HEALTH, SAFETY AND ENVIRONMENT Precautions and Safety Issues Thoroughly read this operator manual, before using this machine. According to the European Guideline for machine safety (EC98-37), this operator manual must be available in the national language(s) of the country where the machine is delivered.
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Conventions Note A note gives additional relevant information.
FUNCTIONAL DESCRIPTION The system feeds, folds and inserts documents into envelopes and then seals and stacks the envelopes. Automatic monitoring ensures the correct number of inserts per envelope. The machine is a sophisticated folding and inserting system which can process large quantities of mail rapidly and easily.
2.1.1 Feeder (1) The Feeder is the feeding part of the system. There are two types of feeders available: the automatic and the special feeder. The automatic feeder does not require any adjustments for the separation. The Feeder is equipped with double feed control. In this way the system can detect faulty sets of documents.
2.1.7 Stacker (7) The documents inserted (or not) are transported to the stacker depending on the programmed job. The stacker automatically stacks inserted documents. 2.1.8 Side exit (8) The documents inserted are transported to the side exit depending on the programmed job.
Operating Controls catch tray operator manual storage space side exit / stacker unit Folder side guides stacker locking handle Folder power inlet, power switch handle for manual envelope transport RS232 connector / USB / modem handle for manual envelope transport unlocking lever for upper unit unlocking handle for rollers envelope track...
Display Buttons The machine has a graphical touch screen. There are three buttons mounted at the display: • A: the clear key When the clear key is pressed during processing documents, the system will stop feeding documents after completing the set. The set will be inserted resulting in a cleared system which is ready to process a new job.
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The job information function is available in all the menus where the button is shown. • : go to the “job selection” menu to select another job (see 3.7.2 ”Select Another Job” on page 31). • : go to the “test run” menu to perform a test run (see ”Perform a Test Run”...
2.4.2 Job Info To enter the “info-job” menu, press The “info-job” menu consists of 3 submenus. If the optional insert‘n Frank™ is used an extra job info screen is available: the “insert‘n Frank™ info” menu, displaying weight information and the franking job (see 3.9.9 ”Mailing/Franking Settings (Option)”...
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The “info-job (2)” menu contains the following extra job information: Gives information about the exit settings. The arrow to the left indicates which envelopes leave from the side exit, the arrow up indicates which envelopes are stacked. The example shows exit settings by batching: 5 envelopes to the side exit, 5 envelopes to the stacker.
2.4.3 Counters To enter the “counters” menu, press from the “main menu (1)”. The “counters” menu shows the following functions: • : press this button to reset the daily job counter and stop counter to zero. • : press this button to enter a stop value.
2.4.5 Job Menu After pressing the button a login menu opens. To prevent jobs being edited or deleted without informing the ‘job owner’, this menu is protected by a PIN-code. The PIN-code is 2546. When a wrong pin code is entered, the cursor is set to the first number to try again.
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After entering the correct pin code the “supervisor menu” appears. This menu enables checking and configuring the system. The “supervisor menu” shows the following functions: • : shows system information, like: The flex certificate, used for OMR The counter since last visit: the counter value since the last service visit The last error generated by the system The screen shows a button : this shows the software versions that are...
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Job Settings (Supervisor) Caution Job settings normally will be changed by a service engineer only. Therefore first consult the supplier’s Helpdesk before changing any settings. Changes to the job settings can result in malfunctioning of jobs. The “job settings” menu (supervisor) can be opened from the “supervisor menu”.
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• Anticipation call for the envelope is used. That means that a (folded) set is leaving the Feeder already before the envelope is ready on the insert position. In mode 1 the envelope is on the insert position already before the set leaves the Feeder. It is advised to use Mode 1 with a paper thickness of 65 g/m or less, a document length of 12 inch (305 mm) or higher, and for situations where Mode 2 is not functioning...
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• The document directly beneath this document must be at least 60 mm (2.4 inch) longer than the BRE. • The upper document must be longer than the set address fold. • The folding mode is either single fold or letter fold (no Z-fold). •...
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Note Remove all paper and close all covers before calibration. • : use this function to align and test the OMR reading head (see ”OMR Test” on page 21). OMR Test The “OMR test” menu can be opened from the “test menu”.
OPERATING INSTRUCTIONS Installation Caution You can severely damage the machine if it is connected to the incorrect power supply. Before plugging in the machine, check if the local voltage is the same as the voltage mentioned on the type plate. Preparation 3.2.1 Document Feed Trays...
