steps can be taken to clear the jam.
Clearing a Jam
1. Look at the Main Screen for a dialogue box describing the Jam.
Once the
Jam has
been
cleared
simply click
on continue
with the
mouse or
press Enter
on the
keyboard
The machine
will stop and
immediately
display a
message
noting where
the jam has
been called
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19
Clearing Jams (cont.)
2. Allow all belts and motors to stop completely before opening a cover or attempting to
clear the jam.
3. If the jam is behind one of the covers, open the cover on the section of the machine
where the jam has occurred. Carefully remove the jammed or damaged envelopes from
the paper path by gently pulling them out.
4. If the jam is in the sort bin area, carefully examine the paper path for any damaged or
jammed envelopes. Carefully remove the Jam making sure that belts and pulleys are
not dislodged.
5. Close all covers! The covers contain safety interlocks that will not allow the machine
to be restarted if left open.
6. If you have opened covers make sure to press the “ON” button (the on button light
should come on) in order to re-start the machine.
7. Appendix A contains a listing of jam messages and how to handle them.
Tips
1. Take your time. Most jams can be cleared in about 20 seconds or less.
2. You will develop the ability to identify jams by ear.
3. Some jams may be difficult. It may be necessary to move belts by pulling or pushing
on them. Always push the belts in their usual direction of travel.
ReRuns and Rejects
The MPS-40 has the ability to distinguish between envelopes that are rejected for
legitimate reasons (damage, unreadable barcodes, too thick etc.), and those which
are only sent to the rerun bin because of Jam clearing procedures. Generally
speaking, the operator can distinguish these items from one another. True ReRuns
can be rerun on the machine while mail designated as rejects must be processed by
hand.
The operator can get accurate information regarding the count of the mail in the
ReRun/Reject bin by clicking on the Tab marked ReRun.
The screen on the next page illustrates how to view detailed information about the
envelopes which have been sent to the ReRun bin and for which reasons.

Sample Screen
Click on ReRun Tab with mouse to
display detailed ReRun information
This screen
can be
displayed
either while
the machine is
running or as
seen above in
the Idle mode.
Notice that
several
categories are
described as
possible
reasons for
envelopes to
be sent to the
ReRun bin
Sample Statistic Screen
Any of the Tab buttons may be clicked with the mouse to obtain additional
information.
One of the
valuable tools
is the use of
the Statistics
Tab.
This screen
provides up to
the minute
detailed
information
about the Job
currently
being run.
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