Formax 7102, 7102XT User Manual
7102 Series / 7102XT Series
High-Capacity Modular Inserter Systems
11/2014
OPERATOR MANUAL
Table of Contents
Introduction ...................................................................................................11
Introduction.......................................................................................................1
Safety notes ...................................................................................................32
Safety notes.....................................................................................................3
Description of machine ................................................................................73
Description of operation...................................................................................7
Identification of parts........................................................................................8
Control Panel ...............................................................................................104
The Job Screen..............................................................................................10
The Run Screen.............................................................................................11
The Menu Screen...........................................................................................20
Running an existing job .............................................................................215
Running an existing job..................................................................................21
Switching the user ......................................................................................236
How to switch the user...................................................................................23
User Access Rights........................................................................................24
Creating a job ..............................................................................................267
Creating a job.................................................................................................26
Creating the Job Settings...............................................................................26
Creating an envelope.....................................................................................45
Creating a document......................................................................................47
Creating an enclosure....................................................................................50
Loading the paper hoppers ........................................................................518
Loading the envelope hopper.........................................................................51
Loading the feeder hopper.............................................................................54
Loading the tower folder hoppers...................................................................56
Daily Mail (Tower Folder)................................................................................66
Adjusting the catch tray..................................................................................69
Operator Maintenance ................................................................................709
Cleaning the sensors......................................................................................70
Clearing paper jams.......................................................................................78
Technical Specification ..............................................................................8110
Inserter head..................................................................................................81
Tower Folder...................................................................................................84
Insert Feeder..................................................................................................86
Feeder Folder.................................................................................................87
Mechanical & Electrical..................................................................................88
Glossary of terms .......................................................................................9111
Glossary of terms...........................................................................................91
Introduction1
Introduction
With this inserter you have an advanced, medium-volume folding and inserting machine.
Its modular construction allows multiple feed units to be fitted, with a maximum of 17 feed
units for 7102XT and 9 feed units for 7102. Its sophisticated software control optimises
the order and flow of documents for collating at the insert head before insertion into the
envelope. All fold and adjustments take place automatically according to the requirements
programmed in by the operator.
In order to ensure the long usage of this machine and its components, and above all the
safe use of the machine, you must read and adhere to the operating instructions and safety
notes. Always be aware of all warnings and notes that are mounted or noted on the machine
itself.
All persons entrusted with the handling of this machine must also be familiar with the
operating manual.
Save this handbook carefully, so that the information it contains may be available at all
times.
Pictograms
General Warnings
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Warning of danger from electricity or electrical shock
Information / Note indicating important information regarding the handling of the machine.
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Notes on the use of this handbook
This document contains all general information and explanatory text necessary in order to
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be able to carry out the operation of the machine.
When some action is expected from the operator, this will always be explicitly stated, and
where relevant, accompanied by an illustration or graphic.
Always read through each step, so that you will obtain all of the necessary information. Do
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not anticipate what you believe will follow in the handbook: It will prevent you from making
mistakes!
Chronology and Reference
This handbook is structured chronologically, and therefore ordered sequentially for the
operationally ready machine. It assumes that the machine has been installed in the correct
environment by an Authorised Service Engineer and that the operator or his or her supervisor
has had a degree of operator training.
When you are unfamiliar with the machine, it is best to read through the handbook from
beginning to end. You will be guided step by step, and in this way you can easily and quickly
have the machine in operation.
If you are already familiar with the machine, it will make things easy if you use this handbook
as a reference work.
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Safety notes2
Safety notes
For your own safety and the operating safety of the machine, read the following notes
carefully before starting your machine. Always be aware of all warnings and notes that are
mounted or noted on the machine itself. Save this handbook carefully, so that the information
it contains may be available at all times.
The machine is of advanced construction and reliable in operation. Nevertheless, the device
does present hazards when operated by untrained personnel. The same applies to use
that is inappropriate and not in keeping with its intended purpose.
In not adhering to this handbook, there is the danger of
• An electrical shock.
• Injuries from the intake at the rotating rollers.
• Damage to the machine.
To stop the machine in an emergency, open any cover.
General safety notes
Please, read these notes with care.
Save these instructions for later use.
All notes and warnings found on the machine are to be followed.
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Installing the machine
The machine must be installed only by an Authorised Service
Engineer.
