small parcel and bundle sorter guidelines small parcel and bundle sorter...u.s. postal service...

Small Parcel andBundle SorterGuidelines

Handbook PO-430December 1991

U.S. Postal ServiceWashington, DC 20260-7100

Small Parcel and Bundle Sorter GuidelinesHandbook PO-430

December 1991

A. ExplanationThis new Handbook PO-430, Small Parcel and Bundle Sorter Guidelines, provides uniform policy,procedures, and guidelines for implementing, using, and maintaining the Postal Service's automatedsmall parcel and bundle sorting equipment .

B. Distribution

1 . Initial .This issuance is being distributed directly to all postal facilities that currently have small parcel andbundle sorter machines .

2. Additional Copies.Order any necessary additional copies of this handbook from your materiel distribution center onForm 7380, MDC Supply Requisition.

C. Comments and Questions

1. Content . Address any comments or questions regarding the content of this handbook to :DISTRIBUTION OPERATIONS DIVISIONUSPS HEADQUARTERS RM 7410475 LENFANT PLAZA SWWASHINGTON DC 20260-7116

2. Clarity . Send any suggestions regarding the language or organization of this handbook to :

DOCUMENT CONTROL DIVISIONUSPS HEADQUATERS RM 2800WASHINGTON DC 20260-1571

D. Issuances RescindedThis issuance of Handbook PO-430 does not replace any previous issuance .

E. Effective DateThis material is effective upon receipt .

Allen R. KaneAssistant Postmaster GeneralDelivery, Distribution, and Transportation Department

SmallParcelandBundle:SorterGuidelinesChapter 1--Introduction

110 Purpose

120 Scope

Chapter 2--SPBS System Overview

210 Purpose

220 Physical and Functional Description221 General222 Computer Workstation223 Power Cabinet

223.1 General223.2 Front Panel223.3 Rear Panel

224 Master Processor Controller225 Induction Station

225.1 General225.2 Input Conveyor225.3 Inclined Conveyor225.4 Operator Keying Station

225.41 General225.42 Operator Controller225.43 Operator Keyboard225.44 Operator Display Panel

225.5 Code/Weigh Module225.51 General225.52 Beam of Lights

225.6 Buffer/45-Degree Module .226 Sort Distribution System.

226.1 General226.2 Carrier Cells226.3 Receiver Modules226.4 Recentering Module

226.41 General226.42 Clear Plastic Barrier

226.5 Sort Output Modules226.6 Drive End Module

226.61 General226.62 Reject : Bin226.63 BOL Detectors226.64 Overflow Chamber (Waterfall)

226.7 Takettp End Module

Handbook PO.430, .December 1991

Contents

227 Sort System Output227.1 General227.2 Output Chute227.3 Control Arm227.4 Framework Support

228 Section Controller -229 Emergency Warning Devices

Chapter 3--Use Criteria

310 Volume Requirements311 General312 Minimum Run Time

320 Sort Programs321 General322 Memory Items323 Distribution Accuracy

330 Authority to Expand Utilization331 Authorization332 Distribution Sort Plans333 Diagram Changes

340 Bin Assignments341 Making Bin Assignments342 Preparing Label Diagram343 Bin Labels

350 Management Operating Data System

Chapter 4--Conditions for Machine .Operation

410 Staffing Guidelines411 General412 Staffing

420 Rotation

430 Environmental Conditions

Contents

ContentsChapter 5--SPBS Operating Procedures

510 Responsibilities511 Supervisors512 SPBS Operators

512.1 Keyers512.2 Sweepers

512.21 General512.22 Sweeping Aids and Descriptions512.23 Sweeping Procedures

512.231 General512.232 Tray or Sack

Replacement512.233 Wiretainer

Replacement512.234 U-cart Replacement512.235 Reject Output512.236 Overflow Chamber

(Waterfall)512.3 Dumpers and Cutters

512.31 General512.32 Dumping Procedures512.33 Culling Procedures

520 Operating Instructions521 Introduction522 Operating Procedures523 Prestart-up Procedures

523.1 General523.2 Supervisor523.3 Maintenance Personnel523.4 SPBS Operator/Keyer

524 Start-up Procedures525 Run Procedures526 Turnoff Procedures

530 Alarm Warn ng System531 Definition

531.1 General531.2 Audio Alarm531 .3 Visual Alarm

532 Emergency Stop Condition533 Emergency Shutdown Procedures

Chapter 6--Management Information

610 System Manager611 Definition

2

Small Parcel and Bundle Sorter Guidelines

612 User Access612.1 General612.2 Procedures

612.21 General612.22 Menu Options612.23 Command Notations612.24 Input Descriptions

620 Supervisor Menu621 Definition622 User Access623 Supervisor Menu Options

623.1 Forecasting ;Rate Report623.2 History Report623.3 Induction Station Production Report623.4 Production Rate Report623.5 Restart Printer

630 Administrator Menu631 Definition632 User Access633 Administrator Menu Options

633.1 Manpower Menu633.11 General633.12 Input Field Description

633.2 Sample Reports Menu633.21 General633.22 User Access633.23 Destination Report633.24 End-of-Run Report .

633.241 General633.242 User Access

633.25 Full Report633.26 Key Code Per Induction Station

Report633.27 System Key Code Report633.28 System Reject Report633.29 System Summary Report

633.3 Volume Reports Menu633.31 General633.32 User Access633.33 System Failure Report633.34 System Log Report

633.4 Begin New Run/Clear Logs633 .5 Sort Plan Menu

633.51 General633.52 User Access633.53 Sort Plan Editor

633.531 User Access633.532 Submenu I - Sort Plan

Type and Name633.533 Submenu 2 - Sort Plan

Configuration

Handbook'PO-430, December 1991


633.534 Submenu 3 - BinConfiguration andCompilation

633.54 Copy Sort Plan633.55 Save Sort Plan on Disk633.56 Send Sort Plan to Master

633.561 General633.562 User Access

633.57 Clear Output Bins634 Utilities Menu

634.1 General634.2 User Access634.3 RS232 Menu634.4 Set Time Menu634.5 Set Date Menu634.6 Status Report

640 Maintenance Menu641 Definition642 User Access643 Configuration Menu

643 .1 General643.2 Change Passwords643.3 Set Alarm Priorities643.4 Set Bin Configuration Parameters643.5 Set Keyboard Configuration Parameters643.6 Display Reason for Reject643.7 Set Sort Plan Default and Page Length643.8 SPBS System Parameters

644 Diagnostics Menu644.1 General644.2 User Access644.3 Check Lights

Handbook PO-430, December 1991

644.4 Exit to DOS644.5 Shell to DOS644.6 Module Configuration644.7 Port Configuration644.8 Start Diagnostics

645 Send Configuration to Master646 Prepare for Final Shutdown

Chapter 7--Safety

710 Introduction

720 Supervisor Responsibilities

730 Employees Responsibilities

740 Maintenance Responsibilities

750 Operational Safety Summary

Appendices

Appendix A - List of ExhibitsAppendix B - List of Acronyms and AbbreviationsAppendix C - Glossary of Terms

Contents

3

Small Parcel and Bundle Sorter - Guidelines

110 Purpose

This handbook establishes methods and tech-niques needed to maximize the utilization of thesmall parcel and bundle sorter (SPBS) mechaniza-tion system. It provides operating guidelines forall levels of management in the regions and di-visions and offers specific instructions for mailprocessing personnel who are trained to operatethe SPBS system .

120 Scope

The Postal Service has developed a system whichmechanizes the sorting of small parcels and bun-dles for efficient distribution and results in sig-


Chapter 1Introduction

120

nificant productivity improvements. This systemprovides for the sorting of small parcels, bundles,and irregular parcel post (IPP) into 100 separateoutput locations. The maximum size and weightof mailpieces that can be processed by the SPBSis 12" x 15" x 8" and 20 pounds . The mechanicalcapacity of the SPBS is - 11,000 pieces per hour .The SPBS can be assembled into' three basic con-figurations by using 90 degree modules (straight,right or left L-shaped, or U-shaped) . This versa-tility allows the SPBS to be designed to complywith nearly all USPS processing facilities andtheir mail handling requirements . See Exhibit 120for samples of typical SPBS configurations .

5

C9

Straight Configuration

.rN` L- Shaped Configuration (Right)

kl `rte. 1

Left Induction e

Power DistributionCabinet and MasterController Workstation(Either Side)

JNO


210 Purpose

This chapter provides an overview of the SPBSfor mail processing personnel who perform op-erating functions in the mechanized distributionof small parcels, bundles, and IPP's .

220 Physical and Functional Description ,

221 General

The SPBS is a series of modular units that arephysically integrated into a single unit excludingthe computer workstation-and power cabinet-(seeExhibit 221). The SPBS achieves the primarymail processing objective of -receiving small par-cels, bundles, and IPP's, and . :sorting them into100 separate output locations . This sorting-equip-ment accepts mail and presents -it to - theoperator/keyer who manually moves . themailpieces one at a time onto the code/weighconveyor. The operator/keyer uses the operator'skeyboard to enter ZIP Code related keycodesbased on mail characteristics and/or address data .This machine is operator paced . The mail that isloaded onto the induction station is automaticallyweighed and a beam of light detects whether themailpiece is too wide, too long, or overheight forprocessing. This is all part of the induction pro-cess. Inducted mail is transferred to a series ofindependent carrier cell units transported by -achain drive system. Each carrier cell unit employsa self-contained discharge belt which ejects mailto 'either' side .of the transport path . A speciallydesigned output chute system at each sort loca-tion transfers discharged mail into output recep-tacles (trays, sacks, U-carts or wire containers) .When the receptacles become full, by weight limi-tations or by visual inspection, a sweep operator(sweeper) is alerted by audible and visual alarmsto replace them. If the destintation output bin isfull or being swept, the mailpiece is discharged tothe reject bin . If for some reason mail is notsorted into its destination output bin or the rejectbin, it is automatically dropped into the overflowchamber. Mail from the overflow chamber andreject bin will be reentered into the input sortsystem or processed manually .


Chapter 2SPBS System Overview

222 Computer Workstation

The computer workstation consists of a personalcomputer (PC), monitor, and printer . The com-puter workstation allows the supervisor to config-ure the:. system software to meet specific needs . Itis menu driven and provides on-line and off-linesystem monitoring. The computer workstation isautomatically powered on when the main powerswitch on the power cabinet is actuated . It goesthrough a booting-up process (start-up) and im-plements a self check routine which, if satisfac-torily completed, continues the system start-upsequence. During the normal operating mode, theworkstation monitor provides several productiondisplays. These displays detail graphically and sta-tistically individual induction station throughput,as well as the total system throughput . The sys-tem manager is the software program that inter-faces the user with the operating environment ofthe SPBS through the computer workstation . Thesystem manager generates various system oper-ational reports from data received from the mas-ter processor controller. The system configurationand sort program information that is loaded ontothe hard disk of the workstation is downloaded tothe master processor controller (MPC) . The MPCthen takes operational control of the SPBS ac-cepting inputs from the operator at the inductionstation. The MPC is the "system brain ."

Note : During mail processing, the MPC continues to inputdata into the computer workstation hard disk storage . This datais then available to produce reports as requested by thesupervisor . Some reports can be generated in an on-line modewhite others must be generated in the off-fine mode . (SeeChapter 6.)

The computer workstation is also used by main-tenance personnel to perform programmed di-agnostic . .routines to locate and isolatemalfunctions. The workstation maintains recordsof all machine failures or operator keying errors .

223 Power Cabinet

223.1 General. The power cabinet is the distribu-tion center for controlling and supplying ACpower throughout the SPBS system . Commer-

223.1

7

OD

Mrr

I

Power Cabinet(MPC)

isual AlarmComputer - KI I I "I, \1/ . Vlqual Alarm

Workstation

InclinedConveyor

I

OverflowChamber

922C)saIt3'I .

Small Parcel and Bundle_Sorter .Guidelines

cially supplied 3-phase, 208-volt AC power isused as the prime power input . The input sourcepower enters through the top of the cabinet and,the output system distribution power leaves at thelower rear -portion' of the cabinet . The distribu-tion of this power is controlled by manually ac-tuated switches, circuit breakers, and electricallyactuated relays. System start-up- and power dis-tribution occurs in the following sequence :

a. The CB1 (main power switch) handle,located on the front of the power cabinet, israised to turn the circuit breaker to the on posi-tion. This supplies power to all system CPUs aswell as to the entire computer workstation .

b. The supervisor turns the workstation on,and then downloads the sort program from theworkstation to the master processor-controller .

c. The system start enable keyswitch on thepower cabinet is turned to the on position todistribute AC power to all the system modules.

d. The chain run keyswitch on the rear ofthe power cabinet is turned to the on position .There is a 10-second delay, and then power issupplied to the main drive motor, starting thedrive chain in motion and transporting 4hecarriercells through the system, During ,the 10-seconddelay, audio and visual =alarms are activated toalert all personnel that the system's drive chain. isabout to run .

e. The • machine operator/keyer turns the -in-duction line . start enable keyswitch to the onposition. Ths provides power' to the inductionline motors and starts movement of the inductionline conveyor belts.

223.2 Front Panel . A description of the powercabinet's front panel switches and indicators isoutlined below (see also Exhibit 223 .2) :

- Control Indicator

Main Switch Off/On .Circuit Breaker (CB1)

L1, L2, and L3Indicator Lights (red)

System Power OnIndicator (green)

Chain Run Meter

Circuit Open Indicator(yellow)


Function

Main circuit breaker forpower cabinet

.3-phase source powerindication .

Lights when CB1 isturned on. Indicatespower on sequence iscomplete .

Indicates chainoperating time .

Lights to indicate anopen circuit breaker.

Control IndicatorStart Enable Keyswitch_

Induction Power Indicator(green)

Sort Power Indicator(green)

Chain Run

Chain Stop Indicator (red)

Emergency StopPush/Pull Switch (red)

Emergency PressedIndicator (red)

Emergency Reset PushButton/Switch

Alarm Reset (momentary)Keyswitch

Auto ModeIndicator(green)

Jog Mode Indicator (blue)

Maintenance Mode .Indicator(yellow)

Call for MaintenanceIndicators 1 through 6(yellow)

.FunctionEnables the sequencingof AC power distributionthrough the system .

Lights when power isapplied to the inductionsystem .

Lights when power isapplied to sortdistribution system .

Lights when chain isrunning .Indicator(green)

Lights when chain hasbeen stopped .

Removes AC powerfrom the entire system,except power for theCPUs and workstation .

Lights when anysystem's emergencystop or interlockswitches is pressed .

Must be pressed afteran emergencyy stopcondition 'to enablepower distribution .

Resets masterprocessor controllerinterruptions after anemergency-resetpushbutton switch hasbeen, pressed to clearan emergency situation .

Lights when keyswitchis in auto position-andindicates SPBS isrunning in operationalmode .

Lights when keyswitchis in jog mode position.and indicates SPBS isrunning in maintenancejog mode.

Lights when 'keyswitchis in maintenanceposition .

Indicates whichinduction stationoperator has pressedthe call maintenancebutton .

