Installation and Operation Manual

MagnaMatch
Match Mail System

5519 W Woolworth Ave

Milwaukee, WI 53218
(414)206-2944
www.magnacraft.net
ISSUE 4 – January 2021
2021 BY MAGNACRAFT
ALL RIGHTS RESERVED
PRINTED IN U.S.A.
TJM Innovations, LLC.
5519 W Woolworth Ave
Milwaukee, WI 53218

ALL RIGHTS RESERVED. NO PART OF THIS PUBLICATION MAY BE REPRODUCED BY ANY MEANS WITHOUT WRITTEN
PERMISSION FROM TJM INNOVATIONS.

THE INFORMATION IN THIS PUBLICATION IS BELIEVED TO BE ACCURATE IN ALL RESPECTS. HOWEVER, TJM
INNOVATIONS CANNOT ASSUME RESPONSIBILITY FOR ANY CONSEQUENCES RESULTING FROM THE USE THEREOF.
THE INFORMATION CONTAINED HEREIN IS SUBJECT TO CHANGE WITHOUT NOTICE. REVISIONS OR NEW EDITIONS TO
THIS PUBLICATION MAY BE ISSUED TO INCORPORATE SUCH CHANGES.

FCC COMPLIANCE STATEMENT

CAUTION: YOUR AUTHORITY TO OPERATE THIS FCC VERIFIED EQUIPMENT COULD BE
VOIDED IF YOU MAKE CHANGES OR MODIFICATIONS NOT EXPRESSLY APPROVED BY THE
PARTY RESPONSIBLE FOR COMPLIANCE TO PART 15 OF THE FCC RULES.

NOTE: THIS EQUIPMENT HAS BEEN TESTED AND FOUND TO COMPLY WITH THE LIMITS FOR
A CLASS A DIGITAL DEVICE, PURSUANT TO PART 15 OF THE FCC RULES. THESE LIMITS ARE
DESIGNED TO PROVIDE REASONABLE PROTECTION AGAINST HARMFUL INTERFERENCE
WHEN THE EQUIPMENT IS OPERATED IN A COMMERCIAL ENVIRONMENT. THIS EQUIPMENT
GENERATES, USES, AND CAN RADIATE RADIO FREQUENCY ENERGY AND IF NOT INSTALLED
AND USED IN ACCORDANCE WITH THE INSTRUCTION MANUAL, MAY CAUSE HARMFUL
INTERFERENCE TO RADIO COMMUNICATIONS. OPERATION OF THIS EQUIPMENT IN A
RESIDENTIAL AREA IS LIKELY TO CAUSE HARMFUL INTERFERENCE IN WHICH CASE THE
USER WILL BE REQUIRED TO CORRECT THE INTERFERENCE AT HIS OWN EXPENSE.

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WARNING
TO REDUCE THE RISK OF FIRE OR ELECTRIC SHOCK, DO NOT EXPOSE THIS PRODUCT TO RAIN OR
MOISTURE. DO NOT INSERT ANY METALLIC OBJECT THOUGH VENTILATION GRILLS.

CAUTION

USERS OF THE SYSTEM ARE RESPONSIBLE FOR CHECKING AND COMPLYING

WITH ALL FEDERAL, STATE, AND LOCAL LAWS AND STATUTES CONCERNING
THE MONITORING AND RECORDING OF VIDEO AND AUDIO SIGNALS. TJM
INNOVATIONS SHALL NOT BE HELD RESPONSIBLE FOR THE USE OF THIS
SYSTEM IN VIOLATION OF CURRENT LAW AND STATUTES.

