| Page 1 | TOC | Nov-19-2019 09:38 |

Table of Contents
1 Read this First ...............................................................................................1
Safety...............................................................................................................1
Declaration of Conformity (EU only).................................................................1
About this manual............................................................................................1

2 Introduction ...................................................................................................3
Introduction......................................................................................................3

3 Description of machine ................................................................................4

Description of operation...................................................................................4
Identification of parts........................................................................................5
Switching on the machine................................................................................8

4 Control Panel ..............................................................................................10

The Job Screen..............................................................................................10
The Run Screen.............................................................................................12
The Menu Screen...........................................................................................24

5 Running an existing job .............................................................................25

Running an existing job..................................................................................25

6 Switching the user ......................................................................................28

How to switch the user...................................................................................28
User Access Rights........................................................................................30

7 Creating a job ..............................................................................................32

Creating a job.................................................................................................32
Creating the Job Settings...............................................................................33
Creating an envelope.....................................................................................56
Creating a document......................................................................................59
Creating an enclosure....................................................................................64

8 Loading the paper hoppers .......................................................................66

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Loading the envelope hopper.........................................................................66

Loading the feeder hopper.............................................................................68
Loading the tower folder hoppers...................................................................71
Daily Mail Tower Folder..................................................................................74
Adjusting the catch tray..................................................................................76

9 Operator Maintenance ................................................................................77

General Cleaning...........................................................................................77
Cleaning the sensors.....................................................................................77
Clearing paper jams.......................................................................................85
Maintaining the Wetter System......................................................................88

10 Technical Specification ..............................................................................89

Inserter head..................................................................................................89
Tower Folder...................................................................................................92
Insert Feeder (Single, Twin & Reading).........................................................94
Feeder Folder.................................................................................................95
Mechanical & Electrical..................................................................................96

11 Glossary of terms .......................................................................................99

Glossary of terms...........................................................................................99

12 INF Output Conveyor - appendix .............................................................107

Introduction..................................................................................................107
Description of machine................................................................................107
Setting up the machine................................................................................110
Using the machine in IMOS.........................................................................111
Operator Maintenance.................................................................................119
Technical Specification.................................................................................121
Troubleshooting Guide.................................................................................122
 | Page 1 | Nov-19-2019 09:38 | Read this First

1 Read this First

Safety 1

English
Ensure you have read and fully understood the safety requirements
in the Safety Guide.

Declaration of Conformity (EU only)

The product presented in this guide meets the requirements of applicable directives. For
more details refer to the Declaration of Conformity. Contact your authorized distributor for
availability of this document.

About this manual

Disclaimer
This Guide is published without any warranty. Improvements and changes to the online
Guide necessitated by typographical errors, inaccuracies of current information, or
improvements to programs and/or equipment, may be made at any time and without notice.
Such changes will, however, be incorporated into new editions of the PDF Guide (if
applicable).

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Symbols
This manual uses the symbols listed below.
1 This symbol... Indicates...
WARNING: Indicates a human safety hazard.
English

ATTENTION: A risk to the equipment or mail could result from an action

you may perform.
NOTE: A remark that explains different cases or specificities.

TIP: Advice to help save you time when processing your mail.

SUPERVISOR: Indicates that you have to use the supervisor menu to

perform the procedure.

Languages
In the EU the user guide must be available in the national language(s) of the country where
the system is delivered. Therefore, if the User Guide is not available in your country’s
language(s), contact your authorized distributor.

Software
The software used for the reading option is based in part on the work of the Independent
JPEG Group.

2
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2 Introduction

Introduction
2
Introduction

English
With this inserter you have an advanced, medium-volume folding and inserting machine.
Its modular construction allows multiple feed units to be fitted, with a maximum of 17 feed
units. Its sophisticated software control optimises the order and flow of documents for
collating at the insert head before insertion into the envelope. All fold and adjustments take
place automatically according to the requirements programmed in by the operator.
In order to ensure the long usage of this machine and its components, and above all the
safe use of the machine, you must read and adhere to the operating instructions and safety
notes. Always be aware of all warnings and notes that are mounted or noted on the machine
itself.
All persons entrusted with the handling of this machine must also be familiar with the
operating manual.
Save this handbook carefully, so that the information it contains may be available at all
times.

Notes on the use of this handbook

This document contains all general information and explanatory text necessary in order to
be able to carry out the operation of the machine.
When some action is expected from the operator, this will always be explicitly stated, and
where relevant, accompanied by an illustration or graphic.
Always read through each step, so that you will obtain all of the necessary information. Do
not anticipate what you believe will follow in the handbook: It will prevent you from making
mistakes!
Chronology and Reference
This handbook is structured chronologically, and therefore ordered sequentially for the
operationally ready machine. It assumes that the machine has been installed in the correct
environment by an Authorised Service Engineer and that the operator or his or her supervisor
has had a degree of operator training.
When you are unfamiliar with the machine, it is best to read through the handbook from
beginning to end. You will be guided step by step, and in this way you can easily and quickly
have the machine in operation.
If you are already familiar with the machine, it will make thing easy if you use this handbook
as a reference work.

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3 Description of machine

Description of operation

The function of the machine is to fold forms to ‘C’, ‘Z’, ‘V’ or double forward fold, either
3 singly, in fixed multiples or in varying groups. Enclosures such as inserts, BR envelopes
etc. may be added. Folded forms and enclosures are collated in the collation area in the
inserter head before insertion into the envelope. Forms may be inserted without sealing
the envelope for subsequent checking or hand insertion.
There is a batch processing facility, allowing a preset number of cycles to be completed
English

before the machine automatically stops.

The machine is OMR/Barcode/2D compatible for use with a reading feeder or tower folder,
allowing a group of forms to be collated on the track prior to folding. A number of barcode
symbologies may be read.
The machine consists of a number of modules, depending upon the build ordered - these
modules are briefly described below:
• Inserter head - Collates all documents in a pocket before insertion, feeds the
envelope, inserts the pack and seals the flap.
• Feeder - Feeds shortform inserts (cards, BR envelopes, booklets etc.) onto the track
for subsequent insertion. Available with single or twin feed hoppers. An
OMR/Barcode/2D version is also available.
• Feeder Folder - Track mounted folder for folding document inserts. Fitted with a
2-plate folder mechanism for C, Z or V folds. Single hopper only.
• Tower Folder - Mounts at the end of the machine. Folds documents either separately
or in groups, using an accumulator if required. Fitted with either a 1 x 1000, 3 x 500
or 1 x 1000 plus 1 x 500 sheet trays. Uses a 3-plate folding mechanism. An
OMR/Barcode version is also available (top or bottom read).
The machine is equipped with PC controlled operating software from where jobs can be
programmed and run. The number of jobs that can be programmed is limited only by the
capacity of the PC. Input is via touchscreen monitor or keyboard/mouse.
A daily mail function can be used as an optional feature on a Tower Folder. This allows
groups of documents, stapled or loose, to be hand-fed; they will then be folded and inserted
into an envelope (flex folder only). If other hoppers are loaded, further forms can be collated.
No manual setting of the fold plates or envelope closer is required, these being adjusted
automatically according to the settings in the selected program.
An optional output conveyor can be specified, to replace the standard receiving tray. This
can be fitted in two possible orientations.

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Identification of parts

The main parts of the machine are shown below.

English

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3
English

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1. Envelope feeder
Holds up to 800 DL envelopes. Fitted with a sensing conveyor that operates on demand
to move the envelope stack forward.
2. Touch-sensitive monitor
Runs the IMOS operating software and responds to button pushes. A keyboard and
mouse are also fitted.
3. Collation and insertion area
Folded forms, either singly or in groups, are collated here into one pack, along with 3
enclosures. The pack in then inserted into the envelope.
4. Feeders/Folders
These are track mounted units, with an end-station variant also available. Up to 17

English
feed trays may be fitted.
The feeder (single or twin) feeds enclosures such as inserts, flyers, BREs etc. The
hopper holds up to 300 BREs. A reading variant for OMR/ BCR/2D is also available,
as is a feeder folder for long documents, with hopper capacity of up to 500 sheets of
A4 80gsm.
5. Tower Folder
This is a folder unit and is only available as an end module. It can be fitted to the
insertion head on its own, or in conjunction with feeders. It is fitted with various options
of feed pods and an accumulator (see following page).
6. Feed Trays
Fitted to the Tower Folder. 3 options available: 3 x 500-Tray, 1 x 500 with 1 x
1000-Trays & 1 x 1000-Tray; all variants can be mark reading as an option.
7. Accumulator
Fitted to the Tower Folder and allows groups of forms to be collated together before
folding as a group. It is an optional item, it is also fitted with a diverter tray (supplied
by default if on reading versions).
8. Closer/Eject Area
This is where the envelope flap is closed and sealed before ejected the filled envelope
into a receiving tray or onto a conveyor.

Items 1, 2, 3 & 8 are all part of the Insertion Head Unit.

