quadient DS-85i Manual
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quadient DS-85i Manual

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Table of Contents

1
Read this First ...............................................................................................1
Safety...............................................................................................................1
Declaration of Conformity (EU only).................................................................1
About this manual............................................................................................1
2
How this Help Works ....................................................................................3
Help Menu........................................................................................................3
User Guide.......................................................................................................4
Remote Assistance (optional)..........................................................................5
3
Meet your Document System ......................................................................6
Introduction......................................................................................................6
System Overview.............................................................................................7
Operating Controls...........................................................................................9
Control Panel.................................................................................................10
How to Operate the Touch Screen.................................................................11
Use a Web Browser.......................................................................................12
What is a Job?...............................................................................................13
Job List...........................................................................................................14
Job Overview.................................................................................................15
High Capacity Document Feeder (HCDF)......................................................18
MaxiFeeder....................................................................................................19
VersaFeeder ..................................................................................................20
Installation of the Side Exit.............................................................................20
Catch Tray for Side Exit..................................................................................21
Automated Insertion Management System (AIMS)........................................23
Shut Down the System...................................................................................23
4
Working with Jobs ......................................................................................24

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  • Page 1: Table Of Contents

    Table of Contents Read this First ....................1 Safety.......................1 Declaration of Conformity (EU only)..............1 About this manual....................1 How this Help Works ..................3 Help Menu......................3 User Guide.......................4 Remote Assistance (optional)................5 Meet your Document System ..............6 Introduction......................6 System Overview.....................7 Operating Controls...................9 Control Panel....................10 How to Operate the Touch Screen..............11 Use a Web Browser..................12 What is a Job?....................13...
  • Page 2 Introduction....................24 Use an Existing Job..................24 Create a New Job..................25 About Automatic Jobs..................26 Create an Automatic Job................26 Create a Manual Job..................27 Create a test mail set..................38 Mail Sets......................43 Change to Another Feeder Tray..............47 Link Feeder Trays...................48 Edit a Job.......................48 Save a Job.....................49 Delete or Move an Enclosure.................50 Copy a Job.....................51 Delete a Job....................51...
  • Page 3 AIMS settings....................98 Reading .......................99 Introduction....................99 BCR Code Description.................100 OMR Code Description................106 Flex Reading Code Description..............111 Create Jobs with Reading................111 Reading Settings..................116 Exit Selection with Reading.................118 Operator Maintenance ................120 Maintenance Schedule................120 Clean and replace brushes................121 Replace or Clean Moistening Cloth.............121 Calibrate Photocells..................122 Fault Finding .....................124 Messages.....................124 Clearing stoppages..................127...

  • Page 5: Read This First

    Read this First Safety Ensure you have read and fully understood the safety requirements in the Safety Guide. Declaration of Conformity (EU only) The product presented in this guide meets the requirements of applicable directives. For more details refer to the Declaration of Conformity. Contact your authorized distributor for availability of this document.
  • Page 6 Symbols This manual uses the symbols listed below. This symbol... Indicates... WARNING: Indicates a human safety hazard. ATTENTION: A risk to the equipment or mail could result from an action you may perform. NOTE: A remark that explains different cases or specificities. TIP: Advice to help save you time when processing your mail.

  • Page 7: How This Help Works

    How this Help Works Help Menu The help button [?] gives access to help topics via a pull-down menu. The contents of the help menu can be different for your situation. The help menu can contain the following topics: • Search; use the search engine to find a specific topic. •...

  • Page 8: User Guide

    User Guide You can use this guide as follows: Use the contents overview to browse the contents. When you are finished you can close the User Guide with the Close button. To keep the topic from the User Guide active, you can use the Minimize button. When you click the active Help button, the User Guide is restored.

  • Page 9: Remote Assistance (Optional)

    Remote Assistance (optional) Ask your authorized distributor if this feature is available for your system/organization. It is necessary that the system is connected to the internet. (Online) Remote Assistance is a tool for help desk guidance. The Remote Assistance screen can be entered by tapping on the "Remote Assistance" button in the Help menu. Add the support key supplied by the support assistant and follow the instructions as indicated by the support assistant.

  • Page 10: Meet Your Document System

    Meet your Document System Introduction The system is a folding and inserting system for processing mail easily. The system: • feeds documents • folds the documents • inserts the documents into envelopes • seals the envelopes • stacks the envelopes Automatic monitoring ensures the correct number of documents per envelope.

  • Page 11: System Overview

    System Overview...
  • Page 12 The figure shows an overview of the system. Document Feeders (1) The Feeders are the feeding part of the system. There are two types of feeders: the automatic and the special feeder. The automatic feeder does not require any adjustments for the separation.

