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Francotyp-Postalia FPi500 User Manual

Folding and inserting machine
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USER'S GUIDE
FOLDING
AND
INSERTING MACHINE

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Summary of Contents for Francotyp-Postalia FPi500

  • Page 1 USER'S GUIDE FOLDING INSERTING MACHINE...
  • Page 2 INTRODUCTION Your folding and inserting machine enables you to fold docu- ments, insert them into envelopes and seal the envelope flaps. Small inserts business reply envelopes (BRE) can be added to folded large format documents, or can be inserted individually, without folding.
  • Page 4 This manual cannot be reproduced, registered or transmitted by any electronic, mechanical or other means, partly or wholly, without permission of your vendor/reseller.
  • Page 5 OFFICIAL STANDARDS In order to comply with standards EN60950 and UL1950, this equipment must be connected to standard installation of the construction industry. In order to protect the internal wiring, pro- tection against 5A current surges is required. This equipment complies with norm 55022, Class A.

  • Page 6: Table Of Contents

    TABLE OF CONTENTS SECTION A: GENERAL PRESENTATION ... 9 1. MACHINE ................11 2. CONTROL PANEL ............12 3. OPENING THE MACHINE AND INTERNAL VIEW ..13 SECTION B: FUNCTIONS........15 1. INSTALLATION AND START-UP .......... 17 1.1 Installing the machine ..........17 1.2 Installation and initial start-up ........
  • Page 7 2.2 Advanced Functions ..........32 2.2.1 Changing the language ......... 33 2.2.2 Settings for envelope formats and special documents ......... 33 2.2.3 Double Document detection activation/ desactivation (Tray C) ........38 2.3 Other Advanced functions ........38 2.3.1 Double Document Detection Activation/ Deactivation for trays A and B.
  • Page 8 2. JAM CLEARING ..............60 2.1 Clearing the feeders (tray A and B) ....... 60 2.2 Unjamming the document path......61 2.3 Unblocking path of small inserts (tray C) ....61 2.4 Clearing the envelope tray ........62 3. CLEANING ................63 3.1 Cleaning the rollers ..........
  • Page 9 Symbols used Indicates necessary information Indicates potential problem area Indicates an idea or interesting point Illustration through an example...

  • Page 10: Section A: General Presentation

    SECTION A: GENERAL PRESENTATION 1. MACHINE ................11 2. CONTROL PANEL ............12 3. OPENING THE MACHINE AND INTERNAL VIEW ..13...
  • Page 11 General presentation...

  • Page 12: Machine

    1. MACHINE Control panel Display Tray A (document feeder) Tray B (document feeder) Envelope tray Tray C (small insert or reply envelope feeder) Catch tray Opening handle of the machine Paper side guide locking levers (trays A and B) Locking levers for trays A and B Locking mechanism for envelope guides Power supply socket On/off switch...

  • Page 13: Control Panel

    2. CONTROL PANEL Display panel Control keys Start and Selection Save to Cancellation stop key memory General presentation...

  • Page 14: Opening The Machine And Internal View

    3. OPENING THE MACHINE AND INTERNAL VIEW To open the machine: Squeeze the handle on the front. Lift the lid of the machine upwards. Opening handle of the machine Envelope exit roller (E) Shutter (7) Moistening tray General presentation...

  • Page 16: Section B: Functions

    SECTION B: FUNCTIONS 1. INSTALLATION AND START-UP ......... 17 1.1 Installing the machine ..........17 1.2 Installation and initial start-up ........19 1.3 Entering the unlocking code ........19 1.4 Selecting the language ........... 20 1.5 Filling the moistening tray ........21 1.6 Double detection tray C ..........
  • Page 17 3. LOADING DOCUMENTS ............. 40 3.1 Loading documents (trays A and B in automatic mode) ............ 40 3.2 Loading documents in manual mode (tray A) ..42 3.3 Loading envelopes ..........43 3.4 Loading small inserts and reply envelopes (tray C) ..........45...

