Installation / Set-up of WJPro / IJ-15K Frankers to DS1000 / DS 1200 Inserters

Transcription

1 Installation / Set-up of WJPro / IJ-15K Frankers to DS1000 / DS 1200 Inserters Written By: Colin Langridge Issue: Draft Date: 08 th May 2008 Issue: 1 Date: 23 rd May 2008 Issue: 2 Date: 06 th June 2008 Issue: 3 Date: 27 th June 2008 Issue: 4 Date: 29 th August 2008 Inserters V4.doc Page 1 of 18

2 The DS1000/1200 inserters can be used in conjunction with the Hasler WJPro (Neopost IJ-15k) franking machine. This gives the inserters the ability to frank mail directly (online) from the inserting machine. The interface for the DS1000 and DS1200 inserters is Franker Interface Electronic Dynamic (E1522AD) See product specification for more details on Mechanical Interface The franker is mechanically installed the same way regardless of the interface type. A franker interface is always required to ensure that the envelope is kept straight and fed correctly / accurately into the franker. The following diagrams show the mechanical interface of the franker with the inserter. The franker interface ribbon cable plugs into Module PCB E. Port A (this is inserter dependent. Please Check with Technical Support Department to ensure the correct connection is used.) The height of 463mm is critical. The franker plinth must be used along with the location rings. This forces the height and alignment to be correct. Inserters V4.doc Page 2 of 18

3 Below are a few photos showing the franker in situate with the inserter and the correct alignment of the envelope into the franker. Franker fitted to the inserter Detail of the franker interface Envelope alignment into the franker Alignment from the franker interface Inserters V4.doc Page 3 of 18

4 The following describes / shows the wiring required for the franker and the inserter. The inserter communicates with the franker via a serial interface. We recommend that the cable be attached to COM port 2 on the franker COM port 2. Use the supplied serial cable to connect to the inserter ( ) Use this port COM 1 if downloading firmware to the franker (see separate instructions on how to do this) Terminator must be connected here as shown SEE FRANKER INSTRUCTION FOR MORE DETAILS / EXPALNATIONS ON ANY ITEM REGARDING THE FRANKER THAT REQUIRES MORE INFORMATION Picture of the rear of the franker showing the electrical interface panel To download firmware to the franker use the supplied serial cable A USB to serial adaptor will need to be used on the inserters PC to provide the necessary serial port. (Depending on the exact hardware configuration of the inserter the USB extension cable may be required) Setting up Communication Ports The inserter communicates with the franker via RS232. The serial commands are sent via a USB to serial adaptor on the inserter PC to a COM port on the franker. The USB to serial adaptor needs to be configured once it has been installed. Follow the instructions provided with the USB to serial adaptor to install this hardware. Once it is installed it needs to be configured within the inserter application and Windows. The part number for the USB to serial adaptor is This is supplied with electronic and dynamic franker interface kits. To set up the USB to serial adaptor navigate to: Control Panel System Hardware Device Manager Ports (Com & LPT) right click for Properties. Please ensure that the settings for the com. Port are as follows: Inserters V4.doc Page 4 of 18

5 Under the Advanced setting set the COM port to the desired number. This port number then needs to be setup in IMOS. Setting the Com port number within IMOS. Go to Engineering, then select External Devices then set the port number for the franker. (This must be the same number as setup for the USB to serial adaptor in the instruction above) Inserters V4.doc Page 5 of 18

6 Setting franker type within IMOS. The franker needs to be selected in the hardware setup. To do this leave the run screen and go to Engineering, Hardware setup screen, Select unit zero, then select edit, then scroll down the list under unit equipment and check Franker Interface. Then under extra settings select the franker type (see product guide for details of the different options). Select the correct option for the interface you desire. Then save changes and send the settings to unit zero. Then go back to the run screen and press Clear and restart then close the application. Then re-open the application. The franker will now be selected in the hardware and be ready to be used. The run screen will look as follows. (Operation instructions are described later) Follow the franker instruction manual for installing the print head, the ink tank and setting up the print head alignment. The franker will need to have credit added before running. Again see franker documentation or contact the local supplier Inserters V4.doc Page 6 of 18