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A safe, level position is necessary, when installing the machine, with sufficient space all
round to operate it. The machine is to be protected from moisture. If moving the machine,
ensure that the castor brakes are off, and push on the stand, not the machine.
Ensure there is at least 1 metre of free space between the operator side of the machine
and a wall or barrier. To provide access to the mains switch, the opposite side of the machine
must be at least 150mm from a wall or barrier. Do not place surrounding furniture or other
objects where your path may be obstructed.
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Electrical danger
The machine may only be connected to a voltage of 230V/50Hz or 115V/60 Hz,depending
upon model.
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The mains plug may only be connected with a socket having an installed protective contact!
The protective effect will be compromised by the use of an extension line without a protective
grounding conductor. All interruptions of the protective grounding conductor, within or
outside of the machine, are prohibited. The device is double pole fused! When fuse failure
occurs, electrical machine parts can still carry voltage. When making the connection to the
mains power, be aware of the connection values on the nameplate. Inspect the voltage
setting on the device’s power input module. Run the supply lines in such a way, that no-one
may trip over them. Do not place any objects upon the supply line. When the machine is
not in use over a long period of time, it should be disconnected from the power supply. In
this way, damage would be prevented in the event of excess voltage. Protect the device
from moisture. When moisture enters the machine, there is the danger of electrical shock.
Never open the machine except the top cover. For reasons of electrical safety, the machine
may only be opened by authorized Service Agents.
Operating safety
Never reach into the machine when it is running! This could only occur if a safety interlock
were to fail.
The danger of injuries exists, through pulling in and crushing on the rotating rollers. In
addition, keep long hair and parts of loose clothing far from the machine in operation. If a
safety interlock fails, your Service Agent must be contacted immediately!
In order to prevent damage to the machine, only factory authorized accessory parts should
be used.
Cleaning the machine
Prior to cleaning the exterior of the machine, it should be disconnected from the power
supply. When cleaning the machine, do not use liquid or spray cleaners, but only a cloth
dampened with water.
Cleaning sensors
When cleaning sensors use only non-flammable airdusters.
Other types may use flammable propellants, which could result in fire or explosion.
Allow machine to be checked by the Service Technician
In the following cases, the mains plug must be unplugged and the device left for the
authorized Service Technician:
• When the mains cable or plug is worn or damaged.
• When water or other liquid has entered the device.
• When the device does not function properly, in spite of following the instructions
provided.
• When the device has fallen down or the housing is damaged.
• When there are noticeable differences in the normal operation of the machine.
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Spare Parts
When repair work is carried out, only original spare parts or spare parts corresponding to
the original parts may be used.
Repairs
Do not disassemble the machine any further than is described in this handbook. Other than
the top cover, the opening of the machine by unauthorized personnel is not permitted.
Repairs may only be carried out by an authorized Service Technician.
Modification is not permitted:
For safety reasons, your own reworking and modifications are not permitted.
Please contact your Service Techncian, for all questions relating to
service and repair. In this way, you ensure the operational safety
of your machine.
End of life
The objectives of the European Community’s environment policy are, in particular, to
preserve, protect and improve the quality of the environment, protect human health and
utilise natural resources prudently and rationally. That policy is based on the precautionary
principle and principles that preventive action should be taken, that environmental damage
should as a priority be rectified at source.
Separate collection of waste is the precondition to ensure reuse and recycling of waste
that is generated at the disposal of electrical or electronic equipment and is necessary to
achieve the chosen level of protection of human health and the environment in the European
Community.
More particularly, certain materials and components of waste electrical and electronic
equipment needs selective treatment as their injudicious handling or disposing of on or into
land, water or air would represent a major threat to the environment and human health.
In order to facilitate collection and treatment separated from normal domestic waste,
electrical and electronic equipment is marked with the following logo:
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Not only are you by law not allowed to dispose of the waste equipment via other
wastestreams, but we encourage you to actively contribute to the success of such collection
and to the common good and better quality of life of present and future generations.
For more information on the correct disposal of this product please contact your local dealer.
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FCC Compliance
This equipment has been tested and found to comply with the limits
for a Class B digital device, pursuant to Part 15 of the FCC Rules.
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This equipment generates, uses and can radiate radio frequency energy and, if not installed
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and used in accordance with the instructions, may cause harmful interference to radio
communications. However there is no guarantee that interference will not occur in a particular
installation.
