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Francotyp-Postalia FPi 500 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 FPi 500

  • 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 format documents can be added to folded large format documents, or can be inserted individually, without folding. This user-friendly machine operates automatically and efficiently. It makes short work of dispatching invoices, mass mailings, payrolls, daily mail, etc.
  • Page 3 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, dual-pole protection against 5A current surges is required. This equipment complies with norm 55022, Class A. INSTALLATION This equipment must be installed close to a grounded electrical AC outlet, and the plug must be protected with a 16A fuse.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SECTION A: GENERAL PRESENTATION ... 7 1. MACHINE ................9 2. CONTROL PANEL ............... 10 3. OPENING THE MACHINE AND INTERNAL VIEW ..... 11 SECTION B: FUNCTIONS ........13 1. INSTALLATION AND START-UP ......... 15 1.1 Installing the machine ..........15 1.2 Installation and initial start-up ........
  • Page 5 2.3.1 Double document detection activation/ deactivation for trays A and B......36 2.3.2 Displaying Job Adjustments ......37 3. LOADING DOCUMENTS ............. 38 3.1 Loading documents (trays A and B in automatic mode) ..............38 3.2 Loading documents in manual mode (tray A) ..40 3.3 Loading envelopes ..........
  • Page 7 Symbols used Indicates necessary information Indicates potential problem area Indicates an idea or interesting point Illustration through an example...

  • Page 8: Section A: General Presentation

    SECTION A: GENERAL PRESENTATION MACHINE ................9 CONTROL PANEL ............10 OPENING THE MACHINE AND INTERNAL VIEW .... 11...
  • Page 9 General presentation...

  • Page 10: Machine

    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 Locking levers for trays A and B Locking mechanism for envelope guides Power supply socket On/off switch...

  • Page 11: Control Panel

    CONTROL PANEL Display panel Control keys Start and Selection Save to Cancellation stop key memory 10 General presentation...

  • Page 12: Opening The Machine And Internal View

    OPENING THE MACHINE AND INTERNAL VIEW Opening the machine - Squeeze the handle on the front - Lift the lid of the machine upwards General presentation 11...
  • Page 13 Internal view of the machine Opening handle of the machine Envelope exit roller (E) Shutter (7) Moistening tray 12 General presentation...

  • Page 14: Section B: Functions

    SECTION B: FUNCTIONS INSTALLATION AND START-UP ........15 Installing the machine Installation and initial start-up Entering the unlocking code Selecting the language Filling the moistening tray Double detection tray C USING THE MACHINE ............. 21 User Mode 2.1.1 Stored job selection 2.1.2 Table of stored jobs 2.1.3...

  • Page 16: Installation And Start-Up

    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 15...
  • Page 17 1.Install the document feeder by inserting its 2 plastic lugs into their respective slit, located on the base of the machine. 2.Hold the feeder towards you, plug the connector to the A/B feeder socket, then replace the feeder properly on the base. 3.Clip the guides onto the back of envelope tray : be careful regarding the position...

  • Page 18: 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 19: Selecting The Language

    5. Once your code is input correctly, press to store 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 enter the following window: MACHINE SETUP...

  • Page 20: 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 21: Double Document Detection Tray C

    3. Remove the strip of 3 stoppers and fill the tank with water through holes.Ensure the brushes are properly impregnated with water. 4. Replace the moistening tray in the machine, with the blue handles towards you. 5. Close the machine 1.6 Double detection tray C This option is deactivated by default.

  • Page 22: Using The Machine

    USING THE MACHINE To use the machine, the following must be specified: - type of document - type of envelope - 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 23: 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 ).
  • Page 24 Trays A and B function Job 3 AUTO A C6/5-DL SEAL alternately, when one tray is empty, the machine switches automatically to the other Trays A and B function Job 4 C6/5-DL SEAL AUTO alternately, and tray C functions simultaneously with whichever tray is operational.

  • Page 25: 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 START S T O P...
  • Page 26 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 27 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 A4 (297 mm), 12" (305 mm), A5 (210 mm) SPECIAL (see "Advanced functions") Press to select format...
  • Page 28 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 29: Locking And Unlocking A Job

    2.1.5 Locking and unlocking a job To protect a job, no line should be selected. If so 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 icon will appear next to the number of the amended job.

  • Page 30: 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 31: 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 32: 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» field using the key, 2.
  • Page 33 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 34 Changing the size: Indicate the height of the envelope or document in millimetres 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 35 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 : 114 mmmmSet Envelope position : + 0 mm Moistening position : 23 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 36 Manual adjustment of special envelopes SPECIAL ENVELOPE SETUP Press to confirm Envelope height : 114 mmmmSet Envelope position : + 0 mm Moistening position : 23 Size: 105 mm to 165 mm, manually adjustable (in 1 mm increments) Position correction:+7 mm to -8 mm, manually adjustable (in 1 mm increments) Moistening position: 13 mm to 45 mm, manually adjustable...

  • Page 37: Double Document Detection Activation/ Deactivation (Tray C)

    2.2.3 Double document detection activation/ deactivation (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 38: 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 095 mm Fold B 103mm Envelope height...

  • Page 39: 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. 1.
  • Page 40 3. Adjust the stackof 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 41: 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 42: Loading Envelopes

    3.3 Loading envelopes 1. Adjust the rear guide to the size of the envelopes. Guide adjusted Guide adjusted for small envelopes for large envelopes 2. Unlock the lever backward to position "locked" position : forward "unlocked" position : backward 3. Adjust the lateral envelope guides Loading documents 41...
  • Page 43 4.Place the envelopes in the envelope tray. The flap should be closed, facing downwards and towards the back of the machine. 5. Adjust the lateral guides to the size of the envelopes, without squeezing them. Bottom of the envelope Top of the envelope 6.

