Page 1
FIRST EDITION
Page 2
1
ENGLISH
TABLE OF CONTENTS
1 Health, Safety and Environment ...................................................... 4
1.1 Precautions and Safety Issues ................................................... 4
2 Functional Description..................................................................... 7
2.1 Overview ...... .................... ...................................................... 7
2.1.1 Feeder (1) .................................................................... 8
2.1.2 Collating Area (2) ............... .. ................. .. .. ................ .. .. 8
2.1.3 Divert (3) ..................................................................... 8
2.1.4 Folder (4) ..................................................................... 8
2.1.5 Inserter (5) .................................................................. 8
2.1.6 Present on Deck (6) ....................................................... 8
2.1.7 Stacker (7) ................................................................... 9
2.1.8 Side exit (8) ................................................................. 9
2.2 Operating Controls ................................................................. 10
2.3 Display Buttons ...................................................................... 11
2.4 Software Description ................. .. .. .. .. ...................................... 11
2.4.1 Main Menu ................................................................... 11
2.4.2 Job Info ...................................................................... 13
2.4.3 Counters ..................................................................... 15
2.4.4 Display Settings ........................................................... 15
2.4.5 Job Menu ..................................................................... 16
2.4.6 Supervisor Menu ............................. .. ........................... 16
3 Operating Instructions .................................................................. 22
3.1 Installation ............................................................................ 22
3.2 Preparation ........................................................................... 22
3.2.1 Document Feed Trays ................................................... 22
3.3 Starting Up ............................................................................ 23
3.4 Loading Documents ................................................................ 24
3.4.1 Document Orientation ................................................... 24
3.4.2 Side Guides ................................................................. 25
3.4.3 Document Separation .................................................... 25
3.4.4 Filling the Document Feed Tray ...................................... 26
3.4.5 Adjustment of the Document Stoppers ............................ 26
3.5 Loading Envelopes .................................................................. 27
3.5.1 Adjusting Side Guides ................................................... 27
3.5.2 Stacker Side Guides ...................................................... 27
3.5.3 Envelope Separation ..................................................... 27
3.5.4 Feeding Envelopes ........................................................ 28
3.6 Sealing Envelopes .................................................................. 28
3.7 Job Selection or AutoSet .......................................................... 28
3.7.1 Using AutoSet .............................................................. 28
3.7.2 Select Another Job ........................................................ 31
3.8 Run the Daily Mail .................................................................. 32
3.9 Create a Job .......................................................................... 33
3.9.1 Job Settings ................................................................. 35
3.9.2 Envelope Settings ......................................................... 35
3.9.3 Document Settings ....................................................... 36
3.9.4 Fold Settings ................................................................ 38
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3.9.5 Optical Mark Recognition Settings (Option) ............ .......... 39
3.9.6 Double Feed Control Settings ......................................... 42
3.9.7 Job Name .................................................................... 43
3.9.8 Exit Select Settings ....................................................... 43
3.9.9 Mailing/Franking Settings (Option) .................................. 44
3.10 Edit a Job .............................................................................. 45
3.11 Copy a Job ............................................................................ 46
3.12 Delete a Job .......................................................................... 46
4 Options.......................................................................................... 48
4.1 Activate an Option .................................................................. 48
4.2 Optical Mark Recognition (OMR) ............................................... 48
4.2.1 Genera l ............................ ............................. .............. 48
4.2.2 Adjustments ................................................................ 49
4.2.3 Document Orientation ................................................... 50
4.2.4 OMR Codes .................................................................. 50
4.2.5 2-track OMR ................................................................ 56
4.3 Online Services ...................................................................... 58
4.3.1 Genera l ............................ ............................. .............. 58
4.3.2 Start-Up Online Services ............................................... 58
4.3.3 Connection .................................................................. 58
4.3.4 Messages .......................... ................. .................. ...... 59
4.3.5 Configuration Menu ....................................................... 60
4.4 Production Feeder ................................................................. 61
4.4.1 Function ...................................................................... 61
4.4.2 Preparations ................................................................ 61
4.4.3 Adjust Side Guides ....................................................... 62
4.4.4 Document Separation .................................................... 62
4.4.5 Feeding Documents ...................................................... 63
4.5 Thin Booklet Feeder
.................. ....................... ...................... .. 63
4.5.1 Installation .................................................................. 64
4.5.2 Operating Controls ........................................................ 65
4.5.3 Side Guide Adjustment .................................................. 65
4.5.4 Document Separation Adjustment .................................. 65
4.5.5 Hopper Capacity ........................................................... 66
4.5.6 Clearing Stoppages ....................................................... 67
4.5.7 Support for Curved Reply Envelopes (option) ................... 67
4.6 Mailing Machine connection ............. .. .. .. .. ................................. 68
4.7 Display Mounted on Inserter Deck ............................................ 68
4.8 Envelope Support ............................................. ...................... 69
4.9 Power Stacker Support ............................................................ 69
4.10 High Capacity Envelope Hopper (EF-4) ...................................... 69
4.11 High Capacity Conveyor Belt (CS-2) .......................................... 70
4.11.1 Installation .................................................................. 71
4.11.2 Operation .................................................................... 71
4.12 Catch tray ............................................................................. 71
4.13 Side Exit on the LH Side .......................................................... 71
5 Maintenance .................................. ......... ....................................... 72
5.1 Operator Maintenance ............................................................. 72
6 Fault Finding.................................................................................. 73
6.1 Error Messages ...................................................................... 73
6.2 Clearing Stoppages ................................................................ 74
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TABLE OF CONTENTS
6.2.1 Exit, Sealing and Inserting Area ...................................... 74
6.2.2 Lower Envelope Track ................................................... 74
6.2.3 Folder ......................................................................... 75
6.2.4 Feeder ........................................................................ 76
6.2.5 Collating Area .............. .. .............................................. 76
6.3 Operator Troubleshooting ........................................................ 76
7 Specifications ..................................... ......... .................................. 80
7.1 Technical Specifications Inserter System ................................... 80
7.2 Configuration Dimensions ........................................................ 80
7.3 Other Specifications ................................................................ 80
7.4 Document Specifications ......................................................... 80
7.5 Envelope and Insert Specifications ............................................ 81
7.6 Specifications Production Feeder ............................................... 82
7.7 Specifications Thin Booklet Feeder
............................................ 83
7.8 Specifications High Capacity Envel ope Hopper ............................ 84
7.9 Specifications High Capacity Conveyor Belt ................................ 84
8 Terminology .................................................................................. 85
Index.............................................................................................. 95
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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.
Warnings
• Disconnect the mains power supply before performing any maintenance.
• If the feed/fold unit and inserter unit have to be physically separated, the operator
should pay attention to the heavy weight of the unit during separation.
• Before connecting check whether the system is suitable for the local mains voltage.
Refer to the type plate.
Safety Precautions
• Only competent personnel should operate this machine.
If incompetent personnel do operate this machine, the m a nufacturer 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, pre f erably close to the machine.
• For safety reason s, it is essential that the machine is con nected to a sock et outlet that
has a protective earth connection.
• Over-current protection in the equipment also relies on the branch circuit protection
(max. 20 A).
• The following part(s) is (are) considered the equipment disconnect device(s):
- Power supply cord plug
- 12-pole connector, located on the right-hand side
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Conventions
Note
A note gives additional relevant information.
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2. FUNCTIONAL DESCRIPTION
The system feeds, folds and inserts documents into envelopes and then seals and stacks
the envelopes. Automatic monitoring ensures the correct number of inserts per envelope.
The machine is a sophisticated folding and inserting system which can process large
quantities of mail rapidly and easily. The system can be operated by means of a user
friendly interface.
The settings of the system (document type, envelope type and fold type) is recorded in
jobs. These jobs can be programmed by an authorized user.
The system is equipped with a variety of special features a s document thickness
detection, programmable jobs, AutoSet, Feeder, double feed control, hopper swap,
multifeed, daily mail, Di vert and Folder.
2.1 Overview
The system consists of the following parts:
1
2
3
4
6
5
7
8
1. Feeder
2. Collating area
3. Divert
4. Folder
5. Inserter
6. Present on deck
7. Stacker
8. Side exit
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8
2.1.1 Feeder (1)
The Feeder is the feeding part of the system. There are two types of feeders available: the
automatic and the special feeder. The automatic feeder does not require any adjustments
for the separation. The Feeder is equipped with double feed control. In this way the
system can detect faulty sets of documents. The Feeder is equipped with cascade mode.
This means that two feeders can be linked as pairs. When the first feeder is empty, the
system switches to the other feeder. Meanwhile the other empty feeder can be refilled
without stopping. It’s also possible to feed multiple documents from one feeder. In this
way more documents can be fed from one station, for example an original and a copy of a
document.
The upper automatic feeder is equipped with a “daily mail” function for processing
documents or sets of documents which cannot be processed automatically (e.g. stapled).
2.1.2 Collating Area (2)
After feeding, the documents are gathered and aligned in the collating area.
2.1.3 Divert (3)
The Divert automatically throws out incorrect sets of documents. In this way the system
does not need to stop. Correct sets will be transported to the Folder unit.
2.1.4 Folder (4)
The Folder unit folds the documents. The following fold types are possible:
•No fold
•Single fold
• Letter fold
• Zig-zag fold
• Double parallel fold
2.1.5 Inserter (5)
After folding the documents are transported to the inserter unit where the documents are
inserted into a waiting envelope. The inserter then seals the envelope (or not) and stacks
them on the stacker. Auto matic monitoring ensures the correct number of inserts per
envelope.
2.1.6 Present on Deck (6)
The documents inserted (or not) can leave the inserter from the upper unit (present on
deck). This can occur when
• Clearing the machine
• Making a test set
• Depending on the OMR (Optical Mark Recognition) code
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2.1.7 Stacker (7)
The documents inserted (or not) are transported to the stacker depending on the
programmed job. The stacker automatically stacks inserted documents.
2.1.8 Side exit (8)
The documents inserted are transported to the side exit depending on the programmed
job. The side exit can be used for sorting and st acking of documents into the catch tra y as
well as transporting to the optional conveyor belt or franking/mailing machine.
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2.2 Operating Controls
U TVW
PQRS
K
L
N
O
H
I
G
C
BA
F
E
D
M
J
Acatch tray
B side exit / stacker unit
C side guides stacker
D power inlet, power switch
E RS232 connector / USB / modem
F unlocking lever for upper unit
G display (operator panel)
H OMR reading head cover
I vertical transport
J hand grip vertical transport cover
K document feed tray
Lcollator arm
M operator manual storage space
NFolder
O locking handle Folder
P handle for manual envelope transport
Q handle for manual envelope transport
R unlocking handle for rollers envelope
track
S water reservoir
T side cover (opened)
U thumb wheel for side guide adjustment
V side guides envelope feed tray
W knob for envelope separation
adjustment
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2.3 Display Buttons
The machine has a graphical touch screen.
There are three buttons mounted at the display:
• A: the clear key
When the clear key is pressed during processing
documents, the system will stop feeding
documents after completing the set. The set will
be inserted resulting in a cleared system which
is ready to process a new job. The envelopes
have to be removed manually if necessary.
When the system is stopped already and the
clear key is pressed, it will process one set of
documents and the system will be cleared.
When a feeder runs empty after the clear key is pressed, an button will be
displayed together with the feeder empty message. By pressing the button
the clear process will be continued ignoring the e mpty feeder.
• B: the start key
When the start key is pressed the system starts processing.
•C: the stop key
After pressing the stop key the system does not stop immediately, but on the first
opportunity while processing. Because of this there can be inc o mplete sets in some
parts of the system.
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.
2.4 Software Description
2.4.1 Main Menu
After starting up, the “main menu (1)” screen will
appear.
The screen shows the selected job number and the
total number of envelopes that have been processed
using this job.
The main menu consists of 2 menus, “main menu
(1)” and “main menu (2)”.
The “main menu (1)” shows 7 different functions:
• : job information (see 2.4.2 ”Job
Info” on page 13): shows job details.