223.2

9

223.3

Control IndicatorDrive Motor OvertempIndicator (red)

Drive Motor OvertempReset Pushbutton

10

- .FunctionReports anover-temperaturecondition in the chaindrive motor .Must be pressed afterovertemp problem isresolved and prior torestarting the drivechain .

223.3 Rear Panel. A description of the powercabinet's rear panel switches and indicators isoutlined below (See also . Exhibit 223 .3) :

Control IndicatorChain Run keyswitch(momentary)Chain Run . Indicator(green)Chain Stop -PushbuttonSwitchChain Stop Indicator (red)

FunctionStarts chain drivemotor.Light% whe chain isrunning,Stops chain drivemotor .Lights after chain isStopped .

224 Master Processor Controller

The master processor controller (MPC) is a print-ed circuit" board mounted in a noise insulatedpanel at the top of the takeup end module . Themaster -processor controller is the primary ` con-troller (system brain) after the system softwareprogram has been downloaded and during opera-tion. It maintains a record of each mailpieceweight and . its destination bin ., If - the weight iswithin tolerance, the weight information is trans-mitted to the master processor controller, wtictimaintains a record of the weight and the sort binin which the mail will be off loaded. The MPCautomatically sends an alert to the sweep areawhen trays are near or at their weight limits. Theweight information - is passed to the inductionstation 45 degree module and the .receiver carriercell belt via induction CPU . The- mail's weightdetermines the ejection speed of the mailpiecefrom the 45 degree conveyor belt and the speedof the receiver carrier cell belt . This combinedcontrol will approximately center the mailpieceon the carrier cell belt.

225 Induction Station

225.1 General . The SPBS system can contain -4,5, or 6 induction stations depending on USPSfacility requirements . Each induction station {seeExhibit 225.1) is comprised of the following pri-mary components:

a. Input conveyorb, inclined conveyorc. Operator keying stationd. Code/Weigh modulee. Buffer/45 degree module

225.2 Input Conveyor. The BOL (beam of , light)detectors at the bottom of the inclined conveyorcontrol the motor that drives the input conveyor .When. the BOL is not blocked, the input con-veyor belt rotates until the mail on the-bottom ofthe inclined conveyor blocks the BOL. The inputconveyor must be fully loaded with mail prior tostarting the SPBS system .

225.3 Inclined Conveyor . The movement of theinclined conveyor belt is controlled by the BOLsat the top and lower end of the inclined, con-veyor, The lower BOL controls the mailflow fromthe input conveyor; the top BOL, controls andpresents the mailflow to the operator .. The beltcontinues to move until, the mail is dropped ontothe keying station area. When the operator movesthe mail onto the code conveyor, the BOLs areunblocked and cause the inclined conveyor motorto move the belt.

225.4 operator Keying Station -

225.41 General. The operator keying station- is aplatform area ' where machine, -operators/keyersperform their keying duties. When the matt piecearrives at the keying station, it must be faced toallow reading of the address information . Theoperator display must indicate that loading andkeying can begin. After the key code is : entered,the operator positions the mail on -the code con-veyor so that its longer dimension is approxi-mately parallel to the V-shaped positioning edgenearest the operator .

225.42 Operator Controller. The operator con-troller located on the code/weigh module near theweigh station provides the following capabilities:




MAWMWcol.rr"A A,M»rG GlenB . BlwR-Red

225.42

Exhibit 223.2, Power Cabinet Front Panel

Exhibit 223.3, Power Cabinet Rear Panel


1 1

-aN

4 45 Degree Conveyer OperatorDisplay Panel(Audio-Visual)

InclinedConveyer

Small-Parcel and Bundle Sorter Guidelines

a . Induction line start enable keyswitch. Al-lows start-up of induction line 25 seconds aftermain transport chain drive is started . The auto-matic sequence of conveyor belt start-up is:

(1) 45

(2) buffer

(3) weigh

(4) code

b. Induction line reset pushbutton switch .Starts up induction line after being stopped dueto oversize or overweight condition .

c . Call maintenance pushbutton switch .Causes light on power cabinet panel to light andalerts maintenance personnel of a problem on aspecific induction line .

d. Emergency stop pushbutton 'switch . Re-moves power from SPBS system except, for thecomputer workstation and master control proces-sor units. It can only be restarted- via the emer-gency reset pushbutton switch located on thepower cabinet's front panel .

225.43 Operator Keyboard . The operator key-board (see Exhibit 225 .43) is attached to thecode/weigh module at the left side of the induc-tion station near the top of inclined conveyor .The keyboard's position is easily adjustable viahand sized grooved plastic knobs . The operatorkeyboard is used to enter the data representingthe sort plan. The keyboard contains the follow-ing keys:

Function

Each key can beprogramed to representan entire sort bindestination or someportion of a sort code .Therefore, in someinstances, it isnecessary to press onlyone key for a code .

Numeric keys

Represents numeric0 through 9

value as shown on key .

Enter key

Functions as a carriagereturn to permit keyingof less than thespecified digits in amulti-digit sort plan .

Note: When the enter key is used, the system fills to the rightof the code with zeros . For example, if you are on a four digitsort plan with an allowable key hit of F1-345, the mailpiece will

Key

Function keys F1,F2,F3,F4


225.44

automatically be inducted upon receipt of the fourth digit Giventhis scenario a key hit of F1-3 enter or F1-34 enter would beacceptable. The code generated by the machine as a result ofthe enter key would be F1-300 and F1-340 . In this case, theassignation of F1-300 and F1-340 must be accomplished inyour sort plan .

Repeat key

Cancel key

Repeats last enteredkeycode.

Pressed when wrongkeycode is entered .When the operatorenters the keycode andit is determined by a_comparison check inthe induction CPU to beinvalid, the operatordisplay gives a visualdisplay and an audioalarm informing theoperator to try again . Ifthe second attemptfails, the mailpiece isautomatically sent tothe reject bin .

225.44 Operator Display Panel. The operatordisplay is a fluorescent type display mounted onthe code/weigh module of the induction stationopposite the operator keyboard . The position ofthe- display can be adjusted vertically and rotatedright or left. The operator display provides thefollowing types of information for the operator :

13

Display

Audio Alert DeviationInstruction

Reposition/rekey Audio-multiple Improperlybeep loaded or

oversize item(first occurrence)

Remove

Audio-multiple Improperlymailpiece

beep loaded or(throwoff) and oversize itemreset (second

occurrence)

Overheight

Audio-multiple Overheightremove and

beep mailpiecereset

Overweight

Audio-multiple Overweightremove and

beep mailpiecereset

Clear line and Local inductionreset station stops

225.44


Exhibit 225.43, Operator Keyboard

14


Small Parcel and. Bundle Sorter Guidelines

Clear line and

Emergency stopreset

(system stopsoperating)

No display

Power failuresinstruction

(system stopsturn-off key,

operating)clear line reset

225.5 Code/Weigh Module

225.51 General . The code/weigh module, is asingle structural unit aligned at one end with theinclined input system and connected at the otherend to a buffer/45 degree module to form aninduction line . This unit is comprised of the fol-lowing:

a. Code conveyor. The code section is whereoperators key code information for bundle sortingbased on mail type . It consists of a motor drivenconveyor belt and four beams of light (BOL),three on one side of the belt and one on theother.

b. Weigh unit conveyor . The weigh unit sec-tion contains a computer-controlled weighingmechanism, a DC motor driven conveyor belt,and two BOLs, one at each end of the belt . Theweigh unit conveyor receives mail from the codeconveyor if all parameters have been satisfied . If-the mailpiece is too heavy, the weigh conveyorstops and the mail must be removed by the oper-ator who must then reset the induction line viathe operator controller reset pushbutton switch .

225.52 Beam of Lights. The BOLs (near theV-shaped positioning edge of the code conveyor)are used to detect if the mail is too long for thesystem. The two BOL's (one above the other)near the end of the code conveyor belt are usedto detect mailpieces with abnormal shapes thatmay cause problems in the machine. The codeconveyor belt-will stop if the BOLs detect out ofspecification parameters or the keycode has notbeen entered, otherwise the code conveyor loadsthe mail onto the weigh module .

225.6 Buffer/45-Degree Module . . Thebuffer/45-degree module is a single structural unitcomprised of the buffer conveyor and 45-degreeconveyor. Nearly all the control electronics forthe entire induction station are housed in thismodule. The buffer section of this module con-sists of a DC motor driven conveyor belt andvertically mounted BOLs. The 45-degree sectioncontains a coMeyor belt supported by several


2262

rollers that allow the belt to be rotated to a45-degree angle toward the direction of the car-rier cell travel . The 45-degree unit is so namedbecause of its 45-degree interface with the re-ceiver module supporting the carrier cells . The45-degree module allow mailpieces to be loadedfrom the induction lines to receiver carrier cellsat a controllable speed .

226 Sort Distribution System

226.1 General . The sort distribution system (seeExhibit 226.1) transports the mailpieces from theoutput of the induction station to the output bins .This system is comprised of the following:

a. Carrier cellsb . Receiver modulesc. Recentering moduled. Sort output modulese . Drive end modulef. Takeup end module

226.2 Carrier Cellsa . The carrier cells are individually con-

trolled units used to carry the mail from aninduction station output to its designated outputbin .

b. The carrier cells are attached to the sortdistribution main drive chain which moves thecells through the sort distribution system at afixed speed. This transport chain forms a continu-ous loop from a sprocket in the drive end mod-ule, through all the sort distribution systemmodules, to a sprocket contained in the takeupend module.

c. There are two main functional compo-nents making up each carrier cell, a conveyor beltand its drive motor . The control electronics forthese cells are mounted on the structural frame-work of the transport modules and apply controlsignals to the cell drive motor via a rail and brushsystem. The motor is reversible and therefore canturn the conveyor belt in either direction. Thisreversible motor allows a mailpiece to be centeredon the cell conveyor belt in either direction, ifinadvertently loaded to an off center position .Also, the mail can be ejected to the right or leftoutput sort bins.

d. Each carrier cell has a bracket mountedon its left side that identifies its position relativeto the cell identified as cell "0" (contains specialbracket) . These brackets are counted (sensed

15

2262


Exhibit 226 .1, Sort Distribution System

1 6



magnetically) by "proximity sensors" on each re-ceiver and output module . Therefore, the MPCknows the position of each cell as it travelsthrough the system.

226.3 Receiver Modules. The receiver module ispart of the sort transport system . located at theend of the 45-degree module of each inductionstation . The receiver module and its carrier cellsare controlled by the induction station it serves .Therefore, the number of receiver modules re-quired for each system is determined by the num-ber of induction stations. The master processorcontroller, through its own proximity sensors,keeps a count of the carrier cells . When an induc-tion station operator inputs a keycode for amailpiece, that information is transferred to theinduction station CPU . The induction stationCPU then requests a carrier cell assignment forthe mailpiece from the MPC. The induction sta-tion CPU uses the input from its receiver mod-ule's proximity sensors to synchronize the45-degree belt with the approaching assigned car-rier cell. When the assigned cell reaches the in-duction line, the induction station CPU sends themotor drive signals to activate the carrier cell'sdrive motor to rotate the conveyor belt and ac-cept the mailpiece .

226.4 Recentering Module

226.41 General. A recentering module is locatedon the last receiver module . It checks formailpiece overhangs by means of a photo-detection system . If an unacceptable overhang ex-ists, the recentering system activates the belt toproperly center the mailpiece on the cell . Themailpiece is then transported by the sort distribu-tion system to a destination bin in the outputsystem.

226.42 Clear Plastic Barrier. The top side of thereceiver modules opposite the induction' stationshas a superstructure supporting a clear plasticbarrier. The last receiver module in a system hasthis barrier on both sides as well as three BOLson each side to allow for recentering ofmailpieces on a carrier cell .

226.5 Sort Output Modules. The sort outputmodules are used to support and control thecarrier cells as they travel through the outputsystem. When a mailpiece goes through the in-duction station, it is assigned a destination binaccording to the sort program. It then transfersthe following information about the mailpiece to

Handbook P0-430, December 1991

226.63

the output module controlling the assigned - des-tination bin :

a. Number of its carrier cell . (This is trackedby proximity sensors on each module .)

b. Destination bin number .c . Weight. The sort output module uses

proximity sensors to detect cell "zero" and countthe carrier cells as they pass . When the mailpiececell is in the section of the track that correspondsto the destination bin, it sends motor drive signalsto the driver board responsible for that sortpoint. The motor drive- board. transfers the cor-rect amount of voltage- with desired polarity tosuccessfully eject the mailpiece to the pro-grammed bin on the right or left . The cell is thencarried by the sort 'transport system downthrough the sort line. When the cell reaches thereject bin (at the drive end module) the last "C"module's section controller sends a signal to ex-ecute the carrier cell test by causing the cellmotor to turn the belt clockwise . This also causesany mail that may not have been ejected pre-viously to be automatically ejected into the rejectbin. When a bin is being swept, the output mod-ule reroutes a mailpiece destined for that bin tothe reject bin. All information pertaining to theoutput status of a mailpiece is sent to the com-puter workstation where it is recorded in memoryto be used for generation of management reports.

226.6 Drive End Module

226.61 General . The drive end module is locatedat the end of the SPBS . The drive end modulecontains the main drive motor which moves thetransport chain (attached to carrier cells)throughout the entire sort distribution system .See Exhibit 226 .1 .

226.62 Reject Bin. The reject bin frameworkstructure is physically part of the' drive end mod-ule. The output section of the reject bin uses asingle chute that outputs mail (rejects) to awiretainer or 1046 hamper and does not use thetray support structure. For design efficiency thereject bin is physically part of the drive endmodule. The reject bin is adjacent to the "oddnumbered" sortation bins, and is not part of the100 assignable sortation points .

226.63 BOL Detectors . Two beam of light (BOL)detectors are located at the top part of the driveend module to monitor any mailpieces or mal-functioning carrier cells traveling through the re-

17

226.64

ject bin area. If this occurs, the MPC is notifiedthat a carrier cell or associated circuitry has mal-functioned but does not stop the machine . Threeretro-reflective BOLs located at the bottom of themodule detect mailpieces that may inadvertentlyfall into this area; in such a case, the systemautomatically stops.

226.64 Overflow Chamber (Waterfall) . If amailpiece has not been rejected in the sort outputsystem or reject bin, the mail is automaticallythrown into the overflow chamber as the carriercell starts its downward rotation on the drive endmodule sprocket: Three retro-reflective BOLs lo-cated at the bottom of the drive end moduledetect mail that may inadvertently fall into thisarea. If these BOLs become blocked, the . SPBSsystem automatically stops .

226.7 Takeup End Module. The take-up endmodule houses the master processor controller(MPC). It also provides the return mechanism forthe transport chain to the drive end module . Thetransport chain (carrier cells in upside down posi-tion) travels from the drive end module throughthe lower part of the transport modules to thetake-up end module . The transport chain travelsaround the large bearing supported sprocket in-side the take-up end module to the top of thefirst receiver module (carrier cells right side up) .

