MBM Corporation 45 User Manual

Page 1
Mailer/inserter Model 45
Operator Manual
Mar 2000
Part No. 45866
Page 2
Table of contents
1. Introduction page
2. Getting to know the Model 45
2.1 Main components 2-1
2.2 The menus, flow chart 2-4
2.3 Explanation of the menus 2-5
3. Operator instructions
3.1 Setting up the Model 45 for different insert sizes 3-1
3.2 Adjusting the envelope feeder 3-3
3.3 Loading envelopes 3-4
3.5 Setup a new job 3-5
3.6 Start inserting 3-6
4. Added features
5. Maintenance
6. Problem solving
7. Specifications
4.1 How to adjust the amount of sealing water 4-1
4.2 How to select language 4-1
4.3 Diagnosis 4-2
5.1 Cleaning the water tray 5-1
5.2 Cleaning the envelope sealing flap 5-2
5.3 Cleaning the envelope feed belts 5-3
5.4 GFI function test and resetting 5-3
6.1 Problem solving 6-1
7.1 Specifications 7-1
7.2 Insert and envelope specifications 7-2
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1. Introduction
The Model 45 is a mailer/inserter that can be used on-line with the collators Model 306/310 and/or booklet feeder Model 46 or for hand­feeding. This operator manual covers the operation of the Model 45 both as a stand­alone unit or connected to the above men­tioned collators. For on-line operation with Model 46, also see Model 46 operator manual.
1.1 Operational safety
Attention to the following notes ensures the continued safe operation of your equipment.
Always connect the equipment to a properly grounded power source receptacle. In doubt, have the receptacle checked by a qualified electrician.
WARNING: Improper connection of the equip­ment grounding conductor can result in electri­cal shock.
Always follow all warnings marked on, or supplied with, the equipment.
Always locate the equipment on a solid sup­port surface with adequate strength for the weight of the machine.
Always exercise care in moving or relocating the equipment.
Always keep magnets and all devices with strong magnetic field away from the machine.
Never use a ground adapter plug to connect the equipment to a power source receptacle that lacks a ground connection terminal.
Never attempt any maintenance function that is not specifically described in this documenta­tion.
Never remove the covers or guards that are fastened with screws.
Never install the unit near a radiator or any other heat source.
Never override or “cheat” electrical or me­chanical interlock devices.
Never operate the equipment if you notice unusual noises or odours. Disconnect the power cord from the power source receptacle and call your customer service engineer to correct the problem.
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2.1 Main components
1
2. Getting to know the Model 45
The Model 45 is easy to use thanks to a fully micro­processor controlled operation. With the 4 buttons on the control panel you can choose between the different menus shown on the LCD display and do your settings. Take a few minutes to become familiar with compo­nents of the Model 45.
2
3
4
rear side
left side
1 Outfeed area 2 Outfeed cover 3 Receiving tray 4 Water bottle
right side
front side
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2.1 Main components, continues
1
2
3
4
5
6
7
8
1 Envelope feeding cover 2 Plastic cover 3 Document table side guides 4 Document table 5 Insert feed belts 6 Oversize envelope (B4) adjustment knobs 7 Ground fault interrupter (GFI) 8 Main power switch, power cord receptacle
and main fuse
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2.1 Main components, continues
1
2
37
4
5
6
1 Studs 2 Connection cable jacks 3 Envelope side guides 4 Envelope rear guide 5 Envelope feed belts 6 Envelope feeding table
8
9
10
11
12
13
7 Envelope separator pads adjustment knobs 8 Control Panel 9 LCD display 10 Control buttons, multi function 11 Maximum load mark (red) 12 Envelope separator pads 13 Out of envelope sensor
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2.2 The menus, flow chart
Main Menu
Feed Mode Menu
Run Mode
Setup Menu
Machine Mode Menu Added Features Menu
Clear Counter Menu
Language MenuWater Amount Adjustment Menu
Diagnosis Menu
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2.3 Explanation of the menus
The Main Menu appears after switching on the power. This is also where you return before starting the job after changing any settings. Use the left button (below the start symbol) to initialize Run Mode. The next button is the reset button which allows you to reset the machine i.e. clear the machine from envelopes and inserts. With the right button you can enter the Setup Menu.
