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.

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.

2. GENERAL

2.1 Denominations

A B C

T S R Q P O

M J L K J

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,

RS232 connector / USB / modem

Knobs for clearing stoppages T

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

2.2 Function Description

The system consists of the following area’s:

1 flexFeed

Collating area powerFold ®

Envelope feeder

Inserter

6 Operating panel

The flexFeed

is the feeding part of the system. The machine selects documents from the feeders according to the applicable job options.

The documents are collected in the collating area before they are transported to the folding area.

In the powerFold ® , the document(s) are folded according to the job specifications.

The envelopes are picked up and transported to the insert position inside the machine.

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.

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.

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.

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.

5. Press .

The main menu screen 1/2 will be displayed.

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:

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.

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.

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.

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

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.

3.7 load’n Go

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 .

5. After a few seconds, the load’n Go

® appear.

display will

6. Press to load one envelope to the insert position in the machine.

7. The envelope is visible through the window in the top cover.

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 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.

- 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.

Address Position

1. When the envelope position and the position of the fingers is correct, press 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 to make another test run.

5. Recheck the position of the address, and adjust as required.

6. Press to leave this screen to return to the main menu or press the to immediately start the job.

Starting the Job

• Press the

button to start the job.

button to stop the job. The machine will stop immediately.

button

• 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

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.

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.

• 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 to return to the main menu screen

Job selection

Press 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 to confirm the selected job.

3. Press to leave this screen without changing job.

Test Run

Press to display the Test Run screen.

1. Press 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 to load a new envelope into the insert position and check the condition again.

3. Press to confirm the insert position.

4. When the envelope position and the position of the fingers is correct, press

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

- Press the

to leave this screen without changing settings.

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.

Counters

Press

1. Press

to display the Counters screen.

to reset the counters to 0.

2. Press to confirm possible changed settings and to return to the main menu.

3. Press 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.

4. Press to program the stop counter.

5. Enter the number of envelopes that must be processed with the numeric keys.

6. Press to confirm possible changed settings and to return to the previous screen.

7. Press to return to the previous screen without changing settings.

Main Menu 2/2

• 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.

Display Settings

Press screen display.

to change settings for the touch

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 to confirm changed settings.

• Press to return to the previous screen without changing settings.

Job Menu

The 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

Programming” on page 21.

• Press to return to the previous screen without changing settings.

Supervisor Menu

Pressing the settings.

gives access to system

The supervisor menu therefore is restricted and protected by a PIN-code.

The supervisor menu will be described in “Supervisor

Menu” on page 20.

• Press to return to the previous screen without changing settings.

• Press to return to the main menu 1/2.

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

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.

• Press job.

to see the details of a certain

Refer to “Job Information” on page 22.

• Press to create a job from scratch.

Refer to “Create Job” on page 23.

• Press

Job” on page 30.

to change a job. Refer to “Edit

• Press 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 31.

• Press to delete a certain job, which is not longer necessary.

refer to “Delete Job” on page 31.

• Press to return to the main menu.

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).

Shows the type of fold.

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 if reading for the selected feeder is switched ON - or OFF - .

Press to view the reading settings for this job. This button is only available when

Optical Mark Recognition (OMR) or BarCode Reading (BCR) is installed and is switched ON in this job.

Press to return to the main menu screen.

4.3 Create Job

• Press in the Job 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).

• Press to confirm the selected free job number and to go to the following screen or press to return to the previous screen.

Job Settings

After pressing displayed.

the job settings screen will be

The following settings are available:

Envelope settings

Document settings

Fold setting

Reading settings (if installed)

Double feed control settings

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 and name.

to save the job with the entered settings under the specified job number

• Press

to return to the previous screen without saving the entered job.

to perform a test run with the present settings. Refer to page 18.

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.

• 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 to confirm changed settings or press screen without changing settings.

Document Settings

This screen enables the setting of the document formats and the number of documents that must be picked from the different feeders.

to return to the previous

• Press to set the number of sheets for the different feeders.

- Press to select a feeder. The selected feeder will be highlighted.

- 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.

• 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.

- Press to display a numeric keypad to enter the exact dimension of the document.

Press 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

- Press to link two highlighted feeders.

The will be displayed between the selected feeders.

Note

When linking two feeders, the program will automatically equal the number and format of the documents in the selected feeders.

• 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.

• Press to confirm changed settings or press screen without changing settings.

Fold Settings

This screen enables the adjustment of the folding dimensions.