  • Page 18: Installation And Start-Up

    1. INSTALLATION AND START-UP 1.1 Installing the machine Upon receiving the machine, check the content according to the list below : Four transparent document-holders Document feeders Trays A and B Base 1 power cord 2 rear guides for envelope tray Installation and start-up...
  • Page 19 Install the document feeder by inserting its 2 plastic lugs into their respective slit, located on the base of the machine. Hold the feeder Clip the guides onto Clip-on the transpa- towards you, plug back rent document the connector to the envelope tray : be holders on trays A A/B Feeder socket,...

  • Page 20: Installation And Initial Start-Up

    1.2 Installation and initial start-up When the machine is powered up, the initialization screen will be displayed for a few seconds. The number displayed is the total number of cycles the machine has performed, all tasks included. INITIALIZATION IN PROGRESS INITIALIZATION IN PROGRESS Total number of cycles : 1234567 (press ESC during...

  • Page 21: Selecting The Language

    5. Once your code is enter correctly, press to store it. 1.4 Selecting the language The default configuration of your machine is English. To modify the language: - If the machine is switched on, switch it off then on again. - During the initialization phase press to display the following screen:...

  • Page 22: Filling The Moistening Tray

    1.5 Filling the moistening tray The moistening tray is a device that enables the machine to moisten the glue on the envelope flap so that it can be sealed. This screen appears each time the machine is started up and remains active for several seconds.

  • Page 23: Double Detection Tray C

    1.6 Double Document Detection Tray C This option is deactivated by default. This function enables the machine to detect the presence of two small inserts passing simultaneously through the insertion circuit. To activate it, select this function, using and enable/disable it, using the key.

  • Page 24: Using The Machine

    USING THE MACHINE To use the machine, the following must be specified: - type of document - type of envelope - feeder trays being trays This information is saved by the machine as a "job", corresponding to a specific application. There are nine (9) jobs which can be stored in memory for later recall.

  • Page 25: Stored Job Selection

    2.1.1 Stored job selection When first entering this screen, no line is active. Pressing the key activates the "Counter" line, and each time this key is pressed, the next line will be selected. Use the keys to select the job number desired (The machine is delivered with 9 pre-stored jobs ) READY : START to process a job to select line to modify...
  • Page 26 Trays A and B function Job 3 AUTO A LETTER 11" alternately, when one tray is empty, the machine switches automatically to the other Trays A and B function Job 4 LETTER 11" AUTO alternately, and tray C functions simultaneously with whichever tray is operational.

  • Page 27: Starting A Job

    2.1.3 Starting a job - Select the line "Job number", with the key. - Choose a job number with . - Load the appropriate trays with your documents. - Press the key to start the cycle. START S T O P The cycle can be interrupted at any time by pressing the key again.
  • Page 28 Selecting trays : To change the tray operating mode in a job. - Select the "Tray" line using the key - Select the desired function using the keys . Tray functions available: AUTO A+C MANUAL A+B AUTO A+B AUTO C MANUAL A+C AUTO A MANUAL A...
  • Page 29 Selection of document format To change the format of the main document in a job - Select the "Document" line using the key - Select the desired format using the keys. Document formats available LETTER 11", LEGAL 14" Press to select format or START to process a job to select line to modify Counter...
  • Page 30 Changing the height of the address This setting enables adjustment of the fold position to have the printed address seen through the envelope window. - Select the line "Address Height" using the key - Change the setting using the keys . - Perform a test run by pressing the key twice.

  • Page 31: Locking And Unlocking A Job

    2.1.5 Locking and unlocking a job To protect a job, no line should be selected. If not press to deselect. To lock a job: - Complete any changes to the settings using the key - Keep this key pressed, - Save to memory using the key - A key-shaped symbol will appear next to the number of the amended job.

  • Page 32: Counter

    2.1.6 Counter The machine has 2 counters. - The first one can be read on the initialization screen when the machine is switched on. It indicates the total number of cycles performed, all jobs included, since the machine was used for the very first time. It cannot be changed. - The second counter, which displays on the main screen, is a meter that monitors activity and it can be returned to zero.

  • Page 33: Advanced Functions

    2.2 Advanced Functions To enter the advanced functions mode: - During initialization, press the key The following screen will appear: INITIALIZATION IN PROGRESS MACHINE SETUP Serial Number : 0000000000 Press to confirm Language : ENGLISH : Env. / Doc. Double Det. Bin C : DISABLE...