Start Reset
The Run Mode indicates that the Model 45 is ready for use. Press the stop button to stop inserting and to return to the Main Menu. If manual mode is chosen from the Feed Mode Menu and no inserts are fed to the document table within 15 seconds the Model 45 will automatically return to the Main Menu.
Stop
In the Setup Menu you can scroll up and down with the buttons below the arrow symbols. The chosen sub­menu will be shown with the text inverted. Confirm your choice by pressing the “OK?” button.
To return to the Main Menu press the “ESC” button.
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2.3 Explanation of the menus, continues
In the Feed Mode Menu you can choose between manual feeding or automatic feeding from a collator and/or booklet feeder. The chosen item will be shown with the text inverted. Confirm your choice by pressing the “OK?” button or cancel with the “ESC” button to return to the Setup Menu.
In the Machine Mode Menu you can choose between inserting with sealing, inserting and no sealing or just to let the Model 45 feed your inserts through the machine (without any envelopes as a bypass function). The chosen mode will be shown with the text inverted. Confirm your choice by pressing the “OK?” button or cancel with the “ESC” button to return to the Setup Menu.
In the Clear Counter Menu you can reset the counter. Confirm your choice by pressing the “OK?” button or cancel with the “ESC” button to return to the Setup Menu.
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2.3 Explanation of the menus, continues
In the Added Features Menu you can access the Water Amount Adjustment Menu, the Language Menu or start the self test program, Diagnosis. The
chosen item will be shown with the text inverted. Con­firm your choice by pressing the “OK?” button or cancel with the “ESC” button to return to the Setup Menu.
NOTE: Choosing “DIAGNOSIS” will immediately start
the built in self test program. Before performing a diagnosis it is very important to read “4.3 Diagnosis” in the section “4 Added Features”.
In the Water Amount Adjustment Menu you can adjust the amount of sealing water in the wetting sys­tem by pressing the corresponding arrow button. The previous setting is indicated by an arrow. Confirm your choice by pressing the “OK?” button or cancel with the “ESC” button to return to the Added Features Menu.
In the Language Menu you can scroll/select which language you want to be displayed using the arrow buttons. The chosen language will be shown with the text inverted. Confirm your choice by pressing the “OK?” button or cancel with the “ESC ” button to return to the Added Features Menu.
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2.3 Explanation of the menus, continues
After choosing “DIAGNOSIS” the display will show what type of self test that is currently performed. During the test you will hear sounds when components are tested.
NOTE: Before performing a diagnosis it is very impor-
tant to read “4.3 Diagnosis” in the section “4 Added Features”.
Normally the message “NO FAULTS FOUND” should be displayed. Press the reset button ( the Added Features Menu. If the self test program would find any errors the dis­play will show the faulty component, its actual status and a fault code. In case of multiple errors there will be an arrow button and a cancel button visible. Scroll with the arrow button and press the “ESC” button to return to the Added Features Menu.
) to return to
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3. Operator instructions
3.1 Setting up the Model 45 for different insert sizes
The holes in the docking plate allows you to move the Model 45 to the front or to the rear depending on the size of the inserts.
A5 Landscape A4 Portrait
A4 Landscape
Move the Model 45 to the front for portrait A4 size inserts and to the rear for landscape A4 or portrait A5 size inserts.
Adjust the document table side guides by sliding them towards or from each other by gripping the side guides by the green dots. Adjust them to the scale mark corre­sponding the insert size. Normal setting is a 2-3 mm play between the inserts and the side guides. If meas­urement “C” (see section 7.2) is large, a larger play has to be accepted, otherwise the envelopes will not be opened for insertion.
CAUTION • Before adjusting the side guides press
the reset button from the Main Menu to avoid damages on the inserting tools.
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3.1 Setting up the Model 45 for different insert sizes, contin­ues
When B4 envelopes (extra wide) is used to accomodate a large packing thickness, the oversize envelope adjustment knobs should be set to their outermost positions to aviod damages to the enve­lopes. Loosen the knobs to adjust.
