Direct Connect

Service Manual

Release Date: October 2003

SV#: 41085-SM
documentation
created by
Tech Pubs:
Isabel Domber

Subject Matter Experts:

Dean Aufmuth, Mike Compos, Keith Douglas, Mike Knezel, John Methias, John Young, Bert LaFrieniere
(TSS)

Manager:
Eric Kothe

©2003 Pitney Bowes Inc.

All rights reserved. This book may not be reproduced in whole or in part in any fashion or stored in a retrieval system
of any type or transmitted by any means, electronically or mechanically, without the express written permission of Pitney
Bowes.

The use of this information by the recipient or others for purposes other than the training of customers on Pitney Bowes
equipment may constitute an infringement of patent rights and/or other intellectual property rights of Pitney Bowes
or others, and Pitney Bowes assumes no responsibility for any such use of the information.

We have made every reasonable effort to ensure the accuracy and usefulness of this manual. However, we cannot
assume responsibility for errors or omissions or liability for the misuse or misapplication of our products.

Except as provided in writing, duly signed by an officer of Pitney Bowes, no license either express or implied, under any
Pitney Bowes or third party’s patent, copyright or other intellectual property rights is granted by providing this
information.
 Direct Connect Service Manual

CAUTION
This manual shows how to access every parameter in Direct Connect (DC).
However, it doesn't provide the information, experience or personal insite
needed to correctly adjust every parameter.

• Make changes with great care.

• Do not change defaults without consulting TSS.
• Using “hold off” on any Photo Cell can change the way the machine
transfers information.
• If you have to use “hold off” on a through beam PC, it is an indication
that something else is wrong.
• Be very careful when changing the Overlap mode (may, never or always)
PC parameter. You may not transfer data correctly. The most critical areas
are the Transport (or Buffer) and the Takeaway.

Version History
The table below summarizes the history of this document. It identifies the version, date of
issue and revisions and changes.

Version Date Changes

SV 41085-SM 10/2003 Initial release

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Direct Connect Service Manual

Direct Connect Version

Most of the screen captures in this book are taken from Version 1.60.0093(D) of Direct
Connect.

Figure 1: Determining the Direct Connect Version

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 Direct Connect Service Manual

Related Documents
SV Number Document Name
Direct Connect Operator’s Guide
SV41105 OG Available on line at
http://pmweb.ct.pb.com/home/custser/cswebsite/Docs.cfm
SV41102 SM R400 and R600 (7/8 and 9 Series) Console Inserter System
Available on line at
http://pmweb.ct.pb.com/home/custser/cswebsite/Docs.cfm
SV41044 SM 11/12 Series Service Manual

SV 41112-SM FlowMaster Installation/Setup and Service Manual

Available on line at
http://pmweb.ct.pb.com/home/custser/cswebsite/Docs.cfm

Direct Connect Fact Sheets/White Papers

Available on line at:
http://pmweb.ct.pb.com/home/se/sseweb/index.cfm
Pitney Bowes Console Specification Book (Spec Book)
Available on line at
http://pmweb.ct.pb.com/home/custser/cswebsite/Docs.cfm

SV41085-TR Direct Connect Prerequisite Primer (distributed before DC

training class)
Direct Connect Training Manual (distributed at DC training
class)

AD11502 Design and Administration Handbook for File Based Direct

Connect Applications - available at:
http://pmweb.ct.pb.com/home/se/sseweb/index.cfm
SV41128-ADG Direct Connect Application Design Guide - available at:
http://pmweb.ct.pb.com/home/se/sseweb/index.cfm

SV 41085-SM v
Direct Connect Service Manual

Acronyms and Abbreviations

The following acronyms and abbrviations arereferred to throughout this manual.

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SV 41085-SM vii
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Typographical and Keyboard Conventions

Use this section to define any particular type faces, text formats and keyboard conventions
that are use throughout this manual.

viii SV SV 41085-SM
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Chapter Summary
The following chapters are included in the Direct Connect Service Manual. A very detailed
Table of Contents follows this section.

Chapter 1 – Introduction
• Overview of DC
• DC architecture
• Mailpieces and Direct Connect
• Integrity
• Networked and file-based processing
• Server directories and files
• Application Flow
• Users and privileges
• Modes
• PBDesktop
• Directory setup
• DesktopVB.ini.

Chapter 2 – Screens, DC Objects and Software

• System model
• Operator controls
• Modes
• Operating systems
• Encoder/multibus/DigiBoard/RocketPort
• 8051 configuration
• Log files
• Diagnostic dumps.

Chapter 3 – Chassis and Feeder Setup

• Basic, advanced and expert chassis setup
• Advanced and expert feeder setup
• Feeder channel setup
• Enabling the collation detect photocells.

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Chapter 4 – Transport
• Transport setup
• Brakes and Clutches
• The debounced photocell
• Transport error detection
• Transport gate solenoid setup
• Motor startup and acceleration
• Bingo diagnostics and status
• Solenoid test options
• 8051 board.

Chapter 5 – Accumulator, Folder, LoCap Divert

• Basic and advanced upper and lower accumulator setup
• Folder, locap divert setup
• Accumulator debounced photocell
• Error detection
• Motor startup, stop, acceleration and deceleration
• Bingo diagnostics
• Solenoid test options• 8051 board.Chapter 6 – MOS
• Theory of operation

Chapter 6 - MOS
• Basic elements
• Initial MOS tuning
• MOS and trayer tuning
• Module base settings
• Takeaway basic, advanced and jam setup
• Sealer, basic and advanced sealer setup
• Edge marker basic and advanced setup
• Vertical stacker basic and advanced setup
• Vaetical stacker objecand PC1 advanced and jam setup
• Mailing machine and meter channel basic, advanced and expert setup
• IST (trayer) basic and advanced setup.

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Chapter 7 – Boards and Proms

• Proms
• Boards
• Bingo diagnostics and status
• Solenoid test options
• 8051 Board.

Chapter 8 – Direct Reports

• Description of Direct Reports
• The Direct Reports configuration setup and advanced setup
• Tweak
• Reports program
• DC.ini
• MachineID and MachineName
• JobID
• Data map setup
• Data collection process
• Other features.

Chapter 9 – ESTOP
• Circuit description
• Troubleshooting procedures.

Appendix A - Physical Connections

Glossary

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DIRECT CONNECT SERVICE MANUAL

TABLE OF CONTENTS

CHAPTER 1: INTRODUCTION ............................................................ 1

Table Of Contents............................................................................... 3

OVERVIEW .......................................................................................... 5
History .................................................................................................................................................5
Direct Connect (DC) and Increased Integrity ...........................................................................6

DC ARCHITECTURE, DIFFERENCES BETWEEN DC & ISC 2.0 .............. 7

Centralized Control ..........................................................................................................................8
Object Oriented Software Design ................................................................................................8
CMMObjects......................................................................................................................................9
Display Object Function............................................................................................................... 10

MAILPIECES AND DIRECT CONNECT ............................................... 10

Bogies................................................................................................................................................ 11

INTEGRITY ........................................................................................ 13
Direct Scan (Non-File-Based) Processing................................................................................ 13
Bar Code Scanning.................................................................................................................... 13
Document Control and Tracking........................................................................................... 13
Direct Connect ............................................................................................................................... 14
Diverting Questionable Mail................................................................................................... 14

NETWORKED AND FILE-BASED PROCESSING .................................. 15

SERVER DIRECTORIES AND FILES ..................................................... 16

Input Files......................................................................................................................................... 16
Input File Requirements................................................................................................................ 16
Interlock Files .................................................................................................................................. 17
Output Files..................................................................................................................................... 17
Select Files ....................................................................................................................................... 17
Log Files............................................................................................................................................ 18
Directories and Drive Mappings.................................................................................................18

APPLICATION FLOW ......................................................................... 19

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EMBEDDED USERS AND PRIVILEGES................................................. 21

Access Levels................................................................................................................................... 21
Administrator.............................................................................................................................. 21
Engineer ....................................................................................................................................... 21
KeyOperator............................................................................................................................... 22
Manager ....................................................................................................................................... 22
Operator...................................................................................................................................... 22
Service .......................................................................................................................................... 22
Passwords......................................................................................................................................... 22
Directory Setup.............................................................................................................................. 23

MODES ............................................................................................. 24
Loading Modes ............................................................................................................................... 25
Creating And Saving Modes ........................................................................................................ 26
Directory Setup.............................................................................................................................. 26
Mode Updater ................................................................................................................................ 27

PBDESKTOP...................................................................................... 29
Accessing the PBDesktop ............................................................................................................ 29
Creating Users and Rights ........................................................................................................... 30
Creating, Editing and Modifying Users, Passwords and Rights...................................... 30
Maintaining Users .......................................................................................................................... 31
Adding a User............................................................................................................................. 31
Editing a User ............................................................................................................................. 32
Deleting a User .......................................................................................................................... 32
Changing the User .................................................................................................................... 33
Viewing/Changing the Current User .................................................................................... 34
Closing the PBDesktop................................................................................................................. 35

DIRECTORY SETUP ........................................................................... 36

Associated Files .............................................................................................................................. 36
Five Access Levels .......................................................................................................................... 36

DSKTOPVB.INI.................................................................................. 38
Changing Access Password.......................................................................................................... 38

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CHAPTER 2: SCREENS, DC OBJECTS AND SOFTWARE..................... 39

Table of Contents.............................................................................. 41

SYSTEM MODEL................................................................................ 43
Direct Reports ................................................................................................................................ 44
Reports Manager............................................................................................................................ 45
Accessory Manager........................................................................................................................ 46
Feeder Performance Manager ..................................................................................................... 47
Bingo Diagnostics .......................................................................................................................... 48
Bingo Status Dialog Box............................................................................................................... 50
Serial Port Diagnostics.................................................................................................................. 51
Scanner Objects ............................................................................................................................. 54
Scan Data Processor................................................................................................................. 54
Scan Processor........................................................................................................................... 56
Login Manager ................................................................................................................................ 57
Operator...................................................................................................................................... 58
Key Operator ............................................................................................................................. 58
Manager ....................................................................................................................................... 58
Administrator.............................................................................................................................. 58
Service .......................................................................................................................................... 58
Engineer ....................................................................................................................................... 58

OPERATOR CONTROLS.................................................................... 59
Start/Stop/One Cycle.................................................................................................................. 59
Hand-Crank Indicator ................................................................................................................... 59
System Menu Commands............................................................................................................. 59
Disable System........................................................................................................................... 60
Reset Counts .............................................................................................................................. 60
Load Mode .................................................................................................................................. 60
Clear Deck ................................................................................................................................... 60

MODES ............................................................................................. 61
Modes and Adjustment Parameters .......................................................................................... 61
Loading Modes ............................................................................................................................... 61
Creating a Mode............................................................................................................................. 63
Storing the Mode........................................................................................................................... 64
Mode Updater ................................................................................................................................ 65
Mode Comparison Feature .......................................................................................................... 67

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OPERATING SYSTEMS ...................................................................... 68

Startup Routines ............................................................................................................................ 68
Network Login ............................................................................................................................ 68
Network Login Using VLMs..................................................................................................... 68
Version Comparison Table...................................................................................................... 69
DC Startup to Edit a DCC File ............................................................................................... 70
Windows NT (Version 160 and Later) File Structure...................................................... 70
3.11 Windows File Structure ................................................................................................. 71
Files To Back Up in Version 160 and Later ........................................................................ 72
Direct Reports............................................................................................................................ 72
Server Drive Mapping............................................................................................................... 73

ENCODER/MULTIBUS/DIGIBOARD/ROCKETPORT ......................... 74
Tech 80 - 5312b Quad Encoder Board.................................................................................. 74
Quad Encoder Board Jumper Settings...................................................................................... 74
Differential Bus Board Jumper Settings .................................................................................... 75
Combination Differential/Encoder Board – ISA Type.......................................................... 75
Combination Differential/Encoder Board – PCI Type.......................................................... 75
Relation Between DigiBoard/RocketPort in Control Computer and the 8051 and
Bingo Boards................................................................................................................................... 76
Serial Communications with the DigiBoard ............................................................................. 77
Serial Communications with the RocketPort........................................................................... 77
Direct Connect and the Encoder ............................................................................................... 78

8051 CONFIGURATION ................................................................... 79

Standard Wiring for DigiBoard/RocketPort to 8051 Cards and Standard Bingo Wiring
............................................................................................................................................................ 79
Multibus Feeder Setup.................................................................................................................. 80
Wiring Differences for High Speed Machines.......................................................................... 80
Arming Feeders .......................................................................................................................... 80
High Speed Machine Chain Offset........................................................................................ 81

LOG FILES ......................................................................................... 82

Syslog.dat ........................................................................................................................................ 82

DIAGNOSTIC DUMPS ....................................................................... 85

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CHAPTER 3: CHASSIS AND FEEDER SETUP ...................................... 87

Table of Contents.............................................................................. 89

CHASSIS BASIC SETUP ..................................................................... 93

Collation Length............................................................................................................................. 93
Job Speeds ....................................................................................................................................... 94
Maximum...................................................................................................................................... 94
Nominal........................................................................................................................................ 94
Minimum ...................................................................................................................................... 94
Allow Data Control Stop.............................................................................................................. 95
Enable Collation Detect ............................................................................................................... 95
Maximum Time in Delay................................................................................................................ 96

CHASSIS ADVANCED SETUP............................................................. 97

Positions/Distances Area............................................................................................................. 98
Lead Edge Guard ....................................................................................................................... 98
Trail Edge Guard........................................................................................................................ 98
Encoder Times Area....................................................................................................................... 99
Stop Time.................................................................................................................................... 99
Exit Time ................................................................................................................................... 100
Adjusting Exit Time..................................................................................................................... 101
Start Timeouts Area Settings................................................................................................... 103
Start Timeout .......................................................................................................................... 103
Accelerate Time ...................................................................................................................... 103
Start Delay ............................................................................................................................... 103
Soft Delay Area Settings ........................................................................................................... 104
Predelay Coasting .................................................................................................................. 104
Brake “Tap” Time.................................................................................................................... 104
Stop Control Area Settings ...................................................................................................... 105
Stop Mode ............................................................................................................................... 105
Cycle Stop on Jams ................................................................................................................ 106
Complete Feeds After Stop ................................................................................................. 106
Inhibit Stops During Exit Time ............................................................................................ 106
Stop Timeouts Area Settings ................................................................................................... 107
Chassis Stop Timeout ........................................................................................................... 107
Feed Stop Timeout ................................................................................................................ 107
Brake On Time......................................................................................................................... 108
Chain Clutch Reenable Time ............................................................................................... 108
Alarms Enabled After Stop ................................................................................................... 108
Post Delay Hold...................................................................................................................... 109

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ADVANCED FEEDER SETUP.............................................................110

Feed Timings Group ................................................................................................................... 111
Dynamic Feed Time................................................................................................................ 111
Standard Feed Time............................................................................................................... 111
Check Time .............................................................................................................................. 111
Check Time Test..................................................................................................................... 112
Delay Time ............................................................................................................................... 112
Arm Time .................................................................................................................................. 113
Use Dynamic Feed Time............................................................................................................ 114
Hold Feeds When Chain Coasting .......................................................................................... 114
Dequalify on Door Opening ..................................................................................................... 114
Collation Detect Functions....................................................................................................... 115
Use Collation Detect PC ...................................................................................................... 115
Cycle Stop on Collation Detect Errors ............................................................................. 116
Delete Missing Mailpieces .................................................................................................... 116
Stop on Missing Mailpieces ................................................................................................. 116
Stop on Unknown Mailpieces.............................................................................................. 117
Dequalify Upstream On Missing......................................................................................... 117
Dequalify Downstream on Unknown ................................................................................. 117

EXPERT CHASSIS SETUP.................................................................118

Feeders Per Pusher ..................................................................................................................... 119
Station Offset Fields................................................................................................................... 119
Chain Offset Field ....................................................................................................................... 120
Pusher Size.................................................................................................................................... 120
Exit Offset ..................................................................................................................................... 121
Max Speed (CPH) ....................................................................................................................... 121

FEEDER CHANNEL SETUP ...............................................................122

Feeder Channel Offsets ............................................................................................................. 122
Station Offset Terms and Definitions ............................................................................... 123
Viewing Offsets in Direct Connect..................................................................................... 124
Feeder Channel Setup................................................................................................................ 125
Verify Insert/Collation Sequence ....................................................................................... 126
Feed Start Timeout ................................................................................................................ 126
Feed Timeout........................................................................................................................... 127
Refeed Delay............................................................................................................................ 127
Blink Period .............................................................................................................................. 127
Over/Under Kit Installed...................................................................................................... 128
Wiring Method ........................................................................................................................ 128

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EXPERT FEEDER SETUP...................................................................129

Locations Relative to Front of Feeder Area Settings ......................................................... 130
Collation Detect PC Location ............................................................................................. 130
Jam Wire Zone Start .............................................................................................................. 131
Jam Wire Zone End................................................................................................................. 131
Door Access Zone.................................................................................................................. 132
Door Access Zone Start ....................................................................................................... 132
Door Access Zone End.......................................................................................................... 133
Insert Drop Zone End............................................................................................................ 133
Return to Previous State After an Error ................................................................................ 133

ENABLING (INTEGRITY OR DECK) COLLATION DETECT PHOTOCELLS

.......................................................................................................134
Chassis Setup Dialog.................................................................................................................. 134
Feeder Setup Dialog................................................................................................................... 135
Collation Detect PC Location .................................................................................................. 136
Use Collation Detect PC ........................................................................................................... 137
Verify Insert/Collation Sequence............................................................................................ 137

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CHAPTER 4: TRANSPORT...............................................................139

Table of Contents............................................................................141

TRANSPORT SETUP........................................................................143
Timers ............................................................................................................................................ 144
Settling Time ........................................................................................................................... 144
Gate Clear Time...................................................................................................................... 144
Dispatcher Parameters............................................................................................................... 144
Max Nesting............................................................................................................................. 144
Min Spacing ............................................................................................................................. 145
Request When Clear .............................................................................................................. 146
Forward Multiple Requests When Hungry ....................................................................... 146

BRAKES AND CLUTCHES ................................................................147

Transport Gate Trap Setup/Timing Area Settings............................................................. 148
Timing Open Delay ................................................................................................................ 148
Timing Open Minimum.......................................................................................................... 148
Timing Closed Delay.............................................................................................................. 148
Timing Closed Minimum ....................................................................................................... 149

DEBOUNCED PHOTOCELL .............................................................150

Leading Edge ................................................................................................................................ 151
Nominal “Off “ Time............................................................................................................... 151
Always Hold Off ...................................................................................................................... 152
Hold “Off” Time ...................................................................................................................... 152
Trailing Edge................................................................................................................................. 153
Nominal “On” Time ................................................................................................................ 153
Always Hold On ...................................................................................................................... 154
Hold “On” Time ...................................................................................................................... 154
Invert Input ................................................................................................................................... 154

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TRANSPORT ERROR DETECTION – TRANSPORT GATES...............155

Detect Jams................................................................................................................................... 156
Jam Types Detected Group...................................................................................................... 156
Creation of Unknowns........................................................................................................... 156
Lead Edge Timeout ................................................................................................................ 157
Photocell Timeout.................................................................................................................. 157
Overruns Before PC ............................................................................................................... 157
Overruns At PC ....................................................................................................................... 158
Next Arrives Before PC Clear .............................................................................................. 158
Previous PC: Overlap Modes.................................................................................................... 159
Don’t Create Unknowns ............................................................................................................ 160
Ignore Unknowns at Start ......................................................................................................... 160
Jam Timeouts Under Photocell ................................................................................................ 161
Jam Timeouts Before Photocell ............................................................................................... 161
Determining Jam Timeout Settings......................................................................................... 161

MOTOR STARTUP AND ACCELERATION........................................162

Transport Advanced Setup....................................................................................................... 162
Motor On Delay .......................................................................................................................... 163
Motor Off Delay .......................................................................................................................... 163
Transport Accelerate Time ....................................................................................................... 164
Transport Deaccelerate Time .................................................................................................. 164
Dequalify Pieces When Interlock Opened ............................................................................ 165
In Own Stations ...................................................................................................................... 165
In Chassis Target Station ..................................................................................................... 165

BINGO DIAGNOSTICS ....................................................................166

BINGO STATUS...............................................................................168

8051 BOARD..................................................................................169

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CHAPTER 5: ACCUMULATOR, FOLDER, LOCAP DIVERT.................173

Table of Contents............................................................................175

ACCUMULATOR SETUP ..................................................................177

Accumulator Usage..................................................................................................................... 177
Collate Mode................................................................................................................................ 179
Errors.............................................................................................................................................. 179
System Stop ID............................................................................................................................ 180

ADVANCED ACCUMULATOR SETUP...............................................181

Flipper Up Time ........................................................................................................................... 182
Flipper Down Time...................................................................................................................... 182
Flipper Delay ................................................................................................................................ 183
Double Page Flipper Delay (Long Flipper Delay)................................................................ 184
Min Dump Spacing Time ........................................................................................................... 184
Max Nesting.................................................................................................................................. 185
Dispatch on Predictions ............................................................................................................ 185

UPPER AND LOWER ACCUMULATOR SETUP..................................186

Input Timeout .............................................................................................................................. 187
Enter Timeout .............................................................................................................................. 187
Settling Time ................................................................................................................................ 188
Clutch On Time ........................................................................................................................... 188
Dump Timeout............................................................................................................................. 188
Accumulator Exit Clear Time .................................................................................................... 189
Min Entrance Gap ....................................................................................................................... 189
Delay from Brake OFF to Clutch ON ..................................................................................... 189
Delay from Clutch OFF to Brake ON ..................................................................................... 190
Debounce PC2x........................................................................................................................... 190
Debounce PC2ax ........................................................................................................................ 190

FOLDER/LOCAP DIVERT SETUP......................................................191

Folder Setup ................................................................................................................................. 191
Elevator Down (No Fold Position).......................................................................................... 191
Advanced Folder Setup.............................................................................................................. 192
Virtual Photocell Delay ......................................................................................................... 192
Fold Plate Removed (Pieces Will Dump)........................................................................... 192

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ACCUMULATOR DEBOUNCED PHOTOCELL...................................193

Leading Edge ................................................................................................................................ 194
Nominal “Off“ Time................................................................................................................ 194
Always Hold Off ...................................................................................................................... 195
Hold “Off” Time ...................................................................................................................... 195
Trailing Edge................................................................................................................................. 196
Nominal “On” Time ................................................................................................................ 196
Always Hold On ...................................................................................................................... 197
Hold “On” Time ...................................................................................................................... 197
Invert Output ............................................................................................................................... 197

ERROR DETECTION ........................................................................198

Detect Jams................................................................................................................................... 199
Jam Types Detected ................................................................................................................... 200
Creation of Unknowns........................................................................................................... 200
Lead Edge Timeout ................................................................................................................ 201
Photocell Timeout.................................................................................................................. 201
Overruns Before PC ............................................................................................................... 202
Overruns at PC........................................................................................................................ 203
Next Arrives Before PC Clear .............................................................................................. 203
Previous PC Overlap Mode....................................................................................................... 204
Don’t Create Unknowns ............................................................................................................ 205
Ignore Unknowns At Start ........................................................................................................ 205
Jam Timeout Under Photocell .................................................................................................. 206
Jam Timeout Before Photocell ................................................................................................. 206

MOTOR STARTUP, STOP, ACCELERATION AND DECELERATION..207

Motor Startup.............................................................................................................................. 207
Settings.......................................................................................................................................... 208
Motor On Delay...................................................................................................................... 208
Motor Off Delay ..................................................................................................................... 208
Accelerate Time ...................................................................................................................... 209
Deaccelerate Time.................................................................................................................. 209
Setting Considerations.............................................................................................................. 210
Acceleration Mismatch.......................................................................................................... 210
Deacceleration Mismatch ..................................................................................................... 210
Deceleration Versus Operator Removal ........................................................................... 210

BINGO DIAGNOSTICS ....................................................................211

SOLENOID SQUARE WAVE TEST ....................................................213

8051 BOARD..................................................................................214

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CHAPTER 6: MOS .........................................................................2197

Table of Contents………………………………………………………..221

THEORY OF OPERATION................................................................225

BASIC ELEMENTS ............................................................................226

INITIAL MOS TUNING PROCEDURES..............................................228

MOS Velocities ............................................................................................................................ 228
IST Velocities................................................................................................................................ 228
Initial Tuning................................................................................................................................. 229
The MOS Run Out Test ............................................................................................................ 229
Immediate Stop Test.................................................................................................................. 230
Restart After Immediate Stop Test ........................................................................................ 231

MOS AND TRAYER (IST) TUNING...................................................232

Introduction.................................................................................................................................. 232
MOS and Trayer (IST) Issues................................................................................................... 232
Shift Configuration Versus Disabling Photocells ............................................................ 232
Motor Control......................................................................................................................... 233
Acceleration Mismatch.......................................................................................................... 233
Deceleration Mismatch ......................................................................................................... 234
Deceleration Versus Operator Removal ........................................................................... 234
Acceleration Timing ............................................................................................................... 234
Multiple Motor Controls and the Takeaway Chassis Interface................................... 235

MODULE BASE SETTINGS ...............................................................236

Motor On Delay .......................................................................................................................... 237
Motor Off Delay .......................................................................................................................... 238
Accelerate Time........................................................................................................................... 238
Decelerate Time .......................................................................................................................... 239

TAKEAWAY BASIC SETUP ...............................................................240

Mode .............................................................................................................................................. 240

TAKEAWAY ADVANCED SETUP ......................................................240

Motor Setup................................................................................................................................. 241
Motor on Delay....................................................................................................................... 241
Motor Off Delay ..................................................................................................................... 242
Accelerate Time ...................................................................................................................... 242
Decelerate Time...................................................................................................................... 243

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TAKEAWAY JAM SETUP...................................................................244

Detect Jams................................................................................................................................... 246
Jam Types Detected Group...................................................................................................... 246
Creation of Unknowns........................................................................................................... 247
Lead Edge Timeout ................................................................................................................ 247
Photocell Timeout.................................................................................................................. 248
Overruns Before PC ............................................................................................................... 249
Overruns at PC........................................................................................................................ 250
Next Arrives Before PC Clear .............................................................................................. 251
Jam Times and Tracking Unknowns ........................................................................................ 252
Merge Collations .................................................................................................................... 252
Previous PC Overlap Mode .................................................................................................. 253
Don’t Create Unknowns ....................................................................................................... 254
Ignore Unknowns At Start.................................................................................................... 254
Jam Timeout Under Photocell ............................................................................................. 255
Jam Timeout Before Photocell............................................................................................. 256
Determining Jam Timeout Settings......................................................................................... 257

SEALER BASIC SETUP......................................................................258

Sealer Control Selection Field ................................................................................................. 259
Error Detection Group............................................................................................................... 260
Missing Envelopes/High Seal Selectors ............................................................................ 260

ADVANCED SEALER SETUP.............................................................261

Sealer Features Group ............................................................................................................... 262
Missing Envelope Threshold ................................................................................................ 262
Missing Envelope Jam Timeout............................................................................................ 262
High Seal Jam Timeout .......................................................................................................... 262
No Seal Solenoid Hold On................................................................................................... 263
Sealer Motor Setup Group ....................................................................................................... 264
Motor On Delay...................................................................................................................... 264
Motor Off Delay ..................................................................................................................... 265
Accelerate Time ...................................................................................................................... 265
Decelerate Time...................................................................................................................... 266

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SEALER ELEMENT JAM SETUP .........................................................267

Element Setup >Detect Jams .................................................................................................... 268
Sealer Entrance/Virtual Mid Setup Jam Types Detected Group..................................... 269
Sealer Exit PC Setup Jam Types Detected Group .......................................................... 269
Creation of Unknowns........................................................................................................... 270
Lead Edge Timeout ................................................................................................................ 270
Photocell Timeout.................................................................................................................. 271
Overruns Before PC ............................................................................................................... 271
Overruns at PC........................................................................................................................ 272
Next Arrives Before PC Clear .............................................................................................. 272
Jam Times and Tracking Unknowns......................................................................................... 273
Previous PC Overlap Mode .................................................................................................. 274
Sealer Entrance/Sealer VMid - Don’t Create Unknowns/Ignore Unknowns at Start
.................................................................................................................................................... 275
Sealer Exit - Don’t Create Unknowns................................................................................ 275
Ignore Unknowns At Start (Sealer Exit PC) ..................................................................... 275
Sealer Entrance/VMid/Exit: Jam Timeout Under Photocell ......................................... 276
Jam Timeouts Before Photocell........................................................................................... 276

EDGE MARKER BASIC SETUP ..........................................................277

Leading Edge Mark Group ........................................................................................................ 278
As Accessory............................................................................................................................ 278
3 Digit Zip Code Change ..................................................................................................... 278
5 Digit Zip Code Change ..................................................................................................... 278
On Field Change ..................................................................................................................... 279
If Mailpiece is Unknown ........................................................................................................ 279
Trailing Edge Mark Group......................................................................................................... 280
Number in a Row to Mark..................................................................................................... 280

ADVANCED EDGE MARKER SET UP ................................................281

Marker Lead Edge Delay............................................................................................................ 282
Marker Trail Edge Delay ............................................................................................................ 282
Marker “On” Time ....................................................................................................................... 282

VERTICAL STACKER BASIC SETUP..................................................283

Mode Group ................................................................................................................................. 283
Mode Selector......................................................................................................................... 283
Classify as “Completed” When Selective.......................................................................... 284
Contents Label............................................................................................................................. 284
Outsort Unknowns ..................................................................................................................... 284
Force All “Bads” to Outsort...................................................................................................... 285

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VERTICAL STACKER OBJECT ADVANCED SETUP............................286

Motor On Delay .......................................................................................................................... 287
Motor Off Delay .......................................................................................................................... 287
Accelerate Time........................................................................................................................... 288
Decelerate Time .......................................................................................................................... 289

VERTICAL STACKER PC1 ADVANCED SETUP..................................290

Door Operation........................................................................................................................... 291
Hold Gate Open ..................................................................................................................... 291
Close Door on Lead Edge..................................................................................................... 291
Look Ahead to Previous Station ......................................................................................... 291

VERTICAL STACKER OBJECT PC JAM SETUP...................................292

Detect Jams................................................................................................................................... 293
Jam Types Detected Group...................................................................................................... 293
Creation of Unknowns........................................................................................................... 294
Lead Edge Timeout ................................................................................................................ 294
Photocell Timeout.................................................................................................................. 295
Overruns Before PC ............................................................................................................... 295
Overruns At PC ....................................................................................................................... 296
Next Arrives Before PC Clear .............................................................................................. 296
Tracking Unknowns and Jam Times ........................................................................................ 297
Previous PC Always/May/Never Overlaps....................................................................... 298
Don’t Create Unknowns ....................................................................................................... 299
Ignore Unknowns at Start .................................................................................................... 299
Timeout Under Photocell ..................................................................................................... 300
Jam Timeout Before Photocell............................................................................................. 300

MAILING MACHINE AND METER CHANNEL BASIC SETUP ..............301

Meter Setup.................................................................................................................................. 301
Error Handling/Not Metered Accessory .......................................................................... 302
Error Handling/Error Limit ................................................................................................... 302

MAILING MACHINE/METER CHANNEL ADVANCED SETUP .............303

Use Meter Interface.................................................................................................................... 303
Verify Trip From Meter .............................................................................................................. 304
Don’t Allow Zero Postage......................................................................................................... 304

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MAILING MACHINE/METER CHANNEL EXPERT (JAM) SETUP .........305

Motor Operation Group............................................................................................................ 306
Motor On Delay...................................................................................................................... 307
Motor Off Delay ..................................................................................................................... 308
Accelerate Time ...................................................................................................................... 308
Decelerate Time...................................................................................................................... 309
Detect Jams................................................................................................................................... 310
Jam Types Detected Group...................................................................................................... 311
Creation of Unknowns........................................................................................................... 312
Lead Edge Timeout ................................................................................................................ 313
Photocell Timeout.................................................................................................................. 314
Overruns Before PC ............................................................................................................... 315
Overruns at PC........................................................................................................................ 316
Next Arrives Before PC Clear .............................................................................................. 316
Ignore Unknowns at Start ......................................................................................................... 317
Jam Times and Tracking Unknowns......................................................................................... 318
Merge Collations .................................................................................................................... 319
Don’t Create Unknowns ....................................................................................................... 320
Jam Timeout Under Photocell ............................................................................................. 321
Jam Timeouts Before Photocell........................................................................................... 322
Determining Jam Timeouts................................................................................................... 322

IST (TRAYER) BASIC SETUP ............................................................323

Stacking Mode ............................................................................................................................. 324
Tail Kick Mode ............................................................................................................................. 324
Bin Done (When Full) Mode..................................................................................................... 324
Maximum Pieces Per Tray (in Count Mode)......................................................................... 325
Tray Breaks................................................................................................................................... 325
Trayer Setup>Default ................................................................................................................. 325

IST (TRAYER) ADVANCED SETUP ...................................................326

Motor On Delay .......................................................................................................................... 326
Motor Off Delay .......................................................................................................................... 326
Transport Accelerate Time ....................................................................................................... 327
Transport Decelerate Time....................................................................................................... 327
Bin Virtual PC Delay ................................................................................................................... 327
Drum Virtual PC Delay............................................................................................................... 328

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CHAPTER 7: BOARDS AND PROMS ................................................329

Table of Contents............................................................................331

PROMS............................................................................................333
Multibus Feeder Setup............................................................................................................... 333

BOARDS..........................................................................................333
Feeder Boards .............................................................................................................................. 333
New DC Systems......................................................................................................................... 333
Physical Connections ................................................................................................................. 334

BINGO DIAGNOSTICS ....................................................................335

BINGO STATUS...............................................................................337

SOLENOID SQUARE WAVE TEST ....................................................338

8051 BOARD..................................................................................339
Setup and Jumper Configuration............................................................................................. 341
8051 Configuration................................................................................................................... 342
Switches 4 and 6.................................................................................................................... 342
Wiring Connections .................................................................................................................... 342
Physical Connections ................................................................................................................. 342

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CHAPTER 8: DIRECT REPORTS .......................................................343

Table of Contents............................................................................345

DIRECT REPORTS (PRODUCTIVITY DATA COLLECTION AND

REPORTING)...................................................................................347
Direct Reports Test.................................................................................................................... 347
Productivity Data Collection Overview ................................................................................. 347

REPORT CONFIGURATION SETUP .................................................348

Single Inserter .............................................................................................................................. 348
Multiple Inserters ........................................................................................................................ 348
Collected Data Elements........................................................................................................... 349
Definition of Timer Elements.................................................................................................... 349
Setup.............................................................................................................................................. 350
Enable Productivity Data Logging...................................................................................... 350
Enable Productivity Data Logging...................................................................................... 351
Top 10 Error/Alarm Logging............................................................................................... 351
Enable Alarm Detail Logging................................................................................................ 352
Meter Info Database Format ............................................................................................... 352
Data Logging Directory ........................................................................................................ 353
Machine Delay (to User Fault) Rollover Period .............................................................. 353
User Stop as Machine Wait.................................................................................................. 354
User Stop Rollover ................................................................................................................. 354
Machine Wait Time Rollover to Operator Wait Time ........................................................ 355
Completed Pieces to Finish Startup .................................................................................. 356
Maximum Time to Correct Error (sec) .............................................................................. 356
Minimum Delay Time (ms) ................................................................................................... 356
Sampling Interval .................................................................................................................... 357

TWEAK (SETTING UP THE REPORT GENERATOR) .........................358

Definition Of Terms.................................................................................................................... 364
Associated Files ........................................................................................................................... 364

DIRECT REPORTS ADVANCED SETUP.............................................365

REPORTS PROGRAM ......................................................................366

Allow Reports to Run ................................................................................................................. 366
Report Program ........................................................................................................................... 366
Command Line ............................................................................................................................. 366
Working Directory ...................................................................................................................... 366

DC.INI .............................................................................................367

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MACHINEID AND MACHINENAME ..................................................367

Machineld...................................................................................................................................... 367
MachineName .............................................................................................................................. 367

JOBID ..............................................................................................368

DATA MAP SETUP...........................................................................369

DATA COLLECTION PROCESS........................................................373

Spawning ....................................................................................................................................... 373
Terminating................................................................................................................................... 373
Archiving Reports ................................................................................................................... 373
Reports .......................................................................................................................................... 374
Definition of Fields ................................................................................................................. 374
Production Graph................................................................................................................... 375
Thru-Put Graph....................................................................................................................... 375
Production Detail Report ..................................................................................................... 376
Operator Summary Report .................................................................................................. 376
Job Summary Report.............................................................................................................. 377
Inserter Summary Report ..................................................................................................... 377
Shift Summary Report ........................................................................................................... 378
Feeder Count Report............................................................................................................. 378
Input Count Report ............................................................................................................... 379
Out Sort Count Report......................................................................................................... 379

OTHER FEATURES...........................................................................380
Excluding Operators and Service Reps From Reports ....................................................... 380
Exporting in Excel........................................................................................................................ 380
Exporting, Appending and Importing ................................................................................ 381
Update Options........................................................................................................................... 382
Loss of Production Data............................................................................................................ 382
Unrecoverable ......................................................................................................................... 382
Recoverable.............................................................................................................................. 382
Special Setup Dialog Boxes ...................................................................................................... 383

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CHAPTER 9: ESTOP ........................................................................385

Table of Contents............................................................................387

CIRCUIT DESCRIPTION...................................................................389
The ESTOP/Interlock Circuit ................................................................................................... 389
The ESTOP Chain Electrical Schematic ................................................................................. 390
Direct Connect Watch-Dog Circuit........................................................................................ 390
ESTOP Electrical Schematic ..................................................................................................... 391

TROUBLESHOOTING......................................................................393
Jumpers To Aid In Troubleshooting ....................................................................................... 393
Things To Remember ................................................................................................................. 393
Troubleshooting Sample Problem: The Machine Won’t Run ........................................... 394
Question 1: Do you have 24vdc?...................................................................................... 394
Question 2: Do you have the feeder board’s lights on for the ESTOP?.................. 394
Question 3: Do you have the feeder board’s lights on for the interlock switches?
.................................................................................................................................................... 394
Question 4: Do you have 24vdc at J23 on the chassis? ............................................. 395
Question 5: Has the Watchdog circuit been disabled (bypassed)? ......................... 395
Notes......................................................................................................................................... 395

APPENDIX ……………………………………………………………....A-1
Physical Connections Diagram………………………………………………………A-3

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Overview
DC Architecture
Mailpieces and Direct Connect
Integrity
Networked and File-Based
Processing
Server Directories and Files
Application Flow
Embedded Users & Privileges
Modes
PBDesktop
Directory Setup
Desktopvb.ini
Chapter 1 – Introduction Direct Connect Service Manual

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CHAPTER 1: INTRODUCTION
Table Of Contents
OVERVIEW .......................................................................................... 5
History .................................................................................................................................................5
Direct Connect (DC) and Increased Integrity ...........................................................................6

DC ARCHITECTURE, DIFFERENCES BETWEEN DC AND ISC 2.0 ......... 7

Centralized Control ..........................................................................................................................8
Object Oriented Software Design ................................................................................................8
CMMObjects......................................................................................................................................9
Display Object Function............................................................................................................... 10

MAILPIECES AND DIRECT CONNECT ............................................... 10

Bogies................................................................................................................................................ 11

INTEGRITY ........................................................................................ 13
Direct Scan (Non-File-Based) Processing................................................................................ 13
Bar Code Scanning.................................................................................................................... 13
Document Control and Tracking........................................................................................... 13
Direct Connect ............................................................................................................................... 14
Diverting Questionable Mail................................................................................................... 14

NETWORKED AND FILE-BASED PROCESSING .................................. 15

SERVER DIRECTORIES AND FILES ..................................................... 16

Input Files......................................................................................................................................... 16
Input File Requirements................................................................................................................ 16
Interlock Files .................................................................................................................................. 17
Output Files..................................................................................................................................... 17
Select Files ....................................................................................................................................... 17
Log Files............................................................................................................................................ 18
Directories and Drive Mappings.................................................................................................18

APPLICATION FLOW ......................................................................... 19

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EMBEDDED USERS AND PRIVILEGES................................................. 21

Access Levels................................................................................................................................... 21
Administrator.............................................................................................................................. 21
Engineer ....................................................................................................................................... 21
KeyOperator............................................................................................................................... 22
Manager ....................................................................................................................................... 22
Operator...................................................................................................................................... 22
Service .......................................................................................................................................... 22
Passwords......................................................................................................................................... 22
Directory Setup.............................................................................................................................. 23

MODES ............................................................................................. 24
Loading Modes ............................................................................................................................... 25
Creating And Saving Modes ........................................................................................................ 26
Directory Setup.............................................................................................................................. 26
Mode Updater ................................................................................................................................ 27

PBDESKTOP...................................................................................... 29
Accessing the PBDesktop ............................................................................................................ 29
Creating Users and Rights ........................................................................................................... 30
Creating, Editing and Modifying Users, Passwords and Rights...................................... 30
Maintaining Users .......................................................................................................................... 31
Adding a User............................................................................................................................. 31
Editing a User ............................................................................................................................. 32
Deleting a User .......................................................................................................................... 32
Changing the User .................................................................................................................... 33
Viewing/Changing the Current User .................................................................................... 34
Closing the PBDesktop................................................................................................................. 35

DIRECTORY SETUP ........................................................................... 36

Associated Files .............................................................................................................................. 36
Five Access Levels .......................................................................................................................... 36

DSKTOPVB.INI.................................................................................. 38
Changing Access Password.......................................................................................................... 38

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OVERVIEW

MENU SYSTEM SYSTEM

BAR DIAGNOSTICS MANAGERS

E-STOP

LOGIN
MANAGER

MODE
MANAGER

MACHINE
ELEMENTS

INSERTER
ALARM OPERATION
MANAGER BUTTONS
Figure 1-1: Direct Connect Main Screen

History
The first intelligent Pitney Bowes inserters employed devices such as data collection cards, shift
registers, zone control boards, nan gates, nor gates, or gates, and gates and lots of discrete
wiring.
The 8300 was the first Pitney Bowes Inserter to use a central processor unit instead of
direct/hard wiring. This change allowed PB to standardize inserter wiring and production for the
first time.
As the technology continued to change, so did the way we built our inserters. That led to the
use of the personal computer as the primary inserter control. The first Pitney Bowes inserter to
use a personal computer was the ISC (Console Quality Enhancement Program) model.

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Direct Connect (DC) and Increased Integrity

Direct Connect provides centralized control. This yields a standard architecture for data transfer
and greater integrity.
Barcode scanners further enhance integrity as well as piece tracking and piece control (from
input to the chassis to the output). Also enhancing integrity are machine configurations that
allow good mail to be separated from bad. Add true file-based processing, output scanning
and/or weight verification, and you have the highest degree of integrity in the industry.
Direct Connect machines dequalify many mailpieces in order to uphold system or processing
integrity. This can reduce the production rate for a given machine cycle. However, Direct
Connect also allows the operating characteristics of solenoids, photocells, paper and mechanics
to improve machine dynamics to enable consistent performance.

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DC ARCHITECTURE, DIFFERENCES BETWEEN DC & ISC 2.0

The basic physical difference between DC and ISC version 1.xx or 2.xx are described in the table
below.
Feature Direct Connect ISC
DC employs tracking photocells on the chassis ISC uses much of the same wiring
and uses centralized control and tracking. and configuration but does not
Tracking track collations on the chassis.
DC has a greater amount of piece tracking and
control over the envelope and inserts.
Bingo cards
and 8051 Both use the same 8051 and Bingo cards.
cards
Feeder
Communication Both use multi-bus and feeder boards plugged into the multi-bus.
and Control
DC uses slave PROMs on the 8051 and a ISC uses PROMs with preloaded
standard feeder PROM. instructions.
DC also has the ability to completely control Different versions and different
feeder, scanner, etc. or relegate certain functions PROMs are used for input feeders
8051 and
to the satellite microprocessor. (burster, hicap, cutter),
Feeder Cards
accumulator and MOS. With ISC
there are variations of variations.
The feeder PROMs also have the
same variations.
ISC has very little software the
A standard set of software tools is used to peak
technician can use to manipulate
Software the performance of photocells, motors,
and enhance the performance of
solenoids and piece tracking and control.
the inserter.
Service and maintenance is easier and more Constant updating of feeder
precise. PROMs etc. is required.
PCs and solenoids with related mechanical
linkage have to be maintained to a higher
degree.
DC’s enhanced piece tracking error messages
display causes and solutions that make the
Service and technician’s search for an answer timely and
Maintenance easier. The same piece tracking software also
detects degradation so the technician knows
which mechanical items need attention.
Improved diagnostics with dialog boxes that
show the physical connection for devices such as
solenoids and photocells reduce repair time and
ensure consistent performance for the life of the
machine.

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Centralized Control
Basically the computer controls nearly everything. The computer reads the state of the inputs
(photocells) periodically and writes outputs (clutches and solenoids).
There are some exceptions to centralized control:
• Burster Board
• High Speed Feeders
• One Cycle Envelope Feeder
Certain functions, for transport gates and retail feeder arming, are performed with Programmed
I/O (Input/Output). Under this scheme, instructions that indicate which outputs to toggle when
an input toggles are downloaded to the 8051.

Object Oriented Software Design

Object oriented software design is a fancy term for “breaking up the software to match the
structure of the machine.”
Direct Connect defines many objects that model different parts of the machine. Examples
include: photocells, transport gates, trayer bins, single doc feeders, etc.
Objects can be contained in other objects.
For example:
• An input contains an accumulator.
• A folder has FIM (Feeder Input Module), a feed module and transport gates
• A transport gate contains a solenoid and a photocell.
• Objects can be “derived” from other objects.
For example:
• All feed modules (cutter, hicap, burster) are derived from the “page feeder” object
• A “nesting feeder” is derived from a single doc feeder.
• The derived class is called a “subclass” or child class, and the derived from class is called
the “super class”, “base class” or “parent” class.

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CMMObjects
All Direct Connect machine control classes are derived either directly or indirectly from one class:
CMMObject. Any object of a class derived from this class can be:
• Enabled or disabled
• Set up via a setup dialog box
• Have the icon associated with it visible (or hidden) on the screen
All CMMObjects can contain other CMMObjects. That is, each CMMObject is or can be a
collation of other CMMObjects. Examples of this are the input section and MOS (Mail Output
System) tables. Their primary function is as a collection of input section or MOS devices.
CMMObjects can also be connected to other CMMObjects. Connections allow state changes in
I/O devices to be propagated. Example: the Folder contains two photocell-tracking objects
(basic elements), which are connected to Photocell Objects, which are contained in Bingo
objects, which are connected to serial port objects, which are contained in the DigiBoard or
RocketPort object.