The following choices are available:

No fold (no settings required)

to return to the previous

Single fold

Letter fold

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 to clear the displayed dimension and enter a new dimension.

• Press to confirm changed settings or press screen without changing settings.

to return to the previous

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”)

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.

Reading Settings (Option)

For a full function description, see chapter “Reading

(option)” on page 34.

In this screen it is possible to enable or disable the

Optical Mark Recognition (OMR) or Barcode Reading

(BCR) function and to adjust the basic settings.

• Press to select a pre-programmed OMR or

BCR 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 reading is disabled.

The number of different codes available depends on the installed options.

• Press to enable a numeric keypad and to enter the position of the first reading mark on the sheet, measured from the top. If you selected BCR, a second keypad is available to enter the length of the code.

• Press or to enter the maximum number of sheets in the set of documents.

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 or BCR codes.

to view the programmed OMR

Refer to “Additional codes” on page 37 for a

description of the codes.

• Press to return to the previous reading settings screen.

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 to confirm changed settings or press

to return to the previous screen without changing settings.

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 to clear a character left of the cursor position (backspace).

• Press again.

to clear all entered characters and start

• Press to confirm changed settings or press

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)

• 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.

• When switched ON, pressing on the second will select if 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 .

* Ask your supplier if this option is available in your country, and for your mailing/franking machine.

• When the printed/franking value is determined by the inserter data, after pressing CONTINUE a menu is entered via which the weight of single documents and envelopes and the envelope width can be entered via the

keys.

and

A mailing/franking job can be selected with

• Press to confirm changed settings or press

to return to the previous screen without changing settings.

Refer to the appendix for an extensive description of this option.

4.4 Edit Job

In this function it is possible to edit and change a programmed job.

1. After pressing the 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 to confirm the selected job number and to go to the following screen or press to return to the previous screen.

4. After pressing , 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 in the Jobs

menu (refer to “Job Menu” on page 21), the

screen will show the Copy Job screen.

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).

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 to confirm the selected job numbers and to make a copy or press to return to the previous screen.

4.6 Delete Job

1. After pressing the 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 or press

to delete the selected job number

to return to the previous screen.

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

2. Enter PIN-code 2546 to enter the Supervisor menu.

The following subchapters describe the functions of the displayed buttons.

Refer to “System Info” on page 32.

Refer to “Options” on page 33.

Refer to “Online Services (Option*)” on page 33.

• Press 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.

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 to return to the previous screen.

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.

1. Press 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.

4. Press to confirm the license key and to return to the Options screen.

5. Press 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 paragraph 7.3 “Online Services” for a comprehensive description of the Online Services.

• Press to return to the Supervisor menu without changing settings.

*Ask your supplier if this option is available.

6. READING (OPTION)

6.1 Introduction

The folding and inserting system can be equipped with reading. 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. Two types of codes are available:

• OMR: Optical Mark Recognition

• Barcode

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 must appear at the same location on every page regardless of the actual code length.

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 with OMR, this is checked on each sheet. If the “page n of m” code is used with BCR, the set will be inserted when n equals m.

Both reading options 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

6.3 Document Orientation

Switch ON the reading-function and set the position

of the reading marks as described in “Reading Settings (Option)” on page 27.

Document orientation:

Fold type Type of documents Loading positions no fold first page single fold

1 2

3 letter fold start reading stop reading address

Double parallel fold Address carrier, face up and leading.

3 2

1 last page

(duplex printed) zig-zag fold start reading stop reading address

Address carrier, face down and trailing.

6.4 Reading 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.

Minimum code/basic commands

In case of OMR 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.

In case of BCR the minimum codes are also for accumulate and insert.

Code Position and Free Area

The code must be printed minimally 15 mm (0.59 inch) away from top and 30 mm (1.18 inch) from the bottom of the sheet. Default the first mark from the top is set to 100 mm

(3.9 inch). From the left hand and right hand side 7 mm (0.28 inch) must be kept clear.

The code must appear in the same location and (in case of OMR) have a consistent number of marks on every page.

Code length and height

OMR:

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

8,5 mm

6,3 mm

Line 1

Line 2

Line 3

- 4 lines free space

Line distance may be 2,54 mm (0.1”) to 6,35 mm

(0.4”).

BCR:

The minimal height of the code is 9 mm (0.35 inch).

Code width, character spacing and pitch

8,5 mm

4,2 mm

OMR:

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”)

4,2 mm

Line 4

Line 5

Line 6

- 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”).