  • Page 13: Operating Controls

    The documents inserted are transported to the side exit depending on the programmed job. The side exit can be used for sorting and stacking of documents into the catch tray as well as transporting to a franking/mailing machine. Envelope Hopper (9) Envelopes that are placed on a stack by the user, are fed one by one into the system by the envelope hopper.

  • Page 14: Control Panel

    A - High Capacity Vertical Stacker L - air plugs for cleaning the sensors M - handle for manual transport of the mail B - loc cover C - unlocking lever for loc N - unlocking handles for rollers envelope track D - power inlet, RS232 connector / USB / modem...

  • Page 15: How To Operate The Touch Screen

    Status LED (C): A status LED indicates the state of the machine, a green LED indicates that the system is switched on, a blinking red LED indicates the system is switched off. The display is a capacitive touch screen. To avoid permanent damage of the display, do not use sharp objects to operate the display.

  • Page 16: Use A Web Browser

    Tap again on a random white space position in order to return to normal view again. Use a Web Browser You can open a web browser in the user interface of the system. Use the web browser as follows: Tap on the icon in the upper left corner of the screen to open the Web browser. You can tap or swipe to navigate through web sites.

  • Page 17: What Is A Job

    Tap the Close button in the upper left corner of the screen to close the web browser. What is a Job? If you have to process a lot of mail sets of the same type (for example bills), you can save the settings to a 'job'.

  • Page 18: Job List

    Job List When you start up the system, the ‘Job list’ menu appears. Open a web browser on page 12 Help menu on page 3 3. Login, see Introduction on page 6 4. Side menu 5. Job list sorting The side menu contains the settings menu (see Settings menu operator).

  • Page 19: Job Overview

    Job Overview If you want more information on a job, select the job in the Job List menu. The touch screen shows the following information of the selected job: • Job name • Job settings (for example the document and envelope type) •...
  • Page 20 The following is a list of symbols or icons and their descriptions. Main document. Document with reading Shows the correct document Shows the correct document orientation; A is the address. orientation; A is the address. Daily mail Enclosure Feature to manually insert mail-sets one by one into the system.
  • Page 21 Dfc/mail set thickness de- Fold type tection This icon shows what kind of Double feed control and/or fold type has been set. mail set thickness detection has been set to 'off'. By default the dfc/mail set thickness detection will be set to 'on' and the icon will not be shown.

  • Page 22: High Capacity Document Feeder (Hcdf)

    High Capacity Document Feeder (HCDF) The High Capacity Document Feeder (HCDF) is an option that can be delivered from factory. The High Capacity Document Feeder has a capacity for up to 725 sheets. The normal document feeder tray has a capacity of 325 sheets. For more information on the operation of the HCDF, refer to the topic on loading documents for the HCDF...

  • Page 23: Maxifeeder

    MaxiFeeder The maxiFeeder is a feeder that can be loaded with a high number of documents. This feeder is intended to be used for Business Reply Envelopes (BRE), but also 'standard' documents up to 356 mm (14") length can be processed with it. For more information on the operation of the maxiFeeder, refer to the topic on loading documents for the maxiFeeder...

  • Page 24: Versafeeder

    VersaFeeder The versaFeeder is used to feed booklets, regardless of the thickness of the cover, to the document flow from the feeder to the inserter. Because of the location of the versaFeeder (downstream the feeder module) documents feeded by the versaFeeder will not be folded. When the versaFeeder is added to the configuration, this is shown in the screens at the operator panel.

  • Page 25: Catch Tray For Side Exit

    The system can be equipped with a side exit and catch tray. The side exit can be fitted instead of the envelope receiving tray. The side exit allows a conveyor or a franking system to be fitted in line with the system. The side exit can also be used with a catch tray to achieve vertical stacking.

  • Page 26: Installation Of The High Capacity Vertical Stacker (Hcvs-1)

    Installation of the High Capacity Vertical Stacker (HCVS-1) The High Capacity Vertical Stacker can be used to stack filled envelopes. The vertical stacker can store up to 325 filled envelopes. In case you have a High Capacity Vertical Stacker, install it as follows on your system: Move the stacker as indicated by the arrow.

  • Page 27: Automated Insertion Management System (Aims)

    Automated Insertion Management System (AIMS) The "Automated Insertion Management System", abbreviated as AIMS, is an optional software feature. AIMS is a software system that monitors the progress of documents in real-time through a Document System (Folder-Inserter) providing various levels of reporting. In addition to reporting on the documents being processed by the Document System, it can also report on the performance of the system or systems processing the documents.

  • Page 28: Working With Jobs

    Working with Jobs Introduction With the system you can process mail sets in the following ways: • Using an existing job. Existing jobs are shown in the Job list and saved via the 'automatic' or 'manual' job creation process. How to use an existing job is described Using an existing job on page 24.

  • Page 29: Create A New Job

    If example mail set is OK: tap [Start]. If the example mail set is not OK: adjust the address position or envelope stop position or check and re-adjust the job settings. If desired tap the counter button to set the counters. See Counter settings.