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IMPORTANT SAFEGUARDS
1. READ INSTRUCTIONS -- All the safety
and operating instructions should be read
before the appliance is operated.
2. RETAIN INSTRUCTIONS -- The safety
and operating instructions should be retained
for future reference.
3. CLEANING -- Unplug video monitor
from the wall outlet before cleaning. Do
not use liquid cleaners or aerosol
cleaners. Use a damp cloth for cleaning.
4. ATTACHMENTS -- Do not use attachments
not recommended by the video monitor or
equipment manufacturer as they may result
in the risk of fire, electric shock or injury to
persons.
5. WATER AND MOISTURE -- Do not use
video monitor or equipment near water --for
example, near a washbowl, sink, in a wet
area, or the like.
6. ACCESSORIES -- Do not place video
monitor or equipment on an unstable cart,
stand or table. The video monitor or
equipment may fall, causing serious injury
to a child or an adult, and serious damage to
the equipment. Wall or shelf mounting
should follow the manufacturer’s
instructions.
7. MOVING – Video monitor or equipment
and cart combinations should be moved with
care. Quick stops, excessive force, and
uneven surfaces may cause the equipment
and cart combination to overturn.
8. VENTILATION -- Slots and openings in the
cabinet and the back or bottom are provided
for ventilation, and to ensure reliable
operation of the video monitor or equipment
and to protect it from overheating. These
openings must not be blocked or covered.
The openings should never be blocked by
placing the video monitor or equipment on a
bed, sofa, rug, or other similar surface.
Video monitor or equipment should never be
placed near or over a radiator or heat
register. Video monitor or equipment
receiver should not be placed in a built-in
installation such as a bookcase unless proper
ventilation is provided.
9. POWER SOURCES -- Video monitor or
equipment should be operated only from the
type of power source indicated on the
marking label. If you are not sure of the type
of power supplied to your home, consult
your video monitor or equipment dealer or
local power company.
10. GROUNDING OR POLARIZATION -- This
video monitor or equipment is provided with a
polarized alternating - current line plug (a plug
having one blade wider than the other). This plug
will fit into the power outlet only one way. This
is a safety feature. If you are unable to insert the
plug fully into the outlet, try reversing the plug.
If the plug should still fail to fit, contact
your electrician to replace your obsolete
outlet. Do not defeat the safety purpose of
the polarized plug.
11. POWER CORDS -- Do not allow anything to
rest on the power cord. Do not locate video
monitor or equipment where the cord will be
abused by persons walking on it
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 Limited Warranty
TJM Innovations warrants the original purchaser of this product that the product will be in good working order for
90 days from the date of purchase. This date will be determined by the date of invoice.
TJM Innovations’s sole and exclusive liability, should this product fail to be in good working order, shall be limited
to repair or replacement of the component, at the option of TJM Innovations. This warranty does not obligate TJM
Innovations to bear the cost of transportation charges in connection with the repair of defective parts. Repair parts
will be furnished on an exchange basis and will be either reconditioned or new. All replaced parts become the
property of TJM Innovations.
This warranty is invalid if the damage or defect is caused by accident, act of God, disaster, misuses, abuse,
vandalism, or unauthorized alteration or repair of the product. Limited warranty service may be obtained by
returning the product during the warranty period to the original dealer or authorized service center and providing
proof of purchase date by receipt or invoice. Returned material must bear an TJM Innovations returned
authorization number on the label. This number is obtained from the customer service department by phone or mail.
If the product is returned for service or modification, the warranty will be voided unless you insure the product at its
present value or assume the risk of loss or damage in transit. You must prepay all shipping charges, and use the
original protective packing material and shipping container or equivalent. Contact your authorized dealer or write
TJM Innovations at the address below for further information prior to shipment of product.
Any implied or expressed warranties for this product, including the implied warranties of merchantability and fitness
for a particular purpose, are limited to the above warranty period, unless an extended warranty and service contract
is purchased. No warranties will apply after the expiration of this period.
TJM Innovations shall in no event be liable for accidental, consequential, contingent, or other damages, including
any lost profits, lost savings, lost time, or equivalents.
This warranty gives you specific legal rights and you may have other rights, which vary, from state to state. Some
states do not allow the exclusion or limitation of incidental or consequential damages or limitations on how long an
implied warranty lasts, so above limitations or exclusions may not apply to you.