A
B
C
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The job information function is available in all the menus where the button
is shown.
• : go to the “job selection” menu to select another job (see
3.7.2 ”Select Another Job” on page 31).
• : go to the “test run” menu to perform a test run (see ”Perform a T est
Run” on page 32).
• : go to the “counters” menu to reset the counter or to set a stop value
(see 2.4.3 ”Counters” on page 15).
• : go to the “AutoSet” menu to start an AutoSet job (see
3.7.1 ”Using AutoSet” on page 28).
• : rotate display 180°. Only available if the insert’n Frank™ / insert’n
Mail option, level 2 or 3, is installed.
• : go to the “main menu (2)”.
The “main menu (2)” shows 6 different functions:
• : job information (see 2.4.2 ”Job
Info” on page 13): shows job details.
• : change display and volume
settings (see 2.4.4 ”Display Settings” on page
15).
• : go to the “job menu” to create,
edit, copy or delete a job (see 2.4.5 ”Job Menu”
on page 16, only for authorized personnel).
• : go to the “supervisor menu” to change system settings (see
2.4.6 ”Supervisor Menu” on page 16, only for authorized personnel).
• : return to the “main menu (1)”.
• : rotate display 180°. Only available if the insert’n Frank™ / insert’n
Mail option, level 2 or 3, is installed.
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2.4.2 Job Info
To enter the “info-job” menu, press .
The “info-job” menu consists of 3 submenus.
If the optional insert‘n Frank™ is used an extra job
info screen is available: the “insert‘n Frank™ info”
menu, displaying weight information and the
franking job (see 3.9.9 ”Mailing/Franking Settings
(Option)” on page 44).
If the optional OMR is used an extra job info screen
is available: the “OMR settings” menu displaying the
available OMR marks and settings (see 4.2.4 ”OMR
Codes” on page 50).
The “info-job” menus display al l relevant information about the selected job.
To return to the “main menu (1/2)”, press .
The “info-job (1)” menu cont a ins the following information:
Shows the feeders selected to pick documents from (black is selected).
The numbers below this icon indicate the number of sheets that must be
picked from the relevant feeders.
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 indicates that for the relevant feeder the Optical Mark Recognition
(OMR) is switched on (optional).
This sign indicates that the relevant feeder is set for daily mail.
Gives information about the envelope size (ISO format or height in mm).
1
2
3
2
3
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The “info-job (2)” menu co ntains t he followin g extr a
job information:
The “info-loading instructions (3)” menu shows the
way you should load documents (see
3.4.1 ”Document Orientation” on page 24) and
envelopes (see 3.5.4 ” Feeding Envelopes” on page
28).
The example shows the following situation:
• Envelopes: flap down and trailing
• Address carrier in lower feeder (feeder 1), face
up and leading
• Document in other feeder (feeder 2), face up
and leading
Gives information about the exit
settings. The arrow to the left indicates
which envelopes leave from the side exit,
the arrow up indicates which envelopes
are stacked. The example shows exit
settings by batching: 5 envelopes to the
side exit, 5 envelo pes to the stacker. See
3.9.8 ”Exit Select Settings” on page 43.
The sign below this icon shows if the
document double feed detection for the
relevant feeder and (optional) Thin Booklet
Feeder is switched on - or off -
. This icon is also shown at the
inserter. In this case it indicates if the
document thickness detection is
switched on - or off - .
Shows the weight settings.
If this sign is shown sealing is on.
Shows the type of fold. The numbers next to this icon indicate the fold
positions.
Shows the document stopper position.
5
5
b
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2.4.3 Counters
T o enter the “counters” menu, press
from the “main menu (1)”.
The “counters” menu shows the following functions:
• : press this button to reset the
daily job counter and stop counter to zero.
• : press this button to enter a
stop value.
The stop counter is switched off when it is set to
zero. The display will show “Stop at off”.
The stop counter can be set between 0 (switched off) and 9999. The system will continue
until the job counter reaches the stop counter value. The system stops and can be restarted.
Note
The counter settings are job related.
2.4.4 Display Settings
To enter the “display settings” menu, press
from the “main menu (2)”.
The “display settings” menu shows the following
functions:
• : 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.
• Rotate display: press the button to rotate the display 180 °.
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2.4.5 Job Menu
After pressing the button a login
menu opens.
To prevent jobs being edited or deleted without
informing the ‘job owner’, this menu is protected by
a PIN-code. The PIN-code is
2546
.
When a wrong pin code is entered, the cursor is set
to the first number to try again.
After 3 times entering a wrong pin code the display
shows the “main menu (1)” again.
After entering the correct pin code the “job menu”
appears.
This menu enables the creation, deletion and/or
editing of jobs.
The “job menu” shows the following functions:
• : job information (see 2.4.2 ”Job
Info” on page 13).
• : create a job (see 3.9 ”Create a
Job” on page 33.)
• : edit a job (see 3.10 ”Edit a Job” on page 45).
• : copy a job (see 3.11 ”Copy a Job” on page 46).
• : delete a job (see 3.12 ”Delete a Job” on page 46).
• : exit and return to the “main menu (1)”.
2.4.6 Supervisor Menu
After pressing the button a login
menu opens.
Enter the PIN-code 2546 to access the “supervisor
menu”.
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After entering the correct pin code the “supervisor
menu” appears.
This menu enables checking and configuring the
system.
The “supervisor menu” shows the following
functions:
• : shows system information,
like:
- The flex certificate, used for OMR
- The counter since last visit: the counter value since the last service visit
- The last error generated by the system
The screen shows a button : this shows the software ve rsions that are
present in the total system.
• : shows option information and system information:
-The chip ID
-The system ID
- The installed options
For installing new options, see 4.1 ”Activate an Option” on page 48.
• : opens the “job settings” supervisor menu (see ”Job Settings
(Supervisor)” on page 18). From this menu system parameters can be set.
• : opens the “test menu” (see ”Test” on page 20). Use this menu to
test the system.
• : opens the “Online Servic es” menu (opti on, see 4.3 ”Online Services”
on page 58). This screen enables to connect the system to a server and receive
messages.
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Job Settings (Supervisor)
Caution
Job settings normally will be changed by a service engineer only. Therefore first consult
the supplier’s Helpdesk before changing any settings. Changes to the job settings can
result in malfunctioning of jobs.
The “job settings” menu ( supervis or) can be o pened
from the “supervisor menu”. From this menu system
parameters can be set. The “job settings” menu
shows the following fu nctions:
• : opens the “mode menu” to set
the output mode for a job (see ”Mode Menu” on
page 18).
• : opens the “document offset”
menu to set the document offset in a set of
documents for a job (see ”Document Offset” on page 19).
• : opens the “BRE offset” menu to set the BRE offset on or off (see
”BRE Offset” on page 19).
• : opens the “flap closer” menu (see ”Flap Closer” on page 20). Use
this function to improve the envelope sealing process.
Mode Menu
When selecting from the “supervisor menu”
, , the “mode menu”
appears.
In this menu for each of the jobs 1 through 25 and
AutoSet a choice can be made between output
Mode 1 and Mode 2 using the button. Mode 2 is
the default setting.
Mode 1 focuses on the versatility of paper
parameters (paper thickness; document length), i.e.
correct operation under even extreme paper conditions.
Mode 2 focuses on high speed and is achieved as follows:
• During multi feed (more than one page from one feeder) the movement on the
collator is minimal. In mode 1 the divert unit will be used for completing the collating
process (less paper on paper transport).
• During the transportation of a set from the collator into the Folder, the next set is
going into the collator already. This results in temporary overlapping sets with two
different transport directions. In mode 1 the set has left the collator completely before
the next set enters the collator.
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• Anticipation call for the envelope is used. That means that a (folded) set is leaving the
Feeder already before the envelope is ready on the insert position. In mode 1 the
envelope is on the insert position already before the set leaves the Feeder.
It is advised to use Mode 1 with a paper thickness of 65 g/m
2
or less, a document length
of 12 inch (305 mm) or higher, and for situations where Mode 2 is not functioning
properly. In all other cases Mode 2 is advised.
If you select Mode 2, select if the reply envelope has a window or not.
Document Offset
When selecting from the “supervisor menu”
, , the “document
offset” menu appears.
The vertical transp ort of documents fed by the
various feeders is arranged in such a way that the
documents are partially overlapping each other. This
overlapping scheme ensures that the documents are
properly aligned in the collator area.
In the “document offset” menu you can set the
extend to which the documents are not overlapping
each other, i.e. the document offset value. The default value is 50 mm (2.0 inch). The
document offset can be varied between 20 mm (0.8 inch) and 75 mm (3.0 inch).
BRE Offset
When selecting from the “supervisor menu”
, , the “BRE offset”
menu appears.
If a document is longer than the set address fold but
shorter than the envelope height, this document
sometimes will be unnecessarily folded. Under
certain conditions this document can be prevented
from being folded. This can be implemented with the
menu “BRE offset” (BRE means Business Reply
Envelope).
For each of the jobs 1 through 25 and AutoSet an offset can be switched on or off
using the button.
In the case of offset “on ” th e las t docu ment that was added to the set will be shifted from
the rest of the set (offsetting). This document will be held back during a certain distance.
This means that the trailing edge of this upper document leaves the collator at last. This
document will not be folded. During the insertion into the envelope the documents of the
set will be realigned.
The conditions are:
• The feeder that supplies this upper document (BRE) is set to one document per set
(no multi feeding).
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• The document directly beneath this document must be at least 60 mm (2.4 inch)
longer than the BRE.
• The upper document must be longer than the set address fold.
• The folding mode is either single fold or letter fold (no Z-fold).
• The upper document must be shorter than the envelope height.
Note
It is possible to use the BRE offset for a BRE and an enclosure (card) in one set. The extra
condition is that this enclosure is equal to or smaller than the set address fold and should
be placed direct underneath the BRE in the set.
The whole BRE offset is based on friction between documents within a set. Therefore it is
necessary to make use of these conditions to reduce the risk of bad transporting, folding
and inserting.
Flap Closer
When selecting from the “supervisor menu”
, , the “flap closer”
menu appears. Use this function to improve the
envelope sealing process for a job. The offset can be
varied between -20 and 20. If for exampl e the offset
is set to +10 the sealing process will be activated 10
pulses later than initially.
For each of the jobs 1 through 25 and AutoSet
an offset can be set.
Test
The “test menu” menu can be opened from the
“supervisor menu”. Use this menu to check the
system, reset all photocells and execute an OMR
test. The menu consists of the following functions:
• : use this function to check if all
motors, clutches and sensors are correctly
connected. This test derives the status of the
actuators and clutches by briefly activating the
actuators and then measuring the current.
Note
Remove all paper and close all covers before testing.
• : use this function to calibrate all photocells.
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Note
Remove all paper and close all covers before calibration.
• : use this function to ali gn and tes t the OMR readi ng he ad (see ”OMR
Test” on page 21).
OMR Test
The “OMR test” menu can be opened from the “test
menu”. Use this menu to align and test the OMR
reading head (see ”Reading Head Position” on page
49). The menu consists of the following functions:
• : align the OMR reading head.
Put a document with reading marks in the
feeder and press this button.
• : shows the mark quality and the
number of read marks from the last processed document. Also the gain of the OMR
amplifier is shown.
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3. OPERATING INSTRUCTIONS
3.1 Installation
Caution
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.
3.2 Preparation
3.2.1 Document Feed Trays
Place the document feed trays in position:
1. Hold the document feeder slightly inclined as
shown in the figure.
2. Place the front end of the document feed tray
underneath the two black rollers.
3. Move the document feed tray upwards (lifting
the black rollers), until it is possible to ‘hook’ the
feeder into place.
4. Move the document feed tray towards the
machine and move the hooks over the mounting
points (on both sides).
5. Let the document feed tray rest on the machine.
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3.3 Starting Up
To start up the system:
1. Connect the machine to the mains power supply .
2. Use the power switch to switch the machine on.
The power switch is located on the back of the
machine.
The display shows “main menu (1)” (the main
displays are described in 2.4.1 ” Main Menu” on
page 11).