  • Page 30: About Automatic Jobs

    About Automatic Jobs You can save every automatically created job and edit it like any job. An Automatic job processes mail sets according to the following rules: • The machine picks one sheet from each filled feeder; • The picked documents will be folded (if necessary) and inserted into an envelope; •...

  • Page 31: Create A Manual Job

    Make sure that the address position and the envelope stop position is correct. If not, adjust the address position envelope stop position. If necessary, tap the counter symbol to set the counters. See counter settings. Tap [Start] to start the job. Tap [Stop] to finish the job.
  • Page 32 Mail Settings Envelope Tap [Envelope]. Select a predefined envelope or create a custom envelope. Optionally tap [Use envelope] to set the use of envelopes to 'off' if you want to Create a job without the use of envelopes. Tap [Sealing] to switch it on or off. By default the envelopes will be sealed.
  • Page 33 Main document Tap [Main document]. Select a predefined document or create a custom document. Change the [Number] to add more than one document from a feeder (multiple sheet feeding). Optionally tap Daily Mail to set Daily Mail to 'on' or tap [Advanced] to set the Settings.
  • Page 34 Tap [Advanced]. Tap Double Feed Control to switch it on or off. Tap Continue on double to switch it on or off. If Continue on double is on, the machine will not stop if two sheets are fed instead of one. The document-set that contains the double sheets will be diverted.
  • Page 35 Confirm the enclosure settings with [OK]. Continue with the fold settings (see Fold settings). Fold Settings Default the machine suggests the most logical fold type. This fold type is highlighted. However, you can select other fold types and change their settings. Tap a fold type.
  • Page 36 Exit Settings In Exit Settings the Fixed exit is selected by default. Optionally tap the [Advanced] button to set the Advanced settings per job. Tap [>]. Continue with Finish the job definition and start the job, or set the counter settings.
  • Page 37 Mode 1 focuses on the versatility of paper parameters (paper thickness; document length), i.e. correct operation under even extreme paper conditions. Mode 2 is the default mode, and focuses on high speed. Use Mode 1 with a paper thickness of 65 g/m2 or less, a document length of 12 inch (305 mm) or higher, and for situations where Mode 2 is not functioning properly.
  • Page 38 can prevent the BRE from being folded. In the case of offset “yes”, the BRE is held back during a certain distance (B in the figure). This means that the trailing edge of the BRE leaves the collator last. The document is not folded. During the insertion into the envelope the documents of the set are aligned.
  • Page 39 Change the Counter Settings The counter settings are job related. In the Counter submenu you can set the (daily) Job counter, the Stop counter and the Job total counter. The following will be shown in the Counter submenu: • Job counter (as shown), the daily job counter: number of mail sets that have been processed using this job, after tapping [Start].
  • Page 40 Tap the [on/off] button to set the Stop counter to ‘on’ or ‘off’. If you set the Stop counter to ‘on’ you can enter the ‘Stop at value’. Enter a value from 5 through 9999. Be aware that when the system stops based on the stop counter, there can still be documents in the system.
  • Page 41 Finish the Job Definition and Start the Job When you have finished the exit settings, the touch screen shows an overview of the job settings. In this screen you can change the following settings: • Move documents between feeders (see Change to an other feeder tray) •...

  • Page 42: Create A Test Mail Set

    Create a test mail set Create a Test Mail Set Before starting an existing job or a new, manual created job, it is possible to create a test mail set. This test run is intended to validate the settings of the Inserting System: •...
  • Page 43 Verify the Insert Position This adjustment must only be checked in case of problems or when changing the envelope type. To verify the insert position: Choose a job and tap [1x] (envelope only). Lift the unlocking lever A of the upper unit and pull up the upper unit. Follow the instructions on screen.
  • Page 44 Tap the envelope button to fetch another envelope. Make sure that the insert position is correct. If not, repeat the steps for adjusting the insert position. Adjust the Envelope Insert Fingers To verify that the position of the fingers is correct: Choose a job and tab [1x] (envelope only).
  • Page 45 Follow the instructions on screen. Tap the arrow to move to the next screen. If the insert fingers are not correct, adjust the fingers as follows: Loosen the knurled knob D on top of each finger. Adjust each finger so that the tip enters about 5 mm (0.2 inch) into the envelope. Re-tighten the knurled knob.
  • Page 46 Adjust the Address Position Adjusting the address position is only possible after creating an example mail set (by using the [1x] button). If the address on your mail is not correctly positioned behind the envelope window, change the address position as follows: Choose a job and tap [1x].