TJM Innovations
5519 W Woolworth Ave
Milwaukee, WI 53218

v
 TABLE OF CONTENTS

SECTION 1: SYSTEM INTRODUCTION………………………………………………1

SECTION 2: SYSTEM INSTALLATION……………………………………………….2

SECTION 3: MAGNAMATCH SYSTEM OPERATION…………………..…….……5

SECTION 4: CONTROLS AND CONNECTIONS…………………………………..…6

APPENDIX A: MAINTENANCE AND TROUBLESHOOTING………..……………9

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 SECTION 1

SYSTEM INTRODUCTION

PURPOSE

The purpose of this manual is to provide installation and operation instructions for the
MagnaMatch matchmail system.

FEATURES

The MagnaMatch system is the perfect low-cost solution for matching a preprinted envelope to
its contents while operating an inserting machine. The system includes a durable 12-inch black-
and-white monitor, 4 ultra compact miniature CCD cameras, mounts, switch, and cables.

Monitor Features
The monitor unit of the MagnaMatch system offers the following:
• 12-inch black-and-white monitor
• Full-screen display – Displays on camera at a time on the screen, full size for easy camera
setup.
• Quad Display – Displays four cameras simultaneously in quadrants on screen.
• Screen-freeze – Displays image of address or number to be matched in each quadrant.
• VCR inputs/outputs – Allows video signal to be sent to a VCR for recording and playback.

Camera Features
The cameras accompanying the MagnaMatch system offer the following:
• 1/3” CCD Image Sensor – A professional-level camera chip that achieves a very high
quality picture.
• Electronic Iris – Automatically adjusts the camera for changes in lighting to ensure an
optimal picture at all times.
• Camera Mount – Allows the cameras to be mounted in each inserter pocket.
• Single Cable – One cable transmits power and video signal to the monitor.

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 SECTION 2

SYSTEM INSTALLATION
INSTALLATION REQUIREMENTS

The MagnaMatch system must be installed by a qualified service person in accordance with local
and national electrical and mechanical codes.

Identify contents of carton

Unpack all system components from the packing material and identify the following:
A. Monitor
B. Four black-and white CCD cameras with mounts
C. Four camera cables

Basic system installation

1. Place the monitor in a convenient location with adequate ventilation. Make sure the monitor
is turned off using the switch on the back panel.

2. Mount the cameras to the rail behind the pockets out of the way of the inserter arms.

3. Mount one camera in front of the envelope flip-over. If necessary, focus the camera by
turning the lens on the front of the camera.

4. Route the camera/power cables to the cameras being careful to avoid all moving parts. Plug
the power and video cables from camera one into the first pin jack and RCA jack on the left,
respectively. Cameras two through four are connected to the right.

Figure 1: Back panel of monitor. (Note: DB-9 connector on back of monitor is for factory
programming of monitor only.)
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Place the plastic cam on the shaft at the end of the inserter. Mount the micro switch under the
cam by drilling and tapping two 6-32 holes. Use the switch to mark the hole locations.

Figure 2: Cam switch mounting location.

5. The cam switch will activate for each cycle of the inserter when the switch’s roller falls into
the cam’s notch. Set the cam so the envelope camera freezes when the envelope is in the
stopped position in the flip-over.

6. Set the thumbwheel switches to the cycle number each camera will freeze at. For example, if
there are cameras in pockets 1, 3, 5 and at the envelope, the thumbwheel switches would be
set to 1359. See table to below.

7. If your first camera is setup to read the bottom side of the insert in pocket 1, then the
envelope thumbwheel switch must be set to 0, which equals 10 cycles. The cam must be set
to freeze camera 1 when the arms are near the insert.

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Pockets with cameras reading top of insert
1 2 3 4 5 6 7 8 9 12 Piece 11 Piece 10 Piece 9 Piece
check check check check
• • • X X • 1239
• • • X X • 1249
• • • X X • 1259
• • • X X • 1269
• • • X X • 1349
• • • X X • 1349
• • • X X • 1359
• • • X X • 1369
• • • X X • 1459
• • • X X • 1459
• • • X X • 1469
• • • X X • 1569
• • • X X • 1569
• • • X X • 2349 1238
• • • X X • 2359 1248
• • • X X • 2369 1258
• • • X X • 2459 1348
• • • X X • 2469 1358
• • • X X • 2569 1458
• • • X X • 3459 2348 1237
• • • X X • 3469 2358 1247
• • • X X • 3569 2458 1347
• • • X X • 4569 3458 2347 1236

Table of possible thumbwheel settings. Pocket 9 is the envelope flip-over.