DigiBoard or RocktetPort

Contains

Port

Connected to

Bingo

Contains

Photocell
Folder
Connected to
Contains

Entrance Exit

Figure 1-2: CMMObjects

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Display Object Function

Use the Display > Object function to browse the hierarchy of objects, see the classes of objects
and view the connections between objects.
• This dialog box is accessible when logged in on the Service level of access.
• Set up any object on the machine, whether or not it is visible on the DC main screen.
• Show or hide any object so it will be visible/invisible on the DC main screen.
1. Click Display > Objects on the DC main menu. The Display Object Info dialog box opens.
2. Click on any item on the list to expand it to reach the desired object.

Figure 1-3: Expanding the Display Object Info List

MAILPIECES AND DIRECT CONNECT

The collation object contains the scan data, mailpiece data, and disposition of the piece. Under
Direct Connect, the quantity of mailpiece data is substantially greater, much more than would be
practical to contain in any scan code.

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Bogies
A bogie is something that is tracked (i.e. "Bogie at 2 o'clock") by Direct Connect. There is
usually one bogie per mailpiece. There can also be multiple bogies per mailpiece (subsetting).
There can also be zero collations per mailpiece (unknown mailpiece, sheet fed but not yet
scanned).
The relationship between collations and bogies is depicted below:

Collation Collation

Bogie Bogie Bogie Bogie

Basic Element Basic Element Basic Element Basic Element

Element Element

Paper Motion
Figure 1-4: The Relationship Between Collations and Bogies

Login at the Service level and select Display > Mailpiece Chain to view these relationships at any
time.

Figure 1-5: Mailpiece Manager Diagnostic Dialog Box

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To view a mailpiece record, click on a bogie on the Mailpiece Manager Diagnostic dialog box
and then click Scan Data to open the Record Display dialog box.

Figure 1-6: Mailpiece Record Display Dialog Box

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INTEGRITY
Integrity (page-to-page match, collation sequence, page sequence, total page count, etc.) starts
with the control document.

Direct Scan (Non-File-Based) Processing

In non-file-based processing, the control document contains the mailpiece data (information that
is unique to that mailpiece). The data is printed on the control document in scan code.
• Scanning sensitivity can be too great or too little and can cause misreads.
• Poor printing can also cause misreads, and both over reading and under reading.
• OMR (Optical Mark Reader) coding has little integrity. An imperfection or a ripple in the
paper can be read as an EOC (End Of Collation) or a select feeder.

Bar Code Scanning

Bar code scanning ensures correct interpretation of scan data. For example, Code 39 must have
nine elements: five bars and four spaces. Three of the elements must be wide. The string must
begin with and end with an asterisk. Combined with a fixed length, you qualify the code six ways
before you begin to interpret it.

Document Control and Tracking

Direct Connect tracks every piece of paper in the input feeder both coming and going and does
not allow another piece on its way before it knows the disposition of the previous piece.

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Direct Connect
In Direct Connect, additional photocells have been added to the chassis deck. They are
purposely placed at an angle to better measure and detect skewed collation. The system knows
where the collating chain is in relation to the feeder.
If a collation is too long, missing, too far in front or too far behind of the collation chain, or if the
sequence of feeding an insert then merging it with the control document is wrong, the system will
dequalify the collation.
Both detected jams and opening of covers also cause a collation to be disqualified.
On the output section, the mailpieces are tracked (both lead and trail edge) and timed from one
PC (photocell) to the next. Their destinations are also tracked and controlled. If a piece does
not arrive at its destination, or an unexpected piece arrives, it will be declared “bad”.

Diverting Questionable Mail

The machine configuration needs to be one that will accommodate separating good mail from
bad. A MOS with a VPS (Vertical Power Stacker) can only outsort good and bad mail together
and should be avoided. Devices like the Locap divert (an output at the folder) should be used
extensively to get questionable mail out of the mail stream as soon as possible.

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NETWORKED AND FILE-BASED PROCESSING

If you are running file-based processing, the inserter is networked to a file server. This allows the
inserter to access the necessary files for file-based processing.
Multiple inserters at the same site networked to a server have several advantages.
• The files needed to run each machine can be copied and shared with great ease.
• All inserters are mapped to their own I:\ drive with the executables and *.ini files and a
\English directory for each inserter. This is done so you can have different
configurations on the same floor.
• Modes, users and reports use common directories and files. Changes to a Mode
parameter or adding a user to the user.dbf are spread across the entire floor.
• When machine configurations are identical, copying a directory from one inserter
directory drive to another simplifies version control and updates.
In direct scanning (without file-based scanning), information encoded in a barcode or set of
OMR marks is mapped into mailpiece data. This mailpiece data is then used to control the
insertion process of the mailpiece.
In file-based processing only a sequential identifier number is scanned and read. Thus, the scan
data read off the page is used to index into a file. Data from the file is then mapped into the
mailpiece and used to control the insertion process.
There are several reasons why a customer may wish to use file-based processing:
• Smaller Barcode. If file-based processing is used, it is possible to reduce the amount of
scan data included on documents. Each document only needs a piece ID and a page
number included in its barcode. All other data can be included in the Input file.
• Greater Capabilities. Since more data can be passed along with each inserted
document, it is possible to pass along large data items, such as the clients' full address.
This data can be used to drive inkjet printers located on the output section of the
inserter or to drive tray tag printers, etc.
• Greater Integrity. Since the control documents are effectively matched against a
machine-readable Input file, a greater level of integrity is possible than with direct
scanning. Only the collations listed in the file can be run and only if they have the same
page count as the file states.
• Closed Loop Processing. When in file-based Mode, the system maintains a record of
each piece processed and its final disposition. This information can be used to automate
the process of reprinting damaged pieces.

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SERVER DIRECTORIES AND FILES

The file server provides a place to store files used in file-based operations. The file server is
usually interfaced with the customer's mainframe so MRDFs (Mail Run Data Files) can be
transmitted from the main frame to the file server. This interface is the responsibility of the
customer.

Input Files
Input files (sometimes called MRDF files) are produced by the same customer mainframe
application that produces the print image file sent to the printer.
• The Input file consists of one record per collation.
• The record contains data about the mailpiece.
• The format of this record varies from customer to customer.
• The customer determines what fields to include in the MRDF record, and the Direct
Connect configuration is updated to match. Examples of fields include:

Field Field Type Sample Description

Record Number ASCII_Number(6) Identifies the record number within the file.
Page Count ASCII_Number(2) Number of pages in collation. This field is
required. All MRDF files must have a page count
field.
Job Id ASCII_Alpha(3) Job ID. This is used to identify the run.
Zip Code ASCII_Number(9) Zip code of mailpiece.
Name ASCII_Alpha(3) Name of customer. This can be used for inkjet
printing or as an identifier to allow the operator
to match the mail to the file.
Address1 ASCII_Alpha(3) Address of customer for inkjet printing.
Address2 ASCII_Alpha(3) Address of customer for inkjet printing.
City ASCII_Alpha(3) City of customer for inkjet printing.
State ASCII_Alpha(3) State of customer for inkjet printing.
Feeder 2 Select ASCII_Binary(1) Feeder 2 select field.
Outsort 1 ASCII_Binary(1) Vertical stacker 1 select field.

Input File Requirements

Input files must meet certain minimum requirements:
• The Input file must start with a record number of 1 and all subsequent records must be
in increasing sequential order. These record numbers match the record numbers printed
on the collations.
• Two fields are required, a piece ID field (usually referred to as a Record number) and a
page count field (gives the number of pages in the collation).

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Interlock Files
Direct Connect produces Interlock files based on an Input file.
• There is one record in the Interlock file for each record in the Input file.
• Direct Connect fixes the Interlock file record format (i.e. it is not configurable).
• The Interlock file is used to record the status of each mailpiece.
• When a mailpiece is correctly processed, the Interlock file is updated to reflect this.
• If an inserter detects a mailpiece that jams or is outsorted, the Interlock file records this
fact.
• Since printed material for a single job can be run across multiple inserters, the Interlock
file can be opened and updated by multiple inserters simultaneously.

Output Files
This is a file that logs data on all types of completed mail, regardless of disposition.
• When the Input file is first opened, the Output file is automatically created and contains
one record per Input file record.
• As mail is run, each record in the Output file is updated.
• The Output file has a user defined record format that can contain data mapped from the
completed mailpieces.
• This file is useful in cases where data is needed on each mailpiece run in a file-based
environment.

Select Files
Once all of the material for a job has been run, a Select file can be produced. A Select file
contains one record for each mailpiece that meets a given criterion. This usually includes
outsorted and/or damaged mailpieces. Once all of the material has been run, the Direct Connect
software produces a Select file using data in the Output file.
• The Select file has a user defined record format that can contain data mapped from the
mailpiece data.
• The contents of each record are user configurable. The user can choose what fields
should appear in the record, and how those fields map to Output file fields and Input file
fields.
• The data in the Select file are usually used to control the customer's print regeneration
process.

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Log Files
As the machine runs, the log file records data on each completed piece.
• Data is always added to the end of the file.
• Log files can be run in a file-based environment but are frequently used for environments
that are not file-based.
• The log file has a user defined record format that can contain data mapped from the
completed mailpieces.

Directories and Drive Mappings

The following are the default directory and drive-mapping assignments for file-based
environments:

File-based Directory Description

I: Main directory, contains executables and . INI files
I:\ENGLISH English language files (*.RDL) are stored here
S: Status directory used for storing machine status
S:\PRODDATA Productivity data is stored here for reporting
O: Modes are stored here. If shared between multiple
machines. Otherwise the Modes are stored in I:
M: MRDF files, and Interlock files
U: Location of USERS.DBF file. This file contains the
user list and passwords.

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APPLICATION FLOW

Figure 1-7: Application Flow

The following is the typical application flow for file-based applications:

1. Statements are printed from the customer maintained mainframe system.
• An application program runs on this computer, produces a print image file and sends it to
the printer.
• In file-based systems, the application also produces a Mail Run Data File (MRDF) or
Input file.
• This MRDF contains one record for each statement to be printed in the order that the
material is printed.
2. The Input File or MRDF is transmitted to the mailroom file server.
• The customer owns the link between the mainframe and the file server.
• The customer chooses the type of link and the software involved.
• The MRDF has a name that uniquely identifies the run.
• For example, a file name might be 03201011.TXT.
• 03 might stand for 2003
• 201 might stand for July 20th (the 201st day of the year)
• 011 might stand for the product code.
3. Printed material is generated from the print image and then assigned to run on one or more
inserters.
4. The inserter operator loads the printed material onto an inserter.
5. The operator opens the Input file that matches material loaded by selecting Open File from
the Input File menu and choosing a file from the list of files available on the server.

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6. Direct Connect creates an Interlock file the first time Input file is opened. This has one
record for each mailpiece and is used to record status.
7. Direct Connect opens the Output file. If there is no Output file in existence for the job then
the Output File is allocated and initialized with one record for each mailpiece in the Input file.
8. As material is run, the Output file and the Interlock file are updated to reflect which pieces
were inserted correctly and which were outsorted or removed.
9. Multiple inserters can run against the same Input file. In this case, the Interlock File is
shared as well.
10. Mailroom managers view progress by viewing the Interlock File (minesweeper) map. This is a
graphic view of which mailpieces have run and which have not.
11. Once all material is run, a Select File can be built from the Output File. The Select File is
transmitted back to the mainframe and can be used to produce reprints for damaged
statements.
12. Depending on how the reprints are produced, they can be run against the original MRDF or
they can use the Select File as an index.

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EMBEDDED USERS AND PRIVILEGES

Access Levels
There are six levels of access under Direct Connect:

Figure 1-8: User Login Access Levels

Administrator
The senior service person on site is usually the Administrator and logs on at that level.
The Administrator:
• Has all the same rights as someone with Service level (assigned to all junior service
personnel at these sites)
• Plus the added ability to make a permanently save a Mode change.

Engineer
Only selected CSRs (Customer Service Representatives) will be given this privilege. The following
dialog box appears when logging on to the Engineer access level.

Figure 1-9: Engineer Access Warning Dialog Box

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KeyOperator
The KeyOperator has more access to this system than Operator, including but not limited to:
• The ability to set basic feeder Modes (such as ON/OFF/SELECT)
• The ability to set over-count for the Input feeder
• The ability to disable the input feeder etc.
Key Operator access does not include Service level items such as adjusting feed times, etc.

Manager
The Manager cannot save or edit Modes and does not have the diagnostics rights that service
does.

Operator
Operators have minimal access to Direct Connect features. This includes:
• Running the machine
• Enabling disabling chassis feeders
• Resetting counts
• Clearing deck
• Powering down the machine.
• The operator can also be set up to temporarily change feeder Mode.

Service
Service can access just about every aspect of the system, but Service cannot save Modes.
What Service can do includes creating settings for all objects and the ability to press
[ALT]+[TAB] to switch to Windows and [ALT]+[F4] to exit from Direct Connect to Windows.

Passwords
Access Level Password
Administrator ADMIN
Engineer (Not published)
Key Operator KEY
Manager SETUP
No password required,
Operator
any entry acceptable
Service PBCSR

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Directory Setup
1. Click Display on the DC main menu.
2. Select Objects from the list to open the Display Object Info dialog box.
3. Expand the Select Object list to reach Login:
4. Model > System Controllers > Login
5. Click [Setup] in the Object Functions area of the Display Object Info dialog box to open
the Login Setup dialog box.

Figure 1-10: Directory Setup Dialog Box

U:\users.dbf is the default setting for the users directory.

• If the directory is not correct, you will always get the six generic users as noted in Figure
1-8.
• On a stand-alone, non-networked machine this directory does not exist. You will get the
standard user imbedded in Direct Connect.

6. Once you are “logged in”, click on the icon to log out. Obtain additional users,
passwords and privileges using the PBDesktop.

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MODES
Modes are files that contain settings for specific customer applications. The Mode contains
many, but not all, Direct Connect settings. There are parameters that may need to be changed
from customer application to customer application. Note that the number of parameters
included in this category is rather large.
Modes include:
• Feed times
• Form lengths
• Scanner settings
• Feed controller settings
• Jam timers
Right-click an entry field on any object setup dialog box to display the blue help screen (see
Figure 1-11). The Category line will tell you if that setting belongs to the Mode category.

Figure 1-11: Blue Help Screen

Under Direct Connect, Modes are very flexible. For instance, subset counts, inter-page gaps and
inter-collation gaps can be set on a per Mode basis.

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Loading Modes
To handle different applications the service personnel on site must set up different Modes. To
load these Modes, perform the following steps:
1. Log on to Direct Connect.
2. Click on the Mode Manager icon. The Modes menu opens.
3. Select Load Mode from the menu to open the Load Mode dialog box.
4. Click on the Mode to select it for the application run needed and press [OK]. The name of
the Mode selected will be displayed in the field at the bottom of the Mode Manager icon.

Figure 1-12: Loading a Mode

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Creating And Saving Modes

Creating Modes on Direct Connect is rather straightforward.
1. Log on to Direct Connect on the $Engineer or Administrator access level.
2. Change the parameters of all the desired objects to their desired state.
3. Click on the Mode Manager icon. A pop-up menu is displayed.
4. Choose Save Mode from the menu list. The Save Mode dialog box opens.
5. Enter the name and description for the Mode. A Mode file is created that includes all of the
current object settings. Click [Ok].

Figure 1-13: Save Mode Dialog Box

Directory Setup
Mode files are stored on disk or on the network as text files. To change the directory where
Direct Connect looks for the Modes, perform the following steps:
1. Click the Mode Manager icon.
2. Select Set Up from the pop-up menu. The Modes Setup dialog box is displayed.
3. Enter the drive and path where the Modes files are kept in the Primary Directory field and
click [Ok].

FIELD
BACKGROUND
TURNS YELLOW
TO INDICATE NEW
SELECTION

Figure 1-14: Modes Setup Dialog Box

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Mode Updater
Since there are so many Mode level parameters, changing these parameters across all Modes can
be rather difficult. The service person has to load each Mode, change the parameter and save
the Mode. If the site has many Modes, this process could be time consuming and error prone.
For this reason, Direct Connect contains a Mode Updater. This updater allows the service
person to make a set of changes to one Mode and propagate only those changes to the rest of
the Modes. To use the Mode Updater, perform the following steps:
1. Click the Mode Manager icon.
2. Select Update Modes from the pop-up menu. The Update Modes dialog box opens.
3. This dialog box will initially contain changes that may be irrelevant or that you do not wish to
propagate. Click [Clear All] to remove all parameters from the dialog box.
4. Load a Mode and make the desired changes to it.

Figure 1-15: Updating a Mode

5. Click the Mode Manager icon and select Update Modes again. The list in the Update
Modes dialog box should now contain one line for each parameter you have changed.
6. Verify that these are the parameters you wish to change.

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7. It is good practice to delete those parameters you don’t want to update before you click
[Update]. The Mode Updater will display a list of Modes.

Figure 1-16: Modes Dialog Box

8. Select all of the Modes or only those Modes to be updated.

9. Click [OK]. The Mode Updater updates the chosen parameters in each of the Modes
selected.

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PBDESKTOP
The PBDesktop provides an interface for maintaining system users. User IDs are generated for
employees requiring access to Direct Connect and mailroom operators who need to log onto the
mail processing equipment.

Accessing the PBDesktop

Each time a user completes his or her work, he/she logs out. This locks access and allows Direct
Connect to associate actions with the user currently logged onto the system.
PB Service should reinforce the user logout procedure with the customer if this is not being done
on a regular basis.

1. Click the Direct Connect Login icon . on the DC main screen. The User Login
dialog box opens.
2. Select the Service access level or higher and click [Ok].
3. Enter a valid password to get access to Direct Connect and click [Ok].

Figure 1-17: User Login Dialog Box

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Creating Users and Rights

In order to track productivity, jobs run and machines run for each operator, create a users list
with unique names, rights and passwords. The customer is responsible for supplying this
information.
The rights and users created in the PBDesktop are different from the embedded users and
rights in Direct Connect. The Desktop has five levels of users (Operator, Key Operator,
Administrator, Manager, and Service).

Creating, Editing and Modifying Users, Passwords and Rights

To create, edit and modify users, passwords and assign rights, log on and launch the PBDesktop.
1. Exit Direct Connect or press [Alt] + [Tab] to minimize Direct Connect and get to the
computer desktop.

2. Double-click on the shortcut icon to the PBDesktop to open the PBDesktop

Log On dialog box.

Figure 1-18: PBDesktop Log On

3. Click [OK] to open the PBDesktop.

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Maintaining Users
To maintain users:
1. From the PBDesktop, select Setup > Maintain Users from the DC main menu. The Users
List dialog box displays.
2. You can now add, edit, or delete users.

Figure 1-19: Maintain User List Dialog Boxes

Adding a User
This selection allows you to add a new user to the system. To add a user, perform the following
steps:
1. From the PBDesktop, choose Setup > Maintain Users. The User List dialog box displays.
2. Click [Add User]. The User Configuration dialog box opens.
3. Fill in the fields and select the desired radio buttons.
4. Click [Add]. The User List dialog box displays with the list containing the new user.
5. Perform another task or click [Done] to close the dialog box.

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Editing a User
This selection allows you to change the user’s configuration on the system. To edit a user,
perform the following steps:
1. From the PBDesktop, select Setup > Maintain Users from the DC main menu. The User List
dialog box displays.
2. Select the desired user from the list and click the [Edit User] button. The User
Configuration dialog box opens.

Figure 1-20: User Configuration Dialog Box

3. Modify the desired fields.

4. Click [OK]. The User List dialog box displays.
5. Perform another task or click [Done] to close the dialog box.

Deleting a User
This selection allows you to remove a user from the system. To delete a user, perform the
following steps:
1. From the PBDesktop, select Setup > Maintain Users. The User List dialog box displays.
2. Select the desired user and click [Delete User].
3. A dialog box prompts you to confirm that you really want to delete this user. Select [OK].
The User List dialog box is displayed with the user removed from the list.
4. Perform another task or choose [Done] to close the dialog box.

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Changing the User

1. Select File > Change User from the PBDesktop menu.
2. A dialog box prompts you to confirm that you want to log out of the PBDesktop.
3. Click [YES]. The Log On dialog box displays.

Figure 1-21: Using Log On to Change the User

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Viewing/Changing the Current User

Select Current User > Setup from the PBDesktop menu to view your own configuration.
• If a user with Service or higher access rights accesses this dialog box, any change made
will take effect when [Add] or [OK] is clicked. This includes a change to the user name
field.
• Changing this field has the effect of creating a new user with all the existing parameters
unchanged if the user name does not already exist.
• If the user name does exist, it will alter the existing user to the current parameters. This
functionality allows the Service level user to use his/her user account as a template.
To change or view the user configuration:
1. Select Setup > Current User from the PBDesktop menu. The User Configuration dialog
box displays.

Figure 1-22: Opening the User Configuration Dialog Box

2. If a Supervisor or higher access level is used to access this dialog box, you can:
• Add a user
• Delete the current user
• Edit any fields in the configuration.
3. To modify the configuration for the current user, change the desired fields and click [OK].
4. To add a user, enter a new user name and modify any other fields that you desire. Click
[Add].

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5. To delete the current user, click [Delete].

6. A dialog box prompts you to confirm that you want to delete this user. Click [OK]; the user
will be deleted.

Closing the PBDesktop

1. Select File > Exit from the PBDesktop menu.
2. A dialog box prompts you to confirm that you want to log out of the PBDesktop.
3. Click [YES]. The PBDesktop closes.

Figure 1-23: Closing the PBDesktop

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DIRECTORY SETUP
In order for Direct Connect to see the new users you have created, you must use the directory the
PBDesktop writes to: PBDESK\DATATABL\USERS.DBF.
Click the Login icon and then select Setup from the list that displays.

Figure 1-24: PBDesktop Login Setup Dialog Box

Associated Files
The access level for the PBDesktop and the rights assigned for each user level is different from
the PBDesktop to the Direct Connect login.

Five Access Levels

The following is a brief description of the access level of each login for the DC environment.
• Operator: Runs mail.
• Key Operator: Operator rights plus set feeder Modes and run Direct Reports.
• Manager: Key operator rights plus access to setup for most modules.
• Supervisor: Manager rights plus they can save/edit Modes and have access to service
diagnostic and can edit the DCC.
• Service: Supervisor rights but cannot edit or save Modes.
DIAGNOSTICS
FEEDER MODE
LOAD MODES

DC REPORTS
EDIT MODES

SCANNER
EDIT DCC
SETUP

OPERATOR YES NO NO NO NO NO NO YES

KEY OPERATOR YES YES NO NO NO NO YES YES
MANAGER YES YES NO YES NO NO YES YES
SUPERVISOR YES YES YES YES YES YES YES YES
SERVICE YES YES NO YES YES YES YES YES

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Figure 1-25: PBDesktop User Configuration Dialog Box

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DSKTOPVB.INI

Figure 1-26: Desktop .INI File

Editing any .INI file should be done only by the most senior and
responsible CSR. Always back the file up before editing.

The desktop has a file called DSKTOPVB.INI. In the section called ISDC, there is a line: IsDC=1.
• If this line is = to 0, then the Factory, Service and Manager users in the PBDesktop
cannot be edited.
• If you are using an OMS, this value must be set to 0 or the OMS will not run.

Changing Access Password

When the wrong people learn the Service password, you will need to change it.
1. Set this value to 1.
2. Edit the user: Service.
3. Change the value back to 1 to let the OMS run

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DC Objects and
Software
System Model
Operator Controls
Modes
Operating Systems
Encoder/Multibus/DigiBoard
/RocketPort
8051 Configuration
Log Files
Diagnostic Dumps
Chapter 2 – Screens, DC Objects and Software Direct Connect Service Manual

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CHAPTER 2: SCREENS, DC OBJECTS AND SOFTWARE

Table of Contents
SYSTEM MODEL................................................................................ 43
Direct Reports ..................................................................................................................................... 44
Reports Manager ................................................................................................................................ 45
Accessory Manager ............................................................................................................................ 46
Feeder Performance Manager.......................................................................................................... 47
Bingo Diagnostics............................................................................................................................... 48
Bingo Status Dialog Box ................................................................................................................... 50
Serial Port Diagnostics ...................................................................................................................... 51
Scanner Objects.................................................................................................................................. 54
Scan Data Processor........................................................................................................................ 54
Scan Processor.................................................................................................................................. 56
Login Manager ..................................................................................................................................... 57
Operator............................................................................................................................................. 58
Key Operator .................................................................................................................................... 58
Manager .............................................................................................................................................. 58
Administrator..................................................................................................................................... 58
Service................................................................................................................................................. 58
Engineer .............................................................................................................................................. 58

OPERATOR CONTROLS.................................................................... 59
Start/Stop/One Cycle....................................................................................................................... 59
Hand-Crank Indicator ........................................................................................................................ 59
System Menu Commands ................................................................................................................. 59
Disable System.................................................................................................................................. 60
Reset Counts ..................................................................................................................................... 60
Load Mode ......................................................................................................................................... 60
Clear Deck.......................................................................................................................................... 60

MODES ............................................................................................. 61
Modes and Adjustment Parameters ............................................................................................... 61
Loading Modes .................................................................................................................................... 61
Creating a Mode ................................................................................................................................. 63
Storing the Mode................................................................................................................................ 64
Mode Updater ..................................................................................................................................... 65
Mode Comparison Feature............................................................................................................... 67

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OPERATING SYSTEMS ...................................................................... 68

Startup Routines................................................................................................................................. 68
Network Login ................................................................................................................................... 68
Network Login Using VLMs............................................................................................................ 68
Version Comparison Table............................................................................................................. 69
DC Startup to Edit a DCC File ...................................................................................................... 70
Windows NT (Version 160 and Later) File Structure............................................................. 70
3.11 Windows File Structure ........................................................................................................ 71
Files To Back Up in Version 160 and Later ............................................................................... 72
Direct Reports................................................................................................................................... 72
Server Drive Mapping...................................................................................................................... 73

ENCODER/MULTIBUS/DIGIBOARD/ROCKETPORT ......................... 74
Tech 80 - 5312b Quad Encoder Board ...................................................................................... 74
Quad Encoder Board Jumper Settings........................................................................................... 74
Differential Bus Board Jumper Settings......................................................................................... 75
Combination Differential/Encoder Board – ISA Type............................................................... 75
Combination Differential/Encoder Board – PCI Type .............................................................. 75
Relation Between DigiBoard/RocketPort in Control Computer and the 8051 and Bingo
Boards.................................................................................................................................................... 76
Serial Communications with the DigiBoard.................................................................................. 77
Serial Communications with the RocketPort ............................................................................... 77
Direct Connect and the Encoder.................................................................................................... 78

8051 CONFIGURATION ................................................................... 79

Standard Wiring for DigiBoard/RocketPort to 8051 Cards and Standard Bingo Wiring79
Multibus Feeder Setup ...................................................................................................................... 80
Wiring Differences for High Speed Machines .............................................................................. 80
Arming Feeders ................................................................................................................................. 80
High Speed Machine Chain Offset............................................................................................... 81

LOG FILES ......................................................................................... 82

Syslog.dat ............................................................................................................................................. 82

DIAGNOSTIC DUMPS ....................................................................... 85

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SYSTEM MODEL

MENU SYSTEM SYSTEM

BAR DIAGNOSTICS MANAGERS

E-STOP

LOGIN
MANAGER

MODE
MANAGER

MACHINE
ELEMENTS

INSERTER
ALARM OPERATION
MANAGER BUTTONS

Figure 2-1: Direct Connect Main Screen

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Direct Reports
Do not confuse this manager with the Reports Manager covered on the following page.
Direct Reports is covered in detail in Chapter 8.

Figure 2-2: Direct Reports Menu

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Reports Manager
The Reports Manager allows the system to display or print the Hard Copy Audit Report that is
the equivalent of the ISC reports.

Figure 2-3: Reports Manager Window

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Accessory Manager
The Accessory Manager is used to set up the default error handling on the inserter. Use this
manager to default all error handling to one set of parameters instead of configuring each feeder
and device on the system individually.
1. Click the Accessory icon on the Systems Manager’s List on the DC main screen.
2. Select Setup > Accessories. The Accessories setup dialog box opens.
3. Highlight the desired accessories and click [Setup]. The Setup dialog box for that accessory
opens.
Note: You may configure this action as a default.

Figure 2-4: Accessory Manager Setup

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Feeder Performance Manager

This feature is found in newer versions of Direct Connect. Use this single dialog box to check on
how all feeders are working.
1. Click the feeder icon on the System Control bar at the top of the DC main screen.
2. Select Performance from the Feeders menu. The Feeder Performance dialog box opens.
Excess jamming or problems that cause a feeder to go into delay are clearly shown. Data in this
dialog box is lost when the machine is powered down.

Figure 2-5: Feeder Performance Manager

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Bingo Diagnostics
Use Bingo Diagnostics to test most electrical items. Also use Bingo Diagnostics to see the
status of the switches and photocells that sent data through the bingos.

Tech Tip: Bingo diagnostics can be very useful, but there is no substitute for using
a voltmeter to measure photocell voltages.

1. Click the Bingo Diagnostics icon on the Master I/O Device List on the DC main
screen to open the list of Bingo Cards.

Figure 2-6: Bingo Card List

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2. Select an item from the list and click [Show] to open the Bingo Diagnostic dialog box.

Figure 2-7: Bingo Diagnostic Dialog Box

• From this dialog box it is possible to view the states of the individual signals and to
toggle the outputs on and off.
• Display this dialog box as the machine runs and watch the dialog box update the states
of the inputs and outputs.
• Also refer to the Direct Connect Physical Connections Diagram in Appendix A.

Return the outputs to the states where they started or reload the mode when the
diagnostics are complete.
Leaving devices energized while running motors (for example, turning on the bingo chassis
brake, exiting and starting the machine from the Start menu) can damage the machine.

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Bingo Status Dialog Box

The Transport Bingo Status dialog box shows the ON or OFF status of Bingo card controlled
devices.
1. Click Display > Objects on the DC main menu. The Display Object Info dialog box opens.
2. Expand the list to reach the desired Bingo connector.
3. Click [Status] to display the connectors on that board.

Figure 2-8: Transport Bingo Status

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Serial Port Diagnostics

Many devices are connected to the Direct Connect via serial ports. This includes 8051 boards
running the slave PROM as well as barcode scanners, scales, meters, and printers. Occasionally
(not often), it is necessary to view the traffic on these serial lines to confirm that the data is
being sent and received. Use Direct Connect serial port objects to view data traffic flowing in
both directions.
Also refer to the Direct Connect Physical Connections Diagram in Appendix A.

1. Click the Serial Port Diagnostics icon on the Master I/O Device List on the DC main
screen to open the list of serial ports on the machine.

LABEL
SHOULD BE
SERIAL I/O

Figure 2-9: Selecting a Serial I/O Diagnostic Dialog Box

2. Click [Diagnostic] to open the Diagnostic dialog box for the port selected
(see Figure 2-10).
This dialog box displays communication data bytes scrolling up the dialog box as they are
transmitted and received. Lines prefixed with a (>) are transmitted text and lines prefixed with a
(<) are for received text. Control characters are also displayed with a (^) in front of them (i.e. ^
M for carriage return).
Traffic is displayed as it occurs. If there is no activity on the line, the display will not scroll. With
a scale, for instance, it may be necessary to physically trip the scale to see traffic. If this dialog
box is kept open as the machine runs, it will display the data transmissions as they occur.

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LABEL
SHOULD BE
SERIAL I/O
NOT
COMMUNICATING

COMMUNICATING

LABEL
SHOULD BE
SERIAL I/O

NOT
COMMUNICATING

COMMUNICATING

Figure 2-10: Hicap_51_Port and AF_Rollup_51_Port Diagnostic Dialog Boxes

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To open the Serial Ports Status dialog box:

1. Click Display > Objects on the DC main menu. The Display Object Info dialog box opens.
2. Expand the Select Object list to reach the desired serial port.
3. Click [Status] to display the Serial Ports Status dialog box.

Figure 2-11: Serial Ports Status Dialog Box

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Scanner Objects
Every Direct Connect system that has scanning features has some type of Scan Data Processor
that can be identified from the icon near the feeder.
In all cases, the scanner controller is connected to a photocell object. The photocell is used to
signal the start of scanning and to track the piece to see if it becomes jammed.

Scan Data Processor

The Scan Data Processor icon is displayed above its associated feeder controller icon on the
DC main screen. The scan data processor decodes the barcode data that is read from the
incoming document.

Figure 2-12: Scan Controller Icon

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A system may contain a set of scan data processors for handling different barcode formats and
various scanning Modes. Four types of scan data processors are used with Direct Connect:
Direct Scan Processor (Not Filed Based): Used when all the mail processing information is
contained in the bar code or OMR mark located on the source document. This scan processor
interprets the scan data and uses it to control inserter operation (e.g., feeder selects or end of
collation).
File-Based Scan Processor: Controls matching the data in the MRDF to the paper on the
inserter. Applies commands from the MRDF to control inserter operation.
File-Based Matching Scan Processor: Used when documents from two inputs are included in
the mailpiece. The source document contains information that also controls the feeding of
another feeder.
Universal Scan Processor: Combines the functions of a scan processor and a scan controller in
direct scanning operations on cutters and bursters.

LOOK AHEAD SCAN

CONTROLLER
SINGLE SCAN
CONTROLLERS

Figure 2-13: Scan Data Processing Icons

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Scan Processor
The Scan Processor links scan data with the physical paper. It is used primarily on an input
feeder to scan the control document or on a matching feeder to scan a matching document.

DIRECT FILE BASED FILE-BASED MATCH UNIVERSAL

Figure 2-14: Scan Controller Icons

Figure 2-15: Scan Data Processor Icon and Menu

The Scan Controller works with an associated scan data processor object, which actually
decodes the data. It performs the following functions:
• Manages multiple scanners
• Time synchronizes the scan data with the paper
• Calls the active scan data processor to decode and act on the data.
Only one processor is used at a time but different processors handle different barcode formats
and various scanning Modes.
• Counts bad scans; too many in a row means a “bad” mailpiece. Outsort if necessary.
There are two types of scan controllers:
• Single: Used when the piece being fed needs to be scanned as it is fed. Commonly used
on high capacity sheet feeders (Hicaps).
• Lookahead: Used when the page needs to be scanned a cycle before it is fed. Used on
bursters and cutters.
In all cases, the Scan Controller is connected to a photocell object. The photocell is used to
signal the start of scanning and to track the piece to see if it becomes jammed.

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Login Manager
Also referred to as the User Manager, the Login Manager controls logging in and out of the
system.
To log on, click the Login Manager icon to display the User Login list of site user
names. The User Login below is the default User Login dialog box.

Figure 2-16: Default User Login Dialog box

Figure 2-17: Login Manager

The user list and passwords are contained in the USERS.DBF file. The PBDesktop software
included in each Direct Connect installation creates the USERS.DBF file. Direct Connect will
search for the USERS.DBF file in any location defined in the Login Manager Setup dialog box.
• In a networked Direct Connect installation, this file is located in the root of drive U:\.
• In a stand-alone system, USERS.DBF is in the C:\pbdesk\datatabl directory.

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There are six levels of user access under Direct Connect:

Operator
Operators have minimal access to Direct Connect features. This includes running the machine,
enabling and disabling chassis feeders, resetting counts, clearing the deck and powering down the
machine. The operator can also be set up to change feeder Mode.

Key Operator
The Key Operator can use the Setup screens in Direct Connect. This includes setting basic
feeder Modes (such as ON/OFF/SELECT), setting over-count for the input feeder, and disabling
the input feeder, etc. Key Operators do not have access to Advanced dialogs in Direct Connect.

Manager
The Manager has access to most of the Advanced dialogs in the Setup areas as well as all of the
Operator and Key Operator privileges.

Administrator
This level of access is now the major user access level. It allows use of all of the Operator,
Manager and Key Operator functions. In addition, a Mode file can be saved at this access level.

Service
Service can access just about every aspect of the system. Service cannot save Modes. The
main advantage of this level of security is the ability to use all of the Advanced dialog boxes. This
includes settings for all objects as well as the ability to use [ALT]+[TAB] to switch to Windows
and [ALT]+[F4] to exit from Direct Connect to Windows.

Engineer
Used primarily at the factory, this access level allows editing of Direct Connect system
configuration as well as access to all adjustment dialog boxes.
Note: The PBDesktop has an unusual way of assigning these rights. The security levels in the
Desktop to not match exactly with DC. In the PBDesktop, the Supervisor access level gives
the user the maximum rights available in Direct Connect.

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OPERATOR CONTROLS
Start/Stop/One Cycle
There is a [Start] button and a [Cycle] button at the bottom of the DC main screen.
• [Start] starts the machine.
• [Cycle] half-cycles the machine by moving the chains one feeder forward.
The Remote Control can also run these functions.

Figure 2-18: System Controls

Hand-Crank Indicator
If the hand-crank is inserted into the machine, the Hand-Crank icon is displayed above the
[Start] and [Cycle] buttons. This prevents the operator from pressing [Start] or [Cycle] while
the crank is in place.

System Menu Commands

Figure 2-19: Opening the System Menu

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Figure 2-20: System Menu

Disable System
Prior to a diagnostic dump, disable the operating system to stop event processing. When the
system is operating, click Menu at the bottom of the DC main screen and select Disable System
from the pop-up System Menu. The Start button will change to a set of circles with a diagonal
line through each. This indicates that the system is disabled.

Figure 2-21: System Disabled Icon

To enable the system, press the Menu button and select Enable System from the pop-up list.
This returns the system to the operational state.

Reset Counts
Click Menu at the bottom of the DC main screen and select Reset Counts from the pop-up
System Menu. All machine components that track piece counts, such as vertical stackers, the
IST and the input, will reset to zero.

Load Mode
Click Menu at the bottom of the DC main screen and select Load Mode from the pop-up
System Menu.
Highlight the required Mode in the selection box and click [Ok].

Clear Deck
To clear the deck, click Menu at the bottom of the DC main screen. Select Clear Deck from the
pop-up System Menu.
Note: This does not start the machine. Instead, it puts the input and chassis in clear deck
Mode. The next time Start is pressed, the input and chassis will clear the deck and the
machine will stop.
The deck can also be cleared using the remote control.

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MODES
Modes and Adjustment Parameters
Modes are files that contain settings for specific customer applications. The Mode contains
many, but not all, Direct Connect settings.
Modes under Direct Connect are very flexible. Virtually all setup parameters that adjust machine
timing and material size can be set on a per Mode basis.

Loading Modes
Modes are created both at the factory and by service personnel at the site to handle different
applications.

1. Click the Mode Manager icon to display the pop-up menu.

2. Select Load Mode to display the Load Mode list.
3. Select the current job application from the list and click [Ok].

Figure 2-22: Load Mode Dialog Box

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In general, there are two levels of parameters or settings within a Direct Connect system:

Level Parameter
MACHINE LEVEL (Base) These are things that are stored as part of the DCC file
but are not stored as part of the Mode files. The DCC
file needs to be saved to make these changes permanent.
These are also things that do not need to change from
Mode to Mode but may change from machine to
machine. Examples of this include:
Scanner head offsets that account for slight differences
between the mounting of otherwise identical machines.
Photocell and signal inversion setups where one
machine may have through beams where another has
reflective photocells.
MODEL LEVEL (Mode) These are parameters that may need to change from
customer application to customer application.
The number of parameters included in this category is
rather large. It includes feed times, form lengths, scanner
settings, feed controller settings, jam timers, etc.

Right-click on the adjustment field for a parameter to display a blue help box. That parameter is
identified category as either a Mode or Base type.

Right-click here to display

the blue help dialog box
for Dynamic feed time
(moving).

Figure 2-23: Identifying a Parameter Category

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Creating a Mode
If users are created through the PBDesktop, only the Supervisor has the right to save or edit
Modes. If using the users embedded in DCC only Engineer and Manager can edit and save
Modes.
Check with the site coordinator or DTS for help to save a Mode.
1. Change the parameters of all the desired objects to what you want them to be.
2. Click on the Mode Manager icon.
3. Choose Save Mode from the pop-up menu to open the Save Mode dialog box.

Figure 2-24: Save Mode Dialog Box

4. Type in the name and description for the Mode.

5. Click [Ok]. A Mode file is created which includes all of the current settings.

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Storing the Mode

Mode files are stored on disk or on the network as text files, typically in drive O:\.
To change the directory where Direct Connect looks for the Modes, perform the following steps:
1. Select the Mode Manager icon on the DC main screen.
2. Select Set Up from the pop-up menu. The Modes dialog box opens.

Figure 2-25: Modes Setup Dialog Box

Direct Connect automatically saves a Mode in a different location as a backup if the location is
specified in the dialog box above.
• Usually this is in a local C:\ drive directory in a networked location.
• The Mode can also be saved to a floppy disk using this system.
The default Mode file that will open every time Direct Connect starts can be set here but this is
not done very often. Normally, the last Mode used before the machine is shut off reappears.

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Mode Updater
Since there are so many Mode level parameters, changing these parameters manually across all
Modes can be rather difficult. The service person has to load each Mode, change the parameter,
and save the Mode. If the site has many Modes, this process can be time consuming and error
prone. For this reason, Direct Connect contains a Mode updater.
This updater allows the service person to make a set of changes to one Mode and propagate
only those changes made to the rest of the Modes.
With a Mode loaded, use the Mode Updater to perform the following steps:
1. Click the Mode Manager icon on the DC main screen.
2. Select Update Modes from the pop-up menu. The Modes dialog box opens.
3. This dialog box may contain changes that are irrelevant or that you do not wish to
propagate.
4. Press [Clear All] to remove all parameters from the dialog box. This step is important!

Figure 2-26: Modes Dialog Box

5. Make the desired changes.

6. Once complete, select Mode Manager > Update Modes again. The list should now contain
one line for each parameter that was changed.

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7. It is good practice to delete those parameters you don’t wish to update and click [Update].
The Mode Updater will display a list of Modes.

Figure 2-27: Update Modes Dialog Box

8. Select some or all of the Modes to be updated.

9. Click [OK]. The Mode Updater saves those parameters in each of the selected Modes.

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Mode Comparison Feature

The Mode comparison feature is new to Direct Connect version 159. It allows two Modes to be
compared for editing or troubleshooting. This feature is available with Service level rights or
higher.
1. Click the Mode Manager icon on the DC main screen to display the pop-up menu.
2. Select Compare Modes to display the Modes list. This example shows the differences
between the current settings and the CTAX1PAG.mod Mode file.
3. Click [Add] at the top of the Modes dialog box to select additional Modes from the list to
add to those displayed in the Modes dialog box for comparison.

Figure 2-28: Compare Modes Dialog Box

4. Select the Differences or All radio buttons in the View field to choose which settings are
displayed.
5. Select files to be compared from the drop-down menus. The menu on the left controls the
column on the left of the View field and the menu on the right controls the column on the
right.

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OPERATING SYSTEMS
Startup Routines
This is the normal order of file execution when the control computer is booted to start Direct
Connect. The autoexec.bat and config.sys files have already configured upper memory and
loaded drivers for the DigiBoard or RocketPort.

Network Login
If the machine is on a network, the following lines are executed in the AUTOEXEC.BAT file,
usually by calling a special .bat file named Startnet.bat to run the network login. The NET.CFG
file in the NWCLIENT directory helps configure the network connection by defining the
workstation network card drive, the letter to log in and preferred server.

Network Login Using VLMs

• CD \NWCLIENT
• LSL
• 3C90X (or whatever net card driver is required)
• IPXODI
• VLM
• CD \
• F:\LOGIN DCx
This series of commands logs the machine into the Novell server. In addition to this file there
may be a Novell login script running to give network rights and map network drive letters for use
by the Direct Connect system. This file is in the C:\NWCLIENT directory and is usually named
login.scr.
If the machine is booting properly and logging on the network, the drive letter mappings display
on the machine monitor as the autoexec.bat file runs.

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Version Comparison Table

Version 158 and 159 Version 160

Icon Command line for Version 158 and 159 Icon Command line for Windows NT based
The DC Startup file in version 158 is named Version 160 and Later is named.
DC.EXE.
The school version of Direct Connect version 158 The school version of Direct Connect version
in the classroom computer starts with: 160 in the classroom computer starts with:
I:\dc.exe /E /L /S3 XXX.dcc I:\dcrun32.exe /E /L /S3 XXX.dcc

Where: Where:
/E allows model editing /E allows model editing
/L allows configuration file loading /L allows configuration file loading from a list of
/Sx sets the initial user access level: DCC files
S0 - user, running /Sx sets the initial user access level:
S1 - manager, running S0 - user, running
S2 – service, running S1 - manager, running
S3 - engineering, real time engine not running S2 – service, running
XXX.dcc = Name of DCC file that will run S3 - engineering, not running
XXX.dcc = Name of DCC file that will run
The command line for general configuration The command line for configuration editing at
editing at the factory is: the factory would be:
X:\dc.exe /E /L /S3 X:\dcrun32.exe /E /L /S3
If a DCC file name is not included on the If a DCC file name is not included on the
command line, the program will present a list for command line, the program will present a list for
the user to select from. All the DCC files are in the user to select from. All the DCC files are in
Drive I:\. Drive I:\.

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DC Startup to Edit a DCC File

Normal startup will NOT allow you to:
• Save any Base parameters by saving the DCC file
• Edit the hardware model in the configuration editor
• Choose between multiple DCC files if they are available.
In order to do any of the above tasks you must:
• Use the /E command switch that allows Mode editing
• Log on to Direct Connect with Engineer rights.

Windows NT (Version 160 and Later) File Structure

File Description
DCRUN32.EXE This file combines the functions of the dc.exe loader program in previous
versions and the hardware description DLL file. When called from the
command line, this file starts DC. It contains hardware element
descriptions for all possible DC machines. This file is the same for all
machines.
XXXXX.DCC This is the Direct Connect Configuration file for each machine. It
configures the DCRUN32.EXE to describe a particular machine
English\*.RDL The ENGLISH subdirectory contains the English language files. These files
contain the text for dialog boxes, messages, etc. Note that the version of
these files must match the DCRUN32.EXE file.
*.mod Mode files. These files set the machine to run a particular job. The
Modes contain timing and operational settings to run a particular job.
DBWIN32.EXE This is the Microsoft Visual C++ Trace utility for NT. This utility provides
a dialog box in which DC writes status messages. DC will run without this
file but much slower. This utility is useful for debugging error situations in
Direct Connect.
DBWIN32.DLL DLL needed for DBWIN32.EXE
DC.INI This file contains parameters relating to the Direct Connect real time
engine (don’t change them). It also contains the machine ID and machine
name of the machine and contains the parameters for the security key
system. The machine ID is used for the reporting package and the
security key. The machine name appears on the title bar. The DC.INI file
is now unique for each machine.