  • Page 47: Mail Sets

    Mail Sets Adjust the Separation of Special Feeders Adjust the separation of special feeders as follows: Push knob A forward until it clicks. Turn knob A counter clockwise to open the separation gap. Place a document on the feeder tray and slide it into the system until it can go no further.
  • Page 48 Pull the knob A back again when ready. Process a Mail Set with BRE or Inserts A mail set with BRE or insert consists of a main document (address carrier), a BRE or an insert and perhaps other enclosures. This set is inserted into an envelope. From the Job list menu, tap [New job].
  • Page 49 Turn down the left side guide A of the upper tray (not applicable when using a High Capacity Document Feeder). Now you can see the Daily Mail handle B. Move the handle B to the right to enable the Daily Mail function. Turn side guide A upwards.
  • Page 50 Enter the envelope height. Tap the [Flap] tab if you use open flap envelopes. Select if you want to feed envelopes with flaps up (On) or with flap down (Off). Tap [OK] to save and close the envelope settings. Complete the Fold Settings and Exit Settings to complete the job and tap [Save] to save the job.

  • Page 51: Change To Another Feeder Tray

    Enter the height of the document. Confirm the document settings with [OK]. Complete the Fold Settings and Exit Settings to complete the job and tap [Save] to save the job. Follow the instructions as described in 'Create a test mail set'.

  • Page 52: Link Feeder Trays

    Tap the dotted box of the feeder tray where you want to move your document to. The new feeder tray is selected for feeding of the document. Tap [Save] to save the feeder tray selection to the job. Link Feeder Trays Link feeder trays as follows: Select a job from the Job list.

  • Page 53: Save A Job

    Tap [Edit]. When you tap [Edit], you enter the guided job flow that enables you to make the desired changes. Make the changes you want to make. When you completed the job programming, tap [Save] to save the changes. Tap [1x] to make sure that the Insert Position and Address Position are correct (see Verifying the Insert Position Adjusting the Address...

  • Page 54: Delete Or Move An Enclosure

    Tap [OK] to save the job. The job is added to the job list. Delete or Move an Enclosure If you want to delete an enclosure in your job or change the order of the enclosures, proceed as follows: From the Job list menu, select a job you want to edit. Tap [Edit].

  • Page 55: Copy A Job

    Copy a Job To copy existing job settings to a new job: Tap and hold the job in the Job list menu. Tab [Copy]. Enter the name of the new job and tab [OK]. Delete a Job To delete an existing job: Tap and hold the job in the Job list menu.

  • Page 56: Rename A Job

    Tap [OK] to confirm. Rename a Job To rename a job: Tap and hold the job in the Job list menu. Tab [Rename]. Enter the name of the new job and tab [OK]. Lock a Job To lock an existing job: Log on as supervisor.
  • Page 57 Tap [Lock]. Tap [OK] to confirm. The job shows a lock in the job list. If the supervisor is logged on, the lock is open. If the operator is logged on, the lock is closed. The operator cannot edit, delete or rename the job, when the job is locked.

  • Page 58: Loading The System

    Loading the System Document Orientation The touch screen shows how to load documents and envelopes into the feeders. The table shows the meaning of the symbols: Address carrier face up and leading (top address) Address carrier face up and leading (bottom address) Address carrier face down and trailing (top address) Enclosure face up Enclosure face down...

