Priority Systems M5000 inserter Operator guide
Below you will find brief information for inserter M5000. The manual outlines the setup and operation of the M5000 inserter, covering steps like loading documents and envelopes, setting up jobs, and troubleshooting common issues. It's a comprehensive guide to understanding and using this machine effectively.
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TABLE OF CONTENTS
1
2
3
4
5
6
7
8
9
10
Health, Safety and Environment ..................................................... 3
Precautions and Safety Issues ................................................... 3
Country specific conditions ....................................................... 4
End of life ............................................................................... 5
General ........................................................................................... 6
Denominations ........................................................................ 6
Function Description ................................................................ 7
Display .................................................................................. 8
Operating Instructions ................................................................... 9
Installation ............................................................................. 9
Preparation ............................................................................ 9
Starting Up ............................................................................ 10
Loading Documents ................................................................ 11
Loading Envelopes .................................................................. 13
Daily Mail .............................................................................. 16
Other Menu Options ................................................................ 17
Job Programming ......................................................................... 21
Job Menu .............................................................................. 21
Job Information ...................................................................... 22
Create Job ............................................................................. 23
Edit Job ................................................................................ 30
Copy Job ............................................................................... 30
Delete Job ............................................................................. 31
Supervisor Menu ........................................................................... 32
System Info ........................................................................... 32
Options ................................................................................. 33
Online Services (Option*) ........................................................ 33
Optical Mark Recognition OMR (option) ........................................ 34
General ................................................................................. 34
Adjustments .......................................................................... 34
Document Orientation ............................................................. 35
OMR Codes ............................................................................ 35
Options ......................................................................................... 39
MaxiFeederTM ........................................................................ 39
Intermediate Transport ........................................................... 40 7.2
Maintenance ................................................................................. 41
Operator Maintenance ............................................................. 41
Fault finding ................................................................................. 42
Error Messages ...................................................................... 42
Clearing Stoppages ................................................................. 43
Operator Troubleshooting ........................................................ 44
Specifications ............................................................................... 48
Technical specifications ........................................................... 48
Configuration dimensions ........................................................ 48
Other general specifications ..................................................... 49
Document specifications .......................................................... 49
Insert specifications ................................................................ 50
Terminology .......................................................................... 51
1
2
1. HEALTH, SAFETY AND ENVIRONMENT
1.1
Precautions and Safety Issues
Thoroughly read this operator manual, before using this machine.
According to the European Guideline for machine safety (EC98-37), this operator manual must be available in the national language(s) of the country where the machine is delivered.
Therefore, if you do not have an operator manual in your country’s language(s), contact your authorized distributor.
Safety Precautions
• Only competent personnel should operate this machine.
If incompetent personnel do operate this machine, the manufacturer does not accept responsibility for any resulting accidents or injuries.
• Only skilled persons, who are aware of the risks involved, may open the protective covers.
For safety reasons, the machine will not function when the covers are open.
• Keep long hair, fingers, jewelry, etc. away from rotating and moving parts.
• The power connection must be easily accessible, preferably close to the machine.
• For safety reasons, it is essential that the machine is connected to a socket outlet that has a protective earth connection.
• The machine has an over-current protection of 20 Amps. However, it is assumed that the main power supply also has a circuit protection.
• Remove the plug of the power supply cord from the socket outlet to disconnect the machine from the power supply.
Conventions
Warning
This symbol:
- identifies situations where improper use of the machine can result in personal injury or permanent/catastrophic damage to the machine.
- indicates that the operator manual should be consulted.
Warning
This symbol indicates a danger caused by high voltage.
Note
A note gives additional relevant information.
3
1.2
Country specific conditions
Denmark
In Denmark, certain types of Class 1 appliances may be provided with a plug that does not provide an adequate earth connection when inserted into a Danish socket outlet.
Make sure the machine has a good functioning connection that has protective earthing.
(the Plug and socket outlet must match).
Japan
• Establish an earth connection before connecting the mains plug to the power supply.
• First disconnect the power supply before removing the earth connection.
Languages
This manual is also available in other languages. For more information, please contact your local supplier.
4
1.3
End of life
The objectives of the European Community's environment policy are, in particular, to preserve, protect and improve the quality of the environment, protect human health and utilise natural resources prudently and rationally. That policy is based on the precautionary principle and principles that preventive action should be taken, that environmental damage should as a priority be rectified at source.
Separate collection of waste is the precondition to ensure reuse and recycling of waste that is generated at the disposal of electrical or electronical equipment and is necessary to achieve the chosen level of protection of human health and the environment in the
European Community.
More particularly, certain materials and components of waste electrical and electronical equipment needs selective treatment as their injudicious handling or disposing of on or into land, water or air would represent a major threat to the environment and human health.
In order to facilitate collection and treatment separated from normal domestic waste, electrical and electronical equipment is marked with the following logo:
Do not mix with normal domestic waste
Please use the subjoined return or collection system dedicated to electrical and electronical waste
.
Equipment produced after August 13,
2005.
Not only are you by law not allowed to dispose of the waste equipment via other wastestreams, but we encourage you to actively contribute to the success of such collection and to the common good and better quality of life of present and future generations.
For more information on the correct disposal of this product please contact your local dealer.
5
2. GENERAL
2.1
Denominations
A B C
E
D
N
H
I
F
G
T S R Q
G
H
E
F
I
J
C
D
A
B
Envelope catch tray
Envelope slide
Display with operating buttons
Upper unit
Locking hand grip upper unit
Document feeders
Collator arm
Collator area
Power inlet, power switch
Knobs for clearing stoppages
O
P
Q
K
L
M
N
R
S
T
P O
M J L K J
Sensors
Bellows
Handle for clearing stoppages
Water reservoir
Side cover (opened)
Ruler
Thumb wheel for side guide adjustment
Side guides envelope hopper
Knob for separation adjustment
Envelope support bracket
6
2.2
Function Description
The system consists of the following area’s:
1
2
5
3
6
4
3
4
1
2
5
6
Document Feeders The machine selects documents from the feeders according to the applicable job options.
Collating area The documents are collected in the collating area before they are transported to the folding area.
Folding area
Envelope feeder
In the folding area, the document(s) are folded according to the job specifications.
The envelopes are picked up and transported to the insert position inside the machine.
Inserter
Operating panel
After the folded package of documents is inserted into the envelope, the glue of the envelope is moistened and the envelope is closed.
The machine is programmed and operated from the operating panel. This panel consists of a touch screen and a separate
Start, Stop and Clear button.
7
2.3
Display
The machine has a graphical touch screen.
A touch screen sensor is a clear glass panel with a touch responsive surface. The touch sensor/panel is placed over a display screen so that the responsive area of the panel covers the viewable area of the display.
This display shows functions and/or buttons, which can be operated by pressing a finger directly on the touch screen on the relevant function or button. The interface recognizes the location of the pressure point and when this is located within the defined area of a button, the user interface reacts with ‘pressing’ this button.
In this way, the user can simply operate the machine by pressing on the displayed buttons and/or functions.
Caution
The display is covered with a thin pressure-sensitive layer. To avoid permanent damage of the display, do not use sharp objects to press on the display.
8
3. OPERATING INSTRUCTIONS
3.1
Installation
Warning
You can severely damage the machine if it is connected to the incorrect power supply.
Before plugging in the machine, check if the local voltage is the same as the voltage mentioned on the type plate.
Incidence of light can cause disturbing reflections in the display, resulting in reduced readability. If necessary, change the position of the machine to improve the readability for the operator.
3.2
Preparation
Document Feeder Trays
Note
The machine can be delivered with a tray to manually adjust the separation. However, this tray fits in all positions, this adjustment is only possible when fitted on the lowest position
(position one).
Place the document feeder trays in position.
1. Hold the document feeder slightly inclined as shown in the figure.
2. Place the front end of the document feeder tray underneath the two black rollers.
3. Move the document feeder tray upwards (lifting the black rollers), until it is possible to “hook” the feeder into place.