Starting Up To start up the system: Connect the machine to the mains power supply. Use the power switch to switch the machine on. The power switch is located on the back of the machine. The display shows “main menu (1)” (the main displays are described in 2.4.1 ”Main Menu”...
Loading Documents 3.4.1 Document Orientation Type of documents one document hopper swap two documents document + enclosure Fold type no fold single fold Address carrier in top feeder. Address carrier in top linked Address carrier in top feeder. Address carrier in top feeder. letter fold double Face up and leading.
3.4.2 Side Guides To adjust the side guides it is best to remove the document feed tray from the feeder as follows: Push handle A downwards. Lift the document feed tray upwards to unhook it and then pull it out from the feeder. Loosen the knob B half a turn.
The document separation for special feeders must be adjusted manually as follows: Push the knob B forward until it clicks. Open the left-hand side guide A by turning it downwards. Place a document on the feed tray and slide it about 60 mm (2.4 inch) into the system (turn the knob B counter clockwise if the separation is set to narrow).
Initially the document stoppers are adjusted for position B. In this position a wide variety of documents can be handled (max. 297 mm; 11.7 inch) and adjustment is not needed. When a job is selected in which a different stopper position has been programmed, the operator has to put the document stoppers in the correct position as indicated by the display.
Turn knob A clockwise until one envelope will pass between the rollers. The bottom envelope must enter the separator first. Now the envelope separation is set. After starting the system it may occur that more than one envelope at a time is pulled in. In that case rotate knob A a quarter turn clockwise.
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Note AutoSet cannot be used together with linked feeders, multifeed, daily mail and OMR functionality. The function AutoSet is not possible in the no envelopes mode or with usage of envelopes with open flap. For the envelope exit only the stacker is possible. Note Before starting AutoSet, be sure that no documents or envelopes are left in the machine.
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Insert Position Note This adjustment must only be checked in case of problems or when changing the envelope type. Lift the unlocking lever of the upper unit and pull up the upper unit. The flap folding line must be positioned under the green indicator B.
If the required address position is beyond the maximum range of 24 mm (0.96 inch), the AutoSet function can not be used. Use a programmed job instead. Press to make another test run. Recheck the position of the address, and adjust as required. Press to leave this screen to return to the “main menu (1)”...
Perform a Test Run To perform a test run: Press to display the “test run” menu. A message can appear: “Set manual feeding” or “Set automatic feeding”. In that case: Check if the daily mail handle is in the correct position (see 3.8 ”Run the Daily Mail”...
Turn left side guide A of the upper tray down. The Daily Mail handle B will become visible. Move the handle to enable the Daily Mail function. Turn left side guide A upwards. Place the document or document set in the feeder.
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Press to confirm the selected free job number. The “job settings” screen opens. The meaning of all buttons and settings will be explained in 3.9.1 ”Job Settings” on page 35. Note A new selected job number starts with default settings. Press to save the job with the entered settings under the specified job number and name.
3.9.1 Job Settings From the “job settings” menu the following settings are available: Envelope settings (see 3.9.2 ”Envelope Settings” on page 35) Document settings (see 3.9.3 ”Document Settings” on page 36) Fold settings (see 3.9.4 ”Fold Settings” on page 38) Optical Mark Recognition (OMR) settings (if installed) (see 3.9.5 ”Optical Mark Recognition Settings (Option)”...
Use the button to switch automatic envelope sealing on, off or OMR (in case of an OMR job, see ”Sealing Control” on page 53). • Press to set a job without inserting the documents in envelopes (no envelope mode). This can be useful for jobs, where documents only have to be sorted and/or folded.
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Press to display a numeric keypad to enter the exact dimension of the document. Dimensions can be entered in mm, inches or as standard ISO paper dimensions (depending on installation settings). The machine will not allow entering dimensions outer technical ranges. The document size can be set between 90 mm (3.54 inch) and 356 mm (14 inch).
Press to enable the Daily Mail function. The icon appears behind the daily mail feeder. If you press again the Daily Mail function will be disabled. Note The daily mail function is only available when OMR is not activated. When daily mail is set the links to the daily mail feeder will be deselected automatically.
Except when no fold is required, the display shows a simple diagram of the document with the fold positions. To change the fold positions press next to a fold. Enter the required position of the relevant fold. The next table shows possible fold positions: Fold type Minimum position Maximum position...
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Flex 1-9 for reading customer specific codes (only if flex dongle is installed) • Read from feeder: press the button to select a feeder to activate OMR on. • Reverse reading: reverse reading means that the insert mark is on the first page of the set.