  • Page 59: Document Feed Trays

    Document Feed Trays Install the Document Feed Trays Place the document feeder trays in position: Hold the document feeder tray slightly inclined as shown in the figure. Place the front end of the document feeder tray underneath the two black rollers.
  • Page 60 Move the document feeder tray upwards (lifting the black rollers), until it is possible to ‘hook’ the feeder tray into place. Move the document feeder tray towards the machine and move the hooks over the mounting points (on both sides). Let the document feeder tray rest on the machine.
  • Page 61 Lift the document feeder tray upwards to unhook it and then pull it out from the feeder. Loosen the knob B half a turn. Grab the side guides in the middle and push them apart as far as possible. Put a small stack of documents between the side guides. Grab the side guides in the middle and push them towards the documents.
  • Page 62 Load Documents Fill the document feeder tray as follows: Open the left-hand side guide A by turning it downwards. The feed rollers will automatically be lifted. Place a stack of documents between the side guides. Turn the left side guide upwards again.
  • Page 63 Document Separation The term ‘Document separation’ refers to the adjustment required for separating the upper document from the rest of the documents in the stack. This prevents pulling too much documents from the stack at the same time. The document separation for the automatic feeders is set automatically; there are no manual adjustments needed.
  • Page 64 Adjust the side guides: Take a stack of documents/BREs and place them in the feeder tray. BREs with flap down and leading (top side pointing to system). Adjust the side guides by turning the thumb wheel A such that the documents/BREs just fit and can move without resistance.
  • Page 65 When the maxiFeeder is used at an automatic separation feeder, the separation is set automatically. The maxiFeeder can also be used on a feeder position with a manually adjusted separation. To adjust, proceed as follows: Remove the document feeder trays 2 and 3. The lowest feeder is feeder 1.
  • Page 66 Load Documents (maxiFeeder) When loading the maxiFeeder, make sure that the document/BREs are positioned parallel in relation to the feeding plate assembly to ensure correct feeding. The feeding plate assembly will be shifted up automatically (when the system starts processing) until documents/BREs are underneath the rubber paper pullers. In case of long documents, use the feeding plate extension B to support the documents.
  • Page 67 To load documents: Squeeze the two blue handles A and B. Shift the feeding plate assembly C to the rear position. Loosen the stack of documents and place them in the feeder tray. BREs with flap down and leading (top side pointing to system).
  • Page 68 High Capacity Document Feeder Adjust the Side Guides To adjust the side guides B: Loosen knob D, which is located underneath the feeder tray, half a turn. Put a small stack of documents between the side guides. Rotate wheel E. The space between the side guides and the documents should be such that the documents have just enough play to move freely.
  • Page 69 Re-tighten knob D. Load Documents (HCDF) To load the document feeder tray: Pull down lever A. The feeder rollers C move up to filling level. Place a stack of documents between the side guides (max. 725 sheets, 80 g/m ). Document Orientation how to place the documents in the feeder tray.
  • Page 70 versaFeeder Adjust the Side Guides The side guides can be adjusted as follows: Place a stack of documents into the feeder tray.
  • Page 71 Adjust the feeder tray side guides B by turning the thumbwheel C. Provide just enough space for the documents to move freely. Too much play causes skewing. Adjust the Document Separation Check before the adjustment that the release handle D for the separation unit is in the closed (down) position.
  • Page 72 Turn the separation adjustment wheel clockwise until a slight resistance is felt on the document when the document is moved backwards and forwards. Turn the separation adjustment wheel clockwise to get more resistance or counter clockwise to lower the resistance. Check the separation before starting the system.

  • Page 73: Load Envelopes

    Support for Curved Reply Envelopes (option for VersaFeeder) Depending on the quality of the paper, the conditions during storage, etc. envelopes can be curved. This can cause smaller reply envelopes to skew while being processed by the versaFeeder. A special support is available to allow curved envelopes to be correctly processed. It can be used for envelopes with a height up to 110 mm (4.33").

  • Page 74: Filling The Sealing Liquid Reservoir

    Loosen a stack of envelopes and place the stack on top of the bottom envelope between the side guides. Move the side guides towards the envelopes. The space between the side guides and the envelopes should be such that the envelopes have just enough play to move freely.
  • Page 75 Fill the reservoir B up to lip C with sealing liquid. Close the front cover A Before you start the job, wait approximately 5 minutes for the brushes to moisten. If the liquid reservoir is almost empty the touchscreen shows a message to warn you that you should refill the reservoir.

  • Page 76: Settings Menu

    Settings menu Open the Settings Menu In the settings menu for the operator it is possible to edit the display settings and to set the localisation. If you want to view or edit any of the Operator Settings: Go to the Job list and tap the side menu on the left side and select [Settings]. Tap [Localisation] if you want to change the document standard, weight standard or the language.

  • Page 77: The Settings Menu Supervisor

    Tap [Display settings] if you want to: - set the 'Key' click to on/off - set the Volume - set the Backlight - set the Brightness To set the backlight and brightness, a test pattern is available as a reference. For more information on Open source licenses, see License information.