227 Sort System Output

227.1 General. The sort system output (see Ex-hibit 227 .1) function begins when the mail isejected from the carrier cell conveyor belt . As themail leaves the carrier cell conveyor belt in thesort distribution system, it is deposited by way ofchute assemblies, into either USPS trays, sacks,U-carts, wiretainers, or the missentlreject bin .Sweep operators are alerted by audiblelvisualalarms, or use, their judgment to determine whenthe bins should be swept or changed. The sortsystem output consists of the following:

a. an output chuteb. a control armc. framework support for trays

227.2 Output Chute. The chute system is madeup of two individual output chutes . The top chuteis basically stationary while the bottom chute iseasily moveable from the maintenance position(fully raised) to the tray operating position(lowered halfway) to the storage position (fully

1s

Small Parce and Bundle Sorter Guidelines

lowered). It can be locked into the maintenanceand operating positions . Output chutes depositthe mail into mail receptacles (tray, sack, U-cart,or wiretainer). Output chutes also direct the mailinto the reject mail bin . Unlike the output chuteto other mail receptacles, the reject bin uses asingle chute that outputs to a USPS 1046 hamperand does not use the metal tray support assembly .

227.3 Control Arm . Each output assembly isequipped with its own control arm assemblymounted between the two chutes which pivotsaway when changing sortation receptacles . Thecontrol arm contains the following :

a. Emergency stop push-pull switch . Illumi-nates when pressed and halts the operation of allmechanical parts. Must be pulled to reset beforerestart can begin . Emergency stop pushbuttonswitch is located on every other control arm as-sembly along the sort output system .

b. Two sweep switches with indicator light(right and left) . These switches are used by thesweeper to perform the bin bypass function . Thesweep switch must be pressed and the sweepswitch indicator light must be flashing beforesweeping, to indicate that the output chute isbeing swept. If the switch is not pressed againafter sweeping, the mail will continue to be di-verted to the reject bin and the light indicator inthe sweep switch will also flash .

c. Bin full indicator light (amber) . Bin fullindicator is located on top of the output controlarm assembly . It lights (steady) when bin is nearweight limitation and is accompanied by a mo-mentary audio alarm. When the containers arefull or when the sweep switch is pressed once orthe sweep button has not been pressed again aftercontainer was exchanged, the amber indicatorlight flashes.

227.4 Framework Support . The tray supportassembly framework supports two plastic mailtrays when opened. The back of the tray supportassembly framework is supported by adjustingpedestal legs; the front two legs are mounted onwheels. The tray support assembly can be movedto the storage position by removing both trays,lowering the chute to its storage position, androlling the assembly frame back against the out-put assembly. In this position, sacks, U-carts orwiretainers must be used . Using the tray supportassembly handle, the assembly framework can bepulled up and repositioned to accommodate plas-tic trays .



ControlArm

PlasticTrays

Exhibit 227.1, Sort System Output

227.4


19

228

228 Section Controller

The section controller monitors the weight ofeach bin by keeping track of the weight of eachmaijpiece. This weight information is sent withthe mailpiece bin destination assignment by theMPC after the mailpiece has been successfullysorted and verified as it passes the reject area .When a section controller determines that a bin isapproaching its weight limitation, it sends analarm signal, as well as flashes a lamp . While thebin is being swept, the section controller inter-rupts the ejection of any mail to the bin, andalerts the master processor controller of the con-dition. This causes any mail scheduled for the binto be sent to the reject bin . The MPC logs therejected pieces and does not send any mail to thatbin, until the sweep switch has been engaged . Thebin sweep switch (right or left) on the control

20


arm assembly must be pressed after the sweep iscomplete. This action . alerts the section controllerthat the bin is again ready to accept mail. TheMPC zeroes the weight count for the bin, andreinstates the bin as a valid sort point .

229 Emergency Warning Devices

The audio/visual devices (three total) aremounted at the top of steel supports located atthe take-up end module, at the last receiver mod-ule, and at the drive end module . These deviceswill be activated for 10 seconds after the chainrun switch is activated. Emergency switch lightsare integrated within the emergency switchesthemselves, to indicate which switch was pressedto stop the SPBS system . There is also an emer-gency switch indicator on the power cabinet itself .



310 Volume Requirements

311 General

The small parcel and bundle sorter has a maxi-mum throughput of 11,000 pieces per machinehour. Daily small parcel, bundle, and IPP vol-umes, and space availability are controlling fac-tors in determining if and how many machinesshould be located in a post office .

312 Minimum Run Time

Volumes sufficient for start-up and operation at athroughput necessary to achieve acceptable pro-ductivity shall be determined locally. A minimumruntime of two hours is suggested .

320 Sort Programs

321 General

Use the small parcel and bundle sorting machine(SPBS) with approved sort programs . Plans andproposed changes in the plan must be approvedby the regional manager, Operations Networks .Sort programs for BBM, First-Class Mail, second-class controlled circulation, Priority, and other(identified locally), may be applied to the SPBSin the order of priority consistent with servicestandards. The associated MOD operation num-bers will be •in the 130 series. Use establisheddistribution sort programs to distribute mail toproper separations . Separate mailpieces toADC/SDC, SCF, incoming primary, incoming sec-ondary, firm, box, or ZIP Code according toapproved sort plan programs .

322 Memory Items

Memory item codes that are assigned to a ZIPCode, route number, firm name, city, or otherunique addresses shall incorporate to the extentpractical specific code combinations that can beassociated with-the address.


Chapter 3Use Criteria

323 Distribution Accuracy

333.2

SPBS operators are required to key at an accu-racy rate of 95 percent .

330 Authority to Expand Utilization

331 Authorization

Postmasters/managers are authorized to establishadditional SPBS tours as needed (e.g ., weekendsor unusual high volume periods) .

332 Distribution Sort Plans

332.1 Distribution sort plans and changes inintra-SCF distribution are approved by the MSCand/or BMC manager ..

332.2 Intra-regional distribution sort plans andchanges are approved by the regional manager,Operations Networks .

332.3 Dispatch make-up must conform to thenational labeling instructions. Any deviationsmust be approved by the Office of DistributionOperations and Networks, Delivery, Distributionand Transportation Department, Headquarters.

333 Diagram Changes

333.1 Postmasters/managers are authorized tomake SPBS diagram changes which may involvethe relocation or exchange of bin locations, butdo not involve the addition or deletion of separa-tion items .

333.2 Postmasters/managers are authorized tomake changes to the incoming diagrams includingadditions, deletions, or combination of local zonesand firm directs as needed .

21

340

340 Bin Assignments

341 Making Bin Assignments

Densities and local service commitments shouldbe the criteria for separation assignments . Binassignments, beginning at bin number one, shouldbe made after considering each of the following :

a. Sort program by ZIP Code densities .b. Sort program by ZIP Code sequence .c . Sort program based upon the most effi-

cient sweep arrangement .d. Sort programs in which any common

separations are in the same location .

342 Preparing Label Diagram

Prepare a labeling diagram of the separation andcode numbers assigned to each bin . This must becompleted prior to machine installation. Bin as-signments for the same sort programs on morethan one machine in an office should be labeledthe same to prevent sweeping errors .

343 Bin Labels

Bin labels should be distinctive by program sothat sweepers do not mistakenly read a labelassigned to another program. Labels must beupdated to reflect any program changes.

22


350 Management Operating Data SystemFollowing is a list of operations numbers andtheir definitions used on the SPBS:Operation Definition

134

SPBS, Outgoing, Preferential135

SPBS, Outgoing, Bulk Business Mail136

SPBS, Incoming, Preferential137

SPBS, Incoming, Bulk Business Mail138

SPBS, Outgoing Priority Mail

Note: Operation 1340 is a composite of Operations 134 and135 . Operation 136C is a cbmposite of Operations 136 and137 .

These operations will be listed as a separatesubtotal within LDC 14 and will not be includedwith the opening and pouching operations . Op-eration 138 will be listed as a separate total with-in LDC-12 and will be included with themechanization operation. The recording of SPBSworkload is covered in section 410 of HandbookM-32, Management Operating Data System forMOD I Offices.



410 Staffing Guidelines

411 General

Normally when the operation is fully staffed, allcraft personnel assigned to the SPBS keying andsweeping operations should be qualified machineoperators/keyers . If there is a need to increase thestaffing of the sweeping operation beyond theassigned sweepers, the additional staffing will befrom the mailhandler craft . Mailhandler craft em-ployees will be assigned to the "input conveyor"which requires dumping and culling of mail forthe induction station and other related duties .

412 Staffing

The number of trained employees required tostaff a SPBS depends upon the number of induc-tion stations in use. Depending on the mail vol-umes, both available and anticipated, the mailcharacteristics, and the sort plan, the SPBS ma-chine should have the following recommendedmaximum crew size (depending on the inductionstations in use during normal operating condi-tions) :

a. 4-Induction Stations-12 positions

1 . Keyers -42. Sweepers -23. Dumpers -44. Cullers

-2

Handbook Po-430, December 1991

Chapter 4Conditions for Machine . Operation

b. 5-Induction Stations-15 positions

1. Keyers -52. Sweepers -23. Dumpers -54. Cullers

-3c. 6-Induction Stations-18 positions

1 . Keyers -62. Sweepers -33. Dumpers -64. Cullers

-3

Note: Trained employees, above the crew requirements areauthorized to provide relief for all types of absences .

420 Rotation

Keyboard operators rotate on a scheduled basis toother assignments. As a matter of day-to-day op-erating procedure, operators will not be requiredto key more than two consecutive hours or sweepfor more than one hour per rotation. Rotationassignments include keying, sweeping, and otherrelated duties .

430 Environmental Conditions

The environmental factors surrounding the SPBSmachine area must be controlled to minimizedistractive factors. The area in and around themachines is restricted to those managers or per-sonnel required in the area . Take care to keep thearea from becoming congested with equipment .

43

23


510 Responsibilities

511 Supervisors

Supervisors responsible for the efficient operationof mechanized equipment must use approvedmail processing criteria and operating proceduresto obtain maximum productivity and utilizationof the equipment. The duties and responsibilitiesof the supervisor include, but are not limited to,the following :

a. Exercise a normal regard for safety of selfand others by ensuring that all established safetypolicies and procedures are followed by all em-ployees .

b. Check with the general supervisor or toursuperintendent for availability and types of mailto be processed .

c. Check with maintenance personnel as tostatus and availability of the equipment.

d. Provide maintenance personnel with theinformation needed to activate the equipment(i.e ., sort program to run and start-up time) .

e. Ensure that a starting assignment rotationof employees has been prepared .

f. Make certain all necessary forms are com-pleted during equipment operation and all re-quired reports are available from the systemcomputer .

g. Ensure that proper containers are in placeat the appropriate bins. For example, when thesort plan dictates the need for a wiretainer, makesure a wiretainer is used .

h . Maintain a continuous, smooth mailflowinto and out of the operation to make sure that:

(1) Mail coming into the area is machine-able, correct for the sort program being used andprocessed in proper time sequence.

(2) Processed mail going out of the area isproperly containerized and labeled .

i. Observe machine operators and supportpersonnel in the performance of their duties . Pro-vide instruction and on-the-job training whenneeded .

Handbook P0.430, December 1991

Chapter 5SPBS Operating Procedures

512.21

j. Inform maintenance personnel of problemareas on the equipment .

k. Inform immediate supervisor of any un-usual situations or difficulties which might occurand make suggestions for solving these problems .

1.

Analyze computer reports and videoscreen (CRT) information as required .

512 SPBS Operators

512.1 Keyers. The machine operator (keyer) per-forms a variety of tasks required to process mailusing the SPBS. The machine operator reports tothe supervisor responsible for the operation andhas the following duties and responsibilities (butis not limited to) :

a. Qualifying on approved SPBS machineprogram.

b. Starting and stop the equipment .c. Adjusting the keyboard position for effi-

cient operation .d. Culling out non-processable items .e.

Keying for a designated period androtates .

f. Clearing jams and resets induction line .g. Notifying supervisor or maintenance per-

sonnel when malfunctions or unsafe conditionsoccur .

h . Remaining at console, keying until re-lieved .

i. Performing other duties as assigned bysupervisor .

512.2 Sweepers

512.21 General. The sweeper is responsible forremoving mail from bins as scheduled, alsoemptying full bins immediately. Sweeping in-volves the physical act of replacing a containerthat has reached its preset weight limit (full) withan empty container . Sweeping operations varyfrom site to site and they must be appropriatelydetailed by the supervisor.

25

512.22

Note: SPBS plastic trays are slightly larger than those usedon the flat sorter. They are used at the bin output to receivethe mail . Where available, a wiretainer (a large wiremeshhamper on wheels) can also be used to receive the mail, butrequires two bins to accommodate its larger size. Trays, sacks,U-carts and wiretainers can all be used and mixed within a sortplan.

Conditions requiring sweeping include :a. Full trays -by weight (visual aids provided)b . Full trays -by volume (no aids provided)c. Full sacks -by weight (visual aids)d. Full sacks -by volume (no aids provided)e. Full U-carts -by weight (visual aids)f. Full U-carts -by volume (no aids provided)g . Full wiretainers -by volume (no aids pro-

vided)h. Full wiretainers -by weight (visual aids) .i. Full reject container (no aids provided)j. Overflow chamber/waterfall (no aids pro-

vided)

512.22 Sweeping Aids and Descriptions.Outlined below is a list of indicators and a de-scription of their functions designed to aid .thesweeping operation :

. a. Amber light (steady illumination) . Traynearly full or has reached 75% of weight limitand must be replaced . Mail will continue to besorted until weight limit is reached .

b. Amber light (flashing illumination accom-panied by a momentary audio alarm) . Tray fulland requires immediate replacement . Mail is be-ing diverted to reject bin .

c. Sweep switch with indicator (left & right) .When the sweep switch is pressed once, bin in-dicator light flashes. This indicates that the bin isbeing swept while the mail is diverted to thereject bin or that the sweep button has not beenpressed again after the container was exchanged .The indicator in the sweep switch will also flash .When the switch is pressed again, the bin indica-tor flashing light and the indicator in the sweepswitch will go out . Mail will again be sorted tothat bin.

512.23 Sweeping Procedures

512.231 General. Sweep mail from bins, as neces-sary using SPBS trays, sacks, U-carts, orwiretainers . As part of the sweep process, thesweeper will engage the sweep switch and ensure

26


that the sweep switch indicator is flashing beforesweeping. Mail which is destined for an outputbin being replaced by a sweeper is, under thiscondition, automatically bypassed to the reject binas a valid reject. Therefore, an empty replacementcontainer must be immediately available at thebin when a full container is to be replaced . Thisminimizes the amount of mail bypassed to thereject bin . Reactivating the sweep switch resetsthe weight counter to zero to begin a new countfor the output. Follow the procedures below tosweep:

a . Gain quick access to outputs requiringservice, as indicated by audio and visual alarms.

b . Visually scan output to ensure no mailbuildup occurs .

c. Visually observe machine indicators andalarms to ascertain the nature of attention re-quired .

d. Visually scan output receptacles . Removeand replace when full.

512.232 Tray or Sack Replacementa . Replace as dictated by audio/visual aids.b. Replace according to dispatch schedule .c. Remove when full and replace with empty

tray or sack. Amber indicator light remains flash-ing until proper sweep button (right or left) onthe control arm assembly is pressed .

