General Specifications

Transcription

1 Contents GENERAL SPECIFICATIONS FOR INTELLIGENT MAILING SYSTEMS Introduction...Page 2 Cut-Sheet Feeders...Page 3 Insert Feeder...Page 4 On-line Feeder Folder...Page 5 On-line Insert Feeder...Page 5 Flat Material Feeder...Page 5 Accumulator Folder...Page 6 Speeds / Volume...Page 7 Cycling Speed Control...Page 8 Envelope Specification...Page 9 Insert Pack...Page 10 Electrical Specification...Page 11 Physical Data...Page 14 Machine Weights...Page 15 Heat & Humidity Data...Page 16 Important Notes...Page 17 Print Sequence & Paper Orientation...Page G3 Series General Specifications Issue 1 September 2013 Page 1

2 Introduction The DS-1200 G3 is the third generation of the DS-1xxx high-volume folder/inserter and has significant technical differences over its predecessor. These differences are detailed in this General Specification which supersedes all previous versions. Please note that Barcode and OMR specifications are the subject of separate documents. See also DS-1200 G3 Barcode Specifications DS-1200 G3 OMR Specifications 1200 G3 Series General Specifications Issue 1 September 2013 Page 2

3 Cut sheet feeders (Hi-Cap & Standard-Cap) for folder and accumulator/folder Depth: 178mm - 406mm (7-16 ) Width: 140mm - 225mm (5 1/2-8 7/8 ) Weight: 70gsm (18lbs bond) minimum 130gsm (32lbs bond) maximum Hopper capacity: (Standard-Cap) Up to 2000 sheets 80gsm (20lbs bond) (Hi-Cap) Up to 5000 sheets 80gsm (20lbs bond) per trolley (second Hi-Cap trolley provided for off-line loading) Glossy, lithographic and lightweight material acceptable, subject to test (applies to all glossy and non-standard stock & paperweights below 80gsm (20 lbs bond)). Non-standard materials may require lower machine speeds to allow reliable processing. Single sheet folding from 70gsm (18lbs bond) minimum to 130gsm (32lbs bond) maximum. 3-plate buckle folder with fully automatic fold plate settings, including auto address adjustment. Fold plate limits: Notes: 53mm (2 ) minimum for all fold plates 230mm (9 ) maximum for fold plate 1 155mm (6 ) maximum for fold plates 2 & 3 1. Special optional long fold plate (220mm) available for fold plate Fully automatic separator settings and double document calibration. 3. OCR/OMR/Barcode/2D Hi Cap Feeder Reader Folder also available with top or bottom reading. 4. Folders use SBR (Styrene Butadiene Rubber) material for the folding rollers. This material is the most effective for longevity against the materials and chemicals being used in the mailing industry. Chemical attack of the fold rollers causing swelling or premature failure is considered to be the responsibility of the customer, either to replace fold rollers or to stop using the chemicals identified as the cause of the problem. 5. Ultrasonic doubles detection available to enhance doubles detection of:- Heavy colour printed materials. Variable (page to page) colour printed materials. Mixed thickness feeding (any thickness variation within the above range can be detected provided it can be passed through the separator) G3 Series General Specifications Issue 1 September 2013 Page 3

4 Insert Feeder: Depth: Width: Weight: Insert thickness: 85mm - 152mm (3 3/8-6 ) for Stations 2, 4, 6 etc. 70mm - 152mm (2 3/4-6 ) for Stations 1, 3, 5 etc. 140mm - 241mm (5 1/2-9 1/2 ) for Station 1 only 140mm - 225mm (5 1/2-8 7/8 ) for Station 2 onwards 70gsm (18lbs bond) minimum 4mm maximum Glossy, lithographic and lightweight material acceptable, subject to test (applies to all glossy and non-standard stock & paperweights below 80gsm (20 lbs bond)). Non-standard materials may require lower machine speeds to allow reliable processing. Hopper capacity: (inserts): Up to 2000 of 80gsm (20lbs bond). (envelopes): Up to 1000 of 80gsm (20lbs bond). Length of available track: 500mm (19.5 ) Hopper loading: Hopper can be back-loaded while machine is running. OCR/OMR/Barcode/2D also available with bottom read only. For wide documents greater than 216mm (8½ ) wide it is necessary to offset the left-hand side guide further to the left by approximately 10mm. This can be done by a technician and will not affect any other feature of the feed unit or machine. This usually carried out for #9 BREs where the additional width would otherwise cause unreliable mailing. Notes 1. Mechanical doubles detection available to enhance doubles detection of:- Heavy colour printed materials. Variable (page to page) colour printed materials G3 Series General Specifications Issue 1 September 2013 Page 4