4. Move the document feeder tray towards the machine and move the hooks over the mounting points (on both sides).
5. Let the document feeder tray rest on the machine.
9
Slide and Envelope Catch Tray
1. Attach the slide as shown in the figure.
2. Position the envelope catch tray into the holes underneath the envelope hopper as shown in the figure.
The distance A should be approximately 1.5 x the envelope height.
3.3
Starting Up
1. Connect the machine to the mains power supply.
2. Use the power switch to switch the machine ON.
The software will ask you to select the required language.
3. Select the required language for the display.
4. The software will ask you if you want the “select language option” to be displayed every time the machine is switched on. Select either Yes or
No.
MAIN MENU 1/2
JOB 1
Total:
0
5. Press .
The Main Menu screen 1/2 will be displayed.
A
other job
Test run
Counters
Load 'n Go
10
3.4
Loading Documents
Document Orientation
one document feeder swap two documents document + enclosure no fold single fold letter fold double parallel fold
Address carrier in upper feeder.
Face up and leading.
Address carrier in upper linked pair feeders.
Face up and leading.
Address carrier in upper feeder.
Face up and leading.
Address carrier in upper feeder.
Face up and leading.
zig-zag fold
Address carrier face down and trailing.
Address carrier in lower linked pair feeders.
Face down and trailing.
Address carrier in lower feeder.
Face down and trailing.
Address carrier in upper feeder.
Face down and trailing.
Adjusting Side Guides
1. Loosen knob B half a turn.
2. Move the side guides outwards.
3. Place a small stack of documents between the side guides.
4. Move the side guides A and C to the document, so the documents have just enough space to slide between the side guides.
5. Tighten knob B.
A C
Document Separation
The term ‘Document separation’ refers to the adjustment required for separating the upper document from the rest of the documents in the stack. This prevents documents being picked up from the stack at the same time.
The document separation for the automatic feeders is set automatically.
The special feeder (fitted in the lowest, first position) can be manually adjusted.
Adjust the manual document separation as follows:
B
11
1. Remove trays 2 and 3:
- Push the handle on the left side of the tray down.
- Lift the tray to unhook it, and then pull it from the feeder.
2. Push knob B until it clicks and stays in place, and then turn it counterclockwise as far as possible.
3. Lower the left side guide A. The feed rollers will move up.
4. Place a document on the feeding tray.
5. Push the document, as far as possible into the machine, without damaging it.
A B
6. Raise the left side guide A until it clicks into place. The feed rollers will move down.
7. Slide the document further into the machine until it stops.
8. Turn knob B clockwise until a slight resistance is felt when moving the document in and out the machine.
If you feel too much resistance, turn knob B counterclockwise.
9. Remove the document.
10. Pull back knob B.
11. Place a stack of documents in the document feeding tray.
12. Fit the removed feeder trays 2 and 3 (refer to “Document Feeder Trays” on page 9).
Feeding Documents
1. Turn the left side guide A downwards
The feed roller will be lifted.
2. Place a stack of documents between the side guides.
3. Turn the left side guide A upwards.
12
3.5
Loading Envelopes
Adjusting Side Guides
Adjust side guides C by rotating thumbwheel D, so that the envelopes:
- fit exactly between the side guides.
- can move freely.
NOTE
If the distance between the side guides is too large, the envelopes will twist sidewards, when transported into the machine.
C
B
A C D
Envelope Separation
1. Turn knob A counterclockwise as far as possible.
2. Slide an envelope (with closed flap) between the rollers in the machine and turn knob
A clockwise until a slight resistance is felt when moving the envelope in and out of the
machine.
When the resistance is too high, turn knob A counterclockwise, until only a slight resistance is felt.
Feeding Envelopes
1. Place the bottom envelope between the rollers
(flap down and trailing - bottom side of envelope pointing to machine).
2. Loosen the stack of envelopes and place the stack on top of the bottom envelope.
3. Shift envelope support B in or out, so that the flap side of the envelope is lifted approximately
20 mm (0.8”).
Turn envelope support B so the weight of the envelopes is distributed evenly on both sides.
13
3.6
Sealing Envelopes
Switch the envelope sealing ON or OFF.
1. Lift the handgrip to open the top cover.
2. Shift the blue handle A towards the envelope sealing or towards the envelop sealing.
3. Close the top cover.
to disable
to enable
A
When the sealing of the envelopes is enabled, the sealing liquid reservoir must be filled.
4. Open the front cover A.
5. Fill the reservoir B to the “Max” level indication with sealing liquid.
6. Close the front cover A.
Before starting the job, wait approximately 5 minutes for the brushes to moisten.
B
3.7
load’n Go
®
A
The load’n Go
®
feature automatically adjusts all machine settings.
When load’n Go
® is started, the machine will pick one sheet from each filled feeder.
The picked documents will be folded (if necessary) and inserted into an envelope.
Using load’n Go
®
1. Load envelopes.
2. Make sure there is sufficient sealing liquid in the sealing liquid reservoir. If the reservoir has just been filled, wait approximately 5 minutes for the
brushes to moisten. See “Sealing Envelopes” on page 14.
3. Load the documents face up and leading.
4. From the Main menu 1/2, press
Load 'n Go
.
MAIN MENU 1/2
JOB 1
Total:
0 other job
Test run
Counters
Load 'n Go
14
5. After a few seconds, the load’n Go
® appear.
display will
6. Press
1x
to load one envelope to the insert position in the machine.
7. The envelope is visible through the window in the top cover.
LOAD 'N GO
1x
1x
Insert position
ESCAPE
Insert Position
Note
This adjustment must only be checked in case of problems or when changing the envelope type.
Check if the flap folding line is positioned underneath the green roller B. If not adjust the
Insert position as follows:
1. Press on the left or right side of to adjust the insert position to the left or the right.
2. Press
1x
the insert position
to load a new envelope into
3. Recheck the insert position, and adjust as required.
4. If necessary adjust the “envelope insert fingers”:
- Open the top cover.
A
B
C
D
- Adjust the outer fingers D approximately 5 - 10 mm (0.2 till 0.4”) from the edges of the envelopes.
- Loosen the knurled knobs C.
- Adjust the fingers A so that the tip is approximately 5 mm (0.2”) inside the envelope.
- Tighten the knurled knobs C.
15
Address Position
1. When the envelope position and the position of the fingers is correct, press
1x
to load a folded sheet into the envelope.
The envelope will be sealed (when enabled, refer to “Sealing Envelopes” on page 14)
and ejected to the envelope tray.
2. Check the position of the address in relation to the address window in the envelope.
3. If necessary, press the Up or Down button to adjust the address.
4. Press
1x
to make another test run.
5. Recheck the position of the address, and adjust as required.
6. Press
OK
to leave this screen to return to the main menu or press the to immediately start the job.
Starting the Job
button
• Press the
• Press the
button to start the job.
button to stop the job. The machine will stop immediately.
• Press the button to clear the document path to prepare the machine for a new job.
3.8
Daily Mail
To process documents or sets of documents, which can not be processed automatically, the top feeder is equipped with a daily mail switch.
Switch to Daily Mail function:
1. Select or change to a job where the Daily Mail function is set to ON.
The Daily Mail function can be recognized by the
B
icon in the Job info screen.
2. Turn left side guide A of the upper tray down.
3. The Daily Mail handle B will become visible.
Move the handle to
Mail function.
to enable the Daily
4. Turn left side guide A upwards.
5. Place the document or document set in the feeder.
If necessary adjust the side guides. Refer to
“Adjusting Side Guides” on page 11.
A
16
6. Press the button to start the job.
The document or document set will be folded and inserted in the envelope as described in the selected job.
7. Place the following document or document set in the feeder. The machine will keep running to process the inserted document or document set.
8. When finished with Daily Mail, press the
9. Turn left side guide A down.
button to stop the job.
10. Move the Daily Mail handle to the ‘AUTO’ position to disable the Daily Mail and to enable the automatic document separation.
3.9
Other Menu Options
After starting up, the Main Menu 1/2 screen will appear.
The screen shows the selected job number and the total number of envelopes that have been processed using this job.
