Formax 7200 User Manual

7200 Series Mid-Volume Modular Inserting System
12/2011
OPERATOR MANUAL FIRST EDITION
1 Introduction ........................................................................................ 3
1.1 Pictograms ........................................................................... 3
1.2 Notes on the use of this handbook ............................................. 4
2 Safety notes ........................................................................................ 4
2.1 General safety notes ................................................................ 5
2.2 End of life ............................................................................... 6
3 Description of machine ........................................................................8
3.1 Description of operation ............................................................ 8
3.2 Identication of parts ............................................................... 9
4 Control Panel ..................................................................................... 11
4.1 The Job Screen .......................................................................11
4.2 The Run Screen ......................................................................12
4.3 The Menu Screen ....................................................................16
4.2.1 The Run Screen displayed .............................................12
4.2.2 To adjust the Envelope Inserter settings ..........................13
4.2.3 To adjust the Document Unit settings ..............................15
5 Running an existing job ..................................................................... 17
6 Switching the user ............................................................................. 19
6.1 How to switch the user ............................................................19
6.2 User access rights ...................................................................19
7 Creating a job .................................................................................... 21
7.1 Creating the Job Settings .........................................................21
7.1.1 Dening the mailset .....................................................22
7.1.2 Dening the fold ..........................................................31
7.1.3 Dening the output settings ..........................................33
7.1.4 Saving the job .............................................................35
7.2 Creating an envelope ..............................................................36
7.3 Creating a document ...............................................................38
7.4 Creating an enclosure .............................................................40
8 Loading the paper hoppers ................................................................ 41
8.1 Loading the envelope hopper ....................................................41
8.2 Loading the versatile feeder hopper ..........................................42
8.3 Loading the ex folder hoppers .................................................45
8.4 Paper Control Lever ................................................................48
8.5 Daily Mail (Handfeed) ..............................................................49
8.5.1 Stapling Restrictions .....................................................49
8.5.2 Using Daily Mail ...........................................................49
8.5.3 Setting the Separator Gap (see also section 8.2 ‘Adjusting the
Separator’). .........................................................................50
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9 Operator Maintenance ....................................................................... 51
9.1 Cleaning the sensors ...............................................................51
9.2 Clearing paper jams ................................................................57
9.3 Changing the feed tyres ..........................................................59
9.4 Adjust the CIS reader ..............................................................60
10 Technical Specication .................................................................... 61
10.1 Inserter head .......................................................................61
10.2 Flex tower ............................................................................66
10.3 Versatile feeder ....................................................................68
10.4 Mechanical & Electrical ..........................................................69
11 Glossary of terms ............................................................................ 70
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1 Introduction
With this inserter you have an advanced, medium-volume folding and inserting machine.
Its modular construction allows up to 8 feed units to be tted, with a maximum of 11 feed trays. Its sophisticated software control optimises the order and ow 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.
1.1 Pictograms
General Warnings
Warning of danger from electricity or electrical shock
Information / Note indicating important information regarding the handling of
the machine.
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1.2 Notes on the use of this handbook
This document contains all general information and explanatory text necessary in order to
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 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 thing easy if you use this handbook as a reference work.
2 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.
IMPORTANT: To stop the machine in an emergency,
open any cover.
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2.1 General safety notes
Caution!
Please, read these notes with care. Save these instructions for later use. All notes and warnings found on the machine are to be followed.
Important! The machine must be installed only by an Authorised
Installing the machine
Ensure there is at least 1 metre of free space between the operator side of
The machine may only be connected to a voltage of 230V/50Hz or 115V/60
Electrical danger
The mains plug may only be connected with a socket having an installed
Service Engineer. A safe, level position is necessary, when installing the
machine, with sufcient 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.
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.
Hz,depending upon model.
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.
Never reach into the machine when it is running! This could only occur if a
Operating safety
The danger of injuries exists, through pulling in and crushing on the rotating
In order to prevent damage to the machine, only factory authorized accessory
Prior to cleaning the exterior of the machine, it should be disconnected from
Cleaning
the machine
When cleaning sensors use only non-ammable airdusters, eg. part number
Cleaning
sensors
safety interlock were to fail. 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!
parts should be used.
the power supply. When cleaning the machine, do not use liquid or spray
cleaners, but only a cloth dampened with water.
9103707C. Other types may use ammable propellants, which could result in re or explosion.
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In the following cases, the mains plug must be unplugged and the device
Allow machine to
When the mains cable or plug is worn or damaged.
be checked
When water or other liquid has entered the device.
by the
When the device does not function properly, in spite of
Service Agent
When the device has fallen down or the housing is
When there are noticeable differences in the normal
When repair work is carried out, only original spare parts or spare parts
Spare Parts
Do not disassemble the machine any further than is described in this
Repairs
Modication is not permitted: For safety reasons, your own reworking and modications are not
Please contact your Service Agent, for all questions relating to service and
left for the authorized Service Agents:
following the instructions provided. damaged. operation of the machine.
corresponding to the original parts may be used.