CAUTION • Only perform the adjustment when the
document table side guides are in their outermost position.
NOTE • If B4 envelopes (extra wide) not is used,
the oversize envelope adjustment knobs
oversize envelope adjustment knobs shown in their outermost position
Depending on the actual packing thickness, the outfeed rollers need to be adjusted. Open the outfeed cover and position the two levers, one on each side, to the re­quired position as shown in the figure.
should be set to their innermost positions.
0 - 7 mm position
5 - 12 mm position
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3.2 Adjusting the envelope feeder
NOTE: It is important for the envelope feeding that the
gap between the envelope separator pads and the envelope feed belts is correct and equal!
Default setting:
Press the envelope feed belt downwards at the arrow and thighten the envelope separation adjustment knob
envelope feed belt
envelope separator pad
until there is no gap between the separator pad and the feed belt. Then loosen the adjustment knob one and a half turn. To facilitate adjustment, use a flash light and/ or a 0.05 mm feeler gauge.
If double feed occurs: Thighten the adjustment knobs.
If miss feed occurs: Loosen the adjustment knobs.
B
A
NOTE: The friction between the envelopes and the
envelope feed belts is also essential for proper envelope feeding. Therefore the rear envelope guide (B) must be adjusted properly.
Envelopes
Place one envelope on the envelope feeder so the right edge stops against the envelope separator pads (A). Loosen the knob on the rear envelope guide (B) and slide it so that it is in line with the left edge of the enve­lope.
Bags
Place one bag on the envelope feeder so the right edge stops against the envelope separator pads (A). Loosen the knob on the rear envelope guide (B) and slide it so that the left edge of the bag reaches the top of the slope.
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3.3 Loading envelopes
envelope low symbol
Slide the envelope feeder side guides away from each other. Load the rest of the envelopes, not higher than up to the red mark, with the flap up and to the left. Slide the envelope feeder side guides towards each other against the envelopes without squeezing.
The right side of the envelope stack should be straight and make sure the envelope low symbol disappears from the display.
NOTE: Before loading the envelopes, fan them
properly to make sure they are not glued together.
3.4 Filling water
Also bend the envelopes perpendicular to
the feed direction, to make sure the envelopes have proper contact with the envelope feed belts.
When running, make sure one or two
envelopes falls down to the feed belts and the rest of the stack should lay onto the rear envelope guide. Adjust the rear guide
if necessary.
The water bottle is mounted upside down and fills water into the wetting system through holes in the cap. Press down the water bottle slightly. Remove the bottle by turning it over and lifting it out. Fill the bottle with fresh water and tighten the cap. Put the bottle back in the same position.
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3.5 Setup a new job
Switch on the power and enter the Setup Menu.
Enter the Feed Mode Menu.
Choose “AUTO” to feed your inserts from a collator or a booklet feeder. Follow instructions in the collator and/or booklet feeder operator manual to setup the collator and/or booklet feeder properly. Choose “MANUAL” to feed your inserts manually. Confirm your choice by pressing the “OK?” button.
Enter the Machine Mode Menu.
Choose the desired machine mode; “INSERT”, “NO SEALING” or “BY PASS”. Confirm your choice by pressing the “OK?” button
If you wish to clear the counter, choose “CLEAR COUNTER” and confirm by pressing the “OK?” button.
Press the “ESC” button to return to the Main Menu.
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3.6 Start inserting
Start the Model 45 by pressing the start button.
The Run Mode indicates that the Model 45 is ready for use. Depending of the chosen machine mode continue as follows:
Insert sensor
“AUTO” mode: Press the calibration test button on
the collator. One set will be fed to the document table and the system will stop. Check that the inserts fed to the document table are correct and put them back. Make sure that the inserts blocks the infeed sensor. Press the start button on the Model 45 and then the start button on the collator.
“MANUAL” mode: Begin inserting by feeding your
inserts manually to the document table. Make sure that the inserts blocks the infeed sensor.