  • Page 44: Loading Small Inserts And Reply Envelopes (Tray C)

    3.4 Loading small inserts and reply envelopes (tray C) 1. Slide the lateral envelope guides apart. 2. Take the stack of small inserts or reply envelopes and jog it on a flat surface. 3. Tip the pressure pad back- ward and holding it there, insert the stack of small inserts or reply envelopes in the tray.
  • Page 45 4. Release the pressure pad and bring the guides together against the small inserts or reply envelopes, without squeezing them. 44 Loading documents...

  • Page 46: Section C: Help And Advice

    SECTION C: HELP AND ADVICE HELP GUIDE ..............47 Error messages Symptoms and remedies JAM CLEARING ............... 58 Clearing the feeders (tray A and B) Unjamming the document path Unblocking path of small inserts (tray C) Clearing the envelope tray CLEANING ...............

  • Page 48: Help Guide

    HELP GUIDE 1.1 Error messages Probable Screen message Remedy Cause(s) CHECK THE • Reinsert envelopes. No envelope in the ENVELOPE TRAY Adjust the guides on holder. • tray E, check that the No envelope fed up by envelope path is clear the machine.
  • Page 49 Probable Remedy Screen message Cause(s) • Release the blue • Stuck Documents locking levers, take out • Document outside the documents. the specification • Separate the docu- DOUBLE ments stuck together. DOCUMENT Replace them in the DETECTION IN trays, lock the levers TRAYS A-B and press START...
  • Page 50 Probable Screen message Remedy Cause(s) KEYBOARD FAULT Check if one key is not When powered up, stuck. one or more keys on the keyboard are depressed. • CHECK THE Envelope size does not Adjust the rear guide REAR GUIDE match the position of of the envelope tray (tray OF THE the rear guide.
  • Page 51 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 52 Probable Remedy Screen message Cause(s) .Ensure the remaining documents are not stuck. DOUBLE Stuck Documents . Check the contents of DETECTION, Document outside the the envelope. If the CHECK specification envelope does not CONTENTS OF detector failure. contain a double docu- ENVELOPE ment, remove the docu- ments from the trays, jog...
  • Page 53 Probable Remedy Screen message Cause(s) The machine was Open the machine, OPEN unable to run through remove the docu- THEN CLOSE its normal cycle. ments if any are THE MACHINE jammed inside and close the machine again. JOB DEFECT Minor defect, it has Select another job become impossible to from the list.

  • Page 54: Symptoms And Remedies

    1.2 Symptoms and remedies Machine jammed CAUSES REMEDIES 1. The authorization code 1. Enter the authorization was not entered. code, see “Installation and Start-up” section. Envelope not closed or improperly closed REMEDIES CAUSES 1. See Remedy insufficient 1. Inadequate moistening moistening 2.
  • Page 55 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 gui- des, see "Loading the docu- ment" 2. Dirty rollers 2.
  • Page 56 4. Document, small insert or 4. Load fewer documents in 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 57 Documents ejected above/below envelope REMEDIES CAUSES 1. Correctly position the 1. Envelopes incorrectly envelopes in their tray, loaded see "Loading the envelopes" 2. See specification 2. Envelope out of specification Insufficient moistening CAUSES REMEDIES 1. Moistening tray empty 1. Fill the moistening tray, see "Installation and Start-up"...
  • Page 58 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 59: 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 60: Unjamming The Document Path

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

  • Page 61: 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 62: 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 63: Internal Rollers

    3.1.1 Internal rollers - Open the machine - Use a cleaning product recommended by your reseller and apply it with a lint-free cloth. Wipe each rubber roller while turning it manually. Rollers to be cleaned - Close the machine 62 Cleaning...

  • Page 64: Envelope Tray Rollers

    3.1.2 Envelope Tray Rollers Use a cleaning product recommended by your re-seller 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 re-seller and apply it with a lint-free cloth.

  • Page 65: 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 120 g or 80 g sheet of paper with the cleaning product supplied by your seller.

  • Page 66: 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. 6.

  • Page 68: Specifications

    SPECIFICATIONS Feeder (Trays A and B) Standard documents A4 (210x297mm), letter US (8 ½ x 11) 2/3 A4 (210x198 mm), 8 ½ x 8 A4 (210 x 148,5 mm), 8 ½ x 5 ½ Other dimensions Width 142 to 226 mm Height 80 to 356 mm In 1 mm increments...
  • Page 69 TRAY B Size Width 142 mm to 226 mm Height 80 to 356 mm Paper quality Coated paper* 90 g/m² to 120 g/m² In automatic mode Printed matter, listing paper, photocopies, offset 80 g/m² to 90 g/m in automatic and manual mode *perform a test.
  • Page 70 TRAY C (enclosed small format documents) Size Width 142 mm to 226 mm Height 80 to 150 mm Paper quality Printed matter, listing paper, Photocopy paper 80 g/m² to 120 g/m Offset paper, Bristol board, *coated paper 80 g/m² to 250 g/m *Coated paper pre-folded 90 g/m²...
  • Page 71 ENVELOPE TRAY Size Width 224 mm to 240 mm Height small 90 mm to 125 mm great 152 mm to 165 mm Folding and insertion capacity Single fold Up to 5 sheets 70 to 80 g/m Up to 3 sheets 86 to 120 g/m Double parallel fold Up to 3 sheets 70 to 85 g/m Up to 2 sheets 86 to 120 g/m...

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