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Specifications 1. Barcode Specifications - Page 1 2. OMR Specifications - Page 31 3. General Specifications - Page 47 Automailer 5 Specification Pack AUTOMAILER 5 PLUS (AM5) BARCODE SPECIFICATION FOR INTELLIGENT MAILING SYSTEMS Contents 1. Introduction Page 2 2. Terminology Page 2 3. PFE Bar Code System Character Definition Page 3 4. PFE Bar Code System Page Layout Arrangement Page 12 5. PFE Bar Code Label Dimensions Page 13 6. Data Logging Page 14 7. Feed Unit Information Page 14 8. Appendix 1 Page 16 9. Appendix 2 Page 29 Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 1 Automailer 5 Specification Pack 1. Introduction The standard PFE Bar Code System will use Code 39 (3 of 9). Code 39 allows the coding of: upper case letters numbers the space character the symbols A to Z 0 to 9 -.$/+% 26 symbols 10 symbol 1 symbol 6 symbols The functions which the PFE Bar Code System supports are • • • • • • • • Grouping of multipage documents Selective feeding from all the feed stations (excluding the prime document station) Divert units ( form diverts and envelope diverts ) Form security numbering Group security numbering Matching ( within a document set and between feed units) Data logging of customer's document number (non-PFE BCS character ) Numeric control & 2 of 5 interleaved (see appendix 1 on page 14) The bar code is composed of a variable number of characters to cater for the required functions above. The minimum number of characters required will be two characters, the smallest size of bar code that code 39 accepts. The bar code may contain additional characters as required by the customer for customer specific functions. Additionally, the bar code requires a stop and a start character to be printed ( * ). The maximum size of bar code, including the stop and start characters, is 20 characters. 2. Terminology The complete bar code as printed on the form is referred to as the BAR CODE LABEL. Within the Bar Code Label there are a number of coded characters, these will be referred to as BAR CODE CHARACTERS. These are numbered from the start of the Bar Code Label to the end of the Bar Code Label Within the Bar Code Label there are a number of coded characters which have defined functions within the PFE Bar Code System these will be referred to as PFE BCS CHARACTER #1, PFE BCS CHARACTER #2 etc. Finally, during the programming of the Automailer 5 Bar Code the position of each PFE BCS CHARACTER within the BAR CODE LABEL will need to be specified. BAR CODE LABEL CHECKSUM CHARACTER This may be printed if it is required by the customer. It will not be used by the Automailer 5, but is treated as part of the customer code. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 2 Automailer 5 Specification Pack 3. PFE Bar Code System Character Definition 3.1. Grouping of multipage documents (Control Character) PFE BCS CHARACTER #1 This character is used primarily for grouping document sets from one feed unit together. PFE BCS CHARACTER #1 =A Demand Feed continues feeding forms =B End of Group stops feeding forms into the collator as this form is the last form of the group which requires insertion into the same envelope. =C End of Group & End of Job stops feeding forms into the collator as this form is the last form of the group which requires insertion into the same envelope, and additionally the Automailer goes into its Auto-end mode as this set of forms is the last of the job. =D Forced Fold forces the sub-group in the collator to be passed to the folder. The remainder of the group continues to be accumulated in the collator, then passed to the folder. All the sub-groups are re-combined at the shuttle. = E to Y Changes made to allow printed barcode on only the first page of a set consisting of a known number of pages. The PFE BCS character value 'E' equals a group of 1. The PFE BCS character value 'F' equals a group of 2, with the barcode printed on the first page only. 'G' equals a group of 3, and so on up to 'Y' which equals 21. 'Z' indicates a group of more than 21 pages. If the first form of the next set does not have a barcode, this is treated as a bad read. If a form within the set does have a barcode, this is treated as a form-sequence error. Because the page count is known in advance, 'too many forms' groups can be diverted singly, preserving the page sequence. =Z Changes made to allow printed barcode on only the first page of a set consisting of more than 21 pages See also Appendix 2 on page 21 for customer 1D grouping. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 3 Automailer 5 Specification Pack 3.2. Selective Feeding from Feed Stations 1 to 4 PFE BCS CHARACTER #2 Length =1 This character is used to control selective feeding from stations 1 to 4 in every combination. (When the length=1, character 1 controls the following feeders) 1 BCS CHARACTER #2 = = = = A B C D = = = = E F G H = = = = I J K L = = = = M N O P Feed Stations 2 3 4 No Feeds 3.3. Selective Feeding from Feed Stations 5 to 8 PFE BCS CHARACTER #2 Length =2 This character is used to control selective feeding from feed stations 5 to 8 in every combination. (When the length=2, character 2 controls the following feeders) 5 BCS CHARACTER #3 Nobody does it better! = = = = A B C D = = = = E F G H = = = = I J K L = = = = M N O P Feed Stations 6 7 8 No Feeds Automailer 5 Specifications - Issue 12 • Page 4 Automailer 5 Specification Pack 3.4. Selective Feeding from Feed Stations 9 to 12 PFE BCS CHARACTER #2 Length =3 This character is used to control selective feeding from stations 9 to 12 in every combination. (When the length =3, character 3 controls the following feeders) 9 BCS CHARACTER #4 = = = = A B C D = = = = E F G H = = = = I J K L = = = = M N O P Feed Stations 10 11 12 No Feeds 3.5. Selective Feeding from Feed Stations 13 to 15 PFE BCS CHARACTER #2 Length =4 This character is used to control selective feeding from feed stations 13 to 15 in every combination. (When the length =4, character 4 controls the following feeders). Feed Stations 13 14 15 BCS CHARACTER #5 = A No Feeds = B = C = D = = = = E F G H Note: Selective feed is selected (like all functions) by specifying a start position in the lable and a length (no. of characters). The length determines which feeders are being selected, eg: Selective feed from station 1-4 Start position =1, length =1, no. of characters =1 Selective feed from stations 1-8 Start position =1, length =2, no. of characters =2 (character 1 controls 1-4, character 2 controls 5-8) Selective feed from stations 1-12 Start position =1, length =3, no. of characters =3 (character 3 controls 9-12) Selective feed from stations 1-15 Start position =1, length =4, no. of characters =4 (character 4 controls 13-15) Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 5 Automailer 5 Specification Pack 3.6. Divert Units ( Form Diverts and Envelope Diverts ) PFE BCS CHARACTER #6 This character is used to control the destination of both unfolded forms into the forms diverters (Diverts 1 to 2) and also the destination of filled envelopes into the envelope diverts (Envelope Diverts 1 to 6). NB 1. Currently, only one twin-bin forms diverter can be fitted to the Automailer 5, which allows forms diverts 1 and 2 to be selected. NB 2. Currently, only three twin-bin envelope diverters can be fitted to the Automailer 5, which allows envelope diverts 1 to 6 to be selected. BCS CHARACTER #6 = = = = = = = = = = = = = = = = = = = = = = = = = = Nobody does it better! A B C D E F G H I J K L M N O P Q R S T U V W X Y Z TBA Form Divert 1 Form Divert 2 TBA Ink Mark 2 / Ouput Conveyor Control Ink Mark 2 and No Seal No Diverts Envelope Divert 1 Envelope Divert 2 Envelope Divert 3 Ink Mark / VS Jog Envelope Divert 1 and Jog Envelope Divert 2 and Jog Envelope Divert 3 and Jog Franker 1 Disable Franker 2 Disable No Diverts and No Seal Envelope Divert 1 and No Seal Envelope Divert 2 and No Seal Envelope Divert 3 and No Seal Ink Mark and No Seal Envelope Divert 1 and Jog and No Seal Envelope Divert 2 and Jog and No Seal Envelope Divert 3 and Jog and No Seal Franker 1 Disable and No Seal Franker 2 Disable and No Seal Automailer 5 Specifications - Issue 12 • Page 6 Automailer 5 Specification Pack 3.7. Form Sequence within a Job PFE BCS CHARACTER #7 This facility is used to ensure that forms are processed through the inserter in the same order that they were printed, and that there are no missing forms. This is achieved by coding each form as it is printed with the alphabetic characters A,B,C......Z. After the Z is printed the sequence restarts at A again. When the forms are read by the barcode reader any deviation from the correct order is detected and an alarm produced. BCS CHARACTER #7 = = = = = = = = = = = = = = = = = = = = = = = = = = = = = cycle restarts at "A" A B C D E F G H I J K L M N O P Q R S T U V W X Y Z A B C etc. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 7 Automailer 5 Specification Pack 3.8. Form Sequence within a Group PFE BCS CHARACTER #8 This facility is used to ensure that forms are processed through the inserter in the same order that they were printed, and that there are no missing forms. This is achieved by coding each form of a group as it is printed with the alphabetic characters A,B,C......Z. At the start of every new group the coding sequence starts at A. If the batch of forms in a group exceeds 26 pages, after the Z is printed the sequence restarts at A again. When the forms are read by the barcode reader any deviation from the correct order is detected and an alarm produced. BCS CHARACTER #8 = = = = = = = = = = = = = = = = = = = = = = = = = = = = = cycle restarts at "A" A B C D E F G H I J K L M N O P Q R S T U V W X Y Z A B C ( printed on page 1 of the group ) ( printed on page 2 of the group ) ( printed on page 3 of the group ) ( etc ) etc. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 8 Automailer 5 Specification Pack 3.9. Matching (within a Document Set and Between Feed Units) PFE BCS CHARACTER #9 This facility is used to ensure that each envelope is only filled with personalised items addressed to one recipient. Hence if there are multiple pages being fed from one feed station each of these pages should have the same match code character. Also, if there are additional personalised inserts being fed from other feed stations then these personalised items should also have the same match code character. The match codes that can be used are the characters A to Z. The characters do not need to be used in any particular sequence, as the Automailer will simply look at each page destined for one envelope, and ensure that all the coded pages carry the same Match code character. In the event that there is a mis-match between the forms an alarm is produced. NOTE: When there is a requirement to match documents from a barcoded unit with documents from an OMR reading feed unit they can be matched using the following matching arrangement. BCS CHARACTER #9 Mark 1 = A 1 – = B 2 = C 3 – = D 4 = E 5 – = F 6 = G 7 – = = = = = = = = H I J K L M N O 8 9 10 11 12 13 14 15 = = = = = = = = P Q R S T U V W 16 17 18 19 20 21 22 23 = = = X Y Z 24 25 26 OMR Match marks Mark 2 Mark 3 Mark 4 – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – Mark 5 – – – – – – – – – – – – – – See also Appendix 2 on page 29 for customer 1D grouping. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 9 Automailer 5 Specification Pack 3.10.Group Sequence PFE BCS CHARACTER #10 This facility is used to ensure that forms are processed through the inserter in the same order that they were printed, and that there are no missing forms. This is achieved by coding each form of a group with the same letter. Each successive group will be printed with the next alphabetic character A,B,C..Z. Each form within a group has the same group sequence character. Each successive group will be printed with the next alphabetic character A,B,C..Z. After the Z is printed the sequence restarts at A again. When the forms are read by the barcode reader any deviation from the correct order is detected and an alarm produced. BCS CHARACTER #10 = Group Sequence A A A B B C D E F F G H I J K L M N N O P Q R S S T U U U V W X Y Z Z A A B Nobody does it better! Customer Page 1 1 1 2 2 3 4 5 6 6 7 8 9 10 11 12 13 14 14 15 16 17 18 19 19 20 21 21 21 22 23 24 25 26 26 27 27 28 1 2 3 1 2 1 1 1 1 2 1 1 1 1 1 1 1 1 2 1 1 1 1 1 2 1 1 2 3 1 1 1 1 1 2 1 2 1 Automailer 5 Specifications - Issue 12 • Page 10 Automailer 5 Specification Pack 3.11. Form in a Group PFE BCS CHARACTER #11 This facility is used to ensure that forms are processed through the inserter in the same order that they were printed, and that there are no missing forms. The character shows the total number of forms in the group. This is achieved by coding each form as it is printed with the alphabetic characters A,B,C......Z. These equate to a numeric value. The character shows the total number of forms in the group. Each form has the same character on it. BCS CHARACTER #11 = A = 0 ( Total number of pages in group is 0 ) = B = 1 ( Total number of pages in group is 1 ) = C = 2 ( Total number of pages in group is 2 ) =D = 3 ( etc ) =E = 4 =F = 5 =G = 6 =H = 7 =I = 8 =J = 9 = K = 10 = L = 11 = M = 12 = N = 13 = O = 14 = P = 15 = Q = 16 = R = 17 = S = 18 = T = 19 = U = 20 = V = 21 = W = 22 = X = 23 = Y = 24 = Z = 25 Examples Nobody does it better! Forms in Group Customer B C C E E E E B D D D C C ONE TWO TWO FOUR FOUR FOUR FOUR ONE THREE THREE THREE TWO TWO Automailer 5 Specifications - Issue 12 • Page 11 Automailer 5 Specification Pack 4. PFE Bar Code System Page Layout Arrangement for Automailer 5 Plus Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 12 Automailer 5 Specification Pack 5. PFE Bar Code Label Details Note: PFE’s Barcode scanning system uses a high speed scanner (2,000 reads per second) which has to see 5 successive identical scans before returning the scan result. If reading is being achieved but the incorrect characters are being returned, look at the following list of parameters. To ensure reliable reading of the Bar Code Label it should be of the following minimum dimensions: 5.1 Bar Code Width Minimum width 8mm for vertical barcode Minimum width 14mm for horizontal barcode Note: The minimum width for vertical barcodes does not include allowance for print variation relative to the edge of the page. If the barcode position varies by, say, +/-2mm then the minimum width of the barcode will be 12mm (8 nominal + print variation). 5.2 Narrow bar Thickness The minimum acceptable thickness for the narrow bar should be 0.01” (0.25mm). Use of the minimum bar thickness is dependent on print and font quality. If reading errors occur increase the minimum bar thickness of the barcode character leaving all other parameters the same. 5.3 Ratio of Wide Bar to Narrow Bar The minimum acceptable ratio between the wide bar and narrow bar thicknesses should be 2.5. However, to achieve a higher level of read reliability the ratio should be increased to 3. 5.4 Quiet Zone There should be a clear area at each end of the bar code of at least 6mm (0.25"). There should be no graphics or text printing or background colour changes on the form in this quiet zone. 5.5 Start and Stop Characters in the Bar Code Label The bar code label requires the printing of an asterisk * at the beginning and also at the end of the label. These are the start and stop characters, which are used in the decoding of the label. 5.6 Maximum Number of Characters in the Bar Code Label The maximum number of characters, including the start and stop characters, in the bar code label that can be read is 20. This includes both the PFE required characters and the customer defined functions. 5.7 Orientation of the Bar Code Label Horizontal or vertical barcodes may be used (see page 10). 5.8 Position of the Bar Code Label The bar code label should be positioned as indicated on the page layout arrangement (see page 10). Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 13 Automailer 5 Specification Pack 6 Data Logging The Automailer 5 has a built-in Data Logging function which will create a logfile of all barcodes read against date, job-name and operator. The data log can be accessed through 'Statistics' in the setup (menu) screen of the operating software. See ‘Automailer 5 Data Logging Specification’. 7 Feed Unit Information 7.1 I.S. Collator (E1561AA, E1562AA and E1563AA) Collation Collation of documents is carried out in the ‘Accumulator’ of the systems unit and allows for up to 8 sheets to be collated together before fold (dependent on material, fold type and envelope capacity). Single page or multiple page sets can be diverted before fold in a Sheet Divert Unit (E1570AA) if fitted. Sheet divert units allow for documents to be diverted for bad read, bad sequence, oversized groups or by OMR/Barcode control. A sheet divert unit is recommended for ease of operation. Collation of documents before fold maintains the production speed of the machine for group sizes of an average of 2 pages per set. Feed Orientation The feed orientation is always face up, head first (relative to the addressed face of the document). Print Sequence Print sequence is always first to last, i.e. page 1 is on top of the printed stack. Reading Surfaces Reading can be carried out on either the top or the bottom surface of the document. This allows for duplex printed material with the OMR/Barcode on the reverse side of the document. 7.2 OMR/Barcode Folder (E1542AA, E1546AA) Collation Collation of forms is always on the Shuttle Bed (after fold). The number of sheets collated in a group is dependent on the material, fold type and envelope capacity. Collation after fold reduces the machine speed with the number of forms in the group. Feed Orientation The feed orientation (relative to the addressed face of the document) can be either: a) Face up, head first (using a ‘Z’ fold) or b) Face down, feet first (using a ‘C’ fold). Print Sequence Print sequence is dependent on feed orientation. If the document orientation is face up, as per a) above, then the print sequence is first to last, i.e. page 1 is on the top of the printed stack. If the document orientation is face down, as per b) above, then the print sequence is last to first, i.e. page 1 is on the bottom of the printed stack and the stack is inverted in the Hi-Cap feeder. Reading Surfaces Reading can be carried out on either the top or the bottom surface of the document. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 14 Automailer 5 Specification Pack 7.3 OMR/Barcode Feeder (E1552AA and E1556AA) Collation Collation of forms is always on the ‘shuttle bed’. Feed Orientation The feed orientation is always face down, feet first (relative to the addressed face of the document). Print Sequence The print sequence is last to first, i.e. page 1 is on the bottom of the printed stack. The stack is inverted in the feeder so that page 1 is fed first. End of Group Mark The end of group mark must appear on the last page of the set which is the last page to be fed. Reading Surfaces Reading is only carried out on the bottom surface of the document. 7.4 OMR/Barcode Feeder with Turnover (E1572AA) Collation Collation of forms is always on the ‘shuttle bed’. Feed Orientation The feed orientation is always face up, head first (relative to the addressed face of the document). Print Sequence The print sequence is last to first, i.e. page 1 is on the top of the printed stack. The stack is the correct way up in the feeder so that page 1 is fed first. End of Group Mark The end of group mark must appear on the last page of the set which is the last page to be fed. Reading Surfaces Reading is only carried out on the bottom surface of the document. General Notes a) The OMR/Barcode head and bracket assembly is not switchable by the operator between top and bottom reading. If reading on both surfaces is required then two reading heads and bracket assemblies must be fitted. b) If it is required to frequently change the OMR/Barcode head position between two different positions then it is recommended that two heads be fitted for ease of operation. c) The sheet divert unit (E1570AA) is not a ‘forms processor’. The sheet divert is provided to reject exceptions only. Any diverted forms should not be reprocessed through the machine. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 15 Automailer 5 Specification Pack 8 Appendix 1 Numeric Custom Barcodes Numeric barcodes are, as the name suggests, barcodes that only contain numeric characters and no alpha characters. The most common form of this used in mailing machines is 2 of 5 Interleaved. 