• Press the button to start the job.
MAIN MENU 1/2
JOB 1
Total:
0 other job
Test run
Counters
Load 'n Go
• Press the button to stop the job. The machine will stop immediately.
• Press the button to clear the document path to prepare the machine for a new job.
The Main menu 1/2 will be displayed.
Job Info
• Press to display all relevant information about the selected job.
Refer to “Job Information” on page 22 for a
detailed explanation of the screen.
• Press
ESCAPE
to return to the Main menu screen
JOB INFO
JOB 1
114
108/216
3
2
1 b
1 297
ESCAPE
17
Other Job
Press job.
other job
to select another predefined
1. Press to select another job number.
The screen shows the job options of the relevant job. (For a description of the items, refer to the previous page).
2. Press
OK
to confirm the selected job.
OTHER JOB
JOB 1
114
OK
108/216
3
2
1
Select job b
1
ESCAPE
1 297
3. Press
ESCAPE
to leave this screen without changing job.
Test Run
Press
Test run
to display the Test Run screen.
1. Press
1x
to load a new envelope into the insert position. This gives the possibility to check the insert position of the envelope.
2. Adjust the position by pressing on to adjust the insert position more to the left or the
right. (Refer to “Insert Position” on page 15).
Press
1x
to load a new envelope into the insert position and check the condition again.
TEST RUN
JOB 1
Total:
0
OK
Insert position
ESCAPE
1x
1x
3. Press
OK
to confirm the insert position.
4. When the envelope position and the position of the fingers is correct, press
1x
to load a folded sheet in the envelope.
The envelope will be sealed (when enabled, refer to “Sealing Envelopes” on page 14)
and ejected to the envelope tray.
5. Press
ESCAPE
to leave this screen without changing settings.
- Press the button to start the job.
- Press the button to stop the job. The machine will stop immediately.
- Press the job.
button to clear the document path to prepare the machine for a new
The Main menu 1/2 will be displayed.
18
Counters
Press
Counters
to display the Counters screen.
1. Press
Reset counters
to reset the counters to 0.
2. Press
OK
to confirm possible changed settings and to return to the Main menu.
3. Press
ESCAPE
to leave this screen without changing settings.
- Press the button to start the job.
- Press the
COUNTERS
JOB 1
Total:
0
OK ESCAPE
Reset counters
Stop at: OFF
button to stop the job. The machine will stop immediately.
- Press the job.
button to clear the document path to prepare the machine for a new
The Main menu 1/2 will be displayed.
COUNTERS
4. Press to program the stop counter.
5. Enter the number of envelopes that must be processed with the numeric keys.
Stop at:
0
6. Press settings and to return to the previous screen.
7. Press
OK
ESCAPE
to confirm possible changed
to return to the previous screen without changing settings.
OK
1
4
7
2
5
8
0
3
6
9
CE
ESCAPE
Main Menu 2/2
MAIN MENU 2/2
JOB 1
• Press will bring you in the second main menu screen 2/2.
Also this screen shows the selected job number and the counters, indicating the programmed number of envelopes to do as well as the total number of envelopes that have been processed using this job.
Total:
0
Display setting
Job menu
Supervisor menu
19
Display Settings
Press
Display setting
screen display.
to change settings for the touch
DISPLAY SETTINGS
enables to change the contrast of the display. The graphic shows the contrast setting.
enables to adjust the volume of the acoustic signals. The graphic shows the volume setting.
• Press
OK
to confirm changed settings.
OK ESCAPE
• Press
ESCAPE
to return to the previous screen without changing settings.
Job Menu
The
Job menu
starts the job menu.
This menu enables the creation, deletion and/or editing of jobs. To prevent jobs being edited or deleted without informing the ‘job owner’, this menu is protected by a PIN-code.
This job menu will be described in “Job
• Press
ESCAPE
to return to the previous screen without changing settings.
Supervisor Menu
Pressing the settings.
Supervisor menu
gives access to system
The supervisor menu therefore is restricted and protected by a PIN-code.
The supervisor menu will be described in “Supervisor
• Press
ESCAPE
to return to the previous screen without changing settings.
• Press to return to the Main Menu 1/2.
JOB ACCESS
Enter pin code
_
1
4
7
1
4
7
8
0
2
5
8
0
2
5
SUPERVISOR ACCESS
Enter pin code
_
3
6
9
3
6
9
CE
ESCAPE
CE
ESCAPE
20
4. JOB PROGRAMMING
4.1
Job Menu
The job menu is protected with a PIN code, to prevent unauthorized editing or deleting jobs.
To enter the job menu:
1. From the Main Menu 1/2 press and
Job menu
2. Enter PIN-code 2546 to enter the job menu.
The job menu contains 5 buttons, which enable different functions. These functions are described in the following subchapters.
.
JOB MENU
JOB 1
• Press job.
to see the details of a certain
Refer to “Job Information” on page 22.
Create job
Edit job
Copy job
Delete job
• Press
Create job
to create a job from scratch.
Refer to “Create Job” on page 23.
ESCAPE
• Press
Edit job
to change a job. Refer to “Edit
• Press
Copy job
to copy a job. This copied job can be edited. In this way it is possible to create a new job, which resembles a certain job.
Refer to “Copy Job” on page 30.
• Press
Delete job
to delete a certain job, which is not longer necessary.
refer to “Delete Job” on page 31.
• Press
ESCAPE
to return to the Main Menu.
21
4.2
Job Information
Job Info
Press to display all relevant information about the selected job.
Gives information about the envelope size
(ISO format or height in mm).
JOB INFO
JOB 1
114
108/216
3
2
1 b
1 297
ESCAPE
Shows the type of fold.
3
2
3
2
1
Shows the feeders selected to pick documents from (black is selected).
The sign below this icon shows if the document double feed detection for the relevant feeder is switched ON - or OFF - .
The number under this icon indicates the number of sheets that must be picked from the relevant feeder.
Is the indication for daily mail.
Below this icon, the format of the document in the relevant feeder is indicated
(ISO standard or height in mm).
This sign indicates that the relevant feeders are linked. This means that when one feeder is empty, the system automatically starts picking documents from the other feeder.
The sign below this icon tells whether the Optical Mark Recognition (OMR) for the selected feeder is switched ON - or OFF - .
Press to view the Optical Mark Recognition (OMR) settings for this job. This button is only available when OMR is installed and when OMR is switched ON in this job.
Press
ESCAPE
to return to the Main menu screen.
22
4.3
Create Job
• Press
Create job
in the Jobs menu to create a new job. This job must be stored under a job number. The screen will show the lowest free job number.
• Press or to consequently select a higher or lower free job number (if available).
CREATE JOB
JOB 9
Select job 9
• Press
OK
to confirm the selected free job number and to go to the following screen or press
ESCAPE
to return to the previous screen.
Job Settings
OK ESCAPE
After pressing displayed.
OK
the job settings screen will be
The following settings are available:
Envelope settings
Document settings
Fold setting
JOB SETTINGS
JOB 9
SAVE name
ESCAPE
Test run
Optical Mark Recognition (OMR) settings (if installed)
Double feed control settings
name
Job name settings
Mailing/Franking settings (if available)
Press each button to set the relevant job item. All these settings will be described below.
• Press to view all relevant information about the selected job.
• Press
SAVE
and name.
to save the job with the entered settings under the specified job number
• Press
ESCAPE
to return to the previous screen without saving the entered job.
• Press
Test run
to perform a test run with the present settings. Refer to page 18.
23
Envelope Settings
In this screen the properties of the used envelopes must be entered.
In the top of the screen, three selection buttons are displayed, from which one can be selected. The selected settings button will be highlighted yellow.
• Press to select an envelope which is entered in the machine with a closed flap.
• Press to select an envelope which is entered in the machine with an opened flap.
ENVELOPE SETTINGS
JOB 8
OK ESCAPE
C6/5
50
• Press to set the job without inserting the documents in envelopes (no envelope mode). This can be useful for jobs, where documents only have to be sorted and/or folded.
• Press to enter the dimensions of the envelope and/or the envelope flap.