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3.4 Loading Documents
3.4.1 Document Orientation
In case the optional extended Folder is installed, the following feeding rules apply to
documents with bottom address position:
hopper swap two documents document + enclosureone document
Fold type
Type of documents
no fold single fold
letter fold
zig-zag fold
double
parallel fold
Address carrier in top feeder.
Face up and leading.
Address carrier in top linked
pair feeders.
Face up and leading.
Address carrier in top feeder.
Face up and leading.
Address carrier in top feeder.
Face up and leading.
Address carrier in bottom feeder.
Face down and trailing.
Address carrier in bottom linked
pair feeders.
Face down and trailing.
Address carrier in bottom feeder.
Face down and trailing.
Address carrier in top feeder.
Face down and trailing.
hopper swap two documents document + enclosureone document
Fold type
Type of documents
no fold single fold
zig-zag fold
Address carrier in top feeder.
Face up and trailing.
Address carrier in top linked
pair feeders.
Face up and trailing.
Address carrier in top feeder.
Face up and trailing.
Address carrier in top feeder.
Face up and trailing.
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3.4.2 Side Guides
To adjust the side guides it is best to remove the
document feed tray from the feeder as follows:
1. Push handle
A
downwards.
2. Lift the document feed tray upwards to unhook
it and then pull it out from the feeder.
3. Loosen the knob
B
half a turn.
4. Grab the side guides in the middle and push
them apart as far as possible.
5. Put a small stack of documents between the side
guides.
6. Grab the side guides in the middle and push
them towards the documents.
The space between the side guides and the
documents should be such that the documents
have just enough play to move freely.
7. Re-tighten knob
B
.
8. Remove the stack of documents.
9. Replace the document feed tray (3.2.1 ”Document Feed Trays” on page 22).
3.4.3 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 picking up to
much documents from the stack at the same time.
The document separation for the automatic feeders is set automatically. There are no
manual adjustments needed.
A
B
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26
The document separation for special feeders must
be adjusted manually as follows:
1. Push the knob
B
forward until it clicks.
2. Open the left-hand side guide
A
by turning it
downwards.
3. Place a document on the feed tray and slide it
about 60 mm (2.4 inch) into the syst em (turn
the knob
B
counter clockwise if the separation is
set to narrow).
4. Push the document between the separation
rollers, which are behind the rubber paper
pullers.
5. Tu rn the knob
B
clockwise to get more
resistance or counter clockwise to lower the
resistance.
The separation is adjusted correctly when a slight resistance is felt on the document.
6. Pull the knob
B
back again when ready.
7. Close the left-hand side guide.
3.4.4 Filling the Document Feed Tray
Fill the document feed tray as follows:
1. Open the left-hand side guide A by turning it downwards.
The feed rollers will automatically be lifted.
2. Place a stack of documents between the side guides.
3. Turn the left side guide upwards again.
4. Feed the documents (depending on the type of documents and the type of fold) as
shown in 3.4.1 ”Document Orientation” on page 24.
3.4.5 Adjustment of the Document Stoppers
The document stoppers mark the position at which the documents coming from the feeder
turn towards the folding area. The position of the document stoppers is automatically
determined by the system during the job programming.
A B
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Initially the document stoppers are adjusted for
position B. In this position a wide variety of
documents can be handled (max. 297 mm; 11.7
inch) and adjustment is not needed.
When a job is selected in which a different stopper
position has been programmed, the operator has to
put the document stoppers in the correct position as
indicated by the display.
To adjust the stopper position:
1. Lift and hold the collator arm
D
.
2. Squeeze the stopper and pull the front side tab
up.
To replace the stopper:
1. Place the flat back tab into the slotted hole .
2. Push the stopper into position.
Stop position
A
can handle documents up to 148 mm (5.8 inch), stop position B can
handle documents up to 297 mm (11.7 inch) and stop position
C
can handle documents
up to 356 mm (14 inch).
3.5 Loading Envelopes
3.5.1 Adjusting Side Guides
Adjust side guides B by rotating thumb wheel C, 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.
3.5.2 Stacker Side Guides
The side guides of the stacker are adjusted
simultaneously with the en vel ope feeder s ide guides
by turning the thumbwheel
C
. There are no
adjustments needed for stacking the inserted
envelopes.
3.5.3 Envelope Separation
To set the envelope separation:
1. T urn knob
A
counter clockwise until two e nvelopes (flap down and trailing), one on top
of the other, can be moved backward and forward between the rollers without
resistance.
A
B
C
D
C
B
A
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28
2. Turn knob A clockwise until one envelope will pass between the rollers. The bottom
envelope must enter the separator first.
Now the envelope separation is set.
After starting the syst em it m ay occur that more than on e envelope at a ti me is pulled in.
In that case rotate knob
A
a quarter turn clockwise. Repeat if necessary to obtain correct
operation.
3.5.4 Feeding Envelopes
1. Place the bottom envelope between the rollers (flap down and trailing - bottom side of
envelope pointing to the machine).
2. Loosen the stack of envelopes and place the stack on top of the bottom envelope.
3.6 Sealing Envelopes
Note
Refer to 5.1 ”Operator Maintenance” on page 72 as well.
When the sealing of the envelopes is enabled, the
sealing liquid reservoir must be filled.
1. Open the front cover B.
2. Fill the reservoir A to the “Max” level indication
with sealing liquid.
3. Close the front cover B.
Before starting the job, wait approximately 5
minutes for the brushes to moisten.
3.7 Job Selection or AutoSet
When you are ready with the preparations
(paragraph 3.2 to 3.6) continue usi ng the AutoSet
function (see 3.7.1 ”Using AutoSet ” on page 28)
or select another job and perform a test run
(3.7.2 ”Select Another Job” on page 31).
The AutoSet feature determines automatically 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 document-set) and the length of the envelope the fold type is
determined.
3.7.1 Using AutoStart
When AutoSet 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.
Only the feeders that feed successfully will be selected. In the AutoSet job only the
Double Feed Control (DFC) of the upper feeder will be selected (automatically).
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Note
AutoSet cannot be used together with linked feeders, multifeed, daily mail and OMR
functionality.
The function AutoSet is not possible in the no envelopes mode or with usage of
envelopes with open flap. For the envelope exit only the stacker is possible.
Note
Before starting AutoSet, be sure that no documents or envelopes are left in the
machine.
1. Load envelopes.
2. Load the documents face up and leading.
Place the address carrier in the upper feeder.
3. From the “main menu (1)”, press
.
The “AutoSet” menu is displayed.
4. Press to load one envelope to
the insert position in the machine.
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30
Insert Position
Note
This adjustment must only be checked in case of problems or when changing the envelope
type.
1. Lift the unlocking lever of the upper unit and pull
up the upper unit.
The flap folding line must be positioned under
the green indicator
B
. If not, adjust the insert
position as follows:
2. Press on the left or right side of to
adjust the insert positi on to t he left or t he right .
Each button stroke stops the next envelope
0.5 mm (0.02 inch) to the right (earlier) or to
the left (later).
3. Press to load a new envelope
into the insert position.
4. Recheck the insert position, and adjust as required.
If necessary adjust the envelope insert fingers, see ”Adjust the Envelope Insert
Fingers” on page 30.
Adjust the Envelope Insert Fingers
To adjust the envelope insert fingers:
1. Loosen the knurled knob
C
on top of each finger.
2. Adjust each finger so that the tip enters about 5 mm (0.2 inch) into the envelope.
3. Re-tighten the knurled knob.
The fingers can be moved sideways to the desired position.
4. Place the outer fingers about 5 to 10 mm (0.2 to 0.4 inch) from the edges of the
envelope.
Check the position of the insert fingers when changing to a different type of envelope.
Address Position
When the envelope position and the position of the fingers is correct:
1. Press to load a folded sheet into the envelope.
The envelope will not be sealed and ejected to the present on deck location.
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 position.
Each key stroke brings the address 1 mm (0.04 inch) with a maximum of 12 mm
(0.48 inch) lower or higher.
A
B
C
D
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If the required address position is beyond the maximum range of 24 mm (0 .96 in ch),
the AutoSet function can not be used. Use a programmed job instead.
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 (1)” or press the
button to immediately start the job.
Starting the Job
To start a job:
1. Press the button to start the job.
During running the display shows the “inserting” menu.
2. Press the bu tton to stop the job. The machine will stop immediately.
3. Press the button to clear the document path to prepare the machine for a new
job.
When a AutoSet job is defined succes sfu ll y these settings can be st ored into a job. Use
the copy function in the job menu (see 3 .11 ”Copy a Job” on page 46) to store the
settings.
3.7.2 Select Another Job
To select another job:
1. Press to select another
predefined job.
2. Press the arrows to select another job number.
The screen shows the job options of the relev ant
job (see 2.4.2 ”Job Info” on page 13).
3. Press to confirm the selected job.
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32
Perform a Test Run
To perform a test run:
1. Press to display the “test run”
menu.
A message can appear: “Set manual feeding” or
“Set automatic feeding”. In that case:
a Check if the daily mail handle is in the
correct position (see 3.8 ”Run the Daily
Mail” on page 32).
b Correct if necessary.
c Press the button.
d Press again.
The “test run” menu displays.
2. Press to load a new envelope into the insert positi on. This gives the
possibility to check and correct the insert position of the envelope (see ”Insert
Position” on page 30).
3. When the envelope position and the position of the fingers is correct, press
to load a folded sheet in the envelope.
The envelope will not be sealed and ejected to the present on deck location.
When finished testing start t he job (see ”Starting the Job” on page 31).
If you want to test if the job’s weight values are correctly communicate d with t he optional
franking machine, use the button. The envelope will be sealed and
transported to the envelope exit.
3.8 Run the Daily Mail
To process documents or sets of documents, which can not be processed automatic a lly
(e.g. stapled documents), the top feeder is equipped with a daily mail switch.
To switch to the daily mail function:
1. Select a job where the daily mail function has been set to “on”:
- From the “main menu (1)”, press .
- Search for a job with the daily mail function using the arrows. The daily mail
function can be recognized by the icon in the “job info” screen.
- Press to select the job and return to the “main menu (1)”.
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2. Turn left side guide A of the upper tray down.
The Daily Mail handle B will become visible.
3. Move the handle to enable the Daily Mail
function.
4. Turn left side guide A upwards.
5. Place the document or document se t in the
feeder.
If necessary adjust the side guid es (see
3.4.2 ”Side Guides” on page 25).
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 button to stop the job.
9. Turn left side guide A down.
10. Move the Daily Mail handle to th e ‘AUTO’ position to disable the Daily Mail and to
enable the automatic document separation.
3.9 Create a Job
To create a new job:
1. Press from “main menu (2)” (see 2.4.1 ”Main Menu” on page 11).
2. Enter the pin code.
The “job menu” opens (see 2.4.5 ”Job Menu” on page 16).
3. Press .
The “create job” menu appears.
4. Click to create a new job using the job
creation wizard or click (experienced
users only).
If you use the job creation wizard the system
stores the new job under the lowest free job
number.
If you use the advanced way you can manually select a free job number to save the
new job. The screen will show the lowest free job number.
Press the arrows to select a higher or lower free job number (if available).
A
B
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34
5. Press to confirm the selected free job number.
The “job settings” screen opens. The meanin g o f all buttons and settings will be
explained in 3.9.1 ”Job Settings” on page 35.
Note
A new selected job number starts with default settings.
6. Press to save the job with the entered sett ings under the specifi ed job number
and name.
To name a job, see 3.9.7 ”Job Name” on page 43.
7. Press to perform a test run with the new job settings (see ”Perform a
Test Run” on page 32).
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3.9.1 Job Settings
From the “job settings” menu the following settings
are available:
3.9.2 Envelope Settings
In this screen the properties of the used envelopes
must be entered. Also the sealing can be switched
on and off.
In the top of the screen, two selection buttons are
displayed, from which one can be selected. The
selected settings button will be highlighted yellow.
• Press to select an envelope size. Use the
upper button to enter the applicable
dimensions.