5 On-Line Feeder Folder: Depth: 149mm - 406mm (5 7/8-16 ) Width: 140mm - 225mm (5 1/2-8 7/8 ) Weight: 60gsm (16lbs bond) minimum 130gsm (32lbs bond) maximum NOTE: 60 gsm material is subject to test and will reduce the machine speed dependent on quality. All other details as per Hi Cap Feeder Folder. On-Line OMR/Barcode Feeder Reader Folder also available with top and bottom reading. On-Line Insert Feeder: NOTES: Depth: 89mm - 152mm (3 1/2-6 ) 1. All other details as per standard Insert Feeder. 2. On-Line OMR/Barcode Insert Feeder is also available with top and bottom reading. 3. All Feeders can also be fitted with Turnover unit to invert the print sequence. Flat Material Feeder: Specification as for Feeder except for the following: NOTES: Weight: 80gsm to 6mm thick books Material type: All material types including stiff or rigid material. 1. All documents greater than 4mm in thickness are subject to test to confirm acceptability, settings and processing speed. 2. Single thickness material of 150gsm or thinner is subject to test to confirm acceptability, settings and processing speed. 2. Mechanical doubles detection available to enhance doubles detection of:- Heavy colour printed materials Variable (page to page) colour printed materials Thick materials (above 0.5mm) Curled Stationery (all feed units) Curled stationery caused by either the print process or storage conditions may cause failure to feed, or skewed feeding. NTL will make every effort to help customers resolve feeding issues. However, feed problems caused by curl in the stationery are the responsibility of the customer G3 Series General Specifications Issue 1 September 2013 Page 5

6 Accumulator Folder Feeder Accumulator Folder (with Hi-Cap or Standard-Cap feeder, single On-Line Interface with Feeder Folder, or 2-Up On-Line Interface with Feeder Folder) Fully automatic separator settings and double document calibration. Depth: 89mm - 406mm (3 1/2-16 ) Width: 149mm - 216mm (5 7/8-8 1/2 ) Max. number of forms: Up to 8 of 80gsm for folding, in C, Z or V fold up to (5 in C or Z fold recommended) Up to 20 for oversize group diverting, 9 recommended. Maximum processing speed 20,000 or 26,000 forms per hour. Barcode / OMR reader: 2D (Datamatrix): 2D (all code types): All Codes: Scanning reader head, top or bottom read. Dedicated 2D Datamatrix reader available. Multiread manually adjusted camera available. Autoread fully automated camera available. Mark Orientation: Mark Size: Diverter (if fitted): Diverter Capacity: Vertical or horizontal. All commonly used OMR marks acceptable. Refer to OMR and Barcode specifications, available separately. 2 bin diversion without stoppage. Forms accumulate in correct order. 250 sheets per bin Form Security Full security checking on barcodes and OMR marks, using (when selected) form security, group security, matching and match on ID field (barcode only). Note: If full security checking is required, one or more of these methods must be used, not total reliance on doubles detection. The latter should only be regarded as first-line security, and its reliability will depend upon similarity of paper weight, colour and ink density. The Technical Support department should always be consulted when the possibility of doubles misreads may occur. AIMS (Automated Insertion Management System) Full data logging and Data management systems available through the AIMS software solution G3 Series General Specifications Issue 1 September 2013 Page 6

