OPEX 3804007 Users Manual
OPERATOR MANUAL
NOVEMBER 2007
Copyright © 2007 OPEX
®
Corporation
All rights reserved. Printed in the United States of America.
No portion of this manual may be reproduced in any form or by any means, or stored in a database
or retrieval system, without the express, written permission of OPEX
®
Corporation.
To request permission, contact:
®
OPEX
Corporation
ATTN: Legal Department
305 Commerce Dr.
Moorestown, NJ 08057-4234
About this manual...
The Mail Matrix Operator Manual uses the following conventions when describing
certain procedures and situations. Please be aware of these conventions when
reading the manual and operating the machine:
The DANGER notation is used to bring specific attention to a part of the machine or a step in
DANGER!
a procedure that, if not followed carefully, can result in fatal or serious personal injury to the
operator. Be very careful to follow any guidelines established within the DANGER notations
to ensure your own safety as well as the safety of other people in your area.
The CAUTION notation is used to alert the reader to something that could cause damage to the
CAUTION
machine and/or minor injury to the operator. Be aware of the information provided in the CAUTION
notations to avoid damaging the machine and the possibliity of harming yourself and/or other people
in your area.
This symbol indicates a potential pinch hazard. The pinch hazard symbols are placed throughout the
machine in places where there is the potential for the operator to get a finger or other article squeezed
between two devices. Exercise caution when working in these areas.
NOTE: Notes often include extra information that is pertinent to the current topic.
These notations can often help you avoid minor problems and use the
machine more efficiently.
Table of Contents
Table of Contents
Chapter 1
Introduction
System Overview ................................................................................................................ 1-1
Specifications ............................................................................................................... 1-2
Safety Precautions ............................................................................................................. 1-4
Options and Configurations ................................................................................................ 1-6
How Mail Matrix Works ..................................................................................................... 1-12
Workflow .................................................................................................................... 1-14
Chapter 2
Operation
Overview ............................................................................................................................. 2-1
Turning the power on/off .............................................................................................. 2-2
Logging in to the Host software .................................................................................... 2-3
Navigating the Host software ....................................................................................... 2-4
Running Jobs ...................................................................................................................... 2-5
Selecting a job .............................................................................................................. 2-5
Setting up your run ....................................................................................................... 2-6
Processing mail ............................................................................................................ 2-8
Chapter 3
Operational Maintenance
Cleaning the System .......................................................................................................... 3-1
iBOT Maintenance .............................................................................................................. 3-2
Removing/Replacing iBOTs ......................................................................................... 3-3
Shift Maintenance ............................................................................................................... 3-6
Appendix A
Statistics
Statistics ............................................................................................................................. A-1
Glossary
Index
iiiMail Matrix Operator Manual
Table of Contents
iv Mail Matrix Operator Manual
Operator Manual
Chapter
Introduction
1
System Overview............................................................................ 1-1
Specifications ............................................................................ 1-2
Safety Precautions ......................................................................... 1-4
Options and Configurations ............................................................ 1-6
How Mail Matrix Works................................................................. 1-12
Workflow.................................................................................. 1-14
Delivery bins
Feeder/Conveyor
iBOT loading
area
Operator station
PC/UPS
iBOT
System Overview
The OPEX Mail Matrix is a mixed mail sorting system that streamlines the sorting
process. The Mail Matrix system can process up to 25,000 pieces per shift, into as
many as 1,020 destinations, and can easily sort the widest range of media and
address formats ever – from letters, flats, magazines and newspapers to small
parcels and interoffice mail – all in a single pass.
Unlike traditional inline machines which use pulleys, belts, and conveyors for transporting the mail piece to its destination, Mail Matrix uses iBOTs (intelligent robotic
wireless vehicles). Delivery bins are installed on both sides of the stacker section,
reducing the amount of space required.
Mail Matrix can be configured for three different modes depending on the desired
throughput and options purchased. These modes are manual feed without image Key from Paper (KFP), manual feed with Key from Image (KFI), and fully automated
with Key from Image (KFI). Fully automated incorporates an optional auto-feeder and
imaging. Depending on the desired throughput, up to 36 iBOTs can be installed on a
machine.