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Switching on the machine

The machine and PC must be switched on separately.

Press the green button at the front of the inserter.

3
English

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Open the cupboard below the Inserter and press the On/Off button on the PC.

English

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4 Control Panel

The Job Screen

This is the screen displayed when the machine starts up.

4
English

1. Run screen
2. Job screen
3. Menus (pull down)
4. Online help
5. Users menu
6. Graphic shows machine configuration
7. New job button
8. List of existing/available jobs

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Press ‘Online Help’ to access this document. Press ‘Remote Assistant’ to access
assistance via Team Viewer - see Remote Assistant on page 23 for further details.
Menus (including Engineer & Admin screens) are only available if logged in as
Supervisor or Engineer.

See Running an Existing Job on page 25 for running an existing

job directly from this screen.

English

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The Run Screen

The Run Screen displayed

4
English

This is the screen you will see after an existing job has been selected in the Job Menu.
1. Job screen
2. Menu screen
3. Online help
4. Users menu
5. Shut down IMOS *
6. Paper load indicators
7. Speed controls & indicator
8. Counter settings
9. Single cycle
10. Autoend
11. Pause
12. Run

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* This button closes down the IMOS operating software - it does not switch the machine
off.
To change the current user or job, click on the buttons and you will be presented with a list
of all those that have been created, and allow you to select any one. Note that to change
to a different user will require the appropriate password to be entered. To view and adjust
the settings for the envelope and document inserters, click on the relevant part of the
machine graphic (see the following pages for details).
Important: you must be logged in as Supervisor to change the current user or job.

Testing the mailset

4
This allows various adjustments to be made before beginning the job, in
order to minimise insertion crashes.

English
1. Press the Single Cycle button to open the following options:

See following page for explanation of each button.

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Present at exit
After pressing Present at exit, the first piece will be processed and the
machine will stop to allow you to adjust the vertical alignment of the
address, if required.

1. Remove the filled envelope and adjust as necessary, as shown below:

4
English

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Finger sequence
Sets the order of insertion of the fingers in the envelope, whether inner
or outer fingers first, or both together.

1. Press Finger Sequence – the machine will feed an envelope into position and present
the following screen:

English
2. Select required sequence. Press Revert to restore machine default.

Envelope Stop Position

Allows the stop position of the envelope at insert to be adjusted.

1. Press Envelope Stop Position – the machine will feed an envelope into position and
present the following screen:

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4
English

2. Adjust as required. Press Revert to restore machine default.

Finger Adjust
Allows the width of the outer fingers to be adjusted.

1. Press Finger Adjust – the machine will feed an envelope into position and present
the following screen:

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English

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Counter settings

4
English

Press the Edit button next to the counters to display

the Job Count and Batch Count box:
1. Applies to current job until it is changed, even if machine is switched off and later
resumed. Press Reset to return to zero.
2. Press Change total to set the total for the job. When total is reached, machine will
continue anyway.
3. Press OK to confirm the change.
4. Select the exit that you want batching to apply to (if required). Note: Exits 2 & 3 will
only appear if one or more Sorters are fitted.
5. Switch batch on if using this function.
6. Set batch mode as follows for when batch quantity is reached:
- Batch and Continue: Machine will pause for the specified pause time and then
resume.
Note: conveyor will continue to run during the pause time.
- Batch and Stop: Machine will stop and resume only when the Run button is pressed.
7. Press Reset at any time to return to zero.
8. Press Change total to set the batch quantity required. Note: This total applies to the
Exit selected above.
9. Select the Exit that you want the Batch Count displayed on the Run Screen to apply
to.
10. Press OK when all settings are complete.

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Adjusting the Envelope Inserter settings

All fine adjustments apply only to the current job and will not affect
any other jobs. Note also that settings available will depend upon
user access rights (see User Access Rights on page 30).

Unit Fine Tuning

1. Select the inserter icon on the machine graphic in the Run screen to display the fine
4
tuning screen.

English

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2. Select Hardware Fine Tuning to display further information.

4
English

You can change:

• Collate Pkt. Adj: Width of collate pocket guides.
• Adjust pawl pause pos: Pause time after insertion. Increase if pawls start
before previous pack has cleared.
• Collate Slowdown: Select ‘Not on Last Form’ for thick packs if final document
in the pack does not feed fully into collate pocket.
• Fingers Adj: Overall width of insert fingers.
• Adjust envelope stop (mm): Stop position for insertion. + = towards exit.
• Finger Sequence: Change if envelopes not opening properly.
• Insert in env position (mm): Pack insertion into envelope. + = past flap crease.
• Envelope Blower: Increase opens envelope more. High for thick packs, low
for single sheets/thin packs.
• Seal Time: Envelope ejects after.
• Adjust wetter start: When wetter beam drops. + = start point towards insertion
area.
• Adjust env seal pos: Envelope into seal rollers. + = further in.
• Adjust env reverse pos: Envelope foward travel after wetting, before reversing
into sealing rollers. + = into output rollers, towards exit.
Note: High-window envelopes, set to 20 - 50mm+.
• Linear Speed: Inserter head speed. Set lower speed if pack is not being fully
inserted, eg. long packs.
• Env Conveyor Drive Delay: Number of envelopes on the conveyor before
conveyor switches back on. Increase if envelopes ‘bunching’.

Hopper Fine Tuning

1. From here you can adjust hopper settings. Select the envelope icon on the machine
graphic in the Run screen to display further information.

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You can change:

• Seal Mode: Eg. select ‘Off’ for later hand insertion of insert etc.

English

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Adjusting the Document Unit settings

The fine tuning options available will depend upon whether a

Feeder or Tower Folder is fitted. Note also that settings available
will depend upon user access rights (see User Access Rights on
page 30).

4 All fine adjustments apply only to the current job and will not affect
any other jobs
English

Unit Fine Tuning

1. Select the document or insert icon on the machine graphic in the Run screen to display
the unit fine tuning screen.

You can change:

• Feed Control Mode: If Off, unit is disused until turned back on.
• Doubles Detect: Turn Off if booklets/thick inserts used (Flex Folder only). If
On, select Optical, Mechanical, or Auto.
• Optical Doubles Sensitivity: (Optical only). Low is more tolerant of high contrast
printing.
Only for Reading units
• Reset Seq. Count: If Sequence OMR marks are in use and job is disrupted,
select to reset the sequence.
• Calibrate Reader: follow the on-screen instructions to calibrate the CIS reader.
• CIS Reader Diagnostics: Displays the label of all documents in the group (up
to 10), as seen by the CIS reader. Confirms that whole label was read, for
example, or compare the images. Contact IPSS department for further diagnostic
options.

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Remote Assistant

Remote Assistant allows the machine’s PC to be remotely accessed by an IPSS support

engineer using TeamViewer. This can help with diagnosing problems.
To use Remote Assistant, contact a support engineer in the IPSS department and then
start Remote Assistant from the Help dropdown.

English
This will start TeamViewer and display an ID and Password.

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Communicate the ID and Password to the support engineer, and the link will then be formed
between you. The support engineer will gain full control of the machine’s PC to allow fault
diagnosis.
To end the Team Viewer session, simply close the App.

The Menu Screen

The Menu screen allows various functions to be selected.

4 1.
2.
Libraries
Setup
3. Services
These functions are described in detail further in this document.
English

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5 Running an existing job

Running an existing job

Paper is normally loaded in the Tower Folder face-up and feet-first

if non-reading, but may be either way up if reading, depending upon
whether top or bottom reading.

When using the cascade function, the Run button must be pressed
while the machine is still running, after you have reloaded the empty 5
hopper. This ensures the paper is fed to its pre-load position.
If this is not carried out the machine will stop, even though the
hopper is full: if this happens, press the Run button to continue.

English
This section describes running an existing pre-programmed job. To create a new job, see
Creating a job on page 32.
If the IMOS operating software is not already running, it must be started using the icon on
the monitor screen. To access the PC to switch it on, open the cupboard door below the
inserter head.
Before running a job, the paper hoppers must be loaded with documents - see Loading the
envelope hopper on page 66 for details.

1. If the Job screen is not already displayed, press the Jobs button at the top and select
the required job from the list (in this case, Mailshot Q3). Use the scroll arrows if
needed.

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5
English

2. Summary of selected job is shown.

3. If you are happy with your selection, press Accept, otherwise, select another job.

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4. Load the paper and envelopes in the hoppers indicated.

English
5. Press the Run button to begin operating.
See also The Run Screen on page 12 for a full description of the controls.

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6 Switching the user

How to switch the user

Each user has their own password and access rights, allocated by the Supervisor. To switch
user, the password must be known.

1. Press the Switch User button in the Job screen

6
English

2. Select the user from the list. Use the scroll arrows if necessary.

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3. Press the Logon button.

English
4. Enter the password using either the keyboard or the on-screen keypad. The user has
now changed.