Note : Use proper lifting techniques at all times to preventinjuries .

512.233 Wiretainer Replacementa . Use with or without audio/visual aids .b . Without visual aids, the decision to ex-

change wiretainer is based on appropriate dis-patch schedules plus one or - more visualobservations. When full, the sweeper must ex-change it .

c. With audio/visual aids operation is thesame as the U-cart.

512.234 U-cart Replacementa. Replace as dictated by audio/visual alarms .b . Replace as a result of dispatch schedule .c. On output control arm, press appropriate

sweep switch. Sweep indicator will light. (Mail isdiverted to reject.)



d. Remove full container, replace with emptycontainer. Amber indicator remains . illuminateduntil proper sweep button (right or left) on theoutput control arm is pressed .

572.235 Reject Outputa. No audio/visual aids are used .b. Visual check is required .c. Sweeper/supervisor judgment decides need

for container replacement .

572.236 Overflow Chamber (Waterfall)a. There are no audio/visual aids. The sweep-

er must perform a visual check .b. To remove mailpieces, open chamber

door, remove mail, and return door to closed(latched) position .

Caution : DO NOT remove or open chamber doorwhile system is running . Always engage emer-gency stop switch before opening door .

c . Mail in the overflow chamber should becollected, deposited in the reject container, andreprocessed through the induction station on ascheduled basis .

Note: Excessive buildup of mail or packages near the . trans-port could cause the entire SPBS system to stop or damagethe machine .

512.3 Dumpers and Cullers

512.31 General. Dumpers will dump mail re-ceived at the SPBS operation onto conveyors .This mail will generally be in sacks, pouches,hampers, or APC or BMC containers . Cullers willensure that mail received by the keyers is withinSPBS processing guidelines . Generally stated thismeans mail within the following range :

(1) - Minimum Size -3.5" x 5.0" x 1/4"(2) Maximum Size -12" x-15" x 8"(3) Minimum Weight - .25 pounds(4) Maximum Weight -20.0 pounds

512.32 Dumping Procedures. The dumper willprovide a 'steady and even flow of mail to theculling belt and/or keyer. Dumpers will also en-sure that the conveyors feeding the inductionstations are not overloaded with mail that couldpossibly fall off the induction station. Mail will becontinuously dumped so as not to let conveyorsrun dry. Dumpers will elbow sacks to make surethat they are-empty . They will also strip the


labels -from dumped sacks and finalize all emptyequipment. The dumping area must have suffi-cient space for staging mail without blocking theaisles.

512.33 Culling Procedures. Cullers will take outall mailpieces that are deemed unacceptable forSPBS processing. These mailpieces will be depos-ited in a throw-off container for manual distribu-tion. Cullers will ensure that the culling beltoperation is appropriate (not too much, not toolittle). They will make sure that all bundledmailpieces are kept faced on the conveyor, to thedegree feasible, so that the mailpieces are faced-up when received by the keyers. Cullers willmaintain the integrity of bundled mail even whenit is culled out into nonmachineable bundles. Allloose or unsecured bundles must be rebandedwhen the integrity of the bundle can be readilymaintained. This applies to both machineable andnonmachineable bundles .

520 Operating Instructions

521 Introduction

The SPBS has three modes of operation : Auto-matic, Jog, and Maintenance . "Automatic" is theonly mode to be used by supervisory and operatorpersonnel. Jog and maintenance operations areused by maintenance personnel only .

522 Operating Procedures

Supervisory personnel are responsible for the safeoperation of the equipment. If any malfunctionsoccur or the equipment does not perform inaccordance with start-up and operational instruc-tions, maintenance personnel must be notified tocorrect the situation .

523 Prestart-up Procedures

523.1 General . Prior to starting the SPBS opera-tion, there are various steps that must be takenby the supervisor, maintenance personnel, andSPBS operators.

523.2 Supervisor . The supervisor must ensurethat :

a . All data and output bins have beencleared from the previous run .

b . Sufficient mail volume is available andproperly prepared for processing on the SPBS .

523.2

27

523.3

have been checked for any mail remaining fromprevious run.

g. Mail has been loaded onto the inclinedconveyor belt (or other feeder unit as appro-priate) .

h. The area surrounding the SPBS has beenchecked for safety hazards and cleanliness .

523.3 Maintenance Personnel. The maintenancepersonnel are responsible for :

a. Routine preventive maintenance .b . Ensuring that the SPBS is ready for safe

operation .c. Setting the main power switch to the on

(up) position.

Note: See maintenance SBPS handbook .

523.4 SPBS Operator/Keyer . Adjust the follow-ing items for efficient operation as determined bythe operator :

a. Keyboard position .b. Display position, if necessary.

524 Start-up Procedures

To begin start-up procedures, supervisors must :. a. Ensure that all personnel are clear of the

equipment and' that the auto/mairit/jog switch is inthe "auto" position .

b. Rotate main switch CB1 (if power has notalready been applied by maintenance) counterclockwise to apply power to the supervisor work-station and all CPUs in the system. The L1, L2,L3, and chain stop indicators on the front panelshould light.

c. Load correct sort plan .d. Turn the on/off switch on the PW/2 to the

on position to download the sort program fromthe workstation to the master processor control-ler. The supervisor menu appears, along with a

28

(6) Downloading Induction Stations(7) Downloading Section Controllersd. Turn the system start enable keyswitch on

the power cabinet clockwise to the on position todistribute AC power to all the system modules .The sort power, induction power, and systempower on indicators will light .

e. Turn the chain run keyswitch on the rearof the power cabinet to the on position to supplypower to the main drive motor. This puts thedrive chain in motion and transports the carriercells through the system. The chain stop indica-tors on the front and rear of the power cabinetextinguish and the chain run indicator lights .

Note: As a safety precaution, a brief delay takes place be-tween turn on and drive motor actuation. During this time, lightsflash and alarms sound at each end of the machine and thelast receiver module.

f. Ensure that each keyer turns the inductionline start enable keyswitch on each of their oper-ator control boxes to the on position to start theinduction line conveyor belts. . The ._operator, dis-play panel will display the following three mes-sages sequentially, one at a time :

(1) Chain Started(2) Starting Belts(3) Load/Key

525 Run Procedures

These procedures must be performed by a trainedoperator. Single mailpieces are moved manuallyby the operator/keyer onto the code conveyor forthe key coding process after which . the mail isautomatically handled by the machine . The ma-chine sorts the mail into designated bins whichare emptied by the sweeper. The trained oper-ators must:

a . Observe the display on the operator dis-play panel at the coding station for indicationsthat loading and keying can begin .



c. All support equipment, such as trays andwiretainers, for sweepers are available, in place,and ready for safe use .

series of message windows that appear momentar-ily on the screen, one at a time, indicating thedownload of software. The messages include :

d. Support personnel and adequate space are (1) Downloading Master Controlleravailable to safely stage mail coming into the (2) Sending Configuration to Masteroperation without blocking aisles.

(3) Configuration Sent to Master Controllere. Support equipment and personnel areavailable to remove processed mail to dispatch or (4) Downloading Sort Plan (Name .Type)other processing areas. (5) Sort Plan (Name.Type) Download Co

f Inclined conveyors and mail transport belts plete


Note: Keying can either precede or follow the loading of mail .One hand sliding the mail onto the load belt is preferred whilekeying with the other .

b. Load mailpieces on the code/weigh .mod-ule so that their longer dimension is roughlyparallel to the V shaped positioning edge nearestthe operator . This is particularly true for largerpieces.

c. The loaded mail advances to end of loadbelt, but may stop to:

(1) Await key entry (operator enter keycodes -if already entered, display instruction isblank) .

(2) Await assignment to a particular carriercell and momentarily stop (no operator action isrequired) .

(3) Indicate a loading irregularity exists asfollows:

Operator Detected


Irregularity

Alarm

Display/instruction

Power failure

No instruction . Clearline and reset(system stopsoperating) .

d. A single audio beep is sounded as the mailleaves the loading belt for entry into the system.This signals the operator to begin the next loadingprocessing cycle .

526 Turnoff Procedures

The following procedures are to be performed bythe supervisor and operator:

a. The supervisor presses the chain stopbutton on the rear of the power cabinet . Thedrive chain stops moving .

b . The keyer turns the start enablekeyswitches (located on the induction station) tothe off position to shut down all induction sta-tions . .

Note: Make sure all reports have been recovered beforeturning off power to the entire system or data will not berecovered. Perform the following procedures only when therewill be no runs for an extended period of time .

c. Turn the on/off switch on the systemworkstation to off.

d . Turn off the CBI switch on the powerpanel .

All power is now removed from the system .

530 Alarm Warning System

531 Definition

531.1 General. An alarm warning system alertspersonnel in the area that the SPBS drive chainwill begin running within 10 seconds . The SPBSutilizes two types of alarm systems, audio andvisual. They are described in the following sec-tions.

531.2 Audio Alarm. An audio alarm device islocated at the last receiver module and at bothends of the machine. The audio alarm sounds for10 seconds after the chain run keyswitch on therear of the power cabinet is activated .

531.3 Visual Alarm. One light post is located atthe takeup end module, one at the last receivermodule, and one at the drive end module . Theselights illuminate for 10 seconds after the chain

531.3.

29

Irregularity

Instruction

Loosely bundled mail

Secure mail if possible .

Tubular mail

Place in throw-offcontainer .

Oversize or overweight

Place in throw-offmail

container.

Machine Detected

Irregularity Audio Display/instructionAlert

Improperly loaded Audio Reposition/Rekey .or oversize item multiple(first occurrence) beep

Improperly loaded Audio Remove mailpiece .or oversize item multiple Place in throw-off(second beep container and reset .occurrence)

Overheight Audio Overheight. Removemailpiece multiple and reset . .

beep

Overweight Audio Overweight. Removemailpiece multiple and reset.

beep

Local induction Clear line and reset.station stops

Emergency stop Clear line and reset(system stopsoperating) .

532

run switch on the rear of the power cabinet isactivated. Additionally, emergency stop lights arelocated in-the emergency stop switches themselvesto indicate which switch was pressed to stop thesystem. There is also an emergency pressed in-dicator on the power cabinet to indicate an emer-gency stop switch was pressed somewhere in thesystem.

532 Emergency Stop Condition

The emergency stop indicator on the power cabi-net lights when the emergency stop switch ispressed to indicate an emergency condition .When an emergencyy condition occurs, all poweris removed from the SPBS except for the CPUpower supplies and power to the keyboard andprinter. The sort program and related data areretained. If an access cover is open or loose, thiswill also cause an . emergency stop condition . Usu-ally two conditions can cause the emergency stopindicator to light :

a. Emergency stop button is pressed .b. Access cover is opened.

533 Emergency Shutdown Procedures

The emergency shutdown procedures below areperformed by the supervisor and operator, asindicated :

30


a. Press the emergency stop switch . on thepower panel (supervisor) or on the operator con-trol box at the induction station (operator) or anyof the emergency stop buttons located at everyother module along the sort distribution section(sweeper). All emergency stop switches are within4 feet of any position on the' SPBS. Whenpressed, all mechanical operations will stop .

b . To reset an engaged emergency stopswitch, pull up the head of the switch system(supervisor or operator) .

c. To restart the machine after resetting theemergency stop switch, reset the power distribu-tion circuitry and the software interrupts first byusing the following procedure:

(1) Press the emergency reset switch on thepower distribution panel. The emergency stop in-dicator light goes out .

(2) Turn the alarm reset keyswitch to resetthe software interrupts .

(3) The chain stop indicator light goes out .(4) Make sure all safety precautions are

adhered to and the supervisor has given an "OK"signal before starting the machine .

(5) The system can now be restarted in thenormal manner .



610 System Manager

611 Definition

All transmissions between the master processor,controller and the workstation are executed byusing the system manager application software .Management information functions center aroundthe supervisor computer workstation (PWI2). Thissoftware and workstation represents the user in-terface to the SPBS. As such, it allows ,the su-pervisor to obtain information to meet specificreporting needs. It is menu driven and providessystem monitoring'* when the SPBS is operational .The system manager handles-all transmissions be-tween the MPC and the workstation . Any errorsreported by the MPC are translated by the systemmanager and displayed on the workstation moni-tor. The SPBS system manager software providesfor sort plan editing and transmission capabilities .It also provides sample run and volume run re-port capabilities, maintenance support functions,and diagnostics. When the SPBS is powered up in"auto" mode and the workstation switch andprinter power switch is turned on, the systemmanager software systematically downloads theoperational code and configuration for all CPUsin the system . SPBS configurations- are preloadedinto the hard disk of the master controller com-puter workstation at the factory as default con-ditions -for a, site. The MPC contains operatingprocedures for SPBS normal operations . All pro-cedures are executed at the PWI2 workstationusing the system manager. The SPBS system pro-vides report generation capabilities at the supervi-sor and administrator menu levels . The reportsprovide an account of machine utilization, systemperformance and operation, and inductionstation/operator performance for full run andsample time periods . Reports provided from thesupervisor menu are generated on-line (i .e ., whilethe chain is running); reports provided from theadministrator menu are generated off-line (i .e .,while the chain is stopped) . See Exhibit 611 for asystem manager menu tree (flowchart) .


Chapter 6Management Information

612 User Access

612.1 General. The SPBS supports two methodsfor generating reports :

a. On-line . Auto/Maint/Jog keyswitch is inthe "auto" position and carrier cell chain is run-ning. All reports and programs on the supervisormenu are executed on-line .

b . Off-line. Auto/Maint/Jog keyswitch is inthe "auto" position and the carrier cell chain isstopped . All sort plan operations, reports(excluding supervisor menu), utilities, configura-tion, 'maintenance, and diagnostics menus are ex-ecuted off-line.

612.2 Procedures

612.21 General .. The procedures in this sectionassume the SPBS system manager applicationsoftware is already loaded and both the work-station and printer power are on.

612.22 Menu Options . To access the variousmenu options use the following :

a . Use the arrow keys and press the returnor enter key .

b . Enter the first letter of the option andpress the return or enter key.

612.23 Command Notationsa. Brackets: Brackets denote keyboard entry

or a specific key to be pressed . Only enter thecontents of the brackets not the brackets them-selves.

b. (CR) . Indicates that the return or enterkey must be pressed to enter data .

c. (ESC) . Escape key is . used to return to theprior menu .

d. File Name . The name of file in use .

612.24 Input Descriptions . The following toolsare used to enter and generate information :

a. Settings . Shows proper input parametersfor entering at prompt(s) on screen display .