7 Setting the franker to communicate with the inserter First download new firmware to the franker. See separate document on how to do this. (Process software download with Hyper- terminal.doc) Once the new firmware has been installed the franker needs to have its COM port setup. See separate document for more details on this. (NEO_MS_TH3_RD439_HR_UserManual_SerialControllerConfiguration.doc) To setup the serial port or the controller mode you need to be logged in as a supervisor. (See franker instruction or contact your local supplier for login) We recommend using COM port 2. Please set this to INSERTER 57K Once the changes have been saved re-boot the franker when prompted Then re-login as a supervisor and setup the connection to the inserter USER SETUP SUPER... DISPL... LANGUAGE AMERICAN ENGLISH SUP BUZZER OFF ON ERR ON KEY CONTRAST CONTROLLER NOT CONN. ELECTRO SERIAL HOME LOGOUT DEFLT OK Set the controller mode to serial and save as the default mode. Then log out from being a supervisor (communication between the inserter and the franker is not possible if the supervisor remains logged in) Inserters V4.doc Page 7 of 18

8 We recommend that the following settings /timers are set-up in the franker. These are specifically for 1000/1200 inserters. To do this you will need to login as a supervisor Please set the following timers Standby 120 Sleep Headset Cleaning Threshold 3600 or 2700 Setting up the inserter to Dynamically Frank The Electronic Dynamic Interface can be setup to operate in one of three modes. Each of the modes has different functionality. Not all of the features are available for all modes. The mode Electronic Dynamic Interface as all of the features and all of the options There are 7 modes of operation Not Used Always (weight Group1) Dynamic (Letter Box) Dynamic (Presorted) Dynamic (Date) Dynamic (Message) Dynamic (Pass Through) The franker mode can be selected from either the output tab (as before) or from the postage-meeting tab See franker documentation for a detailed description of what the different modes do Depending on the franker mode selected different options will selectable Example shows the options when the franker mode is dynamic letterbox Set the default mode to 1or 2 (in m5cfg.ini) if the units for the weight are in the wrong format (g / oz). Inserters V4.doc Page 8 of 18

9 Franker Modes Explanation Always (weight Group1) All envelopes will be franked with the same postage value (this covers the entire weight group thresholds from zero to the maximum weight allowed) all will be logged in the statistics and data-logging file correctly Dynamic (Letter Box) This mode is for non-presorted mail. This mode allows for 4 values and 3 mail classes to be specified. Extra text and/or slogans can be used if required. See Example Below Dynamic (Presorted) This mode is for presorted mail. This mode allows for 4 values and 3 mail classes to be specified. Extra text and/or slogans can be used if required. See Example Below Dynamic (Date) This mode will only frank a date onto the envelope. No postage value or mail class will be printed. To ensure that the statistics/data-logs are correct make sure group one has a zero postage value set. Extra text and/or slogans can be used if required. Dynamic (Message) Text can be defined as required from the franker control panel. In this mode No value or mail class will be printed. To ensure that the statistics/data-logs are correct make sure group one has a zero postage value set. Dynamic (Pass Through) Used for job runs that require none of the envelopes to be franked. To ensure that the statistics/data-logs are correct make sure group one has a zero postage value set. Inserters V4.doc Page 9 of 18

10 Postage A postage value can be set for each group up to three decimal places (99.999) Mail Class A mail class can be set for the first three groups. This can be any text string up-to 24 characters. Print Yes / No The mail class or postage value can be set to print or not print. This allows full flexibility regarding what is franked on the envelope for each group (Group four only has a postage value; the mail class is reserved by the franker) Some Franker modes allow more text or slogans to be printed on the envelope. If the mode allows this then the text / slogan must be programmed using the franker control panel and saved as the default option. (Supervisor access is required for this) If a slogan or additional text is saved as default, it will only be printed on the envelope if the franking mode allows it Franking by OMR When the franking mode is Dynamic Letter box or Dynamic Presorted the franking can be controlled by OMR. (OMR refers to OMR, Barcode, 2D or OCR) OMR Two OMR marks can be programmed to control the 4 groups. (Each group can be programmed for its own value and class. This is completely independent of the weight of the filled envelope) Franker Franker Group If only one OMR mark is used then only two groups can be controlled Label (Barcode, 2D etc) Two characters can be used to control the 4 groups. (Each group can be programmed for its own value and class. This is completely independent of the weight of the filled envelope) For Standard BCS control two new characters have been defined BCS 25 Franker 1 BCS 26 Franker 2 Franker 1 (BCS25) A B A B Franker 2 (BCS26) A A B B Group For other custom controls, where franker control is available then the characters could be numeric if the code supports it. If only one character is used then only 2 groups can be controlled Inserters V4.doc Page 10 of 18