  • Page 34: Changing The Language

    2.2.1 Changing the language The machine’s user default language is set to English. This can be changed by holding down the key while switching the machine ON from the switch located at the back of the machine. 1. Select the "language" line using the key, 2.
  • Page 35 To perform these adjustments : INITIALIZATION IN PROGRESS MACHINE SETUP Serial Number : 0000000000 Press to confirm Language : ENGLISH : Env. / Doc. Double Det. Bin C : ENABLE - Select the line "SET. ENV / DOC" using the key - Enter the manual adjustment menu using the key SELECT THE ENVELOPE FORMAT Press...
  • Page 36 Changing the size: Indicate the height of the envelope or document in millimeters x mm x mm Correcting the stop position of the envelope: You can correct the position of the envelope in order to insert folded leaflets correctly. If the settings are incorrect, the envelope may not be sealed correctly.
  • Page 37 The settings indicated on the following screens are the machine’s default settings. Manual adjustment of standard envelopes STANDARD ENVELOPE SETUP Press to confirm Envelope height : 105 mmmmSet Envelope position : + 0 mm Moistening position : 13 Size: 105 mm to 125 mm, manually adjustable (105, 108, 110, 114, 115, 120 and 125 mm) Position correction: +7 mm to -8 mm, manually adjustable...
  • Page 38 Manual adjustment of special documents SPECIAL DOCUMENT HEIGHT SETUP Press to confirm Size : 178 mm Size: 177 mm to 356 mm, manually adjustable (in 1 mm increments) Using the machine...

  • Page 39: Double Document Detection Activation/ Desactivation (Tray C)

    2.2.3 Double document detection activation/ desactivation (tray C) To activate this mode: - Select the line "Double Det. Bin C", using - Activate or deactivate using the keys - Cancel any changes using the key - Save changes to memory with the key - Exit the mode using the key mode.

  • Page 40: Displaying Job Adjustments

    2.3.2 Displaying Job Adjustments To access this screen: - You should be in user mode. - Press the key and keep it pressed - Press the key The following screen will appear. INFORMATION Press ESC to exit Fold A 089 mm Fold B 097 mm Envelope height...

  • Page 41: Loading Documents

    LOADING DOCUMENTS 3.1 Loading documents (trays A and B in automatic mode) Documents are loaded vertically in the natural direction of reading. The document containing the address must always face the user. When both feeders feed simultaneously (2 documents), the address document must be in tray A.
  • Page 42 3. Adjust the stack of paper by jog- ging it on a flat surface. Insert the documents vertically, facing the user. When feeding 2 do- cuments, the sheet containing the address must always be loaded into tray A. 4. Lock the lateral guides and the blue locking levers. Automatic feeding - Avoid mixing documents of different sizes and weights (thickness) in the same tray.

  • Page 43: Loading Documents In Manual Mode (Tray A)

    3.2 Loading documents in manual mode (tray A) Before selecting manual mode, remove any document previously loaded in tray A. Check and adjust the lateral guides if necessary. Insert a document or a set of docu- ments manually into tray A to start the cycle.

  • Page 44: Loading Envelopes

    3.3 Loading envelopes 1. Unlock the lever backward (to the position) "locked" position : forward "unlocked" position : backward 2. Adjust the lateral envelope gui- 3.Place the envelopes in the envelope tray. The flap should be closed, facing downwards and towards the back of the machine.
  • Page 45 4. Adjust the lateral guides to the size of the envelopes, without squeezing them. Bottom of the envelope Top of the envelope 5. Lock the lever forward (in position It is not necessary to adjust the guides each time envelopes are loaded, as long as the same type of envelope is being used.

  • Page 46: Loading Small Inserts And Reply Envelopes (Tray C)

    3.4 Loading small inserts and reply envelopes (tray C) Slide the lateral envelope gui- des apart. Take the stack of small inserts or reply envelopes and jog it on a flat surface. Tip the pressure pad back- ward and holding it there, insert the stack of small inserts or reply envelopes into the tray.
  • Page 47 Release the pressure pad and bring the guides together against the small inserts or reply envelopes, without squeezing them.