Note: If this file is edited or changed, the system will not load.
Customer.fdb A site-specific file that contains the data formats for MRDFs, Output,
Select and Interlock files or barcode formats in direct control applications.
These formats were formerly stored in Mode files.
VENUE.INI This file contains installation wide settings. These are settings whether
Metric or (Imperial) English units are used for length and weight. Only
editing the VENUE.INI file with a text editor can change these settings.
ERROR.LOG This file contains the outputs of “integrity assurance halts”. This file gets
larger with each integrity assurance halt and should be deleted as part of
regular maintenance.

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3.11 Windows File Structure

The following files are located in either C:\DC or I:\.
File Description
DC.EXE This is the Direct Connect Loader Program. Its primary responsibility
is to load the file DCRUN.DLL (below).
DCRUN.DLL This file provides the main functionality of the DC application. Unless
intentionally customized, this generic file that does not contain any
system specific information. This is the file that is upgraded with a
software change. It is a large file – approximately 4.5 meg.
DC.INI Contains application variables (don’t change them), the machine name
and parameters to determine if Metric or English (Imperial) units are
used for length and weight. Used as the default if VENUE.INI does
not exist.
*.DCC Configuration file. This file is created using the configuration editor
available in the DC application. The file contains the configuration
parameters for the hardware as well as default values for Mode type
parameters for the system. The Mode parameters for the *.DCC file
will be overridden by the values in a *.MOD file if the user chooses to
load a Mode. Typically, there is one configuration per machine but
there may be instances where more than one is required (i.e. rollup
inputs).
English\*.RDL The ENGLISH subdirectory contains English language files. These files
contain the text for dialog boxes, messages, etc.
Note: These files must be upgraded when the DCRUN.DLL file
changes.
*.MOD Mode files. This file contains values for parameters that may change
when multiple applications are run on the system. The parameter
values located in the Mode file override the default values located in
the *.DCC configuration file. There is one file for each Mode created
and the file name matches the Mode name.
DBWIN32.EXE This is the Microsoft Visual C++ Trace utility. This utility allows you
to intercept trace information from Direct Connect. Every now and
then this utility is useful for debugging error situations in Direct
Connect.
DBWIN32.DLL DLL needed for DBWIN.EXE.
AFX.INI INI file needed for DBWIN.EXE.
VENUE.INI Include file. This file contains installation site settings. These are
settings such as whether Metric or English (Imperial) units are
accepted for lengths and weight.
ERROR.LOG Log file. This file contains the outputs of “integrity assurance halts”.
This file gets larger with every assurance halt generated. The contents
of this file are useful to developers to help debug these faults. Delete
this file if it becomes too large and the dumps it contains aren’t of
interest.
SYSLOG.DAT This file contains a record of each time the system is started, a Mode
is saved, a Mode is loaded, etc. Direct Connect automatically keeps
this file small.

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Files To Back Up in Version 160 and Later

Direct Connect version 160 comes with a recovery CD that provides quick operating system
restoration in case of a hard drive failure or if the computer needs to be replaced.

All of the files needed for running Direct Connect are on the CD but some
files, listed below, change during operation and the current versions are
only available through a regular backup.

The standard configuration of version 160 and later includes a BACKUPDC.BAT file with an icon
to activate it on the Windows NT desktop.
This batch file copies the following files to a disk in drive A:\ if your system is not connected to a
network.
If your system is connected to a network, you will have to back these files up manually. See the
Directory Structure section on the next page to find where the files are located.
• DC.INI
• VENUE.INI
• ALL DCC FILES
• ALL MODE FILES
• CUSTOMER.FDB

Direct Reports
If a Direct Connect system has Direct Reports, the settings for that option are on the local drive
as well and should also be backed up.

These files are NOT included in the files saved by the BACKUPDC.BAT file.
PRODDATA.TXT
KEY.MDB
DCREPRTS.MDB

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Server Drive Mapping

The Direct Connect Engineering Group has specified the following drive mappings to provide a
standardized network environment for both simple and complex DC sites with OMS system and
Scitex printing directories.
Direct Connect now has two network volumes, SYS and VOL1, which contain system information.
In a typical network, the SYS volume is a 4-gigabyte partition and VOL1 is a 14-gigabyte
partition.
File details are in the chart below:

File Based Volume and Location Description

Directory
I: SYS:Inserter Main directory, contains executables
and INI files
I:\ENGLISH SYS:Inserter The English language files
(*.RDL) are stored here.
M:\ VOL1:Maildata Input, Output, Interlock and Select
files for file based processing.
N:\ VOL1: Status Same place in the network as drive
VOL1: Status\Proddata N:\ for OMS use.
Cost and Funds
O:\ VOL1: Modes Mode files. This directory is shared
between multiple machines.
P:\ VOL1: PrintBMP Printer data files for Scitex printers.
S:\ VOL1: Status Status directory for machine status
VOL1: Status\Proddata files used by the Remote Monitor or
Direct Reports data. Same place as
drive S:\ for the OMS system.
U: VOL1: Status\Common Location of USERS.DBF file. This file
Cost and Funds contains the passwords for both
Direct Connect and the OMS
system.

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ENCODER/MULTIBUS/DIGIBOARD/ROCKETPORT
Tech 80 - 5312b Quad Encoder Board
Note: This description is for the Old Style encoder board installed before July 2000. See
TSB N806 for a description of the newer type board configuration.
Direct Connect uses the Tech 80 - 5312b Dual Port Quadrature Encoder, PN Y184438, that
recognizes turning backward.
The Quad encoder is a differential type device.
• It produces twin signals that go high and low simultaneously when a pulse occurs for
greater reliability and noise resistance.
• It is much easier to adjust than the older type that did not register a new adjustment
without passing zero.
• Backward movement is displayed as a colored encoder icon on the Direct Connect main
screen.

Quad Encoder Board Jumper Settings

The Tech 80 - 5312b Dual Port Quadrature Encoder Board, PN Y184438, used in Direct
Connect version 159 and earlier, has numerous jumpers. The following are the settings for the
jumpers, switches and resistors:
Jumper/Switch Setting Jumper/Switch Setting
SW1 0 W16 2-3
SW2 3 W17 2-3
W1 OUT W18 OUT
W2 1-2 W19 2-3
W3 OUT W23 9-10
W4 1-2 W24 2-3
W5 OUT W25 1-2
W6 1-2 W26 2-3
W7 OUT W28 1-2
W8 1-2 W32 2-3
W9 OUT W34 1-2
W10 1-2 R1-R12 300 OHM
W11 OUT R13&R15 220 OHM
W12 1-2 R14&R16 150 OHM
W13 1-2

Also refer to the Direct Connect Physical Connections Diagram in Appendix A.

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Differential Bus Board Jumper Settings

The old style Differential Buss Board, PN 8382013, is an ISA device that controls
communication with the enclosure feeder cards.
Its DIP Switch settings are in the chart below:

DIP Switch 1 1 2 3 4
Switch Positions ON ON ON OFF

Combination Differential/Encoder Board – ISA Type

This board, sometimes known as the Bernie Board for designer Bernie Christ, is an ISA board that
combines the two functions and saves a computer ISA slot for other purposes. Its PN is
R6820 70. The chart below gives jumper settings for Direct Connect version 158 and 159
machines. This board is also used in older models.

DIP
P1 P2 P3 P4 Jumper P3 P4 P5
Switch 1
Switch Switch
ON ON ON ON 1-2 1-2 OPEN
Positions Positions

The settings for those can be found in TSB N806.

Combination Differential/Encoder Board – PCI Type

This newest style board, PN Y582000, is used in Direct Connect machines version 160 and
above that run on the Windows NT operating system. The Dell computers that control these
systems have no ISA slots available for the older style Differential and Encoder boards so this
board was designed as a PCI type.
Note: This board has no jumpers to configure.
Both Bingo Diagnostics and Serial Diagnostics are available from the main Direct Connect screen.
See Chapters 4, 5, 6 and 7 for details on the diagnostic system.

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Relation Between DigiBoard/RocketPort in Control Computer and the

8051 and Bingo Boards
The diagram below shows the relation between the DigiBoard (or RocketPort) serial system in
the control Computer and the 8051 and Bingo boards in the inserter. Also refer to the Direct
Connect Physical Connections Diagram in Appendix A.
Input and output activity is routed through the Bingo, 8051 and DigiBoards or RocketPorts.
Some higher-level signaling functions, such as scanners or ink-jet printing, develop serial
communications by themselves and communicate directly with the DigiBoard or RocketPort.

DIRECT CONNECT
CONTROL PC

Scanner
DigiBoard or RocketPort

8051
8051
8051

Bingo Bingo

PC Motor PC Clutch

Figure 2-29: Relation Between DigiBoard/RocketPort in Control Computer and the 8051 and Bingo
Boards

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Serial Communications with the DigiBoard

A DigiBoard PC16e is used up to version 159 for Direct Connect.
This is a 16-port version for Direct Connect systems rather than the 8-port version used in ISC
2.0. The extra ports are needed for meters, Scitex printers, scanners and on machines with long
output sections.
The 16 port DigiBoard is PN Y184407.

Use the DOS DigiBoard drivers - not the Windows drivers used for
ISC 2.0.

These are placed in the C:\DIGI directory. The XIDOSCFG utility is used to configure the board
along with the DIP Switch settings in the chart below. These switch settings determine the
computer upper memory location used by the DigiBoard.
1 2 3 4 5 6 7 8 9 10 11
Switch DS1 OFF ON OFF OFF ON ON ON ON ON ON OFF
Switch DS2 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF

Serial Communications with the RocketPort

Version 160 Direct Connect machines based on the Windows NT operating system use a
RocketPort for serial communications.
• The RocketPort PN is Y185006.
• The RocketPort must be used with Windows NT based Direct Connect software.
• Serial communication and diagnostics inside Direct Connect are the same whether the
RocketPort or DigiBoard communication hardware is used. Select the Serial
Communications icon on the DC main screen to open a scrolling diagnostic screen for
all 8051 cards.
Note: The dialog box will not scroll continuously for serial items like scanners or meters that
only move data when reading or changing values.
• The RocketPort software is part of the standard DC image on the recovery CD. It is
configured as a service of Windows NT and is not visible in the local hard drive.
• The RocketPort in the computer is a PCI type and has no jumpers for configuration.

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Direct Connect and the Encoder

To set up the encoder in Direct Connect perform the following steps:
1. Click the Encoder hot spot on the DC main screen.
2. Select Setup from the pop-up menu. The Chassis Encoder Setup dialog box opens.

NEVER CHANGE
THESE SETTINGS!

Figure 2-30: Chassis Encoder Setup Dialog Box

Encoder settings are more important in Direct Connect than ISC because the position of the
mailpiece is controlled more closely.
• Direct Connect typically knows where each mailpiece is within ½ inch.
• ISC 2.0 frequently will show mailpieces in multiple positions, 4 to 5 inches apart.
Close location control is important for the integrity photocells and for integrity monitoring (the
position of the mail in relation to the doors).

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8051 CONFIGURATION
In general, machines have 8051 boards in each input module. This means shorter data cable
lengths and greater scanner and encoder reliability.
• 8051 boards on Direct Connect systems always use the same PROMs (currently
SLAV1A15 on Windows NT DC versions 160 and above machines) regardless of where
the 8051 card is located.
• Switch 6 is always down.
• Remove any FDSN jumpers on J11.
• Remove any feeder scanner connections on J10 and J6.
• Set JP4 1-2.
• Set JP6 1-2.
• If the 8051 is used on a feeder module (cutter, burster, or Hicap sheet feeder) and is
used for OMR scanning, wire a jumper (PN R583021) between J10 on the 8051 board
to J8 on the same board. This jumpers the lead edge and encoder signals to the correct
inputs for OMR scanning.

Standard Wiring for DigiBoard/RocketPort to 8051 Cards and

Standard Bingo Wiring
The Model Configuration software used to construct Direct Connect machines at the factory
creates a standard wiring configuration for Bingo and serial communications that should be
followed in most cases.
Many serial connections are required to be in a particular place by the DC software. Use Bingo
and serial diagnostic dialog boxes to check for proper connections.

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Multibus Feeder Setup

The following table summarizes the types of PROMs used for the various types of feeders in
Direct Connect systems:

Feeder Type PROM Label Checksum

Single Doc Feeder HRF2A08 or greater Check for current level.
Retail Feeder (24V solenoid) HRF2A08 or greater Check for current level.
Retail Feeder (12V solenoid) IOC1A04 or greater Check for current level.
2 Stage Envelope Feeder (12 Series) HRF2A08 or greater Check for current level.
One Cycle Envelope Feeder OCEFDR 1A02 or greater Check for current level.
Mini Burster HRF2A08 or greater Check for current level.
Heavy Duty Folder Feeder HRF2A08 or greater Check for current level.

Single document feeders and retail feeders on Direct Connect systems have certain wiring
modifications for door switches, and integrity photocells. The enclosure feeder board, PN
382033, is for Direct Connect machines only and is different than the board used for ISC 2.0
machines.
The additional harnessing changes for enclosure feeder boards are shown in the table below:

Connection Description
J1 pin 7 Door sense
J1 pin 8 Door sense
J1 pin 12 5v for integrity PC
J1 pin 10 Gnd for integrity PC
J1 pin 11 Signal for integrity PC

Wiring Differences for High Speed Machines

Arming Feeders

If the normal retail feeder PROM (which does not pulse) is used in the 12-volt
solenoid machines, the solenoids will be damaged!

All 11 and 12 Series machines and some retail 9 Series machines have feeders with 12-volt
solenoids on the demand feed roller.
• The separation solenoid remains at 24 volts. These 12-volt solenoids are pulsed with
24 volts for faster actuation required by these faster machines.
• The normal pulse rate is 24-volt initial activation for 50 milliseconds and then pulses of
20 milliseconds on and 20 milliseconds off.

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High Speed Machine Chain Offset

For the 12 Series, there is a chain-offset field in the Advanced Deck Setup dialog box. This
adjustment allows chain timing to be changed for high-speed operation. This accounts for the
position of the pusher at Encoder = 0.
Note: This box does not work in 8 and 9 series machines.
1. Click the Chassis hot spot on the DC main screen.
2. Select Setup from the drop-down menu to open the Chassis Setup dialog box.
3. Click [Advanced] to open the Chassis Advanced Setup dialog box.

Figure 2-31: Advanced Chassis Setup

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LOG FILES
Syslog.dat
The syslog.dat file lives on the system either in the DC directory of the local drive or the I drive
of a networked system. Each inserter system has its own unique .dat file.
The syslog.dat file provides a way to log information relating to machine configuration and
operation for engineering. Examine this file and relate the information to systems problems; it
could be helpful in troubleshooting symptoms.
This syslog.dat file cannot solve all the problems that may plague a system., but it is a useful
tool to use to diagnose a machine symptom:
• An event that occurred leading up to a failure in the system.
• Track changes that have been made to the parameters of the system.

Example #1: The highlighted event is the failure of the OMS DLL to load.

Figure 2-32: Log File Example 1

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Example #2: The highlighted events are the changing of parameters in the input and scale of the
system.

Figure 2-33: Log File Example 2

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Example #3: The highlighted event is a fatal error (Red Screen).

Figure 2-34: Log File Example 3

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DIAGNOSTIC DUMPS
If the system is having an intermittent problem, capture the operational system parameters for a
software engineer to evaluate. To accomplish this, create a diagnostic dump file.
Note: A Red Screen (fatal error) creates its own error.log file that is similar to the
diagnostic.dmp file.
1. Immediately after the error occurs, click Menu at the bottom of the DC main screen to
disable the system. This freezes the error condition and stops the software from
accumulating data that could displace the data from the error condition.

Figure 2-35: Opening the System Menu

2. Select Disable System from the pop-up System Menu. The Start button will change to a
set of circles with a diagonal line through each. This indicates that the system is disabled.

Figure 2-36: Disabling the System

3. From the DC main menu, click Dump and select To File from the drop-down menu.

Figure 2-37: Creating the Diagnostic Dump

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4. Name the file something that will describe the error condition, such as M1COMERR.DMP,
for a meter 1 communications error.

Figure 2-38: Naming Diagnostic Dump File

5. Zip this file, complete the DC Software Incident Data Sheet and send it to Danbury for
evaluation.
The DC Software Incident Data Sheet is available under Forms on the Customer Service web
site: http://pmweb.ct.pb.com/home/custser/cswebsite/forms2.cfm.
Instructions for sending the form and the file to Danbury are covered in TSB# N940.
6. To re-enable the system, click Menu and select Enable System from the pop-up menu. This
returns the system to the operational state.

Figure 2-39: Enable System (Button Turns to Disable System)

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and Feeder Setup
Chassis Basic Setup
Chassis Advanced Setup
Advanced Feeder Setup
Expert Chassis Setup
Feeder Channel Setup
Expert Feeder Setup
Enabling (Integrity or Deck)
Collation Detect Photocells
Chapter 3 – Chassis and Feeder Setup Direct Connect Service Manual

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CHAPTER 3: CHASSIS AND FEEDER SETUP

Table of Contents
CHASSIS BASIC SETUP ..................................................................... 93
Collation Length.................................................................................................................................. 93
Job Speeds............................................................................................................................................ 94
Maximum............................................................................................................................................. 94
Nominal............................................................................................................................................... 94
Minimum ............................................................................................................................................. 94
Allow Data Control Stop................................................................................................................... 95
Enable Collation Detect.................................................................................................................... 95
Maximum Time in Delay .................................................................................................................... 96

CHASSIS ADVANCED SETUP............................................................. 97

Positions/Distances Area.................................................................................................................. 98
Lead Edge Guard .............................................................................................................................. 98
Trail Edge Guard............................................................................................................................... 98
Encoder Times Area ........................................................................................................................... 99
Stop Time........................................................................................................................................... 99
Exit Time .......................................................................................................................................... 100
Adjusting Exit Time.......................................................................................................................... 101
Start Timeouts Area Settings ....................................................................................................... 103
Start Timeout ................................................................................................................................. 103
Accelerate Time ............................................................................................................................. 103
Start Delay ...................................................................................................................................... 103
Soft Delay Area Settings................................................................................................................ 104
Predelay Coasting ......................................................................................................................... 104
Brake “Tap” Time........................................................................................................................... 104
Stop Control Area Settings........................................................................................................... 105
Stop Mode ...................................................................................................................................... 105
Cycle Stop on Jams ....................................................................................................................... 106
Complete Feeds After Stop ........................................................................................................ 106
Inhibit Stops During Exit Time ................................................................................................... 106
Stop Timeouts Area Settings........................................................................................................ 107
Chassis Stop Timeout .................................................................................................................. 107
Feed Stop Timeout ....................................................................................................................... 107
Brake On Time ............................................................................................................................... 108
Chain Clutch Reenable Time ...................................................................................................... 108
Alarms Enabled After Stop .......................................................................................................... 108
Post Delay Hold............................................................................................................................. 109

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ADVANCED FEEDER SETUP.............................................................110

Feed Timings Group........................................................................................................................ 111
Dynamic Feed Time....................................................................................................................... 111
Standard Feed Time...................................................................................................................... 111
Check Time ..................................................................................................................................... 111
Check Time Test............................................................................................................................ 112
Delay Time ...................................................................................................................................... 112
Arm Time ......................................................................................................................................... 113
Use Dynamic Feed Time................................................................................................................. 114
Hold Feeds When Chain Coasting............................................................................................... 114
Dequalify on Door Opening.......................................................................................................... 114
Collation Detect Functions ........................................................................................................... 115
Use Collation Detect PC ............................................................................................................. 115
Cycle Stop on Collation Detect Errors.................................................................................... 116
Delete Missing Mailpieces ........................................................................................................... 116
Stop on Missing Mailpieces ........................................................................................................ 116
Stop on Unknown Mailpieces..................................................................................................... 117
Dequalify Upstream On Missing................................................................................................ 117
Dequalify Downstream on Unknown ........................................................................................ 117

EXPERT CHASSIS SETUP.................................................................118

Feeders Per Pusher .......................................................................................................................... 119
Station Offset Fields ....................................................................................................................... 119
Chain Offset Field ............................................................................................................................ 120
Pusher Size ........................................................................................................................................ 120
Exit Offset.......................................................................................................................................... 121
Max Speed (CPH)............................................................................................................................ 121

FEEDER CHANNEL SETUP ...............................................................122

Feeder Channel Offsets.................................................................................................................. 122
Station Offset Terms and Definitions ...................................................................................... 123
Viewing Offsets in Direct Connect............................................................................................ 124
Feeder Channel Setup .................................................................................................................... 125
Verify Insert/Collation Sequence .............................................................................................. 126
Feed Start Timeout ....................................................................................................................... 126
Feed Timeout.................................................................................................................................. 127
Refeed Delay .................................................................................................................................. 127
Blink Period ..................................................................................................................................... 127
Over/Under Kit Installed............................................................................................................. 128
Wiring Method ............................................................................................................................... 128

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EXPERT FEEDER SETUP...................................................................129

Locations Relative to Front of Feeder Area Settings .............................................................. 130
Collation Detect PC Location .................................................................................................... 130
Jam Wire Zone Start ..................................................................................................................... 131
Jam Wire Zone End........................................................................................................................ 131
Door Access Zone......................................................................................................................... 132
Door Access Zone Start .............................................................................................................. 132
Door Access Zone End................................................................................................................. 133
Insert Drop Zone End .................................................................................................................. 133
Return to Previous State After an Error..................................................................................... 133

ENABLING (INTEGRITY OR DECK) COLLATION DETECT PHOTOCELLS

.......................................................................................................134
Chassis Setup Dialog ...................................................................................................................... 134
Feeder Setup Dialog........................................................................................................................ 135
Collation Detect PC Location....................................................................................................... 136
Use Collation Detect PC................................................................................................................ 137
Verify Insert/Collation Sequence ................................................................................................ 137

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CHASSIS BASIC SETUP

Click on the Chassis hot spot on the DC main screen. Select Setup from the drop-down menu
to open the Chassis Setup dialog box.

Figure 3-1 :Opening the Chassis Setup Dialog Box

Collation Length
The Collation length field is critical to the operation of the machine.
It is used to determine when the collation detect photocells should be blocked if the material is
too far forward in a delay scenario (i.e. masking detection).
Set this value to the size of the collation in inches. If there are inserts that are longer than the
control document, use the size of the largest insert.

Figure 3-2: Collation Length Field

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Job Speeds
Maximum

Figure 3-3: Job Speeds/Maximum Field

Nominal

Figure 3-4: Job Speeds/Normal Field

Minimum

Figure 3-5: Job Speeds/Minimum Field

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Allow Data Control Stop

When the Allow data control stop check box is selected, most stops will occur at cycle stop
times.

Figure 3-6: Allow Data Control Stop Field

Enable Collation Detect

This parameter is used with the optional MasterTrack collation integrity feature.
The Enable collation detect check box is used to turn all of the collation detect photocells off
and on. When this feature is turned on, each feeder will also need to be enabled if desired. See
“Enabling (Integrity or Deck) Collation Detect Photocells” later in this chapter.
If the MasterTrack chassis tracking option is not installed, then this check box only enables the
other collation detect features that monitor speed, size and position of each piece of material on
the chassis to verify and ensure collation integrity.

Figure 3-7: Enable Collation Detect Field

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Maximum Time in Delay

This setting is the amount of time before the inserter will stop if left in delay. The setting may
have to be increased when a technician is working on the machine or performing diagnostics.

Figure 3-8: Maximum Time in Delay Field

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CHASSIS ADVANCED SETUP

1. Click the Chassis hot spot on the DC main screen.
2. Select Setup from the drop-down menu. The Chassis Setup dialog box opens.
3. Click [Advanced] to open the Chassis Advanced Setup dialog box.

Figure 3-9: Opening Advanced Chassis Setup Dialog Box

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Positions/Distances Area
The Lead edge guard and Trail edge guard parameters determine how much additional
tolerance is added onto the collation length given in the basic Chassis Setup dialog box. These
values are typically given in inches.

Figure 3-10: Chassis Advanced Setup/Positions/Distances Area

Lead Edge Guard

Figure 3-11: Lead Edge Guard Field

Trail Edge Guard

Figure 3-12: Trail Edge Guard Field

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Encoder Times Area

Figure 3-13: Chassis Advanced Setup/Encoder Times Area

Stop Time
The Stop time is the encoder count for controlled stops.
• For most double pusher spacing chassis, use a value of 28.
• For single pusher machines, use a value of 65 as a starting point.
Observe the location of collations when the chassis comes to a stop. Adjust the value to ensure
the collation stops at a control location without extending past the feeder ledge.

Figure 3-14: Encoder Times/Stop Time Field

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Exit Time
The Exit time field is extremely critical. It is used to determine the encoder count at which
material should be shifted from the chassis to the MOS. If this setting is not correct:
• Can result in jams (i.e. unknown piece at PC1) when the machine stops.
• It can also result in data shifting errors where the wrong data is shifted with the pieces on
the MOS.
On double pusher chassis:
• The envelope is completely inserted at approximately encoder count 26.
• The exit time in these cases is 30.
On single pusher chassis:
• The exit time is usually 61.
Note: The size of the envelope and configuration of the take away rollers can affect the
optimal exit time.

Figure 3-15: Encoder Times/ Exit Time Field

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Adjusting Exit Time

Normally it is not necessary to change this setting, but a 9x12 application may warrant change.
Adding an inch to the Exit Offset setting in the Expert Chassis Setup dialog box increases the
Exit time setting on the Advanced Chassis Setup dialog box by three counts.
To change the Exit time, perform the following steps:
1. Go to the Expert Chassis Setup dialog box and change the Exit Offset setting.
2. Click [OK] in each Chassis Setup dialog box.

Figure 3-16: Adjusting Exit Offset

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3. Reopen the Advanced Chassis Setup dialog box. The Exit time will be changed to the new
setting.
In this example, Exit Offset on the Chassis Expert Setup was changed from 12 to 13 inches.
After closing all the Chassis Setup dialog boxes and reopening the Chassis Adva nced Setup
dialog box, the Exit time in the grayed out field has changed from count 29 to count 33.

Figure 3-17: Confirming Exit Time Change

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Start Timeouts Area Settings

Figure 3-18: Chassis Advanced Setup/Start Timeouts Area

Start Timeout

Figure 3-19: Start Timeout Field

Accelerate Time

Figure 3-20: Accelerate Time Field

Start Delay

Figure 3-21: Start Delay Field

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Soft Delay Area Settings

Soft delay deenergizes the clutch and only momentarily energizes the brake.

Figure 3-22: Chassis Advanced Setup /Soft Delay Area

Predelay Coasting

Figure 3-23: Pre-Delay Coasting Field

Brake “Tap” Time

Smaller and greater times can be set. The reaction time of the brake coil is about 20 ms.

Figure 3-24: Brake “Tap” Time Field

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Stop Control Area Settings

Stop Mode
The Stop mode field pull-down menu determines whether even, odd or both cycle stops are used
(i.e. stop at 28, 78 or both).
• Most double pusher machines are set to Odd Cycle Only stop.
• Most single pusher machines are set to Even Cycle Only stop.

Figure 3-25: Chassis Advanced Setup/Stop Control Fields

Figure 3-26: Stop Control/Stop Mode Field

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Cycle Stop on Jams

Figure 3-27: Stop Control/Cycle Stop on Jams Check Box

Complete Feeds After Stop

The Complete feeds after stop check box is a useful parameter that allows any pending feeds to
be completed after the cycle stop is reached.
The machine appears to delay for a brief instant after the cycle stop. This prevents material from
sputtering out on a restart if feeds are in process during a cycle stop (i.e., odd feeders feeding
during and even cycle stop).

Figure 3-28: Stop Control/Complete Feeds After Stop Check Box

Inhibit Stops During Exit Time

This connection is normally made and enabled.

Figure 3-29: Stop Control/Inhibit Stops During Exit Time Check Box

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Stop Timeouts Area Settings

Figure 3-30:Chassis Advanced Setup/Stop Timeouts Area

Chassis Stop Timeout

This parameter is the amount of time from disengagement of the clutch to the time the brake is
engaged.

Figure 3-31: Stop Timeouts/Chassis Stop Timeout Field

Feed Stop Timeout

Figure 3-32: Stop Timeouts/Feed Stop Timeout Field

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Brake On Time

Figure 3-33: Stop Timeouts/Brake on Time Field

Chain Clutch Reenable Time

Figure 3-34: Stop Timeouts/Chain Clutch Reenable Time Field

Alarms Enabled After Stop

Figure 3-35: Stop Timeouts/Alarms Ended After Stop Field

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Post Delay Hold

Figure 3-36: Stop Timeouts/Post Delay Hold Field

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ADVANCED FEEDER SETUP

1. Click on one of the Feeder hot spots on the DC main screen.
2. Select Setup from the drop-down menu.
3. Click [Advanced] on the Feeder object dialog box that opens to display the Feeder
Advanced Setup dialog box.

Figure 3-37: Opening Feeder Advanced Setup Dialog Box

Note: The Current settings on the blue help screens match the actual settings on the
Advanced Feeder Setup dialog box. These Feed Timing settings can be different for each
feeder.

Figure 3-38: Feeder Advanced Setup/Feed Timings Area

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Feed Timings Group

Dynamic Feed Time
The linear speed of the enclosures is the same as the linear speed of the collation pushers. Start
feeding the enclosures when the front of the collating pushers are at the same distance the
enclosure is the from the feeder exit point. The enclosure speed is faster with 6 x 12 and 9 x 12
enclosures.
If anything goes wrong, masking or jamming will occur. Jamming will be detected but masking
often will not. If this feature is used, be careful and do not use it too aggressively.

Figure 3-39: Feed Timings/Dynamic Feed Time (Moving) Field

Standard Feed Time

Set this to the time when the space behind the collating pushers in front of the feeder is the
same as the enclosure length.

Figure 3-40: Feed Timings/ Standard Feed Time Field

Check Time
If the feeder has not yet separated the material, Check time is the encoder count at which the
inserter is placed into soft delay.
A soft delay de-energizes the clutch and taps the brake (energizes the brake for short periods of
time).
Separation is the point at which the feeder photocell (lead edge) becomes blocked.

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Check Time Test

1. Test at maximum operating speed.
2. Make Check Time 6 to 8 counts before Delay Time.
3. Empty the feeder to make it go into delay. Make sure the feeder shows it is in delay.
4. If the machine is in delay but the feeder does not show it is in delay, the Check Time needs
to be set to earlier in the cycle.
5. If the feeder indicated it was in delay, you can decrease the number of encoder counts before
delay.

Figure 3-41: Feed Timings/Check Time Field

Delay Time
Make this setting early enough to keep the leading edge of the collation 1/2-inch from the edge
of the ramp of the feeder feeding.
Also use Check Time to turn off the clutch and effect soft delay. This reduces the amount of
coast normally experienced with a cycle stop.

Figure 3-42: Feed Timings/Delay Time Field

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Arm Time
This optional feature is meant to keep from putting a curl in an enclosure when it waits for long
periods of time to be fed. It allows the service technician to time the arming action so that it is
completed just as the feed occurs. With Direct Connect this will, in theory, also prevent
unnecessary wear on the main clutch/brake. If this field is shaded, the inserter does not have
armed feeders.
Make this setting the encoder count reached when the enclosure is fed into the demand feed
roller and waits until the Feed time setting is reached. The number can be any setting between
Delay time and Feed time.

Figure 3-43: Feed Timings/Arm Time

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Figure 3-44: Feeder Advanced Setup/Mid-Dialog Area Settings

Use Dynamic Feed Time

Figure 3-45: Feeder Advanced Setup/Use Dynamic Feed Time Check Box

Hold Feeds When Chain Coasting

Figure 3-46: Feeder Advanced Setup/Hold Feeds When Chain Coasting Check Box

Dequalify on Door Opening

If the optional MasterTrack chassis tracking option is included, and Dequalify on door
opening is checked, any mailpiece behind a door opened by an operator will be outsorted
automatically. This prevents operator interaction with the mail stream.

Figure 3-47: Feeder Advanced Setup/Dequalify on Door Opening Check Box

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Collation Detect Functions

Figure 3-48: Feeder Advanced Setup/Collation Detect Functions Area

Use Collation Detect PC

Enable collation detect under Chassis setup must also be checked.
If the MasterTrack chassis tracking option is not installed, then this check box only enables
the other collation detect features that monitor speed, size and position of each piece of material
on the chassis to verify and ensure collation integrity.

Figure 3-49: Collation Detect Functions/Use Collation Detect PC Check Box

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Cycle Stop on Collation Detect Errors

Figure 3-50: Collation Detect Functions/Cycle Stop on Collation Detect Errors Check Box

Delete Missing Mailpieces

If the Delete missing mailpieces check box is selected, the next integrity photocell will sense
that the mailpiece is missing. All control data for this collation (select feeds and mailing
envelope) will be removed.

Figure 3-51: Collation Detect Functions/Delete Missing Mailpieces Check Box

Stop on Missing Mailpieces

If this box is selected when the collation expected is missing, an empty set of pushers will stop
the machine.

Figure 3-52: Collation Detect Functions/Stop on Missing Mailpieces Check Box

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Stop on Unknown Mailpieces

Figure 3-53: Collation Detect Functions/Stop on Unknown Mailpieces Check Box

Dequalify Upstream On Missing

If this check box is selected, the collation ahead of the empty set of pushers will also be
dequalified.

Figure 3-54: Collation Detect Functions/Dequalify Upstream on Missing Check Box

Dequalify Downstream on Unknown

If this check box is selected, the collation following what should have been an empty set of
pushers will be dequalified.

Figure 3-55: Collation Detect Functions/Dequalify Downstream on Unknown Check Box

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EXPERT CHASSIS SETUP

1. Click the Chassis hot spot on the DC main screen.
2. Select Setup from the drop-down menu.
3. Click the [Advanced] button to open the Chassis Advanced Setup dialog box.
4. Click the [Expert] button to open the Chassis Expert Setup dialog box.

Figure 3-56: Opening Chassis Expert Setup Dialog Box

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Feeders Per Pusher

The Feeders per pusher field is factory set at:
• 1 for single pusher spacing machines
• 2 for double pusher spacing machines.

Figure 3-57: Chassis Expert Setup/Feeders Per Pusher Field

Station Offset Fields

The Station offset 0 and Station offset 1 fields are critical for the operation of the entire
chassis. These values determine:
• When data is shifted between feeders
• Where Direct Connect thinks the pushers are located at encoder count zero.
1. Set the Station offset 0 field to the distance between the deck plate edge and the ledge in
inches. The ledge is upstream from the edge of the deck plate, so this is a negative value. A
value of –2.7 is often used.
2. Set the Station offset 1 value equal to the sum of the Station offset 0 value and 6.75 (one
half a station). –4.05 is often used.
Note: These values should not change if you "jump" the pushers.

Figure 3-58: Chassis Expert Setup/Station Offset Fields

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Chain Offset Field

The Chain offset value is used to account for the pusher location relative to the deck plate at
encoder count zero.
• Make sure the machine’s mechanical timing is correct.
• Measure the distance between the deck plate and the front of the pusher.
• Use a negative number for situations where the pushers are upstream of the deck plate.

Figure 3-59: Chassis Expert Setup/Chain Offset Field

Pusher Size

Figure 3-60: Chassis Expert Setup/Pusher Size Field

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Exit Offset
This setting is used to change Exit time on the Chassis Advanced Setup dialog box.
Normally it is not necessary to change this setting. It may be necessary to do so with a 9 x 12
application. Adding an inch to the Exit Offset setting will increase Exit Time by three counts.
(See the Advanced Feeder Setup section in this chapter.)

Figure 3-61: Chassis Expert Setup/Exit Offset Field

Max Speed (CPH)

The Max Speed (CPH) field is hard coded by the machine configuration.

Figure 3-62: Chassis Expert Setup/Max Speed (CPH) Field

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FEEDER CHANNEL SETUP

Feeder Channel Offsets

There are certainDirect

physical offsetssoftware
Connect used to is
relate the feeder
a hardware geometry
control. to the
It is not a fixdeck plate.
for hardware
problems.
The relative location within the feeder is negative if it is upstream from the station’s
ledge. These settings are made at the factory and should not be changed under
mostlocation
The relative circumstances.
within the feeder is positive if it is downstream from the ledge.
Check the hardware for problems first!

Collation Detect Photocell must

be located in the negative zone

Jam Wire
Zero Jam Wire
Zone End
Zone Start
Feeder Ledge
Feeder Ledge

Insert Drop Zone End Edge of

- -2.69 inches deck plate

Positive Negative

Zero

13.50

Zone accessible
(gray area) to
operator when
door is opened Units are
expressed
in inches.

Figure 3-63: Feeder Station Offsets

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Station Offset Terms and Definitions

Term Definition
This is the distance straight out from the ledge at which the beam from the
Collation Detect PC
collation detect photocell will be broken. This value is always negative because
Location
it is upstream from the edge of the deck plate.
This is the furthest upstream point that can be accessed by the operator when
the door is opened, typically -13.5 inches. The on-screen indicator for all
Door Access Zone pieces between the zone start and zone end will change to yellow ("maybe")
Start when the door is opened.
Note that this is a negative value because the door switch for a feeder is
mounted on the preceding feeder.
This is the furthest downstream point that can be accessed by the operator
Door Access Zone
when the door is opened. This is typically a smaller negative number such as
End
-5.0 inches
This is the closest point downstream a piece can be and still touch the jam wire
for the station. Typically, the value for this location is zero. The on-screen
Jam Wire Zone Start
indicator for all pieces between the jam zone start and end will change to red if
the jam wire is tripped.
This is the furthest point downstream a piece can be and still touch the jam wire
Jam Wire Zone End
for the station. Typically, the value for this location is 13.50 inches.
Insert Drop Zone This is the furthest upstream the trail edge of the insert normally hits. This is
End typically -2.69inches.

These offsets are very important to Direct Connect. They are used to determine what mailpieces
should be invalidated in the event of a door opening, etc. They are also used to relate encoder
counts to the collation detect photocell.

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Viewing Offsets in Direct Connect

To view these offsets in Direct Connect perform the following steps:
1. Click on one of the Feeder icon hot spots on the DC main screen.
2. Select Setup from the drop-down menu.
3. Click [Advanced] in the Feeder Setup dialog box to open the Advanced Feeder Setup
dialog box.
4. Click [Expert] in the Advanced Setup dialog box to open the Feeder Expert Setup dialog
box.
5. View the offsets in the Expert Setup dialog box.

Figure 3-64: Opening the Expert Feeder Setup Dialog Box to View Feeder Offsets

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Feeder Channel Setup

To open the Feeder Channel Setup dialog box, perform the following steps:
1. Click on one of the Feeder hot spots on the DC main screen.
2. Select Setup from the drop-down menu. The Feeder Setup dialog box opens.
3. Click [Advanced] in the Feeder Setup dialog box to open the Advanced Feeder Setup
dialog box.
4. Click [IO Setup] to open the Feeder Channel Setup dialog box.

Figure 3-65: Opening the Feeder Channel Setup Dialog Box

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The settings regulate how inserts are fed to the deck, but not when or where the inserts are fed.
Use the values in the Setup section as a guide when modifying mechanical timing.

Figure 3-66: Feeder Channel Setup Dialog Box

Verify Insert/Collation Sequence

This feature is very useful in detecting skewed or incompletely fed pieces.
Enable collation detect under Chassis setup. If the MasterTrack chassis tracking option is
not installed, then this check box only enables the other collation detect features that monitor
speed, size and position of each piece of material on the chassis to verify and ensure collation
integrity.

Figure 3-67: Feeder Channel Setup/Verify Insert Collation Sequence Check Box

Feed Start Timeout

The Feed start timeout is the maximum time from the start of a feed (clutch is energized) to
when the feed photocell is blocked.

Figure 3-68: Feeder Channel Setup/Feed Start Timeout Field

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Feed Timeout
The Feed timeout parameter specifies the maximum time an enclosure is allowed to clear the
feeder photocell. The timer starts when the photocell is first blocked in the unarmed mode or
when the feed starts in the armed Mode.

Figure 3-69: Feeder Channel Setup/Feed Timeout Field

Refeed Delay
The Refeed delay is the amount of time, after photocell trail edge, the feeder is required to
remain idle before it can feed another collation.
• This parameter is normally set low (5 or 10) on 12 series systems.
• If a single document feeder is used as a multi-document feeder, a large value may be
needed to ensure paper-settling time before another page is fed.

Figure 3-70: Feeder Channel Setup/Refeed Delay Field

Blink Period
This period is the frequency with which the feeder fault light blinks on and off.

Figure 3-71: Feeder Channel Setup/Blink Period

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Over/Under Kit Installed

The Over/Under kit is a set of decks installed at a feeder. When this kit is installed, the feeder
insert becomes the address-bearing document. This kit feeds the insert on top, masking the
control document, which normally would carry the address. If this box were not checked, the
system would see the insert fed on top as masking and dequalify the collation.

Figure 3-72: Feeder Channel Setup/Over/Under Kit Installed Check Box

Wiring Method
The Wiring method pull-down in the dialog box determines how the feeder door is to be treated:
• Separate switches are used for the door and for the sensor.
• Only a sensor is used.
• The wiring method used for early DC models and retrofits.

Figure 3-73: Feeder Channel Setup/Wiring Method Menu

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EXPERT FEEDER SETUP

To open the Expert Feeder dialog box, perform the following steps:
1. Click a Feeder icon hot spot on the DC main screen.
2. Select Setup from the drop-down menu.
3. Click [Advanced] to open the Feeder Advanced Setup dialog box.
4. Click [Expert] to open the Feeder Expert Setup dialog box.

Figure 3-74: Opening the Feeder Expert Setup Dialog box

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Locations Relative to Front of Feeder Area Settings

Figure 3-75: Feeder Expert Setup/Locations (Relative to the Front of the Feeder) Settings

Collation Detect PC Location

There are several mounting solutions for the collation detect photocell. Each solution yields a
slightly different value for this location offset.
To measure the correct value perform the following steps:
1. Take a piece of paper and push it over the ramp until the photocell is blocked.
2. Measure the amount of paper hanging over the ledge.
3. Use the negative of that value.

Figure 3-76: Locations (Relative to the Front of the Feeder)/Collation Detect PC Location Field

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Jam Wire Zone Start

This is the furthest downstream a mailpiece can hit the jam wire for the station.
All pieces between the Jam wire zone start and Jam wire zone end will be marked red on the DC
screen if the jam wire is tripped. This value is typically zero.

Figure 3-77: Locations (Relative to the Front of the Feeder)/Jam Wire Zone Start Field

Jam Wire Zone End

This is the furthest downstream a mailpiece can hit the jam wire for the station. This value is
typically 13.50 inches.

Figure 3-78: Locations (Relative to the Front of the Feeder)/Jam Wire Zone End Field

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Door Access Zone

If the operator removes everything between Door Access Zone Start and Door Access Zone
End (as selected in the Expert Feeder dialog box), they are disqualified as "maybe" pieces. The
machine will not stop when they fail to appear at the next collation detect photocell.
If the pieces remain on the chassis, they will be outsorted later as suspect pieces.

These parameters
are hard-coded at
machine
configuration.

Figure 3-79: Locations (Relative to the Front of the Feeder)/Door Access Zone Start and End Fields

The Door Access Zone Start and Door Access Zone End are hard-coded when the machine is
configured at the factory.

Door Access Zone Start

This is the furthest upstream point that can be accessed by the operator when the door is
opened.
The icons for all pieces between the zone start and zone end turn yellow (indicating
questionable) whenever the door is opened. This value is typically -13.5 inches.
Note: This is a negative value since the door switch for a feeder is for the door under the
feeder deck. See Figure 3-63: Station Offsets.

Figure 3-80: Locations (Relative to the Front of the Feeder)/Door Access Zone Start Field

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Door Access Zone End

This is the furthest downstream point that can be accessed by the operator when the door is
opened. This is typically -6.00 inches.

Figure 3-81: Locations (Relative to the Front of the Feeder)/Door Access Zone End Field

Insert Drop Zone End

Figure 3-82: Locations (Relative to the Front of the Feeder)/Door Access Zone Start Field

Return to Previous State After an Error

Figure 3-83: Return to Previous State After an Error Check Box

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ENABLING (INTEGRITY OR DECK) COLLATION DETECT

PHOTOCELLS
These photocells are blocked and unblocked by collations on the deck as well as inserts being
fed. Collation detect photocells must be enabled:
• In the Feeder Advanced dialog box.
• In the Feeder Channel Setup dialog box.

Chassis Setup Dialog

The Enable Collation Detect check box in the Chassis Setup dialog box must be checked or the
collation detect feature will not be activated. If this box is shaded, you do not have the
MasterTrack collation integrity feature.
1. Click the Chassis hot spot on the Direct Connect main screen.
2. Select Setup from the menu displayed. The Chassis Setup dialog opens.
3. Select the Enable Collation Detect check box to activate the process.
4. Complete the steps in the Feeder Setup dialog section that follows to enable the collation
detect photocells.

Figure 3-84: Check Box to Enable Chassis Collation Detect

Figure 3-85: Chassis Setup/Enable Collation Detect Check Box

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Feeder Setup Dialog

1. Click on one of the Feeder hot spots on the DC main screen.
2. Select Setup from the drop-down menu.
3. Click [Advanced] on the Feeder object dialog box that opens to display the Feeder
Advanced Setup dialog box.
4. Select the Use collation detect PC check box.

Figure 3-86: Check Box Used to Enable Feeder Collation Detect

5. Click [IO Setup] in the Feeder Advanced Setup dialog box to display the Feeder Channel
Setup dialog box.
6. Click the Verify insert/collation sequence check box.
7. Close the Feeder Channel Setup dialog box.

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Collation Detect PC Location

The feeder uses this value to determine the encoder count at which the collation is supposed to
block the photocell.
There have been several mounting solutions for the collation detect photocell. Each solution
yields a slightly different value for this location offset.
1. Click [Expert] in the Feeder Advanced Setup dialog box to display the Feeder Expert
Setup dialog box.
2. Take a piece of paper and push it over the ramp until the photocell is blocked.
3. Measure the amount of paper hanging over the ledge and use the negative of that value.
4. Type this value in the Collation detect PC location field.