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User Access Rights

There are 4 levels of access rights that can be allocated to each user. These are described
below:

Rights Operator Expert Engineer Supervisor

Operator
Change Jobs Y Y Y Y
Run Machine Y Y Y Y
Programme Jobs N Y Y Y
with
6 Wizard
Add items to Lib- N Y Y Y
raries
from Wizard
English

Add Items to N N Y Y
Libraries from
Outside Wizard
Mechanical Fine N N Y Y
tuning
Document Fine N Y Y Y
tuning
Enter Service N N Y Y
Menu
Enter Admin N N Y Y
Menu
PC Shutdown N N Y Y
on Exit?

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Additionally, the ‘System Security Level’ can be set by a Supervisor. This is the level where
a user does not have to enter a password to perform certain operations. Any access rights
needed above this level will require the user to logon with a password.

Level Effective role of Description On Startup

‘Operator’
Low (default) Least secure Expert Operator Operator can Job screen dis-
run/edit/ create played
jobs but cannot
access the main
menu.
Medium More secure Standard Operat- Operator can Job screen dis-
or only run jobs. played
High Most secure None Operator’ has no User screen dis-
6
access to the played
system. All users
have to logon.

English

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7 Creating a job

Creating a job

Creating a job consists of a number of steps:

• Defining the Mailset (Envelope, document & enclosures)
• Defining the Fold Settings
• Setting required Output Options
• Saving the Job to a Jobname
When defining the Document in the Mailset, OMR or Barcode definitions can be enabled
if required.

7 For an OMR of Barcode definition to be used it must first have been

created - see Creating a document on page 59.
English

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Creating the Job Settings

Creating the Job Settings

1. Press the New button in the Job screen.

You will now need to define the mailset (envelope, documents and enclosures). This English
is described on the following page.

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Defining the mailset

Selecting the envelope

1. Press the Select button to choose an envelope from the available library.

7
English

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2. Select the required envelope from the library and press the OK button.

English
If there are no envelopes in the library, or if you wish to create a
new one, see Creating an envelope on page 56.

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3. You now have a choice: carry on to select a document, or further define the envelope
usage, ie. sealing mode and the order of documents in an envelope.
The following assumes you want to further define the envelope usage. When you
have finished you will return to the screen shown here.
Press the Settings button.

7
English

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4. Select the required Sealing mode (usually this will be ‘Always’). Other options are:
• Off: sealing is disabled.
• No-seal Label Select: reads no-seal character in label.
• Off, flap open: envelope left unsealed with flap open.
• No envelopes: envelope feeding disabled to allow forms only.
Press the Edit advanced button if you wish to change the 'Order of documents in
envelope' setting.

English

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5. Change the order that enclosures are inserted into the envelope (default is Automatic).
If set to Manual, enclosures are inserted in the order created in the job (see Selecting
the enclosure at the end of this section).

7
English

Selecting the document

1. Press the Select button to choose a document from the available library.

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2. Select the required document from the library and press the OK button.

English
If there are no documents in the library, or if you wish to create a
new one, see Creating a document on page 59.

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3. You now have a choice: carry on to select enclosures, or further define the document
usage, eg. form count, cascading, hand-feed etc.
The following assumes you want to further define the document usage. When you
have finished you will return to the screen shown here.
Press the Settings button.

7
English

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4. Set form count for multiples, and if required, select cascading (automatically feed from
another hopper when this one runs out), or Daily Mail (hand-feed).
Press the OK button when done.
For further settings, press the Edit Advanced button.

English

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5. If you wish to choose an orientation other than the auto-selected default, un-tick
the Auto box to enable the selector button.

7
English

The following settings can be made:

• Deskew: Set low if possible; high slows machine down. Turn off if skewing is
not occurring.
• Thickness doubles: can currently be checked optically only on a feeder folder
or feeder, or turned off, if for example, documents are substantially different
from the calibration document, such as abnormally dark with heavy printing.
• Feed control mode: is ‘Feed Always’ as default, but can be turned off to disable
the hopper. It can also be set to ‘Selective Feed’ for reading-enabled units.
This works in conjunction with ‘Select ID’ .
• Select ID: Defines an ID number for document to accord with the Select mark
in the label. This will then feed the document when that mark is read.
• Sequence handling mode: how sequence marks (if used) are handled when
a document set is broken up (eg. to change a job in the middle of a document
set). Set to 'Full' for the first pass, then change to 'Mailset' for the second pass
after the job has been changed. The machine will not then expect an unbroken
sequence.

Selecting the enclosure

1. If you are using enclosures (inserts, BREs, booklets etc.), press the Select button.

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English
2. Select the required enclosure from the library and press the OK button.

If there are no enclosures in the library, or if you wish to create a

new one, see section Creating an enclosure on page 64.

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3. You now have a choice: carry on to select further enclosures if required, remove the
enclosure you have selected, or further define the enclosure usage, eg. form count,
cascading, handfold etc.
The following assumes you want to further define the enclosure usage. When you
have finished you will return to the screen shown here.
Press the Settings button. Settings and Advanced Settings are same for
enclosures as for documents- see steps 4,5 of section Selecting the document

7
English

Documents are normally loaded in the Tower Folder face-up and

feet-first if non- reading, face down and head-first if reading. This
may vary: see also orientation chart in Loading the Tower Folder
hoppers on page 71.

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4. If further enclosures are required, press the Select button and repeat steps 1 to 4.
Repeat as required up to the limit of available stations.
Press the Next button to assign the documents/enclosures to specific hoppers.

English
The mailset is now defined, and the screen will show that this is ticked.

Defining the document placement settings

Only do this if you want to assign documents/enclosures to specific
hoppers, otherwise press Next.

1. Select document to move, then the hopper to assign it to.

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7
English

Press the Next button. The screen will show that document placement is ticked.
Now define the fold settings.

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Defining the fold

1. The machine will automatically select the optimum fold type. If you wish to change
this, deselect ‘Auto’ and set the required fold.

English
The machine may not perform properly if you change the fold
type wrongly.

If you wish to make adjustments to the fold lengths, or just check them, press the
Adjust fold button.

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2. Make adjustments as required and press the OK button.

7
English

For Max. & Min. fold lengths for each fold plate, see Tower Folder
on page 92.

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3. If you wish to make adjustments to, for example, the collation mode or Max no. of
sheets folded together, press the Edit advanced button.

English

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4. The following advanced settings can be made:

7
English

• Collate Mode: when ticked the collate mode is set to 'Singly': folds sheets one
by one. When un-ticked you can choose between:
- Together: collates forms and folds them together.
- Together via Accumulator: is as above, but feeds into accumulator before
folding.
• Maximum in accumulator: Up to 25 depending upon the paper type.
• Maximum Fold (Forms): Number of forms that can be folded together. Groups
bigger will split into a) max number, followed by b) remainder.
• Multi-envelope mode: Allows two separate jobs to be run in succession using
the same document set.
If set to Split Oversized, this splits, folds and inserts as for ‘Maximum Fold’
described above.
If set to Divert Oversized. All groups more than number set in Divert/Split
Threshold will be diverted. For Divert Undersized, the same applies for groups
below the threshold. Machine is then stopped, job is changed and forms in divert
tray are replaced into the document set, and the new job is run.
See also Table 1 below.

If Divert Oversized/Undersized is selected, Divert/Split Threshold

must be set to the same as Maximum Fold (Forms).

• Error handling: Action of machine after bad reads.

• Oversize/Undersize handling: Action of machine after diverting as above.

Not available if Split Oversized is set.

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Table 1
Handling of folded forms
Shown below are handling of oversized/undersized groups under different
circumstances.

Multi envelope Maximum in Divert/Split

Maximum Fold Comment
mode accumulator threshold
When not fold-
ing or diverting,
When folding,
the group or Mechanical lim-
the group or
Split over- subgroup is its of folder and
sub-group is fol- Not used
sized ejected towards accumulator for
ded on reaching
divert or head given stationery
this limit
unit on reaching
this limit 7
The complete
group is as-
Typically used
sembled in the
Not used (As for for diverting

English
accumulator
Split Oversize if Not used (As for large groups for
Divert oversized and then diver-
oversize not yet Split Oversize). re-processing
ted if prime doc-
detected). into a larger en-
ument count is
velope
equal or greater
than this limit
The complete
group is as-
Typically used
sembled in the
Not used (As for for diverting
accumulator
Divert under- Split Oversize if Not used (As for small groups for
and then diver-
sized undersize not Split Oversize). re-processing
ted if prime doc-
yet detected). into a smaller
ument count is
envelope
less than this
limit

Fold settings are now complete. Press the Next button, the screen will show that this
is ticked.

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Defining the output settings

1. Set the settings for Batching. By default Batching is set to off.

7
English

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2. Set Batching to Batch On if required and set required quantity in Batch Quantity.
Set Batch Mode as follows:
Batch and Continue:
Machine will pause for the specified pause time, and then resume.