2 of 5 Interleaved barcodes have a much higher density than the standard 3 of 9 and can subsequently be used where a large number of characters is required (14 – 25) Numeric codes already Supported Automailer 5 already supports two custom numeric codes. However, the functionality of these codes is limited to the specification below. Our standard feature of data logging is supported with all barcode types. Additional functionality for 2 of 5 interleaved If you require additional functionality this can easily be included in our product. However, PFE have to make an additional charge for this additional feature. Please contact PFE sales group who will be able to advise you of the additional cost to achieve your requirements. To simplify the process you will need to order PFE Part number ES1505AA and supply your detailed barcode requirement. PFE Custom Control 1 This option reads numeric characters in 3 of 9 barcode The following functions are supported:a) Grouping 0 = Continuation sheet 1 = End of group b) Sequence 0 – 9 (single character) Notes: 1. These functions can be allocated to any character position in the barcode. I.e. grouping could be character 2 and sequence may be character 5. 2. The whole barcode can be read and data logged up to 25 characters. 3. Grouping can be first of group or end of group Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 16 Automailer 5 Specification Pack PFE Custom Control 2 This option reads numeric characters in 2 of 5 Interleaved barcode The following functions are supported:a) Grouping 0 = Continuation sheet 1 = End of group b) Sequence 0 – 9 (single character) Notes: 1. These functions can be allocated to any character position in the barcode. I.e. grouping could be character 2 and sequence may be character 5. 2. The whole barcode can be read and data logged up to 25 characters. 3. Grouping can be first of group or end of group Additional functionality for 2 of 5 interleaved If you require additional functionality this can easily be included in our product. However, PFE have to make an additional charge for this additional feature. Please contact PFE sales group who will be able to advise you of the additional cost to achieve your requirements. To simplify the process you will need to order PFE Part number ES1505AA and supply your detailed barcode requirement. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 17 Automailer 5 Specification Pack PFE Custom Control 3 This option reads alpha-numeric characters in 3 of 9 barcode The total characters in the label do not include the start and stop characters (‘*’) For each function a start position and length needs to be defined The following functions are supported:- Form Sequence within Group (Package Sheet Number) This uses 2 characters to create a two digit decimal number, which always starts at 1 and ends at the value of the Forms in Group. The Form sequence within Group can have any value between ‘01’ and ‘99’. Form in Group (Pages in Set Number) This defines the number of pages in each set to go into an envelope and is a 2 digit decimal created from 2 barcode characters. Forms in group can have any value from ‘01’ to ‘99’. The value should be the same for all the pages of a set. Grouping An end of group (set) is assumed when the Form Sequence within Group equals the Forms in Group. Customer ID (Policy Number) The policy number is an alpha numeric text string comprising a number characters of the barcode. The customer id must be the for every page of a set as defined above. Selective Feed (Machine Function Characters) Each machine function is an alpha numeric which is converted to ‘base 32’. Base 32 is a 5 BIT word where each BIT is used for a specific machine function. Character X controls BITs 1 to 5. Character Y controls BITs 6 to 10. Character Z controls BITs 11 to 15. Where BIT 1 controls feeder 1, BIT 2 controls feeder 2, etc. The BIT control is 1 = On, 0 = Off Notes: 1. These functions can be allocated to any character position in the barcode. 2. The whole barcode can be read and data logged up to 25 characters. 3. There is no grouping character and end of group is assumed when the Form Sequence within Group equals the Forms in Group. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 18 Automailer 5 Specification Pack PFE Custom Control 4 This option reads numeric characters in 2 of 5 Interleaved barcode The following functions are supported:- Grouping and Envelope Divert Character 1 is used to control grouping and envelope diverts 1 and 2. The character can have a value between ‘0’ and ‘7’. The decimal value is converted into a binary code where:0 = Off 1 = On BIT 1 = Envelope Divert 1 BIT 2 = Envelope Divert 2 BIT 3 = End of Group Form Sequence within Job (Page Sequence) The page sequence number is constructed from 2 characters of the label. The combined character value cycles from ‘01’ to ‘99’ then restarts a ‘01’. It increments for every page fed. Group Sequence The group sequence should increment by 1 with each new set of documents. After 9 it returns to 1. Selective Feed and Autoend Character 5 is used to control selective feeding from stations 1 and 2 and to autoend the machine with the marked document on the output conveyor. The character can have a value between ‘0’ and ‘7’. The decimal value is converted into a binary code where:0 = Off 1 = On BIT 1 = Feeder 1 BIT 2 = Feeder 2 BIT 3 = Stop Ink Marking Character 22 can have a value of ‘0’ to ‘2’ with control parameters as follows:0 = No Ink Mark 1 = Ink Mark 1 2 = Ink Mark 2 Check Digit Character 24 the check digit is to be used to check the value of all the characters. This is a standard feature of 2 of 5 interleaved barcode. Customer ID (Policy Number) The policy number is an numeric text string comprising a number characters of the barcode. The customer id must be the same for every page of a set as defined above. Notes: 1. The positions of these functions are set within the barcode label (NOT able to be allocated to any character position in the barcode) except for Form Sequence within Job, Group Sequence and Customer ID. 2. The whole barcode can be read and data logged up to 25 characters. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 19 Automailer 5 Specification Pack PFE Custom Control 5 This option reads numeric characters in 2 of 5 Interleaved barcode For each function a start position and length needs to be defined The following functions are supported:- GForm Sequence within a Group This uses 1 character to create a 1 digit decimal number, which always starts at the total forms in group and ends at a value of 1. The Form Sequence within Group can have any value between ‘9’ and ‘1’. Forms in Group This defines the number of pages in each set to go into an envelope and is a 1 digit decimal number created from 1 barcode character. Forms in Group can have any value from ‘1’ to ‘9’. The value should be the same for all the pages of a set. Grouping An end of group (set) is assumed when the Form Sequence within a Group is equal to 1. Group Sequence OR Customer ID The group sequence number is a numeric string comprising a number of characters of the barcode. The group sequence must be the same for every page of a set as defined above. The Sequence goes from a maximum ‘’99999’’ to ‘’1’’. After reaching ‘’1’’ the count wraps back to ‘’99999’’. Selective Feed One character is used to control selective feeding from stations 1 and 2. The character can have a value between ‘0’ and ‘7’. The decimal value is converted into a binary code where:0 = Off 1 = On BIT 0 = Feeder 1 BIT 1 = Feeder 2 BIT 3 = Not Used Selective Feed Character Value BIT 0 Feeder 1 BIT 1 Feeder 2 BIT 2 NOT USED 0 0 0 0 1 1 0 0 2 0 1 0 3 1 1 0 4 0 0 1 5 1 0 1 6 0 1 1 7 1 1 1 Notes: 1. These functions can be allocated to any character position in the barcode. 2. The whole barcode can be read and data logged up to 25 characters. 3. Sequence direction is down. 4. Sequence start position is 1. 5. There is no grouping character and EOG is assumed when the form sequence within a group equals the Sequence start position (in this example 1). Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 20 Automailer 5 Specification Pack PFE Custom Control 6 This option reads numeric characters in 2 of 5 Interleaved barcode The following functions are supported: - Form Sequence within Job (Page Sequence) The page sequence number is constructed from 2 characters of the label. The combined character value cycles from ‘01’ to ‘99’ then restarts a ‘01’. It increments for every page fed. Grouping(see note 1) Character 11 is used to control grouping and the force folding of documents. The character can have a value between ‘0’ and ‘7’. The decimal value is converted into a binary code where: - 0 = Off 1 = On BIT 1 = Not used (Matching in a group) BIT 2 = Force Fold BIT 3 = End of Group Customer ID The customer ID is a numeric string comprising a number of characters of the barcode. The customer ID must be the same for every page of a set. Selective Feed Two characters are used to control selective feeding from stations 1,2,3 and 4. The characters can have a value between ‘0’ and ‘7’. The decimal value is converted into a binary code where: - 0 = Off 1 = On Character 1 Character 2 BIT 0 = Feeder 1 BIT 0 = Feeder 4 BIT 1 = Feeder 2 BIT 1 = Not used BIT 3 = Feeder 3 BIT 3 = Not used Output Control (Unseal, Jog)(see note 1) This character is used to control the sealing and jogging of the filled envelope. The character can have a value between ‘0’ and ‘7’. The decimal value is converted into a binary code where: 0 = Off and 1 = On. Character 14 BIT 1 = Not used (ink marking) BIT 2 = Unseal BIT 3 = Jog (for a vertical stacker) Check Digit Character 16 (the check digit) is to be used to check the value of all the characters. This is a standard feature of 2 of 5 interleaved barcode. Notes: 1. The positions of these functions are set within the barcode label (NOT able to be allocated to any character position in the barcode) except for Form Sequence within Job, Selective Feed and Customer ID. 2. The whole barcode can be read and data logged up to 25 characters. 3. Sequence direction and sequence start position are definable. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 21 Automailer 5 Specification Pack PFE Custom Control 7 This option reads numeric characters in 2 of 5 Interleaved barcode The following functions are supported: - Form Sequence within Job (Page Sequence) The page sequence number is constructed from 2 characters of the label. The combined character value cycles from ‘01’ to ‘99’ then restarts a ‘01’. It increments for every page fed. Grouping (see note 1) Character 11 is used to control the grouping (when there is no change in the customer ID) and the force folding of the documents. The character can have a value between ‘0’ and ‘7’. The decimal value is converted into a binary code where: 0 = Off and 1 = On. BIT 1 = Not used (Matching in a group) BIT 2 = Force Fold BIT 3 = End of Group Customer ID This is used to control the grouping. When the customer ID changes EOG is set for the document in front (completing the group). The customer ID must be on every page. Selective Feed Two characters are used to control selective feeding from stations 1,2,3 and 4. The characters can have a value between ‘0’ and ‘7’. The decimal value is converted into a binary code where: 0 = Off and 1 = On. Character 1 Character 2 BIT 0 = Feeder 1 BIT 0 = Feeder 4 BIT 1 = Feeder 2 BIT 1 = Not used BIT 3 = Feeder 3 BIT 3 = Not used Output Control (Unseal, Jog)(see note 1) This character is used to control the sealing and jogging of the filled envelope. The character can have a value between ‘0’ and ‘7’. The decimal value is converted into a binary code where: 0 = Off and 1 = On. Character 14 BIT 1 = Not used (ink marking) BIT 2 = Unseal BIT 3 = Jog (for a vertical stacker) Check Digit Character 16 the check digit is to be used to check the value of all the characters. This is a standard feature of 2 of 5 interleaved barcode. Notes: 1. The positions of these functions are set within the barcode label (NOT able to be allocated to any character position in the barcode) except for Form Sequence within Job, Selective Feed and Customer ID. 2. The whole barcode can be read and data logged up to 25 characters. 3. Sequence direction and sequence start position are definable. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 22 Automailer 5 Specification Pack PFE Custom Control 8 This option reads alphanumeric characters in 3 of 9 barcode The following functions are supported: - Form Sequence within Job The page sequence number is constructed from 1 character of the label. The character value cycles from ‘0’ to ‘9’ then restarts at ‘0’. It increments for every page fed. (Character value can cycle from ‘1’ to ‘9’ then restart at ‘1’) Grouping Grouping is determined depending on the functions selected. There are 4 different ways to group. a) Grouping on customer ID (see below) b) Forms in Group and Form Sequence within a Group When these 2 functions are selected then they control the grouping of the documents. When the form sequence within the group is equal to the forms in group then EOG is set. (Security is maintained by checking the forms in group does not change until the group is complete and that the form sequence within a group in correct) c) Forms in a group and Group sequence EOG is set when the forms fed equals the forms in group. (Security is maintained by Checking the Group sequence is correct for the documents d) Forms in group When forms in group is used but no other sequence is used then we set an implied EOG. This is set when we have fed enough documents (i.e. when we reach the forms in group limit) this option for grouping is the least secure Customer ID This can be used to control the grouping. When the customer ID changes EOG is set for the document in front (completing the group). The customer ID must be on every page if this is being used to control the grouping of the documents. Selective Feed One character is used to control selective feeding from stations 1, 2 and 3. The character can have a value between ‘0’ and ‘7’. The decimal value is converted into a binary code where: 0 = Off 1 = On BIT 0 = Feeder 1 BIT 1 = Feeder 2 BIT 3 = Feeder 3 Selective Feed BIT 0 BIT 1 BIT 2 Character Value Feeder 1 Feeder 2 Feeder 3 0 0 0 0 1 1 0 0 2 0 1 0 3 1 1 0 4 0 0 1 5 1 0 1 6 0 1 1 7 1 1 1 The selective feeders can be changed via the substitution tables. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 23 Automailer 5 Specification Pack Form sequence within a group This uses 1 character to create a one digit decimal number, which always starts at 1 and ends at the value of the Forms in Group. The Form sequence within Group can have any value between ‘1’ and ‘9’. Matching This uses 1 character to create a one digit decimal number; the match character must be the same for each document within the group. The match character will then increment by 1 for the next group. After reaching ‘9’ it returns to ‘1’ Group Sequence This uses 1 character to create a one digit decimal number, the group sequence should increment by 1 with each new set of documents. After reaching ‘9’ it returns to ‘1’. Forms in-group This defines the number of pages in each set to go into an envelope and is a 3 digit decimal created from 3 barcode characters. Forms in group can have any value from ‘001’ to ‘999’. The value should be the same for all the pages of a set. Break Function (now a standard PFE BCS control function) This uses multiple characters within the barcode label to set an event on a change of the defined string (portion of the label). This event is selectable within the configuration of the job. (Possible events are: 1.Nothing 2. Autoend 3. Halt 4. Unseal 5. Ink Mark 1 / jog 6. Ink Mark 2 / Conveyor control Note the break function looks for a change in a defined string within the barcode label therefore the event will happen on the group after the change. BCS Character 6 has been separated into 9 separate functions so that all output processing options are independent of each other BCS 20 Envelope Divert 1 This character is used to control the envelope divert 1. This single character can be either 1 = ON (divert) or 0 = off BCS21 Envelope Divert 2 This character is used to control the envelope divert 2. This single character can be either 1 = ON (divert) or 0 = off BCS22 Envelope Divert 3 This character is used to control the envelope divert 3. This single character can be either 1 = ON (divert) or 0 = off Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 24 Automailer 5 Specification Pack BCS23 Ink Mark 1 / Jog This character is used to control the ink mark1/jog. This single character can be either 1 = ON (ink/jog) or 0 = off BCS24 Ink Mark 2 / Conveyor Control This character is used to control the ink mark 2 / conveyor control. This single character can be either 1 = ON (ink mark 2) or 0 = off BCS25 Franker 1 This character is used to control the franker1 solenoid. This single character can be either 1 = ON (Frank) or 0 = off (Don’t Frank) BCS26 Franker 2 This character is used to control the franker 2 solenoid. This single character can be either 1 = ON (Frank) or 0 = off (Don’t Frank) BCS27 Sheet Divert 1 This character is used to control the sheet divert 1. This single character can be either 1 = ON (divert) or 0 = off BCS28 Sheet Divert 2 This character is used to control the sheet divert 2. This single character can be either 1 = ON (divert) or 0 = off Notes: 1. The whole barcode can be read and data logged up to 25 characters. 2. All sequence characters can be more than one character if required. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 25 Automailer 5 Specification Pack PFE Custom Control 9 This option reads numeric characters in interleaved 2 of 5 barcode The following functions are supported: - Form Sequence within Job The page sequence number is constructed from 1 character of the label. The character value cycles from ‘0’ to ‘9’ then restarts at ‘0’. It increments for every page fed. (Character value can cycle from ‘1’ to ‘9’ then restart at ‘1’) Grouping Grouping is determined depending on the functions selected. There are 4 different ways to group. a) Grouping on customer ID (see below) b) Forms in Group and Form Sequence within a Group When these 2 functions are selected then they control the grouping of the documents. When the form sequence within the group is equal to the forms in group then EOG is set. (Security is maintained by checking the forms in group does not change until the group is complete and that the form sequence within a group in correct) c) Forms in a group and Group sequence EOG is set when the forms fed equals the forms in group. (Security is maintained by Checking the Group sequence is correct for the documents d) Forms in group When forms in group is used but no other sequence is used then we set an implied EOG. This is set when we have fed enough documents (i.e. when we reach the forms in group limit) this option for grouping is the least secure Customer ID This can be used to control the grouping. When the customer ID changes EOG is set for the document in front (completing the group). The customer ID must be on every page if this is being used to control the grouping of the documents. Selective Feed One character is used to control selective feeding from stations 1, 2 and 3. The character can have a value between ‘0’ and ‘7’. The decimal value is converted into a binary code where: 0 = Off 1 = On BIT 0 = Feeder 1 BIT 1 = Feeder 2 BIT 3 = Feeder 3 Selective Feed Character Value 0 1 2 3 4 5 6 7 BIT 0 Feeder 1 0 1 0 1 0 1 0 1 BIT 1 Feeder 2 0 0 1 1 0 0 1 1 BIT 2 Feeder 3 0 0 0 0 1 1 1 1 The selective feeders can be changed via the substitution tables. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 26 Automailer 5 Specification Pack Form sequence within a group This uses 1 character to create a one digit decimal number, which always starts at 1 and ends at the value of the Forms in Group. The Form sequence within Group can have any value between ‘1’ and ‘9’. Matching This uses 1 character to create a one digit decimal number; the match character must be the same for each document within the group. The match character will then increment by 1 for the next group. After reaching ‘9’ it returns to ‘1’ Group Sequence This uses 1 character to create a one digit decimal number, the group sequence should increment by 1 with each new set of documents. After reaching ‘9’ it returns to ‘1’. Forms in-group This defines the number of pages in each set to go into an envelope and is a 3 digit decimal created from 3 barcode characters. Forms in group can have any value from ‘001’ to ‘999’. The value should be the same for all the pages of a set. Break Function (now a standard PFE BCS control function) This uses multiple characters within the barcode label to set an event on a change of the defined string (portion of the label). This event is selectable within the configuration of the job. (Possible events are: 1. Nothing 2. Autoend 3. Halt 4. Unseal 5. Ink Mark 1 / jog 6. Ink Mark 2 / Conveyor control Note the break function looks for a change in a defined string within the barcode label therefore the event will happen on the group after the change. BCS Character 6 has been separated into 9 separate functions so that all output processing options are independent of each other BCS 20 Envelope Divert 1 This character is used to control the envelope divert 1. This single character can be either 1 = ON (divert) or 0 = off BCS21 Envelope Divert 2 This character is used to control the envelope divert 2. This single character can be either 1 = ON (divert) or 0 = off BCS22 Envelope Divert 3 This character is used to control the envelope divert 3. This single character can be either 1 = ON (divert) or 0 = off Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 27 Automailer 5 Specification Pack BCS23 Ink Mark 1 / Jog This character is used to control the ink mark1/jog. This single character can be either 1 = ON (ink/jog) or 0 = off BCS24 Ink Mark 2 / Conveyor Control This character is used to control the ink mark 2 / conveyor control. This single character can be either 1 = ON (ink mark 2) or 0 = off BCS25 Franker 1 This character is used to control the franker1 solenoid. This single character can be either 1 = ON (Frank) or 0 = off (Don’t Frank) BCS26 Franker 2 This character is used to control the franker 2 solenoid. This single character can be either 1 = ON (Frank) or 0 = off (Don’t Frank) BCS27 Sheet Divert 1 This character is used to control the sheet divert 1. This single character can be either 1 = ON (divert) or 0 = off BCS28 Sheet Divert 2 This character is used to control the sheet divert 2. This single character can be either 1 = ON (divert) or 0 = off Check Digit This is a single character used to check the value of all the characters in the label. This is a standard feature of 2 of 5 interleaved barcode. (This feature can be turned on or off depending on the barcode printed, although for security it is recommended that it is used) Notes: 1. The whole barcode can be read and data logged up to 25 characters. 2. All sequence characters can be more than one character if required. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 28 Automailer 5 Specification Pack 9 Appendix 2 Customer ID Control Customer ID control is a technique that allows the customer to use an existing barcode (or any label type including 3 of 9, 2D Data matrix and 12 of 5) to achieve grouping without having to change the barcode for the Automailer 5. Example A customer already has barcodes on their documents as follows:Printed Page Customer Name Page No. 1 2 3 4 5 6 7 8 Mr Smith Mr Jones Account Number For Mailing Mr Ellis Mrs Ellis 1 1 2 3 1 2 3 4 A237455 M726841 M726841 M726841 C839572 C839572 C839572 C839572 ExistingBarcode Label 0101A237455 0201M726841 0202M726841 0203M726841 0301C839572 0302C839572 0403C839572 0404C839572 The existing barcode label gives no indication of end of group. However, the customer ID system can be set up to look at any information in the label for grouping. Example 1: Account Number In this case we can look at just the account number, which starts at character 5 and is 7 characters long. The AM5 software will test each successive document and if the number is the same for these 7 characters then it will group them together. This is correct for the mailing requirement for this particular job run. Example 2: Change of Name Another job run on the same barcode may require to separate documents by name rather than account number. In this case we can set the AM5 to read from character 1 for 2 characters. The software will then compare successive documents looking only at the first 2 characters of the barcode. Characters with the same value will be collated together. Note that in both cases data logging can be independently set to log any part or all of the label. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 29 Automailer 5 Specification Pack Customer ID Control and Insert Matching As part of the customer ID control, PFE can also achieve matching with any other insert station with reading capability, providing that it is in a ‘Feed Always’ mode. To achieve this the both the prime document and the insert use the same characters for the match comparison. Example. Prime document label First character for ID Number of characters for ID Customer ID characters used for grouping 0201M726841 Character 5 7 characters M726841 Insert Label First Character for match ID Number of characters for ID Customer ID characters used for match 678M726841BRE Character 4 7 characters M726841 Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 30 Automailer 5 Specification Pack AUTOMAILER 5 PLUS (AM5) OMR SPECIFICATION FOR INTELLIGENT MAILING SYSTEMS Contents 1. Introduction Page 32 2. Automailer 5 OMR System, All Functions Page 32 3. Print areas (by unit) Page 41 4. Printers Principles Page 44 5. Feed Unit Information Page 46 Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 31 Automailer 5 Specification Pack Section 1 Introduction This specification covers the requirements for OMR marking for Automailer 5 (referred throughout this document as AM5) Intelligent Systems. This specification relates to the OMR functions available, the mark size and positioning of marks on the forms. The full range of OMR facilities is referred to as the AM5 OMR System. This specification consists of 4 sections as follows: Section 1. Introduction (This section). Section 2. AM5 OMR System. This section describes all the OMR functions that are available. Section 3. Print areas. This section deals with the dimensional details and layout requirements for the marks for each of the OMR reading units. Section 4. Printers. This section describes the features of laser printers and continuous forms printers that are relevant to the type and positioning of OMR marks. Section 5. Feed Unit Information. This section describes the functions of the Collator, OMR Folder and OMR Feeder, and gives details of paper orientation etc. Section 2 AM5 OMR System 2.1 Principles As AM5 OMR marks are read using a scanning Barcode head the following rules apply: a) There is complete freedom to position the OMR marks on the document in any position subject to the mechanical reading limitations of specific units (refer to section 5). b) Marks must be equally spaced with a pitch of at least 3mm. c) All marks must be contained in a continuous set of marks with equal spacing contained within a 100mm set, first to last. d) All marks are horizontal with vertical spacing on a portrait document. e) A mark set can be printed ascending or descending, and the gate mark must always be at one end of the set. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 32 Automailer 5 Specification Pack 2.2 Function Descriptions 2.2.1. Gate Mark 1 mark Within the sequence of OMR marks the gate mark must be the first mark of the set (ie. mark at position 1). This ensures that the position of the marks on the form is synchronized to the lead edge of the form, for reliable reading of the following function marks. Additionally, as the OMR system needs to find a gate mark on each page, it will detect unprinted blank pages. Note: The mark set may be printed either way up, i.e. gate mark at the top with marks descending or gate mark at the bottom with marks ascending. In either case, it must always be 'Mark at position 1' when defining the marks in the software. 2.2.2. Grouping of Multi-page Prime Documents 1 mark Multiple pages can be grouped together for insertion into the same envelope. The function mark required is one of the following: a) “End of Group Mark”. Printed on the last page of a group, it is the last sheet to be fed and stops the next page being collated with the group in the collate pocket. b) “Demand Feed Mark”. Printed on all the pages of a group except the last page. (Inverse EOG). c) “First of Group Mark”. Printed on the first page of a group, is fed but held at a hold point while the previous group is sent out of the collate pocket. d) “Demand FOG Mark”(inverse of FOG). Printed on every page of the set except the first page. 2.2.3 Parity Mark 1 mark The function of the parity mark is to check if the correct number of marks have been read. For example, if even parity is being used then on all pages there will be an even number of marks printed, which means that if all the function marks printed excluding the parity mark add up to an odd number, then the parity mark is printed. If all the function marks printed excluding the parity mark add up to an even number, then the parity mark is not printed. The options for the parity marking are: a) Even parity marking. b) Odd parity marking. c) No parity marking. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 33 Automailer 5 Specification Pack 2.2.4 Diverting Forms Before Fold 2 marks The AM5 OMR System allows programming for up to 2 divert bins, which may be fitted to the output of the AM5 Accumulator System. The divert destination is defined by means of a Single Mark. Note: The divert mark can be assigned to bin 1 or bin 2. Divert Bin Destination Mark No. Bin 1 Fold Bin 2 Divert Mark Divert Mark 2.2.5 Ink Mark 1/Jog and Ink Mark 2/Conveyor Control 2 marks Two marks are used here to achieve Ink Marking, jogging (on divert conveyor) and output conveyor control. Ink Mark 1/Jog is used for the existing ink marker A3204A. Ink Mark 2/Conveyor is used to control the existing output conveyor E1520AA. Both Marks can be used to Ink Mark on the Vertical Envelope Stacker E1581AB. Ink Mark 1 also controls the Vertical Stacker (VS) jog. Ink Mark, Jog and Conveyor Control Mark No. No Mark / No Jogging / No Conveyor Control Ink Mark 1 /Jog Ink Mark 2 / Conveyor Control Both Ink Mark 1 /Jog Ink Mark 2 / Conveyor Control 2.2.6 Envelope Unseal 1 mark A single mark may be used to program the wetter to Unseal. If an OMR mark is detected in the Envelope Unseal position on the prime document, when that form is inserted into the envelope, the wetter is lifted clear to prevent sealing of the envelope. This facility could be used where additional manually inserted items need to be added to the envelope, or if an operator audit of the envelope contents needs to be carried out periodically. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 34 Automailer 5 Specification Pack 2.2.7 Output Divert 3 marks A set of up to 3 marks may be used to define one of 6 output processing diverts as the destination of the filled envelope or a straight through path. Each mark independently controls a divert bin as shown below. Divert Bin Output Processing Mark Straight Through Bin Number 1 2 3 (O.P. Mark 1) (O.P.Mark 2) (O.P.Mark 3) 2.2.8 Selective Feeding of Inserts 15 marks The selective feed facility allows the selection of up to 15 inserts to be added to the prime document depending on the OMR marks printed on the prime document. The maximum number of selective feeds is limited to the maximum number of additional feed units fitted. Select From Feed Station 1 Select Feed Mark 1 Select Feed Mark 2 Select Feed Mark 3 Select Feed Mark 4 Select Feed Mark 5 Select Feed Mark 6 Select Feed Mark 7 2 3 4 5 6 7 ––– ––– ––– ––– ––– ––– ––– Etc up to 15 Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 35 Automailer 5 Specification Pack 2.2.9 Form Sequence within a Job 5 marks The purpose of this mark function is to code each page of a print run with a number sequence running from 0 up to 31 and then restarting at 0. This number sequence is printed on each page of a print run, in sequence, regardless of the document sets and customer identities. Therefore, as soon as a loss of sequence is detected, it indicates an error in the page order and stops the machine so that the operator can rectify the fault. This ensures that integrity of document sets is maintained, and that each envelope is filled correctly. This function is achieved by programming up to 5 marks and printing them as a binary sequence as shown below. If a smaller number of marks is required then it is possible to use either four, three, two or one mark, in which case the numbering goes from 0 to 15, 0 to 7, 0 to 3 or 0 to 1 respectively. It is not generally recommended to use less than three marks. The AM5 OMR System can check the numbering in either a count up sequence, or a count down sequence. Additionally, if the forms are printed with no zero, for example, 1 to 7, or 1 to 15, then the checking system can be programmed to exclude zero from the number sequence. Page Sequence Mark No. FSN Mark No.1 0 1 –– 2 3 –– 4 5 –– 6 7 –– 8 9 –– 10 11 12 13 14 15 –– –– –– FSN Mark No.1 –– –– FSN Mark No.3 –– –– –– –– –– –– –– –– FSN Mark No.4 –– –– –– –– –– –– –– –– –– –– –– –– –– –– FSN Mark No.5 Cont..... Page Sequence Mark No. FSN Mark No.1 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 –– –– –– –– –– –– –– –– FSN Mark No.2 –– –– –– –– –– –– –– –– FSN Mark No.3 –– –– –– –– –– –– –– –– FSN Mark No.4 –– –– –– –– –– –– –– –– FSN Mark No.5 –– –– –– –– –– –– –– –– –– –– –– –– –– –– –– –– Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 36 Automailer 5 Specification Pack 2.2.10 Form Sequence within a Group 4 marks The purpose of this function is to code each page of a group of forms with a number sequence running from 0 up to 15 and then restarting at 0 for groups, which exceed 16 pages. This number sequence is printed on each page of a group, which is to be inserted into an envelope. Therefore, as soon as a loss of sequence is detected, it indicates an error in the page order and stops the machine so that the operator can rectify the fault. This ensures that integrity of document sets is maintained, and that each envelope is filled correctly. This function is achieved by programming up to 4 marks and printing them as a binary sequence as shown in the table below. On some of the AM5 infeed units, the forms are fed from the back of the form stack, i.e. in reverse order. In these cases the numbering should be in the feed order of the forms. So, for a five page group, the last page should be numbered 0, with the page count increasing towards page one of the group. If the forms are printed with no zero, i.e. starting at a count of one, then the checking system can be programmed to exclude zero from the number sequence. Note: The normal security system for ensuring that all the printed pages are processed correctly through the AM5 is Form Security Numbering. Group Security Numbering should only be considered when Form Security Numbering cannot be used. Page Sequence (In Page Feed Order) Mark No. GSN Mark No.1 GSN Mark No.1 GSN Mark No.3 GSN Mark No.4 Nobody does it better! 0 1 –– 2 3 4 –– 5 –– –– –– 6 7 –– –– –– –– –– –– –– 8 9 –– 10 11 12 13 14 15 –– –– –– –– –– –– –– –– –– –– –– –– –– –– –– –– –– –– –– Automailer 5 Specifications - Issue 12 • Page 37 Automailer 5 Specification Pack 2.2.11 Group Sequence 4 marks The purpose of this function is to code each group of forms with a number sequence running from 0 up to 15 and then restarting at 0 for the next group. This group sequence is printed on each page of a group, which is to be inserted into an envelope. Therefore, as soon as a loss of sequence is detected, it indicates an error in the page order and stops the machine so that the operator can rectify the fault. This ensures that integrity of document sets is maintained, and that each envelope is filled correctly. This function is achieved by programming up to 4 marks and printing them as a binary sequence as shown in the table below. Group Sequence 0000 0000 0000 1000 1000 0100 1100 0010 1010 1010 0110 1110 0001 1001 0101 1101 0011 1011 1011 0111 1111 Nobody does it better! Customer 1 1 1 2 2 3 4 5 6 6 7 8 9 10 11 12 13 14 14 15 16 Page 1 2 3 1 2 1 1 1 1 2 1 1 1 1 1 1 1 1 2 1 1 Automailer 5 Specifications - Issue 12 • Page 38 Automailer 5 Specification Pack 2.2.12 Matching 5 marks When personalised documents are being fed from more than one OMR station for insertion into the same envelope, it is possible to code the individual pages with the same 5 mark pattern to indicate that the pages belong together. In this situation the OMR marks are read on each individual page at each of the OMR stations. When the two, or more personalised sets of marked documents are merged on the insert track the control system checks if the match marks are the same. If there is a mismatch of the match marks the machine stops with an error message displayed. For the system to continue operation all the forms with OMR match marks which are to be inserted together into one envelope must have the same match code. Any difference in the match code on any page indicates that that page does not belong with the others and stops the inserter until the operator corrects the problem and restarts the system. The match codes can be generated randomly, no particular sequence or order is required. In the table shown on the following page, all of the 32 possible mark combinations are shown with their numerical values. Equivalent Numeric Value Mark No. Match Mk.1 0 1 –– 2 3 –– 4 5 –– 6 7 –– 8 9 10 11 12 13 14 15 –– –– –– –– Match Mk.2 –– –– Match Mk.3 –– –– –– –– –– –– –– –– Match Mk.4 –– –– –– –– –– –– –– –– –– –– –– –– –– –– Match Mk.5 Cont..... Equivalent Numeric Value Mark No. Match Mk.1 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 –– –– –– –– –– –– –– –– Match Mk.2 –– –– –– –– –– –– –– –– MatchMk.3 –– –– –– –– –– –– –– –– Match Mk.4 –– –– –– –– –– –– –– –– Match Mk.5 –– –– –– –– –– –– –– –– –– –– –– –– –– –– –– –– Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 39 Automailer 5 Specification Pack 2.2.13 Halt Function 1 mark The halt function consists of one mark which when detected by the OMR system completes the collation of the document group and all other actions until the document set is ejected on to the track. It then stops the inserter without indexing the track. This allows operator intervention for whatever purpose, for example, to periodically confirm correct operation of the mailing run. Note: If the document with the halt mark also has a divert mark, then as that document never reaches the insert track, it will not cause the system to stop, hence the halt mark should not be used in a set of documents which are marked for diversion. 2.2.14 Force Fold 1 mark This mark is used with multi-page documents, when it is required to break the document group into specific sets, earlier than the maximum fold limit which has been set. When the page with the Force Fold mark arrives in the collator part of the feed unit, the document set up to that page is immediately sent to the folder and on to the track. The track shuttle will not move as the complete set of documents up to the form with the end of group mark has not been processed. The remainder of the forms of the group will be fed and folded in sets equalling the “max for fold” number programmed as a default for the job until the end of group is seen. Then the track shuttle will hand over the group to the next track section. 2.2.15 Page Count Verification 4 marks This is a security facility where binary coding is used ensure that the correct number of pages has been fed from the hopper. The pages are fed from the hopper until the ‘End of Group’ mark is detected. The number of pages that have been fed will be compared with the Page Count Verification marks, and if there is a discrepancy between these two numbers an error will be indicated. The total page count can appear on any page of the set and will be a number between 0 and 15. If the number of pages in the group is greater than 15, the coded number to be printed is the remainder after dividing by 16, eg. if the group has 18 pages, the remainder is 2 which equals mark no. 2. Number of Pages in the Group Page Count No. Page Cnt. Mk. 1 Page Cnt. Mk. 2 Page Cnt. Mk.3 Page Cnt. Mk.4 Nobody does it better! 0 1 –– 2 3 –– –– –– 4 5 –– 6 7 –– –– –– –– –– –– –– 8 9 10 11 12 13 14 15 16 17 18 –– –– –– –– –– –– –– –– –– –– –– –– –– –– –– –– –– –– –– –– –– –– Automailer 5 Specifications - Issue 12 • Page 40 Automailer 5 Specification Pack 2.2.16 Autoend 1 mark This mark may be used at the end of the job when it is required to automatically enter the ‘Autoend’ mode. The system operates by detecting this mark in the last document set, and then setting the ‘Autoend’ mode so that the marked document set is the last to be enveloped and ejected on to the output conveyor. This mark may also be used when there is a requirement to interrupt a job into well defined parts, for example to batch work by post code, or any other defined criterion. 