BCR:

The minimal thickness of a bar in de code is 0.25 mm (0.01 inch).

Additional codes

When it is required to control more functions in the inserter system, additional codes are available.

The following additional functions are possible via software options:

- divert

- stop

- selective feed from station 1

- selective feed from station 2

- sequence check 4, 2 and 1 (respectivily with

1, 2 or 3 marks in case of OMR)

- parity check mark (even, only OMR)

- safety mark (only OMR)

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

General remarks:

- In case of OMR 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 processed by reading.

- The length of the code and the mark definition is a service setting.

- Other functions are possible via special codes

(Flex codes)

Divert

The machine stops, manually remove the set from the collator. Reset and start again.

Stop

The machine stops, manually remove the set from the collator. Reset and start again.

Selective feed

The machine will selectively feed an enclosure when commanded so.

Sequence check (only OMR)

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 (only OMR)

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.

Safety mark (only OMR)

The 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

Page n of m (only BCR)

BCR uses the code “page n of m” to complete a set. If n is less than m, the sheets are accumulated. If n = m, this is the last sheet of the set and the set will be inserted.

Example of OMR code

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

7. OPTIONS

7.1 MaxiFeeder

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 should be installed at the position of feeder no. 1.

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 forward until it hooks behind the frame axle.

3. Connect the connector A to the socket B.

A B

The maxiFeeder TM is auto-detected by the system when it is switched ON. This makes it easy to switch 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

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.

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

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 reading.

7.3 Online Services

The folding and inserting system can be equipped with Online Services. This option enables the machine to connect to a central server. During the connection data is downloaded to and uploaded from the machine. The machine always initiates the connection, it is not possible to make a connection from outside to the machine. Ask your supplier if this option is available.

Start-Up Online Services

To start-up Online Services:

1. Select from the “main menu (2)”.

2. Enter the PIN-code 2546 to access the supervisor menu.

3. Press .

The “Online Services” menu shows the following functions:

•

: opens the “connection” menu to create a connection to a central server and to view the connection history (see

”Connection” on page 42).

: opens the “messages” menu to view received messages (see

”Messages” on page 43).

: opens the “configuration” menus to change Online Services settings

(see ”Configuration Menu” on page 44).

Connection

The machine makes a connection on fixed times. It is possible that you manually connect the machine to the server. To connect to the server:

1. Press menu.

in the “Online Services”

The display shows the “connection” menu.

2. Press to manually connect the machine to the OLS server.

You can view the status of the connection on the screen. The text on the button changes to

Press to terminate connection with the server.

The “connection” menu shows the following functions:

• : opens the “history” menu to view the connection history (see

”History” on page 43).

• : this button appears when the machine received new messages and opens the “messages” menu (see ”Messages” on page 43).

History

The “history” menu shows previous connections of the machine to the server.

1. Press or connection.

to select a previous

2. Press to view details on selected previous connection.

Messages

After pressing in the “Online Services” menu the display will show messages received from the server. A message has content like a new job or new software.

1. Press or to select a message.

2. Press selected message.

for more information over a

In case a new job or new software can be installed the button appears.

To install a new job or new software:

1. Press .

The “new job” menu or the “new software” menu appears. Press more information on the new job or the new software.

2. Press to install the new job or the new software or press

to reject the new job or the new software.

for

After pressing

•

a confirmation menu opens:

In case of a new job press or

(see 4.3 ”Create Job” on page 23).

to select a free job number

Press menu.

to confirm the selected job number or press to return to message

• In case of new software, press to “installation” menu.

to confirm installation or press to return

After confirming the installation of the new job or the new software the “message” menu appears.

Configuration Menu

After pressing in the “Online Services” menu the “configuration” menu opens. Use this menu to modify the OLS settings.

The menu consists of two screens containing the following functions:

• Dial tone detection on / off

This setting is required if no dial tone is heard during establishing a connection. The default value is on. This setting is relevant to some

PABX telephone switch systems.

Press to switch the dial tone detection on or off.

• Telephone number of server: contact your supplier for the telephone number of the

OLS server.

To change the number: a Press . b Enter the correct number using the numeric keypad. c Press to confirm the new number.

• Prefix: use this function in case you need to dial a certain number or string to access an outside line. a Press .

b Enter the correct prefix using the numeric keypad. c Press to confirm the new number.

• Country: enter the country from where you are dialing.