Figure 3-87: Feeder Advanced/Expert Setup Collation Detect Dialog Boxes

Figure 3-88: Feeder Expert Setup/Collation Detect PC Check Box

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Use Collation Detect PC

If you use this feature:
• You must use the Collation Detect feature in the Chassis Setup dialog box.
• You do not have to use the Verify Insert Collation sequence in the Feeder Channel
Setup dialog box.

Figure 3-89: Feeder Advanced Setup/Use Collation Detect PC Check Box

Verify Insert/Collation Sequence

Use the Verify Insert Collation Sequence feature with or without using either the Feeder or
Chassis Collation Detect PC features.

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Transport Setup
Brakes and Clutches
Debounced Photocell
Transport Error Detection
– Transport Gates
Motor Startup and
Acceleration
Bingo Diagnostics
Bingo Status
8051Board
Chapter 4 – Transport Direct Connect Service Manual

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CHAPTER 4: TRANSPORT
Table of Contents
TRANSPORT SETUP........................................................................143
Timers ................................................................................................................................................. 144
Settling Time .................................................................................................................................. 144
Gate Clear Time............................................................................................................................. 144
Dispatcher Parameters ................................................................................................................... 144
Max Nesting.................................................................................................................................... 144
Min Spacing .................................................................................................................................... 145
Request When Clear ..................................................................................................................... 146
Forward Multiple Requests When Hungry .............................................................................. 146

BRAKES AND CLUTCHES ................................................................147

Transport Gate Trap Setup/Timing Area Settings.................................................................. 148
Timing Open Delay ....................................................................................................................... 148
Timing Open Minimum................................................................................................................. 148
Timing Closed Delay..................................................................................................................... 148
Timing Closed Minimum .............................................................................................................. 149

DEBOUNCED PHOTOCELL .............................................................150

Leading Edge..................................................................................................................................... 151
Nominal “Off “ Time...................................................................................................................... 151
Always Hold Off ............................................................................................................................. 152
Hold “Off” Time ............................................................................................................................. 152
Trailing Edge ..................................................................................................................................... 153
Nominal “On” Time ....................................................................................................................... 153
Always Hold On ............................................................................................................................. 154
Hold “On” Time ............................................................................................................................. 154
Invert Input........................................................................................................................................ 154

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TRANSPORT ERROR DETECTION – TRANSPORT GATES...............155

Detect Jams ....................................................................................................................................... 156
Jam Types Detected Group........................................................................................................... 156
Creation of Unknowns.................................................................................................................. 156
Lead Edge Timeout ....................................................................................................................... 157
Photocell Timeout......................................................................................................................... 157
Overruns Before PC ...................................................................................................................... 157
Overruns At PC .............................................................................................................................. 158
Next Arrives Before PC Clear ..................................................................................................... 158
Previous PC: Overlap Modes......................................................................................................... 159
Don’t Create Unknowns................................................................................................................. 160
Ignore Unknowns at Start.............................................................................................................. 160
Jam Timeouts Under Photocell..................................................................................................... 161
Jam Timeouts Before Photocell .................................................................................................... 161
Determining Jam Timeout Settings ............................................................................................. 161

MOTOR STARTUP AND ACCELERATION........................................162

Transport Advanced Setup ........................................................................................................... 162
Motor On Delay............................................................................................................................... 163
Motor Off Delay............................................................................................................................... 163
Transport Accelerate Time............................................................................................................ 164
Transport Deaccelerate Time ....................................................................................................... 164
Dequalify Pieces When Interlock Opened ................................................................................. 165
In Own Stations ............................................................................................................................. 165
In Chassis Target Station ............................................................................................................ 165

BINGO DIAGNOSTICS ....................................................................166

BINGO STATUS...............................................................................168

8051 BOARD..................................................................................169

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TRANSPORT SETUP
1. Click on the Transport hot spot on the DC main screen.
2. Click Setup on the Transport menu that opens.
3. Select the Transport_Gate1 or Gate3 from the Element Setup drop down menu. This is a
dual stage transport. The gates are solenoid operator stops.
4. Click [Setup] to open the Transport_Gate Setup dialog box for the element selected. The
Gate1 and Gate3 dialog boxes are the same.

Figure 4-1: Opening a Transport Gate Setup Dialog Box

The [Setup] button for the Transport Entrance and Transport_Mid elements opens the Setup
dialog box used for error detection. The [Advanced] button on the Transport Gate Setup
dialog box opens the error detection setup for the Transport Gates. See the Transport Error
Detection sections for the Transport Gates and the Transport Entrance/Mid that follow this
section for details about the dialog boxes below.

Figure 4-2: Opening the Transport_Mid Setup Dialog Box

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Timers
Settling Time
The Settling time needs to be long enough to let the collation rest up against the stop and stay
there before the gate is lowered. This helps ensure the collation remains aligned.

Figure 4-3: Setting Time Field

Gate Clear Time

The Gate clear time allows the collation to clear the gate before the gate is released back to the
up position. This keeps the gate from catching the collation and skewing paper.

Figure 4-4: Gate Clear Time Field

Dispatcher Parameters
Max Nesting
This parameter determines how many requests can be forwarded upstream at a time. The higher
this value, the more requests will be issued upstream and the greater the performance. If this
value is too high, then there will be a tendency to have too many collations in progress and
overruns may occur when the machine stops.
As a general rule of thumb, set this parameter equal to the number of stages downstream plus
one. For example, the last transport gate before the deck - the value should be two. For the next
gate upstream, it should be three, and so on.

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On 12 Series systems, the maximum nesting value is typically set as follows:

Stage Nesting Value

Transport Gate 3 2
Transport Gate 2 3
Transport Gate 1 4
Accumulator 6

Figure 4-5: Maximum Nesting Field

Min Spacing
This parameter defines the minimum time to wait between dispatching requests upstream. This
gives the station time to recover from the last piece dispatched. These values are frequently set
to a very low number (i.e. 10 ms) on transport gates for 12 Series. For accumulators, this value
is referred to as Min Dump Spacing.
• Keep this value low - typically 20-60 ms.
• However, setting this value too low can make the system intolerant of folder paper
handling errors.

Figure 4-6: Min Spacing Field

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Request When Clear

This parameter determines whether the system will wait for the current piece to fully exit the
station prior to requesting another piece from upstream. On transport gates this means waiting
for the trail edge before a request is posted upstream.
Selecting the Request When Clear check box on a transport gate greatly reduces performance,
since a collation must leave a gate before one is requested.
The effect ripples through the input wasting 30 ms per stage (if it is checked off at each stage).
This can lead to refeed delays of 90 ms. In general, the Request When Clear check box is never
selected for transport gates unless there are severe paper-handling issues that warrant it.

Figure 4-7: Request When Clear Check Box

Forward Multiple Requests When Hungry

This setting has little or no effect.

Figure 4-8: Forward Multiple Requests When Hungry Check Box

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BRAKES AND CLUTCHES

There are several types of transport gates. Some gates employ a solenoid-operated gate and
others use a set of upper and lower rollers that are stopped and started by brakes and clutches
that trap the collation between them.
1. Click the Transport hot spot on the DC main screen.
2. Select Setup from the menu that opens.
• In DC versions 158 and earlier, the Transport Gate Setup dialog box will open.
• In DC versions 159 and later, the Transport Element Setup dialog box will open.
3. In DC versions 159 and later, select the transport element from those listed in the Element
Setup list.
4. Click [Gate] or [Setup] to open the Transport Gate Setup dialog box.

Note: In DC versions 158

and earlier, clicking Setup
will open this Transport
Gate Setup dialog box.

Figure 4-9: Opening the Transport Gate Setup Dialog Boxes

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Transport Gate Trap Setup/Timing Area Settings

Figure 4-10: Transport Gate Trap Setup Dialog Box:

Timing Open Delay

Figure 4-11: Timing Open Delay Field

Timing Open Minimum

Figure 4-12: Timing Open Minimum Field

Timing Closed Delay

Set this parameter for 5 ms or as required to let the collation get fully into the nip of the rollers

Figure 4-13: Timing Closed Delay Field

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Timing Closed Minimum

Figure 4-14: Timing Closed Minimum Field

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DEBOUNCED PHOTOCELL
The debounced photocell object debounces the signal received from a photocell. The debounce
logic can be applied selectively or all the time. Debounce logic is usually applied selectively to
avoid the time shifting that occurs when debounce logic is always applied.
1. Select Display > Objects from the DC main menu. The Display Object Info dialog box
opens.
2. Expand the Select Object list to reach the Transport Entrance PC4:
Model > I/O Devices > Bingo Cards > Transport Bingo > Transport Entrance PC4
3. Click [Setup] in the Object Functions area in the Display Object Info dialog box to open
the Transport Entrance PC4 setup dialog box.

Figure 4-15: Opening the Transport Element Entrance PC Dialog Box

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Leading Edge
Leading edge refers to the lead edge of the document as it passes over a photocell. Lead edge
occurs when the photocell is first blocked.
Signals are debounced only when there is a transition at the wrong time. This avoids having to
debounce every transition, which has the undesirable effect of shifting data by the debounce
time.
Selectively debounce the lead edge signal by setting the nominal off time equal to the typical
time that the photocell is unblocked between collations.
• If a transition (from unblocked to blocked) occurs before that time has elapsed, the
signal will be debounced (because the transition was not expected).
• If a transition occurs after the time has elapsed, the signal will not be debounced.
Photocells can be debounced all the time or only when they have been off or on for a set period
of time. If a photocell has not been off for more time than the distance between sheets of paper,
set the off time to keep an errant signal from entering the logic.

Figure 4-16: Transport Element Entrance PC Leading Edge Settings Area

Nominal “Off “ Time

This is the time, in ms (milliseconds), between the trailing edge of the previous mailpiece and the
next lead edge. In practice, set this time to something less than the minimum time between
collations.

Figure 4-17: Leading Edge/Nominal “Off” Time Dialog Box

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Always Hold Off

If the Always hold off check box is selected, the photocell lead edge transition signal will always
be debounced.

Figure 4-18: Leading Edge/Always Hold Off Check Box

Hold “Off” Time

Hold off time, in ms (milliseconds), is the time that the photocell signal will be debounced. After
this time, the lead edge signal will be checked again.
• If the signal has returned to an unblocked state, the transition will be ignored.
• If the signal has remained blocked, a valid lead edge will be declared.

Figure 4-19: Hold “Off” Time Dialog Box

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Trailing Edge
Trailing edge refers to the trail edge of the document as it passes over a photocell. Trail edge
occurs when the photocell transitions from blocked to unblocked.
Signals are debounced only when there is a transition at the wrong time. This avoids having to
debounce every transition, which has the undesirable effect of shifting data by the debounce
time.
Selectively debounce the trail edge signal by setting the Nominal on time equal to the typical
time that the photocell is blocked by a collation.
• If a transition (from blocked to unblocked) occurs before that time has elapsed, the
signal will be debounced because a transition was not expected.
• If a transition occurs after the time has elapsed, the signal will not be debounced.
Photocells can be debounced all the time or only when they have been off or on for a set period
of time. If a photocell has not been off for more time than the distance between sheets of paper,
set the off time to keep an errant signal from entering the logic.

Figure 4-20: Transport Entrance PC Trailing Edge Dialog

Nominal “On” Time

This is the time, in ms (milliseconds), between lead edge and trail edge of a collation. In practice,
set this time to something less than the minimum time it takes for a collation to pass over the
photocell.

Figure 4-21: Trailing Edge/Nominal “On” Time Dialog Box

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Always Hold On
If the Always hold on check box is selected, the photocell trail edge transition signal will always
be debounced.

Figure 4-22: Trailing Edge/Always Hold On Check Box

Hold “On” Time

This is the time, in ms (milliseconds), that the photocell signal will be debounced. It is the time
after the trail edge transition when the signal will be checked again.
• If the signal has returned to a blocked state, the transition will be ignored.
• If the signal has remained unblocked, a valid trail edge is declared.

Figure 4-23: Hold “On” Time Dialog Box

Invert Input
Inserters use photocells with both high and low outputs when blocked. DC can run with either
and can use either in any place. If the PC output is wrong, select the invert input check box.

Figure 4-24: Invert Input Check Box

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TRANSPORT ERROR DETECTION – TRANSPORT GATES

1. Click the Transport hot spot on the DC main screen.
2. Select Setup from the Transport menu.
3. Select Transport_Gate1 or Gate3 from the Element Setup drop-down field.
4. Click [Setup] to open the Transport_Gate Setup dialog box.
5. Click [Advanced] on the Transport_Gate Setup dialog box to open the Transport_Gate
Advanced Setup dialog box.

Figure 4-25: Opening the Transport_Gate Advanced Setup Dialog Box

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Detect Jams
This check box determines whether jams will stop the machine. If the box is clear, this photocell
won’t raise any alarms when a jam occurs. Mailpieces may still be dequalified by this photocell,
but the machine will not stop.

Figure 4-26: Detect Jams Check Box

Jam Types Detected Group

Creation of Unknowns
If the Creation of unknowns check box is selected, the machine will stop when an unknown
mailpiece is detected. This occurs when the photocell has a lead edge.

Figure 4-27: Creation of Unknowns Check Box

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Lead Edge Timeout

This check box causes the element to use interval jam detection. A jam will be declared if the
time between lead edge of the previous element and lead edge on this element exceeds the Jam
Timeout before photocell given at the bottom of the dialog box.

Figure 4-28: Lead Edge Timeout Check Box

Photocell Timeout
If this check box is selected, the element detects photocell jams. Jams are declared when the
time between the lead edge and the trail edge at this element exceeds the Jam timeout under
photocell field at the bottom of this dialog box.

Figure 4-29: Photocell Timeout Check Box

Overruns Before PC
Selecting the Overruns before PC check box causes the element to throw an alarm when a lead
edge (for the next piece) occurs on the previous element before lead edge occurs at this
element. Note that this parameter actually affects tracking. It not only determines when alarms
are created, it causes pieces to be marked “bad”.

Figure 4-30: Overruns Before PC Check Box

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Overruns At PC
Selecting the Overruns at PC check box causes the element to stop the machine when a trail
edge occurs on the previous element - before a trail edge at this element occurs. Note that this
actually affects tracking. It not only determines when alarms are thrown, it causes pieces to be
marked as “bad”.

Figure 4-31: Overruns at PC Check Box

Next Arrives Before PC Clear

Selecting the Never arrives before PC clear check box causes the machine to stop when a lead
edge occurs on previous element before the trail edge occurs on this element.

Figure 4-32: Next Arrives Before PC Clear Check Box

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Previous PC: Overlap Modes

Configurable shift states define how the data for a mailpiece is shifted for each edge of every
photocell (PC).
• If no given piece of mail could block any two adjacent photocells at the same time, the
photocells could be set for shifting on both lead edge and trail edge.
• If a mailpiece could block two adjacent photocells:
• One of the two photocells would have to be disabled
or
• The first photocell would have to be set for lead edge shifting.
Direct Connect uses all photocells, including R150 photocells. More tracking photocells improve
throughput as well as integrity. Direct Connect uses three configurations of shift states. They
relate to the condition of the previous PC.
Important: Under Jam types detected, select Overruns before PC, Overruns at PC and
Next arrives before PC clear to accurately check for proper shift configuration.

Condition Shifting Previous PC State

Always Overlap Lead edge Blocked
May Overlap (default) Lead edge Blocked /Unblocked
Never Overlaps Trail edge Unblocked

Figure 4-33: Previous Computer Overlap Selection Field

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Don’t Create Unknowns

This check box prevents the element from creating and passing along unknown mailpieces. The
element may still turn pink on the DC screen when it encounters the unknown. However, it will
not create and pass along information on the unknown. This is useful for situations where ram
blade blocking is possible and where blocks should not be construed as pieces.

Figure 4-34: Don’t Create Unknowns Check Box

Ignore Unknowns at Start

If the Ignore unknown at start check box is selected, unknowns will be ignored if they occur just
after the motors start. The time interval is determined by the lead edge timeout. This prevents
secondary stops after stoppages on the MOS where the material is difficult to control.

Figure 4-35: Ignore Unknowns at Start Check Box

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Jam Timeouts Under Photocell

This field contains the jam timeout for pieces blocking the photocell. This value is used when
Photocell timeout check box is selected. If the photocell is blocked for more than the number of
milliseconds specified here, the machine will stop and the piece will be dequalified.

Figure 4-36: Jam Timeout Under Photocell Field

Jam Timeouts Before Photocell

This field contains the interval timeout for pieces before the PC. Use this value when selecting
the Lead edge timeout check box. If a lead edge is transferred to this element and a lead edge
does not occur within the specified interval, the machine stops and the piece is dequalified.

Determining Jam Timeout Settings

Setting the jam timeouts above can be difficult. One way to do this is to estimate the average
time and multiply that average by 3 or 4. This prevents more than two pieces from being
damaged and eliminates the possibility of "false positives". For instance:
• If you have two PCs that are 10 inches apart and the paper speed is 65 IPS (divide
10 by 65), then 153 ms is a reasonable estimate for the interval timeout.
Multiplying this number by 4 yields 600 ms for the Jam timeout before photocell
interval.
• If the envelope length is 9-1/2 inches, it will take about 146 milliseconds (divide 9.5
by 65) for an envelope to move across the PC. Multiplying this by 4 yields 600 ms.

Figure 4-37: Jam Timeout Before Photocell Field

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MOTOR STARTUP AND ACCELERATION

Transport Advanced Setup
Note: For more information and a detailed discussion of this procedure, refer to the topics
on Initial MOS Tuning Procedures and MOS and Trayer Tuning in Chapter 6.
1. Click on the Transport hot spot on the DC main screen.
2. Select Setup from the menu that displays to open the Transport setup dialog box.
3. Click [Advanced] on the Transport setup dialog box to open the Transport Advanced
Setup dialog box.

Figure 4-38: Opening the Advance Transport Setup Dialog Box

The Transport accelerate time is the time it takes for that module to get to full speed. Added
to Motor on delay, this is the total wait time for the module to start.
The Motor off delay and Transport decelerate time, are the times allowed for the module to
stop and still get any paper or envelope out of that module.

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Motor On Delay
This is the delay between starting the motor and sending a motor start to the next upstream
module.
• The delay should be set large enough to allow the module motor to get a slight head
start over the next upstream module.
• This should not be set so high that it takes forever to start the machine.

Figure 4-39: Motor On Delay Field

Motor Off Delay

The Motor off delay is the time allowed for the module to stop and still get any paper or
envelopes out of the module.
In the application, this is the delay between the exit of the last piece of mail in the module and
the motor stop during a cycle stop condition. Set this large enough to allow mail to run out
correctly, but not so large that the machine takes too long to stop.
• The default value in this DC version is too high. 150 is the new value suggested and it
works well in most cases

Figure 4-40: Motor Off Delay Field

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Transport Accelerate Time

The Transport accelerate time is the time it takes for the module to get to full speed.
In the application, this is the amount of time (in milliseconds) that mail is expected to remain
stationary after the motors are started.
The elements in the base will not be told that the motors are turning until this delay has expired.
• If pieces are marked unknown at startup after an immediate stop, then this value may be
too high.
• If pieces are marked operator removed on restart after an immediate stop, then this
value is too high.
• If, after an immediate stop, pieces are jamming or marked as lost on restart then this
value may be too low.

Figure 4-41: Transport Accelerate Time Field

Transport Deaccelerate Time

The Transport deaccelerate time is the time allowed for the module to stop and still get any
paper or envelopes out of that module.
In the application, this is the amount of time in milliseconds that the mail is expected to remain in
motion after motors are cut.
The elements in the base will not be told that the motors have stopped until this time interval
has expired.
• If pieces are marked unknown or removed by the operator as the machine has immediate
stops, then this value is too low.
• If pieces removed by the operator are listed as unknown, then the value is too high.

Figure 4-42: Transport Decelerate Time Field

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Dequalify Pieces When Interlock Opened

In Own Stations

Figure 4-43: In Own Stations Check Box

In Chassis Target Station

Figure 4-44: In Chassis Target Station Check Box

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BINGO DIAGNOSTICS
1. Click the Bingo Diagnostics icon on the Master I/O Device List on the DC main
screen to open the list of Bingo Cards.
2. Select Chassis 51 Transport Bingo from the list.
3. Click [Show] to open the Diagnostic dialog box.
4. In the Outputs area of the Diagnostic screen, select the check box next to the desired
output to turn on the signal.
• Selecting the Transport_Mocon box indicates that the signal is turned on at the
Transport Bingo, J4.
• In the Transport Bingo Diagnostics dialog box, if the Mocon box for the transport
motor is plugged into the J4 connector and 24vdc is supplied to the Mocon box, the
transport motor should run.

Figure 4-45: Opening the Transport Bingo Diagnostic Dialog Box

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5. Block a photocell or make a switch and watch the box turn red as the photocell or switch is
made to check the inputs.
• If the unused inputs for a Bingo card are masked, blocking an input will not show on the
bingo diagnostics for a second or two.
• If PC7 were plugged into J15 (a masked input), and you try to block the photocell by
moving your finger back and forth across the photocell, you won’t see transitions.
However, if you place an object under the photocell and leave it, you will see the
transition.
• Plug the PC7 into J12 to correct the wiring.
6. If there are unlabeled inputs on a Bingo card, investigate and unplug them. Rapidly changing,
unused inputs can overload the processor on the 8051 board and stop other tasks
performed by the microprocessor from being completed.
Also refer to the Direct Connect Physical Connections Diagram in Appendix A.

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BINGO STATUS
Display the Bingo Status screen to check inputs and outputs.
1. Select Display > Objects from the DC main menu. The Display Object Info dialog box
opens.
2. Expand the Select Object list in the Display Object Info dialog box to reach the Transport
Bingo card: Model > IO Device > Bingo Cards > Transport Bingo
3. Click [Setup] in the Object Functions area to open the Transport Bingo Setup dialog box.
4. Click [Status] in the Object Functions area to open the Transport Bingo Status dialog
box.

Figure 4-46: Opening the Transport Bingo Setup and the Transport Bingo Status Dialog Boxes

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8051 BOARD
Check the communication between the computer DigiBoard/RocketPort and the 8051 by
viewing the messages transmitted on the Diagnostic dialog box. To determine which port the
DigiBoard/RocketPort device needs to be plugged into, refer to the Jack column on the Bingo
card screen.

LABEL
SHOULD BE
SERIAL I/O

Figure 4-47: Opening the Bingo Diagnostic Dialog box

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Further verification can be found at the 8051 cards. Read the scrolling LED display at the MOS
8051 board that says it’s configured as the Hicap. This tells you it is plugged into
RocketPort/DigiBoard port 2 and needs to be placed into RocketPort/DigiBoard port 3.

NOT
COMMUNICATING

Figure 4-48: Diagnostic Dialog box Showing No Communication with the Computer

COMMUNICATING

Figure 4-49: Diagnostic Dialog box Showing Communication with the Computer

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This is a typical protocol for 8051 communications.

Figure 4-50: AF Rollup Port Diagnostic and Setup Dialog Boxes

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Chapter 5:
Accumulator,
Folder, LoCap
Divert
Accumulator Setup
Advanced Accumulator Setup
Upper and Lower Accumulator
Setup
Folder/LoCap Divert
Accumulator Debounced
Photocell
Error Detection
Motor Startup, Stop,
Acceleration and
Deceleration
Bingo Diagnostics
Solenoid Square Wave Test
8051 Board
Chapter 5 – Accumulator, Folder, LoCap Divert Direct Connect Service Manual

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CHAPTER 5: ACCUMULATOR, FOLDER, LOCAP DIVERT

Table of Contents
ACCUMULATOR SETUP ..................................................................177
Accumulator Usage ......................................................................................................................... 177
Collate Mode .................................................................................................................................... 179
Errors .................................................................................................................................................. 179
System Stop ID ................................................................................................................................ 180

ADVANCED ACCUMULATOR SETUP...............................................181

Flipper Up Time................................................................................................................................ 182
Flipper Down Time........................................................................................................................... 182
Flipper Delay ..................................................................................................................................... 183
Double Page Flipper Delay (Long Flipper Delay) .................................................................... 184
Min Dump Spacing Time ................................................................................................................ 184
Max Nesting ...................................................................................................................................... 185
Dispatch on Predictions................................................................................................................. 185

UPPER AND LOWER ACCUMULATOR SETUP..................................186

Input Timeout................................................................................................................................... 187
Enter Timeout................................................................................................................................... 187
Settling Time..................................................................................................................................... 188
Clutch On Time................................................................................................................................ 188
Dump Timeout.................................................................................................................................. 188
Accumulator Exit Clear Time......................................................................................................... 189
Min Entrance Gap ............................................................................................................................ 189
Delay from Brake OFF to Clutch ON .......................................................................................... 189
Delay from Clutch OFF to Brake ON .......................................................................................... 190
Debounce PC2x ............................................................................................................................... 190
Debounce PC2ax ............................................................................................................................. 190

FOLDER/LOCAP DIVERT SETUP......................................................191

Folder Setup...................................................................................................................................... 191
Elevator Down (No Fold Position) .............................................................................................. 191
Advanced Folder Setup .................................................................................................................. 192
Virtual Photocell Delay ................................................................................................................ 192
Fold Plate Removed (Pieces Will Dump).................................................................................. 192

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ACCUMULATOR DEBOUNCED PHOTOCELL...................................193

Leading Edge..................................................................................................................................... 194
Nominal “Off“ Time....................................................................................................................... 194
Always Hold Off ............................................................................................................................. 195
Hold “Off” Time ............................................................................................................................. 195
Trailing Edge ..................................................................................................................................... 196
Nominal “On” Time ....................................................................................................................... 196
Always Hold On ............................................................................................................................. 197
Hold “On” Time ............................................................................................................................. 197
Invert Output.................................................................................................................................... 197

ERROR DETECTION ........................................................................198

Detect Jams ....................................................................................................................................... 199
Jam Types Detected........................................................................................................................ 200
Creation of Unknowns.................................................................................................................. 200
Lead Edge Timeout ....................................................................................................................... 201
Photocell Timeout......................................................................................................................... 201
Overruns Before PC ...................................................................................................................... 202
Overruns at PC............................................................................................................................... 203
Next Arrives Before PC Clear ..................................................................................................... 203
Previous PC Overlap Mode ........................................................................................................... 204
Don’t Create Unknowns................................................................................................................. 205
Ignore Unknowns At Start ............................................................................................................. 205
Jam Timeout Under Photocell....................................................................................................... 206
Jam Timeout Before Photocell ...................................................................................................... 206

MOTOR STARTUP, STOP, ACCELERATION AND DECELERATION..207

Motor Startup .................................................................................................................................. 207
Settings .............................................................................................................................................. 208
Motor On Delay............................................................................................................................. 208
Motor Off Delay ............................................................................................................................ 208
Accelerate Time ............................................................................................................................. 209
Deaccelerate Time......................................................................................................................... 209
Setting Considerations................................................................................................................... 210
Acceleration Mismatch................................................................................................................. 210
Deacceleration Mismatch ............................................................................................................ 210
Deceleration Versus Operator Removal .................................................................................. 210

BINGO DIAGNOSTICS ....................................................................211

SOLENOID SQUARE WAVE TEST ....................................................213

8051 BOARD..................................................................................214

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ACCUMULATOR SETUP
Click on the Accumulator hot spot on the DC main screen and select [Setup] in the menu to
open the Accumulator Setup dialog box.

Figure 5-1: Opening the Accumulator Setup Dialog Box

Accumulator Usage

FIELD BACKGROUNDS
TURN YELLOW TO
INDICATE SELECTION
HAS BEEN CHANGED.

Figure 5-2: Accumulator Usage List

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The Accumulator Usage drop-down menu options determines how the accumulator is used:
Accumulator Used Description

Only the upper accumulator is used. Typically, this Mode is used only for
very high page count applications where the loss of an accumulator is not
Upper Only critical to overall application performance.
The dual accumulator counts as one nesting stage.
If this Mode is used, lower the accumulator nesting parameter by one.
Same as “Upper Only” except that the lower accumulator is used.
Lower Only
If this Mode is used, lower the accumulator nesting parameter by one.
This is the usual accumulator Mode. Here, the upper and lower
Both accumulators are used alternately. The dual accumulator counts as two
nesting stages.
Both/BOC Both accumulators are used at the beginning of a collation (BOC).
In this Mode, the first subset is fed into the folder after all of the other
Both (Reverse Subset) subsets are fed. The dual accumulator counts as only one nesting stage
since one accumulator must be kept open to hold the collation subsets.
Sidetrack This setting is not currently used.

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Collate Mode
The Collate mode drop-down menu controls whether the accumulator accumulates pages,
subsets or collations.
For all practical purposes, this field should always be set to Subsets.

Figure 5-3: Collate Mode Field

Errors

Figure 5-4: Errors List Field

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ADVANCED ACCUMULATOR SETUP

1. Click the Accumulator hot spot on the DC main screen.
2. Select Setup on the Accumulator menu to open the Accumulator Setup dialog box.
3. Click [Advanced] on the Accumulator Setup dialog box to open the Advanced
Accumulator Setup dialog box.

Figure 5-6:Opening the Advanced Accumulator Setup Dialog Box

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Flipper Up Time
This value places a lower limit on the minimum spacing for the accumulator dispatcher. Also use
this value to predict the amount of time it will take for the flipper to move from the lower to the
upper position.
This value has to change based on the type of solenoid used. See the table following Flipper
down time for suggested values.
• Setting this value too high can result in slow performance.
• If this value is set too low, the accumulator may assume that a mailpiece is heading for
the upper accumulator when the piece actually winds up in the lower accumulator.

Figure 5-7: Flipper Up Time Field

Flipper Down Time

This value places a lower limit on the minimum spacing for the accumulator dispatcher. Also use
this value to predict the amount of time it will take for the flipper to move from the upper to the
lower position.
• Setting this value too high can result in slow performance.
• If this value is set too low, the accumulator may assume that a mailpiece is heading for
the lower accumulator when the piece actually winds up in the upper accumulator.

Figure 5-8: Flipper Down Time

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The values change based on the type of solenoid. The following table has suggested values for
the Flipper up time and Flipper down time settings:

Flipper Type Flipper Up Time Flipper Down Time

Single Solenoid 40 120
Dual Solenoid 40 40
UltiMag Flipper 20 20

Flipper Delay
This is the delay from the time the lead edge passes the accumulator entrance photocell to
actuation of the EOC (End of Collation) page solenoid.
• This can be set to zero for many forms.
For longer forms or thinner forms, it may be necessary to set this to a higher value to give the
EOC page a chance to clear the flipper.
• A safe value for this is: (10 x form length>)-(flipper-down-time) or, ten times the form
length minus the flipper down time.
• This equates to 90 ms for an 11-inch form and an UltiMag flipper.
• A value of 70 ms is a good choice for an 11-inch form and a dual solenoid flipper.

Figure 5-9: Flipper Delay Field

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Double Page Flipper Delay (Long Flipper Delay)

This is the same as Flipper Delay except that it is used for double cuts from the east port of a
RAT. Doubled pages require more time to clear the flipper area than standard one-page
collations.

Figure 5-10: Double Page Flipper Delay Field

Min Dump Spacing Time

This value determines the minimum time from trail edge of the accumulator photocell (during
dump) to the next possible accumulator dump operation.
If too small a value is used, there is a potential for overruns before PC4 or for jams in the folder.
A good test is to let the chassis go into delay then stop the machine and remove the collation
from the transport gates. Start the machine and observe the folder exit area. If jams or overruns
occur, increase the setting – typically to 135 ms.
• For 12 series and systems with faster folders, use a lower value.
• For large page counts or bouncing buckle chutes, a higher value may be needed.

Figure 5-11: Minimum Dump Spacing Time Field

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Max Nesting
This value should equal the number of useful stages in the accumulator and transport plus 1.
This can be as high as six or as low as three. The following table gives common values:

Notes:
• Setting this value too low will result in under utilization of the input.
• Setting this value too high will result in overruns occurring in the accumulator when the
machine stops.

Transport Gates Accumulator Usage Max Nesting for Accumulator

Two Both 5
Two Upper Only/Lower Only /Reverse 4
Subset
Three Both 6
Three Upper Only/Lower Only/Reverse 5
Subset

Figure 5-12: Maximum Nesting Field

Dispatch on Predictions

Figure 5-13: Dispatch on Predictions Check Box

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UPPER AND LOWER ACCUMULATOR SETUP

1. Click the Accumulator hot spot on the DC main screen.
2. Select Setup from the drop-down menu.
3. Click [Advanced] on the Accumulator Setup dialog box to open the Accumulator
Advanced Setup dialog box.
4. Click [Upper Accum] to open the Upper Accumulator Setup dialog box. The Upper
Accumulator Setup dialog box opens.

Figure 5-14: Opening the Upper Accumulator Setup Dialog Box

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Input Timeout
This is the amount of time that a page may take to enter the accumulator. For 11-inch forms,
250 ms may be sufficient time. For larger forms (i.e., 14-inch forms), the value used should be
closer to 350 ms.

Figure 5-15: Input Timeout (PC1 to PC2) Field

Enter Timeout

Figure 5-16: Enter Timeout (PC2 Blocked) Field

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Settling Time
This is the amount of time that multiple page collations are allowed to settle in the accumulator
prior to dumping. Typically, the Settling time is set to 20 ms.
• Sometimes, this value is decreased to improve performance in two-page collations.
• This value is sometimes increased for reverse subsetting applications where setting takes
longer.
• Setting this value to be too small will result in "shingled" folds.

Figure 5-17: Settling Time Field

Clutch On Time

Figure 5-18: Clutch On Time

Dump Timeout

Figure 5-19: Dump Timeout Field

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Accumulator Exit Clear Time

Figure 5-20: Accumulator Exit Clear Time Field

Min Entrance Gap

Figure 5-21: Minimum Entrance Gap Field

Delay from Brake OFF to Clutch ON

Figure 5-22: Delay from Brake OFF to Clutch ON Field

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Delay from Clutch OFF to Brake ON

Figure 5-23: Delay from Clutch OFF to Brake ON Field

Debounce PC2x

Figure 5-24: Debounce PC2x Check Box

Debounce PC2ax

Figure 5-25: Debounce PC2ax Check Box

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FOLDER/LOCAP DIVERT SETUP

Folder Setup
1. Click the Folder hot spot on the DC main screen.

2. Select Setup from the drop-down menu to open the Folder Setup dialog box.

Figure 5-26: Opening the Folder Setup Dialog Box

Elevator Down (No Fold Position)

Figure 5-27: Elevator Down (No Fold Position) Check Box

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Advanced Folder Setup

Figure 5-28: Opening the Advanced Folder Setup Dialog Box

Virtual Photocell Delay

Figure 5-29: Virtual Photocell Delay Field

Fold Plate Removed (Pieces Will Dump)

Field 5-30: Fold Plate Removed (Pieces Will Dump) Check Box

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ACCUMULATOR DEBOUNCED PHOTOCELL

The debounced photocell object debounces the signal received from a photocell. The debounce
logic can be applied selectively or all the time. The debounce logic is usually applied selectively
to avoid the time shifting that occurs when debounce logic is always applied.
1. Select Display > Objects from the DC main menu. The Display Object Info dialog box
opens.
2. Expand the Select Object list to reach the desired Bingo card.
3. Click [Setup] on the Display Object Info dialog box to open the Accumulator PC2T setup
dialog box.

Figure 5-31: Opening the Accumulator Photocell Dialog Box

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Leading Edge
Leading edge refers to the lead edge of the document as it passes over a photocell. Lead edge
occurs when the photocell is first blocked.
Selectively debounce the lead edge signal by setting the nominal off time equal to the typical
time that the photocell is unblocked between collations.
• If a transition (from unblocked to blocked) occurs before that time has elapsed, the
signal will be debounced (because the transition was not expected).
• If a transition occurs after the time has elapsed, the signal will not be debounced.
Signals are debounced only when there is a transition at the wrong time. This avoids having to
debounce every transition, which has the undesirable effect of shifting data by the debounce
time.

Figure 5-32: Accumulator Photocell Dialog Box/Leading Edge Parameters

Nominal “Off“ Time

This parameter is the time in ms (milliseconds) between the trailing edge of the previous
mailpiece and the next lead edge. In practice, set this time to something less than the minimum
time between collations.

Figure 5-33: Nominal “Off” Time Field

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Always Hold Off

If the Always hold off check box is selected, the photocell lead edge transition signal will always
be debounced.

Figure 5-34: Always Hold Off Check Box

Hold “Off” Time

Hold off time, in ms (milliseconds), is the amount of time after transition that the photocell
signal will be debounced. It is the time after the lead edge transition when the signal will be
checked again.
• If the signal has returned to an unblocked state, the transition will be ignored.
• If the signal has remained blocked, a valid lead edge will be declared.

Figure 5-35: Hold “Off” Time Field

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Trailing Edge
Trailing edge refers to the trail edge of the document as it passes over a photocell. Trail edge
occurs when the photocell transitions from blocked to unblocked.
Selectively debounce the trail edge signal by setting the Nominal “On” time equal to the typical
time that the photocell is blocked by a collation.
• If a transition (from blocked to unblocked) occurs before that time has elapsed, the
signal will be debounced because a transition was not expected.
• If a transition occurs after the time has elapsed, the signal will not be debounced.
Signals are debounced only when there is a transition at the wrong time. This avoids having to
debounce every transition, which has the undesirable effect of shifting data by the debounce
time.

Figure 5-36: Accumulator Photocell Dialog Box/Trailing Edge Parameters

Nominal “On” Time

Nominal “On” time is the time in ms (milliseconds) between lead edge and trail edge of a
collation. In practice, this time should be set to something less than the minimum time it takes
for a collation to pass over the photocell.

Figure 5-37: Nominal “On” Time Field

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Always Hold On
If the Always hold on check box is selected, the photocell trail edge transition signal will always
be debounced.

Figure 5-38: Always Hold On Check Box

Hold “On” Time

Hold time, in ms (milliseconds), is the time in which the photocell signal will be debounced. It is
the time after the trail edge transition when the signal will be checked again.
• If the signal has returned to a blocked state, the transition will be ignored.
• If the signal has remained unblocked, a valid trail edge is declared.

Figure 5-39: Hold “On” Time Field

Invert Output

Figure 5-40: Invert Input Check Box

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ERROR DETECTION
1. Click on the Accumulator hot spot on the DC main screen.
2. Select Setup on the menu to open the Accumulator Setup dialog box.
3. Click [Advanced] on the Accumulator Setup dialog box to open the Accumulator
Advanced Setup dialog box.
4. Click [PC1] to open the Accumulator_Entrance Setup dialog box.

JAM SETUP

Figure 5-41: Opening the Accumulator Entrance Setup Dialog Box

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Detect Jams
The Detect Jams check box determines whether jams will stop the machine.
• If this check box is selected, jams will stop the machine.
• If this check box is not selected, jams will not raise an alarm
Note: Mailpieces may still be dequalified by this photocell, but the machine will not stop
when the mailpiece is dequalified. The mailpiece will be outsorted later at one of the output
stackers.

Figure 5-42: Detect Jams Check Box

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Jam Types Detected

Detect Jams must be selected or the Jam types detected group will be shaded and unavailable.

Figure 5-43: Jam Types Detected Group

Creation of Unknowns
If this check box is selected, the machine stops when an unknown mailpiece is detected. This
occurs when the photocell detects a lead edge.

Figure 5-44: Detection of Unknowns Check Box

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Lead Edge Timeout

If this check box is selected, the element uses interval jam detection. A jam is declared if the time
between the lead edge of the previous element and lead edge of this element exceeds the Jam
timeout before photocell given at the bottom of this dialog box.

Figure 5-45: Lead Edge Timeout Check Box

Photocell Timeout
If this check box is selected, the element detects photocell jams. Jams are declared when the
time between the lead edge and the trail edge of this element exceeds the Jam timeout under
photocell field at the bottom of this dialog box.

Figure 5-46: Photocell Timeout Check Box

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Overruns Before PC
If this check box is selected, the element will stop the machine when a trail edge occurs on the
previous element before a trail edge occurs at this element.
Note: This action not only determines when alarms are created. It actually affects tracking
and marks pieces as “bad”.
This error can be caused by (but not limited to) one of the following sources:
• Improper roller velocity or idler settings
• Defective/worn bearings, belts, motors or rollers
• Glue on the decks or rollers
• Misaligned assemblies.

Figure 5-47: Overruns Before PC Check Box

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Overruns at PC
This parameter is critical for the correct operation of any Basic Element on the machine. Set
this parameter so that a mailpiece cannot block this photocell and the previous one at the same
time. If this check box is selected, it creates another "shift state". If this check box is cleared
when it should be, you will get errors when the machine is run quickly, but not when it is single
cycled.

Figure 5-48: Overruns At PC Check Box

Next Arrives Before PC Clear

If this check box is selected, the machine stops when a lead edge occurs on the previous element
before trail edge occurs on this element.

Figure 5-49: Next Arrives Before PC Clear Check Box

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Previous PC Overlap Mode

Configurable shift states define how the data for a mailpiece is shifted for each edge of every
photocell (PC).
• If no given piece of mail could block any two adjacent photocells at the same time, the
photocells could be set for shifting on both lead edge and trail edge.
• If a mailpiece could block two adjacent photocells:
• One of the two photocells would have to be disabled.
or
• The first photocell would have to be set for lead edge shifting.
Direct Connect uses all photocells - including R150 photocells. The greater number of tracking
photocells improves throughput as well as integrity.
Direct Connect uses three configurations of shift states. They relate to the condition of the
previous PC.
Important: Under Jam types detected, select Overruns before PC, Overruns at PC and
Next arrives before PC clear to accurately check for proper shift configuration.

Condition Shifting Previous PC State

Always Overlap Lead edge Blocked
May Overlap (default) Lead edge Blocked /Unblocked
Never Overlaps Trail edge Unblocked

Figure 5-50: Previous PC Drop Down Selection Field

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Don’t Create Unknowns

If this check box is selected, the element does not create and pass along unknown mailpieces.
The element may still turn pink on the machine icon on the DC main screen when it encounters
the unknown. However, it will not create and pass along information on the unknown.

Figure 5-51: Don’t Create Unknowns Check Box

Ignore Unknowns At Start

If this check box is selected, unknowns are ignored if they occur just after the motors start. The
time interval is determined by the lead edge timeout.

Figure 5-52: Ignore Unknowns at Start Check Box

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Jam Timeout Under Photocell

This field contains the jam timeout for pieces blocking the photocell. This value is used when the
Photocell timeout check box is selected. If the photocell is blocked for more than the number of
milliseconds specified here, the machine stops and the piece is dequalified.

Figure 5-53: Jam Timeout Under Photocell Field

Jam Timeout Before Photocell

This field contains the interval timeout for pieces before the photocell. Use this value when the
Lead edge timeout check box is selected. If a lead edge is transferred to this element and a lead
edge does not occur within the specified interval, the machine stops and the piece is dequalified.

Figure 5-54: Jam Timeout Before Photocell Field

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MOTOR STARTUP, STOP, ACCELERATION AND

DECELERATION
Motor Startup
Note: For more information and a detailed discussion of this procedure, refer to the topics
on Initial MOS Tuning Procedures and MOS and Trayer Tuning in Chapter 6.
The photocell jam timers must be adjusted to allow time for the motors to start and come up to
speed. This adjustment is particularly necessary if the jam intervals for the photocells are set low
to prevent collateral damage.
• Setting the acceleration timer too low will cause pieces to be listed as “missing” and then
subsequent unknowns to be flagged.
• Setting this value too high can cause flagging of unknowns as material travels faster than
anticipated.

Figure 5-55: Opening the AF Rollup Setup Dialog Box

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Settings
The motor start and accelerate settings are meant to give each motor and its drive train time to
come up to full speed before a load is applied.

Motor On Delay
The Motor on delay is the amount of time, in ms (milliseconds), the start signal is delayed
between starting the motor in one module and sending a motor start to the next upstream
module.
This should be set high enough to allow the module motors to get a slight head start over those
in the next upstream module. Do not make the setting so high that it takes an excessively long
time to start the machine.

Figure 5-56: Motor On Delay Field

Motor Off Delay

The Motor off delay is the delay time allowed in ms (milliseconds) for the module to stop and
still get any paper or envelope out of that module.
This is the between the time the last piece of mail exits the module and the motors stop during a
cycle stop condition. Set this value large enough to allow mail to run out correctly, but not so
large that the machine takes too long to stop.
A value of 500 ms to 1000 ms works for almost all applications.

Figure 5-57: Motor Off Delay Field

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Accelerate Time
The Accelerate time is the time, in ms (milliseconds), it takes for that module to get to full
speed. Mail is expected to remain stationary after the motors are started. The elements in the
base will not be told that the motors are turning until this delay has expired.
The Motor on delay time and Accelerate time, added together, comprise the total time for the
module to wait to start.
• The value is set too high if, after an immediate stop, pieces are marked unknown at
startup
• The value is set too high if, on restart after an immediate stop, pieces are marked
operator removed.
• The value is set too low if, after an immediate stop, pieces are jamming or are being
marked as lost on restart.

Figure 5-58: Accelerate Time Field

Deaccelerate Time
The Motor off delay and Deaccelerate time are the times allowed for the module to stop and
still get any paper or envelope out of that module.
This is the amount of time ms (milliseconds) that the mail is expected to remain in motion after
motors are cut. The elements in the base will not be told that the motors have stopped until this
time interval has expired.
• This value is too low if pieces are marked unknown or operator removed as the machine
immediate stops.
• The value is too high if pieces removed by the operator are listed as unknown.

Figure 5-59: Decelerate Time Field

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Setting Considerations
Acceleration Mismatch
The acceleration of adjacent tables can be mismatched due to the use of different motor types
and the presence of widely varying inertias and drags. This can create a situation where an
upstream motor crashes a piece into a downstream table on restart, because the upstream motor
starts so much faster than the downstream motor.

Deacceleration Mismatch
The opposite problem to acceleration mismatch is deceleration mismatch. This occurs in
immediate stop conditions when an upstream set of motors coasts further than the next set of
motors. This problem can occur between the top edge marker and just about any downstream
device.

Deceleration Versus Operator Removal

The system must be able to distinguish between material coasting during an immediate stop and
the removal of pieces by the operator when the machine stops. If a photocell is blocked as the
machine stops and subsequently becomes unblocked, it can be difficult to determine whether the
piece has coasted and will appear at the next photocell when the machine restarts, or whether
the machine has stopped completely and the operator has removed the piece.
For these reasons, Direct Connect maintains a deceleration timer for each motor control area.
This timer determines when the system believes that the motor will come to a complete stop
after the motors are cut.
• If this value is set too high, the system might construe piece removals made by the
operator as cases where the mailpiece coasted.
• Upon restart, the piece will be listed as an overrun (possibly stopping the machine) and
not as operator removed. This has the undesirable effect of stopping the machine
again.
• If this value is set too low, the system will construe conditions where the mailpiece coasts
as operator removed. Upon restart, an unknown piece will be flagged, possibly
stopping the machine again.