612.24

31

612.24


MaintenanceMenu*

ManPower

Configuration Menu

Change Passwords*Set Alarm PnonnesSet Sin Configuration

ParametersSet Keyboard Configuration.Parameters

Display Reasons For RejectSet Sat Plan Default &Page Length

Set System Parameters

* Password Required

Sample Reports Menu

Destination ReportEnd of Rum ReportFull ReportKey Codes Per Induction

Station ReportSystem Key Code ReportSystem Reject ReportSystem Summary Report

SYSTEM MANAGER

Supervisor Menu

Administrator Menu•FWO=SWQ RateHistory ReportInduction Station ProductionProduction RateRestart PrimerStart SAVS PhaseStop Sample Phase

1Administrator Menu

Volume Reports Menu

End of Run ReportFull Report .Key Codes Per Induction

Station ReportSystem FailureSystem Key Code ReportSystem Log ReportSystem Reject ReportSystem Summary Report

iMaintenance Menu

I

Diagnostics Menu*

Check U"ExI To DOS*Shell TO DOS*Module CoMdguratiat*Pat ConfigurationStan Diagnostics

Begin NewRueCfarLOP

Sort

u

son Plan EditorCopy Son PlanSave To DiskSend Sat Plan o

MasterClear Output

Send Configuration ToMaster

Exhibit 611, System Manager Menu Tree

Stan Sample.

and Menu

RS232 MenuSet Time MenuSet Date Menu .Status Report

Prepare For FinalShutdown

32



b. Enter or return key (CR) . Used to enterdata for operations and to move cursor fromentry to entry (vertically) . Designated by (CR) in ..the procedures.

c. Arrow keys. Used to; `move - cursor, fromentry to entry (horizontally . and vertically) . . .

d. Password. ' A valid password is necessaryfor access to certain menus ands options . Theseinclude administrator menu; maintenance menu;start sample phase ; diagnostic menu; change - :pass-words; exit to DOS; shell 'to DOS-,and-.moduleconfiguration . Must use (CR) to enter_ password .

e. Help key . Pressing function' key 'BFI dis-plays an explanation . of the selected menu inreverse video . .

620 Supervisor Menu

621 Definition

The supervisor menu is the first menu that ap-pears on the system manager screen after startup .It allows access to graphic, instantaneous produc-tion reports (such as induction station productionand productionrate -reports)- The ,supervisormenu also provides a report that allows a look atprevious production (history report) and f Lureproduction (forecasting rate report) . This, is avital tool for assisting supervisors in accomplish-ing daily objectives .This menu branches to theadministrator menu and. the:: maintenance menu inaddition to other, menus. and programs: . .-It alsoaccesses reports . 'Several -of 'these --menus'. op-tions are password protected. The system pass-word is required to change the other-passwordson the system. A request foropassword is in-dicated by a window prompt that appears on thescreen. When an invalid password is entered, anerror message is displayed . For security reasons,passwords are not displayed on -the windowprompt or on the change password menu. Allsupervisor menu options are executed on-line,i .e ., while the carrier chain is running . Followingis a sample supervisor menu screen :


Supervisor, MenuAdministrator MenuForecasting RateHistory Reportinduction Station Production ReportProduction Rate ReportRestart PrinterStart SAYS - PhaseStop Sample Phase

622 . User Access

This section describes the SPBS reports that ap-pear: on the supervisor tnenu. ;These reports aregenerated on-line (i .e.,ewhile the chain is running)and prints -only what is-actually being shown onthe screen (using the print screen key) . To accessthese reports, use the arrow keys to move thecursor to desired reports and press the returnkey .

623 Supervisor Menu Options

623.1 Forecasting Rate Report . This report gen-erates a graphic display of anticipated volumeforecasted from the present time up to the nextfour hours. Data for this report is based onmaintaining current keying rates, which are up-dated every five minutes. This report ,can only begenerated on-line while the chain isrunning. Togenerate this report:

a. Ensure that the supervisor men_ u appearson the screen .

b . _ .Select the "forecasting rate report" option .-c. Graph is. displayed.A- Press ESC to return .to supervisor's .menu .

See Exhibit 623.1 for a=sample forecasting ratereport.

6232 .History ::,Report .; . This report provides agraphic display of system production rate from anhour ago to the present time. It plots the volumeprocessed during that hour and is updated everyfive minutes. This report : can only be generatedon-line while the chain is running . To generatethe report :

a . Ensure that the supervisor menu appearson the screen .

b. Select the "history report" option .c. Graph is displayed .

See Exhibit 623 .2 for a sample history report.

623.2

33

s5 -~I P 60-1iI

55 -1e 50-1c,1 c 45-1le 40-1Is 35-11

30 .:: lIX 25-1I 20 - 11 15 -1• 10.-1• 5-1•

0-1'

now4-

2

hours from now

3

-------------------------------

Exhibit 623.1, Sample Forecasting Rate Report

4

MODE: VOLUME

DATE: 09-19-1989PLAN : TRAINER.IN

TIME: 10:50:22^j

I

1 1000900800700600500400 .300,200100

I

0rI

I

30I

minutes ago

L

Exhibit 623.2, Sample History Report

34


623.2 Small Parcel and Bundle Softer Guidelines

FORECASTING PRODUCTIONMODE: VOLUME DATE: 09-19-1989PLAN: TRAINER . IN TIME: --08:58:39

Small Parcel. and Bundle Sorter Guidelines

623.3 Induction Station Production Report . Theinduction station production report provides pro-duction rate data for each induction station. It-shows the total number . of pieces keyed, rejectedand the . current production rate of mailpieceskeyed and rejected on each induction `station . Thecurrent production rate per minute is obtained bydividing the total processed by the total run time .This report can only be generated on=line whilethe chain is running. To generate report:

a. Ensure that the supervisor menu appearson the screen .

b . Select the "induction station productionrate report" option .

c. I.S. production report is displayed .

See Exhibit 623.3 for a sample induction stationproduction rate report.

623.4 Production Rate Report . : The productionrate report provides graphic production -rate datafor the entire system . This is a valuable tool formonitoring keying performance . The right side ofthe report gives a dynamic bar graph for allinduction stations. This area shows the inductionflow per minute for each induction station . Thisreport also shows the total pieces keyed for all

MODE: VOLUMEPLAN : SIMPLE. IN

ITotal :

pcs keyed

pa rej

CurrentRate:tot per min

pcs rej


50

132 -

4

I.S. Production

SPBS I.S. 1, I.S. 2 LS. 3 I.S. 4 I.S. 5 I.S. 6

---- - .I

induction stations as well as the total productionrate for' the last 20 minutes. The left side of thereport gives a graphic depiction of the SPBSmachine layout. If any run-time faults or systemalarms occur in the system, the correspondingarea of the diagram is highlighted in red. Thisreport can only be generated on-line while thechain is running . To generate this report:

a. Ensure that the supervisor menu appearson the screen .

b . Select the "production rate report" op-tion .

c. Press ESC to return to supervisor's menu .

Note: A hardcopy of this report can be obtained by pressingthe "print screen" key .

See Exhibit-623.4 for a sample production ratereport.

623.5 Restart Printer. This program turns theprinter on-line if currently off-line, assuming theprinter power on switch is set to the on positionand the on-line indicator is lit (green) . No runtime header is printed. This report can_ only beexecuted on-line . To generate this report :

DATE: 09-19-1989TIME: 08:59:04

-----------------------------

Exhibit 623.3, Sample Induction Station Production Rate Report

623.5

35

700 600

650 550

680

28 27 24

18 24 27

17 21

25

0 1 .2

0 0

1

630'

36

a . Ensure that the supervisor menu appearson the screen .

b. Select the "restart printer" option .c. Observe that printer restarts .

630 Administrator Menu

631 Definition .

This menu is found on the supervisor menu andis password protected . All administrator menuoptions are executed off-line, i .e ., while the car-rier cell chain is stopped . Following is a sampleadministrator menu screen :

PRODUCTION RATEMODE: VOLUMEPLAN : SIMPLE.IN

.

I .- ' - . '

I

Tot pcsII

T -.3685-'

1I

graphI I

per minI

Tot ProdI

rateII

~

68 I!per min

I

II II II II II II

total1 1 2 3 4 5 6

L

I 18 1 241 271 171 211 251r _rt_I_--r_r_t--IL~1 LOO-1 19L~L'q820_1

--------------------

Exhibit 623.4, Sample Production Rate Report

Administrator Menu

Maintenance MenuManpower MenuSample Reports MenuVolume Reports MenuBegin New Run/Clear LogsSort Plan MenuStart Sample PhaseUtilities Menu

632 'User Access

To display the administrator menu on the screen :a . Highlight the administrator menu option

on the supervisor menu and press (CR) .b. Enter a valid password and press (CR) .c. The menu is displayed. Use the (ESC) key

to return to the previous menu level, if necessary .

633 Administrator Menu Options

633.1 Manpower Menu

633.11 General. The manpower menu is updatedat the end of each mail run (i .e ., every time asort plan ends or at the end of the day or shift) .

Small Parcel and Bundle Sorter Guidelines .

DATE: 09-19-1989TIME: 09:02.00 .

------------------

I


2 3 4 5 6

I I I I

II . I I I

1I I I I

I.I I I I

II

I

Small Parts-Wand Bundle Sorter Guidelines

These values are read by the program whichgenerates the end-of run report on machine utili-zation and productivity . This program can onlybe executed off-line. To execute :

a. Ensure that the administrator menu ap-pears on the screen .

b. Select the "manpower menu" option .c . The manpower menu appears on the

screen .d . Set manpower menu, as required .

Following is a sample manpower menu :

Manpower Menu

Set Manpower

Input Type Number of People

Set Manpower

Value

99.9

633.12 Input Field Description Following is adescription of requested information :

a. Man power input type . Use the leftft andright arrow keys to set the parameter at one oftwo available input type options : number of peo-ple or total workhours. Enter the number ofpeople or total workhours.

b. Number of people . Enter the total numberof people working with the machine during thesort plan run. This figure correlates to workhoursfor the end of run report. Maximum acceptablevalue is 99 .9 .

c. Total workhours. For total workhours,multiply the number of employees working onthe sort plan by the total processing time for thatsort plan run. Maximum acceptable value is999.9 .

d. Enter setting. Use (CR) to enter the settingand the manpower value .

e. Press (ESC) . Manpower setup is complete .Administrator menu is displayed .

633.2 Sample Reports Menu

633.21 General. The following sections describeeach report on 'the sample reports .menu. Select-ing any of the reports listed in this menu willaccess and print the data compiled during thesample run phase only . This data will not beincluded in the volume reports . All sample re-


633.241

ports are generated off-line (i .e., while the carriercell chain is stopped) . Following is a sample sam-ple reports menu :

Sample Reports Menu

Destination ReportEnd of Run ReportFull ReportKey Codes per Induction Station ReportSystem Key Code ReportSystem Reject ReportSystem Summary Report

633.22 User Access. To display the sample re-ports menu on the screen :

a . Highlight the administrator menu optionon the supervisor menu and press (CR).

b . Enter a valid password and press (CR).c . Highlight the sample reports menu and

press (CR) . The menu is then displayed on thescreen. Use the (ESC) key to return to the pre-vious menu level, if necessary .

633.23 Destination Report. The destination re-port provides bin density information. This reporttracks the weight and number of mailpieces sort-ed to each bin per keycode . This report can onlybe generated off-line. To generate the report:

a. Ensure that the sample reports menuappears on the screen.

b . Select the "destination report" option .c. The destination report starts printing .

See Exhibit 633.23 for a sample destination re-port.

633.24 End-of-Run Report

633.241 General. The end-of-run report (alsoavailable on volume reports menu) provides pro-ductivity data for each induction station and theentire machine. It 'shows the overall efficiency ofeach run based on the following data :

a. Throughput. Total pieces processed perinduction station operational time (hours) .

b. Productivity . Pieces processed per workhour based on the manpower input type andvalue .

37

633241

38

Total Run Time : 1 Hours 2 Minutes 24 Seconds

Total Mail Pieces Sorted : 3535r

------ - ---------------r

D;;t;naWL

Bin # 1

Key Code

Total Mail Pieces: 0

Bin # 100

Small Parcel and Bundle Sorter-Guidelines

--------- -Weight

Total Weight 0.0'

Key Code

Weight

L j

Exhibit 633.23, Sample Destination Report


I

001001

1 .11 .1

Total Mail Pieces: 2

Bin # 2 Key Code

Total Weight 02.2

Weight

i------

Total Mail Pieces : 2

Bin # 3

------002002

Key Code

------2.2

12.2

1

Total Weight 4 .4

1i

Weight

i

003003

1 .1223.3

Total Mail Pieces: 3 Total Weight 6.6

Bin # 4 Key Code W

Total Mail Pieces: 1 Total Weight 0.0

Bin #5 Key Code Weight

Total Mail Pieces : 0 Total Weight 0 .0

Bin # 6 Key Code Weight

Induction Station . Mail Pieces Processed------------- ----------------

1 5052 7003 6004 650

.5 5506 680 .

r . 1I

System Destination Report (Sample Rim)

J

1 .

--i

Machine ID

:INPLANTOffice ID

:UNISYSSort Plan

:SIMPLE .IN

Out Date : 09-19-1989Start Time

:15:15:45

Stop To* : 16:18:09


c. Machine Utilization .

Induction stationoperational time in hours per total run time.

Note: Prior to generating this report, ensure that the man-power menu is set for the desired mode : number of people ortotal workhours . This report can only be generated off-line .

633.242 User Accessa. Ensure that the sample reports menu

appears on. the screen .b. Select the "end-of-run report" option .c. Observe the printing of the end-of-run

report on the printer .

See Exhibit 633.242 for a sample end-of-run re-port .

633.25 Full Report. The full report (also avail-able on volume reports menu) gives the key codeand destination data (cell and weight) for eachmailpiece processed per induction station . Thisreport can only be generated off-line . To generatethe report:

a . Ensure that the sample reports menuappears on the screen .

b . Select the "full reports" option .c. Observe the printing of the full report on

the printer .

See Exhibit 633.25 for a sample system full re-port.

633.26 Key Code Per Induction Station Report .This report (also available on volume reportsmenu) lists the mailpieces processed per induc-tion station and lists sequentially the keystrokesentered for each induction station . The MPCkeeps a record of all keycodes entered on eachinduction station and generates this informationthrough the PW/2. This report can only be gen-erated off-line. To generate the report :

a. Ensure that the sample reports menuappears on the screen .

b . Select the "keycode per induction stationreport" option .

c. Observe the printing of the- inductionstation key code report to the printer .

See Exhibit 633.26 for a sample key code perinduction station report .

633.27 System Key Code Report . The system keycode report (also available on the volume reportsmenu) lists themailpieces processed under each


key code per induction station. This report canonly be generated off-line. To generate the re-port:

a . Ensure that the sample reports menu .appears on the screen .

b. Select the "system key code report" op-tion .

c. Observe the printing of the key codereport on the printer .See Exhibit 633.27 for a sample system key codereport .

633.28 System Reject Report. The system rejectreport (also available on the volume reportsmenu) shows the number of mailpieces sorted tothe reject bin per keycode and lists the reasonsfor reject of a mailpiece . This report can only begenerated off-line. To generate the report :

a. Ensure that the sample reports menuappears on the screen.

b . Select "system reject report" option .c. Observe the printing of the system reject

report on the printer .See Exhibit 633.28 for a sample system rejectreport .

633.29 System Summary Report. The systemsummary report (also available on the volumereports menu) shows the total number ofmailpieces processed by each induction station toa specific destination bin, including reject andmissent mailpieces. This report can only be gen-erated off-line . To generate the report :

a. Ensure that the sample reports menuappears on the screen .

b . Select the "system summary report" op-tion .

c. Observe the printing of the system sum-mary report on the printer .