If this equipment does cause harmful interference to radio or television reception, which
can be determined by turning the equipment off and on, the user is encouraged to try to
correct the interference by one or more of the following measures:
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to which the
receiver is connected.
• Consult the Technical Support department for help.
These limits are designed to provide reasonable protection against
harmful interference in a residential installation.
Changes or modifications not expressly approved by the party
responsible for compliance could void the user’s authority to operate
the equipment.
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Description of machine3
Description of operation
The function of the machine is to fold forms to ‘C’, ‘Z’, ‘V’ or double forward fold, either
singly, in fixed multiples or in varying groups. Enclosures such as inserts, BR envelopes
etc. may be added. Folded forms and enclosures are collated in the collation area in the
inserter head before insertion into the envelope. Forms may be inserted without sealing
the envelope for subsequent checking or hand insertion.
There is a batch processing facility, allowing a preset number of cycles to be completed
before the machine automatically stops.
The machine is OMR/Barcode/2D compatible for use with a reading feeder or tower folder,
allowing a group of forms to be collated on the track prior to folding. A number of barcode
symbologies may be read.
The machine consists of a number of modules, depending upon the build ordered - these
modules are briefly described below:
• Inserter head - Collates all documents in a pocket before insertion, feeds the
envelope, inserts the pack and seals the flap.
• Feeder - Feeds shortform inserts (cards, BR envelopes, booklets etc.) onto the track
for subsequent insertion. Available with single or twin feed hoppers. An
OMR/Barcode/2D version is also available.
• Feeder Folder - Track mounted folder for folding document inserts. Fitted with a
2-plate folder mechanism for C, Z or V folds. Single hopper only.
• Tower Folder - Mounts at the end of the machine. Folds documents either separately
or in groups, using an accumulator if required. Fitted with either a 1 x 1000, 3 x 500
or 1 x 1000 plus 1 x 500 sheet trays. Uses a 3-plate folding mechanism. An
OMR/Barcode version is also available (top or bottom read).
The machine is equipped with PC controlled operating software from where jobs can be
programmed and run. The number of jobs that can be programmed is limited only by the
capacity of the PC. Input is via touchscreen monitor.
A daily mail function can be used as an optional feature on a flex folder or versatile feeder.
This allows groups of documents, stapled or loose, to be hand-fed; they will then be folded
and inserted into an envelope (flex folder only). If other hoppers are loaded, further forms
can be collated.
No manual setting of the fold plates or envelope closer is required, these being adjusted
automatically according to the settings in the selected program.
The envelope output conveyor replace a standard receiving tray, and can be installed
in two possible orientations, straight-on or at a 90-degree angle to the system.
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Identification of parts
The main parts of the machine are shown below.
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1. Envelope feeder
Holds up to RU800 envelopes (;7). Fitted with aVHQVLQJ conveyor
that operates ondemand to move the envelope stack forward.
2. Touch-sensitive monitor
Runs the IMOS operating software and responds to button pushes.
3. Collation and insertion area
Folded forms, either singly or in groups, are collated here into one pack, along with
enclosures. The pack in then inserted into the envelope.
4. Feeders/Folders
These are track mounted units, with an end-station variant also available. Up to 17
feed trays for a ;7 for a may be fitted.
The feeder (single or twin) feeds enclosures such as inserts, flyers, BREs etc. The
hopper holds up to 1000 inserts. A reading variant for OMR/ BCR/2D is
also available, as is a feeder folder for long documents.
5. Tower Folder
This is a folder unit and is only available as an end module. It can be fitted to the
insertion head on its own, or in conjunction with feeders. It is fitted with various options
of feedWUD\V and an accumulator (see following page).
6. Feed Trays
Fitted to the Tower Folder. 3 options available: 3 x 500-Tray, 1 x 500 with 1 x
1000-Trays & 1 x00-Tray; all variants can be mark reading as an option.
7. Accumulator
$WWDFKHG to the Flex Tower and allows groups of forms to be collated together before
folding as a group.,W is also fitted with a diverter tray
8. Closer/Eject Area
This is where the envelope flap is closed and sealed before ejected the filled envelope
into a receiving tray or onto a conveyor.
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Items 1, 2, 3 & 8 are all part of the Insertion Head Unit.
