Operating Guide
F612/F615
Collator
Contents
1. Introduction
page
1.1 Safety
2
2.1 Connect Power
3
2. Installation
3. Getting to know the collator
3.1 Main components
3.2 The control panel
3.3 Output module
4
5
6
4. Operation
4.1
4.2
4.3
4.4
4.5
4.6
4.7
Load paper
Operating the collator
Adjusting the output module
Bin indicators
Correcting counter and stacker position
Setting the total counter to zero
Programming preset counter
and sheet insertion program
4.8 LED indications, third party device
4.9 Disabling stacker motion
4.10 Collator speed adjustment
4.11 Disengaging bin´s with defective sensors
7
7
8
9
9
9
10
10
11
11
11
5. Maintenance
5.1 Cleaning feed rollers and paper separator pad 12
6. Problem solving
6.1 General problems
13
7.1 Model F612/F615 Specifications
14
7. Specifications
1
Introduction
1. INTRODUCTION
This operator manual describes how to operate the Model F612/F615
Collator as a stand alone unit.
1.1 Safety
General
• Know your equipment, especially how to stop it in the event of an
emergency.
• Never reach into the machine while it is on; always wait until the machine
has come to a full stop.
• Never touch moving parts.
• Keep fingers, long hair, jewellery and loose clothing away from moving
parts at all times.
• Use the equipment only for its intended purpose.
• Don’t remove machine covers. Refer servicing to qualified personnel.
Mains Electrical Connection
In some countries the F612/F615 is supplied with a moulded mains lead.
In other countries, or if the supplied lead is not used, the following information
applies:
1. An approved mains lead for the country concerned must be used.
2. The wires in the supplied mains lead are coloured in accordance with
the following code: Green and Yellow Earth
Blue
Neutral
Brown
Live
3. As the colours of the wires in the mains lead of this equipment may not
correspond with the coloured markings identifying the terminals in your
plug, proceed as follows:
The wire which is coloured green and yellow must be connected to the
terminal in the plug which is marked with the letter “E” or by the earth
symbol
or coloured green or green and yellow.
The wire which is coloured blue must be connected to the terminal
which is marked with the letter “N” or coloured black.
The wire which is coloured brown must be connected to the terminal
which is marked with the letter “L” or coloured red.
2
Installation
2. INSTALLATION
2.1 Connect Power
Plug the collator into a suitable power source. Make sure that the collator is
plugged in securely.
WARNING:
This equipment must be earthed.
The socket outlet should be near to the equipment
and should be easily accessible.
3
The Collator
3. GETTING TO KNOW THE COLLATOR
3.1 Main components
1
5
2
6
7
8
9
3
10
4 left side
front
1
2
3
4
5
6
rear
11
right side
Control panel
Adjustable side guide (in each bin)
Load lever
Power switch
Rear side guide (in each bin)
Bin extension tray
7
8
9
10
11
4
Power cord receptacle
Third party receptacle
Conveyor door
Adjustable stacker guide (side)
Adjustable stacker guide (length)
The Collator
3.2 The control panel
1
8
9
2
10
11
3
4
12
13
14
15
16
5
6
7
1 Double feed or paper jam mode
(Shown by bin indicators - firm light)
2 Door open indicator
3 On-line or Off-line/stacking mode
4 Straight/offset stacking in stacking
mode
Module priority change in On-line
mode
5 Counter display
6 Counter reset button
7 Test calibration button
8 Misfeed or bin empty
(Shown by bin indicators flashing)
9 Clear button conveyor belt transport &
connected unit
10 Bin indicators
11 Stacker full or load lever out of
position
12 Set counter
13 Selection programming mode
14 Preset counter
15 Sheet insertion program (only in
stacking mode)
16 Start & stop button
5
The Collator
3.3 Output Module
1
5
2
6
3
7
4
1
2
3
4
5
6
7
Output module top cover
Paper deflector
Output module adjustment lever
Docking studs
Top cover release device (on each side)
Output module
Output module bracket
6
Operation
4. OPERATION
4.1 Load paper
1
2
3
4
5
6
7
Make sure that the sheets are well fanned to avoid misfeeds or double
feeds.
Align the sheets well to achieve a reliable collating operation and good
stacking result.
Make sure that the ink has dried out well.
Press the load lever downwards to release the bins.
Load the sheets into the bins against the rear side guide.