Select the correct country from a list by pressing

• Date and time: enter the current date and time.

or .

a Press . b Enter the correct date and time using the numeric keypad. c Press to confirm the new number.

• Volume of modem: set the modem volume. a Press or to change the volume of the speaker.

Do not set the volume to zero as the sound of the modem is helpful during remote assistance.

Press to confirm modified settings.

8. MAINTENANCE

Warning

• 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.

• The exit sensors have to be cleaned by using a slightly wetted cotton swab.

Lower exit sensor: insert the wetted cotton swab into the hole and spin once.

Upper exit sensor: insert the wetted cotton swab into the hole for upper sensor and spin once.

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.

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 to reset the error (the error screen will disappear).

Special Errors

• Reading errors (when reading 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.

9.2 Clearing Stoppages

Stoppages can occur in the following area’s:

1 -flexFeed ®

2 -Collating area

3 -powerFold

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 powerFold

and flexFeed

B - Collator plate to reach the collator area.

C - Front cover to reach the envelope track and inserter area.

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

to reset the error and restart the job.

powerFold

Remove stoppages from the powerFold ® as follows:

1. Open the top cover A by pulling up the handle.

2. Remove the documents from the powerFold ® .

3. Close the top cover A.

4. Press to reset the error and restart the job.

flexFeed

Remove stoppages from the flexFeed ® as follows:

1. Open the top cover A by pulling up the handle.

2. Remove the documents from the flexFeed

3. Close the top cover A.

4. Press 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.

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 53

“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

Symptom

Flap is wrinkled and sometimes not opened

Machine stops while inserting

(stoppage at the inserting point)

Possible cause

Envelope not within specifications

Flap sticks

Flap curled

Separation set too narrow

Fingers are placed on top of the envelope

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

Refer to section

“Technical specifications” on page 53

Envelope specifications

“Loading Envelopes” on page 13

“Insert Position” on page 15

“Document Settings” on page 24

Envelope specifications

“Technical specifications” on page 53

Envelope glued inside Eliminate faulty envelopes

Window not glued properly

Eliminate faulty envelopes

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

“Maintenance” on page 46

“Sealing Envelopes” on page 14

“Maintenance” on page 46

“Sealing Envelopes” on page 14

“Document Settings” on page 24

“Insert Position” on page 15

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

10. SPECIFICATIONS

10.1 Technical specifications

Type:

Theoretical max. speed

Inserter system for medium office use

3500 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 60950-1

UL Listed I.T.E. (Information Technology Equipment), conform

UL-IEC 60950-1, file E153801

Conform NEN-EN-IEC 60950-1 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

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)

10.5 Insert specifications

Minimum size mm

160

inches 6.3

Maximum size* mm 248

inches 9.7

3.5

162

6.38

1.25

0.4

B-32 35

B-1.25 1.4

130

5.1

3.3

A-12** B-6

A-0.47** B-0.2

60 g/ m

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.

10.6 Specifications maxiFeeder™

Model

Type

MF-2 high capacity feeder

Theoretical max. speed

see 10.1 ”Technical specifications” on page 53

Power consumption low voltage supplied by the inserter system

Approvals

Height

Width length

Weight

Noise level

Operating temperature

Humidity

EMC Certificate conform EMC-Directive.

FCC Certificate conform 47CFR, part 15.

UL Listed I.T.E. (Information Technology Equipment), conform UL-IEC 60950-1, file: E153801.

Conform NEN-EN-IEC 60950-1 and derivatives.

210 mm (8.3 inch)

285 mm (11.2 inch)

425 mm (16.7 inch)

5.05 kg (11.1 lbs)

see 10.3 ”Other general specifications” on page 54

10°C - 40°C (50°F-104°F)

30%-80%

Max. document height 156 mm (6.1 inch)

Feed tray capacity 1200 sheets 80 gr.

320x Business Reply Envelopes

Document / BRE insert specifications

see 10.4 ”Document specifications” on page 54 and 10.5 ”Insert specifications” on page 55

10.7 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.

Term

Business Reply

Envelope (BRE)

Barcode Reading

(BCR)

C-fold

Clear

Daily Mail

Document

Document-set

Double Feed

Control (DFC)

Double Parallel fold

Description

Envelope included in outgoing mail-sets for addressee response purposes.

Barcode Reading is intended for reading and interpreting printed barcodes. The codes give information to the Inserting system about how to build-up and handle a set.

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.

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 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.

Term

Face down

Face down leading

Face down trailing

Description

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

Flexcode OMR

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.