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 Agent.
permitted.
repair. In this way, you ensure the operational safety of your machine.
2.2 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 rectied 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.
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In order to facilitate collection and treatment separated from normal domestic waste, electrical and electronic equipment is marked with the following logo:
Do not mix with normal domestic waste.
Please use the subjoined return or
collection system dedicated to electrical
and electronic waste.
Equipment produced after
August 13 2005
Not only are you by law not allowed to dispose of the waste equipment via other waste­streams, but we encourage you to actively contribute to the success of such collection and to the common good and better quality of life of present and future generations.
For more information on the correct disposal of this product please contact your local dealer.
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3 Description of machine
3.1 Description of operation
The function of the machine is to fold forms to ‘C’, ‘Z’, ‘V’ or double forward fold, ei-
ther singly, in xed 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 compatible for use with a mark-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 briey described below:
- Collates all documents
Inserter head
in a pocket before insertion, feeds the envelope, inserts the pack and seals the
ap.
Versatile-Feeder - Feeds shortform inserts (cards, BR envelopes, booklets etc.) onto the track for subsequent insertion. Avail­able as a single feeder with one feed hopper or a double feeder with two feed hoppers. An OMR/Barcode version (with one feed hopper) is also available.
Feeder Folder - Mounts on the track, either in conjunction with a tower (see below) or as the last station. Fitted with one feed hopper, and folds forms up to 14” long using a 2-plate folding mecha­nism. An OMR/Barcode version is also available.
Tower - Mounts at the end of the machine. Folds documents either sepa­rately or in groups, using an accumula­tor if required. Fitted with either one or two feed pods, each consisting of either
2 x 500 sheet trays or 1 x 1000 sheet
tray. Uses a 3-plate folding mechanism. An OMR/Barcode version is also avail­able.
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 or keyboard/mouse.
A daily post function can be used as an otional feature on a tower. This allows groups of documents, stapled or loose, to be hand-fed; they will then be folded and inserted into an envelope. 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.
An optional output conveyor can be speci-
ed, to replace the standard receiving tray.
This is available in two lengths.
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3.2 Identication of parts
The main parts of the machine are shown below.
1
2
3
4
5
6
8
1 Envelope feeder
Holds up to 800 envelopes (DL). Fiited with a sensing conveyor that operates
on demand to move the envelope stack forward.
2 Touch-screen monitor
Runs the IMOS operating software and responds to button pushes. A key-
board and mouse are also included.
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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.
Note: Items 1, 2, 3 & 8 are all part of the Insertion Head Unit.
4 Versatile Feeder
These are track mounted units, with an end-station variant also available. Up
to 8 may tted (7 if a ex tower unit is tted - see below).
The Versatile Feeder feeds enclosures such as inserts, yers, BREs etc. The
hopper holds up to 1000 80gsm inserts. A mark reading variant for OMR/
Barcode/2D is also available.
5 Flex Tower
This is a folder unit and is only available as an end module. It can be tted
to the insertion head on its own, or in conjunction with Versatile Feeders. It
is tted with various options of feed trays and an accumulator (see following
page).
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6 Feed Pods
Fitted to the Flex Tower. Either a 1-Tray or a 2-Tray Flex Tower is available.
Each one is tted with either 2 x 500-sheet trays, or 1 x 1000-sheet tray;
both variants can be mark reading as an option.
7 Accumulator
Fitted to the Flex Tower and allows groups of forms to be collated together
before folding as a group. It is an optional item, it is also tted with a divert-
er tray.
8 Closer/Eject Area
This is where the envelope ap is closed and sealed before ejected the lled
envelope into a receiving tray or onto a conveyor.
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4 Control Panel
4.1 The Job Screen
This is the screen displayed when the machine starts up.
See section 5
See section 7
See section 6
List of existing jobs– see section 5
Graphic shows machine
conguration
See section 5 for running an existing job directly from this screen.
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4.2 The Run Screen
4.2.1 The Run Screen displayed
This is the screen you will see after an existing job has been selected in the Job
Menu.
See section 4.1
See section 3
See section 6
Paper load indicators
Zero the counts etc.
Pause
Close IMOS*
Autoend
Speed controls & indicator
Count & time indicators
Single cycle
Run
* 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).
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4.2.2 To adjust the Envelope Inserter settings Unit Fine Tuning
All ne adjustments apply only to the current job and will not
affect any other jobs.