A numeric keypad will be displayed to enter the applicable dimensions.
It is also possible to select ISO standard envelopes or dimensions in inches (depends on the installation settings).
• Press
OK
to confirm changed settings or press screen without changing settings.
ESCAPE
to return to the previous
Document Settings
This screen enables the setting of the document formats and the number of documents that must be picked from the different feeders.
DOCUMENT SETTINGS
JOB 8
• Press to set the number of sheets for the different feeders.
3
2
1
1
1
1
- Press to select a feeder. The selected feeder will be highlighted.
OK ESCAPE
- Press or to enter the number of sheets that must be picked from the highlighted feeder.
When the number of documents is 0, the relevant feeder will be deselected.
24
• Press to enter the document height. The height or the ISO format of the document will be displayed next to the relevant feeder.
- Press to select a feeder. The selected feeder will be highlighted.
DOCUMENT SETTINGS
JOB 8
3
2
1
A4
100
100
- Press to display a numeric keypad to enter the exact dimension of the document.
OK ESCAPE
Press
CE
to clear the displayed dimension and to enter a new dimension.
Dimensions can be entered in mm, inches or as standard ISO paper dimensions
(depending on installation settings).
The machine will not allow entering dimensions outer technical ranges.
Feeder 3 (top tray) can not handle documents smaller then 115 mm (4.5”), unless the
Intermediate Transport Option is installed. When Intermediate Transport is installed, the minimum document height is 90 mm (3.5”).
• Press to link two feeders. This function enables to fill two adjacent feeders with the same documents. When the first feeder is empty, the system automatically swaps to the other feeder.
- Press to select two adjacent feeders. The selected feeders will be highlighted
DOCUMENT SETTINGS
JOB 8
3
2
1
A4
100
100
- Press to link two highlighted feeders.
The will be displayed between the selected feeders.
OK ESCAPE
Note
When linking two feeders, the program will automatically equal the number and format of the documents in the selected feeders.
DOCUMENT SETTINGS
JOB 8
• Press function.
to enter the setting of the Daily Mail
This function enables to process documents or sets of documents, which can not be processed automatically. The function is only available for
the top feeder. (Refer also to “Daily Mail” on page 16)
The top feeder will automatically be selected.
• Press to enable the Daily Mail function and press again to disable the function.
OK
3
2
1
A4
100
100
ESCAPE
25
• Press
OK
to confirm changed settings or press screen without changing settings.
ESCAPE
to return to the previous
Fold Settings
This screen enables the adjustment of the folding dimensions.
The following choices are available:
FOLD SETTINGS
JOB 8
No fold (no settings required)
108
Single fold
Letter fold
OK ESCAPE
216
Double parallel fold
Zig-zag fold
Except when no fold is required, the display shows a simple diagram of the document with the fold positions.
• Press next to a fold to display a numeric keypad. Enter the required position of the relevant fold.
• Press
CE
to clear the displayed dimension and enter a new dimension.
• Press
OK
to confirm changed settings or press screen without changing settings.
ESCAPE
to return to the previous
26
Fold Positions
Fold type
Single fold
Letter fold
Zig-zag fold
First fold
Second fold
First fold
Second fold
Double parallel fold
First fold
Second fold
Minimum position
75 mm (2.95”)
75 mm (2.95”)
Position first fold plus 26 mm (1.02”)
75 mm (2.95”)
Position first fold plus 25 mm (0.98”)
75 mm (2.95”)
Position first fold plus 25 mm (0.98”)
Maximum position
Longest document length minus 25 mm (0.98”)
Longest document length minus 50 mm (1.97”)
Longest document length minus 25 mm (0.98”)
Longest document length minus 100 mm (3.94”)
Longest document length minus 75 mm (2.95”)
Longest document length minus 51 mm (2.0”)
Longest document length minus 25 mm (0.98”)
Note
The display will indicate when entered positions are out of range.
Optical Mark Recognition Settings (Option)
For a full function description, see chapter “Optical
Mark Recognition OMR (option)” on page 34.
In this screen it is possible to enable or disable the
OMR function and to adjust the basic settings for
OMR.
OMR SETTINGS
JOB 8
3
2
1
• Press to select a pre-programmed reading code. Each time the button is pressed, the next code is selected.
With this same button it is possible to select OFF, which means that the OMR is disabled.
The number of different codes available depends on the installed options.
OK ESCAPE max
OMR
100
6
• Press to enable a numeric keypad and to enter the position of the first reading mark on the sheet, measured from the top.
• Press or to enter the maximum number of sheets in the set of documents.
27
Note
The maximum number of sheets in a set is 25. When the number of sheets exceeds 6 or
8, depending on the fold, the document can not be folded anymore. In this case, the maximum length of sheets is 148 mm for a C5/6 envelope. Also make sure that the fold is set to No fold.
Ignoring this will certainly lead to stoppages.
When the maximum number of sheets exceeds the programmed maximum number of sheets in a set, the machine stops and error VT:134 will be displayed. After removing the set and pressing the RESET button, the machine will start and repeat the process until an insert or divert mark is encountered, error VT:135 (final set part) will be displayed.
• Press codes.
to view the programmed OMR
Refer to “OMR Codes” on page 35 for a description
of the OMR codes.
• Press
OK
to return to the previous OMR settings screen.
OMR SETTINGS
JOB 8
Start mark
Insert on mark
Parity check
Safety mark
Line spacing
6.00 Lpi
4.23 mm
OK
Double Feed Control Settings
This screen enables to set the Double Feed Controls
(DFC) settings for the different feeders ON or OFF.
Press to select a feeder. The selected feeder will be highlighted.
• Press to switch the DFC control ON or OFF.
When switched ON, a icon is visible beside the relevant feeder.
• Press
OK
to confirm changed settings or press
ESCAPE
to return to the previous screen without changing settings.
DFC SETTINGS
JOB 8
OK
3
2
1
ESCAPE
28
Job Name
It is possible to store the job with a meaningful job name, to easily recognize the job. This name will be displayed in the Main screen during job selection.
• Enter a job name using the alpha-numeric keypad.
• Press
a b
to clear a character left of the cursor position (backspace).
• Press again.
CE
to clear all entered characters and start
JOB NAME
OK
Job name: invoices
1
4 ghi
7 pqrs
/-+
2 abc
5 jkl
8 tuv
0
,.:;
3 def
6 mno
9 wxyz a A a b
CE
ESCAPE
• Press
OK
to confirm changed settings or press
ESCAPE
to return to the previous screen without changing settings.
Mailing/Franking Settings (Option*)
If this machine is connected to a mailing/franking machine, this option allows you to:
- switch automatic mailing/franking ON or OFF.
- remotely select a mailing/franking job
- set the printing/franking value (option)
FRANKING SETTINGS
JOB 8
Franking Yes
Value defined by Franking machine
FrankingJob 2 FIF job num..
• Press the top to select YES when the mailing/ franking machine must print/frank the envelopes or PASS THROUGH to let the envelopes pass through without printing/franking.
OK ESCAPE
• When switched ON, pressing on the second will select whether the mailing/franking value is determined by the MAILING/FRANKING MACHINE or based on the INSERTER
DATA.
• When the printed/franking value is determined by the mailing/franking machine, a mailing/franking job can be selected with or .
• Press
OK
to confirm changed settings or press screen without changing settings.
ESCAPE
to return to the previous
Refer to the appendix for an extensive description of this option.
*Ask your supplier if this option is available in your country, and for your mailing/franking machine.
29
4.4
Edit Job
In this function it is possible to edit and change a programmed job.
1. After pressing the
Edit job
in the Jobs
menu (refer to “Job Menu” on page 21), the
display will show the job information about the presently selected job.
2. Press number.
to select a higher or lower job
3. Press
OK
to confirm the selected job number and to go to the following screen or press
ESCAPE
to return to the previous screen.
EDIT JOB
JOB 1
C6/5
OK
108/216
3
2
1
Select job b
1
ESCAPE
1 A4
4. After pressing
OK
, the job settings screen for the selected job will be displayed.