  • Page 78: Supervisor Settings Menu

    Supervisor Settings Menu Open the Settings Menu (Supervisor) If you want to view or edit any of the Supervisor Settings: Login as Supervisor with pin code 2546.
  • Page 79 Go to the Job list and tap the side menu on the left side and select [Settings]. Configuration Configuration The Configuration menu contains the configuration information settings for the system. System Info The System info part of the Configuration menu shows the following information: •...
  • Page 80 Software Overview The Software overview part of the Configuration menu shows the versions of the software that is present in the total system.
  • Page 81 Licensed Options The Licensed options part of the Configuration menu shows the following information: • Chip ID • Serial number • Installed options The installed options are enabled with 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.
  • Page 82 Online Feature (Licenses) Management At powerup the system does an online check, provided that it is connected to a network, to determine if new features have become available or if the licensed features are still active. If for example the license end date is nearing, the machine will give a popup which license(s) almost expire(s).
  • Page 83 Add a Licensed Option To add a licensed option: In the Configuration, Licensed options screen, enter the license code. Tap [Add]. The system verifies the license key. If the license key has been verified successfully, the option is added to the system and can be used.
  • Page 84 Localisation Tap [Localisation] if you want to change the document standard or the language. When you need a keyboard to enter e.g. a job name, you get a special keyboard in case of Russian, Czech and Katakana. But the keyboard has always a button to switch back to the English keyboard.
  • Page 85 Display Settings the settings menu for the operator on page 72. Date-time Tap [Date/time] to set the: • Date • Time • Date format; you can choose between three format to show the date: dd-mm-yyyy, mm-dd-yyyy or yyyy-mm-dd • Time format; you can choose between a '12 hours' notation or a '24 hours' notation When the system is connected to the internet the time is synchronized automatically.
  • Page 86 Production Settings The Production Settings part of the Settings Menu covers settings regarding the clearing of the envelope track when selecting a (another) job from the job list or when starting a new automatic job. The screen shows three options: •...
  • Page 87 Switch to an existing job If the user selects "Always"; after tapping 1x or Start: the system shows a popup asking to clear the envelopes or continue without clearing. The following two options are possible: The user chooses to clear the envelope: a.
  • Page 88 Create a new automatic job If the user selects "Always"; after tapping 1x the system shows a popup asking to clear the envelopes or continue without clearing. The following two options are possible: The user chooses to clear the envelope: a.
  • Page 89 The Job settings part of the Settings menu covers settings that improve the processing of jobs: • Flap closer offset: to improve the sealing of specific envelopes you can delay or advance the moment of sealing. You enter the number of pulses. A minus value means the sealing is advanced, a plus value means the sealing is delayed.
  • Page 90 • BRE offset: in the case of offset is “yes”, the last document that was added to the set is shifted from the rest of the set (offsetting, see below). • Collator stop optimisation: if set to "off", the system does not show a message, when a collator stop change can improve the system output.
  • Page 91 The conditions are: • No multi-feed is used for the BREs. • The document directly under the BRE must have a height of at least 60 mm (2.4 inch) more than the BRE. • The height of the BRE is more than the set fold length. •...
  • Page 92 License information License information shows information on the open source software that is used in the system. Diagnostics Diagnostics The diagnostics menu contains the basic diagnostics functions available for a supervisor. System Test Use the [System test] to check if all motors, clutches and sensors are correctly connected. The test briefly activates the actuators and clutches and measures the current.
  • Page 93 Remove all documents and envelopes and close all covers before starting the diagnose. Tap [Start test]. When the test is finished, the Status report is shown, showing a list of all problems found during diagnostics. If tests fail, contact your service organization. Maintenance When too much paper dust is built up at the sensors a warning message will be displayed.
  • Page 94 OMR Code Definition The Reading OMR code definition screen shows the configuration of the system for OMR. For every OMR code option, it shows if it is on or off. If it is on, the screen shows information on what the system does, when it reads a mark or no mark. BCR 1D Configuration Sheet The Reading BCR 1D configuration sheet allows you to read a configuration sheet.
  • Page 95 BCR 1D Code Definition The BCR 1D code definition screen shows only information when a configuration sheet is read. It shows which codes are enabled and how they work. BCR 2D Configuration Sheet The Reading BCR 2D configuration sheet allows you to read a configuration sheet. The result is visible in this screen, but also in the BCR 2D code definition screen.
  • Page 96 BCR 2D Code Definition The BCR 2D code definition screen shows only information when a configuration sheet is read. It shows which codes are enabled and how they work. Last Image The Last image screen shows the result of the last code that the system read. The figure shows an example of the image of an OMR code.
  • Page 97 History The History screen shows an overview of the jobs run. Tap on the [History] tab to view the Job history. Tap on the [Today] pull down button if you want to view the jobs that are run 'Today', 'Last week' or 'All'. The history is displayed on the touch screen.

  • Page 98: Connect The System To The Internet

    Connect the System to the In- ternet Options for Connection Connect the system to the internet in one of the following ways: • Wired connection with the gigabit ethernet connection: • Connect with DHCP (Automatic IP address) • Manual Configuration •...
  • Page 99 Open the supervisor settings menu. Tap the Settings tab, [Connectivity]. Tap [LAN settings].

  • Page 100: Set Up A Wireless Connection

    Select Wired from the Connection type pulldown menu. Set Automatically obtain IP address (DHCP) to Yes or No. If Yes, the system connects automatically to the LAN. If No, set up a connection manually. Enter the necessary details to setup a manual connection. Set up a Wireless Connection Set up a wireless connection as follows: Open the supervisor settings menu.
  • Page 101 Select Wireless from the Connection type pulldown menu. Choose if you want to enter the SSID manually or if you want to search for a wireless network. If you want to search for a network, tap [Choose network]. When you have entered the network details or selected a network from the search, tap [Connect] to connect to the network.

  • Page 102: Test The Connection

    Test the Connection When you have connected to a network, test the connection as follows: Open the supervisor settings menu. Tap the Settings tab, [Connectivity]. Tap [Test connections]. Tap the [Test] button. The system tests the IP addresses that are defined at the LAN settings. If the result is 'Not OK', make sure that the settings are correctly defined.