11 Franking date The franking date (franked on the envelope) can be setup to thirty days in advance. This is set on the run screen. When the date needs to be set the following calendar is shown. (Only allows the date to be set, up to 30 days in advance) The franking date is setup in the WJPro setup screen. This is described in detail in a later section. The setup screen allows the operator to set the date, department and pin (if used) as well as the critical metering options for the groups If the date is displayed as 00/00/00 then today s date will be used. The first time that the run button is pressed in a job run the following message is displayed to ensure that the correct date and/or department is set before any envelopes are franked Date format displayed is dependent on the local machine settings within Windows. (Regardless of the displayed date format the franking date sent (and used) will be in the following format MM/DD/YYYY) Inserters V4.doc Page 11 of 18

12 Departments Department settings in the inserter application (IMOS) The inserter application can be configured to use the department modes within the franker. SEE FRANKER DOCUMENTATION FOR DETAILS ON DEPARTMENTS AND HOW TO SELECT AND USE THEM CORRECTLY OFF ON (fixed) Departments feature not used by the inserter. Departments must be set to OFF in the franker as well A configuration uses one department only ON (variable) A configuration can be used for multiple departments logging (as long as they are valid departments defined in the franker) Setting departments to work on the franker (see franker docs for more info) A supervisor must setup the departments on the franker. Default is departments off If not using department s mode, all franked envelopes are logged to a generic general department (no operator access) Once dept ON at the franker a valid department must be selected for the inserter / franker to operate If for a job run the dept is not important then a generic department with a known or PIN (or use the default PIN 0000) must be setup both in the franker and the inserter Error messages if department or pin invalid The inserter / franker will not allow operation if a valid dept and pin have not been entered. If the error is raised at the franker then the inserter will install a general franker error, Please see the franker LCD for the exact error code. Inserters V4.doc Page 12 of 18

13 WJPro Setup Screen WJPro setup screen allows the operator to set the date, department as well as altering the mail class and the postage value for the groups. Date As described in a previous section the franking date can be set up to 30days in advance. The current franking date is displayed on the inserter run screen. To change the franking use the date edit button on the WJPro setup screen Viewing / modifying settings for groups The postage value and the mail class for the groups can be viewed and altered if required from the WJPro setup screen. The settings will be sent to the franker when the OK button is pressed. The franker mode and the metering mode are displayed here for information purposes only. The se settings are a configuration item and can be modified in the configuration screen only Inserters V4.doc Page 13 of 18

14 Warning messages There are various checks to ensure that the correct department, department pin or date is set and sent to the franker. (Some of the checks are by IMOS others are by the franker) Some typical examples are as follows: This means that a job has been asked to run without the department / pin being selected. This example shows that the pin number for the selected department has not been entered (validation of the pin is done by the franker and a fault will be installed if the pin or department are incorrect) It is not permitted to run the inserter / franker with an invalid date. Again a warning message will be displayed prompting the operator Note. All franker errors must be manually cleared on the franker before continuing to process envelopes through the inserter. (The inserter can clear Warnings in the franker such as low ink etc) Inserters V4.doc Page 14 of 18

15 As described in an earlier section the first time a job is run the operator will be prompted to check that all settings (date / department etc) before running the job Saving Modifications to the Postage Value and Mail Class Changes to the postage value or mail class from the WJPro setup screen are not permanent. The new values / settings are sent to the franker and used for the current job run. When the run screen is exited you are prompted to save or discard the changes. If the changes are saved then the configuration is updated. Notes If the department mode is variable then the field can be blank in the configuration If the department mode is fixed then the field must be completed in the configuration Inserters V4.doc Page 15 of 18