All buttons of this screen are described in chapter “Create Job” on page 23.
4.5
Copy Job
1. After pressing the
Copy job
in the Jobs
menu (refer to “Job Menu” on page 21), the
screen will show the Copy Job screen.
COPY JOB
JOB 1
Copy from job 9
2. Use or to select the job to copy from.
Press for more information on the
selected job (refer to “Job Information” on page 22).
Copy to job 1
OK ESCAPE
3. Use copy to.
or to select a free job number to
A warning will be displayed when no more free job numbers are available.
4. Press
OK
to confirm the selected job numbers and to make a copy or press to return to the previous screen.
ESCAPE
30
4.6
Delete Job
1. After pressing the
Delete job
in the Jobs
menu (refer to “Job Menu” on page 21), the
screen will show the Delete Job screen.
2. Use to select the job that must be deleted. The screen shows the details of the selected job.
3. Press
OK
to delete the selected job number or press
ESCAPE
to return to the previous screen.
DELETE JOB
JOB 5
C6/5
OK
106/212
3
2
1
Select job b
1
ESCAPE
2
2
1
A4
A4
100
31
5. SUPERVISOR MENU
The supervisor of the system has the possibility to check and configure the system.
To access the Supervisor menu:
1. From the Main Menu 1/2 press and
Supervisor menu
.
2. Enter PIN-code 2546 to enter the Supervisor menu.
The following subchapters describe the functions of the displayed buttons.
SUPERVISOR MENU
System info
Options
Online services
System info
Refer to “System Info” on page 32.
Options
Refer to “Options” on page 33.
Online services
Refer to “Online Services (Option*)” on page 33.
ESCAPE
• Press
ESCAPE
to return to the previous screen.
5.1
System Info
This screen displays information about:
- the number of inserts since the last service visit.
- The latest displayed error message.
- Information concerning software versions.
SYSTEM INFO
Flex certificate 000000
Counter since last visit 0 last error
INF: 13 An internal error occurred which blocks job execution
Software versions
Inserter 994550 Rev- V00.18
ESCAPE
Note
When the supervisor is not able to solve possible problems, write down the installed software versions and the last error, before contacting the supplier.
• Press
ESCAPE
to return to the previous screen.
32
5.2
Options
This screen displays information about installed software options.
Software options are enabled using license codes.
These license codes, together with the identification number of the machine enable the relevant options.
The enabled and available software options are displayed in this screen.
Contact your dealer for information about these license codes.
OPTIONS
Installed Options:
Also available:
OMR level 3
Insert 'N Frank level 3
FLEX OMR 9 code
ESCAPE Add
1. Press
Add
to activate other software options.
2. Enter the license key code that you received from the supplier to activate the relevant option on this machine
3. Use and to navigate through the entered characters.
ADD OPTIONS
License key:
1
4 ghi
7 pqrs
/-+
2 abc
5 jkl
8 tuv
0
,.:;
3 def
6 mno
9 wxyz a A
4. Press
OK
to confirm the license key and to return to the Options screen.
5. Press
ESCAPE
to return to the Options screen without changing settings.
5.3
Online Services (Option*)
This screen enables to display and change the settings for the Online services.
Refer to the appendix for a comprehensive description of the Online Services.
• Press
ESCAPE
to return to the Supervisor menu without changing settings.
*Ask your supplier if this option is available.
ONLINE SERVICES
CE
ESCAPE
Connection
Messages
Configuration
!!Set Date and Time
ESCAPE
33
6. OPTICAL MARK RECOGNITION OMR (OPTION)
6.1
General
The folding and inserting system can be equipped with Optical Mark Recognition. This allows the system to read special codes that have been printed on the documents. These codes contain information about the processing of the sheets.
The sheets with the printed code are placed in the upper feeder (no. 3). Depending on the programmed code, the other feeders can be used as selective feeders to add enclosures.
With the first four fold types, the first sheet of a set always contains the address. In case of a zig-zag fold, the address has to be printed on the last page of the set. A full length code is printed on every sheet of a set.
The code on the last sheet of the set contains the insert instruction. The other sheets carry the accumulate instruction. If a parity check is used, this is checked on each sheet.
If the set contains only one sheet, it is the “last” sheet. The code must appear in the same location on every page regardless of the actual code length.
This option can be enabled by a special license code (refer to “Options” on page 33).
6.2
Adjustments
Reading head position
The horizontal position of the reading head must be adjusted to the same position of the printed marks on the documents. To adjust the reading head, proceed as follows:
1. Fold a document with reading code on the first mark.
2. Open the top cover.
3. Hold the document in the middle against the ruler.
4. Shift the reading head A so it is positioned exactly above the middle of the reading marks.
5. Divide the paper guides B along the width of the document.
6. When the reading head is adjusted it is possible that paper guides have to be removed and placed on the other side of the reading head.
A B
34
6.3
Document Orientation
Switch ON the OMR-function and set the position of the reading marks as described in
“Optical Mark Recognition Settings (Option)” on page 27.
Document orientation:
Fold type
Type of documents Loading positions no fold first page
1 2
3 single fold letter fold address
OMR start reading
OMR stop reading
Double parallel fold last page
(duplex printed)
Address carrier, face up and leading.
3 2
1 zig-zag fold
OMR start reading
OMR stop reading address
Address carrier, face down and trailing.
6.4
OMR Codes
Printing quality
• Marks should be printed in black.
• Marks on the same sheet must have equal intensity.
• Marks must be printed on the same position on every sheet.
• For matrix printers near letter quality (NLQ) printed characters are preferred to obtain maximum blackness (double strike).
• Be aware of background “noise”. Color changes on the form, background design, a logo or copy on the opposite side of the sheet that will bleed through can be read by the reading head causing disturbances of the OMR function.
• The ribbon or toner quality must be checked before printing.
35
Minimum code/basic commands
The minimum code is one mark in one line (insert).
However for reliability it is advised to use at least 2 marks.
The first line is the start mark.
A mark printed on the second line means insert. No mark on the second line means accumulate.
Start mark
Insert/accumulate
Note
In some cases, on request of the customer, the reading of the basic commands can be reversed by the service organization. This means that no mark is interpreted as an insert command and that for the accumulate command a mark has to be printed.
Length
Above the first mark and below the last mark a space of 8,5 mm (0.33”) must be kept without printing. This means that the minimum code area consists of 6 lines:
- 2 lines to print the (basic) commands
- 4 lines free space
Line distance may be 2,54 mm (0.1”) to 6,35 mm
(0.4”).
8,5 mm
8,5 mm
6,3 mm
Line 1
Line 2
Line 3
Line 4
Line 5
Line 6
4,2 mm 4,2 mm
Code width, character spacing and pitch
The minimum width of the code area is 7 character spaces. From left to right:
- 2 characters space not printed (4,2 mm; 0.17”)
- track mark (3 characters or 6,3 mm; 0.24”)
- 2 character spaces not printed
Pitch 10 or 12 is accepted.
The track mark can be printed using the underline” sign (_), which must have a thickness of at least 0,2 mm (0.08”).
36
Additional marks
When it is required to control more functions in the inserter system, the use of more marks is needed.
The following additional functions are possible via software options:
- divert mark
- stop mark
- 1 mark: selective feed from station 1
- 1 mark: selective feed from station 2
- 1, 2 or 3 marks: respectively sequence check
4, 2 and 1
- 1 mark: parity check mark (even)
Start mark
Insert/accumulate
Divert mark
Stop mark
Selective feed 1
Selective feed 2
Sequence check 4
Sequence check 2
Sequence check 1
Parity (even parity)
Safety mark
- 1 mark: safety mark
General remarks:
- The marks must always be used in the above sequence.
- If a function is suppressed the following function will move upwards one line.
- The chosen code must always be used on all material which must be processed by the Optical Mark Recognition.
- The length of the code and the mark definition is a service setting.
- Other marks/functions are possible via special codes (Flex codes)
Divert mark
The machine stops, manually remove the set from the collator. Reset and start again.