It is also possible to select ISO standard envelopes or dimensions in inches (depends
on the installation settings).
The envelope height can be set between 90 mm (3.5 inch) and 162 mm (6.38 inch).
Use the second button to enter the envelope weight. Weight information is used
for selecting exit settings (see 3.9.8 ”Exit Select Settings” on page 43).
Envelope settings (see 3.9.2 ”Envelope
Settings” on page 35)
Document settings (see 3.9.3 ”Document
Settings” on page 36)
Fold settings (see 3.9.4 ”Fold Settings” on
page 38)
Optical Mark Recognition (OMR) settings (if
installed) (see 3.9.5 ”Optical Mark
Recognition Settings (Option)” on page 39)
Double feed control settings (see
3.9.6 ”Double Feed Control Settings” on
page 42)
Job name settings (see 3.9.7 ”Job Name” on
page 43)
Exit settings (see 3.9.8 ”Exit Select
Settings” on page 43)
Mailing/Franking settings (if installed) (see
3.9.9 ”Mailing/Franking Settings (Option)”
on page 44)
Mail Piece Production Control (MPPC)
settings (if installed)
See the appendix operator manual Mail
Piece Production Control
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Use the button to switch automatic envelope sealing on, off or OMR (in case of
an OMR job, see ”Sealing Control” on page 53).
• Press to set a 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.
Note
When no envelopes is selected the exit will be set to stacker.
Note
When no envelopes is selected the s ide guides of the stacker must be adjusted according
to the width of the used documents. Refer to the section 3.5.2 ”Stacker Side Guides” on
page 27 and use a document instead of an envelope.
3.9.3 Document Settings
This screen enables the setting of the docu ment
formats and the number of documents that must be
picked from the different feeders.
• Press to set the number of sheets for the
different feeders.
- Press to select a feeder or the optional
Thin Booklet Feeder. The selected feeder
will be highlighted.
- Press the arrows to change 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.
Note
When a feeder is set to daily mail the number of documents is always 1 and can not be set
in this screen.
Note
The maximum number of sheets per feeder is 25. When folding is us ed th e maximu m se t
thickness is 8 sheets in letter fold and 10 sheets (80 gr./m2) in single fold. When using
Folder and bottom address (see 3.9.4 ”Fold Settings” on page 38) the number of sheets is
limited further.
• 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.
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- Press to display a numeric keypad to enter the exact dimension of the
document.
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 t echnical r anges. The docume nt size can be s et between 90 mm
(3.54 inch) and 356 mm (14 inch).
The default document size setting of a new job is 297 mm (11.7 inch). This is
position B in the collator area.
When the document size is decrea sed in
such a way that an earlier collator stop
position can be used, a screen will be shown
when the button is pressed. When
YES is selected, each time the job is
selected the paper stoppers have to be set
according to the job. When NO is selected
the original stop position will be used.
• 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 apply the number and format of
the documents of the lowest feeder to the other feeder.
Note
When a feeder is selected for OMR the feeder below can not be linked to this reading
feeder. The reading feeder can be linked to a feeder above when it is not selected for
selective feeding.
• Press to enter the setting of the Daily Mail function.
This function enables to process documents or sets of documents, which can not be
processed automatically (see 3.8 ”Run the Daily Mail” on page 32). The feeder that is
fit for the Daily Mail function will automatically be selected.
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38
- Press to enable the Daily Mail function. The icon appears behind the
daily mail feeder. If you press again the Daily Mail function will be disabled.
Note
The daily mail function is only available when OMR is not activated. When daily mail is set
the links to the daily mail feeder will be deselected automatically.
Note
When the daily mail function is selected DFC is not available.
• Press to enter the document weights for all selected feeders. Weight information
is used for selecting exit settings (see 3.9.8 ”Exit Select Settings” on page 43).
3.9.4 Fold Settings
This screen enables the adjustment of the folding
dimensions and the address type.
If the system is equipped with a third fold table and
turning unit (“extended Folder”) th e “fold settings”
menu consists of two parts:
• In the first part you can set the Address type.
You can switch between Top and Bottom using
the button. If you choose Address type
Bottom you only have three possible fold
settings left.
After pressing the button the second fold setting screen opens.
• In the second fold setting screen you can select
the fold type.
The following choices are available:
No fold (no settings required)
Single fold
Letter fold
Double parallel fold
Zig-zag fold
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Except when no fold is required, the display shows a simple diagram of the document wi th
the fold positions. To change the fold positions press next to a fold. Enter the
required position of the relevant fold.
The next table shows possible fold positions:
Note
The display will indicate when entered positions are out of range.
3.9.5 Optical Mark Recognition Settings (Option)
For a full function description of Optical Mark
Recognition (OMR), see 4.2 ”Optical Mark
Recognition (OMR)” on page 48. Flex-OMR is also
optional. Flex-OMR can read customer specific
codes.
In the “OMR settings” menu it is possible to enable
or disable the OMR function and to adjust the basic
settings for OMR.
The first “OMR settings” menu covers the following
settings:
• Code type: default is the se tting “non e”: OMR i s
disabled.
Change the setting using the button. The following codes are possible:
-1-track OMR
- 2-track OMR (only OMR level 5)
Fold type Minimum position Maximum position
Single fold 75 mm (2.95")
25 mm (0.98") (extended
Folder)
Longest document length
minus 25 mm (0.98")
Letter fold First fold 75 mm (2.95")
25 mm (0.98") (extended
Folder)
Longest document length
minus 50 mm (1.97")
Second fold Position first fold plus
25 mm (0.98")
Longest document length
minus 25 mm (0.98")
Zig-zag fold First fold 75 mm (2.95")
25 mm (0.98") (extended
Folder)
Longest document length
minus 100 mm (3.94")
Second fold Position first fold plus
25 mm (0.98")
Longest document length
minus 75 mm (2.95")
Double parallel
fold
First fold 75 mm (2.95")
25 mm (0.98") (extended
Folder)
Longest document length
minus 50 mm (1.97")
Second fold Position first fold plus
25 mm (0.98")
Longest document length
minus 25 mm (0.98")
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- Flex 1-9 for reading customer specific codes (only if flex dongle is installed)
• Read from feeder: press the button to select a feeder to activate OMR on.
• Reverse reading: reverse reading means that the insert mark is on the first page of
the set. The system will detect the end of a set by detecting the first page of the next
set. Because of the feeding and collating principal reverse reading has the following
limitations:
- The last mark of the code should be printed maximall y 85 mm (3.3 inch) from the
top.
- Enclosures and selective e n closures cannot be handled. When a Thin Booklet Feeder
module is added to the system configuration, enclosures and selective enclosures
can be handled with reverse reading.
When reverse reading is used, the reverse reading symbol ( ) is shown in the
“job info” screen.
In case the feeder runs empty, th e last set is still on the collator because the
beginning of the next set could not be detected. In this case the feeder empty
message contains an function. By pressing the button the set on the
collator will be inserted.
Note
Reverse reading is not available in OMR level 0, 1, 2 and 3.
By pressing the button the next “OMR settings”
menu appears. This menu covers the following
settings:
• 1st mark from top: press to set the
position of the first optical mark, measured from
top of the sheet. The value can be varied
between 15 mm (0.6 inch) and 277 mm
(10.9 inch).
• Max. sheets: select the maximum amount of
sheets in the set of documents using the arrow buttons.
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Note
The maximum number of sheets in a set is 25. When the number of sheets exceeds 8 or
10, depending on the fold, the document can not be folded anymore. In this case, the
maximum length of sheets is 156 mm (6.1 inch) for a C5 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 VS:110 wi ll be displ ayed. Aft er remo ving the
set and pressing the button, the machine will start and repeat the process until an
insert or divert mark is encountered, error VS:135 (final set part) will be displayed.
By pressing the button th e next “OMR settings”
menu appears. This menu covers the following
setting:
• Stop on misread: press to set if the
machine should stop or not on misreading an
optical mark.
When “stop on misread” is set to “yes”, the machine
stops after detecting an OMR misreading. The
incorrect set is diverted. After resetting the mac hine,
the final part of the set is also diverted and the system starts processing again. The
diverted set(s) should be checked by the operator.
When “stop on misread” is set to “no” the machine does not sto p after detecting an OMR
misreading. The incorrect set is div erted. The final part of the set is also div erted and then
the machine starts processing again. After detecting 5 OMR misreadings in a row, the
system stops and an error code is generated.
By pressing the button th e next “OMR settings”
menu appears. Select the button to select if an
envelope leaves from the stacker if an OMR-mark is
read or if no OMR -mark is read (space). For the side
exit the opposite applies.
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3.9.6 Double Feed Control Settings
This screen enables to set the Double Feed Control
(DFC) settings for the different feeders on or off and
to set the thickness measurement.
To set the DFC for the different feeders:
1. Press the button to select a feeder or the
optional Thin Booklet Feeder
.
2. Press the button to sw it ch th e DFC on -
or off - .
If the DFC is on you can set Continue on double on or off using the button. If
Continue on double is on (“yes”), the machine will not stop if two sheets are feeded
instead of one. The document-set containing the double sheets will be diverted.
When a job is started, the first document taken per feeder is used for a reference
measurement. When a document is exceeding that reference thickness an error will be
displayed.
Note
When Daily mail is selected, the DFC will be switched off automatically.
To set the th ickness measurement:
1. Press the button to select the inserter area.
2. Press the button to switch the thickness measurement on - or off - .
If the thickness measurement is on you can set the measurement area:
3. Press the button.
4. Set the measurement area using the arrow buttons and press the button.
The standard position of the measurement area is sufficient for a great variety of
documents. Only when using special types of documents, for example small cards, the
position of the measurement area might be adjusted.
When the set thickness is not corresponding the reference v alue an e rror will be displayed.
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3.9.7 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.
1. Enter a job name using the alpha-numeric
keypad.
2. Press to clear a character left of the curso r
position (backspace).
3. Press to clear all entered characters and
start again.
3.9.8 Exit Select Settings
In the “exit select settings” menu it is possible to
change the sorting of filled envelopes that leave the
system. You can choose between three or eight (if
the optional OMR is ins talled) selection criteria. The
screen dump shows the possible settings for an OMR
job.
Possible exit settings are:
• Select the button to set a preferred exit:
change the setting using the button. The
following settings are possible:
- Stacker: if you select stacker you can choose to let the system continue on the
side exit if the stacker is full
-Side exit
• Select the button if you want to create batches. Alternate batches of inserted
envelopes are stacked or leave from the side exit depending on the preset counter.
The batch counter can be set from 1 to 250 in steps of one in se rte d envelop per exit.
Default the batch counter is set to 50 .
• Select the button if you want to select the exit depending on document-set
thickness. Use this menu to select the exit for document-sets that are too thin or too
thick. At the inserter the thickness is measured and compared to a reference
thickness. Depending o n the selection in this menu the envelopes leave from the
stacker or the side exit. The first document-set determines the reference thickness.
• Select the button if you want to select the exit depending on OMR-marks. The
screen shows the selected exit if no OMR-mark is read (space) or if an OMR-mark is
read. The selection is set in the OMR settings, see 3.9.5 ”Optical Mark Recognition
Settings (Option)” on page 39.
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44
• Select the button if you want to selec t the exit depending on if the envelopes are
closed (sealed) or open (not sealed). This selection is only possible with OMR: no
mark (space) means sealed, a mark means not sealed.
• Select the button if you want to select the exit depending on the weight of the
filled envelope. Use the button to select which envelopes will leave from the
stacker and which from the side exit. The reference weight is calculated depending on
the envelope weight and the weight of the inserted document-set. The weight of the
inserted document-set depends on the amount of sheets (OMR). To change the
default reference weight, press the button.
• Select the button if you want to create batches depending on the OMR-marks.
The batch counter can be set from 1 to 250 in steps of one inserted envelop per exit.
Default the batch counter is set to 50. The preferred exit will change if the batch is
complete or an OMR-mark changes.