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Note The maximum number of sheets in a set is 25. When the number of sheets exceeds 8 or 10, depending on the fold, the document can not be folded anymore. In this case, the maximum length of sheets is 156 mm (6.1 inch) for a C5 envelope. Also make sure that the fold is set to No fold.
3.9.6 Double Feed Control Settings This screen enables to set the Double Feed Control (DFC) settings for the different feeders on or off and to set the thickness measurement. To set the DFC for the different feeders: Press the button to select a feeder or the optional Thin Booklet Feeder.
3.9.7 Job Name It is possible to store the job with a meaningful job name, to easily recognize the job. This name will be displayed in the Main screen during job selection. Enter a job name using the alpha-numeric keypad. Press to clear a character left of the cursor position (backspace).
• Select the button if you want to select the exit depending on if the envelopes are closed (sealed) or open (not sealed). This selection is only possible with OMR: no mark (space) means sealed, a mark means not sealed. •...
The mailing (franking) machine will print/frank the envelopes according to the local mailing (franking) machines settings. If you press the button a screen appears in which it is possible to link a mailing (franking) job to the inserter job. Use the arrow buttons to select a job.
Press to save the job with the entered settings under the specified job number and name. To name a job, see 3.9.7 ”Job Name” on page 43. Press to perform a test run with the new job settings (see ”Perform a Test Run”...
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Enter the pin code. The “job menu” opens (see 2.4.5 ”Job Menu” on page 16). Press The “delete job” menu appears. Press the arrows if you want to select an other job number. Press for job details. Press . The job will be deleted without a warning.
OPTIONS Activate an Option To activate a new option: From the “supervisor menu” choose Software options are enabled using license codes. These license codes, together with the identification number of the machine enable the relevant options. The enabled and available software options are displayed in this screen. Contact your dealer for information about these license codes.
4.2.2 Adjustments Reading Head Position The horizontal position of the reading head must be aligned to the same position of the printed marks on the documents. To align the reading head, proceed as follows: Open the “OMR test” menu from the “Test menu”...
4.2.3 Document Orientation Switch on the OMR-function and set the position of the reading marks as described in “Optical Mark Recognition Settings (Option)” on page 39. Document orientation: Type of documents Fold type direction no fold single fold address start reading first page stop reading letter fold...
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Minimum Code / Basic Commands The minimum code is one mark in one line (insert). However for reliability it is advised to use at least 2 marks. The first line is the start mark (1-track OMR only). A mark printed on the second line means insert. No Start mark mark on the second line means accumulate.
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Additional Marks When it is required to control more functions in the inserter system, the use of more marks is needed. The following additional functions are possible via Start mark software options: Insert/accumulate • Divert mark (divert & continue) Divert & continue Divert &...
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Exit Control The following exit control possibilities are available: • When the “exit control” mark is printed, sets will be sent to the stacker. When no “exit control” mark is printed, sets will leave the machine from the side exit. •...
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Pages numbered 1-2-1-2-1-etc., one sequence mark used (first sequence check position) sheet 1: no mark printed sequence check 1 sheet 2: a mark printed sequence 1 sheet 3: no mark printed sequence check 1 etc. Pages numbered 1-2-3-4-1-2-etc., two marks used (first and second sequence check position) sheet 1: no mark printed sequence check 2...
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sheet 6: a mark printed sequence check 4 no mark printed sequence check 2 a mark printed sequence check 1 sheet 7: a mark printed sequence check 4 a mark printed sequence check 2 no mark printed sequence check 1 sheet 8: a mark printed sequence check 4 a mark printed sequence check 2...
Example Code In this example a set of 8 sheets with three selective feeds (station 2, 3 and 4) and three sequence check marks is shown. • The first position is used for the start mark which must be printed on every sheet. •...
Additional Marks When it is required to control more functions in the inserter system, the use of more marks is needed. The following additional functions are possible via Start mark software options: Insert/accumulate • Divert mark (divert & continue) Divert & continue Divert &...
The “connection menu” shows the following functions: • : opens the “history” menu to view the connection history (see ”History” on page 59). • : this button appears when the machine received new messages and opens the “messages” menu (see 4.3.4 ”Messages” on page 59). History The “history”...
• In case of a new job press to select a free job number (see 3.9 ”Create a Job” on page 33). Press to confirm the selected job number or press to return to message menu. After conforming the installation of the new software or new job the “message” menu appears.
• Volume of modem: set the modem volume. Press to change the volume of the speaker. Do not set the volume to zero as the sound of the modem is helpful during remote assistance. Press to confirm modified settings. Production Feeder 4.4.1 Function The Production Feeder is a feeder that can be loaded with a high number of documents.