Conveyor will continue to run during the pause time.

Batch and Stop: Machine will stop and resume only when the Run button is pressed.
Select Envelope Count under Batch Control, currently the only available option.
Set the Batch Complete Pause Time as described in Batch and Continue above.
3. If a conveyor is fitted, select Conveyor Settings to adjust the Jog functions as follows:
• Single Jog Adjust: Adjusts default jog step (gap) between mailpieces. Note
that steps are unitless.
7
• Batch Complete Jog Step:
Adjusts gap before machine performs action described in ‘Batch Mode’.
• Mark Reading Jog Step:

English
Adjusts gap created after Jog mark is read.
• Autoend Jog Step:
Adjusts gap created before machine autoends.

Output Settings are now complete. If you are using Mail Sorting or Franking, refer to the
Mail Sorting on page 112 and Franking on page 118.
Press Next and the screen will show that this is ticked. You can now save the job.

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Saving the job

Any of the Job Creation screens can be edited by pressing Edit for
the selected job in the Job screen. Note that the Save button will
then be enabled on each screen.

1. Press the keyboard icon to display the virtual keyboard.

7
English

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2. Enter a name for the job using either the virtual or physical keyboard.

English
3. Repeat steps 1 & 2 to enter a brief description for the job. This is the description that
will appear in the job list when the machine is started.
4. Set the Job number control mode. Options are Auto generated; Manual entry (Internal
or External); Read from prime; Read on output; Externally supplied.

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5. Enter a Job number if manual entry control mode is being used. Disabled for all other
modes.
6. Set the AIMS Mode. Options are Off; Statistics; Audit; Verification; Lookup (FBM).
7. Set the Datalogging Mode. Options are Off; Standard; AIMS Statistics Compatible.
See also AIMS User Reference Guide for full details.

You have now successfully created a new job and it will appear in the job list.

Creating an envelope

In order for an envelope to appear in the envelope library, it must first be created.

1. Begin creating a job (see Creating the Job Settings on page 33).
2. At the point where you need to select an envelope, press the New button.
7
English

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3. Enter a name for the envelope: press the virtual keyboard icon and enter the name
using either the physical or virtual keyboard. Select an envelope size. The default
width and height for that type will then be shown. If you want to adjust the size, the
size will change to ‘Custom’.Adjust the flap depth if required.
If you want to adjust the envelope weight and the wetting rate, press the Edit
Advanced button.

English

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4. Adjust the weight as required. Note that the weight is the actual weight of the envelope,
not the paper weight.
Adjust the wetting rate if required. The number shown is the quantity of envelopes
sealed before the pump tops up the wetter tank. Default is 25.
Press the Save button when done.
The envelope will now be available in the envelope library under the name you have
given it.

7
English

The envelope is now fully defined and is available for use.

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Creating a document

In order for a document to appear in the document library, it must first be created.

1. Begin creating a job (see Creating the Job Settings on page 33).
2. At the point where you need to select a document, press the New button.

English

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3. Enter a name for the document: press the virtual keyboard icon and enter the name
using either the physical or virtual keyboard.
Select a form type and size and orientation. The default width and height for that type
will then be shown. If you want to adjust the size, the form type will change to ‘Custom’.
Change the thickness for thick documents, eg. booklets.
If you want to make further adjustments, or select a reading definition, press the Edit
Advanced Button.

7
English

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4. Select the address position. This defaults to ‘Top’; specify middle, bottom or none if
required.
Specify whether the document is to be folded (eg. a booklet would not be) and its
thickness and weight. Note this is the actual weight of the document, not the paper
weight.
The thickness is more applicable to booklets - if no figure is specified, 80gsm paper
will be assumed.
If the document uses an OMR or barcode label, select a reading definition.

This is obtained under licence as an option and must already

exist on the machine.

English

If the document does not use an OMR or barcode label, press the Save button,
otherwise, proceed as follows.

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5. Press the Region of Interest button to specify the position of the label.
Specify Manual for Detection Mode only if specifically required.
By selecting Auto, the label position will automatically be detected. If multiple labels
are present, a dialog box will open when the job is run, allowing the operator to select
the required label.

7
English

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6. Specify the position of the label and select whether edge detection is required – this
detects the edge of the paper and should normally be On.
Turn Off if coloured or densely printed paper is giving false readings: the machine
will then use default dimensions for label position.
Press the Save button when done.

English
The document is now fully defined and is available for use.

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Creating an enclosure

In order for an enclosure to appear in the enclosure library, it must first be created.

1. Begin creating a job (see Creating the Job Settings on page 33).
2. At the point where you need to select an enclosure, press the New button.

7
English

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3. The procedure for defining an enclosure is the same as that for a document, described
in Creating a document on page 59. It is the document type that you select that
determines whether it appears in the document or enclosure library.
See Creating a document on page 59 for the remainder of the settings.

English
The enclosure is now fully defined and is available for use.

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8 Loading the paper hoppers

Loading the envelope hopper

1. Using the black knob, adjust the side guide to give 1-1.5mm clearance each side of
the envelope.

8
English

2. Adjust the angle of the backrest (see below) and load the envelopes into the hopper,
flaps forward, so that the lower edges follow the contour of the surface and down into
the pick-up roller. Move the backrest forward (see below) so the the envelopes are
fully forward, but not tightly packed.

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3. Move the backrest forward by squeezing the handle upwards to release the rollers
from the track.
Adjsut the width of the panels to suit the envelope.
Adjust the angle by slackening the knob each side.
C5: Fully raised
DL/DL+: Fully lowered

English
If the envelope feed is not consistent, try a backrest angle
in-between.

Adjusting the envelope separator

1. To adjust the separator, open the side cover on the insertion head; the adjustor knob
is visible below the envelope conveyor. Turning clockwise decreases the gap,
anti-clockwise increases it.

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8 2. To set the separator gap, empty the hopper, then slide an envelope into the gap and
turn the knob until the separator will just grip the envelope as you withdraw it.
3. Close the side cover when you have finished.
English

Loading the feeder hopper

1. Move the guides to give 1 - 1.5mm clearance each side of the insert.

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2. Draw back the weighted rollers and load the insert pack so that the leading edge is
feeding into the nip of the feed rollers. Move the weighted roller forward to support
the pack.

Twin feeder is shown; single feeder is similar, with one hopper

only.

Adjusting the separator; the separator prevents more than one enclosure being fed
at a time.
1. Feeder: The feeder separator has 4 settings, marked A to D on the slide, or A - C
for Twin Feeder). Before running the job, the gap must be set to suit the thickness of
material being processed - this prevents more than one item being fed at a time. Note
that there is an intermediate setting between each marked position, allowing finer
adjustment.

English

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Slide positions:
A = 0 to 0.75mm
B = 0.75 to 1.5mm
C = 1.5 to 2.5mm
D = 2.5 to 4.0mm
(A - C only on Twin Feeder)

8
English

Most jobs will use position A. If you use the wrong setting, an error
will appear on the control panel.

For problem enclosures, the feed rollers can be changed to optional

alternatives.

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2. Feeder Folder: To increase the separator gap, turn the adjustor wheel downwards
(clockwise). Turn it the other way to decrease the gap.

8
Loading the tower folder hoppers

English
The tower folder may be fitted with 500-sheet or 1000-sheet hoppers. The example shown
has 1 x 500-sheet and 1 x 1000-sheet hoppers.

1. On 500-sheet hoppers, slacken the black knob next to the side guides (arrowed) and
move the guides to give 1-1.5mm clearance each side.

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On 1000-sheet hoppers, press down on the tray to lower it. Slacken the black knob
above the hopper (arrowed) and use the tabs to move the guides to give 1-1.5mm
clearance each side. The tray will raise automatically when the machine is started.

8
2. Tighten the knobs.

Collator
English

1. Raise the top of the accumulator so that it locks in place and place a piece of paper
between the side guides.
If the Tower Folder is fitted with an optional accumulator, the side guides must be
adjusted to suit the paper - use the preset size markings to set the paper width.

2. Slacken the black knob next to the side guides (arrowed) and move the guides to give
1-1.5mm clearance each side.
3. Pull out the handle at the end (arrowed) to lower the accumulator top.

Adjusting the separator

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The separator prevents more than one document being fed at a time.
The separator prevents more than one document being fed at a time.
1. Open the side cover on the operator side and turn the knob in the required direction
to open or close the gap. The markings next to the knob indicate which direction to
turn it.

English
2. To set the separator gap, empty the hopper, then slide a form into the gap and turn
the knob until the separator will just grip the form as you withdraw it.

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Daily Mail Tower Folder

Daily Mail

Daily mail allows a group of forms to be hand-fed, folded and inserted on a Tower Folder.
A group of forms up to a total of 6mm thick may be fed, but be aware of the folding capacity
of 8 forms of 80gsm (20lbs bond). The forms may be stapled or not, as required. See below
for stapling restrictions.