Inserts can be “married together” by choosing “AUTO” mode combined with hand feeding. Reduce the speed on the collator (1000 sets per hour). Feed the docu­ment you want to add before the inserts are fed from the collator.
To stop inserting press the stop button on the Model 45.
CAUTION: The insert feed belts will start to travel in
about 0.7 seconds after the insert sensor is blocked.
NOTE: If the insert sensor is not blocked within 15
seconds in “MANUAL” mode the Model 45 will return from run mode to the Main Menu.
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4. Added features
4.1 How to adjust the amount of sealing water
Enter the Setup Menu.
Enter the Added Features Menu.
Enter the Water Amount Adjustment Menu.
Adjust the amount of sealing water by pressing the corresponding arrow button. The previous setting is indicated by an arrow. Confirm your choice by pressing the “OK?” button or cancel with the “CANCEL” button to return to the Added Features Menu.
Press the “CANCEL” button to return to the Setup
Menu.
4.2 How to select language
Press the “ESC” button to return to the Main Menu.
Enter the Setup Menu.
Enter the Added Features Menu.
Enter the Language Menu.
Select language by scrolling with the arrow buttons. The chosen language will be shown with the text in­verted. Confirm your choice by pressing the “OK?” button or cancel with the “CANCEL” button to return to the Added Features Menu.
Press the “CANCEL” button to return to the Setup
Menu.
Press the “ESC” button to return to the Main Menu.
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4.3 Diagnosis
The diagnosis is a self test program the operator can run in order to verify the status of the Model 45 if some problems are experienced. The self test program will perform a test of the EEPROM, sensors, motors and circuits as well as checking of different voltages.
NOTE: Choosing “DIAGNOSIS” will immediately start
the self test program. Before performing a diagnosis it is very important to:
Remove all envelopes from the envelope feeding table.
Remove all inserts from the document table.
Press the reset button from the Main Menu to
clear the Model 45 from envelopes and in serts inside.
Empty the receiving tray
Reset
CAUTION: Do not attempt to stop the self test program
before it is finished.
To start the self test program from the Main Menu:
Enter the Setup Menu.
Enter the Added Features Menu.
Choose “DIAGNOSIS” and press the “OK” button.
After choosing “DIAGNOSIS” the display will show what type of self test that is currently performed. During the test you will hear sounds when components are tested. Normally the message “NO FAULTS FOUND” should be displayed. If the self test program would find any errors the display will show the faulty component, its actual status and a fault code. In case of multiple errors you can scroll with the arrow button.
Press the “CANCEL” button to return to the Added
Features Menu.
Press the “CANCEL” button to return to the Setup
Menu.
Press the “ESC” button to return to the Main Menu.
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4.3 Diagnosis, continues
Fault code Error message Explanation
1 EEPROM ERROR The EEP ROM is defective.
The unregulated voltage supplied to the
2 UNR. VOLTA GE LOW
3 UNR. VOLTA GE HIGH
4 REG. VOLTAGE LOW The regulated voltage is too low.
5 REG. VOLTAGE HIGH The regulated voltage is too high.
Model 45 is too low and/or the transformer is defective.
The unregulated voltage supplied to the Model 45 is too high a nd/or the transformer is defective.
6 - 19 SENSOR S# ACTUATED
20 COVER OPEN The envelope feeding table is open.
21 INTERLOCK
22 SENSOR S17 ACTUATED Water level low.
31 - 49
(odd No.s only)
32 - 50
(even No.s only)
51 - 56 SE NSOR S# NOT RES PONDING
57 INTERLOCK RE LAY Int er lock relay defec tive.
MOTOR M# OPEN CIRCUIT
MOTOR M# SHORT CIRCUIT
Foreign object is covering the mentioned sensor.
The interlock switch in the envelope feeding cover is actuated.
Interruptio n in the mentioned motor circuit.
Sho rt circuit in the mentio ned motor circuit.
Interrup ti on in the mentioned sensor circuit.
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5.1 Cleaning the water tray
open
closed
5. Maintenance
The water tray should be cleaned at least every other week.
Remove the water bottle.
Pull out and remove the receiving tray.
Open and remove the outfeed cover.