4.4.3 Adjust Side Guides Adjust the side guides: Take a stack of documents/BREs and place them in the feed tray. BREs with flap down and leading (top side pointing to machine). Adjust the side guides by turning the thumb wheel A so the documents/BREs just fit and can move without resistance.
4.4.5 Feeding Documents To feed documents: Squeeze the two blue handles A and B. Shift the feeding plate C to the rear position. Loosen the stack of documents and place them in the feeder. BREs with flap down and leading (top side pointing to machine). The feeding plate assembly will be shifted up automatically (when the system starts processing) until documents/BREs are underneath the rubber paper pullers.
4.5.1 Installation Warning • Always switch off the system before connecting to, or disconnecting from any attached units. Attaching to an Inserter When installing the Thin Booklet Feeder directly to the inserter, install the module in the following manner: Disconnect the inserter connecting cable from the feeder.
4.5.2 Operating Controls Separation adjustment wheel Side guides Hopper side guide adjustment thumbwheel Release handle separation unit Release handle feed unit Feed unit push down area 4.5.3 Side Guide Adjustment The side guides can be adjusted manually as follows: Place a stack of documents into the feeder. Adjust the hopper side guides B by turning the thumbwheel C.
Turn the separation adjustment wheel clockwise to get more resistance or counter clockwise to lower the resistance. Check the separation before starting the system. After starting the system it may occur that more than one document at a time is pulled in. If this happens, turn the separation adjustment wheel more clockwise to obtain correct operation.
4.5.6 Clearing Stoppages When a document is blocked in the separation unit the document can be removed as follows: Open the release handle for the separation unit (D). Remove the documents. If necessary release the feed unit: Place your hand on the push down area F. Push down the release handle E.
To attach the support onto the hopper platform: Hold the support as indicated by the figure. Place both notches C at both sides into the sleeves. Lower the other end of the support. It will lock fully into place. To adjust the support: Loosen knob B slightly by turning it counterclockwise.
Envelope Support Depending on the quality of the paper, the conditions during storage, etc. envelopes can be curved. This can cause smaller envelopes to skew while being processed. A special support is available to allow curved envelopes to be processed correctly. It can be used for envelopes with a height up to 114 mm (4.49 inch).
Fill the envelope hopper with envelopes, positioned upside down. The flaps should face the inserter (flap leading). Tip over the envelopes. Load the envelope feeder of the inserter with about 50 envelopes. Press the green start button. The envelopes on the envelope hopper will be transported towards the feeder of the inserter.
4.11.1 Installation To install the high capacity conveyor belt: Move the conveyor belt to the correct position. Connect the adaptor C to the connecting lead. Connect the mains lead cable to the adapter. Connect the mains lead cable to the socket outlet. 4.11.2 Operation The conveyor belt switch has three positions: •...
MAINTENANCE Warning • Disconnect the mains power supply before performing any maintenance. The user must not attempt to service the appliance beyond that described in this operator manual. All other servicing must be carried out by qualified service personnel only. Please contact your authorized distributor.
FAULT FINDING Error Messages When an error occurs the display shows a screen showing the following information: • An indication of the area in which the error occurred • An error description • A suggested solution behind the pointing hand Press to view more information about the occurred error and about the possible actions to...
Clearing Stoppages Stoppages can occur in the following areas: Exit, sealing and inserting Lower envelope track Folder Feeder Collating area Thin Booklet Feeder (optional, not in figure), see 4.5.6 ”Clearing Stoppages” on page 67 6.2.1 Exit, Sealing and Inserting Area When a stoppage occurs in the exit, sealing and inserting area, remove the material as follows: Open cover A.
If needed, envelopes and documents can be transported manually to the insert table or lower envelope track by means of handle C. To transport an inserted document manually turn handle B. 6.2.3 Folder When a stoppage occurs in the Folder, remove the documents from the Folder as follows: Push the lower end of the locking handle A to open the Folder cover B.
6.2.4 Feeder When a stoppage occurs in the Feeder, remove the documents from the Feeder as follows: Pull the vertical transport hand grip A upward to open the vertical transport cover B. Remove the documents. Close the vertical transport cover B. Press to reset the error and restart the job.
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Note When contacting the service organization, you will also be asked for the last error message and the software version of the installed software. To determine the software version, refer to 2.4.6 ”Supervisor Menu” on page 16. Symptom Possible cause Remedy Reference The system...