8
English

Using Daily Mail

To use daily mail, define a new mailset (as described in Defining the mailset on page 34)
or edit the document settings in an existing job.
Select Settings for the document and set ‘Hopper feed mode’ to Daily Mail.

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Set the accumulator tray

English
• Raise the overguide (1) until it latches in place.
• Unhook the divert tray (2) and remove it to make it easier to feed the paper.
• Slacken the knob (3) and adjust the side guides to suit the paper.

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Auto and manual feed mode

When daily mail has been enabled as described feed the post into the accumulator tray
and press the Run button in the Run screen. A pop-up screen will appear where you have
the possibility to select the Daily Mail Feed Mode:
• Auto feed: Document automatically feeds after small delay.
• Manual feed: Pass finger over divert sensor (4) to feed document.
The machine will wait for 30 seconds after pressing the button - if you exceed this before
inserting the documents, press the button again.
To turn the function off, switch ‘Hopper feed mode’ back to Default in Document Settings.

8
You may find it easier to feed the paper by unhooking the divert
English

tray and removing it.

Manual feed is advised when using smaller documents.

Adjusting the catch tray

If a Catch Tray is being used for ejected envelopes, it should be adjusted
to suit the ejected envelopes.

1. Slacken knob under side guides, and adjust to 2mm clearance each side. Tighten
knobs.

2. Lift and pull backstop, adjust to suit ‘bounce’ of ejected envelopes.

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9 Operator Maintenance

General Cleaning

• Clean all paper transport rollers using water or recommended cleaning fluid, as
instructed by the service engineer.
• Clean all sensors with approved air dusters (both Transmitter and Receiver if
applicable. See section below).
• Clean all covers and touch screen.

Cleaning the sensors

Cleaning the sensors

The optical sensors consist of two halves: emitter and receiver. These can become
obstructed due to paper dust and should periodicaly be cleaned using a nonflammable
9
airduster (Part No. 9103707C). Both halves must be cleaned.
This section shows where the sensors are located. For most sensors, an indicator arrow
is pierced showing you where the jet of the airduster should be directed. For some sensors,

English
the retaining bush is visible next to the lens: ensure you spray into the lens, not the bush.

Cleaning the sensors of each module

Sensors are retained with a bush next to the lens: where this is
visible, ensure that you spray into the lens (arrowed), not the bush.

Insertion head

1. Open the perspex top cover and raise the collate clamshell (closest to the envelope
hopper) so that it locks in place.
Picture shown is viewed looking inside the collation area towards the envelope hopper

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2. Picture is viewed looking inside the collation area away from the envelope hopper.
Clean all sensors arrowed.

9
English

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3. Lower the collate clamshell and open the upper conveyor (furthest from the envelope
hopper) so that it locks in place.
Picture is viewed looking inside the collation area away from the envelope hopper.
Insert the airduster nozzle deep into the hole and spray liberally. Note the the upper
sensor half is not easy to see and is mounted on a bar.
Lower the conveyor.

9
4. Lower the side cover and raise the overguide inside the closer cavity, latching it in
place.

English
Clean the sensors arrowed.

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5. Picture is viewed looking down on the envelope hopper, at the front.

Clean the one-piece reflective sensor.

9 6. Lower the front output cover below the envelope feeder.

Clean the sensors indicated. Note that the upper sensor is in two halves. The lower
sensor is a one-piece reflective type.
English

Feeder
There is a sensor on the feed hopper of a feeder, and a pair located in the lower
conveyor section.

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1. Remove all paper from the feed hopper and direct the airduster into the cutout
indicated.

2. Open the side cover and push the lowermost lever forward to lower the conveyor.
9
Clean the sensor located next to the gearwheel in the centre of the track as shown,
with the upper half directly above it.

English

A single feeder is shown, twin-feeder is similar. Conveyor sensor

applies also to feederfolder.

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Feeder-Folder
There is a sensor in the front transport assembly on a feeder-folder, and another
two on the top. There is also one in the lower conveyor (see Feeder).
1. Raise the cover at the front of the feederfolder. Using the blue tab, release the latch
of the transport assembly and lift it upwards. Direct the airduster into the cutouts
indicated.
Ensure the lever is fully latched when closing.

9
English

2. Raise the top cover. Direct the airduster into the cutout (the lower sensor in the picture),
and into the gap to clean both halves of the upper sensor.

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Tower Folder
1. Open the folder top cover and clean the sensors indicated.
Direct the jet into the gap under the sensors, or into the hole indicated.

English

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2. Open the top cover open, direct the jet into the holes indicated.
Note: The sensors are in two halves, with the opposite halves located in the cover.

9
English

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Clearing paper jams

If paper jams occur, the area affected will normally be shown in the error message on the
screen. Use one of the clearance methods described below to clear the jammed paper.

Inserter Head
1. Open the side cover on the operator side of the machine, and lower the front sealer
cover.

English
Check for jammed paper in the open cavities.
If the paper is not fully visible, turn the blue knobs to wind it into view.
Open the front closer cover using the blue tab and check for jammed paper.

Feeder (Single and Twin) & Feeder Folder

1. Open the side cover on the feeder.

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Use the blue tabs to push forward the levers indicated to open the cavities and access
the jammed paper.
If the paper is not fully visible, turn the blue knobs to wind it into view.

9
Single Feeder is shown; Twin Feeder and Feeder Folder are similar.
English

Tower Folder
1. Open the side cover on the Tower Folder Base Unit.
Using the blue tab, open the folder assembly to access the jammed paper.
If the paper is not fully visible, turn the blue knobs to wind it into view.
When closing the folder assembly, ensure it is fully latched on both sides.

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Tower Unit
Using the release handle, open the top cover to access the jammed paper.
If the paper is not fully visible, turn the blue knobs to wind it into view.

English

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Maintaining the Wetter System

The Wetter system is supplied with sealing fluid:

• A 10-litre bottle of fluid is located in the stand and the tank is refilled automatically
by a pump.
Periodically, the wetter felt should be cleaned.
Open the side cover and withdraw the wetter tank by lifting the blue tab slightly and pulling
out the tank. Use a piece of absorbent material under the drain tube to catch any
drips.
Clean off any gum residues using a damp, lint-free cloth or stiff brush. If the wetter felt is
excessively worn and is not wetting the envelope flaps properly, it must be replaced.

9
English

Changing the jerrycan

The system uses a 10-litre jerrycan of Envelope Sealing Fluid located in the stand below
the Insert Head. When the fluid has run out, open the door and lift out the jerrycan. Unscrew
the top and withdraw the pipe. Fit the top back on to the new jerrycan and replace in the
stand.

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10 Technical Specification

Inserter head

Parameters
Pack thickness Maximum pack thickness is defined as the internal dimension of
a rigid opening that a filled envelope will fall through under its
own weight.

All envelope sizes: up to 6mm (¼”)

Pack clearance The minimum clearances required between the inserts and envelopes
are dependent on insert pack thickness.
Clearance is the total clearance and is defined as the difference between
the largest overall dimensions of the pack and the internal dimensions
of the envelope (see below). The required clearances are summarised
as follows: 10
Pack <3mm: Depth 6mm (¼”) Width 16mm (5/8”)
Pack >3mm <6mm: Depth 12mm (½”) Width 19mm (¾”)

English

Cycling speed DS-180i: Up to 4500 envelopes per hour (based on 1 x A4 folded sheet
into a C6/5 envelope).
DS-180i Prod. Pack: Up to 5500 envelopes per hour (based on 1 x A4
folded sheet into a C6/5 envelope).
Speeds for other conditions available on request.

Monthly volume DS-180i: Up to 150,000 filled envelopes per month.

DS-180i Prod. Pack: Up to 180,000 filled envelopes per month.
Envelope Hop- Up to 800 of 90gsm (24lbs bond)
per Capacity

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Envelope Minimum: 70gsm (18lbs bond)

weight Maximum: 100gsm (28lbs bond)
General envel- • Envelope to be good quality machine-fill type. Dimensions and
ope require- quality to be consistent across manufactured batches.
ments • Side seams must be securely glued to the top of the seam.
• Flap crease must be pre-scored to enable the envelope flap to
open flat.
• No glue seepage must be evident on interior or exterior of envel-
ope.
• Windows to be securely affixed to within 1.5mm (1/16”) of top and
side edges. Top edge to be flat and free from puckering.
Receiving tray Up to 300 filled envelopes (assumes 1 document inserted)
capacity (option-
al)

Envelope details

10
English

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10

English

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Envelope seal- Built-in wetter tank, automatically pump-fed by 10-litre jerrycan located
ing fluid in stand. Optional low-level float switch available.