Select the inserter icon on the machine graphic in the Run screen to display the
ne tuning screen. Select
Hardware Fine Tuning to display further information. You can change:
a: The width of the collate pocket guides.
b: The overall width of the
insert ngers.
c: The time allowed for
the ap to seal before the
envelope is ejected. d: Adjustment of the point
at which the wetter beam
drops to wet the ap. +ve
increases wetting in 1mm steps (moves start point
towards insertion area).
e: Adjustment of the point at which the wetter beam lifts. +ve increases duration, ie. a greater length of ap is wetted befor the beam is lifted.
f. Adjustment of the amount of envelope travel into the sealing rollers. +ve = fur-
ther forward, away from exit direction.
g. Adjustment of the envelope stop position for insertion. +ve = further forwards, towards exit direction.
h. Adjustment of the amount of insertion of the insert pack into the env = further forwards past the ap crease.
i. Adjustment of the amount of envelope foward tra reversing to enter the sealing rollers. +ve = further forward into the output rollers,
towards the exit direction. Note: for high-window envelopes, this should be
set to 20 - 50mm +ve.
vel after ap wetting, before
elope. +ve
When all adjustments are complete, select the ‘Unit’ button for hopper set­tings, as described overleaf.
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Hopper Fine Tuning
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. You can change:
a: 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. b: The setting of the amount of envelope deskew required. Note a higher level will
slow the machine more.
Important: All ne adjustments apply only to the current job and will not
affect any other jobs.
Important: All ne adjustments apply only to the current job and will not affect any other jobs
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4.2.3 To adjust the Document Unit settings
Unit Fine Tuning
The ne tuning options available will depend upon whether a Versatile Feeder or Flex Folder is tted.
Select the document or insert icon on the machine graphic in the Run
screen to display the ne tuning screen.
Hopper Fine Tuning
From here you can adjust hopper settings. You can select:
a: Feed Always or not. If you select Off, the unit is disused until it is turned back on again.
b: Whether doubles detection is turned on or off. Turn off if
booklets or very thick inserts are being fed. Note: refers only to optical detection - mechanical detection may also be t­ted.
c: 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 nal 2 documents in the group
and can be useful for error checking by conrming that the whole label was read, for exam-
ple, or comparing the 2 images.
Important: All ne adjustments apply only to the current job and will not affect any other jobs
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4.3 The Menu Screen
The Menu screen allows various functions to be selected. These functions are de­scribed in detail further in this document.
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5 Running an existing job
This section describes running an existing pre-programmed job. To create a new
job, see section 7. 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 below the inserter head.
Before running a job, the paper hoppers must be loaded with stationery - see sec­tion 8 for details.
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).
2 Summary of se-
lected job is shown.
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 but-
ton to begin operating.
See also section 4.2 for a full description of the controls.
Paper is normally loaded in the Tower face-up and feet-rst if non-
reading, face down and head-rst if reading. This may vary: see
also appendix A.
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6 Switching the user
6.1 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.
1 Press the Switch
User button in the Job
screen
2 Select the user
from the list. Use the
scroll arrows if necessary.
3 Press the Logon
button.
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4 Press the Login button.
6.2 User Access Rights
4 Enter the password
using either the keyboard or the on-screen keypad.
The user has now changed.
There are 4 levels of access rights that can be allocated to each user. These are described below:
Rights Operator Expert
Operator
Change Jobs Y Y Y Y Run Machine Y Y Y Y Programme Jobs
with Wizard Add items to
Libraries from Wizard
Add Items to Libraries from Outside Wizard
Mechanical Fine tuning
Document Fine tuning
Enter Service Menu N N Y X Enter Admin Menu N N X Y Avoid PC shutdown
on IMOS Exit
N Y Y Y
N Y Y Y
N N Y Y
N N Y Y
N Y Y Y
N Y Y
Engineer Supervisor
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7 Creating a job
Creating a job consists of a number of steps:
Dening the Mailset (Envelope, document & enclosures)
Dening the Fold Settings
Setting required Output Options Saving the Job to a Jobname
When dening the Document in the Mailset, OMR or Barcode denitions can be en­abled if required.
Note that for an OMR of Barcode denition to be used it must rst have
been created - see section 7.3.
7.1 Creating the Job Settings
1 Press the Cre-
ate Job button in the Job
screen.
2 Press the Auto-
matic button.
You will now need to dene the mailset (envelope, documents and enclosures). This
is described on the following page.
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7.1.1 Dening the mailset
Selecting the envelope
3 Press the Select
button to choose an en­velope from the available library.
4 Select the required
envelope from the library and press the OK button.
If there are no envelopes in the library, or if you wish to create a new one, see section 7.3.
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