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BINGO DIAGNOSTICS
Use the Bingo Diagnostic dialog box to check the input.
Block a photocell or make a switch and watch the box turn red as the PC is blocked or the switch
is made.
1. Click the Bingo Diagnostics icon on the Master I/O Device List on the DC main
screen to open the list of Bingo Cards.
2. Select the Accumulator Bingo card from the list.
3. Click [Show] to open the Diagnostic dialog box.
4. In the Outputs section of the Diagnostic dialog box, select the check box next to the
desired output to turn on the signal. The check in the AF_Rollup_Mocon box indicates that
the signal is turned on at the AF_Rollup_Mocon, J6.
• If the Mocon box for the accumulator motor is plugged into the J4 connector and 24vdc
is supplied to the Mocon box, the accumulator motor should run.
• If the unused inputs for a Bingo card are masked, blocking an input will not show on the
Bingo Diagnostic dialog box for a second or two.

Figure 5-60: Opening the Accumulator Bingo Diagnostic Dialog Box

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5. If PC3 is plugged into J16 (a masked input) and you try to block the PC by moving your
finger back and forth across the PC, you will see no transitions.
If you place an object under the PC and leave it, you will see the transition. Then plug the
PC3 into J15, the correct wiring.
6. If you find that there are unlabeled inputs on a Bingo card, investigate and unplug them.
Note: Rapidly changing unused inputs can overload the microprocessor on the 8051 board
and other tasks performed by the microprocessor won’t be completed.

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SOLENOID SQUARE WAVE TEST

Note: The test described on the following page can also be used.
1. Select Display > Objects from the DC main menu. The Display Object Info dialog box
opens.
2. Expand the Selext Object list to reach the desired connector on the Bingo card.
3. Click [Test] on the Display Object Info dialog box to open the Test Output dialog box for
that connector.
4. Select the Square wave, Period radio button and enter the Square wave, Period in
milliseconds.
This test allows you to leave the DC workstation display and observe the solenoid operation.

Figure 5-61: Opening the Accumulator Flipper Test Dialog Box

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8051 BOARD
1. Click the Serial Ports icon on the Master I/O Device List on the DC main screen to
open the Ser ial I/O Card. dialog box.
Note: The label says Bingo Cards but it really is the Serial I/O Card dialog box.
2. Select AF_Rollup_51from the list displayed in the dialog box.
3. Click [Diagnostic] to open the AF_Rollup_51_Port Diagnostic dialog box.
Check communication between the computer RocketPort/DigiBoard and the 8051 board by
viewing the messages transmitted in the Diagnostic dialog box. The Jack column and the
corresponding number refer to the RocketPort/DigiBoard port the device needs to be plugged
into.
Check communication between the computer RocketPort/DigiBoard and the 8051 board by the
viewing messages transmitted on the Diagnostic dialog box. The Jack column and the
corresponding number refer to the RocketPort/DigiBoard port that the device needs to be
plugged into.

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(SERIAL I/O
CARD)

NOT
COMMUNICATING

COMMUNICATING

Figure 5-62: Viewing the AF Rollup Port Diagnostic Dialog Box

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For further verification, view the Diagnostic dialog box for the 8051 cards. Read the scrolling
dialog box at the MOS 8051 board that says it’s configured as the Hicap. This tells you it is
plugged into RocketPort/DigiBoard port 2 and needs to be placed into RocketPort/DigiBoard
port 3.
This is typical protocol for 8051 communications:

Figure 5-63: Opening the AF Rollup 51 Port Setup Dialog Box

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Theory of Operation
Basic Elements
Initial MOS Tuning Procedures
MOS and Trayer (IST) Tuning
Module Base Settings
Takeaway: Basic, Advanced & Jam
Setup
Sealer: Basic, Advanced & Jam
Setup
Edge Marker: Basic & Advanced
Setup
Vertical Stacker: Basic, Object, PC1
& Jam Setup
Mailing Machine: Basic, Advanced
& Expert Meter Channel
Setup
IST (Trayer): Basic & Advanced
Setup
Chapter 6 – MOS Direct Connect Service Manual

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CHAPTER 6: MOS
Table Of Contents
THEORY OF OPERATION................................................................225

BASIC ELEMENTS ............................................................................ 226

INITIAL MOS TUNING PROCEDURES..............................................228

MOS Velocities ............................................................................................................................ 228
IST Velocities................................................................................................................................ 228
Initial Tuning................................................................................................................................. 229
The MOS Run Out Test ............................................................................................................ 229
Immediate Stop Test.................................................................................................................. 230
Restart After Immediate Stop Test ........................................................................................ 231

MOS AND TRAYER (IST) TUNING...................................................232

Introduction.................................................................................................................................. 232
MOS and Trayer (IST) Issues................................................................................................... 232
Shift Configuration Versus Disabling Photocells ............................................................ 232
Motor Control......................................................................................................................... 233
Acceleration Mismatch.......................................................................................................... 233
Deceleration Mismatch ......................................................................................................... 234
Deceleration Versus Operator Removal ........................................................................... 234
Acceleration Timing ............................................................................................................... 234
Multiple Motor Controls and the Takeaway Chassis Interface................................... 235

MODULE BASE SETTINGS ...............................................................236

Motor On Delay .......................................................................................................................... 237
Motor Off Delay .......................................................................................................................... 238
Accelerate Time........................................................................................................................... 238
Decelerate Time .......................................................................................................................... 239

TAKEAWAY BASIC SETUP ...............................................................240

Mode .............................................................................................................................................. 240

TAKEAWAY ADVANCED SETUP ......................................................240

Motor Setup................................................................................................................................. 241
Motor on Delay....................................................................................................................... 241
Motor Off Delay ..................................................................................................................... 242
Accelerate Time ...................................................................................................................... 242
Decelerate Time...................................................................................................................... 243

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TAKEAWAY JAM SETUP................................................................... 244

Detect Jams................................................................................................................................... 246
Jam Types Detected Group...................................................................................................... 246
Creation of Unknowns........................................................................................................... 247
Lead Edge Timeout ................................................................................................................ 247
Photocell Timeout.................................................................................................................. 248
Overruns Before PC ............................................................................................................... 249
Overruns at PC........................................................................................................................ 250
Next Arrives Before PC Clear .............................................................................................. 251
Jam Times and Tracking Unknowns ........................................................................................ 252
Merge Collations .................................................................................................................... 252
Previous PC Overlap Mode .................................................................................................. 253
Don’t Create Unknowns ....................................................................................................... 254
Ignore Unknowns At Start.................................................................................................... 254
Jam Timeout Under Photocell ............................................................................................. 255
Jam Timeout Before Photocell............................................................................................. 256
Determining Jam Timeout Settings......................................................................................... 257

SEALER BASIC SETUP.....................................................................258

Sealer Control Selection Field ................................................................................................. 259
Error Detection Group............................................................................................................... 260
Missing Envelopes/High Seal Selectors ............................................................................ 260

ADVANCED SEALER SETUP.............................................................261

Sealer Features Group ............................................................................................................... 262
Missing Envelope Threshold ................................................................................................ 262
Missing Envelope Jam Timeout............................................................................................ 262
High Seal Jam Timeout .......................................................................................................... 262
No Seal Solenoid Hold On................................................................................................... 263
Sealer Motor Setup Group ....................................................................................................... 264
Motor On Delay...................................................................................................................... 264
Motor Off Delay ..................................................................................................................... 265
Accelerate Time ...................................................................................................................... 265
Decelerate Time...................................................................................................................... 266

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SEALER ELEMENT JAM SETUP .........................................................267

Element Setup > Detect Jams ................................................................................................... 268
Sealer Entrance/Virtual Mid Setup Jam Types Detected Group..................................... 269
Sealer Exit PC Setup Jam Types Detected Group .......................................................... 269
Creation of Unknowns........................................................................................................... 270
Lead Edge Timeout ................................................................................................................ 270
Photocell Timeout.................................................................................................................. 271
Overruns Before PC ............................................................................................................... 271
Overruns at PC........................................................................................................................ 272
Next Arrives Before PC Clear .............................................................................................. 272
Jam Times and Tracking Unknowns......................................................................................... 273
Previous PC Overlap Mode .................................................................................................. 274
Sealer Entrance/Sealer VMid - Don’t Create Unknowns/Ignore Unknowns at Start
.................................................................................................................................................... 275
Sealer Exit - Don’t Create Unknowns................................................................................ 275
Ignore Unknowns At Start (Sealer Exit PC) ..................................................................... 275
Sealer Entrance/VMid/Exit: Jam Timeout Under Photocell ......................................... 276
Jam Timeouts Before Photocell........................................................................................... 276

EDGE MARKER BASIC SETUP ..........................................................277

Leading Edge Mark Group ........................................................................................................ 278
As Accessory............................................................................................................................ 278
3 Digit Zip Code Change ..................................................................................................... 278
5 Digit Zip Code Change ..................................................................................................... 278
On Field Change ..................................................................................................................... 279
If Mailpiece is Unknown ........................................................................................................ 279
Trailing Edge Mark Group......................................................................................................... 280
Number in a Row to Mark..................................................................................................... 280

ADVANCED EDGE MARKER SET UP ................................................281

Marker Lead Edge Delay............................................................................................................ 282
Marker Trail Edge Delay ............................................................................................................ 282
Marker “On” Time ....................................................................................................................... 282

VERTICAL STACKER BASIC SETUP..................................................283

Mode Group ................................................................................................................................. 283
Mode Selector......................................................................................................................... 283
Classify as “Completed” When Selective.......................................................................... 284
Contents Label............................................................................................................................. 284
Outsort Unknowns ..................................................................................................................... 284
Force All “Bads” to Outsort...................................................................................................... 285

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VERTICAL STACKER OBJECT ADVANCED SETUP............................286

Motor On Delay .......................................................................................................................... 287
Motor Off Delay .......................................................................................................................... 287
Accelerate Time........................................................................................................................... 288
Decelerate Time .......................................................................................................................... 289

VERTICAL STACKER PC1 ADVANCED SETUP..................................290

Door Operation........................................................................................................................... 291
Hold Gate Open ..................................................................................................................... 291
Close Door on Lead Edge..................................................................................................... 291
Look Ahead to Previous Station ......................................................................................... 291

VERTICAL STACKER OBJECT PC JAM SETUP...................................292

Detect Jams................................................................................................................................... 293
Jam Types Detected Group...................................................................................................... 293
Creation of Unknowns........................................................................................................... 294
Lead Edge Timeout ................................................................................................................ 294
Photocell Timeout.................................................................................................................. 295
Overruns Before PC ............................................................................................................... 295
Overruns At PC ....................................................................................................................... 296
Next Arrives Before PC Clear .............................................................................................. 296
Tracking Unknowns and Jam Times ........................................................................................ 297
Previous PC Always/May/Never Overlaps....................................................................... 298
Don’t Create Unknowns ....................................................................................................... 299
Ignore Unknowns at Start .................................................................................................... 299
Timeout Under Photocell ..................................................................................................... 300
Jam Timeout Before Photocell............................................................................................. 300

MAILING MACHINE AND METER CHANNEL BASIC SETUP ..............301

Meter Setup.................................................................................................................................. 301
Error Handling/Not Metered Accessory .......................................................................... 302
Error Handling/Error Limit ................................................................................................... 302

MAILING MACHINE AND METER CHANNEL ADVANCED SETUP .....303

Use Meter Interface.................................................................................................................... 303
Verify Trip From Meter .............................................................................................................. 304
Don’t Allow Zero Postage......................................................................................................... 304

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MAILING MACHINE AND METER CHANNEL EXPERT (JAM) SETUP..305

Motor Operation Group............................................................................................................ 306
Motor On Delay...................................................................................................................... 307
Motor Off Delay ..................................................................................................................... 308
Accelerate Time ...................................................................................................................... 308
Decelerate Time...................................................................................................................... 309
Detect Jams................................................................................................................................... 310
Jam Types Detected Group...................................................................................................... 311
Creation of Unknowns........................................................................................................... 312
Lead Edge Timeout ................................................................................................................ 313
Photocell Timeout.................................................................................................................. 314
Overruns Before PC ............................................................................................................... 315
Overruns at PC........................................................................................................................ 316
Next Arrives Before PC Clear .............................................................................................. 316
Ignore Unknowns at Start ......................................................................................................... 317
Jam Times and Tracking Unknowns......................................................................................... 318
Merge Collations .................................................................................................................... 319
Don’t Create Unknowns ....................................................................................................... 320
Jam Timeout Under Photocell ............................................................................................. 321
Jam Timeouts Before Photocell........................................................................................... 322
Determining Jam Timeouts................................................................................................... 322

IST (TRAYER) BASIC SETUP ............................................................323

Stacking Mode ............................................................................................................................. 324
Tail Kick Mode ............................................................................................................................. 324
Bin Done (When Full) Mode..................................................................................................... 324
Maximum Pieces Per Tray (in Count Mode)......................................................................... 325
Tray Breaks................................................................................................................................... 325
Trayer Setup > Default............................................................................................................... 325

IST (TRAYER) ADVANCED SETUP ...................................................326

Motor On Delay .......................................................................................................................... 326
Motor Off Delay .......................................................................................................................... 326
Transport Accelerate Time ....................................................................................................... 327
Transport Decelerate Time....................................................................................................... 327
Bin Virtual PC Delay ................................................................................................................... 327
Drum Virtual PC Delay............................................................................................................... 328

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THEORY OF OPERATION
The Mail Output Section (MOS) transports and tracks assembled and inserted mailpieces to the
their final destination on the inserter system.
Based upon the disposition of the mailpieces in progress, the Direct Connect software settings
will determine whether the piece will be:
• Sealed or not sealed
• Outsorted
• Postage printed or not printed
Direct Connect is configured for integrity and productivity. It detects errors such as bad scans,
doubles, skewed pieces on the deck, missing pieces, jammed pieces, etc. Open covers can also
compromise integrity. These pieces can be flagged by Direct Connect and are handled according
to the Direct Connect settings.
Pieces are tracked along the MOS unit with both physical and virtual photocells (PCs). Every
piece must be tracked at each photocell and accounted for.
• If a mailpiece misses a photocell, or a photocell is blocked unexpectedly, the
corresponding mailpieces will be marked as “bad” and outsorted to the appropriate
vertical stacker as configured in the Direct Connect.
• Pieces can also be flagged as “bad” if more than one mailpiece occupies the same space
simultaneously, arrives at a photocell location too late or blocks a photocell location for
too long.

Figure 6-1: Mail Output Station (MOS)

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BASIC ELEMENTS
A basic element is connected to a photocell and a motor control signal. It is used as part of
some other machine elements. These basic elements are contained in a large number of other
machine elements. Some examples are: takeaway, sealer, most MOS devices, trayer, transport
gates, folder accumulator, FIM.
The logic used to track mail in the MOS is the same as the input section. The MOS is thought of
as a collection of basic elements, which inherit behavior from the inputs and outputs; hence all of
these objects share the basic element settings.
Each of the basic elements can be set up through the Display > Objects menu. Select one of the
photocells and press [Setup] on the Display Object Info dialog box as follows:
1. Select Display > Objects from the main DC menu. The Display Object Info dialog box
opens.
2. Expand the Select Object list to reach the Takeaway 1 object:
Model > Machine Elements > MOS > Takeaway > Takeaway 1

Figure 6-2: Expanding the Select Object List to Reach the Takeaway

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3. Click [Setup] in the Object Functions area of the Display Object Info dialog box to open
the Takeaway Setup dialog box.

Figure 6-3: Opening the Takeaway Object Setup Dialog Box

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INITIAL MOS TUNING PROCEDURES

Important:
• Verify the MOS sub-system velocities after the sub-system has been running for at least
15 minutes.
• Always measure belt speed between pulleys on the belt surface that contacts the
material. Never measure belt speed on a pulley.
Few MOS units are really capable of completely recovering from immediate stops. The goal is to
set Motor on delay, Motor off delay, Accelerate time, and Decelerate time for each device
and MOS table so that the machine performs well both when cycle stopping and immediate
stopping. Generally, these parameters are located on the Jam or Advanced Setup dialog box for
each MOS component.

MOS Velocities

Module Speed Measurement Point

Aligner 80 ips Drive roller
3Sealer 72 ips Red belt idler roller
VS1 74 ips Exit drive roller
R150 80 ips Keypad

Devices from this point outward can vary depending upon system configuration. The important
thing to remember is to slightly increase the speed of each subsequent module until reaching the
stacker.

IST Velocities

Module Speed Measurement Point

IST ramp 115 ips Drive roller
IST turn-up 122 ips Green belt
IST drum 123 ips Green belt
IST bin 124 ips Black roller
IST bin 133 ips Green belt

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Initial Tuning
Use the following procedures to tune the key motion control parameters to get a given MOS
running its best.
The following table gives the default motor control parameters for the various MOS tables.
Note: Under DC Version 158, each device also includes its own motor control parameters.
Set these parameters to the MOS table values below:

Parameter Takeaway Sealer MOS Tables & Trayer

Devices
Motor on delay 120 50 50 700
Motor off delay 500 500 500 500
Accelerate time 330 330 220 700
Decelerate time 550 550 440 1200

1. Initially, set the MOS to default values.

Once the initial values are set, they can be adjusted to match the actual dynamics of the
particular MOS.
2. Set the Jam time and Interval time on the MOS basic elements to 600 ms.

The MOS Run Out Test

1. Cycle stop the MOS when it is full of mail.
• The MOS should run out and no mail should be left on the MOS.
• The motors should not remain on too long after the machine stops.
2. Adjustments:
• If mail is left on the MOS, increase the Motor off delay for one or more tables or
devices.
• If the motors run too long after run out, try lowering the Motor off delay.
Generally, these parameters are located in the Advanced Setup or the Expert (Jam) Setup
dialog box for each element. These dialog boxes are shown in the individual MOS element
sections that follow in this chapter.

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Immediate Stop Test

Once the MOS passes the MOS Run Out Test, run the Immediate Stop Test to see if the MOS
correctly tracks mail as the machine comes to an immediate stop.
No emphasis is placed on restarting afterwards at this time.
1. Create an immediate stop in the trayer while the machine is running.
• The MOS should come to an immediate stop.
• If the system is equipped with a top edge marker, physically remove pieces that may have
run together in this area.
2. Look at the photocell element icons on the DC Main screen.
• The boxes should either be unblocked (gray) or good (green.)
• There should be no unknown (pink) boxes.
3. Adjustments:
• If there are unknown (pink) boxes, then the device or table in question is coasting
farther than Direct Connect thinks it is. Increase the Decelerate time for the device or
table.
• If pieces are being listed there as lost, jammed before or jammed, the Decelerate time
setting is too high for the device in question.
• If pieces are being listed as operator removed, then the Decelerate time value is set too
low.
4. Select Display > Mailpiece Chain from the DC main menu.
• After the machine is stopped, the mailpiece chain should match reality: Each mailpiece
on the chain should match the mailpieces left on the MOS.
• Pieces may get outsorted as the machine restarts. This could be due to restart issues so
don't worry about outsorts (yet).
• If you have an old style top edge marker, the mail may physically run into other pieces of
mail as the machine stops. This issue cannot be corrected with software. Remove the
merged mailpieces by hand.
5. Repeat this test as many times as is needed to get good immediate stopping.

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Restart After Immediate Stop Test

Once the Immediate Stop Test is passed on a regular basis, set the Accelerate and Motor on
times. Use this test to adjust the Accelerate time and the Motor on delay parameters located
in the Expert (Jam) Setup dialog boxes.
1. While the machine is running, create an immediate stop on the trayer or the last photocell of
the MOS.
• The machine will come to an immediate stop.
• If you have a top edge marker you may have to physically remove pieces from this area
that have run together in this area.
2. Restart the machine.
• If no mail is outsorted, then the MOS passes and you are done.
3. If there are still problems, open the Trayer Runout Bin History List to find out what
element marked a mailpiece as “bad”.
• If unknown pieces are winding up in the runout bin, look in the Mailpiece Manager's Jam
List for information on where pieces went “bad”.
• If a mailpiece jammed on restart at a given element, then the Accelerate time for that
element is too low.
• If a mailpiece went missing before a given element, then the Accelerate time for that
element is too low.
• If a mailpiece is marked as operator removed (and then subsequently shows up as
unknown) then the Accelerate time is too high.
• If a piece jams over a photocell and the photocell is the first photocell in a given motor’s
area, then the Motor on delay setting may be too high.

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MOS AND TRAYER (IST) TUNING

Introduction
The MOS (Mail Output Section) and the trayer comprise the last two sections of most inserters.
These sections have much in common. Both deal with completed envelopes and both lack
staging areas to hold mailpieces when the machine stops.
In this section the following will be discussed:
• Commonly encountered issues relating to motion control on the MOS and trayer.
• How to set up the basic elements on the MOS (i.e. how to customize the shift
configuration).
• How to configure the other MOS bases, the trayer, vertical stackers, edge markers, and
mailing machines
• How to troubleshoot common MOS problems.

MOS and Trayer (IST) Issues

There are various recurring issues relating to the MOS and trayer. These issues come up on
almost every system and can affect the operation of the MOS as well as the trayer.

Shift Configuration Versus Disabling Photocells

Under ISC1A and 1C, the MOS supports configurable shift states. This defines how the piece
data is shifted down the MOS for each photocell edge.
• If a mailpiece cannot block two adjacent photocells at the same time, then the
photocells can be set for shifting on both lead edge and trail edge. The accessory
controller would set up two shift states for these photocells and could track multiple
mailpieces per photocell. A mailpiece could block one photocell while another was in
transit to the next photocell.
• If a mailpiece can block two adjacent photocells, then one of the two photocells
would have to be disabled or the first photocell would have to be set for lead edge
shifting.
• With lead edge shifting, the accessory controller creates only one shift state. On lead
edge, the data for the mailpiece enters this shift state. Then, on lead edge at the next
photocell, the data is transferred to the next photocell.

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Motor Control
The MOS has evolved considerably over the last few years in terms of the number of
independent motor control areas. Many DC systems have one motor control per device and
almost all have motor controls that are, at the least, split out by table.
The separation of motor controls into tables or devices is important.
• This allows downstream tables to run out after a jam.
• This also gives some amount of control of the acceleration of tables on a restart after an
immediate stop.
The MOS of a CQEP machine was never really intended to recover properly from an immediate
stop condition.
The motors have varying amounts of inertia and drag. Mailpieces run together on an immediate
stop.
• Fixed frequency AC motors and DC motors with slow start-constant speed controllers
cause mailpieces to run together on startup.
• Some devices, such as the top edge marker (which uses AC motors), are so problematic
that there is no way to immediately stop with mailpieces in this area without causing a
physical jam.
• The meter also has a well-known problem. It completes its trip cycle during immediate
stops. The meter is designed to always return home. The meter will not leave the
cylinder in the wrong position during an immediate stop. Any mailpiece in the meter will
collide with the piece ahead.

Acceleration Mismatch
Adjacent table accelerations can be mismatched due to the widely varying inertias and drags in
the different motor types used. This can create a situation where an upstream motor, which
starts very much faster than the downstream motor, crashes a mailpiece into a downstream table
on restart.
• This problem is common between the last MOS table and the trayer ramp area. A DC
motor with a slow start controls the trayer ramp. It often requires more time to start
then the last MOS table.
• Another example occurs at the beginning of the MOS - between the takeaway and the
main chassis. Here, the main chassis is often tuned to minimize slow start (to prevent
sputtering of inserts). The takeaway has a single DC motor with a slow start and a
considerable load. In this case, the chassis can actually run material together in the PC2
area.
This problem is solved by placing delays between the startup of adjacent motors. A delay
between the takeaway startup and the deck start prevents the deck from over-running the
takeaway.

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Deceleration Mismatch
Deceleration mismatch is the opposite problem to acceleration mismatch. This occurs on
immediate stop conditions when an upstream set of motors coasts further than the next set of
motors.
This problem occurs between the top edge marker and just about any downstream device. The
top edge marker contains an AC motor, (no short circuit braking) bearings, and chains. It has a
distinct tendency to coast further than any other MOS device. When there is mail in the device
and an immediate stop occurs, mailpieces run together.
Unfortunately, there is no software currently available that can fix this problem. Some kind of
sequenced stop could be performed on immediate stops but this would violate the safety
requirement of an immediate stop.

Deceleration Versus Operator Removal

Another issue that arises on the MOS and the trayer is when a photocell is blocked as the
machine stops and subsequently becomes unblocked. The system has to distinguish between:
• Material coasting during an immediate stop
• Possible operator removal of pieces when the machine stops for other reasons.
It can be difficult to determine whether the piece has coasted and will appear at the next
photocell when the machine restarts, or the machine has completely stopped and the operator
has removed the mailpiece.
Direct Connect maintains a deceleration timer for each motor control area to help the system
determine when the motor will come to a complete stop after the motors are cut.
• If this value is set too high, pieces removed by an operator will be will be seen as a
situation where the mailpiece coasted. The piece will be listed “overrun” upon restart
(possibly stopping the machine) and not as an operator removal.
• If this value is set too low, conditions where the mailpiece coasts will be construed as
operator removal. Upon restart, an unknown piece will be flagged (also possibly
stopping the machine).

Acceleration Timing
A similar timer is provided for motor startup. Here, the photocell jam timers must be adjusted to
allow for when the motors are started. This adjustment is particularly important if the jam
intervals for the photocells are set low to prevent “collateral damage”.
• Setting the acceleration timer too low will cause pieces to be listed as “missing” and flag
subsequent mailpieces as unknown.
• Setting this value too high can flag mailpieces as unknown when material travels faster
than anticipated.

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Multiple Motor Controls and the Takeaway Chassis Interface

At the beginning of the takeaway, the red belts are powered from the chassis motor. However,
the photocells are connected into the takeaway object. This is further complicated by the fact
that envelopes over takeaway element 2 can either be driven from the red belt (by the chassis
motor) or the takeaway rollers.
To solve this problem, takeaway photocell 1 is connected to the chassis encoder for its transport
running sense. The chassis encoder gates the jam timers for this element.
• If the encoder speed is sampled and is above the transport running speed threshold,
mailpieces in this area are considered to be moving.
• If the sampled encoder speed is below the threshold, mailpieces in this area are assumed
not to be moving.
Select the Ch assis Encode r icon hot spot, choose Setup from the menu to open the Chassis
Encoder Setup dialog box and adjust this parameter.

Figure 6-4: Adjusting the Running Speed Threshold

Do not set the Running speed threshold for machines above 500 CPH (Cycles per Hour). If
the running speed threshold for the chassis encoder is set too high, then the chassis is seen as
stopped when it is still moving. Mailpieces will be listed as operator removed and flagged as
unknowns when the machine restarts.
Takeaway element number 2 is also connected to the chassis encoder for its transport running
sense. Mailpieces entering this element (i.e. mailpieces that have not reached lead edge of
photocell 2) are assumed to be under the control of the red belt.
Pieces that have reached lead edge are assumed to be moving based on the takeaway motor
state.

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MODULE BASE SETTINGS

Just as basic elements and basic element settings occur throughout the software, so do the
settings for module bases. These settings are found throughout the MOS and in the input
section.
1. Select Display > Objects from the DC main menu. The Display Object Info window opens.
2. Expand the Select Object list to reach the MOS_Table-1 object:
Model > Machine Elements > MOS > MOS_Table_1
3. Click [Setup] in the Object Functions area of the Display Object Info dialog box to open
the MOS_Table_1 Setup dialog box.

Figure 6-5: Opening the MOS Table Setup Dialog Box

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In general, there is one module base for every independent motor control signal on the machine.
Note: These parameters are only accessible in earlier versions of DC.
The following are the setup parameters for the module base:

Motor On Delay
This is the delay between starting the motor and sending a motor start to the next upstream
module.
In order for downstream mailpieces to get underway and avoid combining bogies in photocell
locations:
• Set this interval large enough to allow the module motors to get a slight head start over
the next upstream module.
• Do not set the interval so high that it takes forever to start the machine.

Recommended Settings
• A value of 50 ms is good for most MOS tables.
• Because of the amount of time the IST requires to achieve operating velocity, trayers
require a very high value: 1200 ms.
• The takeaway also requires a higher value of about 120 ms. This larger time period is
true for heavy assemblies and many devices with multiple pulleys and belts.

Figure 6-6: Motor on Delay Field

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Motor Off Delay

This is the delay between the exit of the last piece of mail in the module and the motors stopping
during a cycle stop condition. It is the time allowed for the module to stop and still get any
mailpieces out of the module.
• This should be set large enough to allow mail to correctly run out, but not so large that
the machine takes too long to stop.
• A value of 500 ms to 1000 ms works for almost all applications.

Figure 6-7: Motor Off Delay (ms) Field

Accelerate Time
This is the amount of time (in milliseconds) that mail is expected to remain stationary after the
motors are started. The elements in the base will not be told that the motors are turning until
this delay has expired.
• If pieces are marked unknown at startup after an immediate stop, this value may be too
high.
• If pieces are marked operator removed on restart after an immediate stop, then this
value is too high.
• If, after an immediate stop, pieces are jamming or are being marked as lost on restart, this
value may be too low.

Recommended Settings
A general rule of thumb:
• Use a high value for the trayer 700 ms.
• Other MOS tables should be around 220 ms.
• The sealer and takeaway may be higher at 350 ms.

Figure 6-8: Accelerate Time (ms) Field

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Decelerate Time
This is the amount of time in ms (milliseconds) that the mail is expected to remain in motion after
motors are cut. This is the time allowed for the module to stop and still get any mailpieces out of
the module.
The elements in the base will not be told that the motors have stopped until this time interval
has expired.
• If pieces are marked unknown or operator removed as the machine immediate stops,
this value is too low.
• If pieces removed by the operator are marked unknown, this value is too high.
Recommended settings:
• A general rule of thumb is to use a high value for the trayer 1200 ms.
• Other MOS tables should be around 440 ms to 600 ms.

Figure 6-9: Decelerate Time (ms) Field

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TAKEAWAY BASIC SETUP

1. Click the Tak eaway hot spot on the Direct Connect main screen.
2. Select Setup from the drop-down menu. The Takeaway Mode dialog box opens.

Mode
The Mode selected has no affect at this time. In the future, it is planned that the MOS jam times
and tracking will be configured based on the size of the mailpiece envelope.

Figure 6-10: Opening the Takeaway Mode Dialog Box

TAKEAWAY ADVANCED SETUP

Click [Advanced] on the Takeaway Mode dialog box to reach the Takeaway Advanced Setup
dialog box.

Figure 6-11: Opening the Takeaway Advanced Setup Dialog Box

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Motor Setup
Motor on Delay
This is the delay between starting the motor and sending a motor start to the next upstream
module.
In order for downstream mailpieces to get underway and avoid combining bogies in photocell
locations:
• Set this interval large enough to allow the module motors to get a slight head start over
the next upstream module.
• Do not set the interval so high that it takes forever to start the machine.

Recommended Settings
• A value of 50 ms is good for most MOS tables.
• Because of the amount of time the IST requires to achieve operating velocity, trayers
require a very high value: 1200 ms.
• The takeaway also requires a higher value of about 120 ms. This larger time period is
true for heavy assemblies and many devices with multiple pulleys and belts.

Figure 6-12: Motor On Delay Field

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Motor Off Delay

This is the delay in ms (milliseconds) between the exit of the last piece of mail in the module and
the motors being stopped during a cycle stop condition.
• Set this value large enough to allow mail to correctly run out.
• Do not set this value so large that the machine takes too long to stop.

Recommended Settings
• A value of 500 ms to 1000 ms works for almost all applications.

Figure 6-13: Motor Off Delay (ms) Field

Accelerate Time
This is the amount of time in ms (milliseconds) that mail is expected to remain stationary after
the motors are started. The elements in the base will not be told that the motors are turning
until this delay has expired.
• If pieces are marked unknown at startup after an immediate stop, then this value may be
too high.
• If pieces are marked operator removed on restart after an immediate stop, then this
value is too high.
• If pieces are jamming or are being marked as lost on restart after an immediate stop, then
this value may be too low.

Recommended Settings
• Use a high value for the trayer - 700 ms.
• Other MOS tables should be around 220 ms.
• The sealer and takeaway may be higher at 350 ms.

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Figure 6-14: Accelerate Time (ms) Field

Decelerate Time
This is the amount of time in ms (milliseconds) that the mail is expected to remain in motion after
motors are cut. The elements in the base are not told that the motors have stopped until this
time interval has expired.
• If pieces are going unknown or operator removed as the machine immediate stops, then
this value is too low.
• If pieces removed by the operator are listed as unknown, then the value is too high.

Recommended Settings
A general rule of thumb:
• Use a high value for the trayer 1200 ms.
• Other MOS tables should be around 440 ms to 600 ms

Figure 6-15: Decelerate Time Dialog Box

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TAKEAWAY JAM SETUP

While the settings and descriptions described below apply specifically to the takeaway
photocells, all of these parameters also exist for all of the other photocells on the MOS and
trayer.
1. Click the Takeaway hot spot on the on the Direct Connect main screen.
2. Select Setup from the menu that opens.
3. Click [Advanced] in the Takeaway dialog box that opens.
4. Make a selection from the Takeaway Element selection field in the Takeaway advanced
setup dialog box.
5. Click [Setup] to open the Takeaway Element (Jam) Setup dialog box selected.

JAM SETUP

Figure 6-16: Alternate Way to Open the Takeaway Element Setup Dialog Box

This dialog box can also be reached through a path from the main menu to the Display Object
Info dialog box as described in Basic Elements. See Figure 6-5in this chapter.

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Note: The settings for Takeaway_2 and Takeaway_3 are similar but not the same as the
settings for Takeaway_1. Differences are highlighted in the boxed areas shown in
Figure 6-17.

Figure 6-17: Takeaway Element Setup Dialog Boxes

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Detect Jams
Jams will stop the machine if this check box is selected.
If this check box is not selected, alarms should not be raised by this photocell. Mailpieces can
still be dequalified, but the machine will not stop when the mailpiece is dequalified.

Figure 6-18: Detect Jams Check Box

Jam Types Detected Group

If the Detect Jams check box is not selected, all boxes listed in the Jam types detected group
will be shaded and unavailable.

Figure 6-19: Takeaway Setup Jam Types Detected Group

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Creation of Unknowns
If this check box is selected, the machine will stop when an unknown mailpiece is detected. This
occurs when the photocell has a lead edge.

Figure 6-20: Creation of Unknowns Check Box

Lead Edge Timeout

If this check box is selected, the element will use interval jam detection.
A jam will be declared if the time between the lead edge of the previous element and lead edge
on this element exceeds the Jam timeout before photocell given at the bottom of the dialog
box.
This error can be caused by (but not limited to) one of the following sources:
• Improper roller velocity or idler settings
• Defective/worn bearings, belts, motors or rollers
• Glue on the decks or rollers
• Misaligned assemblies.

Figure 6-21: Lead Edge Timeout Check Box

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Photocell Timeout
If this check box is selected, the element will detect a photocell jam.
These jams are declared when the time between the lead edge and trail edge of this element
exceeds the Jam timeout under photocell at the bottom this dialog box.
This error can be caused by (but not limited to) one of the following sources:
• Improper roller velocity or idler settings
• Defective/worn bearings, belts, motors or rollers
• Glue on the decks or rollers
• Misaligned assemblies.

Figure 6-22: Photocell Timeout Check Box

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Overruns Before PC
If this check box is selected, the element will throw an alarm when a lead edge occurs on the
previous element (for the next piece) before the lead edge occurs at this element.
Note: This action not only determines when alarms are created, it actually affects tracking
and causes pieces to be marked as “bad”.
This error can be caused by (but not limited to) one of the following sources:
• Improper roller velocity or idler settings
• Defective/worn bearings, belts, motors or rollers
• Glue on the decks or rollers
• Misaligned assemblies.

Figure 6-23: Overruns Before PC Check Box

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Overruns at PC
Selecting this check box causes the basic element to stop the machine when a trail edge occurs
on the previous element before a trail edge occurs at the Overruns at PC element.
Note: This action not only determines when alarms are created, it actually affects tracking. It
causes pieces to be marked as “bad”.
This error can be caused by (but not limited to) one of the following sources:
• Improper roller velocity or idler settings
• Defective/worn bearings, belts, motors or rollers
• Glue on the decks or rollers
• Misaligned assemblies.

Figure 6-24: Overruns at PC Check Box

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Next Arrives Before PC Clear

If this check box is selected, the machine stops when a lead edge occurs on the previous element
before trail edge occurs on this element.
This error can be caused by (but not limited to) one of the following sources:
• Improper roller velocity or idler settings
• Defective/worn bearings, belts, motors or rollers
• Glue on the decks or rollers
• Misaligned assemblies.

Figure 6-25: Next Arrives Before PC Clear Check Box

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Jam Times and Tracking Unknowns

Figure 6-26: Jam Times and Tracking Unknowns Group

Merge Collations
This selection is available on older DC models. This parameter has no effect on the operation of
the machine.

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Previous PC Overlap Mode

Configurable shift states define how the data for a mailpiece is shifted for each edge of every
photocell (PC).
• If no given piece of mail could block any two adjacent photocells at the same time, the
photocells could be set for shifting on both the lead edge and trail edge.
• If a mailpiece could block two adjacent photocells
• One of the two photocells would have to be disabled
or
• The first photocell would have to be set for lead edge shifting.
Direct Connect uses all photocells - including R150 photocells. More tracking photocells
improve throughput as well as integrity. Direct Connect uses three configurations of shift states.
They relate to the condition of the previous PC.
Important: Under Jam types detected, select Overruns before PC, Overruns at PC
and Next arrives before PC clear to accurately check for proper shift configuration.

Condition Shifting Previous PC State

Always Overlap Lead edge Blocked
May Overlap (default) Lead edge Blocked /Unblocked
Never Overlaps Trail edge Unblocked

Figure 6-27: Previous PC Overlap Mode Selection Field

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Don’t Create Unknowns

If this check box is selected, the element will not create unknown mailpieces and pass along
unknown mailpieces at start. The element icon can still turn pink on the DC main screen when it
encounters an unknown mailpiece. However, it will not create and pass along information on the
unknown. This is useful for situations where ram blade blocking is possible and where blocked
PCs should not be construed as mailpieces.
Ignore unknowns at start is not available if Don’t create unknowns is selected.

Figure 6-28: Don’t Create Unknowns Check Box

Ignore Unknowns At Start

This setting is not used at Takeaway_1.
Ignore unknowns at start is not available if Don’t create unknowns is selected.
If this check box is selected, unknowns are ignored if they occur just after the motors start. The
time interval is determined by the Lead edge timeout. This is useful for preventing secondary
stops after stoppages on the MOS where the material is difficult to control.
Note: The setting unit is measured in co, which stands for encoder counts.

Figure 6-29: Ignore Unknowns At Start Check Box

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Jam Timeout Under Photocell

This field contains the jam timeout for pieces blocking the photocell. This value is used when
Photocell timeout is selected.
If the photocell is blocked for more than the number of milliseconds specified here, the machine
will stop and the mailpiece will be dequalified.
Note: The setting unit is measured in co, which stands for encoder counts.
This error can be caused by (but not limited to) one of the following sources:
• Improper roller velocity or idler settings
• Defective/worn bearings, belts, motors or rollers
• Glue on the decks or rollers
• Misaligned assemblies.

Figure 6-30: Jam Timeout Under Photocell Field

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Jam Timeout Before Photocell

This field contains the interval timeout for pieces before the photocell. This value is used when
the Lead edge timeout check box is selected.
If a lead edge is transferred to this element and a lead edge does not occur within the specified
interval, the machine will stop and the piece will be dequalified.
Note: The setting unit is measured in co, which stands for encoder counts.

Figure 6-31: Jam Timeouts Before Photocell Field

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Determining Jam Timeout Settings

Setting the jam timeouts can be difficult. One way to set them is to estimate the average time
and multiply that average by 3 or 4. This prevents more than two pieces from being damaged
and eliminates the possibility of "false positives". For instance:
• If you have two photocells that are 10 inches apart and the paper speed is 65 IPS
(divide 10 by 65), then 153 ms is a reasonable estimate for the interval timeout.
Multiplying this number by 4 yields 600 ms for the Jam timeout before photocell
interval.
• If the envelope length is 9-1/2 inches, it will take about 146 milliseconds (divide 9.5 by
65) for an envelope to move across the photocell. Multiplying this by 4 yields 600 ms.
• The Jam timeout before photocell setting for Takeaway_2 must match the Jam
timeout before photocell Takeaway_1 setting.

Figure 6-32: Comparing the Takeaway Element Jam Timeout Before Photocell Fields

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SEALER BASIC SETUP

1. Click on the Sealer hot spot on the DC main screen.
2. Select Setup from the drop-down menu. The Sealer Setup dialog box opens.

Figure 6-33: Opening the Advanced Sealer Setup Dialog Box

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Sealer Control Selection Field

FIELD BACKGROUNDS
TURN YELLOW TO
INDICATE NEW
SELECTION

Figure 6-34: Sealer Setup Dialog Box Fields

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Error Detection Group

Missing Envelopes/High Seal Selectors
The Missing Envelopes and High Seal drop-down menus display the selected output
devices/actions to be used in the event of an error.

FIELD BACKGROUNDS
TURN YELLOW TO
INDICATE NEW
SELECTION

Figure 6-35: Error Detection Fields

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ADVANCED SEALER SETUP

1. Click on the Sealer hot spot on the DC main screen.
2. Select Setup from the drop-down menu. The Sealer Setup dialog box opens.
3. Click [Advanced] on the Sealer Setup dialog box to open the dialog box for the Advanced
Sealer Setup features.

Figure 6-36: Opening the Advanced Sealer Setup Dialog Box

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Sealer Features Group

Missing Envelope Threshold

Figure 6-37: Missing Envelope Threshold Field

Missing Envelope Jam Timeout

Figure 6-38: Missing Envelope Jam Timeout Field

High Seal Jam Timeout

Figure 6-39: High Seal Jam Timeout Field

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No Seal Solenoid Hold On

Figure 6-40: No Seal Solenoid Hold On Field

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Sealer Motor Setup Group

Figure 6-41: Motor Setup Group

Motor On Delay

This is the delay between starting the motor and sending a motor start to the next upstream
module. In order for downstream mailpieces to get underway and avoid combining bogies in
photocell locations:
• Set this interval large enough to allow the module motors to get a slight head start over
the next upstream module.
• Do not set the interval so high that it takes an excessively long time to start the machine.

Recommended Settings:
• A value of 50 ms is good for most MOS tables.
• Because of the amount of time the IST requires to achieve operating velocity, trayers
require a very high value: 1200 ms.
• The takeaway also requires a higher value of about 120 ms. This larger time period is
true for heavy assemblies and many devices with multiple pulleys and belts.

Figure 6-42: Motor On Delay Field

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Motor Off Delay

This is the delay between the exit of the last piece of mail in the module and the motors being
stopped during a cycle stop condition. This is the time allowed for the module to stop and still
get any mailpieces out of the module.
Set this parameter large enough to allow mail to correctly run out, but not so large that the
machine takes too long to stop.
A value of 500 ms to 1000 ms works for almost all applications.

Figure 6-43: Motor Off Delay Field

Accelerate Time
This is the amount of time in ms (milliseconds) that mail is expected to remain stationary after
the motors are started. The elements in the base will not be told that the motors are turning
until this delay has expired.
• If pieces are marked unknown at startup after an immediate stop, this value may be too
high.
• If pieces are marked operator removed on restart after an immediate stop, this value is
too high.
• If, after an immediate stop, pieces are jamming or are marked as lost on restart, this value
may be too low.
A general rule of thumb:
• Use a high value for the trayer 700 ms.
• Other MOS tables should be around 220 ms.
• The sealer and takeaway may be higher at 350 ms.

Figure 6-44: Accelerate Time Field

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Decelerate Time
This is the amount of time (in milliseconds) that the mail is expected to remain in motion after
motors are cut. This is the time allowed for the module to stop and still get any mailpieces out of
the module.
The elements in the base will not be told that the motors have stopped until this time interval
has expired.
• If pieces are marked unknown or operator removed as the machine immediate stops,
this value is too low.
• If pieces removed by the operator are marked unknown, the value is too high.

Recommended Settings:
• A general rule of thumb is to use a high value for the trayer 1200 ms.
• Other MOS tables should be around 440 ms to 600 ms.

Figure 6-45: Decelerate Time Field

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SEALER ELEMENT JAM SETUP

1. Click on the Sealer hot spot on the DC main screen.
2. Select Setup from the drop-down menu. The Sealer Setup dialog box opens.
3. Click [Advanced] on the Sealer Setup dialog box to open the dialog box for the advanced
Sealer features.
4. Make a selection from the Element Setup field and click [Setup] to open the Sealer
Element (Jam) Setup dialog box.

Figure 6-46: Opening the Sealer Entrance and Mid Element Setup Dialog Boxes

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The Setup dialog boxes for the Sealer Entry PC and the Sealer Virtual Middle PC
(see Figure 6-49) are identical. Additional fields are available for the Sealer Exit PC (see Figure
6-50) dialog box.

Figure 6-47: Opening the Sealer Exit Setup Dialog Boxes

Element Setup > Detect Jams

This parameter determines whether jams will stop the machine. If this check box is not selected,
alarms should not be raised by this photocell.
Note: Mailpieces may still be dequalified by this photocell; it will not stop the machine when
the mailpiece is dequalified.

Figure 6-48: Detect Jams Check Box

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Sealer Entrance/Virtual Mid Setup Jam Types Detected Group

These fields are not applicable on a virtual PC and are not accessible for the Sealer Entrance and
Virtual Midpoint PCs.

Figure 6-49: Jam Types Detected Group Fields

Sealer Exit PC Setup Jam Types Detected Group

These fields are used to set up the Sealer Exit PC.
If Detect Jams is not selected in the Sealer Exit Setup dialog box, the Jam types detected
group will be shaded and unavailable.

Figure 6-50: Sealer Exit Setup Jam Types Detected Group

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Creation of Unknowns
If this check box is selected, the machine will stop when an unknown mailpiece is detected. This
occurs when the photocell has a lead edge.

Figure 6-51: Creation of Unknowns Check Box

Lead Edge Timeout

If this check box is selected, the element will use interval jam detection. A jam will be declared if
the time between the lead edge of the previous element and lead edge on this element exceeds
the Jam timeout before photocell given at the bottom of the dialog box.