Move the adjustable side guides up against the sheets until there is no
clearance.
Raise the load lever to actuate the feed rollers.
4.2 Operating the Collator
1
2
3
4
5
6
Set the on/off switch to on position. The counter display will show ”HEJ”
to confirm that the collator is OK.
Select output mode:
- Offset/straight stacking mode.
- On-line mode.
Select stacking mode if set to stacking:
- Straight stacking.
- Offset stacking.
Set the adjustable stacker guide (side) to the selected paper size.
Set the adjustable stacker guide (length) to the paper size.
Press test/calibration button. The collator will adjust the number of bins
used and the paper quality in each bin and is now ready for operation.
Check the result to make sure that it is OK and press start.
If not correct, repeat the test/calibration.
7
Operation
4.3 Adjusting the output module
paper
deflector
The purpose of the output module is to ensure that
the set from the collator is fed correctly to the inserter
document table. To achieve this, the position of the
output module is adjustable to match different paper
sizes and how the set is orientated.
paper
guide
adjustment
lever
output module
bracket
On the output module bracket there is an adjustment
lever and a scale. The adjustment lever can be
placed in five different positions, where a higher
number places the output module closer to the
collator. To change position of the adjustment lever,
first push the output module towards the collator
until it locks in the innermost position.
The recommendations in the table below are
guidelines. The adjustments can vary depending on
paper quality, paper weight etc.
output module locked in the
innermost position
Paper size
Feed direction
Adjustment lever position
A4
Portrait
Output module in innermost
position.
3
A4
Landscape
8.5" x 11"
Portrait
5
8.5" x 11"
Landscape
3
Note: Before moving the adjustment lever, push
the output module towards the collator
until it locks and the adjustment lever
moves freely.
The leading edge of the set should land between
the feeding belts on the inserter document table.
When necessary, adjust the paper deflector.
output module in the outermost
position (adjustment lever in pos. 1)
Change the position of the adjustment lever if:
• The set bounces back, up on the inserter
document table side guide - move the adjustment
lever to a higher number.
• The set stays on the paper guide - move the
adjustment lever to a lower number.
8
Operation
4.4 Bin Indicators
LED Status
Description
Notes
Continuous
light
Double sheet/Jam detect
Can be caused by:
Double sheets
Paper jam
Different paper quality or print
compared to the calibrated set
Reduced paper feeding
capability
Incorrect paper length
(compared to the calibrated
length)
Flashing slow
Misfeed indication
Load/check paper.
If continuous misfeed, clean the
feed rollers (see section 5.1)
Flashing fast
Comes on after the calibration cycle. The
bin sensor that is flashing is incapable of
sensing double sheets but is operational
and still capable of detecting misfeeds.
The other bins are OK and calibrated.
4.5 Correcting counter and stacker position
Step # Description
Action
Notes
1
Press and release "Counter
reset button".
In offset stacking mode
the stacker will cycle
once.
Reduce the total
counter value by 1
set.
4.6 Setting the Total Counter to Zero
Step # Description
Action
1
Press "Counter reset button" and hold
down for more than one (1) second.
To zero the total
counter.
Notes
9
Operation
4.7 Programming preset counter & sheet insertion program
Step # Description
Action
Notes
1
Select program
mode.
Press "Selection programming mode"
until the LED indicating the program to
be set is lit (preset counter or sheet
insertion program).
2
View program mode.
Press "Counter reset button".
3
Program a new
value.
Press "Counter reset button" to
access the last digit.
The display will show
the value flashing.
Press "Selection programming mode"
to change the setting.
Repeat
these
two
steps
Press "Counter reset button" to
confirm the setting and access the
second digit.
Repeat this for the remaining (2) digits
starting with pressing "Selection
programming mode".
After adjusting the last digit, press
"Counter reset button" to confirm the
settings made.
Display shows 000
4.8 LED indications, third party device
LED Indication Description
Continuous
light
On-line mode selected
Flashing
Connected unit stopped
Notes
LED indication,
On-line
10
Operation
4.9 Disabling stacker motion
Step # Description
Action
Notes
1
Disable stacker
motion.
Press and hold down "Straight/offset
stacking" for more than two (2)
seconds.
For handling of
extreme light weight
papers.
2
Reinstate stacker
motion.
Press and release "Straight/offset
stacking".