  • Page 103: Reading

    Reading Introduction Code Types The reading option allows the system to read special codes that are printed on the documents. The code contains information about the processing of the documents. The system can read the following code types: • BCR 1D: One dimensional barcode •...

  • Page 104: Bcr Code Description

    General Requirements for Printing Codes If you print documents for reading: • Make sure the ribbon or toner quality is sufficient. • Print the code in black on white background. • Codes on the same sheet must have equal intensity. •...
  • Page 105 Supported 1D barcodes Code 39 Interleaved 2 of 5 Code 128, horizontal printed Note: A vertical printed "Code 128" is not supported. It may work but it is not recommended because it is very sensitive to speed variations. - Minimum line thickness of a bar: 0,20 mm (0.008") - Maximum line thickness of a bar (smallest element): 0,50 mm (0.02") - The thickness ratio of thick bars versus thin bars: 2.2 - Preferred print quality: 600dpi...
  • Page 106 Supported 2D barcodes Datamatrix - Minimum cell size 0,30mm (0.012”) - Maximum cell size 0,50mm (0.02”) - Label size 30mm (1.18”) square max - Preferred print quality 600dpi - Print drift from page to page +/- 2mm max - Colour background: White - Datamatrix can be read in all directions - Minimum white space 2mm (0.08”), all around.
  • Page 107 - Minimum cell size 0,30mm (0.012”) - Maximum cell size 0,50mm (0.020”) - Label size 30mm (1.18”) square max - Preferred print quality 600dpi - Print drift from page to page +/- 2mm (0.08") max - Colour background: White - QR can be read in all directions - Minimum white space 4mm (0.20”), all around.
  • Page 108 Position of the code on the document Leading and trailing margins Barcode should be positioned at least 7 mm (0.28") from the trailing and leading edge of the sheet. LH and RH margins * Document width <=210mm, maintain at least 2mm (0.08”) clearance from both side edges. Document width >210mm, maintain at least 5mm (0.2”) clearance from both side edges.
  • Page 109 Increased Reading Speed To obtain an increased reading speed, resulting in a higher output, the following requirements should be met: • the reading marks / barcode should be printed between 7 mm and 85 mm measured from the top of the sheet; •...

  • Page 110: Omr Code Description

    BCR advanced license For the BCR advanced license the following functions are available: • The basic functions (insert/accumulate, Customer ID). • Sheet sequence - Every sheet has a number, regardless of the document set it is part of. If a sheet is missing, an error is generated. •...
  • Page 111 Minimum line thickness of a mark: 0.2 mm (0.008 inch). Default the first mark from the top is set to: 100 mm (3.9 inch). This parameter is set in the job settings. The code must have a consistent number of marks on every page. The white area in the picture shows the limits where the code can be printed.
  • Page 112 OMR basic license For the OMR basic license the following functions are available: • Start mark: indicates the start of the code. • Insert/Accumulate: defines when a document set is complete and must be inserted into an envelope. • Parity check: by adding a parity mark the reading code can be checked. The sum of the marks must be even.
  • Page 113 OMR advanced license For the OMR advanced license the following functions are available: • The basic functions (Start, Insert, Parity, Safety). • Divert (Divert & Continue) - The set will be diverted and the system continues. • Stop (Divert & Stop) - The set will be diverted and the system stops indicating error (FT1-RE1-000 Reading stop - Stop mark read).
  • Page 114 OMR general remarks General remarks: • In case of OMR the marks must always be used in the sequence as shown in the figure. • If a function is suppressed the following function will move upwards one line. • The mark definition is a service setting. An Example of OMR Code In the figure the legend for the following example is shown.

  • Page 115: Flex Reading Code Description

    Flex Reading Code Description With "Flex reading" also non-standard codes and alternative document handling algorithms can be recognized. Flex reading can be activated by a system specific license code and by a customer specific setting that is saved in a physical dongle. With Flex three types of reading can be supported: •...
  • Page 116 Select the code type [BCR 1D] or [BCR 2D]. Load a sample document in the feeder tray as indicated. 10. Tap [Verify] to find the barcode(s) on the sheet. • If multiple barcodes are found you can select the correct barcode from the list. 11.
  • Page 117 In the settings menu, tap the [Reading] tab. Tap [BCR 1D configuration sheet] or [BCR 2D configuration sheet]. Tap [Read configuration sheet]. Load the configuration sheet as indicated and tap [READ]. Tap [Save] to save the new barcode definition. After reading a configuration sheet, jobs with BCR reading might have changed.
  • Page 118 Create an OMR Job To create a job with OMR: From the Job list menu, tap [New job]. Choose [Manual] to define the job settings. Select an envelope. Tap [Main document]. Tap [Custom]. Enter the document size or select a standard type. Tap the [Reading] tab.
  • Page 119 13. Tap the information button to verify the read OMR marks. 14. Tap [OK] and follow the remaining steps to complete the job. 15. When you completed the job creation, tap [Save] to save job. If required the maximum number of sheets can be reconfigured. Refer to Reading Settings for more details on how to change these settings.