See Exhibit 633.29 for a sample system summaryreport .

633.3 Volume Reports Menu

633.3

39

$313

Small Parcel and Bwdle Sorter Guidelines

7 ~~

-

Endcf Run Report (Sample Run)

L !

Machine ID : UNPLANT

-

Office ID : UNISYS '

Sort Plan : SIMPLE.IN

Out Date :~

'

!Start Time : 15:15:45

Stop Time :/ Total Run Time : 1 Hours 0 Minutes 0 Seconds

_

.

~

-_~

~

End of Run Report (Sample Run)

~ ~

~

Induction Station

Total

L

Exhibit 633.242, Sample End-of-Run Report

~

~|

40


u

| 1 2 3 4 5 6 SPBS-----

~ Total Pieces Prooeased :

505 700 600 GR) 5}O 1580 3685~ \.S.- Op Time (Hours) :

0.8 1 .0 1 .0 .1 .0 1 .0 5.6~ Throughput (Pieces/Hour) :' 631 700 600 650 687 680 3685~

Productivity

~ (Pieces/Workhour) : 368.5

! Machine Utilization :

80% 100% 100% 100% 80% 100% 93%) (Induction Station Op Time/Total Run Time)


6333

r ~

I

System Full Report

Run)

~

.

~/

~~

Machine ID : INPLANT)

Office ID : UNISYS~

Sort Plan : SIMPLE.IN

Out Date : 09-20-19M~

Start Time : 15:15:45

Stop Time : 15:18:09-Total RunTime : UHours 2 Minutes 24 Seconds~

./

Total Mail Pieces Sorted : 45

Induction Station

Mail Pieces Pnomessed__________

!

1

5'~~

2

5 \~

3

27 ~~~

4

2~~

5

3~~

6

3L~ .~_-

\(

Full Report

Page:(Sample Run)

1

\______- _________- ___________________-

~

L

Whibit 633.25, Sample System Full Report

!!!~!


Z41

------------

# Code IS

. Int Act Cell Weight Reason for Reject-----------

' 1 012 3 12 12 0 0.0~ 2 012 2 12 101 10 5.5 Bin Being Swept

3 003 3 3 3 22 1 .3! 4 C6B 5 5B EW 28 19/ 5 C68 3 58 58 34 0.4/ 6 069 6 69 69 51 1 .7/ 7 C68 3 58 68 E9 16~ 8 D28 1 58 58 64 0L7~ 9 058 4 58 58 69 0'4! 10 058 2 58 58. 75 1 .2 '~ 11 068 6 58 58 8018

633.3

42

-------------------------

.

Exhibit 633.26, Sample Key Code Per Induction Station Report

SrnawPan:V and Bundle Sorter Guidelines

r 1

Total Run Time : I Hours 45 Minutes 05 SecondsI

Total Mail Pieces Sorted: 6116F

~ lKeyCodeReport (Sample Run)

Page: 1

~~

for Induction Station 1

r ~---1

Handbook PO-430 December 991

I Induction Station Mail Pieces Processed__________ ----------

1 9692 7393 16094 710.5 788

'

6 1301

}

.

System Key Code Report (Sample Run)

I

I- ~ !

~ Machine ID : INPLANT~ Office ID : UNISYS! Sort Plan : SIMPLEIN Out Date : 09-19-1989~ Start Time : 1210I0 Stop Time , : 01 :45:05

Key Code------------

1 .0125 012

10 01313 01217 013

-Small Pareel and Bundle Sorter Guidelines

633.3'