  • Page 48: Section C: Help And Advice

    SECTION C: HELP AND ADVICE 1. HELP GUIDE ................ 49 1.1 Error messages ............. 49 1.2 Symptoms and Remedies ........55 2. JAM CLEARING ..............60 2.1 Clearing the feeders (trays A and B) ....... 60 2.2 Unjamming the document path ........ 61 2.3 Unblocking path of small inserts (tray C) ....

  • Page 50: Help Guide

    HELP GUIDE 1.1 Error messages Probable Screen message Remedy Cause(s) Reinsert envelopes. CHECK THE • No envelope in the Adjust the guides on tray E, ENVELOPE TRAY holder. check that the envelope • No envelope fed up by path is clear (open the ma- the machine.
  • Page 51 Probable Remedy Screen message Cause(s) • Release the blue locking • Stuck Documents DOUBLE levers, take out the docu- • Document outside DOCUMENT ments. the specification DETECTION IN • Separate the documents TRAYS A-B stuck together. Replace them in the trays, lock the levers and press START S T O P...
  • Page 52 Probable Screen message Remedy Cause(s) Check if one key is not KEYBOARD FAULT When powered up, one or more keys on stuck. the keyboard are depressed. • Adjust the rear guide of the CHECK THE Envelope size does not envelope tray (tray E) REAR GUIDE match the position of according to the size of the...
  • Page 53 Probable Screen message Remedy Cause(s) REMOVE THE Open the entry of the Document(s) jammed DOCUMENTS tray, using the lever, in the entry of the FROM THE ENTRY remove the jammed feeder A (and/or B) OF TRAYS A + B document and return stopping the cycle.
  • Page 54 Probable Remedy Screen message Cause(s) Ensure the remaining do- Stuck Documents DOUBLE cuments are not stuck. Document outside the DETECTION, Check the contents of the specification or detector CHECK envelope. If the envelope failure. CONTENTS OF does not contain a double ENVELOPE document, remove the do- cuments from the trays, jog...
  • Page 55 Probable Remedy Screen message Cause(s) Open the machine, remove The machine was unable OPEN the documents if any are to run through its normal THEN CLOSE jammed inside and close cycle. THE MACHINE the machine again. Select another job from the Minor defect, it has JOB DEFECT list.

  • Page 56: Symptoms And Remedies

    1.2 Symptoms and remedies Machine jammed CAUSES REMEDIES 1/ The authorization code 1/ Enter the was not entered. authorization code, see “Installation and Start- up” section. Envelope not closed or improperly closed REMEDIES CAUSES 1/ See Remedy insufficient 1/ Inadequate moistening moistening 2/ Select "SEAL"...
  • Page 57 2/ Exit roller wet 2/ Wipe the exit roller, see section "Cleaning the rollers" Faulty fold CAUSES REMEDIES 1/ Side-guides incorrectly 1/ Adjust the document, small locked or unlocked insert and envelope guides, see "Loading the document" 2/ See the chapter 2/ Dirty rollers "Cleaning the rollers"...
  • Page 58 4/ Document, small insert 4/ Load fewer documents in or envelope trays the trays- see overloaded specification 5/ Trays incorrectly locked 5/ Lock the trays Address incorrectly positioned in the window REMEDY CAUSE 1/ Adjust the height of the 1/ Fold in wrong place address in your job.
  • Page 59 Documents ejected above/below envelope REMEDY CAUSE 1/ Correctly position the 1/ Envelopes incorrectly envelopes in their tray, see loaded "Loading the envelopes" 2/ See specification 2/ Envelope out of specification Insufficient moistening CAUSE REMEDY 1/ Moistening tray empty 1/ Fill the moistening tray, see "Installation and Start-up"...
  • Page 60 2/ See Specifications 2/ Type or size of fold unsuited to envelope 3/ See Specifications 3/ Documents or envelopes outside the specifications or distorted 4/See Section "Cleaning the 4/ Dirty rollers rollers" 5/ See Section "Loading the 5/ Lateral guides incorrectly documents"...