10
Tower Folder
English

Parameters
Paper Size Minimum width: 140mm (5½”)
Maximum width: 228mm (9”)
Minimum length: 140mm (5½”)
Maximum length: 406mm (16”)
Note: The maximum suggested width difference between inserts is
32mm (1¼”): this may be increased subject to test. If this difference
is exceeded, the insertion fingers will not cover the edges of the narrow
insert and may cause insertion problems. Sandwiching a narrow in-
sert between two wider ones may resolve this.
Paper weight Minimum 60gsm (16lbs bond)
Maximum 120gsm (32lbs bond) for folded documents
Maximum 4mm thick for unfolded inserts (subject to test)

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Folding capa- C, Z or V-fold: 8 sheets 80gsm (20lbs bond)*

city Double-forward fold: 4 sheets 80gsm (20lbs bond)*
* Up to 2 x 8 split sets into one envelope dependent upon
pack thickness.
Fold lengths Fold Plate 1: 229mm Max, 48mm Min.
Fold Plate 2: 229mm Max, 50mm Min.
Fold Plate 3: 202mm Max, 50mm Min.
Hopper capa- Tower Folder can be ordered in 3 configurations as follows:
city
3 x 500 sheets of 80gsm (20lbs bond)
1 x 1000 sheets of 80gsm (20lbs bond)
1 x 500 + 1 x 1000 sheets of 80gsm (20lbs bond)

10
Daily mail Up to 8 sheets of 80gsm (20lbs bond) for C, Z or V fold, up to 4 sheets
of 80gsm (20lbs bond) for double forward fold. May be stapled or not.
Max. thickness of staple 3mm. Allowable staple positions are shown

English
below.

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Insert Feeder (Single, Twin & Reading)

Parameter
Insert Sizes Minimum width: 140mm (5½”)*
(Single Feeder) Maximum width: 241mm (9½”)
Minimum length: 76mm (3”) for module 1; 89mm (3½”) for following
modules
Maximum length: 152mm (6”)
*For individual items. Min. pack width: 210mm (8¼”)
Paper Minimum 60gsm (16lbs bond) min.
weight(Single/Read- Maximum 4mm (5/32”) thickness
ing Feeder)
Hopper capa- Up to 300 BREs or 150 2mm booklets
city Note: Quantities shown above are maxima. Depending upon other
conditions, actual quantities may be lower than those shown.
Insert Sizes Minimum width: 140mm (5½”)*
(Twin Feeder) Maximum width: 241mm (9½”)
10 Minimum length: 76mm (3”) for module 1; 89mm (3½”) for following
modules
Maximum length: 152mm (6”)
*For individual items. Min. pack width: 210mm (8¼”)
English

Paper Minimum 60gsm (16lbs bond) min.

weight (Twin Maximum 2mm (5/64”) thickness (top tray)
Feeder) Maximum 4mm (5/32”) thickness (lower tray)
Hopper capa- Up to 200 BREs or 100 2mm booklets
city Note: Quantities shown above are maxima. Depending upon other
conditions, actual quantities may be lower than those shown.
Requirements Enclosures must be flexible enough to suit path constraints.
Some enclosures may require special tyres.

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 | Page 95 | Nov-19-2019 09:38 | Technical Specification

Feeder Folder

Parameters
Depth: 140mm (51/2”) min. (89mm (3½”) for unfolded inserts)
406mm (16”) max. (139mm (5½”) for unfolded inserts)
Width: 140mm (51/2”) min. (Widths below 168mm (6.6”) require narrow envel-
ope kit A0023968).
229mm (9”) max.
Thickness: 60gsm (16lbs bond) min.
70gsm (18lbs bond) min. for OMR/Barcode paper
120gsm (32lbs bond) max.
Depth of output 89mm (31/2”) min.
doc: 152mm (6”) max.
Hopper capa- Up to 500 sheets of 80gsm (20lbs bond)
city:
Daily Mail: Up to 3 sheets (C or Z fold) or 5 sheets (V fold) of 80gsm (20lbs bond).
May be stapled or not, but staples on ‘Z’ fold only. Max. thickness of
staple 2mm. Allowable staple positions shown below. Note: all daily
10
mail forms must be the same length.
Note: Daily Mail is not available as an option if a CIS reader is fitted.

English

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 | Page 96 | Nov-19-2019 09:38 | Technical Specification

Mechanical & Electrical

Noise level: <73dbA (following ISO 11202).

Power Requirement and Voltage Tolerance:
230V / 50 Hz (voltage tolerance +10%/10%); 115V / 50/60 Hz (voltage tolerance +6%/10%)
Operating Temperature:
10 - 40 deg C (50 - 104 deg F)
Operating humidity:
30 - 80% RH
Electrical:

230VAC 115VAC
Frequency 50Hz 60Hz
Input Current Head: 1A Head: 2A
Single Feeder: 0.5A Single Feeder: 1A
Twin Feeder: 0.5A Twin Feeder: 1A
10 CIS Feeder: 0.5A CIS Feeder: 1A
Tower Folder: 1A Tower Folder: 2A
PC & Monitor: 1.2A PC & Monitor: 2.4A
English

Display Properties:

Screen Size: 22”

Screen Resolution: 1920 x 1080 pixels, full HD
Screen Technology: Full Color Touch Screen

Processing Speed:

Machine
DS-180i 4500 filled envelopes per hour.
DS-180i Prod. Pack. 5500 filled envelopes per hour.

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 | Page 97 | Nov-19-2019 09:38 | Technical Specification

Dimensions and weight

Module Depth (mm) Width (mm) Height (mm) Weight (kg)

Inserter head 471 1063 612 80
(excl. monitor)
Inserter head 525 - 812 -
(incl. monitor)
Single Feeder 471 408 514 28
Reading Feeder 471 408 554 34
Twin Feeder 471 408 695 43
Feeder / Folder 471 408 710 45
Tower Folder 471 875 917 92

10

English

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 | Page 98 | Nov-19-2019 09:38 | Technical Specification

Ambient light
Although the machine may operate in sunlight, it is not designed for use in direct sunlight,
or where sunlight is exposed to the machine through windows or skylights. The light-sensitive
sensors can be affected in these conditions. It is therefore recommended to:
1. Locate the machine out of direct sunlight
2. Protect the machine from direct sunlight using blinds or similar blocking devices.
If the machine can only be located where it may be exposed to direct sunlight, then please
contact Technical Support department, who may be able to advise on the use of blocking
material on the inside of the Perspex cover where necessary.

1. All stationery should be allowed to acclimatise near the

machine for at least 24 hours before use to prevent rapid
absorption of moisture in the material, or condensation forming
on the machine. Failure to acclimatise the material may cause
pre-gumming of envelopes or otherwise impair machine
performance.
2. The machine will function with humidity levels lower than 30%
RH, but high levels of static may be generated, impairing
machine performance.
3. The machine will function with humidity levels higher than 80%
10 RH, but moisture absorption into the material may impair
machine performance.
4. Condensation must not be present under any circumstances.
5. The machine will function at temperature levels above 28 deg
English

C (82 deg F) and below 18 deg C (64 deg F). However,

temperature levels outside these limits may impair the machine
performance.
6. Material processed directly from laser printers may have high
levels of static causing material to stick together. If double
feeding occurs, then Hi-Grip separators may be required -
contact IPSS department.

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11 Glossary of terms

Glossary of terms

Term Description
Address carrier The address carrier is the document that
carries the address of the person for who the
mail set is meant. The address carrier can
consist of one or more sheets, from which
at least the first sheet must contain the ad-
dress. The address must remain visible while
enclosures are added and the document set
is folded. The fold type and selected envel-
ope must ensure that the address is visible
behind the window in the envelope. For per-
sonalized mailings there is always an ad-
dress carrier present as long as envelope
printing is not supported. Normally there is
one address carrier.
Address position 11

English
Position of the address on the address carri-
er, measured from the upper left corner. The
address position consists of a horizontal x
coordinate, a vertical y coordinate, a horizont-
al width w and a vertical height h.

Automatic The feature of an inserting system to auto-

matically determine its job settings by
measuring the sizes of documents and envel-
ope. From all feeders that are loaded one
sheet will be taken. Based on the maximum
document length (which is also the length of
the document set) and the length of the en-
velope the fold type is determined.

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Automatic job A job that is created with the Automatic job

functionality.
Barcode Reading (BCR) Barcode Reading is intended for reading and
interpreting printed barcodes. The codes give
information to the inserting system about
how to build-up and handle a set.
Business Reply Envelope (BRE) Envelope included in outgoing mail sets for
addressee response purposes.
Cascading See Feeder linking.
C-fold See Letter fold.
Daily Mail Capability of an inserting system to manually
insert mail sets one by one into the system,
which are then inserted into an envelope.
Optionally, depending on settings, additional
enclosures can be added and the mail set
can be folded. This function is intended for
small amounts of mail that each can have a
different build-up.
Deskew A system of straightening a skewed docu-
ment or enclosure by driving it into a set of
11 drive rollers that have been briefly stopped.
This removes the skew, and after a set peri-
od of time, the rollers restart. Deskew slows
the machine down and can be disabled or
adjusted for amount of deskew for forms that
English

are not prone to skewing.