F~ ~

~

Key Code Report

Run)

~~~ ~~

~

Macbhne ID : INPLANT !)

Office ID : UNISYS~

Sort Plan : SIMPLE . IN ~

Out Date : 09-19-1989 !~

Start Time : 15:15:45

Stop Time : 16:18:09 ~!

Totai Run Time :1 Hours 2KAinuhaa 243eomndo

!

~ Total Mail Pieces Sorted : ~~35__

_ ~--

^

!

i

Key Code Report (Bun)

Page: 1

! 4

L

Exhibit 633.27, Sample System Key Code Report

Handbook pO-430 December 1991

~

43

Mail Pieces processed------------

1

` 001 12 OC2 23 QOU3 24 004 15 ODS 16 006 17 007 1W 008 1~ 009 1

10 010 111 Oil 112 012 313 O13 114 014 115 0`16 1

~ 16 016 1. 17 017 118 O1~ 119 019 120 000

Induction Station

Mail Pieces Processed__________ .

' 5052 7003 6004 6505 5506 6880

633.3

Small Parcel . and Bundle Sorter Guidelines

r 7 --!

!

emoonmeject Report glarnple Run)- __________________________________--

Machine m : INPLANT !!

Office ID : UNISYS .

/!

Sort Plan : SIMPLEJN

OutDate : 09-11198M!

atartTime : 15 :`a:45

Stop line : 1618XG !!

Total Run Tmnm : ,*purs 2 Minutes 24 Seconds !!

Total Mad Pieces Sorted : 3535r l!

mdummnaumon

wal/pwnewp"omassed !! !

1

5052

700!

3

60m

/!

«

sso

/!

-

/s

~

sso!

e

68m'

/

[' System Bowl Qiort (Semo*non)

1

~

~~

l

!eiq#

~~Code

m ml*mm=s Processed

Reason for Reject

Ii ---

-~` !~

1

Mm

2

emewirigAMA !!

2

mm

1

Bin awmgewwW !

!

o

M0

1

So Being Imp !!

4

om2

2 oma~ngemww#

!L ~

Exhibit 633.28, Sample System RejectReport

r----~!

System Summary Report (Sample Run

! i

!

MeomineuJ .UyPWANT ~

!!

Office ID UNISYS!

Sort Plan . SIMPLEIN :

Out Date : 09-19-1989!

Start Time . 15 :15 :45 :

Stop Time : 16:18:09!

Total Run Time . 1 Hours 2:Minutes 24 Seconds !(

Total Mail Pieces Sorted : 3535 . }r 1!

Induction Station

Mail Pieces Processed !! !

1

505!

!2

700!

!a

600!

!-4

650u

550!'

!6

680!

!r 1! System Summary Report (Sample Run)

Page: 1 ! l

!

Destination

Mail Pieces Processed

!i !

1.

5!

2

10~

3

5-----------------------------------

Exhibit 633.29, Sample System Summary Report

44

Handbook PO-43p December 1991

Small Parcel and-Bundle Sorter Guidelines

633.31 General. This section describes the re-ports on the volume reports menu . Selecting anyof the reports listed in this menu will generatethe report for the entire volume run in the lastsort plan. All volume reports are generated off-line, i .e., while the carrier cell chain is stopped .Most of the reports on this menu are duplicatedin the sarriple reports menu and have the sametitle. For this reason, only two reports unique tothis particular menu are described in this section .Following is a sample volume reports menu :

Volume Reports Menu

*End of Run Report*Full Report*Key Codes Per Induction Station ReportSystem Failure*System Key Code ReportSystem Log Report*System Reject Report*System Summary Report

'Described in sample reports menu .

633.32 User Access . To display the volume eports menu on the screen:

a. Highlight the administrator menu optionon the supervisor menu and press (CR) .

b. Enter a valid password and press (CR) .c . Highlight the volume reports menu and

press (CR)'.

-d. The menu is then displayed on the screen .e . Use the (ESC) key to return to the pre-

vious menu level, if necessary .

633.33 System Failure Report . The system fail-ure report lists system failures and the number ofoccurrences during the run (or since the lastclearing of data from the system or log clear) . Italso tracks the amount of downtime associatedwith each failure occurrence . This report can onlybe generated off-line . To generate the report :

a . Ensure that the volume reports menuappears on the screen .

b . Select the "system failure report" option .c. Observe the printing of the system failure

report on the printer .


See Exhibit 633.33 for a sample system failurereport .

633.34 System Log Report. The system log re-port lists system operational errors, includingpower failures, emergency stops, system problemsand carrier cell failures since the last clearing ofdata. Each event is logged by time of occurrenceand is assigned an alarm priority rating . Thisreport can only be generated off-line. To generatethe report:

a. Ensure that the volume reports menuappears on the screen .

b. Select the "system log report" option .c . Observe the printing of the system log

report on the printer .See Exhibit 633.34 for a sample system log re-port .

633.4 Begin New Run/Clear Logs. This programclears all data collected for the last sort run .Whenever this option is selected, it begins a newsortation process .

Note: Prior to starting this program, ensure that all reports aregenerated. This program can only be executed off-line .

To execute this report :-a . Ensure that the administrator menu ap-

pears on the screen .b. Select the "begin new run/clear logs"

option .c. Enter (Y) and press (CR) to clear logs .d. Confirmation message window appears :

"Logs Cleared, Ready for New Run ."e. Press (ESC) .f The administrator menu is displayed .

Following is a . sample begin new run/clear logsmenu:

633.5 Sort Plan Menu

633.51 General: The sort plan menu providessort plan editing and generating capabilities aswell as plan storage and loading for the SPBSsystem. The sort plan capability is designed toallow as much flexibility as possible for individual

Clear Logs

Enter Y to Clear Logs :

633.51

45

633ZI

Small Parcel and Bundle-Soner Guidelines

_- ~~ ~_- ~~~~System Failure Report (Volume Run)

- - ~~~~.'

Machineh8mchime82 .- QNPLANT

'.

~Office ID .- UNISYS -

Sort Plan~SQMPLE.UN

Out Date : 09-18-1989 ~'

QQ+~MW :°0̂5290-AAA

-Qt- me : 14:46:04 ~.

'̀~

Total qunTinne .0 Hours 1OMinutes 18Seconds[

-- -

~~_~~ ~~ _ - /-~--~~--~----~~~~~~~~-~-~- ~ - _~

l~_

.'System Failure Report

'Page-

\|

.~-

.

.~

Seq #

Description

Number

Tat Time (m)____

-

~~,.~_cy

}1

Switch Struck

1

8 +~ j

ReportExhibit 633.33, Sample System Failure

L

~

ILog Report (Volume Run)

-------------------------------------Machine ID : INPLANT

Office ID : UNISYS !Sort Plan : SIMPLE IN

Out Date : 09-18-1989 !Start Time : 143148

Stop Time : 14:46:04 !Total Run Thmw : 0 Hours , 0 Minutes 24 Seconds

Total Mail Pieces Sorted: 6116 !--~----~~--~7~

YSymtem Log Report

rage: 1 \~---7~

~~--~----1

Exhibit 633-34, Sample System Log Report

!

4$

Handbook PO^430,December 1s91

Snq # Unit Alr. #

Description

Dale

Time

Pri!!~ 1 IS-3

25

- Not Ready Yet

09-18-1989 14:33:19 1

'~ 2 IS-3

28

Fault kdm< 28 >

0~1~19~ 14:38:36 1

!i 3 SC-6

98

Driver Board

Result

09-18-1989 14:40:291

~~ ~--~ ~__j


offices to tailor sort plans to their specific needs .In order to utilize this flexibility, the mail type,destination bin assignments, keycodes and theirrelationships must all be considered. The SPBSsort plan uses alphanumeric keycodes up to fivedigits (actual keyhits inp :- :. by the operator) toaccess a bin location through a look-up table .These keycodes may be actual ZIP Codes or somerelation to a ZIP Code or mail type, dependentupon the local office design . For example, theoperator could key all 5 digits of the zip code, orthe first three digits, or a function key (Fl, F2,F3, or F4) and the last 2 digits, where the func-tion key represents the mail type (i .e ., letter-bun-dles or flats) . Note that the F1-F4 function keyson the operator keyboard represent alpha des-ignations, such that FI key = A, F2 key= B, F3key = C, and F4 key = D. Specific values canalso be assigned to the operator keyboard's fourfunction keys (F1, F2, F3, F4). For example, F1may represent a grouping of numbers, such as aZIP Code (e.g., F 1 = 19301, F2 = 19382,) . Thusa single function key could be used to inductmail. The value assigned to a function key maybe as many digits in length as the keyhit plan .This means that in a 5 digit sort plan, a functionkey value may equal 1, 2, 3, 4, or 5 digits . In sucha plan, if the value is less than the full five digits,additional keystrokes would be necessary to in-duct mailpieces. In the SPBS system only one sortplan can be selected at a time . All inductionstations use the same sort plan . The SPBS sortplan menu is found on the administrator menu .All sort plans are generated and manipulated off-line, i .e ., while the carrier cell chain is stopped .Following is a sample sort plan menu :

Note : The sort plan function keys are accessible from all sortplan submenus. These function keys are helpful for use withthe sort plan editor menu .

Sort Plan Me u

Sort Plan -EditorCopy Sort PlanSave to DiskSend Sort Plan to MasterClear Output Bins

633.52 User Access. To display the sort planmenu from the supervisor menu :

a. Highlight the administrator menu andpress (CR),

b . Enter a--valid password and press (CR) .


c. Highlight the sort plan menu and press(CR). The menu is then displayed on the screen .

d. Use the (ESC) key to return to theprevious menu level, if necessary .

633.53 Sort Plan Editor

633.531 Submenu I - Sort Plan Type and Name.The SPBS sort plan editor is used to create andedit plans for the SPBS . When creating. a plan,there are several options which must be selectedbefore keycodes are entered. The first submenuallows you to designate the sort plan type and toname the plan. The four sort plan types are :

a. IN - Incoming mail (.IN)b. OUT - Outgoing mail (.OU)c. MIX - Incoming and Outgoing mail (.MI)d. TEST - Testing Purposes (.TE)

Note: Prior to starting this procedure, ensure that the SPBS isoff-line (chain must be stopped) .

Following is a sample sort plan editor menu :

SORT PLAN EDITOR

SORT PLAN TYPE: IN OUT MIXED TEST

SORT PLAN FILE NAME :

633.532

633.532 User Access. To access the sort planeditor menu :

a. Ensure that the sort plan menu is dis-played on the screen .

b. Select "the sort plan editor" option .c. Sort plan editor menu appears.d. Enter the sort plan type and name :(1) Type = IN, OUT, MIX, TEST. Use right

or left arrow key to select the type until thecorrect type is highlighted, then press (CR).

(2) Filename = 1-8 alphanumeric charactername.

e . To edit an existing file, enter the filename, then press (CR) .

f. To create a new file, press (CR) :(1 .) Enter new file name and (CR) .(2 .) Enter valid reply and (CR) to the mes-

sage "File does not exist . Do you wish to createit? (YIN) ."

47

633.533

Note: Press N and (CR) to enter a new file nameif the file name entered is incorrect .

(3.) Press Y and (CR) . Submenu 2 is dis-played .

633.533 Submenu 2 - Sort Plan Configuration .This screen allows you to designate the following :keycode format (number and type of keyhits),missent bin number and container type, and func-tion key designation . Observe the confirmationwindow display message "Do you want to changethese values? (YIN)." Type N (CR). Submenu 3 isdisplayed. Type Y (CR) to change the values . SeeExhibit 633 .533 for a sample sort plan configura-tion.

633.534 Submenu 3 - Bin Configuration andCompilation . This screen allows you to enter anew sort plan or edit an existing sort plan . Thecolumns of the bin configuration display include :

a. An error message column .b. Sequence number column . Each sort plan

line has its own sequence number.c. Codes A and B ranges column. Beginning

and end of an inclusive range of keycodes .d. Destination assignment column. Bin des-

tination number and container type-tray, sack,U-cart, or wiretainer .

e. Comments column . A weight limit can bespecified separately for each bin in the system .Depending on the container type, maximumweight values between 20 pounds and 200 poundscan be assigned, as well as the wiretainer with noweight limit. There are thirty different containertype/weight values available in this section of thesort plan. Each value is a two character code . Thefirst letter indicates the container type (T-tray,S-sack). The second character indicates the maxi-mum weight limit for_ that bin . A list of containertypes can be displayed in the sort plan editor bypressing the F8 function key. The destinationassignment part of the sort plan is sent to the SCupon initialization (download 'and is containerspecific). The SC needs this information to deter-mine whether or not to keep weight data for aparticular output destination . For example, if thedestination is classified as a sack, tray, or U-cart,the SC will keep weight data . But if the destina-tion is classified as a wiretainer with no weightlimit, the SC will not keep the weight data . Whenthe sort plan is successfully compiled, the com-piled code is automatically saved to the hard disk .Whenever an existing sort plan is edited, it must

48


be compiled (physically using F6 to compile) toensure that the proper information is sent to theMPC. See Exhibit 633.534 for a sample binconfiguration/compilation menu and valid con-tainer types screen .

63354 Copy Sort Plan . This program is a harddisk copy option used to copy the file to a filewith another name, another type (i .e ., in, out,mix, or test) or overwrite one existing file withanother. To execute:

a . Ensure that the sort plan menu is dis-played .

b . Select "copy sort plan ."c. Enter sort plan type and name .d. Confirmation window appears .e . Press (ESC). Sort plan copy is complete

and sort plan menu is displayed .

Following is a sample copy sort plan menu :

Copy Sort Plan

From Sort Plan type

inFrom Sort Plan name

To Sort Plan type

inTo Sort Plan name

633.55 Save Sort Plan on Disk. This programallows . the sort data to be saved on a floppydiskette. The diskette must be formatted and in-serted into the drive of the PW/2 prior to enter-ing data. Following is a sample save sort plan ondisk menu :

Save Sort Plan on Disk

From Sort Plan Type'

inFrom Sort Plan name

To Sort Plan type

inTo Sort Plan name

633.56 Send Sort Plan to Master

633.567 General. This program allows the load-ing of a new sort plan to the MPC . It sends thesort plan (parameters and information) to themaster controller in less than two minutes . Priorto downloading a new sort plan, ensure:



SORT PLAN EDITOR

KEY CODE FORMAT : NNNNN

FILE NAME : FAC.IN

Key Code Format : NNNNN

Missent Bin Number: 101

Missent Bin Container (T/W) : T

F1 Key: A

F2 Key: B

F3 Key: C

F4 Key: D

Do you want to change these values? (Y/N)


Exhibit 633.533, Sample Sort Plan Configuration

633.561

49

633.561

50

ESC ExitF6 Compile

ESC ExitF6 Compile

Fl HelpF7 Save

Fl HelpF7 Save

F2 InsertF8 Containers

F2 InsertF8 Containers


F4 PrintF9 Clear Line

F4 PrintF9 Clear Line

F5 Next ErrorFl 0 Erase Line

F5 Next ErrorFl 0 Erase Line

Exhibit 633.534, Sample Bin Configuration/Compilation Menu (and Valid Container TypesScreen)


SORT PLAN EDITOR

KEYCODE FORMAT : NNN FILE NAME : EXAMPLE.TE

EER SEQ CODE A CODE B DEST# CONT COMMENTS

1 001 001 TI Now Bin 1 is a 60 lb tray .2 002 002 TE3 003 003 TE4 004 004 TE5 005 005 TI So is Bin 5 .6 006 006 TE7 007 007 TE8 008 008 TE9 009 009 TE

10 010 010 TE TfThe others remain 40 lb trays ..11 oil . 011 TE-12 012 012 TE13 013 013 W7 Bins 13/15 are wiretainers .14 014 014 TE Tray.15 015 015 W7

SORT PLAN EDITOR

KEValid Container TypesType

TE

ER

Traysrays Sacks U-Carts

MWWWOrs

TA 20 lbs SA 20 lbs U1 75 lbs

W6 200 lbsTB 25 .-bb SB 25 lbs U2 100 lbs

W7 no weight limitTO- 30 lbs SC 30 lbs U3 125 lbsTD 35 lbs SD 35 lbs U4 150 lbsTE 40 lbs SE 40 lbs U5 175 lbsTF 45 lbs SF 45 lbs U6 200 lbsTG 50 lbs SG 50 lbsTH 55 lbs SH 55 lbsTI 60 lbs S1 60 lbsTJ 65 lbs SJ 65 lbsTK 70 lbs SK 70 lbs


a. All reports from last sort plan run havebeen generated.

b . All bins have been swept .c. Weight data for bins has been cleared .

Following is a sample send sort plan to mastermenu:

Send Sort Plan To Master

Sort Plan type IN, OUT, MIX, or TEST

Sort Plan name

633.562 User Accessa . Ensure that the sort plan menu appears

on the screen .b . Select the "send sort plan to master ."c. Enter sort plan type and name:(1) Sort plan type = In, Out, Mix, or Test(2) Sort plan name = Eight characters maxi-

mumd. Use the right and left arrow keys to select

the sort plan type and press (CR) . Enter the sortplan name and press (CR) . The screen displays alist of information which will be sent to the MPC .

e. Use (CR) to enter data .f. Confirmation window displays three mes-

sages, one at a time :(1) "Downloading Sort Plan (Name.Type)"(2) "Sort Plan (Name .Type)"(3) "Logs Cleared, Ready for New Run"g. Press (ESC) . Sort plan menu is displayed .

633.57 Clear Output Bins. This program sends amessage to the master processor controller toclear the weight register data in the section con-trollers. The weight data should be cleared anytime there is a system-wide sweep of the bins .This program can only be executed -off--line. Toexecute :


Following is a sample clear output bins menu :

Weight Data has been Cleared

634 Utilities Menu

634.1 General . The utilities menu is shown inexhibit 634.1 . This menu is found on the admin-istrator menu . All utilities menu options are ex-ecuted off-line, i .e. ; while the carrier cell chain isstopped. Following is a sample utilities menu :

Utilities Menu

RS232 MenuSet Time MenuSet Date MenuStatus Report

634.4

634.2 User Access. To display the utilities menuon the screen :

a . Highlight the administrator menu optionon the supervisor menu and press (CR) .

b . Enter a valid password and press (CR).c . Highlight the utilities menu option and

press (CR) .d. The menu is displayed on the screen . Use

the (ESC) key to return to the previous menulevel, if necessary .

634.3 RS232 Menu . This program is used toselect the baud rate value for the RS232 interface.Allowable values are 300, 600, 1200, 2400, 4800,and 9600. This program can only be executedoff-line.

634.4 Set Time Menu. This program is used toenter a new time. All values for the three timeparameters -- hour, minute, and second -- mustbe entered to change the time. This program canonly be executed off-line . To execute:

a. Ensure the utilities menu appears on hescreen .

51

a.screen .

b.

Ensure the sort plan menu appears on the

Select the "clear output bins" option .

b .c.(1)

Select the "set time menu" option .Enter the following time setting :Hour = Valid range is 0-23 .

c . Press (ESC) . (2) Minute = Valid range is 0-59.d. The sortplan menu is displayed . (3) Second = Valid Range is 0-59 .

Following is a sample set time menu:

Set Time Menu

Set Hour 'Set MinuteSet Second

52

634.5 Set Date Menu . This program is used toenter a new date. All values for the three dateparameters -- month, date, and year -- must beentered to change the date . This program canonly be executed off-line . To execute :

a . Ensure the utilities menu appears on thescreen .

b. Select the "set date menu" option . . .c. Enter each of the following date settings :(1) Month = Use left or right arrow keys to

advance the month displayed to the presentmonth .

(2) Date = Valid entries are 1-30, 1-28, or1-31 (1-29 for leap year) .

(3) Year = Valid entries are 1980 -2099(must be four digits) .

d. Press (CR) to enter data .e. Press (ESC). Set date is complete .f. The utilities menu is displayed .

Following is a sample set date menu :

Set Date Menu

Set-MonthSet DateSet Year

634.6 Status Report. The status report showsmailpiece processing status data for a particulartimeframe input by the supervisor . A specifictime range or system manager default range(entire sort plan run time) may be selected . Thisreport is sent over a RS232 line to another pieceof SPBS equipment. It complies the same data asthe system summary report and is available on atemporary file on the disk called"STATDATA.'FMP" . This report can only be

b . Select the "status report" option .c . Enter begin report time and end report

time and press (CR).d. Note that the status report is not dis-

played or printed out, but saved on file"STAT.DATA.TMP."See Exhibit 634.6 for a sample status report .

640 Maintenance Menu

641 Definition

The maintenance menu is found on the admin-istrator menu and is password protected . Allmaintenance menu options are executed off-line,i.e ., while the carrier cell chain is stopped. Fol-lowing is a sample maintenance menu :

Maintenance Menu

Configuration MenuDiagnostics MenuSend Configuration to MasterPrepare for Final Shutdown

642 User Access

To display the maintenance menu on the screen :a. Highlight the administrator menu option

on the supervisor menu and press (CR) .b. Enter a valid password and press (CR).c. Highlight the "maintenance menu" option

and press (CR) .d. Enter a valid password and press (CR) .

The menu is displayed .e. The (ESC) key returns you to the pre-

vious menu level .

643 Configuration Menu

643.1 General . It is necessary for the SPBSsystem to be configured with specific operatingspecifications before sorting takes place . SPBSsystem configurations are loaded onto the harddisk of the workstation during initial site installa-tion as default conditions for a particular site .However, if these conditions change, the new


634.5 Small Parce and Bundle Sorter Guidelines

d. Press (CR) to enter values . generated off-line, i .e.,while the chain is stopped .e . Press (ESC) . Set time is complete . To generate this report:

f. Utilities menu is displayed . a. Ensure that the utilities menu appears onthe screen.


STATUS REPORT DATA ENTRY

Use "T" "j" "--*" and "+-" to move, Return to accept & ESC to Exit

Enter Start and End Times (HH:MM:SS, HH:MM, HH)Default Start Time - Beginning of Run Time LogDefault End Time - End of Run Time Log

Begin Report Time - .End Report Time -