• Select the button if you want to select the exit depending on the weight of the
filled envelope and OMR-marks. Use the button to select which envelopes will
leave from the stacker and which from the side exit. The reference weight is
calculated depending on the envelope weight and the weight of the inserted
document-set. To change this default reference weight, press the button.
Press the button to see which exit the system chooses, depending on
the weight and the OMR-marks.
3.9.9 Mailing/Franking Settings (Option1)
If this machine is connec ted to a mailing/franking
machine, this option allows you to select the
franking mode.
Press the button to select:
•Pass through
The mailing (franking) machine will let the
envelopes pass through without printing/
franking. Press the button to return to
the “job menu”.
•Franking machine
1. Ask your supplier if this option is available in your country, and for your mailing/franking
machine.
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The mailing (franking) machine will print/frank the envelopes according to the local
mailing (franking) machines settings.
If you press the button a screen appears
in which it is possible to link a mailing (franking)
job to the inserter job. Use the arro w buttons to
select a job. If no link is required, select
“Current job” . Press the button to return
to the “job menu”.
• Inserter data
The mailing (franking) machine wil l pr int/frank
the envelopes according to the weight and size
data communicated by the inserter.
If you press the button a screen appears via which the weight of single
documents and envelopes and the envelope width can be entered. Use the
and buttons to enter these data. Press the
button to return to the previous screen.
To link a ma iling (franking) job to the inserter job, use the arrow buttons to select a
job. If no link is required, select “Current job”. Press the button to return to
the “job menu”.
Refer to the appendix for an extensive description of this option.
3.10 Edit a Job
To edit an existing job:
1. Press from “main menu (2)”
(see 2.4.1 ”Main Menu” on page 11).
2. Enter the pin code.
The “job menu” opens (see 2.4.5 ”Job Menu” on
page 16).
3. Press .
The “edit job” menu appears.
4. Press the arrows if you want to select an other job number.
5. Press to confirm the selected job number.
The “job settings” screen opens. Refer to 3.9.1 ”Job Settings” on page 35 for the
meaning of all buttons and settings.
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46
6. Press to save the job with the entered sett ings under the specifi ed job number
and name.
To name a job, see 3.9.7 ”Job Name” on page 43.
7. Press to perform a test run with the new job settings (see ”Perform a
Test Run” on page 32).
3.11 Copy a Job
To copy existing job settings or AutoSet jobs to a new job:
1. Press from “main menu (2)” (see 2.4.1 ”Main Menu” on page 11).
2. Enter the pin code.
The “job menu” opens (see 2.4.5 ”Job Menu” on
page 16).
3. Press .
The “copy job” menu appears.
4. Press the arrows if you want to select an other
job number to copy from or to copy to.
Note
You can only copy job settings to new jobs.
5. Press for details of the job to copy from.
6. Press to copy the job settings.
If all jobs are programmed the display shows “No more free jobs”.
It is possible to copy an AutoSet job into a job. Before an AutoSet job can be copied
AutoSet must be defined successfully (see 3.7.1 ”Using AutoSet” on page 28).
3.12 Delete a Job
To delete an existing job:
1. Press from “main menu (2)” (see 2.4.1 ”Main Menu” on page 11).
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2. Enter the pin code.
The “job menu” opens (see 2.4.5 ”Job Menu” on
page 16).
3. Press .
The “delete job” menu appears.
4. Press the arrows if you want to select an other
job number.
5. Press for job details.
6. Press . The job will be deleted without a warning.
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4. OPTIONS
4.1 Activate an Option
To activate a new option:
1. From the “supervisor menu” choose .
Software options are enabled using license codes. These l icense 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.
2. Press to activate other software options.
3. Enter the license key code that you received
from the supplier to activate the relevant option
on this machine.
Use the arrow keys to navigate throug h the
entered characters.
4. Press to confirm the license key and to
return to the “options” menu.
5. Switch the system off and on.
4.2 Optical Mark Recognition (OMR)
4.2.1 General
The folding and inserting system can be equipped with Optical Mark Recognition (OMR, 1track or 2-track) or Flex-OMR. 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. With Flex-OMR, the system can also ‘read’ customer specific codes. The system
can be equipped with two reading heads (2-track OMR, see 4.2.5 ” 2-track OMR” on page
56).
The sheets with the printed code are placed in a feeder. Depending on the programmed
code, the other feeders can be used as selective feede r s to add enclosures.
In case of a zig-zag fold, the address has to be printed on the last page of the set. With
the other fold types, the first sheet of a set always contains the address. 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.
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4.2.2 Adjustments
Reading Head Position
The horizontal position of the reading head must be aligned to the same position of the
printed marks on the documents. To align the reading head, proceed as follows:
1. Open the “OMR test” menu from the “Test
menu” (refer to 2.4.6 ”Supervisor Menu” on
page 16).
2. Press to start the alignment
procedure.
3. Put a document with reading marks in the
feeder (either feeder 1 or 2, depending on the
selected job).
4. Press .
The document will be transported to the reading
head position.
5. Open the special OMR reading head cover in the
feeder.
6. Shift the reading head until the red pointer is
positioned exactly above the middle of the
reading marks.
7. Open the vertical transport cover and remove the document.
8. Press to determine the alignment.
9. Press to finish the alignment procedure.
Note
When the reading head is aligned it is possible that paper guides have to be removed and
placed on the other side of the reading head.
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4.2.3 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 39.
Document orientation:
4.2.4 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 quali ty (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.
Fold type
Type of documents
no fold single fold
letter fold
zig-zag fold
double
parallel fold
Address carrier, face up and leading.
Address carrier, face down and trailing.
address
direction
first page
OMR
start reading
OMR
stop reading
address
direction
(duplex printed)
last page
OMR
start reading
OMR
stop reading
1
2
3
3
2
1
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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 (1-track OMR only).
A mark printed on the second line means insert. No
mark on the second line means 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.
Code Position and Free Area
• The code must be printed minimally 15 mm (0.59 inch ) away from top and 20 mm
(0.79 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 have a consistent number of marks on
every page.
• For each additional mark one additional line is necessary.
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 ar ea 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").
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").
Start mark
Insert/accumulate
Line 1
Line 2
Line 3
Line 4
Line 5
Line 6
8,5 mm
8,5 mm
4,2 mm4,2 mm
6,3 mm
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52
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 (divert & continue)
• Stop mark (divert & stop)
• 1 mark: selective feed from station x (max. 6
depending on configuration)
• 1 mark: selective feed from (optional)
Thin Booklet Feeder
• Exit control mark
• Present on deck & continue mark
• Present on deck & stop mark
• Sealing control mark
• 1, 2 or 3 marks: respectively se quence c heck 4,
2 and 1
• 1 mark: parity check mark (even)
• 1 mark: safety mark (1-track OMR only)
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 (Divert & Continue)
The set will be diverted and the system continues.
Stop Mark (Divert & Stop)
The set will be diverted and the system stops indicating error VS:113 (stop mark read).
2-track OMR: the Divert and Stop mark are combined in one mark (see 4.2.5 ”2-track
OMR” on page 56).
Selective Feed Mark
The machine will selectively feed an enclosure when commanded so.
Start mark
Divert & continue
Divert & stop
Insert/accumulate
Selective feed 1
Selective feed 2
Selective feed 3
Selective feed 4
Selective feed 5
Selective feed 6
Selective feed VersaFeeder
Exit control
Present on deck & continue
Present on deck & stop
Sealing control
Sequence check 4
Sequence check 2
Parity (even parity)
Safety mark
Sequence check 1
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Exit Control
The following exit control possibilities are available:
• When the “exit control” mark is printed, sets will be sent to the stacker . When no “exit
control” mark is printed, sets will leave the machine from the side exit.
• When the “exit control” mark is printed, sets will leave the machine from the side exit.
When no “exit control” mark is printed, sets will be sent to the stacker.
Present on Deck & Continue
When the “present on deck & continue” mark is printed, sets will be sorted and leave from
the upper unit. The system does not stop processing.
Note
The envelopes will not be sealed.
Present on Deck & Stop
When the “present on deck & stop” mark is printed special sets will be sorted and leave
from the upper unit. However in this case the system will stop.
Note
The envelopes will not be sealed.
Sealing Control
When the “sealing control” mark is printed, sets will not be sealed. When no “sealing
control” mark is printed, sets will be sealed.
Sequence Check
Sheets in a stack can accidentally get out of sequence or can be missing. This can be
detected by the machine: each sheet has a number that forms part of the reading code.
These are the available possibilities:
• Pages are numbered 1-2-1-2-1-etc. This requires one additional sequence mark.
• Pages are numbered 1-2-3-4-1-2-3-4-12-etc. (see figure). This requires two
additional sequence marks.
• Pages are numbered 1-2-3-4-5-6-7-8-12-3-etc. This requires thre e additional
sequence marks.
1
A
A
B
B
B
C
C
2
3
4
5
6
7
#1
#2
#3
#4
#1
#2
#3
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54
Pages numbered 1-2-1-2-1-etc., one sequence mark used (first
sequence check position)
Pages numbered 1-2-3-4-1-2-etc., two marks used (first and second
sequence check position)
Pages numbered 1-2-3-4-5-6-7- 8-1-2-etc., three marks used (first,
second and third sequence check position)
sheet 1: no mark printed sequence check 1
sheet 2: a mark printed sequence 1
sheet 3: no mark printed sequence check 1
etc.
sheet 1: no mark printed sequence check 2
no mark printed sequence check 1
sheet 2: no mark printed sequence check 2
a mark printed sequence check 1
sheet 3: a mark printed sequence check 2
no mark printed sequence check 1
sheet 4: a mark printed sequence check 2
a mark printed sequence check 1
etc.
sheet 1: no mark printed sequence check 4
no mark printed sequence check 2
no mark printed sequence check 1
sheet 2: no mark printed sequence check 4
no mark printed sequence check 2
a mark printed sequence check 1
sheet 3: no mark printed sequence check 4
a mark printed sequence check 2
no mark printed sequence check 1
sheet 4: no mark printed sequence check 4
a mark printed sequence check 2
a mark printed sequence check 1
sheet 5: a mark printed sequence check 4
no mark printed sequence check 2
no mark printed sequence check 1
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Parity Mark
By adding a parity mark the reading code can be checked. When the 1-track code is used
the sum of the marks has to be even.
Safety Mark (only 1-track 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.
Examples of OMR Code
In the figure the legend for the following example is
shown. In this example feeder station 1 is the
reading feeder. The feeder stations 2 through 6 are
selected for selective feeding.
sheet 6: a mark printed sequence check 4
no mark printed sequence check 2
a mark printed sequence check 1
sheet 7: a mark printed sequence check 4
a mark printed sequence check 2
no mark printed sequence check 1
sheet 8: a mark printed sequence check 4
a mark printed sequence check 2
a mark printed sequence check 1
etc.
Normal paper flow Skewed paper flow
Start mark Start mark
Safety mark Safety mark
reading direction reading direction
accumalate
mark printed
no mark printed
insert
no selective feed
wanted, mark not
printed
selective feed
wanted, mark
printed
or
reading feeder 1
selective feeder 2
selective feeder 3
selective feeder 4
selective feeder 5
selective feeder 6
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56
Example Code
In this example a set of 8 sheets with three s elective
feeds (station 2, 3 and 4) 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, 4 and 5 are reserved for selective
feeding from station 2, 3 and 4. 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 3 is required. Print a
mark on position 5 when a selective feed from
station 4 is required. The marks ar e printed on
the last sheet of the set.
• Position 6, 7 and 8 are used for the sequence check marks. The meaning of the
sequence check marks is explained in section ”Sequence Check” on page 53.
4.2.5 2-track OMR
2-track OMR uses two OMR-tracks to read OMR data from. The main purpose of 2-track
OMR is reliability. The marks on the second track are inverted. This means that when a
mark is read at the first track no mark (space) is expected at the second track. Two track
OMR is only possible when the feeder is equipped with two reading heads and OMR level 5
is installed.
The insert/accumulate and divert (stop and continue) are combined in two marks. The
start mark and safety mark are not available in 2-track OMR.