Pull out the hose, open the tap and empty the water
tray.
Close the tap and put the hose back in position.
Unlock the water tray by pushing it to the left and fold
it downwards.
Clean the water tray.
Hold the guide plate in the correct position (see
picture on next page) while folding the water tray upwards until it snaps into locked position.
Caution: Check that the guide plate behind the water
tray is in the correct position. Incorrect posi­tion causes sealing jam.
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5.1 Cleaning the water tray, continues
guide plate
correct position
water tray
5.2 Cleaning the envelope sealing flap
lift painted plate here
envelope sealing flap
1
2
The envelope sealing flap (stainless steel) and a guide plate (stainless steel) under it, aswell as the painted plate under the two leftmost rollers will eventually need cleaning due to glue build-up.
Clean the envelope sealing flap and the guide plate
by lifting app. 10mm at the green dot. To facilitate cleaning, the rightmost roller can be removed. Press down the envelope sealing flap and remove the roller by pushing it to the rear (1) and lifting the front end (2).
Clean the painted plate under the rollers. If neces-
sary remove the painted plate by lifting the rightmost edge as shown in figure (and same place opposite side). Close the envelope feeding table and pull the plate out towards the receiving tray.
incorrectly positioned guide plate
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5.3 Cleaning the envelope feed belts
Clean the envelope feed belts using a mild soap deter­gent every 10 000 feeds or earlier if needed.
envelope feed belts
5.4 GFI function test and resetting
WARNING: DO NOT use the Model 45 if the following
test fails. No additional testing should be performed. Call for service.
window
black button
red button
When testing the Ground Fault Interruptor (GFI ), the Model 45 power cord must be connected to the wall receptacle and the main power switch in the ON (1) position.
Press the red ”TEST”- button.
Press the black ”RESET”-button. A red flag should
appear in the window of the GFI.
Press the red ”TEST”- button. The red flag should
disappear.
Press the black ”RESET”-button again. The Model
45 should now be ready to use.
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6.1 Problem solving
6. Problem solving
This section explains possible causes and what ac­tions to take if an error message should appear in the display. Allways remove envelopes and inserts in the same direction as they travel through the Model 45. If problem could not be solved - call for service.
Displayed message/symbol Explanation/Possible
causes
Water level low Fill water according to section 3.4.
Stacker full. Stop signal sent to collator and/or booklet feeder (if attached).
Envelope feeder empty. Stop si gnal sent to collator and/or booklet
feed er (if a ttached) .
Envelope co uld not be
fed fr om envelo pe feed er.
Envelope miss occurs
when the envelope s does
not have proper contact
wi th the envelo pe feed
belts (i.e. when the
ENVELOPE MISS
REMOVE SET FROM INFEED TABLE
friction is to low).
The collator has stopped due to some error or calibration.
Actio n
Empty the receiving tray.
Load more envelopes.
1. Check that the envelope s are bent according to section 3.3.
2. Check adjustment of the envelope separation pads according to section 3.2.
3. C heck the ad justme nt of the envelope rear guide according to section 3.2. Check/clean the feed belts a ccord ing to section 5.3.
See collator operator manual and Model
45 operator manual 3.6.
The interlock switch in the plastic cover is actuated.
INTERLOC K
NOTE: These symbols can appear allthough action as above is not
necessary. For instance, an air buble in the water hose could cause the water level symbol to appear intermittently. Once the air buble disappears, water level warning symbol extinguishes automatically. If problem percists for certain amount of time, the machine stops. Above means when attending a stoped machine, fault message may already have been corrected.
1. Re move obstac le. If nece ss a ry slide t he envelope feeding table open and open the envelope feeding cover.
2. If a collator is attached, check that the paper feeder on the collator does not have contact with the plastic cover on the Model
45.
3. After obstacle is removed, follow on screen instruction.
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6.1 Problem solving, continues
Disp layed message/symbo l Explanation/Possible
causes
The interlock switch in the plastic cover was
actuated but obstacle is INTERLOC K RESET SYSTEM
THE TOP C OV E R IS
OPEN
FLAP OPENER MISS
SEALING JAM
no longer actuating the
interlock switch.