Mail Matrix features include:
1 Introduction
• Scalable feed rate: 600–3600 pieces/hour (1 piece/second)
• Expandable delivery bins (30–1020) and iBOT configurations for growth
• Capable of sorting mail into compact front and rear delivery bins
• Unmatched mixed media handling and single pass sorting
• User-friendly Microsoft Windows interface that allows the operator to independently set up sorting jobs as well as modify, update, and maintain a database
• Wide range of options for sorting by name, department, P.O. Box, building,
division, mail stop, and more
• Ability to import organizational databases in various formats into the job setup
and execute sorting rules
• Easily sorts mail into delivery bins that simplify removal by mailroom sweepers
• Low maintenance
• Operable in such working environments as warehouses and lockbox operations
1-1Mail Matrix Operator Manual
1 Introduction
Specifications
Performance specifications
Maximum
throughput
Physical specifications
Length
Width
Height
Power requirements
Envelope/Document size
Mixed media
Length
Width
Maximum weight per
piece
3600 pieces/hour (1 piece/second)
60 inches (add 44.5 inches for each 90-bin expansion module)
143 inches
88 inches
• 120/208 VAC, single phase
• 60 Hz, 3 wire system
•24amps
Letters, flats, magazines, newspapers
5.0–15 inches
2.75–12 inches
32 ounces
Thickness
0.007–1.0 inch
Environmental specifications
Agency approvals
Sound level
Temperat u r e
Humidity
UL, CE
80 dB Maximum
50° to 90° F
5% to 95% RH
1-2 Mail Matrix Operator Manual
1 Introduction
1-3Mail Matrix Operator Manual
FCC / Industry Canada Statement
The Mail Matrix system incorporates wireless devices:
Transceiver, 2033210
This device complies with Part 15 of the FCC Rules. Operation is subject to the
following two conditions:
1 This device may not cause harmful interference, and
2 This device must accept any interference received, including interference that may
cause undesired operation.
iBOT, 2032610
! "#$%"&#
This device complies with Part 15 of the FCC Rules. Operation is subject to the
following two conditions:
1 This device may not cause harmful interference, and
2 This device must accept any interference received, including interference that may
cause undesired operation.
Any changes/modifications to the wireless devices not approved by OPEX
Corporation could void the user's authority to operate the system.
1 Introduction
Safety Precautions
Follow these safety precautions to avoid injury when operating the Mail Matrix.
Failure to follow these precautions may result in severe personal injury or damage to
the machine.
Charging rail. Hands should be kept clear of the charging rails when the doors are
closed. Shorting of the charging rails with either a watch or ring may result in
electrical shock or death.
Be careful when removing/replacing iBOTs. In order to increase the iBOTs payload
capacity, the iBOT was designed to be as light as possible. As a consequence the
iBOTs are not indestructible. Care should be taken when removing or installing the
iBOTs.
Keep loose objects away from any exposed, moving parts of the machine. The
moving parts of the Mail Matrix, such as the conveyor, can become jammed and/or
damaged by foreign objects. Also, keep hands, hair, loose clothing or jewelry away
from the moving parts.
Do not attempt to clean the machine while it is running. A cloth (or similar material)
should never be used to clean moving parts such as belts or rollers. The use of such
material on moving mechanisms can result in damage to the machine or severe
personal injury. If a belt, roller, gate or similar part needs to be cleaned, hand-crank
the part during cleaning or clean it while stationary.
Do not use flammable, high pressure, “canned air” to clean paper scraps and dust from
the machine.
Familiarize yourself with the location of machine Emergency Stop Switches. The e-
stop is installed on the input conveyor. An e-stop is also installed on the optional
auto feeder. E-Stop switches enable a quick stop of all motors in the machine in the
event of an emergency involving potential personnel injury.