The table on the next page supplies an overview of the OMR-marks for 2-track OMR. A
stands for the first track, B for the second track.
Sheet 1 Sheet 2 Sheet 3 Sheet 4 Sheet 5 Sheet 6 Sheet 7 Sheet 8
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- = Mark, - = No mark
* In the OMR settings menu the Stacker and Side exit can be swapped
A B A B A B A B
Accumulate/insert
- -
=acc.
- -
=insert
- -
= divert &
continue
- -
= divert &
stop
Divert & Cont./Stop
- -------
Selective feed 1
- -
= Feed from station 1
- -
= Do not feed from station 1
Selective feed 2
- -
= Feed from station 2
- -
= Do not feed from station 2
Selective feed 3
- -
= Feed from station 3
- -
= Do not feed from station 3
Selective feed 4
- -
= Feed from station 4
- -
= Do not feed from station 4
Selective feed 5
- -
= Feed from station 5
- -
= Do not feed from station 5
Selective feed 6
- -
= Feed from station 6
- -
= Do not feed from station 6
Thin Booklet Feeder
- -
= Feed from thin booklet feeder
- -
= Do not feed from thin booklet feeder
Exit control
- -
= Stacker*
- -
= Side exit*
Pres. on Deck and
cont.
- -
= Present on Deck + cont.
- -
= Do not use P. on D.+ cont.
Pres. on Deck and stop
- -
= Present on Deck + stop
- -
= Do not use P. on D.+ stop
Sealing control
- -
= Do not seal
- -
= Seal
01 23 45 67
Sequence check 4
-- -- -- ---- -- -- --
Sequence check 2
-- ---- ---- ---- --
Sequence check 1
----------------
Parity (even parity)
- -
or
- -
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52
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 (divert & continue)
• Stop mark (divert & stop)
• 1 mark: selective feed from station x (max. 6
depending on configuration)
• 1 mark: selective feed from (optional)
Thin Booklet Feeder
• Exit control mark
• Present on deck & continue mark
• Present on deck & stop mark
• Sealing control mark
• 1, 2 or 3 marks: respectively se quence c heck 4,
2 and 1
• 1 mark: parity check mark (even)
• 1 mark: safety mark (1-track OMR only)
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 (Divert & Continue)
The set will be diverted and the system continues.
Stop Mark (Divert & Stop)
The set will be diverted and the system stops indicating error VS:113 (stop mark read).
2-track OMR: the Divert and Stop mark are combined in one mark (see 4.2.5 ”2-track
OMR” on page 56).
Selective Feed Mark
The machine will selectively feed an enclosure when commanded so.
Start mark
Divert & continue
Divert & stop
Insert/accumulate
Selective feed 1
Selective feed 2
Selective feed 3
Selective feed 4
Selective feed 5
Selective feed 6
Selective feed VersaFeeder
Exit control
Present on deck & continue
Present on deck & stop
Sealing control
Sequence check 4
Sequence check 2
Parity (even parity)
Safety mark
Sequence check 1
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The “connection menu” shows the following functions:
• : opens the “history” menu to view the connection history (see
”History” on page 59).
• : this button appears when the machine received new messages and
opens the “messages” menu (see 4.3.4 ”Messages” on page 59).
History
The “history” menu shows previous connections of
the machine to the server.
1. Press or to select a previous
connection.
2. Press to view details on selected
previous connection.
4.3.4 Messages
After pressing in the “Online Service s”
menu the display will show messages received from
the server. A message has content like new s oftware
or a new job.
1. Press or to select a message.
2. Press for more information over a
selected message.
In case new software or a new job can be installed
the button appears.
To install new software or a new job:
1. Press .
The “new software” menu or the “new job” menu appears. Press for
more information on the software or the job.
2. Press to install the new software or the new job or press
to reject the new software or new job.
After pressing a confirmation menu opens:
• In case of new software, press to confirm installation or press to return
to “installation” menu.
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60
• In case of a new job press or to select a free job number (see 3.9 ”Create
a Job” on page 33).
Press to confirm the selected job numb er or press to return to message
menu.
After conforming the installation of the new software or new job the “message” menu
appears.
4.3.5 Configuration Menu
After pressing in the “Online Service s”
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:
aPress .
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.
aPress .
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 or .
• Date and time: enter the current date and time.
aPress .
b Enter the correct date and time using the num eric keypad.
c Press to confirm the new number.
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• 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.
b Press to confirm modified settings.
4.4 Production Feeder
4.4.1 Function
The Production Feeder 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 356 mm (14") length can be processed with it. It is possible to i nstall
two Production Feeders to the system.
4.4.2 Preparations
The Production Feeder sho uld be installed at the
position of feeder no. 1 and / or 4.
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 Production Feeder.
2. Move the Production Feeder forward until it hooks
behind the frame axle.
3. Connect the connector A to the socket B.
The Production Feeder is auto-detected by the system when it is switched on. This makes it
easy to switch over from the standard document feed tray to the Production Feeder and vice
versa.
Note
To allow easier hooking on of the Production Feeder it is advised to put the feeding plate in
the rear position (see 4.4.4 ”Document Separation” on page 62).
To make use of a Production Feeder it is not necessary to (re-)program the jobs.
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62
4.4.3 Adjust Side Guides
Adjust the side guides:
1. Take a stack of documents/BREs and place them
in the feed tray.
BREs with flap down and leading (top side
pointing to machine).
2. Adjust the side guides by turning the thumb
wheel A so the documents/BREs just fit and can
move without resistance.
Too much play causes skewing.
4.4.4 Document Separation
When the Production Feeder is used at an automatic separation feeder, th e separation is set
automatically.
The Production Feeder can also be used on a feeder position with a manually adjusted
separation.
To adjust, proceed as follows:
1. Remove feeders 2 and 3.
Note
The lowest feeder is feeder 1.
2. Squeeze the tw o blue handl es A and B and shift
the feeding plate C as far as possible to the
front.
3. Push knob D forward until it clicks.
4. Place a document/BRE on the feed tray and slide
it in the machine till the leading edge is not
visible anymore. Turn knob
D
counterclockwise if
the separation is set to narrow.
5. Push the document/BRE between the rollers.
6. Turn knob
D
clockwise to get more resistance
and counterclockwise if the separation is set to
narrow.
The separation is adjusted correctly when a
slight resistance is felt on the document/BRE.
7. Pull knob D back when ready.
8. Remount feeders 2 and 3.
A
A B C
D
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4.4.5 Feeding Documents
To feed documents:
1. Squeeze the two blue handles A and B.
2. Shift the feeding plate C 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 syste m starts
processing) until documents/BREs are underneath the rubber paper pullers.
Note
When filling the Production Feeder, make sure that the document/BREs are positioned
parallel in relation to the feed plate to ensure correct feeding.
Note
When longer documents are used, plate C can be extended by pulling out the adjustable
feed plate extension.
4.5 Thin Booklet Feeder
The Thin Booklet Feeder is used to feed booklets,
regardless of the thickness of the cover, to the
document flow from the feeder to the inserter.
Because of the location of the Thin Booklet Feeder
(downstream the feeder modul e) docume nts fe eded
by the Thin Booklet Feeder will not be folded.
When the Thin Booklet Feeder
is added to the
configuration this is shown in the screens at the
display. The figure shows an example.
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64
4.5.1 Installation
Warning
• Always switch off the system before connecting to, or disconnecting from any
attached units.
Attaching to an Inserter
When installing the Thin Booklet Feeder directly to the
inserter, install the module in the following manner :
1. Disconnect the inserter connecting cable from
the feeder.
Put the connecting cable to the right hand side
of the feeder.
2. Lift the feeder and uncouple it from the inserter.
Move the feeder to create enough space for the
Thin Booklet Feeder.
3. Place both hands under the left and right-hand
side panel of the Thin Booklet Feeder.
4. Lift the Thin Booklet Feeder above the fixing plates and lower it until it locks into place.
Both sides are now locked.
5. Place both hands under the left and right-hand side panel of the feeder module.
6. Lift the feeder above the Thin Booklet Feeder
fixing plates and lower it unt il it locks into
place. Both sides are now locked.
Connection Cable
1. Connect the 12-pole conne ctor of the inserter to the 12-pole socket located on the
right-hand side of the feeder.
2. Connect the 12-pole connector of the Thin Booklet Feeder
to the 12-pole socket of the
feeder.
Power Inlet
The power inlet is located on the right-hand side of the feeder and contains the main fuse.
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ENGLISH
4.5.2 Operating Controls
A Separation adjustment wheel
BSide guides
C Hopper side guide adjustment thumbwheel
D Release handle separation unit
E Release handle feed unit
F Feed unit push down area
4.5.3 Side Guide Adjustment
The side guides can be adjusted manually as
follows:
1. Place a stack of documents into the feeder.
2. Adjust the hopper side guides
B
by turning the
thumbwheel
C
.
Provide just enough space for the documents to
move freely. Too much play causes skewing.
4.5.4 Document Separation Adjustment
Note
Check before the adjustment that the release handle D for the separation unit is in the
closed (down) position.
The document separation can be adjusted manually
as follows:
1. Turn the separation adjustment wheel
A
counter
clockwise until a document can be moved
backwards and forwards without resistance.
2. Turn the separation adjustment wheel clockwise
until a slight resistance is felt on the document
when the document is moved backwards and
forwards.
When adjusting the document s eparation take into acc ount the tensi ve force
of the separation rollers.
C
B
A
D
E
F
C
B
A
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66
Turn the separation adjustment wheel clockwise to get more resistance or counter
clockwise to lower the resistance.
Check the separation before starting the system. After starting the system it may occur
that more than one document at a time is pulled in. If this happens, turn the separation
adjustment wheel more clockwise to obtain correct operation. For poor feeding turn the
separation adjustment wheel counter clockwise.
4.5.5 Hopper Capacity
To avoid irregular feeding there are three levels for the maximum heights of the hopper
capacity . The symbols for these three levels are printed on the right hand side guide of the
hopper. The level indication is a guideline.
Maximum hopper capacity for single shee ts: minimum sheet qual ity: 80
gr/m
2
(maximum height: 50 mm).
Maximum hopper capacity for booklets with a weak cover (maximum
height: 150 mm).
Maximum hopper capacity of booklets with a tough cover (maximum
height: 250 mm).
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4.5.6 Clearing Stoppages
When a document is blocked in the separation unit
the document can be removed as follows:
1. Open the release handle for the separation unit
(D).
2. Remove the documents.
If necessary release the feed unit:
1. Place your hand on the push down area
F
.
2. Push down the release handle
E
.
3. Open the feeder.
The documents can be removed from the
transportation area and from the rear side of the
separation rollers.
4. Close the feed unit:
a Place your hand on the push down area
F
.
b Push the feed unit down until it locks into
place.
5. Place release handle
D
of the separation unit in
the closed position.
6. Press at the inserter to reset the error
and restart the job.
4.5.7 Support for Curved Reply
Envelopes (option)
Depending on the quality of the paper , the conditions
during storage, etc. envelopes can be curved. This
can cause smaller reply envelopes to skew while
being processed by the Thin Booklet Feeder
.
A special support is available to allow curved
envelopes to be correctly processed. It can be used
for envelopes with a height up to 110 mm (4.33").
C
B
A
D
E
F
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68
To attach the support onto the hopper platform:
1. Hold the support as indicated by the figure.
2. Place both notches
C
at both sides into the
sleeves.
3. Lower the other end of the support. It will lock
fully into place.
To adjust the support:
1. Loosen knob
B
slightly by turning it
counterclockwise.
2. Move both parts of the support in or outwards
until the ruler indicates the height of the
envelope (the side of the plate
A
is indicator).
3. Turn knob
B
clockwise to tighten the support.
4.6 Insert’n Frank™ (insert’n Mail)
If this machine is connected to a mailing/franking machine, insert’n Frank™ allows you to:
• Switch automatic mailing/franking on or off
• Remotely select a mailing/franking job
• Set the printing/franking value (option)
• Automatically set the printing/franking value using the inserter data
For programming this option refer to 3.9.9 ”Mailing/Franking Settings (Option)” on page
44.