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Control Panel4
The Job Screen
This is the screen displayed when the machine starts up.
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See Running an Existing Job on page 21 for running an existing
job directly from this screen.
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The Run Screen
The Run Screen displayed
This is the screen you will see after an existing job has been selected in the Job Menu.
* This button closes down the IMOS operating software - it does not switch the machine
off.
To change the current user or job, click on the buttons and you will be presented with a list
of all those that have been created, and allow you to select any one. Note that to change
to a different user will require the appropriate password to be entered. To view and adjust
the settings for the envelope and document inserters, click on the relevant part of the
machine graphic (see the following pages for details).
Important: you must be logged in as Supervisor to change the current user or job.
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Address adjustment
After pressing the Run button, the first piece will be processed and the machine will stop
to allow you to adjust the vertical alignment of the address, if required.
Remove the filled envelope and adjust as necessary, as shown below:
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Counters Settings
Press the Edit button next to the counters to display the Change Counter box as
1.
follows:
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Adjusting the Envelope Inserter settings
Unit Fine Tuning
All fine adjustments apply only to the current job and will not affect
any other jobs. Note also that settings available will depend upon
user access rights (see User Access Right on page 24).
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1. Select the inserter icon on the machine graphic in the Run screen to display the fine
tuning screen.
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2. Select Hardware Fine Tuning to display further information.
You can change:
- The width of the collate pocket guides.
- The overall width of the insert fingers.
- The time allowed for the flap to seal before the envelope is ejected.
- Adjustment of the point at which the wetter beam drops to wet the flap. +ve
increases wetting in 1mm steps (moves start point towards insertion area).
- Adjustment of the amount of envelope travel into the sealing rollers. +ve = further
forward, away from exit direction.
- Adjustment of the envelope stop position for insertion. +ve = further forwards,
towards exit direction.
- Adjustment of the amount of insertion of the insert pack into the envelope. +ve
= further forwards past the flap crease.
- Adjustment of the amount of envelope forward travel after flap wetting, before
reversing to enter the sealing rollers. +ve = further forward into the output rollers,
towards the exit direction. for high-window envelopes, this should be set to
20 - 50mm +ve.
- Adjustment of inserter head speed. Set a lower speed if insert packs are not
being fully inserted, eg. for long packs.
- Control of blower fan which assists envelope opening. Increase to open envelope
more, eg. for thick packs, decrease for single sheets or thin packs.
- Changing finger sequence if envelopes are not opening properly. Try other
settings if this is the case.
- Adjustment of number of envelopes that will feed before the detection flags
switches the conveyor back on after it has stopped. Increase number if envelopes
are ‘bunching’.
- Adjustment of degree of pause of the insertion pawls after inserting pack.
Increase if pawls start moving too soon and contacting inserted pack before it
has moved towards closer.
- Control of the overlap of sealed packs on the output conveyor. Higher number
will increase conveyor speed and reduce overlap.
- Collate Slowdown: Select ‘Not on Last Form’ for thick packs if the final document
in the pack does not feed fully into the collate pocket.
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3. When all adjustments are complete, select the 'Unit' button for hopper settings, as
described below.
Hopper Fine Tuning
1. From here you can adjust hopper settings. Select the envelope icon on the machine
graphic in the Run screen then Document Fine Tuning to display further information.
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You can change:
- Whether or not the envelope is sealed. Select ‘Off’ if, for example, later hand
insertion of an insert or any other item will be required.
- The setting of the amount of envelope deskew required. use higher settings
only when necessary – machine operates faster on lower settings.
All fine adjustments apply only to the current job and will not affect
any other jobs
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Adjusting the Document Unit settings
Unit Fine Tuning
The fine tuning options available will depend upon whether a
Feeder or Tower Folder is fitted. Note also that settings available
will depend upon user access rights (see User Access Rights on
page 24).
1. Select the document or insert icon on the machine graphic in the Run screen to display
the fine tuning screen.
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Hopper Fine Tuning
1. From here you can adjust hopper settings (depends per module due to DFC).
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You can select:
- Feed Always or not. If you select Off, the unit is disused until it is turned back
on again.
- Whether doubles detection is turned on or off. Turn off if booklets or very thick
inserts are being fed. If turned on, select whether Optical or Mechanical detection,
or Auto (software decides).