information must be entered into the workstation .The configuration menu is found on the main-tenance menu. All configuration menu optionsare executed off-line, i .e., while the chain isstopped. Following is a sample change configura-tion menu :

Configuration MenuChange PasswordsSet Alarm PrioritiesSet Bin Configuration ParametersSet Keyboard Configuration ParametersDisplay Reasons for RejectSet Sort Plan Defaults and Page LengthSet System Parameters

643.2 Change Passwords . The system password isrequired to access this menu . Once entered, thisprogram allows any of the passwords to bechanged .

643.3 Set Alarm Priorities . This program dis-plays the master list from the "ALARM .DAT"file of all SPBS run time fault (RTF) messages, inaddition to error numbers and rankings. Theranking specifies which output device is used todisplay the RTF when the PC is on line . All


Exhibit 634.6, Sample Status Report

643;6

on-line RTFs are saved to the file "Faults .Log."Priority rankings can be changed using this pro-gram. The fault messages cannot be changed .

643.4 Set Bin Configuration Parameters . Thisprogram designates the bin destinations used forsorting SPBS -mailpieces. The bin configurationmust correlate, directly to the sort plan loaded .The SPBS can accommodate up to 100 physicalbins. Enabled bins are indicated by a Y ; disabledbins by an N . See Exhibit 643 .4 for a sample setbin configuration -menu . -

643.5 Set Keyboard Configuration Parameters .This program sets the values of the operatorkeyboard for use with the SPBS system . It config-ures the enter (ENT), repeat (REP) cancel(CAN), reject (REJ) keys, and function keys. SeeExhibit 643.5 for a sample set keyboard configu-ration menu.

643.6 Display Reason for Reject. This programdisplays the master file "REJECT .DAT," whichgives a list of reasons for mail to be sorted to thereject bin . The list cannot be changed . The reasonfor reject description is displayed on the systemreject report . This program can only be executedoff-line. To execute:

53

643.6


BIN CONFIGURATION

Use 't", ' .", '-- and 'f-- to move - ESC to E,dt

-Physical Bins: 16Enabled Bins: 13 0

12345678910

1

2

3Y N YY N Y

Exhibit 643.4, Sample Set Bin Configuration Menu

KEYBOARD CONFIGURATION

Exhibit 643.5, Sample Set Keyboard Configuration Menu

54


4 5 6 7 8 9 0Y Y N Y Y Y Y 10Y Y Y 20

30405060708090100110


a . Ensure that the ' configuration menu ap-pears on the screen .

b. Select the "display reason for reject op-tion .

c. The reason for reject menu appears on thescreen .

d. Press (ESC). The configuration menu isdisplayed .See Exhibit 643.6 for a sample reason for rejectscreen .

643.7 Set Sort Plan Default and Page Length .This program sets the system defaults for sortplans and the page length. The active default sortplan is that which was last downloaded to theMPC upon initial .configuration and/or _SPBSstart-up. If another sort plan was downloaded andrun, this then becomes the system's active defaultsort plan. Do not change active - sortplan defaultparameter while in use. Do not change the sortplan default name in the parameter until all per-tinent reports have been gathered . SPBS reportgeneration depends on this file to supply thename of the sort plan for the report being gen-erated. See Exhibit 643 .7 for a 'sample sort plandefaults and page length screen .

643.8 SPBS System Parameters. This programprovides the capabilities for setting up certainSPBS default values. In addition to the configura-tion item, it lists an allowable range for each andthe present value . See Exhibit 643.8 for a sampleSPBS system parameters menu .

644 Diagnostics Menu

644.1 General. The diagnostics menu is found onthe maintenance menu and is password protected .All diagnostics menu options are executed off-linewhile the carrier cell is stopped. Following is asample diagnostics menu:


Diagnostics Menu

Check LightsExit to DOSShell to DOSModule ConfigurationPort ConfigurationStart Diagnostics

644.7

644.2 User Access . To display the maintenancemenu on the screen:

a. Highlight the administrator menu andpress (CR) .

b . Enter a valid password and press (CR).c. Highlight the diagnostics menu option and

press (CR) . The menu is displayed .d. Use the (ESC) key to return to the

previous menu level, 'if necessary.

644.3 Check Lights. This program verifies theoperation of lamps on the SPBS system . A faultybulb can be observed at this time .

644.4 Exit to DOS. This program provides apermanent exit from the system manager software.to the workstation. operating system, MS-DOS .Once selected, DOS command can be entered. Tore-enter the system manager at the supervisormenu, enter (SPBS) and press (CR) .

644.5 Shell to DOS . This program provides atemporary leave from the system manager . Youcan access MS-DOS while not fully exiting thesystem manager . To return to the system managerat the diagnostic menu, enter exit and press thereturn or enter key .

644.6 Module Configuration . This program setsup the configuration of the SPBS sortation lineper module in sequential order from the induc-tion station receiver module to the waterfall . Thisis normally established during initial setup andshould not be changed unless the size of thesystem is decreased or expanded .

644.7 Port Configuration. This program estab-lishes the configuration of the fiber optic inter-faces from the MPC to each induction andsection controller. These parameters are set uponinstallation of the system and should not bechanged unless the MPC loses contact with one ofthe boards or a major failure occurs in a specificsection. The configuration is determined by des-

55

644.7

REASON FOR REJECTPush ESC to exit

I - Assigned`To Reject2 - Bin Over Weight3- Bin Being Swept -4- System Overload : >20 bundles5- Not Assigned To Reject6- Driver Board Failed7- Carr. Cell Motor Over Current8 - . .Emergency Stop/Power Failure9- Missent Bin = Reject Bin10 . - Bin Not Enable11 - Not Used12- Not Used13- Not Used14- Not Used15- Not Used

Exhibit 643.6, Sample Reason for Reject Screen

SORT-PLAN DEFAULTS AND PAGE LENGTHPush RETURN to accept - ESC to exit

Length of Printer Page (lines)(48/78)

62INPUT Default Sort Plan(.IN)OUTPUT Default Sort Plan

GOU) :MIX Default Sort Plan(-MI)TEST Default Sort Plan(.1-E)ACTIVE Default Sort Plan

: BBM.ou

Exhibit 643.7, Sample Sort Plan Defaults and Page Length Screen

Small Parcel and- Bundle Sorter Guidelines

56



SPBS SYSTEM PARAMETERS

Push RETURN to accept - ESC to exit

Exhibit 643.8, Sample SPBS System Parameters Menu

ignation of the side of the induction station(right/left) and by the maximum number of car-rier cells .

644.8 Start Diagnostics. This program performsdiagnostics for the induction stations and sectioncontroller serial ports and the MPC . All passesand failures (reject) are listed on the diagnosticsresults menu. Failures and unused units arehighlighted in red. The "Auto/Maint/Jog"keyswitch on the power cabinet must be set tothe "Maint" position when performingdiagnostics.

645 Send Configuration to Master

This program is used to send the configuration tothe master processor controller. If the bin con-figuration is changed, it recompiles and sends thenew sort plan .

646 Prepare for Final Shutdown

This program is used during turnoff proceduresafter the chain stop button on the rear of thepower cabinet is pressed. It disengages all bat-teries on the master processor controller and the


induction and section controller boards . To ex-ecute :

a. Ensure that the maintenance menu ap-pears on the screen .

b . Select the "prepare for final shutdown"option .

c . A window displaying the message "EnterY to Being Shutdown" appears.

Note: If Y and (OR) are entered, the message "Preparationfor Final Shutdown Started" is displayed. If shutdown is notpermitted at this time, the message "Preparation for ShutdownNot Started" is displayed . If N and (CR) are entered, themessage "Shutdown Preparation Aborted by User" is dis-played-d.

Press (ESC) .e. The maintenance menu is displayed .

Following is a sample final SPBS shutdownmenu:

~Fnal SPBS Shutdow

Enter Y to Begin Shutdown

646

57

I - Maximum Parcel Weight (lbs .) (1/20) : 20

2 - Maximum Parcel Length (inches) (5/19) : 19

3 - Display KEY CODE (Y/N) . Y

4 - Number of Beeps for ALARM Errors (1/5)

: 1

5 - Time of Each ALARM Beep (msec)(50/1000) : 50

6 - Number of Beeps for VALID Keys (1/5)

: 17 - Time of Each VALID Key Beep (msec)(5b/1000) : 50

8 - Number of Beeps for INVALID Mail Piece (1/5)

: 1

9 - Time of Each INVALID Mail Piece BEEP (msec)(50/1000) : 50


710 Introduction

Safety is the responsibility of every individual inthe U.S. Postal Service. It is imperative that everyemployee understand and observe all of the USPSsafety standards and procedures .

720 Supervisor Responsibilities

The supervisor has overall responsibility for thesafety of the personnel involved with the equip-ment during its operation . The responsibility in-cludes, but is not limited to, the following :

a . Enforcing all current safety rules andregulations and local policies to ensure the use ofsafe operating procedures .

b. Observing employees and immediatelycorrecting any unsafe acts, practices, operationalerrors, or poor work habits.

c . Ensuring that all personnel are aware ofsafe and proper use, maintenance, and protectionof Postal Service equipment .

d. Investigating all accidents occurring withinthe area of responsibility to determine the causeand corrective action to be taken .

e . Ensuring that the equipment is not op-erated by personnel without proper authority ortraining .

f. Ensuring that all safety guards, interlockswitches, and other safety devices are operableand being used when the equipment, is processingmail. At 'no time will any safety guard or inter-lock switch be disabled for any reason .

g. Maintaining a clean and safe work area byenforcing good housekeeping practices .

h . Using the proper method of summoningmedical aid in case of an emergency.

730 Employees Responsibilities

All employees are responsible for protectingthemselves, their fellow employees, the mail, andU.S. Postal Service equipment and property . Thiscan only be accomplished when each individualunderstands and-'observes proper safety standards


Chapter 7Safety

740

and procedures at all times. Following are someof the common sense safety precautions that mustbe observed by all personnel when working on oraround mechanical, electrical, and electronicequipment:

a. Know how to summon medical aid in caseof an emergency .

b. Never use toxic or flammable solvents forcleaning purposes.

c. Do not operate equipment without properauthority or proper training .

d. Always use safety devices and safetyguards properly .

e. In the event of an electrical fire, alwaysuse a - halon-type extinguisher. Never use a drychemical extinguisher, as it may destroy theequipment. Never use water, soda-acid, or anyother liquid stream extinguisher because theypresent a shock hazard to the user and will causeconsiderable damage to the electrical equipment .

f. Never attempt making adjustments to theequipment or reach into the enclosures on theequipment unless you are a qualified maintenanceperson with the necessary training and qualifica-tions to work in this area.

g. Notify your supervisor immediately if youobserve an unsafe condition or someone using anunsafe practice so that prompt corrective actioncan be taken .

740 Maintenance Responsibilities

Personnel working on this equipment must un-derstand and apply safety precautions in allphases of maintenance.

a. Maintenance personnel are responsible forperforming maintenance assignments in a mannersuch as not to endanger themselves or others .

b . Maintenance personnel must support ef-forts to properly maintain effective safeguardsand protective devices on this equipment .

59

750 Operational Safety Summary

It is the responsibility of each individual operat-ing this equipment to understand and observeestablished safety standards and procedures . Alsoadhere to the following :

a. Employees must not wear loose-fittingclothing, jewelry, ties, of other articles that couldbecome caught in the machine .

b . . Keep hair away, from the equipmen toavoid its becoming entangled in the machine .,

c. Keep . fingers, hands, and .arms clear ofmoving parts when the equipment is in operation .

d . . Always engage emergency stop switchbefore clearing any debris from the . transportunits .

e. Make certain that all personnel are clearof moving parts before starting equipment .

f Know the location and use of all emer-gency stop switches on the equipment.

g. Do not place .. extraneous items . (personalor other) on the equipent .

60

Small Parcel :.and_ Bundle* Sorter-Guidelines

h. Always engage any of the emergency stopswitches if a system failure occurs . If failure per-tains only to an induction station, press the callmaintenance switch .

i. Keep all access doors closed during mail-processing operations unless maintenance person-nel are making observations .

j. No eating, drinking, or smoking ispermitted . i n

the work area even if the equipment

is not in operation .k. No employee will be permitted to use any

type of portable listening devices (i.e., "WalkMan" radios) in the equipment area.

1. Keep aisles and work areas neat and clearof all extraneous materials (i .e., empty trays,string, rubber bands, paper,,or,labels)-, m

. Always be alert' when the start-up alarmsounds .

n. Do not participate in horseplay or otherinappropriate behavior .



Appendix AList of Exhibits

Exhibit

TitleNumber

Chapter 1

120

Typical SPBS Configurations

Chapter 2

221

SPBS System223.2

Power Cabinet Front Panel223.3

Power Cabinet Rear Panel225.1

Induction Station225.43

Operator Keyboard226.1

Sort Distribution System227.1

Sort System Output

Chapter 6

611

System Manager Menu Tree623.1

Sample Forecasting Rate Report623.2

Sample History Report623.3

Sample Induction Station Production Rate Report623 .4

Sample Production Rate Report633.23

Sample Destination Report633 .242

Sample End-of-Run Report633.25

Sample System Full Report633.26

Sample Key Code Per Induction Station Report633.27

Sample System Key Code Report633.28

Sample System Reject Report633.29

Sample System Summary Report633.33

Sample System Failure Report633.34

Sample System Log Report633.533

Sample Sort Plan Configuration633.534

Sample Bin Configuration/Compilation Menu (and ValidContainer Types Screen)

634.6

Sample Status Report643.4

Sample Set Bin Configuration Screen643.5

Sample Set Keyboard Configuration Screen643.6

Sample Reason for Reject Screen643.7

Sample Sort Plan Defaults and Page Length Screen643.8

Sample SPBS System Parameters Menu


61



Appendix BList of Acronyms and Abbreviations

BOL

Beam of light

CPU

Central processing unit

HD

High density

IC

Induction controller

IS

Induction station

ISC

Induction station controller

IPP

Irregular parcel post

MPC

Master process controller

MS-DOS

Microsoft disk operating system

PCB

Printed circuit board

PWA

Printed wiring assembly

P/W2

Unisys workstation

PC

Personal computer

SC

Section controller

SPBS

Small parcel bundle sorter

63


"A" ModulePart of the sort distribution system . Connectsto and controls sort points of "B" module .

Aux ModulePart of the sort distribution system . Allowsfor system configuration flexibility and iscontrolled by the "C" module .

"B" ModulePart of the sort distribution system . Connectsto and is controlled by an "A" module .

Beam of Light (BOL)Optical mailpiece detectors located in theinduction and sort distribution area . SPBSuses three types: retro-reflective, thru-scan,and retro-scan .

Buffer ConveyorLocated between the weigh and 45-degreeconveyors, it contains an array of BOLs usedto determine the length, width, and height ofa mailpiece. Synchronizes the induction linewith the main transport.

Bundle BumpEjection of a mailpiece into an output bin .

"C" ModulePart of the sort distribution system outputsection. Connects to the drive end moduleand controls the reject bin and chain motor

. speed. Also controls the aux module.

Carrier CellTransporting unit that accepts a mailpiecefrom the 45-degree conveyor and transportsit to a destination bin . Each carrier cellcontains a bi-directional conveyor belt toeject the mail into the output chute .

ConveyorFirst conveyor of induction line after theinclined conveyor where operator codesinformation for bundle sorting based on ZIPCode data .


Appendix -CGlossary of Terms

Appendix C

Control ArmAn assembly located in the sort distributionarea that contains the bin reset button,emergency stop switch, dispatch labels, andretainer latch release . Indicates that a bin hasbeen swept .

CullersPostal personnel who manually removeirregular I parcels and mailpieces,non-machineable third and fourth class items,such as sackable rolls and tubes, small cubes,small fragile parcels, sackable films, paper orsleeve wrapped catalogs, and non-caseableflats from the culling belt . At the same timethis mail will be separated by the cutters ontoa conveyor to the SPBS induction station or1046/1047 hampers for further handling . Theculler maintains the integrity of machineablebundles and if necessary, re-bandsnon-machineable bundles into machineablebundles .

Drive End ModuleContains the chain motor located at theopposite end of the takeup module .

DumperPostal personnel who receive mail in sacks,pouches, hampers, or BMC containers anddump this mail onto a culling belt .

Emergency Stop SwitchA switch and indicator light assembly locatedalong the sort distribution system area . Anemergency stop switch is also contained onthe operator control box. When pressed,power to all induction lines is removed .

Fiber Optic InterfaceCable interface used for induction or sectionCPU communications from the MPC to allother CPUs .

FootprintLength and width of a mailpiece asdetermined by the BOLs of the buffermodule.

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Appendix_ C

45-Degree ConveyorUsed to transfer mailpieces from theinduction line to the receiver module of thesort distribution system.

Hatchment Covers"Skin" of the SPBS. Opening the hatchmentcover creates an emergency stop condition .

Interlock, SwitchesContains two micro switches and is locatedbehind each hatchment cover and overflowchamber. Removal of a hatchment sends anemergency stop message to the workstationmonitor .

Inclined Conveyor (LC.)Transports mailpieces to the keying operatorcoding station .

Induction ControllerAn induction CPU that controls themailpiece flow through the induction lineonto the sort distribution receiver modules .

Induction Station (IS.)Area where operator codes packages andassigns bin destination . Consists of operatorcontrol panel, display, and keyboard .

Irregularity (anomaly)Abnormal machine function or irregularmailpieces resulting in audio/visual displayindications or machine shutdown .

Master Processor Controller (MPC)Controls SPBS system operation . Responsiblefor cell movement, status. control andreporting, and output destination binassignment.

MS-DOSMicro-soft disk operating system softwareused in the supervisor computer workstation .

Operator Control BoxServes as induction control interface to MPCand IC. Contains four switches (reset, call formaintenance, on/off key, and emergencystop) .

Operator DisplayAudio/visual display for operator instruction .

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Operator KeyboardKeypad used for entering a mailpiecekeycode based on sort program .

Overflow Chamber (waterfall)Receives any mail not ejected along the sortdistribution path or to the reject bin .

Power CabinetDistributes AC power to the system and islocated next to the computer workstation .

Proximity SensorsLocated in the takeup module . Used to keeptrack of the position of the carrier cells .

Reject BinMailchute used for rejected mail located nearthe drive end module .

Receiver/Recentering ModuleActivates carrier cell conveyor to accept andre-center mailpiece from 45-degree conveyor .

Section ControllerMonitors the flow of a mailpiece through itssort distribution line and provides control formailpiece ejection .

Sort Points/PairsOutput chute for mail . SPBS has dischargecapability for either side of the machineknown as a sort pair. Two sort points equalone sort pair .

SweeperPostal personnel responsible for emptyingoutput bins when full .

System ManagerSpecialized hardware and software that allowsUSPS personnel to interface with the SPBS.Generates sort programs, runs reports, andcontrols maintenance diagnostics and tests .

Takeup ModuleContains the MPC and is located at theopposite end from the drive end .

Transport ChainTransports the carrier cells through the sortdistribution system .



Turn-End ModuleOptional curved units that allow the SPBS tobe configured in either a right or left "L"shape. Two turn modules can be used toform a "U" shape .

Type 89 ConveyorAccepts incoming mail for processing anddeposits it - in the hamper of the SPBSinclined -conveyor.


Appendix C

Throw Off ContainerUsed by operator to deposit mail deemedunacceptable for mail processing on theSPBS.

Weigh ConveyorConveyor that weighs mailpiece and islocated between coding and buffer modules .

WiretainerA "wire container" output receptacle thatreceives sorted bundles . It is similar in size toa 1046 hamper .

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small parcel and bundle sorter guidelines small parcel and bundle sorter...u.s. postal service...

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