4.7 Display Mounted on Inserter Deck
The inserter can be equipped with a display mounted
on top of the inserter deck. This display can be
pushed down and rotated 180°. In this way
operators standing on the other side of the system
also can operate the machine.
C
B
A
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ENGLISH
4.8 Envelope Support
Depending on the quality of the paper , the conditions
during storage, etc. envelopes can be curved. This
can cause smaller envelopes to skew while being
processed.
A special support is available to allow curved
envelopes to be processed correctly. It can be used
for envelopes with a height up to 114 mm (4.49
inch).
4.9 Power Stacker Support
Depending on the inserted type and amount of
documents, the filled envelopes may get stack fanshaped at the stacker.
To prevent this, an optional power stacker support
can be used in order to stack the envelopes
correctly.
4.10 High Capacity Envelope Hopper
(EF-4)
For feeding large amounts of envelopes a high
capacity envelope hopper can be installed.
To start up the high capacity envelope hopper:
1. Switch on the hopper.
2. Put an envelope in the envelope height
measurement area.
3. Rotate thumbwheel A to adjust the envelope
height setting. The envelope should fit exactly in
the space indicated by the arrows.
4. Rotate thumbwheel B to adjust the side guides
so, that the envelopes:
- Fit exactly between the side guides
- Can move freely
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70
5. Fill the envelope hopper with envelopes,
positioned upside down. The flaps should face
the inserter (flap leading).
6. Tip over the envelopes.
7. Load the envelope feeder of the inserter with
about 50 envelopes.
8. Press the green start button.
The envelopes on the envelope hopper will be
transported towards the feeder of the inserter.
Envelopes will be transported and dropped in
the inserter feeder until the envelopes reach a
certain level. At that moment a sensor will
detect the envelopes and the high capacity
envelope hopper will stop transporting.
When the sensor does not detect envelopes anymore the hopper will start again and
the process will be repeated.
4.11 High Capacity Conveyor Belt (CS-2)
The high capacity conveyor belt is designed for envelope transport from the inserter or
franking device. The conveyor belt has two operation modes:
• The belt moves continuously.
• The belt moves in intervals. The belt moves about 45 mm (1.7 inch) each time a
sensor detects the passage of an envelope.
The guide plate and side guides prevent the envelopes from falling off the belt.
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4.11.1 Installation
To install the high capacity conveyor belt:
1. Move the conveyor belt to the correct position.
2. Connect the adaptor C to the connecting lead.
3. Connect the mains lead cable to the adapter.
4. Connect the mains lead cable to the socket outlet.
4.11.2 Operation
The conveyor belt switch has three positions:
•Mode D: the belt moves in intervals.
•Mode E: the belt is switched off.
•Mode F: the belt moves continuously.
4.12 Catch tray
For stacking envelopes leaving from the side exit a catch tray can be mounted.
4.13 Side Exit on the LH Side
In stead of a side exit at the right hand side of the system it is also possible to install a
side exit on the left hand (LH) side.
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72
5. MAINTENANCE
Warning
• Disconnect the mains power supply before performing any maintenance.
5.1 Operator 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.
Maintenance
frequency
Maintenance
Daily • 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.
Weekly • 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 ho les 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.
Note
When finished cleaning the sensors always calibrate the sensors
(see ”Test” on page 20).
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ENGLISH
6. FAULT FINDING
6.1 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 Optical Mark Recognition is enabled)
The document set is diverted. The operator must remove the document set and has to
complete the set manually!
• Technical errors
The display shows a message. The erro r cannot be solved by oper ating 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”.
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74
6.2 Clearing Stoppages
Stoppages can occur in the
following areas:
A Exit, sealing and inserting
BLower envelope track
CFolder
D Feeder
ECollating area
F Thin Booklet Feeder
(optional, not in
figure), see 4.5.6 ”Clearing
Stoppages” on page 67
6.2.1 Exit, Sealing and
Inserting Area
When a stoppage occurs in the exit, sealing and
inserting area, remove the material as follows:
1. Open cover
A
.
2. Remove all material.
3. Close the cover.
4. Press to reset the error and restart the
job.
6.2.2 Lower Envelope Track
When a stoppage occurs in the lower envelope trac k,
remove the envelopes as follows:
1. Open the side cover.
2. Pull down the blue handle
A
and remove the
envelope(s) from the lower envelope track.
3. Close the side cover.
4. Press to reset the error and restart the
job.
EDCBAA
A
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ENGLISH
If needed, envelopes and documents can be transported manually to the insert table or
lower envelope track by means of handle
C
. To transport an inserted document manually
turn handle
B
.
6.2.3 Folder
When a stoppage occurs in the Folder, remove the
documents from the Folder as follows:
1. Push the lower end of the locking handle
A
to
open the Folder cover
B
.
2. Remove the documents from the Folder.
Note
If necessary use the delive red pin to turn the rollers.
Do not forget to remove the pin when finished.
3. Close the Folder cover.
4. Press to reset the error and restart the
job.
A
B
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76
6.2.4 Feeder
When a stoppage occurs in the Feeder, remove the
documents from the Feeder as follows:
1. Pull the vertical transport hand grip A upward to
open the vertical transport cover B.
2. Remove the documents.
3. Close the vertical transport cover B.
4. Press to reset the error and restart the
job.
6.2.5 Collating Area
When a stoppage occurs in the collating area,
remove the documents from the collating area as
follows:
1. Lift and hold the collator arm
A
.
2. Remove the documents.
3. Lower the collator a rm.
4. Press to reset the error and restart the
job.
6.3 Operator Troubleshooting
To resolve problems:
1. Write down the error.
2. Try to solve the problem by consulting the troubleshooting table.
3. Switch the inserter off and on again, to verify system operation.
4. When the error still occurs contact your service organization.
B
A
A
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77
ENGLISH
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 2.4.6 ”Supervisor Menu” on page 16.
Symptom Possible cause Remedy Reference
The system
cannot be started
after switching
on.
System not
connected to mains.
Connect the system
to the mains.
-
Fuse is blown. Replace fuse below
power switch.
-
A cover is opened. Close the covers. -
System stops with
envelope at insert
position (flap not
open).
Envelopes stacked
reversed in the feed
tray.
Check envelope feed
adjustments. Place
envelopes correctly
in feed tray.
“Loading Envelopes” on
page 27
Envelope flap sticks. Store envelopes
according to
specifications.
“Envelope Settings” on
page 35
Wrong envelope type
used (not according
specifications or job
settings).
Change envelopes
according to
specifications.
“Envelope Settings” on
page 35
Envelopes are
double fed.
Envelope separation
not correctly set.
Adjust envelope
separation.
“Envelope Separation”
on page 27
Envelopes not placed
properly in the feed
tray.
Check and replace if
needed.
“Loading Envelopes” on
page 27
Envelope stop
skewed.
Side guides of the
envelope feed tray
are set too wide.
Check side guides
and adjust if needed.
“Loading Envelopes” on
page 27
Envelopes are fed
irregularly.
Feed tray almost
empty.
Refill feed tray. “Loading Envelopes” on
page 27
Separation set too
narrow.
Adjust envelope
separation.
“Envelope Separation”
on page 27
Side guides set too
narrow.
Check side guides
and adjust if needed.
“Loading Envelopes” on
page 27
Envelope support not
positioned correctly.
Reposition the
envelope support.
“Loading Envelopes” on
page 27
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78
Flap is wrinkled
and sometimes
not opened.
Envelope not within
specifications.
Check specifications
and change
envelopes if needed.
“Document
Specifications” on
page 80
Flap sticks. Store envelopes
according to
specifications.
“Document
Specifications” on
page 80
Flap curled. Envelopes stored or
manufactured
improperly.
“Document
Specifications” on
page 80
Separation set too
narrow.
Adjust envelope
separation.
“Envelope Separation”
on page 27
Fingers are placed
on top of the
envelope.
Fingers adjusted too
deep into the
envelope.
Check fingers
position, adjust if
needed.
“Insert Position” on
page 30
Envelope stops too
early.
Check envelope stop
position, adjust if
needed.
“Insert Position” on
page 30
System stops
while inserting
(stoppage at the
inserting point).
Fingers not correctly
adjusted.
Check fingers
position, adjust if
needed.
“Insert Position” on
page 30
Inserted document
too long for used
envelope.
Check fold settings. “Fold Settings” on
page 38
Envelope throat
incorrect.
Check envelope
specifications.
“Envelope Settings” on
page 35
Envelope glued
inside.
Eliminate faulty
envelopes.
-
Window not glued
properly.
Eliminate faulty
envelopes.
-
Symptom Possible cause Remedy Reference
Page 80
79
ENGLISH
Flap not
sufficiently
moistened.
Water level low. Check water level,
refill if needed.
“Sealing Envelopes” on
page 28
Brushes dry. Check brushes,
replace if needed by
the extra soaked set.
“Sealing Envelopes” on
page 28
Brushes dirty . Check brushes, clean
if needed.
“Operator Maintenance”
on page 72
Moistening felt dry. Check the mo istening
felt, refill water tray
if needed.
“Sealing Envelopes” on
page 28
Moistening felt dirty. Check the moistening
felt, clean if needed.
“Operator Maintenance”
on page 72
Moistening brushes
inactive.
Activate the
moistening brushe s .
“Sealing Envelopes” on
page 28
Brushes worn out. Replace brushes. “Operator Maintenance”
on page 72
Moistening felt worn
out.
Replace moistening
felt.
“Operator Maintenance”
on page 72
Envelope not
always ejected
from sealer.
Inserted document
too big.
Check fold settings,
adjust if needed.
“Fold Settings” on
page 38
Document not
inserted deep
enough.
Check adjustment of
envelope stop
position and fingers.
“Insert Position” on
page 30
Sealing area dirty. Clean sealing area. “Operator Maintenance”
on page 72
No document fed. Feeder empty. Refill feeder. “Filling the Document
Feed Tray” on page 26
Separation set too
wide / too tight.
Adjust the
separation.
“Document Separation”
on page 25
Side guides set too
narrow.
Adjust the side
guides.
“Side Guides” on
page 25
Skewed
documents fed.
Side guides set too
wide.
Adjust side guides. “ Side Guides” on
page 25
Double
documents fed.
Separation set too
wide.
Adjust the
separation.
“Document Separation”
on page 25
Document
stoppage at
collating area.
Stopper position set
incorrect.
Adjust stopper
position.
“Adjustment of the
Document Stoppers” on
page 26
Symptom Possible cause Remedy Reference
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80
7. SPECIFICATIONS
7.1 Technical Specifications Inserter System
7.2 Configuration Dimensions
7.3 Other Specifications
7.4 Document Specifications
Type folder and inserter system for medium office use.
Theoretical max.
speed
4300 inserts per hour, depending on application.
Power consumption 100V AC/50Hz/4.0 Amps.
115V AC/50/60Hz/4.0 Amps.
230V AC/50Hz/2 Amps.
Fuse 100/115 Vac: T 5.0 A, 125 V
Time lag, 5.0 Amps. rated current, 125 V.
230 Vac: T 3.15 A H, 250 V
Time lag, 3.15 Amps. rated current, high breaking capacity,
250 V
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 derivatives.
2 stations 4 stations 6 stations
Height
Width
Length
820 mm (32.3 inch)
460 mm (18.1 inch)
(with catch tray 750 mm/
29.5 inch)
1500 mm (59.1 inch)
820 mm (32.3 in ch) 920 mm (36.2 inch)
Weight 118.5 kg (261 lbs) 124.2 kg (274 lbs) 140.0 kg (308 lbs)
Noise level <70 dBA (according to ISO 11202)
Operating temperature 10°C - 40°C (50°F-104°F)
Humidity 30%-80%
Paper quality minimum 60 g/m² (15 lb bond)
maximum 250 g/m² (62.5 lb bond), when folded max. 170 g/
m² (42.5 lb bond)
Booklets up to approximately 2 mm (0.08 inch) thickness,
depending on stiffness
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ENGLISH
7.5 Envelope and Insert Specifications
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 c onditions.