7 Speeds/Volumes Cycling Speed and Production Rate: At a cycling speed of 12,000 cycles per hour a production rate of 7,500 filled envelopes can be expected, with 1 C folded document plus 1 insert (includes hopper refill time). Note that cycling speeds for G3 are controlled by licences for both the inserter and accumulator. Refer to the table in the section Cycling speed control for cycling speed details. The production rate is in a similar ratio to the cycling speed for most applications. Note: In certain cases the software and firmware will automatically reduce the cycling speed to accommodate particular configurations and material types. This is particularly true for large envelope formats as follows:- 1. Envelope depths greater than 163mm. Machine speed reduced to speed 13 (circa 11,000cph cycling speed with a single A4, half folded page). 2. Envelope depths greater than 160mm AND a flap depth greater than 45mm. Machine speed reduced to speed 13 (circa 11,000cph cycling speed with a single A4, half folded page). 3. Envelope depths greater than 125mm AND IJ series (WJ Pro) Franker fitted. Machine speed reduced to speed 13 (circa 11,000cph cycling speed with a single A4 or letter, half folded, page). Volume: Typically 750,000 filled envelopes per month. Higher voulumes achievable, subject to workflow organisation, shift work and associated service and maintenance schedules. Fold Rollers: Folders use SBR (Styrene Butadiene Rubber) material for the folding rollers. This material is the most effective for longevity against the materials and chemicals being used in the mailing industry. Chemical attack of the fold rollers causing swelling or premature failure is considered to be the responsibility of the customer, either to replace fold rollers or to stop using the chemicals identified as the cause of the problem G3 Series General Specifications Issue 1 September 2013 Page 7

8 Cycling Speed Control The DS-1200 G3 allows the independent speed control of:- The inserter (8k, 10K & 12K filled envelopes/hour) The cut-sheet accumulator channel (20K or 26K sheets/hour) The independent speed control allows the following process flexibility* The DS-1200 G3 is licensed for speed control. All machines can be upgraded in speed by obtaining a higher licence level. *Values given in this introduction are not absolute and are only provided as a guide to cycling speed/production output. Actual performance is dependent on material, setup, process control, etc G3 Series General Specifications Issue 1 September 2013 Page 8

9 Envelope Specification Max. 171mm (6¾") Min. 89mm (3½") 20º Maximum Max. 255mm (10") - Min. 171mm (6 3/4") Max. 62mm (2½") Min. 25mm (1") Max. 25mm (1")* Min. 9mm (3/8")* * Note that insert finger position is dependent on throat dimensions. Job to job variations could require different settings. Envelope Requirements: Weight: 80gsm (20lbs bond) minimum. Envelopes to be good quality machine-fill envelope. Dimensions and quality to be consistent across manufactured batches. 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. Windows to be clear (completely transparent) if output reading is required. (If window is made from recyclable material and is translucent, then it is subject to test). Side seams to be securely glued up to top of seam. Position of internal side seams to give a recommended 5mm (3/16 ) clearance or overlap to the edge of any insert. Pre-scored flap crease to enable the envelope flap to open flat. No twisting, curling or distortion evident. No glue seepage on interior or exterior of envelope. Paper smoothness: Sheffield units. Large printed areas require approval from the Technical Support Dept. Envelopes not meeting the above requirements may be acceptable, subject to testing and approval by Technical Support Dept. Envelopes not meeting the above requirements may affect machine performance. Thick packs are often difficult to eject when run in combination with thin pack work. To overcome this, additional transport wheels and tyres are provided with each machine; these allow the user to increase the amount of drive for the wetter. The wheels/tyres replace the plain rollers on the the wetter carrier assembly A2661A G3 Series General Specifications Issue 1 September 2013 Page 9

10 The 1200 is fitted with semi-automated finger settings which the operator is advised to set for specific envelope throat depths. For Z folded material, the fingers should be set further into the envelope by 5mm. Insert Set (contents of envelope): Max. Set Depth: Max. Set Width: Max. Set Thickness: 160mm 241mm 8mm (uncompressed, and after inserting in envelope) Where the insert is greater in depth than the folded prime document, this must be by no more than 7mm. Insert Set Clearances (recommended): Width Clearance = 2 x Thickness of contents, then add 16mm. Minimum total clearance = 19mm, maximum = 32mm. Example: For 5mm thickness of contents: Envelope width = Insert set width + 26mm Depth Clearance = Thickness of contents, then add 8mm. Example: For 5mm thickness of contents: Envelope depth = Insert set depth + 13mm Insert Set Width Variation: The maximum difference in width between all documents of the insert set must be less than 60mm. Important: Most envelopes within these specifications will be suitable, but final acceptability of any envelope is subject to test. Hopper Capacity: Up to 2000 envelopes 80gsm (20lbs bond) G3 Series General Specifications Issue 1 September 2013 Page 10