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Symptom Possible cause Remedy Reference Flap is wrinkled Envelope not within Check specifications “Document and sometimes specifications. and change Specifications” on not opened. envelopes if needed. page 80 Flap sticks. Store envelopes “Document according to Specifications” on specifications. page 80 Flap curled.
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Symptom Possible cause Remedy Reference Flap not Water level low. Check water level, “Sealing Envelopes” on sufficiently refill if needed. page 28 moistened. Brushes dry. Check brushes, “Sealing Envelopes” on replace if needed by page 28 the extra soaked set. Brushes dirty.
SPECIFICATIONS Technical Specifications Inserter System Type folder and inserter system for medium office use. Theoretical max. 4300 inserts per hour, depending on application. speed Power consumption 100V AC/50Hz/4.0 Amps. 115V AC/50/60Hz/4.0 Amps. 230V AC/50Hz/2 Amps. Fuse 100/115 Vac: T 5.0 A, 125 V Time lag, 5.0 Amps.
Paper size Minimum width: 130 mm (5.1") Maximum width: 242 mm (9.5"), when folded 230 mm (9.1") Minimum length: 90 mm (3.5") Maximum length: 356 mm (14.0") Folding capacity Single fold - 10 sheets (max. 80 g/m²) Letter fold / Z-fold - 8 sheets (max. 80 g/m²) Double parallel fold - 4 sheets (max.
• We recommend that materials to be handled are stored at a temperature of 20°C (68°F) with a relative humidity factor of 50%. If difference in temperature occurs between store room and mailing area, the material has to be stored near the machine at least 24 hours before use.
Specifications Thin Booklet Feeder Model VF-3 Type booklet feeding device for medium office use Theoretical max. see 7.1 ”Technical Specifications Inserter System” on page 80 speed Power consumption 100V AC/50Hz/2.0 A 115V AC/50/60Hz/2.0 A 230V AC/50Hz/1 A Approvals EMC Certificate conform EMC-Directive. FCC Certificate conform 47CFR, part 15.
Specifications High Capacity Envelope Hopper Model EF-4 Type High Capacity Envelope Feeder (HCEH) Power consumption 24V-1A max. Approvals EMC Certificate conform EMC-Directive. FCC Certificate conform 47CFR, part 15. CB Certificate conform IEC 60950-1. UL Listed I.T.E. (Information Technology Equipment), conform UL-IEC 60950-1, file: E153801. Conform NEN-EN-IEC 60950-1 and derivatives.
TERMINOLOGY Term Description Address carrier The address carrier is the document that carries the address of the person for who the mail-set is meant. The address carrier can consist of one or more sheets, from which at least the first sheet must contain the address.
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DFC sensors exist on Feeders (double sheet detection). Currently DFCs on Formax inserting systems perform relative measurements, which means that they need a cycle to 'learn' the thickness of a sheet.
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Term Description Feed tray Part of the feeder that contains the stack of documents. Flexcode OMR An OMR code for which the meaning of the OMR marks can be programmed in a dedicated way for a specific customer. This is normally used to support the OMR codes from other suppliers.
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Term Description Multifeed The feature of an Inserting System in which more than one sheet is taken from a Feeder. Optical Mark Recognition OMR code Standard 1-track OMR code definition. Specifies the amount of reading definition marks used and the functionality linked to each of them (how each should be interpreted).
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Term Description Tray Contains a stack of paper for a printer or inserter. This paper is supplied to the machine for further processing. Booklet feeding device for medium office use. Thin Booklet Feeder Vertical transport The vertical transport section between feeders and collator. Z-fold A Z-fold means that a document is folded twice in such a way that each folded flap is on a different size of the folded document, resulting...
Index offset 19 orientation 24 separation 25 settings 36 address carrier 85 specifications 80 address position 30, 85 stopper 26 document orientation extended Folder 24 batch 43 normal 24 BRE offset 19 OMR 50 brush 28 document stoppage brush replacement 72 see stoppage business reply envelope 85 document-set 85...
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feed tray 87 name 43 installation 22 new 33 feeder 86 select another 31 automatic 8, 25 settings 35 install 22 settings (supervisor) 18 link 37 start 31 load 26 remove 25 side guides 25 letter fold 87 special 8, 26 loading envelopes 27 feeder linking 86 AutoSet 28, 87...
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system info 17 operating instructions 22 Optical Mark Recognition see OMR technical specifications option high capacity conveyor belt 84 activate 48 high capacity envelope hopper 84 information 17 inserter 80 license code 48 Production Feeder 82 other job 31 Thin Booklet Feeder 83 overview 7 telephone number 60 test menu 20...
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