The envelope feeding
table i s open.
1. The flap on the
envelope could not be
opened when the
envelope was positi oned
before i nserting.
2. The flap on the
envelope was already
open when the envelope
was fed.
Malfunction when sealing. Slide the envelope feeding table open.
Actio n
Press the reset button. Press the start button. Start the collator (if attached).
Close the envelope feeding table.
Slide the envelope feeding table open. Remove the envelope . Close the envelope feeding table. Press the reset button.
1. Check that the envelopes are loaded with the flap up, closed and towards the envelope rear guide according to section
3.3.
2. Check that the envelopes not already are accidentally sealed.
3. Check that the flap not is to he avi ly curved .P ress the start b utton. Start the collator (if attached).
Remove the envelope . Close the envelope feeding table. Press the reset button.
1. Check/fill water according to section 3.4.
2. Check that the gui de plate is in the correct po s i ti on according to s e ctio n 5.1 .
3. Check/clean according to sections 5.1 and 5.2. P ress the start button. Start the c ollator (i f attached).
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6.1 Problem solving, continues
Displayed message/symbol Explanation/Possible
causes
Malfuncti on when inserting.
INSERTER ERROR
Envelope jam under the envelope
feeding cover.
FEED ERROR
Insert(s) or e nvelope inside the machine .
REMOVE PAPER
Actio n
Clear the d o cument table. Slide the envelope feeding table open. Remove envelope and i nserts. Close the envelope
feeding table. Press the reset button.
Check the ad justme nt of the document
table side guides according to section 3.1. If the inserts a re clos e t o mi nimum recommended specifi ca ti ons for actual envelope size (see section 7.2) you might have to exceed the recommended play of 2-3 mm. Press the start button. Start the collator (if attached).
Slide the envelope feeding table open. Open the envelope feedi ng cover. Remo ve
the envelope. Close the envelop e feeding cover. Close the envelope feeding table. Press the reset button. Press the start button. S tart the collator (if attached).
Slide the envelope feeding table open. Remove envelope and inse rts. Close the envelope feeding table. Press the reset button. S tart the collator (if attached). If problem continues, check that the enve lope s fed not are to heavily curved .
1. Envelope is not removed after a feed error.
2. Double feed ing of envelopes.
REMOVE ENVELOPE
Jam in unit feeding Model
45.
FEEDER JAM
Slide the envelope feeding table open. Open the envelope feedi ng cover. Remo ve
the envelope. Close the envelop e feeding cover. Close the envelope feeding table. Press the reset button. Press the start button. S tart the collator (if attached).
Follow actual operator manual to clear jam. Press the reset button. Press the start button. S tart the collator (if attached).
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7.1 Specifications
SPE CIFICATIONS MODEL 45
Envelope size Min. See next page
Envelope loading c a pa city 100 mm
Paper size Min. See next page
Paper weight Min. 60 gsm
7. Specifications
Max. See next page
Max. See next page
Max. -
Maximum speed Up to 3600 e nvelopes/hour
Max packing thickness 12 mm
Misfee d d etecti on Yes
Jam detection Yes
Envelope low detection Yes
Stacker full detection Yes
Availibility factor
Height 560 mm
Width 1150 mm
Depth 640 mm
80% at 36 00 envelope s/hour (2 minutes stop / 10 minute period)
Weight 83 kg
Volta ge 105 /115 /1 25/220 /2 30 /2 40 volt, 50-60 Hz
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7.2 Insert and envelope specifications
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7.2 Insert and envelope specifications, continues
OK!
OK!
AVOID
OK!
OK!
mailpoint or pointed type flap with window positioned off center of envelope
The envelopes should have edge-tight gluing on windows to avoid jam and inserts getting caught between the edge of the patch and the window. Use envelopes where the window is positioned off centre of the envelope to avoid the pointed part of the flap to getting caught in the window.
Avoid using envelopes with square types of flaps, the straight edge of the flap could easily get caught in the window.
mailpoint or pointed type flap with window positioned across center of envelope
AVOID
AVOID
AVOID
wallet or square type flap
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