11 Electrical Specification Input Voltage 60Hz or 50Hz (± 10% maximum) Power Connector Machine fitted with BS A IP44 industrial free plug connector, conforming to EN & 2 and CEE17. Mating socket required at supply source. Notes: 1. For 115v supplies with rated current greater than 15A it is acceptable to replace the supplied plug with a NEMA L14-30 (4-pin device), or a 3-pin higher current rated device, wired to achieve 230V (X and Y, or Live and Neutral pins are hot with respect to ground). The connector used must comply with UL requirements and have a UL reference number. Note that both Live and Neutral are fused in the machine. 2. For countries using 230V who wish to change away from the supplied plug please note that the replacement device used must have a rated current carrying capability greater than 30A and meet all safety requirements for that country. 3. Changing the supplied plug negates any responsibility of the Company for the safety integrity of the machine. 4. Changing the supplied plug must be carried out by a qualified electrician. 5. If 2 x Hi-Cap Feeder Folders, a Hi-Cap and a Std-Cap Feeder Folder or an OMR/Barcode Feeder Reader Folder with any other unit are located next to each other on the same track pair, it is necessary to order and fit an additional power supply kit to ensure correct operation. See following page for details of current ratings G3 Series General Specifications Issue 1 September 2013 Page 11

12 Current Rating: RATED CURRENT Head 6A 3A Track Pair 2A 1A Insert Feeder 2A 1A Std-Cap Feeder Folder 2A 1A Hi-Cap Feeder Folder 2.5A 1.25A Std-Cap Accumulator 1 4A 2A Hi-Cap Accumulator 1 5A 2.5A Vertical Stacker 2A 1A Typical Sytem Total A 12.75A Max. Allowable Rated Current 30A PEAK CURRENT 30A Any System Rated Current + 6A Rated Current + 3A Max. Peak Current 36A 33A See also Standby Power Consumption on the following page. 1 Std-Cap/Hi-Cap Feeder Accumulator Folder comprises: Accumulator Unit OMR/Barcode 2D Reader Std-Cap/Hi-Cap Feeder Folder 2-Bin Divert 2 Typical system (8 station) comprises: 115v 230v Head Qty. 1 6A 3A 2 Station. Module Qty. 4 8A 4A Insert Feeder Qty. 5 10A 5A Std-Cap Feeder Folder Qty. 1 2A 1A Hi-Cap Feeder Folder Qty A 1.25A Hi-Cap Accumulator Qty 1 5A 2.5A 33.5A 16.75A 1200 G3 Series General Specifications Issue 1 September 2013 Page 12

13 STANDBY POWER CONSUMPTION UNIT DESCRIPTION Power (Watts) Comment Head Power Suppply Track Pair + 2 Feeders* Power Supply Track Pair + 2 Folders Power Supplies Vertical Stacker 55 IMOS PC 94 LIS PC 90 Total (Typical 4-Station Sytem) 655 * Or 1 Feeder & 1 Folder. See also Standby Noise Level on page G3 Series General Specifications Issue 1 September 2013 Page 13

14 Physical Data: Notes: 1. For normal operator access, allow 1m from any point of the machine. 2. Accumulator (with feeder) can be withdrawn 160mm on runners. Floor Loading (normal): 41.5 x 10 3 kg/m 2 (59 lb mass/in 2 ) Normal floor loading assumes all four feet of each unit (head or station pair) are correctly adjusted and equally in contact with floor. Floor Loading (worst case): 83 x 10 3 kg/m 2 (118 lb mass/in 2 ) Worst case floor loading assumes only two feet of each unit (head or station pair) are correctly adjusted and in contact with floor G3 Series General Specifications Issue 1 September 2013 Page 14

15 Weights: Weight (Kg) Unit Description Unpacked Packed Insert Head x Insert Feeders* x Feeder Folders* Feeder + Folder* Accumulator (on stand) Diverter (on stand) Hi-Cap Insert Feeder Spare Trolley Std-Cap Insert Feeder Vertical Stacker (+trays) Vertical Stacker (-trays) Output Conveyor Bin O/P Processor Bin O/P Processor Bin O/P Processor M/bag Trolley+2 bags** Divert Conveyor Franker I/F + Table * Supplied as a pair, includes track unit. ** Load capacity = 36kgs per mailing. Franker not included G3 Series General Specifications Issue 1 September 2013 Page 15