Figure 6-52: Lead Edge Timeout Check Box

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Photocell Timeout
If this check box is selected, the element will detect photocell jams. These jams are declared
when the time between the lead edge and trail edge of this element exceed the Jam timeout
under photocell field at the bottom this dialog box.

Figure 6-53: Photocell Timeout Check Box

Overruns Before PC
If this check box is selected, the element will create an alarm when a lead edge occurs on the
previous element (for the next piece) before lead edge occurs at this element.
Note: Unlike most other check boxes in the Jam types detected group, this parameter
actually affects tracking and marks mailpieces as “bad”.

Figure 6-54: Overruns Before PC Check Box

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Overruns at PC
If this check box is selected, the element will stop the machine when a trail edge occurs on the
previous element before a trail edge at this element occurs.
Note: This not only affects when alarms are created, it actually affects tracking and marks
mailpieces as “bad”.

Figure 6-55: Overruns at PC Check Box

Next Arrives Before PC Clear

If this check box is selected, the machine will stop when a lead edge occurs on the previous
element before the trail edge occurs on this element.

Figure 6-56: Next Arrives Before PC Clear Check Box

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Jam Times and Tracking Unknowns

Figure 6-57: Tracking Jam Times and Unknowns Group

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Previous PC Overlap Mode

Configurable shift states define how the data for a mailpiece is shifted for each edge of every
photocell (PC).
• If no given piece of mail could block any two adjacent photocells at the same time, the
photocells could be set for shifting on both lead edge and trail edge.
• If a mailpiece could block two adjacent photocells:
• One of the two photocells would have to be disabled.
or
• The first photocell would have to be set for lead edge shifting.
Direct Connect uses all photocells - including R150 photocells. More tracking photocells
improve throughput as well as integrity. Direct Connect uses three configurations of shift states.
They relate to the condition of the previous PC.
Important: Under Jam types detected, select Overruns before PC, Overruns at PC
and Next arrives before PC clear to accurately check for proper shift configuration.
Condition Shifting Previous PC State
Always Overlap Lead edge Blocked
May Overlap (default) Lead edge Blocked /Unblocked
Never Overlaps Trail edge Unblocked

Figure 6-58: Previous PC Overlap Mode Selection Field

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Sealer Entrance/Sealer VMid - Don’t Create Unknowns/Ignore Unknowns at Start

These fields are not used for the Sealer Entrance and Virtual Midpoint PC Setup.

Figure 6-59: Don’t Create Unknowns/Ignore Unknowns at Start Check Boxes

Sealer Exit - Don’t Create Unknowns

This check box causes the element to not create unknown mailpieces and pass along unknown
mailpieces. The element may still turn pink when it encounters the unknown. It will not,
however, create and pass along information on the unknown. This is useful for situations where
ram blade blocking is possible and where blocks should not be construed as pieces.

Figure 6-60: Don’t Create Unknowns Check Box

Ignore Unknowns At Start (Sealer Exit PC)

Selecting this check box will cause unknowns to be ignored if they occur just after the motors
start. The time interval is determined by the lead edge timeout. This is useful for preventing
secondary stops after stoppages on the MOS where the material is difficult to control. This
option is not available if Don’t create unknowns is selected.

Figure 6-61: Ignore Unknowns at Start Check Box

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Sealer Entrance/VMid/Exit: Jam Timeout Under Photocell

This field contains the jam timeout for pieces blocking the photocell. This value is used when the
Photocell Timeout check box is checked. If the photocell is blocked for more than the number
of milliseconds specified here, the machine will stop and the piece will be dequalified.

Figure 6-62: Jam Timeout Under Photocell Check Box

Jam Timeouts Before Photocell

This field contains the interval timeout for pieces before the photocell. This value is used when
the Lead edge timeout check box is selected. If a lead edge is transferred to this element and a
lead edge does not occur within specified interval here, the machine will stop and the piece will
be dequalified.

Figure 6-63: Jam Timeout Before Photocell Check Box

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EDGE MARKER BASIC SETUP

1. Click the Edge Marker hot spot on the DC main screen.
2. Click Setup on the drop-down menu to open the Edge Marker Setup dialog box.

Figure 6-64: Opening the Edge Marker Setup Dialog Box

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Leading Edge Mark Group

As Accessory

Figure 6-65: Leading Edge Mark > As Accessory Selector and Field

3 Digit Zip Code Change

Figure 6-66: Leading Edge Mark > 3 Digit Zip Code Selector

5 Digit Zip Code Change

Figure 6-67: Leading Edge Mark > 5 Digit Zip Code Selector

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On Field Change

Figure 6-68: Leading Edge Mark > On Field Change Selector and Field

If Mailpiece is Unknown

Figure 6-69: Leading Edge Mark > If Mailpiece Unknown Selector

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Trailing Edge Mark Group

The selections available for the Trailing Edge Mark group are the same as those in the Leading
Edge Mark group.

Figure 6-70: Trail Edge Mark Group

Number in a Row to Mark

Figure 6-71: Number in a Row to Mark Field

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ADVANCED EDGE MARKER SET UP

1. Click the Edge Marker hot spot on the DC main screen.
2. Click Setup on the drop-down menu to open the Edge Marker Setup dialog box.
3. Click [Advanced] to open the Advanced Edge Marker Setup dialog box.

Figure 6-72: Opening the Edge Marker Advanced Setup Dialog Box

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Marker Lead Edge Delay

Figure 6-73: Marker Lead Edge Delay Field

Marker Trail Edge Delay

Figure 6-74: Marker Trail Edge Delay Field

Marker “On” Time

Figure 6-75: Marker “On” Time Field

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VERTICAL STACKER BASIC SETUP

1. Click the Vertical Stacker hot spot on the DC main screen.
2. Select Setup from the drop-down menu to open the Vertical Stacker Setup dialog box.

Figure 6-76: Opening the Vertical Stacker Setup Dialog Box

Mode Group
Mode Selector

FIELD
BACKGROUNDS
TURN YELLOW
TO INDICATE
NEW SELECTION

Figure 6-77: Mode Selection Field

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Classify as “Completed” When Selective

Figure 6-78: Classify as “Completed” When Selective Check Box

Contents Label
Select the Contents Label field and enter desired contents description. The yellow background
indicates the contents of the field have been changed.

Figure 6-79: Contents Label Field

Outsort Unknowns

Figure 6-80: Outsort Unknowns Check Box

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Force All “Bads” to Outsort

Figure 6-81: Force All “Bads” to Outsort Check Box

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VERTICAL STACKER OBJECT ADVANCED SETUP

1. Click the Vertical Stacker hot spot on the DC main screen.
2. Select Setup from the drop-down menu to open the Vertical Stacker Setup dialog box.
3. Click [Advanced] on the Vertical Stacker Setup dialog box to open the dialog box for the
Vertical Stacker Object Advanced Setup features.

Figure 6-82: Opening the Vertical Stacker Advanced Setup Dialog Box

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Motor On Delay
This is the delay, in ms (milliseconds), between starting the motor and sending a motor start to
the next upstream module.
• This should be set large enough to allow the motors of the module to get a slight head
start over the next upstream module.
• This should not be set so high that it takes an excessively long time to start the machine.

Recommended Settings:
• A value of 50 ms is good for most MOS tables.
• Trayers require a very high value 1200 ms.
The takeaway also requires a higher value of about 120 ms.

Figure 6-83: Motor On Delay Field

Motor Off Delay

This is the delay, in ms (milliseconds), between the exit of the last piece of mail in the module and
the motors being stopped during a cycle stop condition.
• Set this value large enough to allow mail to correctly run out.
• Do not set this value so large that the machine takes too long to stop.

Recommended Setting:
• A value of 500 ms to 1000 ms works for almost all applications.

Figure 6-84: Motor Off Delay Field

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Accelerate Time
This is the amount of time in ms (milliseconds) that mail is expected to remain stationary after
the motors are started. The elements in the base will not be told that the motors are turning
until this delay has expired.
• If pieces are marked unknown at startup after an immediate stop, then this value may be
too high.
• If pieces are marked operator removed on restart after an immediate stop, then this
value is too high.
• If pieces are jamming or are being marked as lost on restart after an immediate stop, then
this value may be too low.
A general rule of thumb:
• Use a high value for the trayer - 700 ms.
• Other MOS tables should be around 220 ms.
• The sealer and takeaway may be higher at 350 ms.

Figure 6-85: Accelerate Time Field

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Decelerate Time
This is the amount of time in ms (milliseconds) that the mail is expected to remain in motion after
motors are cut. The elements in the base are not told that the motors have stopped until this
time interval has expired.
• If pieces are going unknown or operator removed as the machine immediate stops, then
this value is too low.
• If pieces removed by the operator are listed as unknown, then the value is too high.
A general rule of thumb:
• Use a high value for the trayer 1200 ms.
• Other MOS tables should be around 440 ms to 600 ms

Figure 6-86: Decelerate Time Field

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VERTICAL STACKER PC1 ADVANCED SETUP

1. Click the Vertical Stacker hot spot on the DC main screen.
2. Select Setup from the drop-down menu to open the Vertical Stacker Setup dialog box.
3. Click [Advanced] to open the Vertical Stacker Advanced Setup dialog box.
4. Click [Setup PC1] on the Vertical Stacker Advanced Setup dialog box to open the dialog
box for the Vertical Stacker 1_a Object Setup features.

Figure 6-87: Opening the Vertical Stacker PC1 Setup Dialog Box

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Door Operation
Hold Gate Open

Figure 6-88: Hold Gate Open Check Box

Close Door on Lead Edge

Figure 6-89: Close Door on Lead Edge Check Box

Look Ahead to Previous Station

Figure 6-90: Look Ahead to Previous Station Check Box

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VERTICAL STACKER OBJECT PC JAM SETUP

• Click [Advanced] on the VS1_a Setup dialog box to open the VS1_a Advanced Setup
dialog box
or
• Click [Setup PC2] on the VS1 Advanced Setup dialog box to open the VS1_b Setup
dialog box.

Figure 6-91: Opening the Vertical Stacker Object Jam Setup Dialog Box

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Detect Jams
• If this check box is selected, jams will stop the machine.
• If this check box is not selected, this photocell will not raise alarms.
Note: Mailpieces may still be dequalified by this photocell, but the dequalified mailpiece will
not stop the machine.

Figure 6-92: Detect Jams Check Box

Jam Types Detected Group

Detect Jams must be selected or the Jam types detected group will be shaded and unavailable.

Figure 6-93: Jam Types Detected Group

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Creation of Unknowns
If this check box is selected, the machine will stop when an unknown mailpiece is detected. This
occurs when the photocell has a lead edge.

Figure 6-94: Creation of Unknowns Check Box

Lead Edge Timeout

If this check box is selected, the element will use interval jam detection.
A jam will be declared if the time between the lead edge of the previous element and the lead
edge on this element exceeds the Jam timeout before photocell interval given at the bottom of
the dialog box.

Figure 6-95: Lead Edge Timeout Check Box

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Photocell Timeout
If this check box is selected, the element will detect photocell jams.
These jams are declared when the time between the lead edge and trail edge of this element
exceed the Jam timeout under photocell interval given at the bottom this dialog box.

Figure 6-96: Photocell Timeout Check Box

Overruns Before PC
If this check box is selected, the element will create an alarm when a lead edge occurs on the
previous element (for the next piece) before the lead edge occurs at this element.
Note: This action not only determines when alarms are created, it actually affects tracking
and causes pieces to be marked as “bad”.

Figure 6-97: Overruns Before PC Check Box

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Overruns At PC
If this check box is selected, the element will stop the machine when a trail edge occurs on the
previous element before a trail edge occurs at this element.
Note: This action not only determines when alarms are created, it actually affects tracking
and marks pieces as “bad”.
This error can be caused by (but not limited to) one of the following sources:
• Improper roller velocity or idler settings
• Defective/worn bearings, belts, motors or rollers
• Glue on the decks or rollers
• Misaligned assemblies.

Figure 6-98: Overruns at PC Check Box

Next Arrives Before PC Clear

If this check box is selected, the machine will stop when a lead edge occurs on the previous
element before a trail edge occurs on this element.

Figure 6-99: Next Arrives Before PC Clear Check Box

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Tracking Unknowns and Jam Times

Figure 6-100: Tracking Unknowns and Jam Times Group

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Previous PC Always/May/Never Overlaps

Configurable shift states define how the data for a mailpiece is shifted for each edge of every
photocell (PC).
• If no given piece of mail could block any two adjacent photocells at the same time, the
photocells could be set for shifting on both lead edge and trail edge.
• If a mailpiece could block two adjacent photocells:
• One of the two photocells would have to be disabled
or
• The first photocell would have to be set for lead edge shifting.
Direct Connect uses all photocells - including R150 photocells. More tracking photocells
improve throughput as well as integrity. Direct Connect uses three configurations of shift states.
They relate to the condition of the previous PC.
Important: Under Jam types detected, select Overruns before PC, Overruns at PC and
Next arrives before PC clear to accurately check for proper shift configuration.

Condition Shifting Previous PC State

Always Overlap Lead edge Blocked
May Overlap (default) Lead edge Blocked /Unblocked
Never Overlaps Trail edge Unblocked

Figure 6-101: Previous PC Overlap Mode Selection Field

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Don’t Create Unknowns

If this check box is selected, the element will not create unknown mailpieces and pass along
unknown mailpieces. The element may still turn pink on the DC main screen when it encounters
the unknown. However, it will not create and pass along information on the unknown mailpiece.
This is useful for situations where ram blade blocking is possible and where blocks should not be
construed as pieces.

Figure 6-102: Don’t Create Unknowns Check Box

Ignore Unknowns at Start

If this check box is selected, unknown mailpieces will be ignored if they occur just after the
motors start. This is useful for preventing secondary stops after stoppages on the MOS where
the material is difficult to control. The time interval is determined by the Lead edge timeout.
Ignore unknowns at start is not available if Don’t create unknowns is selected.

Figure 6-103: Ignore Unknowns at Start Check Box

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Timeout Under Photocell

This field contains the jam timeout for pieces blocking the photocell. This value is used when the
Photocell timeout check box is selected. If the photocell is blocked for more than the number of
milliseconds specified here, the machine will stop and the piece will be dequalified.

Figure 6-104: Jam Timeout Under Photocell Field

Jam Timeout Before Photocell

This field contains the interval timeout for pieces before the photocell. This value is used when
the Lead edge timeout check box is selected. If a lead edge is transferred to this element and a
lead edge does not occur within the interval specified here, the machine will stop and the
mailpiece will be dequalified.

Figure 6-105: Jam Timeout Before Photocell Field

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MAILING MACHINE AND METER CHANNEL BASIC SETUP

R150 mailing machines are configured as part of MOS tables when the DCC is built.
1. Click on the Mailing Machine hot spot on the DC main screen.
2. Select Setup from the drop-down menu to open the Meter Setup dialog box.

Figure 6-106: Opening the Meter Setup Dialog Box

Meter Setup

BACKGROUND TURNS
YELLOW TO INDICATE
SELECTION HAS
BEEN CHANGED

Figure 6-107: Meter Control Menu

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Error Handling/Not Metered Accessory

Figure 6-108: Not Metered Accessory Field

BACKGROUNDS
TURN YELLOW TO
INDICATE SELECTION
HAS BEEN CHANGED

Figure 6-109: Not Metered Accessory Menu

Error Handling/Error Limit

Figure 6-110: Error Limit Field

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MAILING MACHINE/METER CHANNEL ADVANCED SETUP

Use this dialog box to enable and disable the mailing machine. It also allows selective metering.

Figure 6-111: Opening the Meter Advanced Setup Dialog Box

Use Meter Interface

Select the Use meter interface check box only if:
• A meter link box has been fitted to the system
• A meter channel is configured as part of the DCC.
If there is no meter link box on the system, the fields shown are shaded and not accessible.

Figure 6-112: Use Meter Interface Check Box

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Verify Trip From Meter

Figure 6-113: Verify Trip From Meter Check Box

Don’t Allow Zero Postage

Figure 6-114: Don’t Allow Zero Postage Check Box

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MAILING MACHINE/METER CHANNEL EXPERT (JAM) SETUP

JAM SETUP

Figure 6-115: Opening the Meter Expert (Jam) Setup Dialog Box

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Motor Operation Group

Figure 6-116: Motor Operation Group

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Motor On Delay
This is the delay between starting the motor and sending a motor start to the next upstream
module.
• This delay allows downstream mailpieces to get underway and avoids combining bogies
in photocell locations:
• Set this interval large enough to allow the module motors to get a slight head start over
the next upstream module.
• Do not set the interval so high that it takes forever to start the machine.

Recommended Settings:
• A value of 50 ms is good for most MOS tables.
• Because of the amount of time the IST requires to achieve operating velocity, trayers
require a very high value: 1200 ms.
• The takeaway also requires a higher value of about 120 ms. This larger time period is
true for heavy assemblies and many devices with multiple pulleys and belts.

Figure 6-117: Motor On Delay Field

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Motor Off Delay

This is the delay between the exit of the last piece of mail in the module and the motors being
stopped during a cycle stop condition. The interval allows mailpieces to clear the module before
it stops.
This should be set large enough to allow mail to correctly run out, but not so large that the
machine takes an excessively long time to stop.
A value of 500 ms to 1000 ms works for almost all applications.

Figure 6-118: Motor Off Delay Field

Accelerate Time
This is the amount of time in ms (milliseconds) that mail is expected to remain stationary after
the motors are started. The elements in the base will not be told that the motors are turning
until this delay has expired.
• If pieces are marked unknown at startup after an immediate stop, this value may be too
high.
• If pieces are marked operator removed on restart after an immediate stop, this value is
too high.
• If, after an immediate stop, pieces are jamming or are being marked as lost on restart, this
value may be too low.
A general rule of thumb:
• Use a high value for the trayer 700 ms.
• Other MOS tables should be around 220 ms.
• The sealer and takeaway may be higher at 350 ms.

Figure 6-119: Accelerate Time Field

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Decelerate Time
This is the amount of time in ms (milliseconds) that the mail is expected to remain in motion after
motors are cut. The interval allows mailpieces to clear the module before it stops.
The elements in the base will not be told that the motors have stopped until this time interval
has expired.
• If pieces are marked unknown or operator removed as the machine immediate stops,
this value is too low.
• If pieces removed by the operator are marked unknown, the value is too high.

Recommended settings
• A general rule of thumb is to use a high value for the trayer 1200 ms.
• Other MOS tables should be around 440 ms to 600 ms.

Figure 6-120: Decelerate Time Field

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Detect Jams
JAM
SETUP

Figure 6-121: Expert Meter Setup Detect Jams Group

The status of this check box determines whether jams will stop the machine. If the check box is
not selected, alarms should not be raised by this photocell.
Note: Mailpieces may still be dequalified by this photocell, but the machine will not stop
when the mailpiece is dequalified.
If this check box is not selected, all boxes listed in Jam types detected below it will be shaded
and unavailable.

Figure 6-122: Detect Jams Check Box

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Jam Types Detected Group

If Detect Jams is not selected, all the check boxes in this group will be shaded and unavailable.

Figure 6-123: Jam Types Detected Group

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Creation of Unknowns
If this check box is selected, the machine will stop when an unknown mailpiece is detected. This
occurs when the photocell has a lead edge.
This error can be caused by (but not limited to) one of the following sources:
• Noise
• Scraps or debris passing under photocell
• Vibration/misalignment of photocell
• Loose connections.

Figure 6-124: Creation of Unknowns Check Box

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Lead Edge Timeout

If this check box is selected, the selected element uses interval jam detection.
A jam will be declared if the time between the lead edge of the previous element and the lead
edge on this element exceeds the Jam timeout before photocell setting given at the bottom of
the dialog box.
This error can be caused by (but not limited to) one of the following sources:
• Improper roller velocity or idler settings
• Defective/worn bearings, belts, motors or rollers
• Glue on the decks or rollers
• Misaligned assemblies.

Figure 6-125: Lead Edge Timeout Check Box

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Photocell Timeout
If this check box is selected, the element selected detects photocell jams.
These jams are declared when the time between the lead edge and trail edge of this element
exceed the Jam timeout under photocell setting at the bottom of this dialog box.
This error can be caused by (but not limited to) one of the following sources:
• Improper roller velocity or idler settings
• Defective/worn bearings, belts, motors or rollers
• Glue on the decks or rollers
• Misaligned assemblies.

Figure 6-126: Photocell Timeout Check Box

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Overruns Before PC
If this check box is selected, the element selected causes an alarm when a lead edge occurs on
the previous element (for the next piece) before lead edge occurs at this element.
Note: This action actually affects tracking and marks pieces as “bad” - unlike most other
check boxes in the Detect Jams group.
This error can be caused by (but not limited to) one of the following sources:
• Improper roller velocity or idler settings
• Defective/worn bearings, belts, motors or rollers
• Glue on the decks or rollers
• Misaligned assemblies.

Figure 6-127:Overruns Before PC Check Box

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Overruns at PC
If this check box is selected, the element will stop the machine when a trail edge occurs on the
previous element before a trail edge occurs at this element.
Note: This action not only affects when alarms are created, it actually affects tracking and
marks pieces as “bad”.
This error can be caused by (but not limited to) one of the following sources:
• Improper roller velocity or idler settings
• Defective/worn bearings, belts, motors or rollers
• Glue on the decks or rollers
• Misaligned assemblies.

Figure 6-128: Overruns at PC Check Box

Next Arrives Before PC Clear

If this check box is selected, the machine will stop when a lead edge occurs on the previous
element before trail edge occurs on this element.
This error can be caused by (but not limited to) one of the following sources:
• Improper roller velocity or idler settings
• Defective/worn bearings, belts, motors or rollers
• Glue on the decks or rollers
• Misaligned assemblies.

Figure 6-129: Next Arrives Before PC Clear Check Box

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Ignore Unknowns at Start

If this check box is selected, unknowns will be ignored if they occur just after the motors start.
The time interval is determined by the Lead edge timeout. This is useful for preventing
secondary stops after stoppages on the MOS where the material is difficult to control.

Figure 6-130: Ignore Unknowns at Start Check Box

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Jam Times and Tracking Unknowns

Figure 6-131:Tracking Unknowns and Jam Times Group

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Photocell Never Overlaps Previous

This parameter is critical for the correct operation of any basic element on the machine. Set
this parameter so that a mailpiece cannot block this PC and the previous PC simultaneously.
Selecting this check box creates another shift state. If this check box is cleared when it should be
selected, errors will occur when the machine is run quickly, but not when it is single cycled.

Figure 6-132: Photcell Never Overlaps Previous Check Box

Later versions offer a configurable shift state to define how the data for a mailpiece is shifted for
each edge of every photocell (PC).
• If no given piece of mail could block any two adjacent photocells at the same time, the
photocells could be set for shifting on both lead edge and trail edge.
• If a mailpiece could block two adjacent photocells, one of the two photocells would have
to be disabled or the first photocell would have to be set for lead edge shifting.
Direct Connect uses all photocells - including R150 photocells. More tracking photocells
improve throughput as well as integrity. Direct Connect uses three configurations of shift states.
They relate to the condition of the previous PC.
Important: Under Jam types detected, select Overruns before PC, Overruns at PC and
Next arrives before PC clear to accurately check for proper shift configuration.
Condition Shifting Previous PC State
Always Overlap Lead edge Blocked
May Overlap (default) Lead edge Blocked /Unblocked
Never Overlaps Trail edge Unblocked

Merge Collations
This parameter does not affect machine operation.

Figure 6-133: Merge Collations Check Box

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Don’t Create Unknowns

If this check box is selected, the element will not create unknown mailpieces and pass along
unknown mailpieces.
The element may still turn pink when it encounters the unknown. However, it will not create and
pass along information on the unknown. This is useful for situations where ram blade blocking is
possible and where blocks should not be construed as pieces.
Note: Ignore unknowns at start is not available if Don’t create unknowns is selected.

Figure 6-134: Don’t Create Unknowns Check Box

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Jam Timeout Under Photocell

This field contains the jam timeout for pieces blocking the photocell.
This value is used when the Photocell timeout check box is selected. If the photocell is blocked
for more than the number of milliseconds specified here, the machine will stop and the piece will
be dequalified.

Figure 6-135: Jam Timeout Under Photocell Field

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Jam Timeouts Before Photocell

This field contains the interval timeout for pieces before the photocell.
This value is used when the Lead edge timeout check box is selected. If a lead edge is
transferred to this element and a lead edge does not occur within the specified interval, the
machine will stop and the piece will be dequalified.

Figure 6-136: Jam Timeout Before Photocell Check Box

Determining Jam Timeouts

Setting the jam timeouts can be difficult. One way to set them is to estimate the average time
and multiply that average by 3 or 4. This prevents more than two pieces from being damaged
and eliminates the possibility of false positives.
For instance:
• If you have two photocells that are 10 inches apart and the paper speed is 65 ips (divide
10 by 65), then 153 ms is a reasonable estimate for the interval timeout. Multiplying
this number by 4 yields 600 ms (milliseconds) for the Jam timeout before photocell
interval.
• If the envelope length is 9-1/2 inches, it will take about 146 ms (divide 9.5 by 65) for
an envelope to move across the photocell. Multiplying this by 4 yields 600 ms.

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IST (TRAYER) BASIC SETUP

1. Click the Trayer hot spot on the DC main screen.
2. Select Setup from the drop-down menu. The Trayer Setup dialog box opens.

Figure 6-137: Opening the Advanced Trayer Setup Dialog Box

3. Click [Advanced] on the Trayer Setup dialog box to open the dialog box for the Trayer
Advanced Setup features.

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Stacking Mode

Figure 6-138: Stacking Mode Selection Field

Tail Kick Mode

Figure 6-139: Tail Kick Mode Selection Field

Bin Done (When Full) Mode

Figure 6-140: Bin Done Mode Selection Field

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Maximum Pieces Per Tray (in Count Mode)

Figure6-141: Maximum Pieces per Tray (in Count Mode) Field

Tray Breaks

FIELD
BACKGROUNDS
TURN YELLOW TO
INDICATE NEW
SELECTION

Figure 6-142: Tray Brakes Selection Fields

Trayer Setup > Default

Figure 6-143: Trayer Default Values Dialog Box

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IST (TRAYER) ADVANCED SETUP

Figure 6-144: Opening the Trayer Advanced Setup Dialog Box

Motor On Delay

Figure 6-145: Motor on Delay Field

Motor Off Delay

Figure 6-146: Motor Off Delay Field

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Transport Accelerate Time

Figure 6-147: Transport Accelerate Time Field

Transport Decelerate Time

Figure 6-148: Transport Decelerate Time Field

Bin Virtual PC Delay

Figure 6-149: Bin Virtual PC Delay Field

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Drum Virtual PC Delay

Figure 6-150: Drum Virtual PC Delay Field

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PROMS
PROMS
Boards
Bingo Diagnostics
Bingo Status
Solenoid Square Wave Test
8051 Board
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CHAPTER 7: BOARDS AND PROMS

Table of Contents
PROMS............................................................................................333
Multibus Feeder Setup............................................................................................................... 333

BOARDS..........................................................................................333
Feeder Boards .............................................................................................................................. 333
New DC Systems......................................................................................................................... 333
Physical Connections ................................................................................................................. 334

BINGO DIAGNOSTICS ....................................................................335

BINGO STATUS...............................................................................337

SOLENOID SQUARE WAVE TEST ....................................................338

8051 BOARD..................................................................................339
Setup and Jumper Configuration............................................................................................. 341
8051 Configuration................................................................................................................... 342
Switches 4 and 6.................................................................................................................... 342
Wiring Connections .................................................................................................................... 342
Physical Connections ................................................................................................................. 342

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PROMS
CQEP, the predecessor to direct Connect, uses PROMs with preloaded instructions.
Different versions and different PROMs are used for input feeders (burster, hicap, cutter),
accumulator and MOS. With CQEP you end up with variations on variations.
The feeder PROMs also have the same variations.
8051 boards on Direct Connect systems always use the same PROMs currently SLAV1AXX (the
latest version as of 1/23/03) on Windows NT DC versions 160 and above machines) regardless
of where the 8051 card is located.

Multibus Feeder Setup

The following table summarizes the types of PROMs used for the various types of feeders in
Direct Connect systems:
Feeder Type PROM Label Checksum
Single Doc Feeder HRF2A08 5A86
Retail Feeder (24V solenoid) HRF2A08 5A86
Retail Feeder (12V solenoid) IOC1A04 0D90
2 Stage Envelope Feeder (12 Series) HRF2A08 5A86
One Cycle Envelope Feeder OCEFDR 1A02 C260
Mini Burster HRF2A08 5A86
Heavy Duty Folder Feeder HRF2A08 5A86
Burster/Folder HRF2A08 5A86

BOARDS
Feeder Boards
Single document feeders and retail feeders on Direct Connect systems have certain wiring
modifications for door switches and integrity photocells. The separation of the jam signal from
the interlock signal is accomplished via "cut and jumper" of the 8742 feeder board, Part Number
8282008. This cut and jumper is standardized in Part Number 8382033.

New DC Systems
New Direct Connect systems include new feeder boards, Part Number 8382033, and not the
old feeder boards, Part Number 82008. The additional harnessing changes are summarized
below:
Connection Description
J1 pin 7 Door sense
J1 pin 8 Door sense
J1 pin 12 5v for integrity PC
J1 pin 10 Gnd for integrity PC
J1 pin 11 Signal for integrity PC

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Physical Connections
Also refer to the Direct Connect Physical Connections Diagram in Appendix A.

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BINGO DIAGNOSTICS

1. Click the Bingo Diagnostics Icon on the Master I/O Device List on the DC main
screen to open the list of Bingo Cards.
2. Select the Chassis 51 Transport Bingo from the list.
3. Click [Show] to open the Diagnostic dialog box.

Figure 7-1: Opening the Transport Bingo Diagnostic Dialog box

4. In the Outputs section of the Diagnostic dialog box, click the check box next to the desired
output to turn on the signal. The check in the Transport_Mocon box indicates that the
signal is turned on at the Transport Bingo, J4.
5. If the Mocon box for the transport motor is plugged into the J4 connector and 24vdc is
supplied to the Mocon box, the transport motor should run.

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6. Block a photocell or make a switch and watch that the box turns red as the photocell or
switch is made to check the inputs.
7. If the unused inputs for a Bingo card are masked, blocking an input will not show on the
Bingo diagnostics for a second or two.
8. If PC7 is plugged into J15 (a masked input in most systems), and you try to block the
photocell by moving your finger back and forth across the photocell, you will see no
transitions, but if you place an object under the photocell and leave it you will see the
transition. Ten plug PC7 into J12, the correct wiring.
9. If there are unlabeled inputs that show ON on a Bingo card, investigate and unplug them.
Note: Rapidly changing unused inputs can overload the processor on the 8051 board and
cause the microprocessor not to complete other tasks.

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BINGO STATUS
Display this Bingo Status dialog box to check inputs and outputs.
1. Click Display on the DC main menu.
2. Select Objects from the list displayed. The Display Object Info dialog box opens.
3. Expand the Select Object list in the Display Object Info dialog box to reach the Transport
Bingo card:
Model > IO Device > Bingo Cards > Transport Bingo
4. Click [Setup] under Object Functions to open the Transport Bingo Setup dialog box.
5. Click [Status] under Object Functions to open the Transport Bingo Status dialog box.

Figure 7-2: Opening the Transport Bingo Setup and Status Dialog Boxes

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SOLENOID SQUARE WAVE TEST

This test allows you to leave the DC workstation monitor to observe the solenoid operation.
1. Click Display on the DC main menu.
2. Select Objects from the list displayed. The Display Object Info dialog box opens.
3. Expand the Select Object list to reach the Transport Gate1_Brake1:
Model > IO Devices > Bingo Cards > Transport Bingo > Transport Gate1_Brake1
4. Click [Test] under Object Functions on the Display Object Info dialog box to open the
Test Output Transport Gate1 dialog box.
5. Select the Square wave radio button and enter the Square wave Period in milliseconds.

Figure 7-3: Opening the Square Wave Test Output Dialog Box

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8051 BOARD
To check communication between the computer RocketPort/DigiBoard board and the 8051,
view the messages transmitted in the Diagnostic dialog box. To determine which
RocketPort/DigiBoard port the device needs to be plugged into, refer to the Jack column on the
Bingo card screen.
Make further verification at the 8051 cards. Read the scrolling LED display at the MOS 8051
board. If it indicates that it’s configured as the Hicap you would know it’s plugged into
RocketPort/DigiBoard port 2 and needs to be placed into RocketPort/DigiBoard port 3.
If you are having problems with a 8051 communicating, move its plug to another port and see if
that 8051 will communicate. If that is the case, either the board is improperly configured or the
board or PROM is defective.

Figure 7-4: Opening the Bingo Diagnostic Dialog Box

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This dialog box shows no communication with the computer:

NOT
COMMUNICATING

Figure 7-5: Bingo Diagnostic Dialog Box Showing No Communication with the Computer

This dialog box shows communication with the computer.

COMMUNICATING

Figure 7-6: Bingo Diagnostic Dialog Box Showing Communication with the Computer

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Setup and Jumper Configuration

This is typical protocol for 8051 communications:

Figure 7-7: Opening the 8051 Setup Dialog Box

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8051 Configuration
• 8051 boards on Direct Connect systems always use SLAV1A07 PROMs regardless of
where the 8051 is located.
• Remove any FDSN jumpers on J11.
• Remove any feeder scanner connections on J10 and J6.
• Set JP4 to 1-2.
• Set JP6 to 1-2.

Switches 4 and 6

S4 Setting S6 Setting Baud Rate

Off Off 19.2k
Off On 38.4k
On Off 57.6k
On On 115.2k

If the 8051 is used on a feeder module (C, B, or H) and is used for OMR (Optical Mark Reader)
scanning, then wire a jumper (PN R583021) between J10 on the 8051 board and J8 on the
same board. This jumper’s lead edge and encoder signals to the correct inputs for OMR
scanning.

Wiring Connections
There are standard wiring connections but they, like all standards, are only standard the day they
are made. Before the documentation can be made they are no longer the standard. Because DC
shows the connection to the Bingo cards and 8051 boards it is always best to check the
machine for the proper connection.
For the connection for the feeder cards and harnesses, see the schematics and wiring diagrams.

Physical Connections
Also refer to the Direct Connect Physical Connections Diagram in Appendix A.

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Reports
Direct Reports Productivity Data
Collection and Reporting
Report Configuration Setup
Tweak (Setting Up the Report
Generator)
Direct Reports Advanced Setup
Reports Program
DC.ini
MachineId and MachineName
JobId
Data Map Setup
Data Collection Process
Other Features
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CHAPTER 8: DIRECT REPORTS

Table of Contents
DIRECT REPORTS (PRODUCTIVITY DATA COLLECTION AND
REPORTING)...................................................................................347
Direct Reports Test.................................................................................................................... 347
Productivity Data Collection Overview ................................................................................. 347

REPORT CONFIGURATION SETUP .................................................348

Single Inserter .............................................................................................................................. 348
Multiple Inserters ........................................................................................................................ 348
Collected Data Elements........................................................................................................... 349
Definition of Timer Elements.................................................................................................... 349
Setup.............................................................................................................................................. 350
Enable Productivity Data Logging...................................................................................... 350
Enable Productivity Data Logging...................................................................................... 351
Top 10 Error/Alarm Logging............................................................................................... 351
Enable Alarm Detail Logging................................................................................................ 352
Meter Info Database Format ............................................................................................... 352
Data Logging Directory ........................................................................................................ 353
Machine Delay (to User Fault) Rollover Period .............................................................. 353
User Stop as Machine Wait.................................................................................................. 354
User Stop Rollover ................................................................................................................. 354
Machine Wait Time Rollover to Operator Wait Time ........................................................ 355
Completed Pieces to Finish Startup .................................................................................. 356
Maximum Time to Correct Error (sec) .............................................................................. 356
Minimum Delay Time (ms) ................................................................................................... 356
Sampling Interval .................................................................................................................... 357

TWEAK (SETTING UP THE REPORT GENERATOR) .........................358

Definition Of Terms.................................................................................................................... 364
Associated Files ........................................................................................................................... 364

DIRECT REPORTS ADVANCED SETUP.............................................365

REPORTS PROGRAM ......................................................................366

Allow Reports to Run ................................................................................................................. 366
Report Program ........................................................................................................................... 366
Command Line ............................................................................................................................. 366
Working Directory ...................................................................................................................... 366

DC.INI .............................................................................................367

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MACHINEID AND MACHINENAME ..................................................367

Machineld...................................................................................................................................... 367
MachineName .............................................................................................................................. 367

JOBID ..............................................................................................368

DATA MAP SETUP...........................................................................369

DATA COLLECTION PROCESS........................................................373

Spawning ....................................................................................................................................... 373
Terminating................................................................................................................................... 373
Archiving Reports ................................................................................................................... 373
Reports .......................................................................................................................................... 374
Definition of Fields ................................................................................................................. 374
Production Graph................................................................................................................... 375
Thru-Put Graph....................................................................................................................... 375
Production Detail Report ..................................................................................................... 376
Operator Summary Report .................................................................................................. 376
Job Summary Report.............................................................................................................. 377
Inserter Summary Report ..................................................................................................... 377
Shift Summary Report ........................................................................................................... 378
Feeder Count Report............................................................................................................. 378
Input Count Report ............................................................................................................... 379
Out Sort Count Report......................................................................................................... 379

OTHER FEATURES...........................................................................380
Excluding Operators and Service Reps From Reports ....................................................... 380
Exporting in Excel........................................................................................................................ 380
Exporting, Appending and Importing ................................................................................ 381
Update Options........................................................................................................................... 382
Loss of Production Data............................................................................................................ 382
Unrecoverable ......................................................................................................................... 382
Recoverable.............................................................................................................................. 382
Special Setup Dialog Boxes ...................................................................................................... 383

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DIRECT REPORTS (PRODUCTIVITY DATA COLLECTION

AND REPORTING)
Direct Reports are the tools we use to maintain the inserters and mailroom operating efficiency.
They are not an accounting system used to provide piece-to-piece accounting (file based
processing) nor are the meant to account for postage and fees (OMS with Cost and Funds
accounts for postage).

Direct Reports Test

Direct Reports count pieces processed with 99% accuracy (99% free from jams and processing
errors) when the inserter is running. This feature is so valuable that Service has requested that
Direct Reports be installed on all inserters.
Run 20 pieces of mail and the reports will account for 20 pieces. Then, run another 20 and hold
the door open on a vertical stacker. The reports will account for fewer than 20 pieces. The
machine will stop for an integrity error because pieces were outsorted as a result of physical
intervention. Pieces are not counted until all pieces en route are cleared from the MOS, chassis
and input sections. The effect is, on a good running machine, 99% of all mail is accounted for.
This figure is high enough to give an accurate measure of productivity.
Note: This test reveals that Direct Reports cannot be used for piece-to-piece accounting.
This package, Productivity Data Collection and Reporting, was not designed for piece-level
tracking. It is strictly a means by which to provide insight into a mailroom’s overall Inserting
productivity.

Productivity Data Collection Overview

Productivity Data Collection provides insight into a mailroom’s overall inserting productivity.
Elements such as job start and end times, machine fault times, operator fault times, and effective
completed mailpieces per hour are captured on a per inserter basis.
The Report Generator is the tool that presents the collected data. The Report Generator allows
report generation based on the parameters in the Direct Reports dialog box.

Figure 8-1: Direct Reports Main Dialog Box

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REPORT CONFIGURATION SETUP

The package consolidates data across multiple inserters in a network environment or runs stand-
alone in single inserter environments.
The Direct Reports reporting package consists of two parts:
• The first part is the Direct Reports Manager object. This object must be configured
into the Direct Connect DLL for each inserter. This object is responsible for collecting
data about machine performance and logging it to a set of flat files (plain old text files) in
a specified directory.
• The second part is Direct Reports, a report generator package. It is a Microsoft Access
database that imports data from the flat files and uses it to produce reports.

Single Inserter
If Direct Reports are used in a single inserter environment:
• The Direct Reports Manager is set to write to the local hard drive.
• Typically, the flat files are stored in the C:\PRODDATA directory.
• The Microsoft Access database is also loaded onto the local drive in the C:\PRODDATA
directory.
• The Access Report Generator is configured to look for the flat files on the local (C:) hard
drive.

Multiple Inserters
If Direct Reports are used in a multiple inserter environment on a network:
• The Microsoft Access software is loaded onto an additional workstation in the mailroom.
• The Direct Reports Manager is set up to log to the S:\PRODDATA directory.
• Each inserter is set to log to this directory on the server.
• The Direct Reports Manager on each inserter will append data to the flat files without
over-writing the data from other inserters.
• The Report Generator is configured to look for its data on the S: drive as well.

The Direct Reports Report Generator produces reports for all the inserters simultaneously.

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Collected Data Elements

Timer Elements Counter Elements Static Elements

Start Time Pieces Fed Machine ID
End Time Pieces Completed Mode ID
Run Time Number of Delays File ID (if applicable)
Delay Time Number of Machine Stops Job ID
Machine Stop Time Number of User Stops Operator ID
User Stop Time Enclosure Feeder Sheet Counts
Machine Fault Time Input Feeder Sheet Counts
User Fault Time Outsort Counts by Outsort Type

Definition of Timer Elements

All internal time elements are related to Universal Coordinated Time: seconds elapsed since
midnight (00:00:00) January 1, 1970.
Element Definition
Start Time Time at which the data collection instance was started
End Time Time at which the data collection instance was
terminated
Run Time Chassis Cycling Time
Delay Time Chassis Delay Time
Machine Stop Time Time Interval the Inserter remains in a stopped state
due to machine initiated stoppages
User Stop Time Time Interval the Inserter remains in a stopped state
due to user initiated stoppages
Machine Wait Time Down Time allocated against the Inserter
User Wait Time Down Time allocated against the User

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Enable Productivity Data Logging

This check box enables the logging of data to the PRODDATA.TXT flat file.
This box should always be checked.

Figure 8-3: Enable Productivity Data Logging Check Box

Top 10 Error/Alarm Logging

This check box enables the logging of data to the ALARM10.TXT and the ERROR10.TXT flat
files.
• The Top 10 Error Summary identifies the top 10 reasons contributing to mailpiece
disqualification.
• All top 10 error summary data is stored in a database file named ERROR10.TXT.
These files contain information on the 10 most frequent reasons that the machine stopped
(alarms) and the top ten reasons for mailpiece dequalification (errors).

Figure 8-4: Enable Top 10 Error/Alarm Logging Check Box

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Enable Alarm Detail Logging

This check box enables logging of alarm detail information to the ALARMDET.TXT file. The
Error Detail identifies each inserter alarm (inserter initiated stops). All error detail data is stored
in a database file named ALARMDET.TXT.
At present, there is no report generated to show details of the ALARMDET.TXT. One is being
developed.

Figure 8-5: Enable Alarm Detail Logging Check Box

Meter Info Database Format

The Meter Info database contains a snapshot of each meter’s serial number, run postage, and the
ascending/descending registers at the beginning and end of each transaction. All meter info data
is stored in a database file named METERS.TXT.
The Meter Info database also provides aesthetics to the Mode name on the reports.

Figure 8-6: Enable Meter Info Logging and Parse Dirty Mode Indicator Check Boxes

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Data Logging Directory

This field contains the name of the directory in which the flat files are created and updated. This
should be set to S:\PRODDATA\ for network configurations and C:\PRODDATA\ for
standalone configurations.
Note: This directory should always end in a "\" character.

Figure 8-7: Data Logging Directory Field

Machine Delay (to User Fault) Rollover Period

This interval determines how long a delay is tolerated before it is entered as operator wait time.
This guards against the operator placing the machine in delay and going on break. Small delays
are credited as delay time. Larger delays are credited as Operator Fault Time.

Figure 8-8: Machine Delay (to User Fault) Rollover Period Field

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User Stop as Machine Wait

When this check box is selected, an operator initiated stop is counted as machine wait time or
down time. This box is normally left unchecked.

Figure 8-9: Log User Stop (up to User Stop Rollover) as Machine Fault Time Check Box

User Stop Rollover

This interval determines how much of an operator initiated stop will be credited under machine
fault time before rolling over to operator wait time.
This parameter is used only if the above Log User Stop (up to user stop rollover) as machine
fault time is checked.

Figure 8-10: User Stop Rollover Period Field

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Machine Wait Time Rollover to Operator Wait Time

1. Select Display > Objects from the main DC Menu. The Display Object Info dialog box
opens.
2. Expand the Select Object list to reach Performance:
Model > System Controllers > Performance
3. Click [Setup] under Object Functions in the Display Object Info dialog box to open the
Performance Setup dialog box.

Figure 8-11: Opening the Performance Setup Dialog Box

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Completed Pieces to Finish Startup

Figure 8-12: Completed Pieces to Finish Startup Field

Maximum Time to Correct Error (sec)

This is the amount of time the operator has to correct a machine fault and restart the machine.
Any time in excess of this interval is logged as Operator Wait Time.
This interval needs to recognize the amount of time the operator has to react to the machine and
still meet production goals.

Figure 8-13: Maximum Time to Correct Error Field

Minimum Delay Time (ms)

Figure 8-14: Minimum Delay Time Field

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Sampling Interval

Figure 8-15: Sampling Interval Field

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TWEAK (SETTING UP THE REPORT GENERATOR)

1. Select the Direct Reports icon from the DC main screen.
2. Select Reports from the menu list that opens. The Direct Reports dialog box opens.

Figure 8-16: Opening the Direct Reports Dialog box

3. Press the [Shift] + [Control] + [E] on the keyboard at the same time. The GorillaWare
dialog box opens.

Figure 8-17: GorillaWare Dialog Box/Tweak Enabled

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4. Click [OK].
Note: Press [Shift] + [Ctrl] + [D] to disable Tweak when finished.

Figure 8-18: GorillaWare Dialog Box/Tweak Disabled

5. Use the four small, unlabeled buttons just above the Exit icon in the Direct Reports dialog
box to set up the reports for your machine and customer.

Figure 8-19: Location of Reports Setup Buttons

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6. Double-click the left most button to display the Reports and Queries Options dialog box.
7. Check the box next to the fields listed to select those reports to be run. These changes will
be shown on the Direct Reports - Reports and Queries Options dialog box.

Figure 8-20: Reports and Queries Options Dialog Box

8. The Number Of Feeder Positions entry is critical. Click on the down arrow next to each
Station label and select the size of the chassis. If you have a 16 station chassis, set number
of feeders to 16.
• If the feeders are numbered from back to front (feeder next to the input is feeder #1,
like Bell & Howell) then you can reassign the feeder numbers in the reports.
9. Click [Close] at the upper left of the Reports and Query Options dialog box to return to
the main Direct Reports screen.