2.2.17 Machine Control By Document Criteria Automailer 5 can change the control mode for a number of non-OMR, document related criteria. The document criteria of a specific group can be used to control the following modules: a) Divert Before Fold This can be controlled by setting the maximum number of prime document pages to less than the maximum for folding. b) Halt On Track This can be controlled by setting ranges by number of prime document pages or weight groups so that a change in range causes the machine to halt with a message “Group is out of range”. All the groups downstream of the out of range group will be processed and ejected out of the machine. The out of range group will be stopped at the insert station. The operator can then choose to: 1) Continue job with new number of prime documents/weight group 2) Remove out of range group and continue job with same number of prime documents/weight group c) Output Processing Divert The output processing diverts can be controlled by number of prime documents/weight group range. Section 3 Print Areas and OMR Mark Definitions This section details the position on the document where the OMR marks can be correctly read, and the definition of the marks in terms of width, length, spacing, set length and clear areas. The print area will be specific to groups of units using the same mechanisms as follows: Automailer 5 OMR Modules GROUP A E1542AA E1546AA E1561AA E1562AA E1563AA Hi-Cap OMR/Barcode Folder On-Line OMR/Barcode Folder Hi-Cap Collator On-Line Collator 2-Up On-Line Collator GROUP B E1552AA E1556AA (E1572AA OMR/Barcode Feeder On-Line OMR/Barcode Feeder Insert Turnover) Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 41 Automailer 5 Specification Pack 3.1 Group A Print Areas and OMR Mark Definitions NOTE: pitch can be as small as 2mm provided accuracy of pitch is better than 10% line-to-line and line-to-gate. Width must be minimum 8mm not including print tolerance errors (i.e. if print tolerance is +/- 2mm in same print run, then mark width must be 12mm) Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 42 Automailer 5 Specification Pack 3.2 Group B Print Areas and OMR Mark Definitions NOTE: pitch can be as small as 2mm provided accuracy of pitch is better than 10% line-to-line and line-to-gate. Width must be minimum 8mm not including print tolerance errors (i.e. if print tolerance is +/- 2mm in same print run, then mark width must be 12mm). Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 43 Automailer 5 Specification Pack Section 4 Printers 4.1 Introduction The forms, which constitute the prime documents processed through AM5 will be printed either on laser printers or impact printers. Impact printers will in turn divide into two categories. The first: printers where each character is composed of an array of dots, and hence there is a graphics capability. The second: printers where, each character is printed as a single impact of one of a set of predefined characters, which generally does not include any graphics symbols. In both cases specific requirements for character type and quality are defined in later paragraphs. 4.2 Print Order and Orientation 4.2.1 General All OMR and barcode requirements for AM5 will always be read at the OMR/Barcode unit, which is downstream of any guillotine or merging devices. Subsequently, the forms are always in finished, cut-sheet form when being read and processed. Marks which are removed during on-line processing cannot be used on AM5. 4.2.2 Orientation and Order (Group A) All group A units require the paper to be fed face up, head first, eg. from page 1 first to page 10 last. This will ensure that page 1 always appears in the window of the envelope. If an OMR folder is being used, i.e. no accumulator fitted, it is possible to load the forms face down, tail first, eg. from page 1 first to page 10 last. It should be noted that the stack order here is reversed (i.e. this option allows for reverse order printing). 4.2.3 Orientation and Order (Group B) All group B units require the paper to be fed face down, feet first, eg. from page 1 first to page 10 last. This requires the stack to be compiled in reverse order. 4.2.4 Orientation and Order using Turnover (Group B) The insert turnover option allows the forms to be loaded in correct print sequence, i.e. face up and head first. 4.3 Printed Characters Used as OMR Marks For laser printers, marks can be defined as shown in section 3 on page 26 (width >8mm, thickness >0.5mm). For impact printers the following characters are suggested: For Portrait printed documents, marks are horizontal. Therefore use: ___ Underscore - Three underscores next to each other, usually no gaps between them. For Landscape printed documents marks are vertical. Therefore use: Lower case ‘L’ Three lower case ‘L’s (appearing as 'l') on consecutive lines, with no line spacing, to produce a continuous line. 'Arial' font must be used. Note that there are at present no other characters suitable for OMR marks for impact printers. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 44 Automailer 5 Specification Pack 4.4 Optimising OMR Characters for Best Reading Performance 4.4.1 Mark Density The greater the density the better the read. 4.4.2 Mark Line Depth (thickness) The thicker the line the better the read. A thicker line helps to prevent dirt, ghosting or other poor quality printing defects from being detected as an OMR mark. 4.4.3 Mark Pitch The Automailer 5 OMR/Barcode scanner deals only with fixed pitch, i.e. the distance between each successive mark must be the same for the whole mark set. The smaller the pitch the better the read. The reader head takes a ‘snap shot’ of the OMR set as it passes under the scanner and the narrower the snap shot is the easier it is for the read head to interoperate the results. PFE recommend a 3mm pitch. 4.4.4 Mark Depth to Line Depth Ratio The ratio between the line pitch and the line depth is recommended to be approximately 4:1. If a wide pitch is being used the line thickness may become too large. In this case it is recommended to at leadt have a line thickness of 1mm. 4.4.5 Pitch Tolerance The pitch tolerance is recommended to be better than the following: a) Pitch Tolerance Line to Line: 15% of the Pitch b) Pitch Tolerance Each Line to Gate:15% of the Pitch Tolerance For a 3mm pitch this allows an error of 0.5mm for one line relative to another (as per a) above. This is not a progressive tolerance (see b) above. 4.4.6 Mark Set Length The minimum mark set length achievable (distance between the first and last mark) is recommended. The maximum mark set length is 100mm. 4.4.7 Mark Width The width of each line should be greater than 8mm. This does not allow for print variations. If the OMR marks move relative to the edge of the page by, say, +/- 2mm then the line width should be increased to 12mm. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 45 Automailer 5 Specification Pack 5 Feed Unit Information 5.1 Collators (E1561AA, E1562AA and E1563AA) Collation Collation of documents is carried out in the ‘Accumulator’ of the systems unit and allows for up to 8 sheets to be collated together before fold (dependent on material, fold type and envelope capacity). Single page or multiple page sets can be diverted before fold in a Sheet Divert Unit (E1570AA) if fitted. Sheet divert units allow for documents to be diverted for bad read, bad sequence, oversized groups or by OMR/Barcode control. A sheet divert unit is recommended for ease of operation. Collation of documents before fold maintains the production speed of the machine for group sizes of an average of 2 pages per set. Feed Orientation The feed orientation is always face up, head first (relative to the addressed face of the document). Print Sequence Print sequence is always first to last, i.e. page 1 is on the top of the printed stack. Reading Surfaces Reading can be carried out on either the top or the bottom surface of the document. This allows for duplex printed material with the OMR/Barcode on the reverse side of the document. 5.2 OMR/Barcode Folder (E1542AA, E1546AA) Collation Collation of forms is always on the Shuttle Bed (after fold). The number of sheets collated in a group is dependent on the material, fold type and envelope capacity. Collation after fold reduces the machine speed with the number of forms in the group. Feed Orientation The feed orientation (relative to the addressed face of the document) can be either: a) Face up, head first (using a ‘Z’ fold) or b) Face down, feet first (using a ‘C’ fold) Print Sequence Print sequence is dependent on feed orientation. If the document orientation is face up, as per a) above, then the print sequence is first to last, i.e. page 1 is on the top of the printed stack. If the document orientation is face down, as per b) above, then the print sequence is last to first, i.e. page 1 is on the bottom of the printed stack and the stack is inverted in the Hi-Cap feeder. Reading Surfaces Reading can be carried out on either the top or the bottom surface of the document. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 46 Automailer 5 Specification Pack 5.3 OMR/Barcode Feeder (E1552AA, E1556AA) Collation Collation of forms is always on the ‘shuttle bed’. Feed Orientation The feed orientation is always face down, feet first (relative to the addressed face of the document). Print Sequence The print sequence is last to first, i.e. page 1 is on the bottom of the printed stack. The stack is inverted in the feeder so that page 1 is fed first. Reading Surfaces Reading is only carried out on the bottom surface of the document. End of Group Mark The end of group mark must appear on the last page of the set which is the last page to be printed. 5.4 OMR/Barcode Feeder with Turnover (E1572AA) Collation Collation of forms is always on the ‘shuttle bed’. Feed Orientation The feed orientation is always face up, head first (relative to the addressed face of the document). Print Sequence The print sequence is first to last, i.e. page 1 is on top of the printed stack. The stack is the correct way up in the feeder so that page 1 is fed first. End of Group Mark The end of group mark must appear on the last page of the set which is the last page to be fed. Reading Surfaces Reading is only carried out on the bottom surface of the document. General Notes a) The OMR/Barcode head and bracket assembly is not switchable by the operator between top and bottom reading. If reading on both surfaces is required then two reading heads and bracket assemblies must be fitted. b) If it is required to frequently change the OMR/Barcode head position between two different positions then it is recommended that two heads be fitted for ease of operation. c) The sheet divert unit (E1570AA) is not a ‘forms processor’. The sheet divert is provided to reject exceptions only. Any diverted forms should not be reprocessed through the machine. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 47 Automailer 5 Specification Pack AUTOMAILER 5 PLUS (AM5) GENERAL SPECIFICATIONS Contents Feeders & Folders Page 49 Collator Page 51 Speeds / Volume Page 51 Envelope Specification Page 52 Insert Pack Page 52 Electrical Specification Page 53 Physical Data Page 55 Machine Weights Page 56 Heat & Humidity Data Page 57 Important Notes Page 57 Print Sequence & Paper Orientation Page 58 Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 48 Automailer 5 Specification Pack Hi-Cap or Lo-cap 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: (Lo-Cap) 2000 sheets 80gsm (20lbs bond) (Hi-Cap) 5000 sheets 80gsm (20lbs bond) per trolley (second Hi-Cap trolley provided for off-line loading) Glossy material acceptable, subject to test. 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: 53mm (2”) minimum for all fold plates 230mm (9”) maximum for fold plate 1 155mm (6”) maximum for fold plates 2 & 3 Fully automatic separator settings and double document calibration. OMR/Barcode Hi Cap Folder also available with top or bottom reading. Feeder: 3 Depth: 85mm - 152mm (3 3/8” - 6”) for Stations 2, 4, 6 etc. 70mm - 152mm (2 /4” - 6”) for Stations 1, 3, 5 etc. Width: 140mm - 241mm (5 1/2” - 9 1/2”) for Station 1 only 140mm - 225mm (5 /2” - 8 7/8”) for Station 2 onwards Weight: 70gsm (18lbs bond) minimum Insert thickness: 4mm maximum 1 Glossy material acceptable, subject to test. Hopper capacity: (inserts) 2000 of 80gsm (20lbs bond). (envelopes) 1000 of 80gsm (20lbs bond). Length of available track: 500mm (19.5”) Hopper loading: Hopper can be back-loaded while machine is running. OMR/Barcode also available with bottom read only. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 49 Automailer 5 Specification Pack On-Line 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 Folder. On-Line OMR/Barcode Folder also available with top and bottom reading. On-Line Feeder: Depth: 89mm - 152mm (3 1/2” - 6”) NOTE: All other details as per standard Feeder. On-Line OMR/Barcode Feeder also available with top and bottom reading. NOTE: All Feeders can also be fitted with Turnover unit to invert the print sequence. Curled Stationery Curled stationery caused by either the print process or storage conditions may cause failure to feed, or skewed feeding. PFE 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, not PFE. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 50 Automailer 5 Specification Pack Collator (with Hi-Cap or Lo-Cap folder, single On-Line Interface with Folder, or 2-Up On-Line Interface with Folder) Fully automatic separator settings and double document calibration. Depth: Width: 149mm - 406mm (5 7/8” - 16”) 149mm - 216mm (5 7/8” - 8 1/2”) Max. number of forms: 8 of 80gsm for folding, in ‘C’, ‘Z’ or ‘V’ fold (5 in ‘C’ or ‘Z’ fold recommended) 20 for oversize group diverting, 9 recomended Maximum processing speed 21,000 forms per hour. Barcode / OMR reader: Mark Orientation: Mark Size: Scanning reader head, top or bottom read Vertical or horizontal All commonly used OMR marks acceptable. Refer to PFE document ‘Specifications for Automailer 5 Plus’, covering OMR and Barcode specifications. Diverter (if fitted): 2 bin diversion without stoppage. Forms accumulate in correct order. 250 sheets per bin Diverter Capacity: 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. PFE Technical Support should always be consulted when the possibility of doubles mis-reads may occur. Data Logging Data logging capacity included when using barcodes. Data is logged for date, time, selected barcode characters, number of pages in group, destination and output or crash information where applicable. Note: Barcode data can also be used for diverting. See ‘Automailer 5 Data Logging Specification’. Production Rate: Typically 5000 filled envelopes per hour, with 1 ‘C’ folded document plus 1 insert (includes hopper refill time). Cycling Speed: Up to 8000 envelopes per hour Volume: Typically 500,000 filled envelopes per month Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 51 Automailer 5 Specification Pack Envelope Specification Max. 62mm (21/2”) Min. 25mm (1”) Max. 171mm (63/4”) Min. 89mm (31/2”) 0 20 Maximum Max. 25mm (1”)* Min. 9mm (3/8”) Max. 263mm (103/8”) - Min. 171mm (63/4”) * Executive flap envelopes with ‘V’ throat also acceptable. Envelope Requirements: Weight: 80gsm (20lbs bond) minimum. Good quality machine envelopes, with windows securely gummed and side seams glued up to the top. Hopper Capacity: 1000 envelopes 80gsm (20lbs bond). Insert Pack: Max. Pack Depth: Max. Pack Width: Max. Pack Thickness: 154mm 241mm 8mm (uncompressed, and after inserting in envelope) Min. clearance between insert pack width and envelope to be 12mm (nominally 6mm either side). The prime document must be greater in depth than the maximum insert depth less 7mm. Insert Pack Width Variation: The maximum difference in width between all documents of the insert pack must be less than 60mm. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 52 Automailer 5 Specification Pack Electrical Specification Input Voltage 115v @ 60Hz or 230v @ 50Hz (± 10% maximum) Power Connector Machine fitted with BS4343 32A IP44 industrial free plug connector, conforming to EN60309 1 & 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 Automailer 5. 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 PFE 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 Folders, a Hi-Cap and a Lo-Cap Folder or an OMR/Barcode 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 184-156 to ensure correct operation. See following page for details of current ratings. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 53 Automailer 5 Specification Pack Current Rating: RATED CURRENT UNIT DESCRIPTION @ 115v @230v Head 4A 2A 2 Stn. Module (Track Pair) 1A 0.5A Feeder 1A 0.5A Lo-Cap Folder 3A 1.5A Hi-Cap Folder 4.6A 2.3A Lo-Cap Collator 1 6.3A 3.2A Hi-Cap Collator 1 8A 4A 28.6A 14.3A 30A 30A Typical System Total 2 Maximum Allowable Rated Current PEAK CURRENT Any System Rated Current + 6A Rated Current + 3A Maximum Peak Current 36A 33A Lo-Cap/Hi-Cap Collator comprises: Collator Unit OMR/Barcode Reader Lo-Cap/Hi-Cap Feeder Folder 2-Bin Divert 1 2 Typical system (8 station) comprises: Head 2 Station. Module Feeder Lo-Cap Folder Hi-Cap Folder Hi-Cap Collator Nobody does it better! Qty. 1 Qty. 4 Qty. 5 Qty. 1 Qty. 1 Qty 1 115v 4A 4A 5A 3A 4.6A 8A 28.6A 230v 3.5A 2A 2.5A 1.5A 2.3A 4A 14.3A Automailer 5 Specifications - Issue 12 • Page 54 Automailer 5 Specification Pack Physical Data: Notes: 1. For normal operator access, allow 1m from any point of the machine. 2. Collator (with feeder) can be withdrawn 160mm on runners. Floor Loading (normal): 41.5 x 103 kg/m2 (59 lb mass/in2) 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 103 kg/m2 (118 lb mass/in2) Worst case floor loading assumes only two feet of each unit (head or station pair) are correctly adjusted and in contact with floor. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 55 Automailer 5 Specification Pack Weights: Weight (Kg) Unit Description Unpacked Packed Head 286 443 2 Station Track Unit 110 126 Feeder (with perspex cover & Feeder Interface) 36 48 Folder (with perspex cover) 35 38 Lo-Cap Feeder: 80 110 Hi-Cap Feeder: 115 157 78> 107 37> 50 191 235 90> 110 35> 45 66> 80 Output Conveyor 33 48 1 Bin o/p Processor 20 26 2 Bin o/p Processor 36 42 3 Bin o/p Processor 52 58 M/Bag Trolley+2Bags** 15 25 Franker I/F+Table † 25 45 Single Divert Conveyor 40 60 Track & 2 Feeders 182 N/A Track & 1 Feeder 146 N/A Lo-Cap Collator/Folder 255 N/A Ho-Cap Collator/Folder †† 290 N/A Feeder only < Trolley only* < Collator Collate unit only (on stand) < Reader only (on stand) < Diverter only (on stand) < Combined Modules * Hi-Cap Feeder is supplied with 2 trolleys, separately packed. ** Load capacity = 36kgs per mailing. † Franker not included. †† Add a further 37kg for extra trolley, packed and supplied separately. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 56 Automailer 5 Specification Pack Maximum Heat Output (BTU/hour): Rated current x Rated Volts x 3.412 (eg. 11,222 BTU/hour for ‘typical’ configuration described on page 54). Maximum Heat Output (Watts): Rated Current x Rated Volts (eg. 3.289 kW for ‘typical’ configuration described on page 54). Operating Temperature: 18 - 28 deg C (64 - 82 deg F) Operating humidity: 30 - 80% RH Noise Level: Without 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) 79dBA Note: 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. 1643 With collator: 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 sepatarors may be required for the sheet feeders (Hi-Cap and Lo-Cap). Request Hi-Grip Separator Assembly C8171A. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 57 Automailer 5 Specification Pack 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 Product Code Paper Orientation Print Sequence Fold Type for Top Address Fold Type for Bottom Address OMR/Barcode Reader Position (see note 1) Feeder E1550AA Face down, feet first N/A N/A N/A N/A Lo-Cap/Hi-Cap Folder E1540AA E1541AA Face down, feet first N/A C or V Z or V + Turnover N/A Hi-Cap Collator E1561AA Face Up, Head first Forward (A-Z) C or V Z or V + Turnover Top Reader OMR/Barcode Feeder E1552AA Face Up, Head first Reverse (Z-A) See note 2 N/A N/A Bottom Reader OMR/Barcode Feeder with Turnover E1552AA + E1572AA Face down, feet first Forward (A-Z) See note 3 N/A N/A Bottom Reader OMR/Barcode Hi-Cap Folder E1542AA Face Up, Head first Forward (A-Z) Z or V * Z + Turnover or V + Turnover Top Reader OMR/Barcode Hi-Cap Folder E1542AA Face down, feet first Reverse (Z-A) C or V Z or V + Turnover Bottom Reader On-Line Feeder E1555AA Face down, feet first N/A N/A N/A N/A On-Line Folder E1545AA Face down, feet first N/A C or V Z or V + Turnover N/A On-Line Collator E1562AA E1563AA Face Up, Head first Forward (A-Z) C or V Z or V + Turnover Top Reader OMR/Barcode On-Line Feeder E1556AA Face down, feet first Reverse (Z-A) See note 2 N/A N/A Bottom Reader OMR/Barcode On-Line Feeder with Turnover E1556AA + E1572AA Face Up, Head first Forward (A-Z) See note 3 N/A N/A Bottom Reader Output Conveyor E1520AA Window Face Up Reverse (Z-A) N/A N/A N/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 OMR Feeder. 2. For an OMR /Barcode 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 an OMR/Barcode 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 OMR/Barcode 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. Nobody does it better! Automailer 5 Specifications - Issue 12 • Page 58

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