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.

flexFeed ®

Insert

The flexFeed ® is the feeding part of the system.

• 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

Job counter

• Information about the batch size

The counter that registers the number of mail-sets that is produced as part of a specific job.

Term

Letter fold

Description

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 ®

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.

load’n Go

Multifeed

Operator

® maxiFeeder

OMR

OMR code definition

job

Optical Mark

Recognition

(OMR) powerFold

Reading error

A job that is created with the load’n Go

functionality.

Feeder with high capacity feeder tray (e.g. 1200 sheets, 80 grs). Max. height of documents 156 mm.

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.

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.

The powerFold

can fold up tot 8 pages.

Condition in which the system could not reliably read or interpret the 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.

Term

Single fold

Description

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

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.

Tray

• Check if 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.

Vertical Transport The vertical transport section between feeders and collator.

Z-fold 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

EC DECLARATION OF CONFORMITY FOR ELECTRICAL PRODUCTS

(According to Annex III B of the Low Voltage Directive)

Manufacturer: Neopost Technologies BV

Address: De Tijen 3, 9201 BX Drachten

The Netherlands, herewith declares that the:

DS-70,

• which this declaration refers to, is in accordance with: the conditions of the Low Voltage Directive 2006/95/EC

• and the following Directive:

EMC Directive 2004/108/EC

• and is in conformity with the following harmonised standard(s) or other such specifications:

EN 60950-1 (2001)

EN 55022 (1998)

EN 55024 (1998)

ENV 50204 (1995)

EN 61000-3-2 (2000)

EN 61000-4-2 (1995)

EN 61000-4-3 (1996)

EN 61000-4-4 (1995)

EN 61000-4-5 (1995)

EN 61000-4-6 (1996)

EN 61000-4-11 (1994)

The Netherlands, Drachten, 01-03-2007

F. Bosveld

Managing Director

This is a class A product. In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures.

Note: this equipment has been tested and found to comply with the limits for 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 this 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.

EC DECLARATION OF CONFORMITY FOR ELECTRICAL PRODUCTS

(According to Annex III B of the Low Voltage Directive)

Manufacturer: Neopost Technologies BV

Address: De Tijen 3, 9201 BX Drachten

The Netherlands, herewith declares that the:

MF-2,

• which this declaration refers to, is in accordance with: the conditions of the Low Voltage Directive 2006/95/EC

• and the following Directive:

EMC Directive 2004/108/EC

• and is in conformity with the following harmonised standard(s) or other such specifications:

EN 60950-1 (2001)

EN 55022 (1998)

EN 55024 (1998)

ENV 50204 (1995)

EN 61000-3-2 (2000)

EN 61000-4-2 (1995)

EN 61000-4-3 (1996)

EN 61000-4-4 (1995)

EN 61000-4-5 (1995)

EN 61000-4-6 (1996)

EN 61000-4-11 (1994)

The Netherlands, Drachten, 01-03-2007

F. Bosveld

Managing Director

This is a class A product. In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures.

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.

Annons

TABLE OF CONTENTS

1. HEALTH, SAFETY AND ENVIRONMENT

1.1

Precautions and Safety Issues

Warnings

Safety Precautions

Conventions

1.2

Country specific conditions

Denmark

Japan

Languages

1.3

End of life

2. GENERAL

2.1

Denominations

2.2

Function Description

2.3

Display

3. OPERATING INSTRUCTIONS

3.1

Installation

3.2

Preparation

Document Feeder Trays

Slide and Envelope Catch Tray

3.3

Starting Up

3.4

Loading Documents

Document Orientation

Adjusting Side Guides

Document Separation

Feeding Documents

3.5

Loading Envelopes

Adjusting Side Guides

Envelope Separation

Feeding Envelopes

3.6

Sealing Envelopes

3.7

load’n Go

Using load’n Go

Insert Position

Address Position

Starting the Job

3.8

Daily Mail

3.9

Other Menu Options

Job Info

Job selection

Test Run

Counters

Main Menu 2/2

Display Settings

Job Menu

Supervisor Menu

4. JOB PROGRAMMING

4.1

Job Menu

4.2

Job Information

Job Info

4.3

Create Job

Job Settings

Envelope Settings

Document Settings

Fold Settings

Fold Positions

Reading Settings (Option)

Double Feed Control Settings

Job Name

Mailing/Franking Settings (Option*)

4.4

Edit Job

**Mailing/Franking Settings (Option*)**

**Online Services (Option*)**