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10. Double-click the second button from the left just above the Exit icon to display the Feeder
Report Labels dialog box.

Figure 8-21: Feeder Report Labels Dialog Box

11. Click the down arrow below the Station field to open the list of input feeders, enclosure
feeders and scanning feeders and select the appropriate feeder name for each feeder on the
machine.
12. Click [Close] on the upper left corner of the Feeder Report Labels dialog box to return to
the main Direct Reports window.

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13. Double-click the third button from the left, just above the Exit icon, to display the Utilities
Option dialog box.
14. Click the box next to Customer Name.
Editing the customers name produces a Warning dialog box:

Figure 8-22: Customer Name Warning Dialog Box

and the following red screen:

Figure 8-23: Direct Reports Red Screen Dialog Box

This is normal and acceptable.

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15. Type in the Customer Name. The name typed in the Customer Name field shows on the
Reports.
16. The fourth button displays the Close dialog box. Click [Close] when you have finished
editing.

Figure 8-24: Direct Reports Close Dialog Box

17. Press [Shift] + [Ctrl] + [D] to disable Tweak.

Figure 8-25: Tweak Disabled Dialog Box

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Definition Of Terms
Field Name Description
Job As defined in the Mailpiece Manager/Default Map
Operator Operator Name
Inserter Inserter Name
Start Date/Time Timestamp for transaction start
Machine Wait Time Total Time due to machine initiated stops
Operator Rate Per/Hour Pieces Fed/Total Time (Including Operator Wait Time)
Operator Wait Time Total Time due to operator initiated stops; excessive wait time from machine
initiated stops
Run Time Total Time machine running (not in a stopped state) plus Machine Delay Time
Total Invoices Total Pieces Fed
Total Mailpieces Total Pieces Fed
Invoices Per/Hour Total Invoices divided by Run Time + Machine Wait Time
Inserter Rate Per/Hour Total Invoices divided by Run Time + Machine Wait Time
Total Time Total Time reported (sum of Machine Wait Time, Operator Wait Time and
Run Time)
Chassis Speed Number of machine cycles divided by the total time.
Mailpieces Per Hr Total mailpieces divided by run time +Machine wait time

Associated Files
The file that the Direct Report Manager writes to is named in the Advanced Setup dialog box.
• C:\proddata on non-networked machines
• S:\proddata on multiple or networked machines.
The following files are in \proddata:
• Proddata.txt
• Alarm10.txt
• Alarmdet.txt
• Error10.txt.
The Archive directory is located at:
• C:\proddata\Archive on non-networked machines
• S:\proddata\Archive when networked.
The file that runs the Report Generator is Dcreprt**.mdb and is usually in the C:\ or
S:\proddata directory. It can be anywhere, but must be looking for either C:\proddata or
S:\proddata.txt.
In Setup under Direct Reports in the Data Logging Directory field, you can only define one of
these two directories. Any other directory in the Report Generator will not find proddata.txt.

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DIRECT REPORTS ADVANCED SETUP

This dialogue box is similar to the Properties dialog box for a Windows icon.
1. Select the Direct Reports icon from the DC main screen.
2. Select Setup from the menu list. The Direct Reports Setup dialog box opens.
3. Click [Advanced] to open the Direct Reports Advanced Setup dialog box.

Figure 8-26: Opening the Direct Reports Advanced Setup Dialog Box

The Timing section in the Advanced Setup dialog box is not used with Direct Reports and can
be ignored. (It is the same class object as Cost Manager.)

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REPORTS PROGRAM
The Report Program field displays the directory from where the dcreprt**. MDB is run.

Allow Reports to Run

Reports will run only if this check box is selected. If the inserters are networked, leave this box
unchecked.
Check this box for stand-alone inserters only. It is not a good practice to let reports be
generated from two places at once from the same proddata.txt file.

Figure 8-27: Allow Reports to Run Check Box

Report Program

Figure 8-28: Report Program Field

Command Line

Figure 8-29: Command Line Field

Working Directory

Figure 8-30: Working Directory Field

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DC.INI
In order for Direct Reports (and the remote monitor, if applicable) to work correctly, there are a
few fields in the DC.INI file that must be set up correctly. These fields help uniquely identify
each machine and are important when setting up machines in multiple inserter sites.
The DC.INI file contains the sections listed below. Within each section there are parameters and
values. Most parameters within this file should never be touched. The section of interest to
Direct Reports is the MachineModel section shown below:
• MachineModel
• ElementTableSize=40
• IOTableSize=40
• KeyOperatorHelpFile=english\imc110e.hlp
• MachineID=10
(These are the names
• MachineName=DC1 shown on the reports.)
• OperatorHelpFile=english\imc110e.hlp
• ServiceHelpFile=english\imc110e.hlp
• SystemTableSize=8
• TotalMMOs=750

MACHINEID AND MACHINENAME

The parameters of interest are Machineld and MachineName.

Machineld
Set MachineId to a number that uniquely identifies the machine within the inserters on site.

MachineName
Choose a machine name that is appropriate for the machine and acceptable for use on reports
generated by Direct Reports. The naming convention should be done prior to installation. If you
change MachineName after production data has been collected you will have data written to
both names. If DC9 was changed to DC09 you will have production data for both until you
delete the data for the time period that the machine was known as DC9.

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JOBID
In order for the Direct Reports reporting package to work correctly, each mailpiece should have a
JobId defined. For some customers, this is easy since they run MRDFs that defines a JobId.

Do not create different modes to help the customer track jobs. This
becomes difficult to administer.
Use the System Parameter or Job Manager features to track jobs.
IMPORTANT
For other customers, special care must be taken to fill in the JobId field with something
appropriate. One approach is to fill the JobId field in with the name of the currently loaded
Mode.

1. Select the Mailpiece Manager icon from the DC main menu.

2. Select Setup from the list that opens. The Mailpiece Manager dialog box opens.
3. Click [Default Map] to open the Data Map Setup dialog box.

Figure 8-31: Opening the Mailpiece Manager Default Map Dialog Box

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DATA MAP SETUP

This dialog box gives mapping rules that are used to initialize mailpiece data for newly created
mailpieces on the system.
To add a rule that maps the ModeID mailpiece field into the JobID field:
1. Click [Delete] at the bottom of the Data Map Setup dialog box to clear the Target/Source
list field.

Figure 8-32: Data Map Setup Dialog Box

2. Click [New] to open the Select target field list dialog box.

Figure 8-33: Select Target Field Dialog Box

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3. Use the up and down arrows to scroll through the list until you reach JobID.

Figure 8-34: Target Field Selected

4. Click to select JobID. Right-click on any item on the list to get information about the
selected item.
5. Click [Ok] to continue.
The Data Map Field Setup dialog box opens.

Figure 8-35: Data Map Setup Field Dialog Box

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6. In the Input Records area, scroll through the Field list and select Mode.
7. Click [Add] just below Input Records. (There are two other fields with [Add] buttons in
this dialog box. Be careful to use the proper one.)

Figure 8-36: Selecting the Input Record Field

8. 0.Mode is displayed in the Data Map area/Mapping Equation field. Click [O k] to close the
Data Map Field Setup dialog box.

Figure 8-37: Closing the Data Map field Setup Dialog Box

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The Data Map Setup dialog box reopens and the following is displayed in the
Target/Source field: 0.JobID = 0.Mode

Figure 8-38: Completed Data Map

9. Click [Ok].
The change may not take effect instantly. A number of mailpieces must run before they will be
correctly marked with the Mode in their JobID fields. What ever you equate JobID to in the
Data Map Setup dialog box will be recorded in Direct Reports as JobId.
This change only affects the currently loaded Mode. To change the customer’s other Modes, save
the current Mode and use the Mode Updater.

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DATA COLLECTION PROCESS

Spawning
A data collection instance is spawned by the detection of an active Mode, User and Job.
• Mode is activated by changing or loading a Mode.
• Logging In activates User.
• Job is activated when the first “good” page of a collation enters the accumulator and the
mailpiece data mapping includes this JobId. Pre-job setup time is not collected.

Terminating
A data collection instance is terminated when a change in Mode, User or Job is detected, or the
user resets the counts.
• A new instance is immediately spawned if the change meets the spawning criteria
described above.
• If zero (0) pieces are processed within a collection instance, no data is logged.

Archiving Reports
1. Create the directory C:\proddata\archive to archive.
2. Select Archive Functions at the bottom of the Direct Reports main screen.
3. Select Write Out Archive File < - To this Date.
4. Select the date range from the pull-down list.
5. Use the same steps for reading in an Archive file.
6. When archiving, you clear the MDB and the Proddat.txt of all data from the date you
selected back.

Figure 8-39: Archive Reports Dialog Box

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Reports
Select the reports you wish to view or print by the above criteria and date range.

Figure 8-40: Direct Reports/Report Selection Area

Definition of Fields
Field Name Description
Job As defined in the Mailpiece Manager/Default Map
Operator Operator Name
Inserter Inserter Name
Start Date/Time Timestamp for transaction start
Machine Wait Time Total Time due to machine initiated stops
Operator Rate Pieces Fed/Total Time (Including Operator Wait Time)
Per/Hour
Operator Wait Time Total Time due to operator initiated stops; excessive wait time from
machine initiated stops
Run Time Total Time machine running (not in a stopped state) plus Machine Delay
Time
Total Invoices Total Pieces Fed
Total Mailpieces Total Pieces Fed
Invoices Per/Hour Total Invoices divided by Run Time + Machine Wait Time
Inserter Rate Per/Hour Total Invoices divided by Run Time + Machine Wait Time
Total Time Total Time reported (sum of Machine Wait Time, Operator Wait Time and
Run Time)
Chassis Speed Number of machine cycles divided by the total time
Mailpieces Per Hr Total mailpieces divided by run time +Machine wait time.

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Production Graph

Figure 8-41: Direct Reports/Production Graph

Thru-Put Graph

Figure 8-42: Direct Reports/Thru-Put Graph

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Production Detail Report

Figure 8-43: Direct Reports/Production Detail Report

Operator Summary Report

Figure 8-44: Direct Reports/Operator Summary Report

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Job Summary Report

Figure 8-45: Direct Reports/Job Summary Report

Inserter Summary Report

Figure 8-46: Direct Reports/Inserter Summary Report

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Shift Summary Report

Figure 8-47: Direct Reports/Shift Summary Report

Feeder Count Report

Figure 8-48: Direct Reports/Feeder Count Report

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Input Count Report

The Input Sub-Feeders are additional ports for input feeders. (North port, east port, merging
RATs, etc.)

Figure 8-49: Direct Reports/Input Count Report

Out Sort Count Report

Figure 8-50: Direct Reports/Out Sort Count Report

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OTHER FEATURES
Excluding Operators and Service Reps From Reports
Click the down arrow next to the Operator field to access a list of operators to exclude from the
reports.

Figure 8-51: Opening the Exclude User List Dialog Box

Exporting in Excel

Click the Export*.XLS icon to set up exporting in Excel and access the Append,
Import & Export dialog box.

Figure 8-52: Opening the Export to Excel Dialog Box

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Exporting, Appending and Importing

Exporting proddata.txt is different than copying the proddata.txt. You actually export the
information from the Report Generator to a directory or disk. The data remains in the Report
Generator and is exported at the same time.
Append Proddata will let you add a proddata.txt to an existing prodatta.txt without destroying
the existing data.
Use Import Proddata to get information that was not written to the C:\proddata or the
S:\proddata into the report engine.

Figure 8-53: Dialog Boxes Used to Import, Append and Export Proddata

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Update Options
1. Click [Up Date Options] at the bottom of the Direct Reports screen. There are two
choices:
• Update on launch - Yes
• Update on launch - No
2. Select the choice to indicate which action you want to take place.

Loss of Production Data

Unrecoverable
Production data is unrecoverable:
• If Direct Reports Manager being disabled in one or more inserter Modes.
• If an abrupt program termination occurs, such as after a red screen is displayed or when
an incorrect power down sequence is used.
Note: This will also cause a lost OMS transaction.
• If an incorrect Direct Reports Archive procedure is used.
Note: This will not cause a lost OMS transaction. The proper archive procedure is to
first ensure that all inserters are idle, then to perform an update data at a Direct Reports
workstation, and then to perform an archive at the Direct Reports workstation.

Recoverable
An inserter, Workstation, or online DFWorks platform could lock proddata.txt. Data is lost if
proddata.txt is locked at the time that the target inserter is attempting to log a transaction.
The target inserter will keep the transaction in memory and transfer it along with the next
transaction.
In the event proddat.txt is locked three times in succession, the inserter will dump the
transaction into a file named proddata.que, in the same directory as proddata.txt.
The records in proddata.que have to be manually added to proddata.txt. One way to do this is
move the proddata.que to another directory, change the name to proddata.txt and then
append it to the existing proddata.txt.

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Special Setup Dialog Boxes

1. Double click the Shift area to access the setup dialog box and define shifts.

Figure 8-54: Direct Reports Focus Reports on Area

Figure 8-55: Direct Reports/Define Shift Dialog Box

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2. Double click the Print Selected Reports or View Selected Reports icon (Figure 8-53) to
open the Default Records Setup dialog box.
The dialog box is the same for both Print and View Selected Reports.

Figure 8-56: Direct Reports/Print/View Selected Reports Dialog Box

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Chapter 9: ESTOP
Circuit Description
Troubleshooting
Chapter 9 – ESTOP Direct Connect Service Manual

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CHAPTER 9: ESTOP
Table of Contents

CIRCUIT DESCRIPTION...................................................................389
The ESTOP/Interlock Circuit ................................................................................................... 389
The ESTOP Chain Electrical Schematic ................................................................................. 390
Direct Connect Watch-Dog Circuit........................................................................................ 390
ESTOP Electrical Schematic ..................................................................................................... 391

TROUBLESHOOTING......................................................................393
Jumpers To Aid In Troubleshooting ....................................................................................... 393
Things To Remember ................................................................................................................. 393
Troubleshooting Sample Problem: The Machine Won’t Run ........................................... 394
Question 1: Do you have 24vdc?...................................................................................... 394
Question 2: Do you have the feeder board’s lights on for the ESTOP?.................. 394
Question 3: Do you have the feeder board’s lights on for the interlock switches?
.................................................................................................................................................... 394
Question 4: Do you have 24vdc at J23 on the chassis? ............................................. 395
Question 5: Has the Watchdog circuit been disabled (bypassed)? ......................... 395
Notes......................................................................................................................................... 395

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CIRCUIT DESCRIPTION
The ESTOP/Interlock Circuit
The ESTOP/interlock electrical circuit stops or prevents the starting of a specific unit’s motors
or all motors in the system.
• The ESTOP switch causes an immediate stop of all motors in the system.
The error message does not give the physical location of the switch that stopped the
system.
• Interlock switches cause an isolated stop of the motors in the specific unit.
The error message will show the general physical location of the switch that stopped the
specific unit.
• Once the current has passed through the fuse, Watchdog circuit, hand crank switches
and all ESTOPs, the circuit becomes three parallel circuits. Each circuit provides the 24
VDC through that section’s interlocks to the solid-state motor control relays for the
MOS, chassis and input.

24 Volts

Watchdog
Circuit

E-STOP switches

Module Module
Interlocks Interlocks

Module
Interlocks

Module Module Module

Motors Motors Motors

Figure 9-1: E Stop Chain

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The ESTOP Chain Electrical Schematic

Electrical schematics are a must for troubleshooting.
The schematic from the 11 and 12 Series Service Manual, SV 41044-SM, is concise and a good
one with which to start. A copy of the schematic is attached at the end of this section.
A copy of the Pin-to-Pin line drawing from SV 41044-SM is also attached.

Direct Connect Watch-Dog Circuit

Direct Connect systems contain a Watchdog circuit at the very top of the E-stop chain. This
circuit is a dry-contact relay board with two relays located near the chassis power supply under
the computer.
The board is wired in series with the top of the ESTOP chain.
The control inputs to the relay are wired to the chassis Bingo.
• One relay is a straight relay that enables the chain.
• The second relay is a watchdog relay which is strobed several times a second in order to
maintain 24v to the chain.
The Watchdog circuit checks the computer to make sure it is still working or running the
program.
• If the program has stopped, it will stop pulsing the Watchdog and an ESTOP occurs.
• The DC program also detects if the Watchdog circuit has been jumped.
If the circuit has been jumped, DC disables the Watchdog circuit and will not allow the inserter to
start.

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ESTOP Electrical Schematic

Figure 9-2: ESTOP Electrical Schematic

SV 41085-SM
Direct Connect Service Manual Chapter 9 - ESTOP

TROUBLESHOOTING
Jumpers To Aid In Troubleshooting
Jumper Part Number/Rev
JMOC MOS jumper part number R683074 Rev C
JMOCA Input jumper part number R683151 Rev B
J3 feeder board jumper part number Jr683073 Rev B
Cutter jumper part number Y183085
Berg jumpers (for bingo card TO 1221
interlock connections)

Things To Remember

Never leave a jumper installed on a machine turned over to an operator.

Observe the “Lock-Out Tag-Out” procedures.

• Each part of the circuit is very simple.

• Keep your trouble shooting techniques simple.
• There are a lot of mini circuits in the ESTOP chain; it is a big circuit with a lot of
connections.
• Every technician has had his/her challenges with the ESTOP circuit. Be familiar with the
wire connections for the plugs, boards and switches.
• Use jumpers to isolate the problem to a portion of the circuit.
• Don’t rely on a DVOM. Jumpers are simple, uncomplicated devices that are easy to use
and subject to little interpretation.
• Using a jumper is a only a suggestion; There are may ways to find a solution.

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Troubleshooting Sample Problem: The Machine Won’t Run

It would be impossible to explore every known problem or to anticipate everything that might
occur in the future. The intent of this section is to provide an example of how the
troubleshooting process works.
The following is a sample troubleshooting procedure for the ESTOP circuit. It is assumed that
you will take the initiative and apply basic logic.
1. Install a jumper on the MOS.
2. If you still can’t start the machine, install a jumper on the Input.
3. If the machine starts, remove the jumper from the MOS to confirm that the problem is only in
the input.

Question 1: Do you have 24vdc?

1. IF NO use 24vdc Quick check:
a) Push an ESTOP - does the light come on?
b) Try another device - i.e. feeder cover door.
c) IF NO, check 24vdc from the fuse (use a DVOM). Then, follow the schematic.
2. IF YES: then go to question 2.

Question 2: Do you have the feeder board’s lights on for the ESTOP?
1. IF NO: place a jumper at JMOC (MOS).
2. IF NO: place a jumper at JMOCA (INPUT).
3. IF NO: check the ESTOPs on the feeders use a J3 jumper on the feeders that have an ESTOP.
4. IF NO: Check the Watch Dog.
5. IF NO: Refer to the schematic.
6. IF YES: go to question 3.

Question 3: Do you have the feeder board’s lights on for the interlock switches?
1. IF NO: check the feeder doors. The current comes from the input to the chassis, then from
the feeder closest to the input, then to the next inline feeder to the envelope feeder and
then the chassis Bingo. Then, follow the schematic.
2. IF NO: Install jumpers at the MOS and then, if needed, install a jumper on the Input. Then,
follow the schematic.
3. IF NO: Install jumpers on the feeders at J3 as needed.
4. IF YES: Go to question 4.

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Question 4: Do you have 24vdc at J23 on the chassis?

1. IF NO: Check the ribbon connection to the Chassis 8051 (use DC bingo diagnostics for
correct connection).
2. IF NO: Follow the schematic.
3. IF YES: Go to question 5.

Question 5: Has the Watchdog circuit been disabled (bypassed)?

Notes
• There are several switches In the Input tied to the same accumulator bingo card plug.
• The two FIM cover switches and the dual accumulator are all wired in series to J18.
• The two buckle chute switches are wired in series to J17. (Follow the schematic.)
• Switch semantics: The magnetic switches used for most interlocks are often drawn
incorrectly.
They are a normally closed switches held open by the presence of a magnet. Continuity
is through the normally open contacts (held closed by the magnet).
• When connected to a Bingo card, continuity is between pins 1 and 2.
• When connected to a feeder card, continuity is between pins 1 and 2 of the plug in
the harness.
• The Watchdog circuits will not function if the DC system is disabled or if the DCC was
saved disabled.
• The MOS can have several tables and several JMOCBs.
• Install the jumper (JMOC) at the very end of the MOS to eliminate the IST.
• Install the jumper (JMOC) at any other juncture to include or eliminate a portion or
all of the MOS. (Follow the schematic)
• Use Berg jumpers between pins 1 & 2 on J17, J18, J19, & J20 on the Bingo cards to
bypass the interlock switches that may be connected to those plugs.
The following table lists the chassis Bingo card internal wiring with the ESTOP and interlock
connection:

Bingo Plug Description

Chassis Bingo J6 Watchdog Strobe
Chassis Bingo J7 Watchdog Enable
Chassis Bingo J23 Chassis Interlock (not whole chain!)
Transport Bingo J17 Transport Interlock
Transport Bingo J23 System E-STOP
Transport Bingo J24 Input Interlock

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Physical Connections

Physical Connections Diagram

APPENDIX A Direct Connect Service Manual
Physical Connections

Appendix A-2 SV 41085-SM

Direct Connect Service Manual APPENDIX A
Physical Connections

Physical Connections Diagram

Physical Connections
Chassis Multibus
Encoder Cable
Chassis 8742 Feeder Cards
Direct Connect
PC
Env. Olo Fdr. Fdr.
Fdr. Sta. 2 3
Position 0 Pos. 1 Pos. 2 Pos. 3
Ribbon Multibus Multibus Multibus
Quad Encoder Bd. Cable Cable Cable Cable
Digi or Pocket Port
Multibus J9-J16
Cable Inputs

J17-J20
Digi or Rocket Port Interlocks
J1-J8
Bingo
J1 J2 J3 J4 Outputs E-Stop
J35
MOCOM
Box
Serial ASCII

Ribbon
Motor
Cable Ribbon
Cable J15 J17

J8 J5 J4 J9 Interlock
Switch
Serial 8051 J35 Bingo
Cable J3
J17 Out
Serial ASCII

2 Volts

Photocell
OMR Input
Scanner LED

Clutch
Out
J8 J5 J4 J9

8051
J17

Fasterm II Bingo
Decoder
J35
Barcode Scanner

File: Physical Connections.eps

Figure A-1: Physical Connections Diagram

SV 41085-SM Appendix A-3

APPENDIX A Direct Connect Service Manual
Physical Connections

Appendix A-4 SV 41085-SM

 Glossary
Glossary of Terms
Glossary Direct Connect Service Manual

Glossary-2 SV 41085-SM
Direct Connect Service Manual Glossary

A
Access Level
Method of ensuring computer/database security by allowing specific individuals to perform
certain designated functions.

Accordion Fold
Type of fold resembling the bellows of an accordion. It derives its name from the fact that the
document fold looks like the letter “Z” when laid on a flat surface and viewed from one end.

Account Number
Each customer is assigned a unique number for identification purposes. It is essentially the
same as a credit card number or a bank account number. Refers to a customers grouping of
transactions and is also a method of grouping postal transactions for record keeping purposes
in the Operating System.

Accumulator
A transport or conveyor that accepts individual documents and temporarily stores (“buffers”)
them until they are assembled into a collated set intended for a single addressee. The maxi-
mum size of the collated set can vary from one application to the next.

Acronym
A word derived from the first letters or groups of letters in a multiword descriptive noun or other
expression, often serving as a mnemonic, such as RAM (random access memory) and
AUTOEXEC.BAT (automatically executed batch file).

Active Window
In an environment capable of displaying multiple on-screen windows, the window containing the
display or document that will be affected by current cursor movements, commands, and text
entry.

Adapter
A printed circuit board that enables a personal computer to use a peripheral device, such as a
CD-ROM drive, modem, or joystick, for which it does not already have the necessary connec-
tions, ports, or circuit boards. Commonly, a single adapter card can have more than one adapter
on it. Also called interface card. See also controller, expansion board, network adapter, port,
video adapter.

Add-on
A hardware device, such as an expansion board or chip, that can be added to a computer to
expand its capabilities.

Address
The ultimate destination of a mailpiece. It is also a computer buzz word that refers to a group
of digits or characters that tells a computer where certain information is stored.

Address Bearing
The document upon which the customer address is printed. It is usually the top document of
a collation, and is usually the control document.

ADF
Automated Document Factory

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Direct Connect Service Manual Glossary

Code 3 of 9 Scanning (“Code 39™”)

Barcode similar to the Universal Product Code (UPC) imprinted on the packaging of many con-
sumer products. This barcode is printed on the documents processed by the Input Module, and it
contains all of the control functions required to process the documents.
Each Code 39™ segment consists of alternating wide and narrow vertical stripes that represent
letter and number characters. Each character is represented by five bars and four intervening
spaces. Each bar or space can be one of two widths—“wide” or “narrow.” The particular pattern
of wide and narrow bars determines the character being encoded. In all cases, each character is
made up of three wide and six narrow elements. (The name “39” comes from the code structure
which has three wide elements out of a total of nine elements.)
A scanner reads the 3 of 9 characters on the Input Module as they feed through the module.
Two types of Scanner are used - a Fixed Beam Scanner and a Moving Beam Scanner. The
customers application determines which type is used.

Collation
An assembly of two or more documents and/or inserts intended for a single addressee/account
resulting in the assembled mailpiece minus the envelope. The Inserter Module produces these
collations prior to the inserting process.

Configuration
Refers to equipment modules combined into a system to process a document or group of docu-
ments.

Continuous Form/Webs
The Web is a series of continuously connected forms that are either folded in stacks or wound
on a roll. The forms are fed through a printer and then through the Burster or Cutter. The
connection is perforated to allow the forms to be separated into individual documents in the
Input Module.

Control Document
The document containing OMR codes or barcodes that control inserter functions such as feeder
selection, sorting, postage metering, etc. The control document is usually, but not always, the
address-bearing document.

Conveyor
Belts or chain-drive mechanisms that transport the document, collation, or mail-piece from
one station to another throughout the entire inserter system. (See Transport)

Conveyor Chain/Pusher
Two-link chains and several vertical extensions called Pushers run the entire length of the in-
serter. They are used to transport and push the collation from the Input Module to the Output
Module.

Covered Photocell
A condition where a document covers a photocell. Operation stops when a photocell is covered
(or blocked) for a specified time interval. Photocells tell the inserter where a document is (or
should be) at any given time and are used for machine control.

CSR
Customer Service Representative

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Glossary Direct Connect Service Manual

Aerate
Fanning a stack of paper helps separate individual sheets from each other. By riffling the sheets
to admit air, aeration improves feeding and helps maintain system productivity. If you are having
problems with double feeds or poor feeding, try aerating the paper before you do anything else.

Air Pump
An inserter option which supplies pressurized air to help separate the envelope window from the
envelope throat. This helps the collation get into the envelope with greater ease.

Alert and Clear

An available option that, when a specific code is read, clears the deck of material and stops the
system. The Input Feeder stops feeding, but the last set fed will be processed through the Input
Module, the Inserter, and the Output. The system completely stops when the mailpiece is at the
Stacker. This option is generally used to complete the last collation of a run and makes setting
up the next job easier.

Alignment Station
An area that occupies an Enclosure Station. It contains guides and material control devices
used to align, “on center”, the collation being sent by the Conveyor Pushers. Also see Observa-
tion Station.

Allocate
To reserve a resource, such as sufficient memory, for use by a program.

Alpha
A term often used to refer to a software product that has been completed and is ready for initial
testing in a laboratory. (Compare beta.)

Alphanumeric
Consisting of letters or digits, or both, and sometimes including control characters, space char-
acters, and other special characters.

Alphanumeric
Describes a set of characters containing single digit numbers and the letters of the alphabet,
along with punctuation marks and symbols.

Ampere (A)
A unit of electric current expressed as a value (e.g., 20A) to describe the force of that cur-
rent. Commonly found in inserter systems specifications. In Ohm’s Law; Ampere(I) = Voltage
(E)/Resistence (R).

Analog
Pertaining to or being a device or signal having the property of continuously varying in strength
or quantity, such as voltage or audio.

Analog Line
A communications line, (e.g. standard telephone line), that carries continuously varying signals.

Antivirus Program
A computer program that scans a computer’s memory and mass storage to identify, isolate, and
eliminate viruses, and that examines incoming files for viruses as the computer receives them.

Glossary-4 SV 41085-SM
Direct Connect Service Manual Glossary

Application
1.) A general term that defines the requirements of a particular system before it is manufac-
tured. It can also define a specific customer job - which documents are to be used for the job
and how they are to be processed. 2.) A program designed to assist in the performance of a
specific task, such as word processing, accounting, or inventory management.

Architecture
1. The physical construction or design of a computer system and its components. 2. The data-
handling capacity of a microprocessor. 3. The design of application software incorporating proto-
cols and the means for expansion and interfacing with other programs.

Archive (n.)
1. A tape or disk containing files copied from another storage device and used as backup stor-
age. 2. A compressed file.

Archive (v.)
To copy files onto a tape or disk for long-term storage. 2. To compress a file. Also see backup.

ARP (Address Resolution Protocol)

A TCP/IP protocol for determining the hardware address (or physical address) of a node on a
local area network connected to the Internet, when only the IP address (or logical address) is
known.

ArcServe
Utility used to back up and restore critical OMS files.

ARU (Automatic Response Unit)

The computer which responds when you use Pitney Bowes' Postage-by-Phone™ Service.

Ascending Register
A counter on a postage meter that displays total amount of postage used. (See Descending
Register)

Attenuation
The weakening of a transmitted signal, such as the distortion of a digital signal or the reduction
in amplitude of an electrical signal, as it travels farther from its source. Attenuation is usually
measured in decibels and is sometimes desirable, as when signal strength is reduced electroni-
cally, for example, by a radio volume control, to prevent overloading.

Authorization
In reference to computing, especially remote computers on a network, the right granted an
individual to use the system and the data stored on it. Authorization is typically set up by a
system administrator and verified by the computer based on some form of user identification,
such as a code number or password. Also called access privileges, permission.

AUTOEXEC.BAT
A special-purpose batch file (set of commands) that is automatically carried out by the MS-DOS
operating system when the computer is started/restarted. Created by the user or (in later
versions of MS-DOS) by the operating system at system installation, the file contains basic
startup commands that help configure system to installed devices and to the user's preferences.

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Glossary Direct Connect Service Manual

AutoPlay
A feature in Windows 95/98/2000 that allows it to automatically operate a CD-ROM. When a CD
is inserted into a CD-ROM drive, Windows looks for a file called AUTORUN.INF on the CD. If the
file is found, it opens it and carries out its instructions, which are usually to set up an application
from the CD-ROM on the computer's hard disk or to start the application once it has been
installed.

Autosave
A program feature that automatically saves an open file to a disk or other medium at defined
intervals or after a certain number of keystrokes to ensure that changes to a document are
periodically saved.

B
Backfeed
This term means feeding the address-bearing document from the last (highest numbered) feeder
rather than the first feeder (closest to the envelope feeder.)

Back End
1. In a client/server application, the part of the program that runs on the server. (See alsoclient/
server architecture.)

Background
In the context of processes or tasks that are part of an operating system or program, operating
without interaction with the user while the user is working on another task. Background pro-
cesses or tasks are assigned a lower priority in the microprocessor's allotment of time than
foreground tasks and generally remain invisible to the user unless the user requests an update or
brings the task to the foreground.

Background Printing
The process of sending a document to a printer at the same time that the computer is perform-
ing one or more tasks.

Backslash
The character (\) used to separate directory names in MS-DOS path specifications. When used
as a leading character, it means that the path specification begins from the topmost level for
that disk drive.

Backup
A duplicate copy of a program, a disk, or data, made either for archiving purposes or for safe-
guarding valuable files from loss should the active copy be damaged or destroyed. The backup is
used to recover information lost from or destroyed on the original medium as a result of error or
equipment problems.

BAFT (Burst/Accumulate/Fold/Transport)
A self-contained Input Module that feeds and bursts (separates) a continuous forms web, accu-
mulates the separated collation into a single set intended for a single addressee/account, folds
the collated set and then transports it to the Inserter Module.

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Barcode
A series of alternating white and dark lines or bars that represent numbers and/or letters. The
code is typically read by an optical scanner and converted to its alphanumeric equivalent. Also
see code 39 and Post Net Code.

Basis Weight
A fixed weight per 500 sheets of paper (one ream) of different paper grades weighed by their
designated basic sheet size. Basic sheet size for bond and ledger is 17” x 22”, offset is 25” x 38”,
cover is 20” x 26”, index is 25.5” x 30.5”, and Bristol is 22 1/2” x 28 1/2”. Standard bond paper
for copiers and general laser printer use is 20 pound.

Batch
A group of documents or data records that are processed as a unit.

Batch file
An ASCII text file containing a sequence of operating system commands. When the user types a
batch filename at the command prompt, the commands are processed sequentially. Also called
batch program.

Batch Job
A program or set of commands that runs without user interaction.

Batch Processing
Execution of a batch file.

Batch Program
A program that executes without interacting with the user.

Benchmark
A computer printed line used in the Optical Mark Recognition (OMR) Scanning System. It is the
first line in a series of lines. When read, it instructs the system to begin scanning for more lines.
The Benchmark becomes the main timing mark in OMR Scanning Systems.

Binary Numbers
The base-two number system digital computers use. Only 1s and 0s are used to form all numbers
and letters.

Bit
A contraction of binary digit. A bit can be either 0 or 1 and is the smallest unit of information
recognizable by a computer.

BOC (Beginning Of Collation)

This is a code or barcode on a document that designates it as the first document of a new set.
When the BOC document is recognized, a signal is sent to the previously fed documents,
telling them that this is the first document of a new set. This BOC document is then either
stopped in the Input Feeder or directed to another accumulator as the first page of a new set.

Bond Paper
A grade of paper characterized by strength, durability and permanence. Bond papers are
usually rag or sulfite types, and are commonly used for business forms, letterheads, and so
on. It is typically used on the Sheet Feeder and is referred to as “cut sheets”.

Bottom Edge Marker

See Edge Marker.

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Bottom Scanning
The scanning of dash codes by an optical sensor mounted below the paper path. Documents are
fed faced down to permit the codes to be scanned.

Blue Box Help

When using the Direct Connect Operating System, this is the Help menu displayed under the
pointer (on a specific subject) when the right button on the mouse is clicked.

BTU (British Thermal Unit)

A value used to describe the amount of heat generated by a piece of equipment.

Burst
The process of mechanically separating adjacent pages from a continuous forms web by applying
pressure to the horizontal perforation that divides them. A Burster is used to separate the
continuous web into individual pages.

Byte
An element of data made up of eight data bits. Can represent an alphabetic or special character.

C
Center Slitter
A device installed on a Forms Conveyor that vertically slits a two-up web (side-by-side docu-
ments) into two webs for processing on the Burster or Cutter.

Central Processing Unit (CPU)

Technically, the logic and arithmetic circuitry inside a computer. It's the place where data actu-
ally gets processed. CPU is often used to refer to a “big” computer as distinct from its peripheral
devices such as printers.

Channel
The horizontal row of OMR lines on a document read by an optical scanner. A document with two
rows of OMR lines would be said to have two channels. A maximum of four channels or Scanners
can be used on an Input Module.

Chip (paper)
The perforation between two documents cut away by the Cutter. This area is removed to create
a smooth edge on the document that does not show the perforation between documents.

Clear Deck
An operating sequence that clears all the mailpieces from the system. It is essentially an
orderly shutdown of the system that is normally used at the end of a job.

CMMS
Client Mail Management System. A computer that captures all the data between the MDS and
OMS.

Code
A system of symbols used to transmit a message in a compact form. (See OMR and Barcode)

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CTOP (Count Operation)

The method by which document feeding is stopped when a count set by the operator is
reached. For example, if the counter on the Input Module is set for “2,” the Input Module will
stop feeding documents after the second document has been fed. These two documents then
become a collated set, and the system then feeds two more documents and so on.

Curl
Refers to an upward or downward bend or roll at the edge of material. Curl is a consequence of
the manufacturing process. The condition is aggravated by poor storage and handling conditions,
especially temperature changes and high humidity.

Cursor
A blinking line or box on a computer screen that shows you where to enter data.

Cut Sheets
Refers to individual sheets, including those that are laser-printed, which are fed from the Sheet
Feeder in the Input Module.

Cutter
An Input Module that feeds a one-up or two-up continuous web, removes the Sprocket Strips,
and cuts the Web into individual documents. The Cutter can make a single cut at each perfora-
tion, or it can cut on each side of the perforation, thus removing the perforation or chip from the
document.

Cycle
The amount of time it takes the Timing Disk to make one revolution, or the combination of all
functions required to compile and process one mailpiece.

D
Daisy Chain
A set of devices connected in series.

Data
Information processed or produced by a computer.

Database
A file composed of records, each containing fields with a set of operations for searching, sorting,
recombining, and other functions.

Data File
A collection of related records organized in a logical way. A Mail Run Data File (MRDF) contains
all of the information required to process each document, collation and mailpiece throughout the
system.

Data Transfer
Movement of information from one location to another, either within a computer (from a disk
drive to memory), between a computer and an external device (between a file server and a
computer on a network), or between separate computers.

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DBA (Database Administrator)

One who manages a database. The administrator determines the content, internal structure,
and access strategy for a database, defines security and integrity, and monitors performance.

DC (Direct Connect)
Direct Connect is an advanced, data based inserter control system. It is used to control all
system functions, and also extend the capability of the system by directly connecting it to the
customers data processing systems.

Debounce
A Photocell signal can be commanded, via software, to ignore minor Photocell signal fluctuations
caused by the movement of documentation over or under the photocell.

Debug
To detect, locate, and correct logical or syntactical errors in a program or malfunctions in
hardware. In hardware contexts, the term troubleshoot is the term more often used, especially
when the problem is a major one.

Deck
The platform underneath inserter feeders on which mailpieces are transported and inserts drop
to the Enclosure Feeders to be included in a collation.

Dedicated Line
1. A communications channel that permanently connects two or more locations. 2. A telephone
line that is used for one purpose only, such as to receive or send faxes or to serve as a modem
line.

Default
A choice made by a program when the user does not specify an alternative. Defaults are built
into a program when a value or option must be assumed for the program to function.

Default Printer
The printer to which a computer sends documents for printing, unless an alternative is specified.

Deflector Plate
A curved metal deflector installed in a Folder instead of a Fold Plate. The deflector plate is used
to redirect a document past a Fold Plate position and into the next set of Rollers.

Delay
A waiting state (delay) during which the Conveyor Chains and Pushers stop to allow any Feeder
to complete its feed cycle. For example, if an Enclosure Feeder is out of material, the Conveyor
Chains and Pusher go into a delay state until receiving an insert.
As it applies to Scanning, “delay” refers to the distance between the lead edge of a document
and a point located approximately one inch before the OMR mark. This delay is also referred to
as a “scan delay.”

Delete
To eliminate text, a file, or part of a document with the intention of removing the information
permanently.

Depth
Refers to the dimension of a document, insert, or envelope when it is fed from a Module. (See
Width)

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Descending Register
Also called “Postage Unused”, this display on a postage meter shows the total amount of post-
age remaining in the meter. (See Ascending Register)

Deselect
To reverse the action of selecting an option, a range of text, a collection of graphical objects,
and so on.

Desktop
An on-screen work area that uses icons and menus to simulate the top of a desk.

Desktop Computer
A computer that fits conveniently on the surface of a business desk. Most personal computers
as well as some workstations can be considered desktop computers.

Destination
The location (drive, folder, or directory) to which a file is copied or moved.

Device
A piece of hardware that performs a specific function. A printer is an example of a device.

Diagnostic Program
Special programs that troubleshoot problems and help “diagnose” the solution.

Dialog Box
In a graphical user interface, a special window displayed by the system or application to solicit a
response from the user.

Direct Mail Processing

When mail is processed this way, all of the control data is located in a Scan Code on the Control
Document. The alternative method is File Based or Indirect Mail Processing, where all of the
control information is indirectly referenced.

Directory
A catalog for filenames and other directories stored on a disk. A directory is a way of organizing
and grouping the files so that the user is not overwhelmed by a long list of them. The topmost
directory is called the root directory; the directories within a directory are called subdirectories.

Directory Tree
A graphic display listing the directories and subdirectories on a hard disk in tree form, with
subdirectories shown as branches of the main directory.

Disable
To suppress something or to prevent it from happening. Disabling is a method of controlling
system functions by disallowing certain activities.

Disconnect
To break a communications link.

Disk Drive
An electromechanical device that reads from and writes to disks.

Disk Partition
A logical compartment on a physical disk drive.

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Display
The visual output device of a computer, which is commonly a CRT-based video display.

Display Screen
The part of a video unit on which images are shown.

Distribution List
A list of recipients on an e-mail mailing list.

DOS Prompt
The visual indication from the MS-DOS command processor that the operating system is ready to
accept a new command. The default DOS prompt is a path followed by a greater-than sign (for
example, C:>).

Double
The feeding of two or more documents when only one is expected. A double feed is a fault
which is often due to improper loading of materials, or misadjustment of the feeder.

Double-click
To press and release a mouse button twice without moving the mouse. Double-clicking is a
means of rapidly selecting and activating a program or program feature.

Double Detector
Feeders are usually equipped with a sensing device that detects the presence of a double feed
by sensing extra thickness or by candling the paper with light. When a double feed is detected,
the Feeder declares a fault and stops the transport, or outsorts the mailpiece to a Vertical
Stacker.

Double Fold
A letter fold in which the document is folded twice, once in half and then in half again.

Download
In communications, to transfer a copy of a file from a remote computer to the requesting com-
puter by means of a modem or network.

Downtime
The amount of time a system fails to run because of a fault or preventative maintenance.

Drag
In graphical user interface environments, to move an image or a window from one place on the
screen to another by "grabbing" it and pulling it to its new location using the mouse. The mouse
pointer is positioned over the object, and the mouse button is pressed and held while the mouse
is moved to the new location.

Drag-and-Drop
To perform operations in a graphical user interface by dragging objects on the screen with the
mouse.

Drive Mapping
The assignment of a letter or name to a disk drive so that the operating system or network
server can identify and locate it. For example, in PCs, the primary drive mappings are A: and B:
for floppy disk drives and C: for the hard disk.

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Driver
A hardware device or a program that controls or regulates another device. A device driver is a
device-specific control program that enables a computer to work with a particular device, such
as a printer or a disk drive.

Drop-down Menu
A menu that drops from the menu bar when requested and remains open without further action
until the user closes it or chooses a menu item.

Dual Web
Two continuous webs that are sequentially or simultaneously processed through two separate
Input Modules.

Duplex
Printing on both sides of the sheet of paper.

E
East/West Printing
Sequence for printing documents on a web of continuous forms by printing left to right when
facing the printed web. Page one is on the left and page two is on the right.

Edge Marker
A Solenoid operated, inked roller installed on the Output or in the Sealer. It is used to mark the
top or bottom edge of a mailpiece so that the operator can identify it as a ZIP code break, or an
exception mailpiece (overweight, for example.)

Edge Trimmer
Rotary knife assembly that trims the sprocket strips from the edges of a continuous form web.

Edit
To make a change to an existing file or document.

Emergency Stop Switch (ESTOP)

A safety control which stops inserter operation immediately when pressed. Inserter chassis have
several of them mounted throughout the system.

Emulate
For a hardware or software system to behave in the same manner as another hardware or
software system. In a network,microcomputers often emulate mainframes or terminals so that
two machines can communicate.

Emulation
The process of a computer, device, or program imitating the function of another computer,
device, or program.

Enable
To activate or turn on.

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Enclosure Feeder
An inserter module which feeds one or more inserts down to the inserter deck to form a collation.
There are two types of enclosure feeders used in inserter systems:
-- Single Cycle Enclosure Feeder feeds the insert to the deck in one inserter cycle.
-- Two Cycle Enclosure Feeder feeds the insert to the deck in two inserter cycles.

Enclosure Station
Refers to the mounting location of an Enclosure Feeder, an Alignment Station, or an Observation
Station on the inserter deck. Stations are numbered from 1 to X, with 1 closest to the Envelope
Feeder.

Encoder Pulses
An Encoder generates pulses that are converted to counts. The encoder makes one revolution
for every insert cycle which translates to 100 counts. These counts are used as references to
activate Inserter Module functions such as feed time and jam time.

Envelope Feeder
Part of an inserter module that separates an envelope from a stack, opens the envelope flap,
and then feeds the envelope into the Inserting Area. There are two types of Envelope Feeders
used in inserter systems: The One Cycle Envelope Feeder feeds the envelope to the Inserting
area in one inserter cycle. The Two Cycle Envelope Feeder the envelope is fed to the Inserting
Area in two inserter cycles.

EOC (End Of Collation)

This is an OMR line or 3 of 9 barcode on a document that designates it (the document) as the
last one in a collated set. That complete set is then fed to the Accumulator. (See BOC)

Erase
To remove data permanently from a storage medium.

Error
A value or condition that is not consistent with the true, specified, or expected value or condi-
tion. In computers, an error results when an event does not occur as expected or when impos-
sible or illegal maneuvers are attempted. In data communications, an error occurs when there is
a discrepancy between the transmitted and received data.

Error File
A file that records the time and type of data processing and transmission errors.

Error Message
A screen prompt produced by a computer that generally alerts you to a hardware or software
problem, or to an illegal command.

Ethernet
A Local Area Network (LAN) product that lets many devices send information to each other.

Exception
A term referring to those documents or mailpieces which require special (manual) handling and
are therefore outsorted from the mail stream. They may be diverted into an Output Stacker for
special handling.

Executable Program
A program that can be run.

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Execute
To perform an instruction.

Exit
In a program, to move from the called routine back to the calling routine.

Expansion Board
A circuit board that is plugged into a computer's bus (main data transfer path) to add extra
functions or resources to the computer. Typical expansion boards add memory, disk drive control-
lers, video support, parallel and serial ports, and internal modems.

Export
To move information from one system or program to another.

Extract
To remove or duplicate items from a larger group in a systematic manner.

F
Face Down
Loading a document with its printed side down.

Face Up
Loading a document with its printed side up.

Failure
The inability of a computer system or related device to operate reliably or to operate at all. A
common cause of system failure is loss of power, which can be minimized with a battery-powered
backup source until all devices can be shut down.

Failure Rate
The number of failures in a specified time period. Failure rate is a means of measuring the reliabil-
ity of a device, such as a hard disk.