16 Account Info / Counters This information can be requested from the franker by navigating from the Run screen to the main menu, selecting Admin and then selecting WJ /IJ Account information. The following dialog box is displayed. This gives access to the following information: Licence Number of the PSD Credit Used Credit Remaining on the franker Number of Items Franked Head Cleaning This is an automated process based on a timer set in the franker (default 2700). The inserter will stop processing envelopes whilst the head clean is performed and then start up automatically and continue to process envelopes without operator intervention (It is recommended to set the head-cleaning timer to the default setting of 2700 seconds or the maximum value of 3600 seconds) Please note the head cleaning process can take up to 40 seconds to complete. Inserters V4.doc Page 16 of 18

17 Error Messages and Warning Messages The inserter will install numerous error / warning messages. The table below outlines these. Fault codes and Warning Message installed by the Inserter Fault Description Action Extra Information Code 420 WJPro/IJ-15K Requires Attention Franker Requires a Manual Head Clean Applies for the mechanical interface only 421 WJPro/IJ-15K Ink Level is Low 422 WJPro/IJ-15K Funds Level is Low Check Ink Level. See franker docs for details Check credit remaining. See franker docs for details 423 Franker Error Generic Franker Error. Check franker LCD for details 424 WJPro/IJ-15K Emergency Stop Check the Franker for exact Fault. Warning message. Inserter will still run. Check ink level. (A fault will be installed when ink is empty) Warning message. Inserter will still run. Check credit level. (A fault will be installed when no credit remains) See Franker Instructions for Details of how to clear the fault See Franker Instructions for Details of how to clear the fault 425 WJPro/IJ-15K Head Cleaning Requested 426 No Acknowledge Message Received from WJPro/IJ-15K 427 No Status Message Received from WJPro/IJ-15K 428 Checksum Error on the Message received from WJPro/IJ-15K 429 No Error Message Received from WJPro/IJ-15K 430 Warning / Message Received from WJPro/IJ-15K 431 Communication Error with WJPro/IJ-15K Wait for cleaning to finish. Inserter will re-start automatically Check Franker is online and in the correct mode Check Franker is online and in the correct mode Check Franker is online and in the correct mode Check Franker is online and in the correct mode Check the Franker for the Generic Warning Message Check Franker is online and in the correct mode Auto head clean and re-start for electronic interfaces. Timer for head clean set in the franker Franker has not responded to a command from the inserter. Check all settings / connections are correct and the franker is not in a fault condition Franker has not sent its current status to the inserter. Check all settings / connections are correct and the franker is not in a fault condition Message from the franker is corrupted. Check all settings / connections are correct Requested error message was not received. Check all settings / connections are correct and look at the franker LCD for the error Check franker LCD for exact warning. Press run to clear the warning and continue processing Check all settings / connections are correct and the franker is not in a fault condition Inserters V4.doc Page 17 of 18

18 All errors related to the franker (excluding communication errors) are Generic Franker Errors code 423. The exact fault will be displayed on the franker LCD and has to be cleared via the franker control panel. The inserter will check that the franker has had the error cleared and is ready to resume, before sending any more envelopes / commands to it. (If the error is not cleared or the franker is not ready then it will be re-installed) Warning messages such as codes 421 or 423 do not stop the inserter from processing envelopes and sending commands to the franker. The message displayed is for information only. It is up to the operator decide the best course of action. Warning messages can be cleared from the inserter (not necessary to use the franker control panel) Jam Clearing If a jam occurs in the franker and the envelope cannot be cleared from either end then the franker can be moved from the envelope path and the lower transport roller assembly removed (see franker documentation for instructions) We believe jammed envelopes can be cleared for almost all jams without the need to remove the lower conveyor. The franker can be moved from the envelope path and rested on the franker table in front of the plinth. This is also a good place to put the franker if maintenance is required. (The ink heads and ink tank can be replaced with the franker in the normal operating position) Error Tagged Documents Documents that have been error tagged can be no franked (dynamic no franking ensures the envelope is completely blank nothing is franked on the envelope) if required. To achieve this, the following settings are required: Error Handling Group Security = Handle at Output = Error Tag Possible corrupt group To ensure that the statistics and the data logging are correct it is recommended to set up one of the groups to have a zero value (use group four as this already has no mail class associated with it) The error tagged envelopes can be unsealed and or jogged on the vertical stacker if required. (Set the seal mode and/or the VS Jog mode to Errors to achieve the required option) Inserters V4.doc Page 18 of 18