- Optical doubles sensitivity (valid only if Optical Doubles On is selected). Low
set-ting is more tolerant to high contrast printing.
- Amount of deskew; use higher settings only when necessary – machine operates
faster on lower settings.
- Only for Reading units. Reset Seq. Count - if Sequence OMR marks are being
used and the job is disrupted for any reason, select this button to reset the
sequence.
- Only for Reading units. Retrieve CIS Image - if selected, images of the label
as seen by the CIS reader will be displayed. The images will be of the final 2
documents in the group and can be useful for error checking by confirming that
the whole label was read, for example, or comparing the 2 images.
-
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All fine adjustments apply only to the current job and will not affect
any other jobs
The Menu Screen
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The Menu screen allows various functions to be selected. These functions are described
in detail further in this document.
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Running an existing job5
Running an existing job
This section describes running an existing pre-programmed job. To create a new job, see
Creating a job on page 26.
If the IMOS operating software is not already running, it must be started using the icon on
the monitor screen. To access the PC to switch it on, open the cupboard door below the
inserter head.
Before running a job, the paper hoppers must be loaded with stationery - see Loading the
paper hoppers on page 51 for details.
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Paper is normally loaded in the Tower face-up and feet-first if
non-reading, but may be either way up if reading, depending upon
whether top or bottom reading. See also appendix A.
When using the cascade function, the Run button must be pressed
while the machine is still running, after you have reloaded the empty
hopper. This ensures the paper is fed to its pre-load position.
If this is not carried out the machine will stop, even though the
hopper is full: if this happens, press the Run button to continue.
1. If the Job screen is not already displayed, press the Jobs button at the top and select
the required job from the list (use the scroll arrows if needed).
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2. Summary of selected job is shown.
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3. If you are happy with your selection, press Accept, otherwise, select another job.
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4. Load the paper and envelopes in the hoppers indicated.
5. Press the Run button to begin operating.
See also The Run Screen on page 11 for a full description of the controls.
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Switching the user6
How to switch the user
Each user has their own password and access rights, allocated by the Supervisor. To switch
user, the password must be known.
Press the Switch User button in the Job screen1.
2. Select the user from the list. Use the scroll arrows if necessary.
3. Press the Logon button.
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4. Enter the password using either the keyboard or the on-screen keypad. The user has
now changed.
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User Access Rights
There are 4 levels of access rights that can be allocated to each user. These are described
below:
with
Wizard
raries
from Wizard
Libraries from
Outside Wizard
tuning
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OperatorRights
Operator
SupervisorEngineerExpert
YYYYChange Jobs
YYYYRun Machine
YYYNProgramme Jobs
YYYNAdd items to Lib-
YYNNAdd Items to
YYNNMechanical Fine
YYYNDocument Fine
tuning
YYNNEnter Service
Menu
YYNNEnter Admin
Menu
YYNNPC Shutdown
on Exit?
Additionally, the ‘System Security Level’ can be set by a Supervisor. This is the level where
a user does not have to enter a password to perform certain operations. Any access rights
needed above this level will require the user to logon with a password.
Level
of ‘Operator’
Expert OperatorLeast secureLow (default)
More secureMedium
Standard Operator
Operator can
run/edit/
create jobs but
cannot access
the main menu.
Operator can
only run jobs.
On StartupDescriptionEffective role
Job screen
displayed
Job screen displayed
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NoneMost secureHigh
Operator’ has no
access
to the system. All
users
have to logon.
User screen
displayed
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Creating a job7
Creating a job
Creating a job consists of a number of steps:
• Defining the Mailset (Envelope, document & enclosures)
• Defining the Fold Settings
• Setting required Output Options
• Saving the Job to a Jobname
When defining the Document in the Mailset, OMR or Barcode definitions can be enabled
if required.
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For an OMR of Barcode definition to be used it must first have been
created - see Creating a document
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Creating the Job Settings
Press the Create Job button in the Job screen.
1.
You will now need to define the mailset (envelope, documents and enclosures). This
is described on the following page.
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Defining the mailset
Selecting the envelope
1. Press the Select button to choose an envelope from the available library.
2. Select the required envelope from the library and press the OK button.
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If there are no envelopes in the library, or if you wish to create a
new one, see Creating an envelope on page 45.
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