Paper size Minimum width: 130 mm (5.1")
Maximum width: 242 mm (9.5"), when folded 230 mm (9.1")
Minimum length: 90 mm (3.5")
Maximum length: 356 mm (14.0")
Folding capacity Single fold - 10 sheets (max. 80 g/m²)
Letter fold / Z-fold - 8 sheets (max. 80 g/m²)
Double parallel fold - 4 sheets (max. 80 g/m²)
Envelope sizes Standard BRE (Business Reply Envelopes)
Envelope quality minimum 80 g/m² (20 lb bond)
maximum 120 g/m² (30 lb bond)
A B C D E F G
Minimum size mm 160 90 32 10 - 84
60 g/m
2
inches 6.3 3.5 1.25 0.4 - 3.3
60 g/m
2
Maximum size* mm 248 162 B-32 75 A-12** B-6 2.5*
inches 9.7 6.38 B-1.25 2.9 A-0.47** B-0.2 0.1
* Booklets up to approximately 2 mm ( 0.08 inch) thickness, depending on stiffness
** When insert is more than 1 mm (0.04 inch): A-15 mm / A-0.6 inch
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82
• 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 .
7.6 Specifications Production Feeder
Model MF-1
Type high capacity feeder
Theoretical max.
speed
see 7.1 ”Technical Specifications Inserter System” on page 80
Power consumption low voltage supplied by the inserter system
Approvals EMC Certificate conform EMC-Directive.
FCC Certificate conform 47CFR, part 15.
UL Listed I.T.E. (Information Technology Equipment),
conform UL-IEC 60950, file: E153801.
Conform NEN-EN-IEC 60950 and derivatives.
Height
Width
length
210 mm (8.3 inch)
285 mm (11.2 inch)
425 mm (16.7 inch)
Weight 5.05 kg (11.1 lbs)
Noise level see 7.3 ”O ther Specifications” on page 80
Operating
temperature
10°C - 40°C (50°F-104°F)
Humidity 30%-80%
Feed tray capacity 1200 sheets A4 80 gr.
320x Business Reply Envelopes
Document / BRE
insert specifications
see 7.4 ”Document Specifications” on page 80 and
7.5 ”Envelope and Insert Specifications” on page 81
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ENGLISH
7.7 Specifications Thin Booklet Feeder
Model VF-3
Type booklet feeding device for medium office use
Theoretical max.
speed
see 7.1 ”Technical Specifications Inserter System” on page 80
Power consumption 100V AC/50Hz/2.0 A
115V AC/50/60Hz/2.0 A
230V AC/50Hz/1 A
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 derivatives.
Height
Width
length
407 mm (16.0 inch)
440 mm (17.3 inch)
500 mm (19.7 inch)
Weight 30.5 kg (67.2 lbs)
Noise level < 68 dB(A) =/- 2 dB(A) following ISO 7779 / DIN EN 2779
part 7
Operating
temperature
10°C - 40°C (50°F-104°F)
Humidity 30%-80%
Paper quality, feed
unit
minimum 80 g/m² (15 lb bond) single sheets (max. 500 sheets)
Booklets up to approximately 2.5 mm (0.09") thickness
Paper quality,
transport unit
minimum 60 g/m² (15 lb bond)
thickness up to 3.2 mm (0.13")
Document size Minimum width: 120 mm (4.7")
Maximum width: 243 mm (9.6")
Minimum length: 90 mm (3.5")
Maximum length: 162 mm (6.4")
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84
7.8 Specifications High Capacity Envelope Hopper
7.9 Specifications High Capacity Conveyor Belt
Model EF-4
Type High Capacity Envelope Feeder (HCEH)
Power consumption 24V-1A max.
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 derivatives.
Height 200 mm (7.9 inch)
Width 375 mm (14.8 inch)
Length 670 mm (26.4 inch)
Weight 22 kg (48.4 lbs)
Operating
temperature
10°C - 40°C (50°F-104°F)
Humidity 30%-80%
Envelope sizes see 7.5 ”Envelope and Insert Specifications” on page 81
Feeder capacity max. 1000 envelopes
Model CS-2
Type High Capacity Conveyor Belt (HCCB)
Power consumption 24V-1A max.
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 derivatives.
Height
Width
length
440 mm (17.3 inch) (including support legs)
315 mm (12.4 inch)
1310 mm (51.6 inch)
Weight 19,5 kg (42.9 lbs)
Noise level approx. 62 dB(A), following ISO 11202
Theoretical max.
speed
between 20 mm/s and 150 mm/s
Operating
temperature
10°C - 40°C (50°F-104°F)
Humidity 30%-80%
Document / envelope
size
Minimum length 80 mm (3.2 inch)
Maximum width 260 mm (10.2 inch)
Max. capacity to be
transported
1000 envelopes. with a maximum weight of 5 kg (11 lbs)
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ENGLISH
8. 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 th e address is v isible be hind 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)
Envelope included in outgoing mail-sets for addressee response
purposes.
C-fold See Letter fold.
Clear The function of an inserting system in which all mail-sets in progress
are finished and the document path is left empty.
Daily Mail 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, additiona l en closures 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.
Document 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.
Document-set 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.
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Double Feed
Control (DFC)
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 Formax 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.
Double parallel
fold
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.
Extended Folder
Option, makes bottom address applications and short folds possible.
Face down Situation in which the front of a sheet is facing downwards when
placed in a document feeder.
Face down
leading
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.
Face down
trailing
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 feed tray.
Feeder linking 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.
Term Description
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ENGLISH
Feed tray Part of the feeder that contains the stack of documents.
Flexcode OMR 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.
Feeder
The Feeder is the feeding part of the system.
Insert • An insert is the action of inserting a document-set into an
envelope.
• For native English speaking customers an insert is also a short ,
not to be folded document, usually an enclosure.
Inserter 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 t he Modules that cooperate to perform the inserting
function (accumulate documen t-s et, fold and insert) and have a single
point of control.
Insert‘n Frank™
(mailing
machine)
Interface for the Neopost franking machine.
Divert
To avoid stoppages the Divert diverts duplicate on faulty documents
before folding them while the system is still running.
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
Job counter The counter that registers the number of mail-sets that is produced as
part of a specific job.
Letter fold 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.
Synonym: C-fold.
Linking See Feeder Linking.
AutoSet
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.
AutoSet job A job that is created with the AutoSet functionality.
Production Feeder Feeder with high capacity feed tray (e.g. 2000 sheets A4 80gr).
Term Description
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Multifeed The f eature of an Inserting System in which more than one sheet is
taken from a Feeder.
OMR Optical Mark Recognition
OMR code
definition
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).
Operator The person operating an Inserting System.
Optical Mark
Recognition
(OMR)
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.
Folder
The Folder can fold up tot 10 pages.
Reading error Condition in which the system could not reliably read or interpret the
OMR reading marks from a sheet.
Reading marks Marks added to documents containing finishing instructions that can
be identified by an OMR head and interpreted according to the used
OMR code definition.
Remote
diagnostics
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 engineer s are also
responsible for preventive maintenance.
Single fold A single fold implies the document/set is folded once. The f old-position
is adjustable. This fold is illustrated in the picture below:
Stacker Used as storage for filled envelopes.
Stop counter Counter which sets the amount of envelopes to be filled. After filling
this amount of envelopes the system will stop (even during a clear).
Supervisor 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.
Test run 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.
Thickness
detection
Checks the thickness of the document set. If the thickness is less or
more than the set value an error message is displayed.
Term Description
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ENGLISH
Tray Contains a stack of paper for a printer or inserter. This paper is
supplied to the machine for further processing.
Thin Booklet Feeder
Booklet feeding device for medium office use.
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 flap 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
Term Description
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ENGLISH
Index
A
address carrier 85
address position 30, 85
B
batch 43
BRE offset 19
brush 28
brush replacement 72
business reply envelope 85
button 11
C
calibrate photocell 20
catch tray 10, 71
cleaning 72
clear button 11, 31
collating area 8
collator arm 10
configuration 60
configuration dimensions 80
connection 58
connection history 59
contrast 15
conveyor belt, high capacity 70
counter 15
cover
side 10
D
daily mail 32, 85
daily mail handle 33
daily mail settings 37
date online services 60
DFC
continue on double 42
settings 42
diagnostics 20
dial tone detection 60
display 10
contrast 15
on inserter deck 68
rotate 12, 15
settings 15
Divert 8, 87
document 85
feed tray 10
height 36
offset 19
orientation 24
separation 25
settings 36
specifications 80
stopper 26
document orientation
extended Folder 24
normal 24
OMR 50
document stoppage
see stoppage
document-set 85
double feed control 8, 86
double feed control settings 42
double feeding 77, 79
double parallel fold 86
E
envelope 86
feed 28
insert position 30
load 27
no envelope mode 36
quality 81
sealing 28
separation 27
settings 35
size 35, 81
specifications 81
envelope feeder
side guides 27
envelope hopper, high capacity 69
envelope support 69
error messages 73
errors
reading errors 73
technical errors 73
exit select settings 43
extended Folder 86
F
face down 86
face down leading 86
face down trailing 86
face up 86
face up leading 86
face up trailing 86
feed
document 26
envelopes 28
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feed tray 87
installation 22
feeder 86
automatic 8, 25
install 22
link 37
load 26
remove 25
side guides 25
special 8, 26
feeder linking 86
AutoSet 28, 87
fill water reservoir 28
flap closer 20
flex certificate 17
Feeder 8
Flex-OMR 48
fold
C 85
double parallel 38
letter 38
none 38
single 38
zig-zag 38
fold settings 38
Folder 8
franking
settings 44
franking machine 68
fuse 80
H
high capacity envelope hopper 69
I
insert 87
insert position 30
insert specifications 81
insert’n Frank 68
inserter 8
installation 22
J
job 87
copy 46
counter 87
create 33
delete 46
edit 45
info 13
job menu 16
name 43
new 33
select another 31
settings 35
settings (supervisor) 18
start 31
L
letter fold 87
loading envelopes 27
M
Mail Piece Production Control 35
main menu 11
maintenance 72
Production Feeder 61, 87
document separation 62
feed documents 63
installation 61
side guides 62
message 59
mode menu 18
modem 10
modem volume 61
MPPC 35
multifeed 88
N
noise level 80
number of sheets 36
O
offset
BRE 19
document 19, 20
OMR 88
1-track 39, 48
2-track 39, 56
adjustments 49
align heads 49
codes 50
description 48
document orientation 50
Flex-OMR 48
reading head position 49
reverse reading 40
settings 39
test 21
OMR reading head door 10
online services 17, 58
operating controls 10
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ENGLISH
operating instructions 22
Optical Mark Recognition
see OMR
option
activate 48
information 17
license code 48
other job 31
overview 7
P
paper quality 80, 83
paper size 81
photocell calibration 20
power consumption 80
power stacker support 69
power switch 10
R
reading head position 49
RS232 connector 10
S
safety 4
seal envelopes 28
sensor dusty 72
set automatic feeding 32
set manual feeding 32
side cover 10
side exit 10, 71
single fold 88
software description 11
software version 17
speed 18
stacker 10, 88
side guides 27
start button 11, 31
starting the job 31
stop button 11, 31
stop counter 88
stoppage 74
collating area 76
exit 74
Feeder 76
inserting area 74, 78
lower envelope track 74
Folder 75
sealing area 74
Thin Booklet Feeder
67
supervisor menu 16
system ID 17
system info 17
T
technical specifications
high capacity conveyor belt 84
high capacity envelope hopper 84
inserter 80
Production Feeder 82
Thin Booklet Feeder
83
telephone number 60
test menu 20
test run 32, 88
thickness detection 42, 88
touch screen 11
tray 89
troubleshooting 76
U
USB 10
V
Thin Booklet Feeder 63
curved reply envelope 67
document separation 65
hopper capacity 66
installation 64
side guide adjustment 65
volume acoustic signals 15
W
water reservoir 10
Z
Z-fold 89
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