1-4 Mail Matrix Operator Manual
1 Introduction
The Mail Matrix system incorporates emergency-stop buttons and door interlocks to
help keep the operator safe.
Emergency stop buttons
The big, red, mushroom-shaped emergency stop (e-stop) buttons can be used to stop
the machine in an emergency. If necessary, push one of the e-stops and the machine
will stop immediately. To restart the machine, twist the knob clockwise, clear the
machine, and restart the machine from the Run screen.
Interlock system
When the machine is running, the rapidly-moving iBOTs can pose a safety hazard for
the operator. For your safety, magnetic interlocks have been installed on the front
and rear doors of the Mail Matrix machine. The interlock system will shut the
machine down whenever a door is opened.
1-5Mail Matrix Operator Manual
1 Introduction
Options and Configurations
The Mail Matrix base system includes:
• Key from Paper (KFP) Module with one integrated key-and-drop station
• OPEX DRS (Directory Retrieval System)
• 30 delivery bins
• 3 iBOTs
• 2 large mail tubs
• Host PC with Microsoft Windows® XP
FIGURE 1: Mail Matrix base system
1-6 Mail Matrix Operator Manual
1 Introduction
Optional enhancements include:
• Delivery-bin expansion modules Up to 11 additional expansion modules (90 bins
each) can be installed to increase the bin capacity to 1020 bins.
1-7Mail Matrix Operator Manual
1 Introduction
• Image capture/MLOCR (Multi-Line Optical Character Recognition) The image
capture/ MLOCR option captures images of mail pieces and automatically
determines bin destination. This enhancement is made up of a camera and light
arrangement to capture the image of the piece, as well as the MLOCR software,
which can interpret the images from the camera and send the necessary
addressee information along to the DRS for bin assignment. The image capture/
MLOCR option eliminates the need for the operator to identify the recipient and
enter the information for each piece manually.
1-8 Mail Matrix Operator Manual
1 Introduction
• Auto-Feeder an installed auto-feeder provides automated mail feed to the mail
input module. The auto-feeder (along with additional iBOTs) can increase the
throughput up to 3600 pieces/hr. (MLOCR required).
1-9Mail Matrix Operator Manual
1 Introduction
• Key From Image (KFI) Module Additional keying stations can be used in
conjunction with the image capture/MLOCR option. These KFI (Key From Image)
modules allow additional operators to identify pieces that could not be identified
by the MLOCR and DRS.
1-10 Mail Matrix Operator Manual
• Additional iBOTs Mail Matrix can support a total of 36 iBOTs.
1 Introduction
•Mail Cart(s)Mail carts are available to aid in the process of sweeping the bins.
1-11Mail Matrix Operator Manual
1 Introduction
How Mail Matrix Works
The Mail Matrix system uses three software applications to control and run the
system: the Host software, the OPEX Directory Retrieval System (DRS), and the
Keying Station application.
Mail is input in to the system by either the operator or an installed auto-feeder,
which can automatically place mail onto the conveyor. The operator can either look
at each piece and use a Keying Station to identify the intended recipient in the site’s
database, or an installed camera can take an image of each piece and the Mail Matrix
can use software to sort it.
Host software
The Mail Matrix Host software provides the operator’s main interface with the
system’s controls. Use the Host software to select and run jobs and view statistical
reports on the machine.
Directory Retrieval System (DRS)
The OPEX Directory Retrieval System (DRS) references a database containing
recipient names and bin assignments. The DRS attempts to find a matching recipient
for each piece keyed in by the operator (or identified by the image capture/MLOCR
system, if installed), then assigns the mail to the bin specified for that recipient.
1-12 Mail Matrix Operator Manual
1 Introduction
Keying Station
Use the Keying Station application to enter the names of mail recipients. After the
recipient has been identified by the Keying Station, drop the piece onto the conveyor
which will the piece to an available iBOT.
The Keying Station software is found on the Host PC (at the operator station), as well
as any installed KFI (Key From Image) modules, where remote operators can identify
recipients for pieces that the MLOCR software was not able to identify.
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