  • Page 61: Jam Clearing

    JAM CLEARING 2.1 Clearing the feeders (tray A and B) Switch off the machine. Tip the feeder forward and unplug the connector. Take out the feeder from the base. Remove the jammed document through the lower part of the feeder. After unjamming, place the feeder back on the base and plug in the feeder connector.

  • Page 62: Unjamming The Document Path

    2.2 Unjamming the document path 8 8 8 8 8 Open the machine, remove any E E E E E documents in areas 1 to 8 and behind the shutter 7 (to release the jammed documents, turn blue flywheel or roller E). 7 7 7 7 7 2.3 Unblocking path of small inserts (tray C) Pinch the opening control...

  • Page 63: Clearing The Envelope Tray

    2.4 Clearing the envelope tray In case of Envelope jamming, perform the following procedure: - Open the machine, take out the jammed envelope(s) through the internal paper path. - if some envelopes are still jammed, close the machine, remove the envelope stack and take out the last envelope squeezed by the rollers.

  • Page 64: Cleaning

    CLEANING 3.1 Cleaning the rollers The cleaning of the rollers offers the following benefits: - Improved paper take-up from the document, small insert and envelope trays, - Reduced risk of paper jams, - Preserves the roller material. To ensure optimal working of the machine, we recommend to clean all rollers at the same time.

  • Page 65: Internal Rollers

    3.1.1 Internal rollers - Open the machine - Use a cleaning product recommended by your vendor/ reseller and apply it with a lint-free cloth. Wipe each rubber roller while turning it manually. Rollers to be cleaned - Close the machine Cleaning...

  • Page 66: Envelope Tray Rollers

    3.1.2 Envelope Tray Rollers Use a cleaning product recommended by your vendor/reseller and apply it with a lint-free cloth. Wipe each rubber roller while turning it manually. 3.1.3 Tray C Rollers Use a cleaning product recommended by your vendor/reseller and apply it with a lint-free cloth. The rollers identified by a yellow arrow (rear view with tray C lowered) are the ones to be cleaned.

  • Page 67: A/B Feeder Rollers

    3.1.4 A/B Feeder Rollers - Power up the machine - Select feed method "AUTO 1" - Impregnate 25 mm of the lower part of a 24 lbs bond sheet of paper with the cleaning product supplied by your service provider. - Place the sheet of paper in the tray, with the strip impregnated with the cleaning product at the bottom.

  • Page 68: Cleaning/Replacing Moistening Brushes

    3.2 Cleaning/Replacing moistening brushes 1. Open the machine 2. Remove the moistening tray by holding it with the blue handles. 3. Remove the 3 brushes 4. Clean them with a thin trickle of water 5. If these brushes are worn, replace them with new ones.

  • Page 70: Specifications

    SPECIFICATIONS Feeder (Trays A and B) Standard documents 1/2" A4 (210 x 297mm), LETTER US (8 x 11") 1/2" LEGAL (8 x 14") Other dimensions Width " to 8 " (142 to 226 mm) 1/8" Height to 14" (80 to 356 mm) In 1 mm increments Paper quality Coated paper*...
  • Page 71 Tray B Size Width " to 8 " (142 to 226 mm) 1/8" Height to 14" (80 to 356 mm) Paper quality Coated paper* 24 lbs to 32 lbs In automatic mode Printed matter, listing paper, photocopies, offset 20 lbs to 24 lbs in automatic and manual mode *perform a test.
  • Page 72 Tray C (enclosed small format documents) Size Width " to 8 " (142 to 226 mm) 1/8" 7/8" Height to 5 (80 to 150 mm) Paper quality Printed matter, listing paper, Photocopy paper 24 lbs to 32 lbs Offset paper, Bristol board, *Coated paper 24 lbs to 65 lbs *Coated paper...
  • Page 73 Envelope Tray Size Width " to 9 " (224 mm to 240 mm) Height " to 4 " (90 mm to 125 mm) Folding and insertion capacity C fold Up to 5 sheets 20 lbs Up to 3 sheets 24 lbs to 32 lbs Double parallel fold Up to 3 sheets 20 lbs (hand feed only)

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