Document A document is one of the components of a
mail set. A document can consist of one or
more sheets. Documents can be divided into
address carriers and enclosures. For person-
alized mailings there is always one address
carrier and an optional number of enclosures.

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Document set The document set is the physical collection

of address carrier and enclosure(s) that is
under production in the inserting system. The
document set is completed during production
and is to be inserted into the envelope. The
number of enclosures can range from 0 to
the limit imposed by the number of available
feeders, whilst observing the overall pack
thickness. Once the document set has been
inserted into an envelope it is called mail set.
Double Document Detection Double Document Detection is the sensor
that measures the thickness of a sheet to
check if the inserting system does not acci-
dentally take more sheets than intended. DD
sensors exist on feeders (double sheet de-
tection). Currently DD detection on Neopost
inserting systems perform relative measure-
ments, which means that they need a cycle
to ‘learn' the thickness of a sheet. Also the
length of the document is measured so partly
overlapping sheets will be detected.
Double parallel fold The double parallel fold is a type of fold
where the document is first folded halfway 11
and the resulting folded set is again folded
halfway. This fold is illustrated in the picture
below. The position of both folds is ad-
justable.
English

Envelope The envelope is the packaging of a mail set.

Window envelopes are envelopes that have
a transparent section through which the ad-
dress on the address carrier can be read.
Besides the normal top closing window en-
velopes there are also bottom closing envel-
opes.

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Face down Situation in which the front of a sheet is fa-

cing downwards when placed in a document
feeder.
Face down leading Situation in which the front of a sheet is fa-
cing downwards and the top of the sheet is
closest to the separation unit in a document
feeder, ie. the front end of the tray
Face down trailing Situation in which the front of a sheet is fa-
cing downwards and the bottom of the sheet
is closest to the separation unit in a docu-
ment feeder, ie. the front end of the tray.
Face up Situation in which the front of a sheet is fa-
cing upwards when placed in a document
feeder.
Face up leading Situation in which the front of a sheet is fa-
cing upwards and the top of the sheet is
closest to the separation unit in a document
feeder, ie. the front end of the tray.
Face up trailing Situation in which the front of a sheet is fa-
cing upwards and the bottom of the sheet is
closest to the separation unit in a document
11 feeder, ie. the front end of the tray.
Feeder A feeder is a module for the input of docu-
ments to the inserting system. The feeder
separates documents sheet by sheet from
English

the stack of documents in the feeder tray.

Feeder linking (Cascading) The ability to load two feeders with the same
document type where the inserting system
automatically switches to a second feeder
when the first feeder is empty and vice versa.
In the mean time the first feeder can be re-
filled, so the inserting system can keep run-
ning without having to stop for refilling the
feeders.
Feeder tray Part of the feeder that contains the stack of
documents or envelopes.

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Flexcode OMR An OMR code for which the meaning of the

OMR marks can be programmed in a dedic-
ated way for a specific customer. This is
normally used to support the OMR codes
from other suppliers
FlexFeed® The flexFeed® is the feeding part of the
system.
High Capacity Feeder Feeder that has a capacity up to 1000 sheets
(on a Tower Folder).
Insert • To insert is the action of inserting a
document set into an envelope.
• For native English speaking custom-
ers an insert is also a short document,
not to be folded, usually an enclosure.
Inserter An inserter is the module where the docu-
ment set is inserted into the envelope, the
envelope is closed and if necessary sealed.
Inserting system The system of all the modules that cooperate
to perform the inserting function (accumulate
document set, fold and insert) and have a
single point of control.
InsertnFrank™ (mailing system) Interface for the Neopost franking system.
11
Job A job is an actually produced collection of
mail sets based on a certain job definition at
a certain point in time for a specific purpose.
It consists of: English
• The job definition used for the produc-
tion
• Information about the batch size
Job counter The counter that registers the number of mail
sets that is produced as part of a specific
job.
Letter fold (also known as C-fold) Fold type in which a document set is folded
twice in which the folded flaps are on top of
each other. This fold is illustrated below. The
position of both folds is adjustable.
Linking See Cascade
MaxiFeeder™ Feeder with high capacity feeder tray.

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Multiples The feature of an inserting system in which

more than one sheet is taken from a feeder.
OMR Optical Mark Recognition (see further table
entry).
OMR code definition Standard 1-track OMR code definition. Spe-
cifies the amount of reading marks used and
the functionality linked to each of them (how
each should be interpreted). A definition is
a licensed option.
Operator The person operating an inserting system.
Optical Mark Recognition Optical Mark Recognition is intended for
(OMR) reading and interpreting printed codes.
These codes are one or more black marks
which are read from a document. These
marks give information to the inserting sys-
tem about how to build-up and handle a set.
Output Conveyor Fitted at the output for filled envelopes to be
ejected onto. Higher capacity alternative to
a receiving tray. 2 lengths are available.
Pod/Tower Unit The feed hopper unit fitted to a Tower Folder.
11 Available with either 3 x 500-sheet trays, 1
x 500-sheet + 1 x 1000-sheet trays or 1 x
1000-sheet tray.
Reading error Condition in which the system could not reli-
English

ably read or interpret the OMR reading marks

or barcode from a sheet.
Reading marks Marks added to documents containing finish-
ing instructions that can be identified by an
reading head and interpreted according to
the used OMR code definition.
Receiving tray Fitted at the output for filled envelopes to be
ejected into. Basic alternative to an Output
Conveyor.
Remote diagnostics The feature that makes it is possible to ana-
lyze a problem on an inserting system from
a remote location.

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Service engineer Technical engineer whose task it is to resolve

problems with systems in the field. Besides
dealing with problems, service engineers are
also responsible for preventive maintenance.
Single fold A single fold implies the document set is fol-
ded once. The fold position is adjustable.
This fold is illustrated below:

Stop counter Counter which sets the amount of envelopes

to be filled. After filling this amount of envel-
opes the system will stop.
Supervisor Person who is responsible for the technical
state of the system. Normally a supervisor
has access to programming functions, which
are restricted for standard users.
Test run A test run is intended to validate the settings
of the inserting system:
• Inspect and adjust the stop position of
the envelope. 11
• Check the fold settings for one set.
• Check whether the address is correctly
positioned behind the envelope win-
dow. English
Tray (or hopper) Contains a stack of paper for a printer or in-
serter. This paper is supplied to the system
for further processing.
Vertical transport The vertical transport section between hop-
pers and folder/ collator below .

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Z-fold (also known as zigzag fold) A Z-fold means that a document is folded
twice in such a way that each folded flap is
on a different size of the folded document,
resulting in a Z-shape. This fold is illustrated
below.
The position of both folds is adjustable.

11
English

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12 INF Output Conveyor - ap-

pendix

Introduction

Introduction

With this conveyor you have an ouput device intended for use with a DS-180i Series
folder/inserter. It provides a means of receiving filled envelopes and turning certain sizes
through 90º in order to correctly orientate them for subsequent franking operation: this is
mainly applicable to C4 envelopes, and C5 with vertical windows. Its operation is
programmed within IMOS and is job-specific.
In order to ensure the long usage of this machine and its components, and above all the
safe use of the machine, you must read and adhere to the operating instructions and safety
notes. Always be aware of all warnings and notes that are mounted or noted on the machine
itself.
All persons entrusted with the handling of this machine must also be familiar with the
operating manual. Save this handbook carefully, so that the information it contains may be
available at all times.

Description of machine 12
Machine options English

The function of the INF Output Sorter is to receive mailpieces from a DS-180i Series
folder/inserter and direct them to two or more output paths, eg. Output Conveyors.
An INF Conveyor can also be fitted, either in conjunction with the Output Sorter or
individually, to direct mailpieces to a franker.

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Sorter – Up to 2 Sorters can be fitted with 3 Output Conveyors.

INF Conveyor – Conveyor for delivering mailpieces to a franker. Can be fitted to a

Sorter output or on its own.

12
English

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Description of INF Conveyor

The function of the INF Conveyor is to receive mailpieces from a DS-180i Series inserter
and feed them into a franker.
The INF Conveyor can be fitted to the inserter exit or to an exit from an Output Sorter.

The operation of the machine is job-specific and is programmed within IMOS.

The machine can be used in a number of configurations:
• With a franking machine alone.
• With a franking machine and feeder.
• With a franking machine, feeder, scale and franker conveyor.
• Any of the above with an output conveyor, either straight or side-on.
See the following page for configuration layouts.

Layout Configurations

Shown below are examples of INF Conveyor configurations. Please note that other
configurations are possible.
12
English

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Setting up the machine

INF Conveyor adjustments

Backstop

If the INF Turner is fitted directly to the Inserter exit, an adjustable Perspex backstop will
be attached. This must be correctly set to that as the envelopes ‘bounce back’ after contact,
the opposite edge aligns with the datum side-guide on the other side.