4.10 Collator speed adjustment
Step # Description
Action
Notes
1
Enter speed
adjustment mode.
Press and hold "Selection
programming mode" for more than two
(2) seconds.
The last bin LED
lights and counter
display shows speed
in sets/h :10
2
Select collating
speed.
Press "Selection programming mode".
The counter will
display the speed in
sets/h :10
3
Confirm adjustment.
Press and hold "Selection
programming mode" for more than two
(2) seconds (the bin LED will go out).
The counter will now
display the counter
value.
4.11 Disengaging bins with defective sensors*
Step # Description
Action
Notes
1
Isolate defective bin
sensors and
disengage these
bins.
Press and hold "Test and calibration"
for more than five (5) seconds.
The electronics check
all bin sensors and
disengages the bins
with defective sensors.
2
Re-engage bins after
correction of the
problem.
Press and hold "Test and calibration"
for more than five (5) seconds.
* This process can also be used to disengage bins with other problems. In this
case the feed roller shaft is removed and a sheet inserted (80 gsm or heavier) in
the bin to cover the bin sensor (simulating a defective sensor). Pressing “Test/
calibration” for more than five (5) seconds will now disengage this bin.
11
Maintenance
5. MAINTENANCE
5.1 Cleaning feed rollers and paper sensor pad
If misfeeding starts occuring more frequently, clean the feed rollers.
If double feeding starts occuring more frequently, clean the separator pads.
1
Remove the feed roller assembly shaft by pressing it to the left side.
The right end of the feed roller assembly will now be released and the
assembly can be removed.
2
Clean the feed rollers and the separator pad with an alcohol based liquid.
paper separator pad
feed rollers
Press to the left
Lift out this side
12
Problems?
6. PROBLEM SOLVING
6.1 General Problems
Problem
Possible causes
Action
The machine is
inoperative and the
letters "HEJ" are not
shown in the display
when the machine is
switched on.
Stacker tray blocked and can not
reach home position.
Switch the machine off. Unblock
tray and switch machine on.
The machine is
inoperative as the
start button is
pressed.
Machine in jam condition.
Clear jam.
Load lever in lower position.
Raise load lever to upper position.
Stacker full.
Empty stacker.
Conveyor door open.
Close door.
Attached units shut down.
Correct problem in third party
device.
Feed rollers need cleaning.
Check/clean (see section 5.1).
Paper separator pad needs
cleaning.
Check/clean (see section 5.1).
Sheets not fanned enough
(ink/powder/cutting burrs etc. will
make this a very important step).
Check/fan sheets.
Paper quality out of
specification.
Check specifications.
Different paper quality or print
impression in the bins since
previous calibration.
Perform calibration cycle.
Mixed sheets (mixed paper
qualities).
Check the sheets.
Machine has accidently entered
service mode.
Switch machine off and then back
on.
Repeated
misfeeds/double
feeds.
Incorrect double
feed/jam indication.
Front panel
commands
inoperative.
13
Specifications
7. SPECIFICATIONS
7.1 Model F612/F615 Specifications
Model F612/F615
Number of bins
6 (F612), 10 (F615)
Bin capacity
Sheet size
Paper weight
20 mm
Min
139 x 210 mm
Max
320 x 450 mm
Min
40* gsm
Max
200* gsm
Adjustable speed
1000/1500/1800/2200/2600/2800/3000/3200/3400/3600
sets per hour
Double feed detection
Yes, sensor in each bin
Misfeed detection
Yes
Empty bin detection
Yes
Paper jam detection
Yes
Stacker full detection
Yes
Set counter
Yes
Preset counter
Yes
Sheet inserting program
Yes
Receiving tray
Offset/straight stacking
Height
700 mm
Width
575 mm
Depth
525 mm
Weight
65 kg
Voltage
230/240V 50Hz
The machine design and specifications are subject to change without notice
*Depending on paper quality and printing method
14
Notes
15
Notes
16
We have made every reasonable effort to assure the accuracy and usefulness
of this guide, however we cannot assume responsibility for errors or omissions
or liability for the misuse or misapplication of our products.
FOR SERVICE AND SUPPLIES:
3001 Summer Street, Stamford,
Connecticut 06926
www.pitneybowes.com
Form No. SDC489 RevB (9-22)
© Pitney Bowes Limited, 2022
Printed in England
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