16 Maximum Heat Output (BTU/hour): Rated current x Rated Volts x (eg. 11,222 BTU/hour for typical configuration described on page 56). Maximum Heat Output (Watts): Rated Current x Rated Volts (eg kw for typical configuration described on page 56). Operating Temperature: deg C (64-82 deg F) Operating humidity: 30-80% RH Noise Level: Without collator: With collator: Note: Less than 78dBA, measured at 1.6m height, 1m from cover where noise level is at its highest. Less than 81dBA, measured at 1.6m height, 1m from cover where noise level is at its highest. Measurements taken using averaging of peaks. Leq (8): Note: 79dBA Leq (8) is lower than the first action level required by: Europe - Physical Agents (Noise) Directive 2003/10/C UK - Health & Safety. The Control of Noise at Work Regulations 2005 statutory instruments 2005 No Standby Noise Level: less than 56dBA, measured at 1.6m height, 1m from cover where noise level is at its highest. Note: Background ambient noise must be at least 10db(A) lower than the standby noise level for comparison purposes. 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: a) Locate the machine out of direct sunlight b) 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 covers where necessary G3 Series General Specifications Issue 1 September 2013 Page 16

17 Important Notes: 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% RH, but moisture absorption into the material may impair machine performance. 4. Condensation must not be present under any circumstances. 5. To ensure safe operation and provide for maintenance access, a minimum of 1m of free space should be available between any part of the machine and a wall or other structure. 6. The machine will function temperature levels above 28 deg C (82 deg F) and below 18 deg C (64 deg F). Temperature levels outside these limits may impair the machine performance. 7. 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 for the sheet feeders (Hi-Cap and Std- Cap). Request Hi-Grip Separator Assembly C8171A G3 Series General Specifications Issue 1 September 2013 Page 17

18 Print Sequence and Paper Orientation The following table shows the print sequence, paper orientation and OMR/ Barcode reader position for all units, see also the qualifying notes below. Unit Insert Feeder Lo-Cap/Hi-Cap Feeder Folder Hi-Cap Accumulator OMR/Barcode Reader Insert Feeder OMR/Barcode Feeder with Turnover OMR/Barcode Hi-Cap Feeder Reader Folder OMR/Barcode Hi-Cap Feeder Reader Folder Paper Orientation Face down feet first Face down feet first Face up head first Face up head first Face down feet first Face up head first Face down feet first Print Sequence Forward (A-Z) Reverse (Z-A) See note 2 Forward (A-Z) See note 3 Forward (A-Z) Reverse (Z-A) Fold Type for Top Address C or V C or V Z or V* C or V Fold Type for Bottom Address Z or V + Turnover Z or V + Turnover Z + Turnover or V + Turnover Z or V + Turnover OMR/Barcode Reader Position (see note 1) Top Reader Bottom Reader Bottom Reader Top Reader Bottom Reader On-Line Insert Feeder Face down feet first On-Line Feeder Folder Face down feet first C or V Z or V + Turnover On-Line Accumulator Face up head first Forward (A-Z) C or V Z or V + Turnover Top Reader OMR/Barcode On-Line Insert Feeder Face down feet first Reverse (Z-A) See note 2 Bottom Reader OMR/Barcode On-Line Feeder with Turnover Face up head first Forward (A-Z) See note 3 Bottom Reader Output Conveyor Window face up Reverse (Z-A) NOTES: 1. Reader location (top or bottom) assumes marks are on the address side of document. All reader heads can be positioned on the top or bottom except for the Reader Insert Feeder. 2. For Reader Insert Feeder, documents must be in reverse print sequence (Z-A) with the end-of-group mark on the last page of the set (page Z). 3. For Reader Insert Feeder with Turnover, documents must be in forward print sequence (A-Z) with the end of group mark on the last page of the set (page Z). 4. For all reading units, unless otherwise stated, end of group can be on first or last page of a group. 5. The folder also allows for double forward fold for long forms. 6. Undercollation of the output is available on request to turn the print sequence to foward (A-Z). 7. *Z fold for A-Z printing will reduce the cycling speed of the machine to 7,200 cycles per hour maximum ( due to 1 fold). To maintain full machine speed use Z-A printing G3 Series General Specifications Issue 1 September 2013 Page 18