12
English

The angle of the conveyor will further assist in alignment with the datum side-guide.
The backstop is not fitted when the INF Turner is fitted to a Sorter.

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Sorter adjustments

Catch Tray
The Sorter can be optionally fitted with a catch tray at either exit. This receives the envelopes
in a stack to allow subsequent hand removal. It is adjustable to suit a variety of envelope

ze
si.

Using the machine in IMOS

Using the machine in IMOS 12

The DS-180i with INF Conveyor/ Sorter must be switched on English
in the following order:
1. INF Conveyor and/or Sorter (plug the power supply in).
2. DS-180i Inserter (wait for Ready message on screen).
3. Franker system (wait for its startup routine to finish.

When the machine is running, the following must be observed.

• If communication is lost between the DS-180i and the Franker, an error message on
the DS-180i screen will instruct you to turn the Franker off and on. Before switching
back on, check the Franker screen to ensure it is off - it may take some seconds.
• When the DS-180i stops, the Franker will run on for a longer period. To stop it sooner,
press the Pause button on the DS-180i screen.
• Periodically, the Franker base unit will need to update information: this will cause a
delay in the startup routine.

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Mail Sorting

Mail sorting allows weight groups to be defined and added to a numbered Mail Sort, which
can then be directed to a particular exit. It applies only when one or more sorters are fitted,
which may optionally also be fitted with 1 or 2 conveyors.
A Mail Sort is part of the Postal Product and is a set of criteria than determines how the
mail pieces within it are treated when they reach the sorter. The criteria are the Weight
Group and Exit Selection OMR mark (or BCR character): these two criteria use a priority
basis to determine the exit at the sorter.
In addition to weight groups, an Exit Selection mark or character can be used to differentiate
12 Mail Sorts. If weight groups are being used, these must first be defined and named in
a Postal Product. This is carried out in the Menu screen.
The example below shows the maximum configuration of 2 sorters and 3 output conveyors.
English

Postal Products
1. Select Postal Products in the Menu screen.

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2. Select Create New (or Edit for an existing Postal Product).

3. Set the weight groups as required - note that the minimum weight of each group is the
same as the maximum weight of the previous group.

The Postal Product list can be ordered by Name or Date Created.

12
Mail Sorts
English
1. In the Mail Sorting part of the Output Settings screen, select the Mail Sorting button.

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2. Select options as described on the following page.

3. Select the Postal Product defined in step 1 of "Postal Product".
4. Select the Sort Criteria, and then the required Mail Sort associated with it (by default,
the last Mail Sort selected will be used).
5. Set the priority required for each line. As each Mail Sort can have a number of
12 combinations of criteria, some of which may overlap, you can determine which has
priority.
The example above shows Weight Group 1 and Exit Selection marks 1 & 2 are all
contained in Mail Sort 2; you could change the priority so that mailpieces with Exit
English

Selection Mark 1 have priority over those in Weight Group 2 instead of the priority
they currently have.
Select any priority number to switch on the scroll arrows. After making changes, select
a number again to switch them off.
Select Save when you have finished: your Sort Settings are now saved to the Postal
Product.
6. If Batching is being used, select the Settings button.
Batching for Sorted Mail is the same as for Unsorted Mail, described in Output settings
on page 116.

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Output Placement

Your settings may be different from those shown here, depending

upon the hardware fitted.

Output Placement allows you to determine which exit each Mail Sort is directed to.

12

1. Select the Ouput Placement button in the Output Settings screen.

English
2. To change a Mail Sort (or Unsorted Mail) from one exit to a different one, select it,
then select the new position. If you want to reset your changes to the default position,
select Auto place mail sorts.
Output Settings are now complete.

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Output settings

See also the chapter "Creating a job on page 32" for full details of
creating/editing a job.

The Output Settings in the job control how the INF Output Sorter is used. The settings are
defined when the job is created, or can be added or changed later by editing the job.
Output settings are described below and assume that the envelope, document and
enclosures have already been set up.

1. Select Settings for Unsorted Mail in the Output Settings screen.

12
English

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2. Set Batching to Batch On if required and set required quantity in Batch Quantity.
Set Batch Mode as follows:
• Batch and Continue: Machine will pause for the specified pause time, and then
resume.
Note: conveyor will continue to run during the pause time.
• Batch and Stop: Machine will stop and resume only when the Run button is
pressed.
Select Envelope Count under Batch Control, currently the only available option.
Set the Batch Complete Pause Time as described in Batch and Continue above.
When settings are complete, press the Save button.
3. If a conveyor is fitted, select Conveyor Settings to adjust the Jog functions as follows:
• Single Jog Adjust: Adjusts default jog step (gap) between mailpieces. Note
that steps are unitless.
• Batch Complete Jog Step: Adjusts gap before machine performs action
described in ‘Batch Mode’.
• Mark Reading Jog Step: Adjusts gap created after Jog mark is read.
• Autoend Jog Step: Adjusts gap created before machine autoends.
When settings are complete, press the Save button.

12
English

Output Settings for unsorted mail is now complete. If you are using Mail Sorting, see Mail
Sorting.

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Franking

If a franker is fitted, you must define which Mail Sort it is being used for, and select its
settings.

1. Select the Franking button in the Output Settings screen.

12
This option will only be available if a franker is fitted.
English

2. Choose which Mail Sort (or Unsorted Mail) that the franker is to be used for.

Mail Sorting must be set to Yes.

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3. Select the Settings button and adjust settings as described below:

Franker Control: Select Not Used (franker is switched off), Dumb (franker is under
manual control), Pass Through (envelopes pass unfranked) or Franking Machine
(franker is under control of inserter and will frank when envelopes pass).
Franking Job: Select preset job (if available) or the Current Job that the franker is
programmed with.

If an IS-5000/6000 Franker (with integral conveyor) is fitted to the

INF Conveyor, its print heads will park after a period of inactivity,
such as the DS-180i not running, or envelopes being sorted but
not fed to the franker.
When this occurs, the next envelope that is fed to the franker will
be held at the exit of the INF Conveyor for about 10 seconds while
the print heads unpark. The system will then continue operating as
normal.

Operator Maintenance

Cleaning Sensors

The machine uses optical sensors to track the movement of mailpieces along the paper
path. These sensors must be regularly cleaned to prevent false readings.
The sensors are in 2 halves, upper and lower: both halves must be cleaned. They are fitted
12
only to the Sorter; locations are indicated below. Use a non-flammable airduster (part
number 9103707C), spraying liberally onto each lens – direct the nozzle upwards for the
upper half. English

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 | Page 120 | Nov-19-2019 09:38 | INF Output Conveyor - appendix

INF Conveyor Sensors

There is only one sensor fitted to the INF Conveyor, on the output edge just before the
franker.

The Output sensor is a one-piece reflective type.

Cleaning the conveyor belt

Staining or soiling of the conveyor belts on the INF Conveyor and Sorter may occur after
12 a long period of use. To clean the belts, a lint-free cloth dampened with water will normally
be sufficient. For more stubborn soiling, a foam-type surface cleaner can also be used.

To avoid damaging the belts, do not use strong, spirit-based

cleaners.
English

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Technical Specification

Physical sizes

O/A Sizes: 1600mm (63”) Length (including backrest)

420mm (16½”) Width
435mm (17”) Height
Weight: 25.5Kgs (56lbs)
Speed: 4m/minute Max. Linear Speed (controlled by inserter)
Selectable jog function for batching.

Electrical

Electrical Voltage: 24VDC (supplied via DIN lead from inserter)

Rating: Power: 12W Max.
Fuse: N/A
12
English

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Troubleshooting Guide

Troubleshooting Guide

If operating problems cannot be resolved using the following guide, the Technical
Department must be contacted for further assistance.

PROBLEM SUGGESTED CAUSE AND REMEDY

1. Envelopes not franking. 1. Ensure ‘Franker Control’ is set to ‘Franking
Machine’ and a franking job is selected.
(Franking on page 118).
2. INF Conveyor is not moving. 2. Check DIN lead is properly connected to
inserter.
3. Envelopes failing to contact datum edge 3. Perspex backstop is set too far away to
side-guide and failing to turn when they allow sufficient ‘bounce-back’ (INF Conveyor
should. adjustments).
4. Envelopes failing to turn properly. 4. a) Ensure adjustable panel is lowered
when turning envelopes (INF Conveyor ad-
justments).
b) Clean conveyor belt surface (Cleaning
the conveyor belt on page 120).
12 5. Envelopes ejecting from wrong exit. 5. Ensure exit is allocated correctly in Output
Placement on page 115.
6. Envelopes with unexpected Sort Criteria 6. Ensure ‘Priority’ is correctly set in Edit -
English

are exiting. Sort Settings dialog (Mail Sorting on page

112).
7. Envelopes failing to leave Sorter properly. 7. Clean conveyor belt surface (Cleaning the
conveyor belt on page 120).

122