Stop mark
The machine stops, manually remove the set from the collator. Reset and start again.
Selective feed mark
The machine will selectively feed an enclosure when commanded so.
Sequence check
Sheets in a stack can accidentally get out of sequence or can be missing. This can be detected by the sequence check.
Each sheet has a binary code that is a part of the reading code.
Parity mark
By adding a parity mark the reading code can be checked. When the OMR-2 code is used the sum of the marks has to be even.
37
Safety mark
he safety mark is used as an extra security. With skewed paper the reading head can miss part of the reading code. In these situations the safety mark is not read, and the system will give an error.
The safety mark also indicates the end of the reading code.
This mark must always be present on the document if it has been activated as an OMR code.
Normal paper flow
Start mark
Skewed paper flow
Start mark
Safety mark reading direction
Safety mark reading direction
Example
In the figure the legend for the following example is shown. In this example feeder station 3 is the reading feeder. The feeder stations 1 and 2 are selected for selective feeding.
or mark printed no mark printed accumalate insert no selective feed wanted, mark not printed selective feed wanted, mark printed reading feeder 3 selective feeder 2 selective feeder 1
In this example, a set of 8 sheets with two selective feeds (station 2 and 1) and three sequence check marks is shown.
• The first position is used for the start mark which must be printed on every sheet.
• The second mark position is used for the insert/ accumulate command. The mark is printed on the last sheet of the set (inserting is required).
• Position 3 and 4 are reserved for selective feeding from station 2 and 1. Print a mark on position 3 when a selective feed from station 2 is required.
Print a mark on position 4 when a selective feed from station 1 is required.
• Position 5, 6 and 7 are used for the sequence check marks.
Sheet 1 Sheet 2 Sheet 3 Sheet 4 Sheet 5 Sheet 6 Sheet 7 Sheet 8
38
7. OPTIONS
7.1
MaxiFeeder
TM
Function
The MaxiFeeder
TM
is a feeder that can be loaded with a high number of documents. This feeder is intended to be used for Business Reply Envelopes (BRE), but also "standard" documents up to 156 mm length can be processed with it.
Preparations
The MaxiFeeder
TM of feeder no. 1.
should be installed at the position
It can be placed into position in the same way as the other document feeders are fitted.
Proceed as follows:
1. Lift the paper feed rollers with the front edge of the MaxiFeeder
TM
.
2. Move the MaxiFeeder
TM behind the frame axle.
forward until it hooks
3. Connect the connector A to the socket B.
The MaxiFeeder
TM
is auto-detected by the system when it is switched ON. This makes it easy to switch
A B over from the standard document hopper to the MaxiFeeder
TM
and vice versa.
Note
To allow easier hooking on of the MaxiFeeder
TM rear position (see section "Separation").
it is advised to put the feeding plate in the
To make use of a MaxiFeeder
TM
it is not necessary to (re-)program the jobs.
Adjusting Side guides
Adjust the side guides:
1. Take a stack of documents/BREs and place them in the feeder tray.
BREs with flap down and leading (top side pointing to machine).
2. Adjust the side guides by turning the thumbwheel G so the documents/BREs just fit and can move without resistance.
Too much play causes skewing.
G H I J
39
Document Separation
When the MaxiFeeder
TM automatically.
is used at an automatic separation feeder, the separation is set
The MaxiFeeder
TM separation.
can also be used on a feeder position with a manually adjusted
To adjust, proceed as follows:
1. Remove feeders 2 and 3.
E
2. Squeeze the two blue handles C and D and shift the feeding plate F as far as possible to the front.
3. Push knob E forward until it clicks and turn it counterclockwise as far as possible.
4. Place a document/BRE on the feeding tray and slide it in the machine till the leading edge is not visible anymore.
5. Push knob E forward until it clicks and turn it clockwise till a slight resistance is felt when moving the document/BRE in and out the machine.
When the resistance starts becoming to big, turn knob E counterclockwise.
6. Pull knob E back when ready.
7. Remount feeders 2 and 3.
C D F
Feeding Documents
1. Squeeze the two blue handles C and D.
2. Shift the feeding plate F to the rear position.
3. Loosen the stack of documents and place them in the feeder.
BREs with flap down and leading (Top side pointing to machine).
The feeding plate assembly will be shifted up automatically (when the system starts processing) until documents/BREs are underneath the rubber paper pullers.
Note
When filling the MaxiFeeder
TM
, make sure that the document/BREs are positioned parallel in relation to the feed plate to ensure correct feeding.
7.2
Intermediate Transport
This option enables the handling of smaller documents from feeder no. 3 (top tray).
Without Intermediate Transport
With Intermediate Transport
Minimum document height
115 mm (4.5”)
90 mm (3.5”)
This option is not possible in combination with Optical mark Recognition.
40
8. MAINTENANCE
Disconnect the mains power supply before performing any maintenance.
The user must not attempt to service the appliance beyond that described in this operator manual. All other servicing must be carried out by qualified service personnel only.
Please contact your authorized distributor.
8.1
Operator Maintenance
Maintenance frequency
Daily
Weekly
Maintenance
• Check the system functions.
• Keep the system in proper condition by removing dust, paper remains, etc.
• When dirty, clean the sealing table and rubber rollers with a slightly wetted cloth, soaked in warm water.
• When dirty or saturated, clean the brushes of the envelope sealing.
The machine is delivered with an extra set of brushes. To always have one clean set available, it is recommended to soak one set in water and use the other set.
Remove the brushes one by one by pulling them down from the brush holder.
Replace the brushes and make sure that the studs on the brushes are fitted in the corresponding holes in the brush holder.
• Check moistening cloth and replace if necessary.
When dirty or saturated, clean the moistening cloth and the reservoir.
• Clean feed and insert rollers as instructed by the Service Engineer.
When necessary • When the display warns about dusty sensors, the sensors on the envelope or document path must be cleaned using the bellows that is located behind the side cover.
Place the bellows in the hole and firmly squeeze a few times to blow the dust from the sensor.
Repeat this procedure for the hole to clean the flap sensor.
41
9. FAULT FINDING
9.1
Error Messages
When an error occurs the display shows a screen showing the following information:
- An indication of the area in which the error occurred.
- An error description.
- A suggested solution behind the pointing hand.
!
Envelope too short
Remove envelope
Reset
Press to view more information about the occurred error and about the possible actions to avoid the error from re-occurring.
After solving the problem, press
Reset
to reset the error (the error screen will disappear).
Envelope length measured is shorter than expected check envelope type ande envelope job settings
INS: 22
Special Errors
• Reading errors (when Optical Mark Recognition is enabled)
The document stops in the collator area. The operator must remove the document(s) from the collator area and must complete the set manually!
• Technical errors
The display shows a message. The error cannot be solved by operating personnel and assistance of the service support is needed.
Warning screen
When a cover is opened, the display shows a warning screen with the message “Cover open and a suggested solution “Close cover”.The black arrow or a black feeder indicates where the problem occurs.
42
9.2
Clearing Stoppages
Stoppages can occur in the following area’s:
1 -Feeding area
2 -Collating area
3 -Folding area
4 -Lower envelope track
For clearing stoppages, three sections of the system can be opened (A, B and C).
A - Top cover to reach the folding and feeding area.
B - Collator plate to reach the collator area.
C - Front cover to reach the envelope track and
inserter area.
A
1
4
3
2
C B
Lower envelope track
Remove the envelopes as follows:
1. Open the side cover C.
2. Lower and hold the handle D to the left and remove the envelope(s) from the lower envelope track.
3. Release the handle D.
4. If necessary, the envelopes and documents can be transported manually by turning the blue knob E clockwise.
5. Turn the blue knob F clockwise to manually transport envelopes through the lower envelope track.
6. Close the side cover.
7. Press
Reset
C
to reset the error and restart the job.
E
F
D
43
Folding area
Remove stoppages from the folding area as follows:
1. Open the top cover A by pulling up the handle.
2. Remove the documents from the folding area.
3. Close the top cover A.
4. Press
Reset
to reset the error and restart the job.