Fan Fold
(See Accordion Fold)

FAT (File Allocation Table)

A table/list maintained by some operating systems to manage disk space used for file storage.
Files on a disk are stored, as space allows, in fixed-size groups of bytes (characters). A single
file can be scattered in pieces over many separate storage areas. A file allocation table maps
available disk storage space so it can mark flawed segments that should not be used and can
find/link the pieces of a file. In MS-DOS, the file allocation table is commonly known as the FAT.

Fatal Error
An error that causes the system or application program to crash -- that is, to fail abruptly with
no hope of recovery.

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Fault Tolerance
The ability of a computer or an operating system to respond to a catastrophic event or fault,
such as a power outage or a hardware failure, in a way that ensures that no data is lost and any
work in progress is not corrupted. This can be accomplished with a battery-backed power sup-
ply, backup hardware, provisions in the operating system, or any combination of these. In a
fault-tolerant network, the system has the ability either to continue the system's operation
without loss of data or to shut the system down and restart it, recovering all processing that
was in progress when the fault occurred.

Feature
A unique, attractive, or desirable property of a program or of a computer or other piece of
hardware.

Feed Count
The number of documents fed from a feeder. This count is used for verification and for feeder
control.

Feed Rollers
The rollers that feed a document or insert from a stack.

Feed Stop
Refers to the method used to stop feeding a document when a collation is complete; a predet-
ermined count (CTOP) or end-of-collation (EOC) code is typically used.

Feed Time
The amount of time it takes a Module to feed and insert an envelope or a document.

File Based Mail Processing

A method of processing mailpieces where the processing instructions for the inserter are con-
tained in a Mail Run Data File (MRDF) on a network computer. A scan code (piece identifier) on
the document directs the control computer in the inserter to the corresponding data record in
the MRDF file. This is also known as Indirect Processing because the control information does not
come directly from a barcode or OMR Type Mark on the document.

File Conversion
The process of transforming the data in a file from one format to another without altering its
contents.

File Fragmentation
The breaking apart of files into small, separate segments for storage on disk.

File Recovery
The process of reconstructing lost or unreadable files on disk. Files are lost when they are
inadvertently deleted, when on-disk information about their storage is damaged, or when the
disk is damaged. File recovery involves the use of utility programs that attempt to rebuild on-disk
information about the storage locations of deleted files.

File Server
A file storage device on a local area network that is accessible to all users on the network. On
local area networks, a file server is often a computer with a large hard disk that is dedicated
only to the task of managing shared files.

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File Sharing
The use of computer files on networks, wherein files are stored on a central computer or a
server and are requested, reviewed, and modified by more than one individual. When a single file
is shared by many people, access can be regulated through password protection, security
clearances or file locking to prohibit changes to a file by more than one person at a time.

File Transfer
The process of moving or transmitting a file from one location to another, as between two pro-
grams or over a network.

Firmware
Software routines stored in read-only memory (ROM). Unlike random access memory (RAM),
read-only memory stays intact even in the absence of electrical power. Startup routines and
low-level input/output instructions are stored in firmware. It falls between software and hard-
ware in terms of ease of modification.

Flavor
One of several varieties of a system, having its own details of operation. UNIX in particular is
found in distinct flavors, such as BSD UNIX or AT&T UNIX System V.

Folder
This is the Input Module that folds the document/collated set into the selected fold.

Forms Conveyor
The input device that accepts a two-up printed continuous web, and then separates the web
into two individual webs by making a cut in the center of the web. The separated webs are then
processed on either a Burster or a Cutter.

Fragmentation
Scattering of parts of the same disk file over different areas of the disk. Fragmentation occurs
as files on a disk are deleted and new files are added. It slows disk access and degrades the
overall performance of disk operations. Utility programs are available for rearranging file storage
on fragmented disks.

Front
The end of the inserter on which the envelope feeder is mounted.

FTP (File Transfer Protocol)

Protocol used for copying files to and from remote computer systems on a network using TCP/IP,
such as the Internet. This protocol also allows users to use FTP commands to work with files,
such as listing files and directories on the remote system.

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G
GIF (Graphics Interchange Format)
A graphics file format developed by CompuServe and used for transmitting raster images on the
Internet. An image may contain up to 256 colors, including a transparent color. The size of the
file depends on the number of colors actually used.

Graphical User Interface (GUI)

A type of environment that represents programs, files, and options by means of icons, menus,
and dialog boxes on the screen. The user can select and activate these options by pointing and
clicking with a mouse or, often, with the keyboard. A particular item (such as a scroll bar) works
the same way to the user in all applications, because the graphical user interface provides
standard software routines to handle these elements and report the user's actions.

H
HAFT (High Capacity Sheet Feed/Accumulate/Fold/Transport)
A self contained Input Module that feeds cut sheets, gathers them to form a collation set in-
tended for a single addressee, folds the set and then conveys it to the inserter. All devices in
this module are integrated and cannot be separated. The Sheet feeder is always connected to
the Accumulator using this machine.

Half Fold
A type of fold in which the document is folded in half.

Hand Crank
Process of cranking the Inserter Module by hand to move the Conveyor Chains and Pushers
forward or backward. It is usually performed to set up the equipment or to clear a jam.

HDFF (Heavy Duty Sheet Feeder/Folder)

A special purpose Feeder that occupies two feed stations on an inserter deck. It separates a
single document from a stack, and then folds it and feeds it to the inserter chassis. It can also
be equipped with an optional scanning device.\

Hardware
The physical components of a computer system, including any peripheral equipment such as
printers, modems, and mouse devices. Compare firmware, software.

Help
The capability of many application programs to display advice or instructions for using their
features when so requested by the user, as by a screen button or menu item or a function key.
The user can access help without interrupting work in progress or leafing through a manual.

Help Desk
Technical support staff who help solve users' problems with hardware or software systems or
refer such problems to those who can solve them.

High Cap Cut Sheet Feeder

(See Sheet Feeder)

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Highlight
To alter the appearance of displayed characters as a means of calling attention to them, as by
displaying them in reverse video (light on dark rather than dark on light, and vice versa) or with
greater intensity. Highlighting is used to indicate an item, such as an option on a menu, that is
to be acted on in some way.

Host
The main computer in a system of computers or terminals connected by communications links.

HTML (Hypertext Markup Language)

The markup language used for documents on the World Wide Web.

Hub
In a network, a device joining communication lines at a central location, providing a common
connection to all devices on the network; a common connection point for devices in a network.

Hyperlink
The user activates the link by clicking on the linked element, which is usually underlined or in a
color different from the rest of the document to indicate that the element is linked.

I
Icon
A small image displayed on the screen to represent an object that can be manipulated by the
user.

IDE (Integrated Device Electronics)

A type of disk-drive interface in which the controller electronics reside on the drive itself, elimi-
nating the need for a separate adapter card.

Initialize
To prepare a storage medium, such as a disk or a tape, for use. This may involve testing the
medium's surface, writing startup information, and setting up the file system's index to storage
locations.

Ink Jet Station

An output device used to print addresses, the Post Net Code, the return addresses, and other
advertisement on a mailpiece.

Input
The process of entering data into the computer or the data entered, or a signal that is origi-
nated by a device such as a switch or photocell is considered input.

Input Device
A peripheral device whose purpose is to allow the user to give input to a computer system.
Examples of input devices are keyboards, mice, joysticks, and styluses.

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Input File
In File Based Processing, the Input File contains the information needed to process the
mailpieces. An Input File is also called an MRDF. Each mailpiece is assigned a record in the Input
File. Each of those records contains a variety of information about the mailpiece, (i.e. piece ID,
address, feeder selects, and accessory selects.)

Input Module
The Input Module processes the computer generated documents into collated sets for the
Inserter Module.

Insert
The material fed from an Enclosure Feeder. For example, a newsletter, a promotional piece, a
business reply card, a business reply envelope, all of which can be added to other documents
fed from the Input to become a collated set.

Inserting Area
The area where the throat of the envelope is opened and the collations are inserted into the
envelopes. Two types of Inserting mechanisms are used:
-- A ram device that supports the collation and “rams” it into the envelope.
-- A set of Insert Pushers that push the collation into the envelope.

Inserter Module
A device that accepts the documents from the Input Module, feeds inserts, and then as-
sembles them into a collated set that is inserted into an opened envelope. The finished item
is called a mailpiece. A typical Inserter consists of an Envelope Feeder, one or more Enclosure
Feeders that feed the inserts, a Chassis that contains the Chains and Pushers that collate the
inserts, and a device to insert the collation into an envelope to form the finished mailpiece. The
finished mailpiece is then conveyed to the Output Module.

Install
To set in place and prepare for operation. Operating systems and application programs commonly
include a disk-based installation program that does most of the work of setting up the program
to work with the computer, printer, and other devices.

Interactive
Characterized by conversational exchange of input and output, as when a user enters a question
or command and the system immediately responds.

Interface
1. The point at which a connection is made between two elements so that they can work with
each other. 2. Software that enables a program to work with the user (the user interface, which
can be a command-line interface, menu-driven, or a graphical user interface), with another
program such as the operating system, or with the computer's hardware.

Intranet
A network designed for information processing within a company or organization. Its uses include
such services as document distribution, software distribution, access to databases, and training.

IP (Internet Protocol)
The protocol within TCP/IP that governs the breakup of data messages into packets, the routing
of the packets from sender to destination network and station, at the destination.

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IP Address (Internet Protocol Address)

A 32-bit (4-byte) binary number that uniquely identifies a host (computer) connected to the
Internet to other Internet hosts, for the purposes of communication through the transfer of
packets. An IP address is expressed in "dotted quad" format, consisting of the decimal values of
its four bytes, separated with periods; for example, 127.0.0.1.

ISC (Inserter Control System)

The Inserter System Controller is a computer based inserter control system that uses micropro-
cessors to control all system functions.

ISO (International Organization for Standardization)

An international association of countries of which each is represented by its leading standard-
setting organization. The ISO works to establish global standards for communications and infor-
mation exchange.

ISP (Internet Service Provider)

A business that supplies Internet connectivity services to individuals, businesses, and other
organizations.

IST (Intelligent Stacker Trayer)

An output device that stacks mailpieces vertically in Stacker Bins that can easily be transferred
to standard post office mail trays. An IST can also be configured to sort mail.

J
Java
An object-oriented programming language, developed by Sun Microsystems, Inc. Similar to C++,
Java is smaller, more portable, and easier to use than C++ because it is more robust and it
manages memory on its own. Java was also designed to be secure and platform-neutral (mean-
ing that it can be run on any platform) through the fact that Java programs are compiled into
bytecodes, which are similar to machine code and are not specific to any platform. This makes it
a useful language for programming Web applications, since users access the Web from many
types of computers.

Job
The mail run being processed by the inserter is called a job. A collection of tasks viewed by the
computer as a unit is also called a job.

Job Queue
A list of programs or tasks waiting for execution by a computer. Jobs in the queue are often
ordered according to some basis of priority.

JPEG (Joint Photographic Experts Group)

An ISO/ITU standard for storing images in compressed form using a discrete cosine transform.
JPEG trades off compression against loss.

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K
Kbps (kilobits per second)
Data transfer speed, as on a network, measured in multiples of 1,024 bits per second.

Kernel
The core of an operating system--the portion of the system that manages memory, files, and
peripheral devices; maintains the time and date; launches applications; and allocates system
resources.

L
L1 cache
A memory cache built into i486 and higher-level processors. The L1 cache, typically containing 8
KB, can be read in a single clock cycle, so it is tried first. The i486 contains one L1 cache; the
Pentium contains two, one for code and one for data. Also called level 1 cache, on-chip cache.

L2 cache
A memory cache consisting of static RAM on a motherboard that uses an i486 or higher-level
processor. The L2 cache, which typically contains 128 KB to 1 MB, is faster than the system
DRAM but slower than the L1 cache built into the CPU chip.

LAN (Local Area Network)

A group of computers and other devices dispersed over a relatively limited area and connected
by a communications link that enables any device to interact with any other on the network.
LANs commonly include microcomputers and shared resources such as laser printers and large
hard disks. The devices on a LAN are known as nodes, and the nodes are connected by cables
through which messages are transmitted.

Landscape
Refers to orientation for printing or processing information. (See Portrait)

Launch
To activate an application program (especially on the Macintosh) from the operating system's
user interface.

Lead Edge
The first edge of a document to enter a module or device.

Leapfrog
On Back Feed Inserters, the upward slope of the Inserter Deck that “leapfrogs” a collation on
top of the insert that was fed in from the Enclosure Feeder. Since the address bearing document
is fed from the last feed station, it must be kept on top of the collation.

LED (Light-Emitting Diode)

A semiconductor device that converts electrical energy into light, used, for example, for the
activity lights on computer disk drives.

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Left
Side of the Inserter that is on your left when you are standing at the rear of the Input Module
and facing the Insert Module.

Legacy
Of or pertaining to documents or data that existed prior to a process or technique that requires
translating old data files to a new system.

Line Spacing
The distance between two OMR lines printed on a document.

Log
A record of transactions or activities that take place on a computer system. See logarithm.

Log off
The process of terminating a session with a computer accessed through a communications line.
Also called logout.

Log on
The act of identifying yourself to your computer. Usually required for security reasons.

Loop
The length of web between two paper handling devices. A Loop exists between the Forms
Conveyor and either the Burster or Cutter when processing two-up webs.
“Loop” also refers to a series of computer instructions that are executed repeatedly until a
specific result is obtained, or some predetermined condition is met.

Low Angle
This is the slanted position of the stack of inserts or envelopes in a Feeder. Certain inserts feed
better at a low angle (for example, card stock, end-folded material and accordion-folded mate-
rial.) (See High Angle)

M
Mailing Machine
This is the envelope handling device that serves as the base for a postage meter and also
houses the meter drive mechanisms. (See Postage Meter)

Mailpiece
A predetermined combination of documents and inserts in an envelope.

Mailpiece ID
This is the unique number within a job that identifies a particular mailpiece. The mailpiece ID is
coded onto the control document of the mailpiece and it is used to match the document to the
corresponding record in the MRDF file.

Male Connector
A type of connector that has pins for insertion into receptacles. Male connector part numbers
often include an M (male) or P (plug). For example, a male DB-25 connector might be labeled DB-
25M or DB-25P.

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Mapped Drives
In the Windows environment, network drives that have been assigned local drive letters and are
locally accessible.

Masking
The address does not show through the window for any number of reasons. For example, the
insert may have been folded and/or inserted incorrectly, or an insert blocks the address in the
window.

Matching
The process of gathering together those documents intended for a single addressee. The docu-
ment match is achieved using OMR codes or 3 of 9 codes.

MDS (Mail Data Station)

Either an S309/Meter or Paragon

Menu
A list of options from which a user can make a selection in order to perform a desired action,
such as choosing a command or applying a particular format to part of a document.

Menu Bar
A rectangular bar displayed in an application program's on-screen window, often at the top, from
which menus can be selected by the user. Names of available menus are displayed in the menu
bar; choosing one with the keyboard or with a mouse causes the list of options in that menu to
be displayed.

Menu Item
A choice on a menu, selectable by either the keyboard or a mouse. In some instances, a menu
item that is not available (that is, not appropriate) for a given situation is "grayed" (dimmed in
comparison to the valid menu choices).

Merge
The process of combining documents from two different web streams to form a collation. When
processing two different streams, the web documents must be matched to insure that they
belong to the same account or addressee.

Metering
Imprinting an envelope with the correct postage as it passes through the Mailing Machine and
Postage Meter.

Microprocessor
A central processing unit (CPU) on a single chip. A modern microprocessor can have over 1
million transistors in an integrated-circuit package that is roughly 1 inch square. Microprocessors
are at the heart of all personal computers. When memory and power are added to a micropro-
cessor, all the pieces, excluding peripherals, required for a computer are present.

Middleware
Software that sits between two or more types of software and translates information between
them. Middleware can cover a broad spectrum of software and generally sits between an appli-
cation and an operating system, a network operating system, or a database management sys-
tem.

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Migration
The process of making existing applications and data work on a different computer or operating
system.

Misalignment
This is used when two or more devices are not at the same level, either vertically or horizontally.
For example, a Photocell can be misaligned to the LED, or two Output devices may be misaligned
to each other.

Mismatch
A condition that occurs when documents intended for two different addressees are collated
together by mistake.

Mismatch Count
The maximum number of consecutive mismatches permitted before an error is declared and
the inserter system stops.

Mode
1. The operational state of a computer or a program. For example, edit mode is the state in
which a program accepts changes to a file. 2. In Direct Connect, Mode Files are used to set the
inserter for a particular job. Some of the settings that are saved in a Mode include System
Timing Parameters, controlling a Mailpiece on the Output, the location of the Input and Output
Files, and the Icons displayed on the screen. Also see Job.

Modem
A communications device that enables a computer to transmit information over a standard
telephone line. Because a computer is digital (works with discrete electrical signals representing
binary 1 and binary 0) and a telephone line is analog (carries a signal that can have any of a
large number of variations), modems are needed to convert digital to analog and vice versa.

MOS (Mail Output System)

(See Output)

Motherboard
The main circuit board containing the primary components of a computer system. This board
contains the processor, main memory, support circuitry, and bus controller and connector.

MRDF (Mail Run Data File)

Used in conjunction with Direct Connect (DC). DC improves matching application performance by
using the sequence numbering of the MRDF to automatcially correct for mismatch errors. When a
mismatch occurs, the bad pieces are outsorted and the mail stream is resynchronized, normally
without any operator intervention.

MSM (MailStream Monitor)

Information workstaion designed to collect data processed in the mailroom.

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N
Nested
When an enclosure or envelope slips within another enclosure or envelope. In other words, one
envelope or enclosure is linked with the one either in front of it or behind it.

Network
A group of computers and associated devices that are connected by communications facilities. A
network can involve permanent connections, such as cables, or temporary connections made
through telephone or other communication links. A network can be as small as a local area
network consisting of a few computers, printers, and other devices, or it can consist of many
small and large computers distributed over a vast geographic area.

Network Administrator
The person in charge of operations on a computer network.

Network Device Driver

Software that coordinates communication between the network adapter card and the computer's
hardware and other software, controlling the physical function of the network adapter card.

Network Directory
On a local area network, a directory on a disk that is located on a computer other than the one
the user is operating. A network directory differs from a network drive in that the user has
access to only that directory. Whether the rest of the disk is accessible to the user depends on
whether he or she has been granted access rights by the network administrator.

NIC (Network Interface Card)

An expansion card or other device used to connect a computer to a local area network.

Node
In local area networks, a device that is connected to the network and is capable of communi-
cating with other network devices.

North/South Printing
Refers to the direction of printing documents from top to bottom on a web of continuous forms
when facing the printed web.

NTP (Network Time Protocol)

A protocol used for synchronizing the system time on a computer to that of a server or other
reference source such as a radio, satellite receiver, or modem.

Numeric
A reference to numerals, as opposed to letters or other symbols. Customer accounts are usually
processed in numerical sequence.

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O
Observation Station
This is typically in an area that is occupied by an Enclosure Feeder. It contains guides and
material control devices used to align “on center,” the collation conveyed by the Conveyor
Pushers. This can also be called an Alignment Station.

OCR (Optical Character Recognition)

This technology uses a TV Camera, a special computer, and software to recognize computer
generated characters on a document.

ODBC (Open Database Connectivity)

In the Microsoft WOSA structure, an interface providing a common language for Windows appli-
cations to gain access to a database on a network.

OEM (Original Equipment Manufacturer )

The maker of a piece of equipment. In making computers and related equipment, manufacturers
of original equipment typically purchase components from other manufacturers of original equip-
ment, integrate them into their own products, and then sell the products to the public.

Offline
In reference to a computing device or a program, unable to communicate with or be controlled
by a computer. 2. In reference to one or more computers, being disconnected from a network.

OMR (Optical Mark Recognition)

The technique of using a line scanner and software to recognize computer generated lines on a
document that instruct the inserter to perform a task.

OMS (Operation Management System)

Software tool used for collecting and reporting postage meter data based on various types of
information (transactions, machines, jobs, etc.).

One Cycle
Refers to the amount of time it takes for the Timing Disk to make one revolution, after which
the system stops.

One-Up Web
A series of single documents printed on a continuous web, then to be processed by either the
Burster or the Cutter.

Online
In reference to a computing device or a program, activated and ready for operation; capable of
communicating with or being controlled by a computer. 2. In reference to one or more comput-
ers, connected to a network.

Open Architecture
Any computer or peripheral design that has published specifications. A published specification
lets third parties develop add-on hardware for a computer or device.

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Operating System
The software that controls the allocation and usage of hardware resources such as memory,
central processing unit (CPU) time, disk space, and peripheral devices. The operating system is
the foundation on which applications are built.

Operating System Module

This is the Module that integrates and controls all system functions. It contains the computer,
the terminal, software and electrical hardware for the system.

Operator Side
The side of the inserter where the operator stands to run the system. This can be on either the
right side or the left side of the inserter.

Optical Sensor
Also called a Scanner, this Electro-optical device reads the OMR or barcodes printed on a docu-
ment.

Output File
This file contains one record for each mailpiece processed through the Output Module. It can
also be used to verify mail processing or create the reprint file.

Output Module
Contains the Output Takeaway, an Aligner, a Sealer, a Stacker, and several other Output devices
that the customer may require. Examples include Mailing Machines, Markers, Vertical Stackers,
Weigh on the Fly Scales and the Intelligent Stacker Trayer.

Outsort
A mailpiece diverted to a designated stacker for manual handling.

Overcount
A value on a counter that identifies the maximum number of forms to be fed from a document
feeder per set. When this value is reached, a fault is declared and the system stops or the set is
outsorted. This feature activates when the number of documents in a set exceeds the capacity
of a folder.

Overweight Mailpiece
A mailpiece that exceeds the maximum weight limitation may be diverted, deflected, or ink
marked as required by the application.

P
Packet
A unit of information transmitted as a whole from one device to another on a network.

Page Sequence Verification

Document verification method that checks for the correct sequence of documents within a set;
most useful in sheetfeed applications to detect the sequence of the documents in an account.

Page-to-Page Match Verification

An option that verifies that all documents belong to the same set. A Scan Code, identical on
all documents in a set, is used to ensure that all documents do belong to the same set.

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Paper Flutter
The up and down movement of paper (document, Inserts, etc.) at high speed.

Parallel
Of or relating to electronic circuits in which the corresponding terminals of two or more compo-
nents are connected. 2. In data handling, of or relating to handling more than one event at a
time, with each event having its own portion of the system's resources.

Parallel Communication
The type of communication used between two devices or modules. With Parallel Communication,
the signals are sent on several parallel lines.

Parallel Port
The input/output connector for a parallel interface device.

Parameter
In programming, a value that is given to a variable, either at the beginning of an operation or
before an expression is evaluated by a program. Until the operation is completed, a parameter is
effectively treated as a constant value by the program. A parameter can be text, a number, or
an argument name assigned to a value that is passed from one routine to another. Parameters
are used as a means of customizing program operation.

Parse
To break input into smaller chunks so that a program can act upon the information.

Partition
A logically distinct portion of memory or a storage device that functions as though it were a
physically separate unit. 2. In database programming, a subset of a database table or file.

PB Desktop
Pitney Bowes software application.

PBP (Pitney Bowes Postage-by-Phone Center)

Customers can call in to have their postage automatically refilled.

Peripheral
In computing, a device, such as a disk drive, printer, modem, or joystick, that is connected to a
computer and is controlled by the computer's microprocessor.

Photocell
An electrical device that senses paper movement by generating an electrical signal when the
paper arrives or leaves. These signals are also called Lead Edge or Trail Edge signals. Photocells
are used in inserter transports to time the equipment and sense faults.

PKUNZIP
A shareware utility program that uncompresses files compressed by the PKZIP shareware utility
program. PKUNZIP is generally made available with PKZIP; distribution of PKUNZIP for commercial
purposes is not permitted without permission from its publisher, PKware, Inc.

PKZIP
A widely used shareware utility program for compressing files. Developed by PKware, Inc., in
1989 and available from a wide variety of sources, PKZIP can combine one or more files into a
compressed output file having the extension .zip. A companion utility program, PKUNZIP, is
required to uncompress the compressed files.

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Piece Count
Total number of enclosures or mailpieces processed. Piece count is usually tallied per-shift or
per-day. Direct Connect Inserters have a built-in report function that keeps track of piece count
information and prints out a report.

Platform
The foundation technology of a computer system. In everyday usage, the type of computer or
operating system being used.

Plug-in
A small software program that plugs into a larger application to provide added functionality.

Point-and-Click
Enabling a user to select data and activate programs by using a mouse or other pointing device
to move a cursor to a desired location ("point") and pressing a button on the mouse or other
pointing device ("click").

Pop-up Menu
In a graphical user interface, a menu that appears on-screen when a user selects a certain item.
Pop-up menus can appear anywhere on the screen and generally disappear when the user
selects an item in the menu.

Pop-up Window
A window that appears when an option is selected. Typically, the window remains visible until the
mouse button is released.

Power down
To shut down (a computer); to turn off the power.

Power up
To start up a computer; to begin a cold boot procedure; to turn on the power.

Portrait
Refers to a orientation of paper or information from top to bottom. (See Landscape)

Postage Meter
An electronic or electromechanical device that stores postage and prints it by means of a re-
volving die.

Postage Weight Break

The weight point at which any additional weight will cause a mailpiece to require the next higher
postage. Typically, breaks are in one ounce increments.

Post Net Code

Imprinted on an envelope, Postnet is a barcode representing an addressee's nine-digit ZIP Code.
The code is scanned by automated sorting equipment at a postal distribution center.

Power Stacker
An endless belt conveyor that horizontally stacks finished mail in an orderly fashion.

Preferences
A menu choice in many graphical user interface applications that allows the user to specify how
the application will act each time it is used. For example, in a word processing application the
user may be allowed to specify whether the ruler will appear, whether the document will appear
in the same way as it will print (including margins), and other choices.

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Preventative Maintenance (PM)

A scheduled inspection of the entire system, usually based on the number of documents or
mailpieces processed.

Print Server
A workstation that is dedicated to managing printers on a network. The print server can be any
station on the network.

Prioritized Select
An option that ensures that feeding selectable inserts will not cause a mailpiece to exceed a
specified weight. Each Enclosure Feeder will feed an insert based on an assigned priority.

Production Work Order

Statement of work presented to manufacturing that explains the type of system purchased by
the customer. It includes a list of all the Modules and Devices required to process the customers
application and a description of the types of jobs that must be processed.

Program
A sequence of instructions that can be executed by a computer. The term can refer to the
original source code or to the executable (machine language) version. Also called software. See
also program creation, routine, statement.

Program File
A disk file that contains the executable portion(s) of a computer program. Depending on its size
and complexity, an application or other program, such as an operating system, can be stored in
several different files, each containing the instructions necessary for some part of the program's
overall functioning.

PROM (Programmable Read Only Memory)

An Integrated Circuit Chip that is programmed for a specific module or function.

Prompt
In command-driven systems, one or more symbols that indicate where users are to enter com-
mands.

Proxy Server
A firewall component that manages Internet traffic to and from a local area network (LAN) and
can provide other features, such as document caching and access control.

Purge
To eliminate old or unneeded information systematically; to clean up, as files.

Q
Query
1. The process of extracting data from a database and presenting it for use. 2. A specific set of
instructions for extracting particular data repetitively.

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Quiet Zone
This is the area immediately before and after the Barcode on a document that does not contain
any computer printing or preprinted information..

R
Radio button
In graphical user interfaces, a means of selecting one of several options, usually within a dialog
box. A radio button appears as a small circle that, when selected, has a smaller, filled circle
inside it.

RAID (Redundant Array of Independent Disks)

A data storage method in which data, along with information used for error correction, such as
parity bits or Hamming codes, is distributed among two or more hard disk drives in order to
improve performance and reliability.

RAM (Random Access Memory)

Semiconductor-based memory that can be read and written by the central processing unit (CPU)
or other hardware devices.

Random Access
The ability of a computer to find and go directly to a particular storage location without having
to search sequentially from the beginning location. The human equivalent of random access
would be the ability to find a desired address in an address book without having to proceed
sequentially through all the addresses.

RAS (Remote Access Server)

A host on a local area network that is equipped with modems to enable users to connect to the
network over telephone lines.

RAT (Right Angle Transport)

An Input Module mounted on the right side of the inserter that transports documents from an
Input Feeder to the Insert Module.

README
A file containing information that the user either needs or will find informative and that might not
have been included in the documentation. README files are placed on disk in plain-text form
(without extraneous or program-specific characters) so that they can be read easily by a variety
of word processing programs.

Read-Only
Capable of being retrieved (read) but not changed (written). A read-only file or document can be
displayed or printed but not altered in any way.

Real-Time
Of or relating to a time frame imposed by external constraints. Real-time operations are those in
which the machine's activities match the human perception of time or those in which computer
operations proceed at the same rate as a physical or external process.

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Reboot
To restart a computer by reloading the operating system.

Recycled Content Paper

A paper product that contains recovered paper materials. The recycled content is measured as a
percentage of the paper’s weight.

Registration
Small circular marks appearing on the edge to ensure the correct alignment of all page elements
(type, artwork, color blocks between passes through a color printing press, etc.) during printing.
In paper handling equipment, registration usually refers to aligning a sheet against a guide of
some type to assure proper feeding.

Registry
A central hierarchical database in Windows 95 and Windows NT used to store information neces-
sary to configure the system for one or more users, applications, and hardware devices. The
Registry contains information that Windows 95 and Windows NT continually reference during
operation, such as profiles for each user, the applications installed on the computer and the
types of documents each can create, property sheet settings for folders and application icons,
what hardware exists on the system, and which ports are being used.

Reload
To load a program into memory from a storage device again in order to run it, because the
system has crashed or the program's operation was otherwise interrupted.

Remote
Not in the immediate vicinity, as a computer or other device located in another place (room,
building, or city) and accessible through some type of cable or communications link.

Remote Access
The use of a remote computer.

Reset Button
A device that restarts a computer without turning off its power.

Resource File
A file that consists of resource data and the resource map that indexes it.

Response Time
The time, often an average, that elapses between the issuance of a request and the provision of
the data requested (or notification of inability to provide it.

Reverse Stack
A method of collating documents in an accumulator. When reverse accumulating, the documents
are stacked under each other to form a set.

Roll Feeder
A device that is used to feed a large roll of continuous documents to the Burster or Cutter.

Root Directory
The point of entry into the directory tree in a disk-based hierarchical directory structure.
Branching from this root are various directories and subdirectories, each of which can contain
one or more files and subdirectories of its own.

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Router
An intermediary device on a communications network that expedites message delivery. On a
single network linking many computers through a mesh of possible connections, a router receives
transmitted messages and forwards them to their correct destinations over the most efficient
available route. On an interconnected set of local area networks (LANs) using the same commu-
nications protocols, a router serves the somewhat different function of acting as a link between
LANs, enabling messages to be sent from one to another.

Run Time
1. The time period during which a program is running. See also compile time, dynamic allocation,
dynamic binding, link time. 2. The amount of time needed to execute a given program.

Run-time Error
A software error that occurs while a program is being executed, as detected by a compiler or
other supervisory program.

S
Scale
(See WOF)

Scan
The process of reading an OMR or barcode imprinted on a document to control various ma-
chine functions.

Scan Area
A specified area within which OMR or barcodes must appear if they are to be read properly.

Scan Delay
This is the area between the Lead Edge of the document and the scan area.

Scanner
An optical input device that uses light-sensing equipment to capture an image on paper or some
other subject. The image is translated into a digital signal that can then be manipulated by
optical character recognition (OCR) software or graphics software.Three types scanners are
used:
1) OCR Scanner or Camera reads OCR characters
2) OMR Scanner that recognizes the presence or absence of a computer printed line
3) A Barcode Scanner that recognizes and decode the barcode.

Scan Zone
The area on a document where the OMR codes are scanned. The codes must be printed within
the zone specified.

Schematic
A diagram that shows a circuit's components and the connections between them using lines and
a set of standard symbols to represent various electronic components.

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Scratch
A memory region or file used by a program or operating system to hold work in progress tempo-
rarily. Created and maintained usually without the end user's knowledge, the scratch is needed
only until the current session is terminated, at which time the data is saved or discarded.

Screen Shot
An image that shows all or part of a computer display.

Scroll
To move a document or other data in a window in order to view a particular portion of the
document. Scrolling may be controlled by the mouse, arrow keys, or other keys on the keyboard.

Scroll bar
In some graphical user interfaces, a vertical or horizontal bar at the side or bottom of a display
area that can be used with a mouse for moving around in that area. Scroll bars often have four
active areas: two scroll arrows for moving line by line, a sliding scroll box for moving to an arbi-
trary location in the display area and gray areas for moving in increments of one window at a
time.

SCSI (Small Computer System Interface)

A SCSI interface is used to connect microcomputers to SCSI peripheral devices, such as many
hard disks and printers, and to other computers and local area networks.

SCSI Port
A SCSI host adapter within a computer, which provides a logical connection between the com-
puter and all of the devices on the SCSI bus.

Sealer
A mechanical device on the Output that moistens the envelope flap.

Search Engine
A program that searches for key words in documents or in a database.

Selectable Feeder
A feature that permits the operator to reassign any selectable feeder. For example, feeding from
Feeder 1 when Feeder 2 is selected.

Select Enclosure Feeder

An Enclosure Feeder that operates only when a Select Feeder Code is provided.

Select Feeder Codes

OMR lines that, when read, allow an Enclosure Feeder to feed an insert at the proper time.

Selective Metering
An inserter option that allows the mailpieces to be metered or not metered, based on the weight
of the mailpiece. A dash code, the total weight, or a signal from a Weigh-on the-Fly scale is
used to determine that the correct postage is applied to the mailpiece.

Selective Sealing
This is an inserter option that allows the mailpieces to be sealed or not sealed. A dash code or
other feature will determine if the mailpiece is sealed or not sealed.

Separator
A device which separates a document, insert, or envelope from a stack and feeds it into a
feeder. It is adjustable, to minimize double feeding.

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Serial Communication
The type of communication used between two devices or modules. With Serial Communication,
all signals are sent on a line in one long stream.

Serial Port
An input/output location (channel) that sends and receives data to and from a computer's
central processing unit or a communications device one bit at a time. Serial ports are used for
serial data communication and as interfaces with some peripheral devices, such as mice and
printers.

Server
1.) On a local area network (LAN), a computer running administrative software that controls
access to the network and itsresources, such as printers and disk drives, and provides resources
to computers functioning as workstations on the network. 2.) On the Internet or other network,
a computer or program that responds to commands from a client. For example, a file server may
contain an archive of data or program files; when a client submits a request for a file, the server
transfers a copy of the file to the client.

Service Pack
A service pack is a means by which product updates are distributed. It keeps the product cur-
rent and extends and updates your computer's functionality so you'll never have to worry about
becoming out of date. A service pack includes updates, system administration tools, drivers, and
additional components. All are conveniently bundled for easy downloading. A service pack is
cumulative; that is, each new service pack contains all the fixes in previous service packs, as
well as any new fixes.

Set
Group of documents that are collected in the Accumulator for a single address or account.

Set-to-Set Sequence Verification

An option that ensure the sequence of sets of documents is correct. This feature insures that all
the sets are in the correct sequence as they are fed, and that all the mailpieces are in ZIP code
sequence.

Setup Program
A built-in BIOS program for reconfiguring system parameters to accommodate a new disk drive.

Setup Wizard
A structured series of questions and options that leads a user through the process of installing a
new program.

Shareware
Copyrighted software that is distributed on a try-before-you-buy basis. Users who want to
continue using the program after the trial period are encouraged to send a payment to the
program's author.

Sheet Feeder
An Input Module that feeds and separates a cut sheet from a document stack.

Shut down
To close a program or operating system in a manner ensuring that no data is lost.

Single Web
A mode of operation that feeds using only one web.

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Glossary Direct Connect Service Manual

Skew
Occurs during paper handling resulting in a slight misalignment of a document, enclosure or
envelope as it feeds through or is transported through a module.

Slitter
(See Center Slitter)

Sort
Refers to the separating of mailpieces into ZIP Code categories to take advantage of postal
discounts.

Specification
1.) A detailed description of something. 2.) In relation to computer hardware, an item of informa-
tion about the computer's components, capabilities, and features. 3.) In relation to software, a
description of the operating environment and proposed features of a new program. 4.) In infor-
mation processing, a description of the data records, programs, and procedures involved in a
particular task.

Split Drive
An inserter equipped with two drive systems, one for the Conveyor Chains and Pushers, and one
for the Feeders. If a Feeder does not feed, the Conveyor Pushers are delayed but the feeder
keeps driving the insert down to the deck. When the insert is fed, the Conveyor Pusher resumes
operation. (See Delay)

Sprocket Strips
These are the perforated edge strips of paper along the sides of the continuous webs. The
punched holes are used for registration during printing and also to feed the web through the
Form Conveyor, the Burster, and the Cutter.

Stacker
An output unit that stacks the mailpieces. There are several types of stackers used in the
Output:
-- Continuous Belt type, also called a Power Stacker, a Vertical Stacker
-- Intelligent Stacker Trayer (IST)

Stacking
The process of stacking mail in an orderly fashion. Mail can be horizontally or vertically stacked.
(See Vertical Stacker, IST, and Power Stacker)

Stand-alone
Of, pertaining to, or being a device that does not require support from another device or system,
for example, a computer that is not connected to a network.

Standard Fold
A three-panel fold made by tucking the bottom panel of the folded piece under the top panel. It
is sometimes referred to as a ”C” fold.

Status
The condition at a particular time of any of numerous elements of computing--a device, a com-
munications channel, a network station, a program, a bit, or other element--used to report on or
to control computer operations.

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Direct Connect Service Manual Glossary

System
Any collection of component elements that work together to perform a task. Examples are a
hardware system consisting of a microprocessor, its allied chips and circuitry, input and output
devices, and peripheral devices; an operating system consisting of a set of programs and data
files; or a database management system used to process specific kinds of information. A typical
Inserter system consists of one or more input modules, an insert module, an output module and
an operating system.

System Administrator
The person responsible for administering use of a multiuser computer system, communications
system, or both. A system administrator performs such duties as assigning user accounts and
passwords, establishing security access levels, allocating storage space, and watching for
unauthorized access to prevent viruses from entering the system.

System Disk
A disk that contains an operating system and can be used to boot a computer. Also called
startup disk.

System Error
A software condition that renders the operating system incapable of continuing to function
normally. This type of error usually requires rebooting the system.

System Failure
The inability of a computer to continue functioning, usually caused by software rather than
hardware.

T
Tabletop System
A compact inserter system for applications that do not require the high-volume capacity
offered by inserter systems. Another division of Pitney Bowes sells this line of equipment.

Tape
A thin strip of polyester film coated with magnetic material that permits the recording of data.
Because tape is a continuous length of data storage material and because the read/write head
cannot "jump" to a desired point on the tape without the tape first being advanced to that
point, tape must be read or written sequentially, not randomly (as can be done on a floppy disk
or a hard disk).

Tape Drive
A device for reading and writing tapes.

Task
A stand-alone application or a subprogram that is run as an independent entity.

Taskbar
A graphic toolbar used in Windows 95 to select, via the mouse, one of a number of active appli-
cations.

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Glossary Direct Connect Service Manual

Temporary File
A file created either in memory or on disk, by the operating system or some other program, to be
used during a session and then discarded.

Throughput
A measure of the data transfer rate through a typically complex communications system or of
the data processing rate in a computer system.

Top Edge Marker

(See Edge Marker)

Total Page Count Verification

An option that ensures that the total number of documents in a set is correct. This feature
detects duplicate, blank, and missing pages within the set.

Total Weigh
An option used to process mixed weight mailpieces. The operator determines and assigns a unit
of weight to each document, insert, and envelope. As the inserter runs, Total Weigh calculates
the weight of the entire mailpiece and then directs the mailpiece to the correct Mailing Machine
or Vertical Stacker.

Touch Screen
A computer screen designed or modified to recognize the location of a touch on its surface. By
touching the screen, the user can make a selection or move a cursor.

Tractor
The pin-feed drive mechanism that engages the sprocket holes of continuous web forms.

Traffic
The load carried by a communications link or channel.

Trail Edge
The trailing edge of a document as it feeds through a device or module.

Transfer
The movement of data from one location to another.

Transfer Rate
The rate at which a circuit or a communications channel transfers information from source to
destination, as over a network or to and from a disk drive. Transfer rate is measured in units of
information per unit of time--for example, bits per second or characters per second--and can be
measured either as a raw rate, which is the maximum transfer speed, or as an average rate,
which includes gaps between blocks of data as part of the transmission time.

Transport/Buffer
Input device that conveys folded or unfolded collations from the Folder to the Inserter Chassis.

Trim and Vac

Option available for Bursters and Cutters that vacuums away Sprocket Strips and paper chips
cut from the documents fed through the Input Module and deposits them in a waste bin.

Troubleshoot
To isolate the source of a problem in a program, computer system, or network and remedy it.

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Direct Connect Service Manual Glossary

Truncate
To cut off the beginning or end of a series of characters or numbers; specifically, to eliminate
one or more of the least significant (typically rightmost) digits. In truncation, numbers are simply
eliminated, unlike rounding, in which the rightmost digit might be incremented to preserve accu-
racy.

Two-Up Web
Side-by-side printed documents on a continuous web. They are usually center slit to divide
them into two separate webs for the Burster or Cutter.

U
Unknown Mailpieces
Collation in process where the data is lost and the collation is outsorted.

Unshielded cable
Cable that is not surrounded with a metal shield. If the wires in an unshielded cable are not at
least twisted around each other in pairs, the signals they carry have no protection from interfer-
ence by external electromagnetic fields. Consequently, unshielded cable should be used only over
very short distances.

Untracked Collation
In Direct Connect, an untracked collation is one for which there is no collation data. The Icon
for this collation is a magenta Question Mark.

Unzip
To uncompress an archive file that has been compressed by a program such as compress, gzip,
or PKZIP.

UPS (Uninterruptible Power Supply)

A device, connected between a computer (or other electronic equipment) and a power source
(usually an outlet receptacle), that ensures that electrical flow to the computer is not inter-
rupted because of a blackout and, in most cases, protects the computer against potentially
damaging events, such as power surges and brownouts. All UPS units are equipped with a bat-
tery and a loss-of-power sensor; if the sensor detects a loss of power, it switches over to the
battery so that the user has time to save his or her work and shut off the computer.

User Account
On a secure or multiuser computer system, an established means for an individual to gain access
to the system and its resources. Usually created by the system's administrator, a user account
consists of information about the user, such as password, rights, and permissions.

Username
The name by which a user is identified to a computer system or network. During the logon
process, the user must enter the username and the correct password. If the system or network
is connected to the Internet, the username generally corresponds to the leftmost part of the
user's email address.

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Glossary Direct Connect Service Manual

User Profile
A computer-based record maintained about an authorized user of a multiuser computer system.
A user profile is needed for security and other reasons; it can contain such information as the
person's access restrictions, mailbox location, type of terminal, and so on.

Utility Program
A program designed to perform maintenance work on the system or on system components (e.g.,
a storage backup program, disk and file recovery program, or resource editor).

V
Variable
In programming, a named storage location capable of containing data that can be modified during
program execution.

Version
A particular issue or release of a hardware product or software title.

Version Number
A number assigned by a software developer to identify a particular program at a particular stage,
before and after public release. Successive public releases of a program are assigned increasingly
higher numbers. Major changes are usually marked by a change in the whole number, whereas for
minor changes only the number after the decimal point increases.

Vertical Stacker
An Output device that will divert and stack mailpieces for special handling and is often referred
to as VS-1, VS-2, and so on.

Virus
An intrusive program that infects computer files by inserting in those files copies of itself. The
copies are usually executed when the file is loaded into memory, allowing them to infect still
other files, and so on. Viruses often have damaging side effects--sometimes intentionally, some-
times not.

Volume
A disk or tape that stores computer data. Sometimes, large hard disks are divided into several
volumes, each of which is treated as a separate disk.

Volume Label
A name for a disk or tape.

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Direct Connect Service Manual Glossary

W
WAN (Wide Area Network)
A communications network that connects geographically separated areas.

Web
A series of Fan-folded continuous forms used on a computer printer.

Width
The side-to-side dimension of a document, insert, or envelope, as it is fed.

Windows NT
An operating system released by Microsoft Corporation in 1993. The Windows NT operating
system, sometimes referred to as simply NT, is the high-end member of a family of operating
systems from Microsoft. It is a completely self-contained operating system with a built-in graphi-
cal user interface. Windows NT is a 32-bit, preemptive multitasking operating system that fea-
tures networking, symmetric multiprocessing, multithreading, and security.

Wizard
An interactive help utility within an application that guides the user through each step of a
particular task.

WOF (Weigh-On-the Fly™) Scale

An Output device that weighs mailpieces as they move across the scale platform. The scale is
an intelligent device that signals the appropriate postage meter to imprint the envelope with the
correct postage. It can also be used to confirm the integrity of the mailpieces by checking for
the correct weight of all contents.

Workgroup
A group of users working on a common project and sharing computer files, often over a local
area network.

Workstation
A combination of input, output, and computing hardware that can be used for work by an indi-
vidual.

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Z
ZIP Code
A numbered coding system that speeds mail sorting and processing.
The following information is taken directly from the Domestic Mail Manual published by the U.S.
Postal Service:
“The most complete ZIP Code is a nine-digit number divided by a hyphen between the fifth and
sixth digits. The Postal Service has adopted the term ‘ZIP+4’ as its trademark for the nine-digit
ZIP Code. The first three digits identify the delivery area of the sectional center facility (SCF) or
major city post office serving the area in which the address is located. The next two digits (the
fourth and fifth) identify the delivery area of the associate post office or branch station of the
major city post office serving the address. The sixth and seventh digits (the first two digits
following the hyphen) identify an area known as a ‘sector.’ The eighth and ninth digits identify a
smaller area known as a ‘segment.’ The final four digits of the ZIP+4 code identify specific geo-
graphic locations such as a side of a street between intersections; both sides of a street be-
tween intersections; individual buildings; a floor or group of floors in a large building; a firm within
a building; a span of boxes on a rural route; or a group of post office boxes in which mail delivery
will be made by a single employee.”

Zone
This is an electronic window that is used to determine the position of a Benchmark or other OMR
codes, or the area that is used to scan for the Barcode.

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Printed by Document Solutions Center, a division of Pitney Bowes Management Services
Engineering the flow of communication

37 Executive Drive
Danbury, Connecticut 06810-4182
Tel: 800.983.9368
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Email: [email protected]
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SV 41085-SM 10/03 © 2003 Pitney Bowes Inc. All rights reserved. Printed in USA