Note: Camera four thumbwheel switch position 0 is actually 10.

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 SECTION 3

MagnaMatch SYSTEM OPERATION

Quad Display Mode

When the MagnaMatch system is turned on the monitor shows a quad display, where there is a
quad screen with all four camera positions displayed simultaneously. The red light over the Q/A
button should be continuously lit, and the green lights over each camera select button should
illuminate steadily for all active cameras.

Full-Screen Display
Full-screen display shows a full-screen picture of the selected camera. To change to the full-
screen display of one camera from the quad mode, press the Q/A button once, then press the
desired camera select button. The monitor will display a full-screen picture of that location. The
green light over the camera button will illuminate.

Operation with Inserting Machine

1. As the inserting machine operates, video pictures on the monitor screen will freeze showing
images of the matching mail pieces. When a video image is frozen, the LED above the
camera button will blink.

2. If there is a mis-match or material is removed from the inserter you must press the reset
button on the front of the monitor.

3. The LED’s above each camera button indicate the status of each camera. When an LED is
on, that camera is connected to the monitor.

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 SECTION 4

CONTROLS AND CONNECTIONS

Camera Connections

The cameras have a cable attached to their back which should be connected to the twelve foot
video and power cable supplied. The red connector is for power, 8-12 Vdc, and the yellow
connector is for video.

Monitor Controls and Connections

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Power cord – This power cord should be plugged into a 120V AC 60Hz grounding outlet.

Camera 1 through Camera 4 – These connections are for use with the supplied cameras. The
camera video and power are passed through this connection.

Monitor Controls

A. Q/A(quad/auto) button and light – This button is used to place the monitor into the quad or
sequential switcher mode of operation. The light will flash when the monitor is in the
sequential switcher mode, which is not used.

B. Camera buttons and lights – These buttons are used to select a camera to be displayed on
the screen. The lights illuminate when the corresponding camera is displayed on the screen.
These lights will flash when a picture has been frozen in the quad display mode.

C. VCR button and light – This button is used to change the monitor display from the camera
to the VCR. The light illuminates when the monitor is in the VCR review mode.

D. Talk button and call light- NOT USED

E. Volume control – NOT USED

F. H-Hold (horizontal hold) control – This control is used to adjust the horizontal stability of
the picture.

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G. Bright control – This control is used to adjust the overall brightness of the monitor picture.
Turn this control counter-clockwise to decrease the contrast level and clockwise to increase
the contrast level

H. Contrast control – This control is used to adjust the overall contrast of the monitor picture.
Turn this control counter-clockwise to decrease the contrast level and clockwise to increase
the contrast level.

I. Power switch – This switch will turn on the monitor on or off without affecting the switcher
section of the monitor.

1. Main power switch – This switch is used to turn on or of all power to the monitor.

2. Bell switch – NOT USED

3. Dwell time – NOT USED

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 APPENDIX A

MAINTENANCE AND TROUBLESHOOTING

PREVENTIVE MAINTENANCE
Use of preventive maintenance allows detection and correction of minor faults before they
become serious enough to cause equipment failure.

Every three months, perform the following:

1. Inspect all connecting cabling for deterioration or other damage.

2. Clean components with a damp clean cloth.

3. Verify that all of the mounting hardware is secure.

TROUBLESHOOTING
If problems occur during installation, verify that the equipment has been wired properly and
installed in accordance with the procedures in this manual. Because this system can contain
several pieces of equipment, it may be necessary to verify that each piece has been installed and
is operating correctly. Once the problem is isolated to a specific part, refer to the corresponding
section of the manual for further information.

The following problems and solutions highlight basic troubleshooting guidelines.

Problem Possible Solution

a. No video 1. Verify power to all parts in the system.

2. Verify that the power switches are in the on position.

b. Video, but no control 1. Power down the system using the power switch on the back for
one minute and then turn the power back on .