Feeding area
Remove stoppages from the feeding area as follows:
1. Open the top cover A by pulling up the handle.
2. Remove the documents from the feeding area.
3. Close the top cover A.
4. Press
Reset
Reset
to reset the error and restart the job.
Collating area
Remove stoppages from the collating area as follows:
1. Move the collator plate B down.
2. Remove the documents from the collator area.
3. Move the collator plate B up in position.
4. Press to reset the error and restart the job.
9.3
Operator Troubleshooting
1. First write down the error.
2. Try to solve the problem by consulting the table below.
3. Switch the inserter OFF and ON again, to verify system operation.
4. When the error still occurs contact your service organization.
Note
When contacting the service organization, you will also be asked for the last error message and the software version of the installed software. To determine the software
version, refer to “System Info” on page 32.
44
Symptom
The machine is not starting after switching ON
Machine stops with envelope at insert position
(flap not open)
Possible cause
Machine not connected to mains
Fuse blown
A cover is opened
Envelopes stacked reversed in the hopper
Remedy
Connect the machine to the mains
Replace fuse below power switch
Close the covers
Check envelope feed adjustments. Place envelopes correctly in hopper
Refer to section
-
-
-
“Loading Envelopes” on page 13
“Envelope Settings” on page 24
Envelope specifications Envelope flap sticks Store envelopes according to specifications
Wrong envelope type used (not according specifications or job settings)
Change envelopes according to specifications
“Envelope Settings” on page 24
“Technical specifications” on page 48
“Loading Envelopes” on page 13
Envelopes are double fed
Envelope stop skewed
Envelopes are fed irregularly
Envelope separation not correctly adjusted
Envelopes not placed properly in the hopper
Check separation settings, adjust if needed
Check and replace if needed
Side guides of the envelope hopper are set too wide
Check side guides and adjust if needed
Hopper almost empty Refill hopper
Separation set too narrow
Side guides set too narrow
Envelope support not positioned correctly
Check separation settings, adjust if needed
Check side guides and adjust if needed
Reposition the envelope support
“Loading Envelopes” on page 13
“Loading Envelopes” on page 13
“Loading Envelopes” on page 13
“Loading Envelopes” on page 13
“Loading Envelopes” on page 13
“Loading Envelopes” on page 13
45
Symptom
Flap is wrinkled and sometimes not opened
Fingers are placed on top of the envelope
Machine stops while inserting
(stoppage at the inserting point)
Possible cause
Envelope not within specifications
Flap sticks
Flap curled
Separation set too narrow
Fingers adjusted too deep into the envelope
Envelope stops too early
Fingers not correctly adjusted
Inserted document too long for used envelope
Envelope throat incorrect
Remedy
Check specifications and change envelopes if needed
Store envelopes according to specifications
Envelopes stored or manufactured improperly
Check separation settings, adjust if needed
Check fingers position, adjust if needed
Check envelope stop position, adjust if needed
Check fingers position, adjust if needed
Check fold settings
Check envelope specifications
Envelope glued inside Eliminate faulty envelopes
Window not glued properly
Eliminate faulty envelopes
Refer to section
“Technical specifications” on page 48
Envelope specifications
Envelope specifications
Envelope specifications
“Loading Envelopes” on page 13
“Document Settings” on page 24
Envelope specifications
“Technical specifications” on page 48
-
-
46
Symptom
Flap not sufficiently moistened
Possible cause
Water level low
Brushes dry
Envelope not filled properly or envelope flap not closed properly
Brushes dirty Check brushes, clean if needed
Moistening cloth dry Check the moistening cloth, refill water tray if needed
Moistening cloth dirty Check the moistening cloth, clean if needed
Moistening brushes inactive
Activate the moistening brushes
Inserted document too big
Document not inserted deep enough
Check fold settings, adjust if needed
Check adjustment of envelope stop position and fingers
No document fed Feeder empty
Skewed documents fed
Separation set too wide
Side guides set too narrow
Side guides set too wide
Remedy
Check water level, refill if needed
Check brushes, replace if needed by the extra soaked set
Refer to section
“Sealing Envelopes” on page 14
“Sealing Envelopes” on page 14
“Sealing Envelopes” on page 14
“Sealing Envelopes” on page 14
“Document Settings” on page 24
Refill feeder
“Loading Documents” on page 11
Adjust the separation “Document Separation” on page 11
Adjust the side guides
Adjust side guides
“Adjusting Side Guides” on page 11
“Adjusting Side Guides” on page 11
47
10. SPECIFICATIONS
10.1 Technical specifications
Type:
Theoretical max. speed
Inserter system for medium office use
3000 inserts per hour, depending on application
Power consumption:
100V AC / 50 Hz / 5.0 Amps
115V AC / 60 Hz / 5.0 Amps
230V AC / 50 Hz / 2.5 Amps
Fuse
100/115 V AC: T 5.0 A, 125 V. Time lag, 5.0 Amps rated current, 125 V.
230 V AC: T 2,5 A H, 250 V. Time lag, 2.5 Amps rated current,
High breaking capacity, 250V.
Approvals:
EMC Certificate conform EMC-Directive
FCC Certificate conform 47CFR, part 15
CB Certificate conform IEC 60950
UL Listed I.T.E. (Information Technology Equipment), conform
UL-IEC 60950, file E153801
Conform NEN-EN-IEC 60950 and derivates
10.2 Configuration dimensions
Length:
Width:
Height:
765 mm on covers
1120 mm including hopper (90 mm) and collator /doc.hoppers
(265 mm)
1260 - 1360 mm including standard Exit (catch tray)
1200 mm including side exit
460 mm (the optional side exit is 90-195 mm outside side cover)
680 mm
48
10.3 Other general specifications
Noise level
<70 sBA (68 dBa)
Operating temperature 10°C - 40°C
Power requirements
Weight
230V/50Hz (voltage tolerance: +10%/-10%)
115V/60Hz (voltage tolerance: +6%/-10%)
100V/50Hz (voltage tolerance: +6%/-10%)
Whole system: 73 kg
10.4 Document specifications
Paper quality
Paper size
Folding capacity
Envelope sizes
Envelope quality
minimum 60 gr/m² (15 lb bond) maximum 250 gr/m² (62.5 lb bond), when folded max. 170 gr/m² (42.5 lb bond)
Booklets up to approximately 1 mm (0.04 inch) thickness, depending on stiffness
Minimum width: 130 mm (5.1")
Maximum width: 236 mm (9.3"), when folded max. 230 mm (9.1")
Minimum length: 90 mm (3,5"), the minimum document length used for the upper feeder is 115 mm (4.5")
Maximum length: 356 mm (14")
Single fold - 8 sheets (max. 80 gr/m²)
Double fold - 6 sheets (max. 80 gr/m²)
Standard BRE (Business Reply Envelopes) minimum 80 gr/m² (20 lb bond) maximum120 gr/m² (30 lb bond)
49
10.5 Insert specifications
Minimum size mm
A
160
inches 6.3
Maximum size* mm
248
inches 9.7
B
90
3.5
162
6.38
C
32
1.25
D
10
0.4
B-32 35
B-1.25 1.4
E
130
5.1
F
84
3.3
A-12** B-6
A-0.47** B-0.2
G
60 g/ m
2
60 g/ m
2
2.5***
0.1
* Maximum insert specifications are based on single sheets. When multiples are
handled, more room inside the envelope is needed depending on the application.
** When insert is more than 1 mm (0.04 inch): A-15 mm / A-0.6 inch
*** Booklets up to approximately 1 mm (0.04 inch) thickness, depending on stiffness
Remarks:
• The specification of the paper handling equipment is often wider than that of the envelopes and documents handled. The condition of material handled will limit the specified environmental conditions.
• We recommend that materials to be handled are stored at a temperature of 20°C (68°F) with a relative humidity factor of 50%. If difference in temperature occurs between store room and mailing area, the material has to be stored near the machine at least 24 hours before use.
• Self-copying paper may cause rubber parts to wear quicker. The rubber used in this machine has the best resistance to Wiggins Teape material.
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10.6 Terminology
Term Description
Address Carrier The address carrier is the document that carries the address of the person for who the mail-set is meant. The address carrier can consist of one or more sheets, from which at least the first sheet must contain the address. The address must remain visible while enclosures are added and the document-set is folded. The fold type and selected envelope must ensure that the address is visible behind the window in the envelope. For personalized mailings there is always an address carrier present as long as envelope printing is not supported. Normally there is one address carrier.
Address position Position of the address on the address carrier, measured from the upper left corner. The address position consists of a horizontal x coordinate, a vertical y coordinate, a horizontal width w and a vertical height h.
Business Reply
Envelope (BRE)
C-fold
Clear
Daily Mail
Document
Document-set
Envelope included in outgoing mail-sets for addressee response purposes.
See Letter fold.
The function of an inserting system in which all mail-sets in progress are finished and the document path is left empty.
Capability of an inserting system to manually insert mail-sets one by one into the system, which are then inserted into an envelope.
Optionally, depending on settings, additional enclosures can be added and the mail-set can be folded. This function is intended for small amounts of mail that each can have a different build-up.
A document is one of the components of a mail-set. A document can consist of one or more sheets. Documents can be divided into address carriers and enclosures. For personalized mailings there is always one address carrier and an optional number of enclosures.
The document-set is the physical collection of address carrier and enclosure(s) that is under production in the Inserting System. The document-set is completed during production and is to be inserted in the envelope. The number of enclosures can range from 0 to the limit opposed by the number of available Feeders. Once the document set has been inserted into an envelope it is called mail-set.
51
Term
Double Feed
Control (DFC)
Double Parallel fold
Description
Double Feed Control is the sensor that measures the thickness of a sheet to check if the inserting system does not accidentally take more sheets than intended. DFC sensors exist on Feeders (double sheet detection). Currently DFCs on Neopost inserting systems perform relative measurements, which means that they need a cycle to 'learn' the thickness of a sheet.
Also the length of the document is measured so partly overlapping sheets will be detected.
The double parallel fold is a type of fold where the document is first folded halfway and the resulting folded set is again folded halfway.
This fold is illustrated in the picture below. The position of both folds is adjustable.
Envelope
Face down
Face down leading
Face down trailing
The envelope is the packaging of a mail set. Window envelopes are envelopes that have a transparent section through which the address on the address carrier can be read. Besides the normal top-closing window envelopes there are also bottom-closing envelopes.
Situation in which the front of a sheet is facing downwards when placed in a document feeder.
Situation in which the front of a sheet is facing downwards and the top of the sheet is closest to the separation unit in a document feeder.
Situation in which the front of a sheet is facing downwards and the bottom of the sheet is closest to the separation unit in a document feeder.
Face up Situation in which the front of a sheet is facing upwards when placed in a document feeder.
Face up leading Situation in which the front of a sheet is facing upwards and the top of the sheet is closest to the separation unit in a document feeder.
Face up trailing Situation in which the front of a sheet is facing upwards and the bottom of the sheet is closest to the separation unit in a document feeder.
Feeder A Feeder is a Module for the input of documents to the inserting system. The Feeder separates documents sheet by sheet from the stack of documents in the feeder tray.
Feeder linking
Feeder tray
The ability to load two feeders with the same document type where the Inserting System automatically switches to a second feeder when the first feeder is empty and vice versa. In the mean time the first feeder can be refilled, so the inserting system can keep running without having to stop for refilling the feeders.
Part of the feeder that contains the stack of documents.
52
Term
Flexcode OMR
Insert
Job counter
Letter fold
Description
An OMR code for which the meaning of the OMR marks can be programmed in a dedicated way for a specific customer. This is normally used to support the OMR codes from other suppliers.
• An insert is the action of inserting a document-set into an envelope.
Inserter
• For native English speaking customers an insert is also a short, not to be folded document, usually an enclosure.
An Inserter is the Module where the document-set is inserted into the envelope, the envelope is closed and if necessary sealed.
Inserting System The system of all the Modules that cooperate to perform the inserting function (accumulate document-set, fold and insert) and have a single point of control.
Job A job is an actually produced collection of mail-sets based on a certain
Job Definition at a certain point in time for a specific purpose. It consists of:
• The Job definition used for the production
• Information about the batch size
The counter that registers the number of mail-sets that is produced as part of a specific job.
Fold type in which a document-set is folded twice in which the folded flaps are on top of each other. This fold is illustrated in the picture below. The position of both folds is adjustable.
Linking load’n Go
® load’n Go
®
job
MaxiFeeder
TM
Multifeed
OMR
OMR code definition
Operator
Synonym: C-fold.
See Feeder Linking.
The feature of an Inserting System to automatically determine its Job settings by measuring the sizes of documents and envelope. From all
Feeders that are loaded one sheet will be taken. Based on the maximum document length (which is also the length of the documentset) and the length of the envelope the fold type is determined.
A job that is created with the load’n Go
®
functionality.
Feeder with high capacity feeder tray (e.g. 2000 sheets A4 80gr).
The feature of an Inserting System in which more than one sheet is taken from a Feeder.
Standard 1-track OMR code definition.
Specifies the amount of reading marks used and the functionality linked to each of them (how each should be interpreted).
The person operating an Inserting System.
53
Term
Optical Mark
Recognition
(OMR)
Reading error
Description
Optical Mark Recognition is intended for reading and interpreting printed codes. These codes are one or more black marks which are read from a document. These marks give information to the Inserting system about how to build-up and handle a set.
Condition in which the system could not reliably read or interpret the
OMR reading marks from a sheet.
Reading marks
Remote diagnostics
Marks added to documents containing finishing instructions that can be identified by an OMR head and interpreted according to the used
OMR code definition.
The feature that makes it is possible to analyze a problem (on an
Inserting System) from a remote location.
Service engineer Technical engineer whose task it is to resolve problems with systems in the field. Besides dealing with problems, service engineers are also responsible for preventive maintenance.
Single fold A single fold implies the document/set is folded once. The fold-position is adjustable. This fold is illustrated in the picture below:
Stacker
Stop counter
Supervisor
Test run
Tray
Vertical
Transport
Used as storage for filled envelopes.
Optional a horizontal unit can be delivered.
Counter which sets the amount of envelopes to be filled. After filling this amount of envelopes the system will stop (even during a clear).
Person who is responsible for the technical state of the machine.
Normally a supervisor has access to programming functions, which are restricted for standard users.
A test run is intended to validate the settings of the Inserting System:
• Inspect and adjust the stop position of the envelope.
• Check the fold settings for one set.
• Check whether the address is correctly positioned behind the envelope window.
Contains a stack of paper for a printer or inserter. This paper is supplied to the machine for further processing.
The vertical transport section between feeders and collator.
54
Term
Z-fold
Description
A Z-fold means that a document is folded twice in such a way that each folded flaps is on a different size of the folded document, resulting in a Z-shape. This fold is illustrated in the picture below. The position of both folds is adjustable.
Synonyms: zigzag fold
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Key features
Automatic envelope insertion
Document folding
Envelope sealing
Job programming
Load'n Go® feature
Daily Mail function
Optical Mark Recognition (OMR)
Double feed control
Supervisor menu
Detailed specifications
Frequently asked questions
Refer to the "Loading Documents" section on page 11 of the operator guide. It explains how to adjust the side guides, set document separation, and feed documents into the machine.
See the "Job Programming" chapter (page 21) of the manual. It guides you through creating, editing, and copying jobs, which involve configuring envelope settings, document formats, folding options, and other parameters.
The Load'n Go® feature (page 14) automatically adjusts the machine settings for a quick and easy setup. It picks one sheet from each feeder, folds them (if necessary), inserts them into an envelope, and seals it. This feature is ideal for simple insertion jobs.
Refer to the "Fault finding" chapter (page 42). It provides information on clearing stoppages, identifying error messages, and performing operator troubleshooting steps.
The "Specifications" chapter on page 48 lists the technical specifications for the machine, including dimensions, document and insert specifications, and terminology used in the manual.