  • Page 120: Reading Settings

    Select the code type [Flex ..]. Depending on the flex code type the OMR or BCR settings have to be configured. Follow the remaining steps to complete the job. If required the maximum number of sheets can be reconfigured. Refer to Reading Settings for more details on how to change these settings.
  • Page 121 • Maximum number of sheets: use the [-] or [+] button to select the maximum amount of sheets in the set of documents. • Stop on sheet overflow: defines if the system should stop or not when a set exceeds the maximum number of sheets, as defined at the "Maximum number of sheets setting".

  • Page 122: Exit Selection With Reading

    • Stop on misread: defines if the system should stop or not when a code is misread. In case of “on”, the system stops after a misread. The incorrect set is diverted. After resetting the system, the final part of the set is also diverted and the system starts processing again.
  • Page 123 When you have a job with reading, more exit selection options are available: • Fixed Exit: tap [Settings] to select which exit must be used for this job. If you select stacker, you can choose to let the system continue on the side exit if the stacker is full.

  • Page 124: Operator Maintenance

    Operator Maintenance Maintenance Schedule 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.

  • Page 125: Clean And Replace Brushes

    Clean and replace brushes When dirty or saturated, clean the brushes of the envelope sealing or replace them as follows: Moisten the new brushes in water. Remove the brushes one by one by pulling them down from the brush holder. Replace the brushes.

  • Page 126: Calibrate Photocells

    Remove the cover with moistening cloth D. Remove clips C to remove the moistening cloth. Clean or replace the cloth. Calibrate Photocells When too much paper dust is built up at the sensors, a warning message is displayed. In that case, calibrate the photocells as follows: Log in as supervisor.
  • Page 127 Choose which photocells you want to calibrate. Remove all documents and envelopes and close all covers before starting the calibration. Tap [Calibrate photocells].

  • Page 128: Fault Finding

    Fault Finding Messages Introduction There are three different types of messages: • Indications • Warnings • Errors Indications When you run a job, indications can appear like the ones in the example.
  • Page 129 Warning message When a warning message is shown, the screen shows the following information: • An indication of the area in which the event occurred • A warning description • A suggested solution behind the arrow • An event message number; use this number in case that you call support Tap the [i] button to view more information about the event.
  • Page 130 When an error occurs the touch screen shows a screen with the following information: • An indication of the area in which the error occurred • An error description • A suggested solution behind the arrow • An event message number; use this number in case that you call support Tap the [i] buttons to view more information about the occurred error and about the possible actions to avoid the error from re-occurring.

  • Page 131: Clearing Stoppages

    Clearing stoppages Clear Stoppages For clearing of stoppages, five system sections can be opened: A - loc, to reach the exit, sealing and inserting area B - side cover, to reach the lower envelope track C - Folder unit cover, to reach the folding area D - vertical transport cover, to reach the vertical transport and feeding area E - collator arm, to reach the collating area...
  • Page 132 Envelope Hopper When an envelope gets stuck in the envelope hopper, remove the envelope as follows: Pull down small lever B. Pins C will come down. Push lever A to the right and hold it. Pins C will go up. Remove the stuck envelope.
  • Page 133 Remove all material. Close the upper unit. Tap [x] to reset the error and restart the job. Lower Envelope Track When a stoppage occurs in the lower envelope track, remove the envelopes as follows: Open the side cover. Pull down the blue handle A.
  • Page 134 Remove the envelope(s) from the lower envelope track. If needed, envelopes can be transported manually to the insert table or lower envelope track by means of handle C. To transport a mail set manually turn handle B. Close the side cover. Tap [x] to reset the error and restart the job.
  • Page 135 Remove the documents from the Folder unit. Use the delivered pin to turn the rollers. The pin is delivered in the spare parts bag. Remove the pin when finished. Close the Folder unit cover. Tap [x] to reset the error and restart the job.
  • Page 136 Feeders When a stoppage occurs in the Feeders, remove the documents from the Feeders 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: push the bottom side of the cover towards the system, and next the top of the cover.
  • Page 137 Collating Area When a stoppage occurs in the collating area, remove the documents from the collating area as follows: Lift and hold the collator arm A. Remove the documents. Lower the collator arm. Tap [x] to reset the error and restart the job. versaFeeder When a document is blocked in the separation unit the document can be removed as follows:...

  • Page 138: Operator Troubleshooting

    Remove the documents. If necessary open the feed unit: - Place your hand on the push down area F. - Push down the release handle E. Remove the documents from the transportation area and from the rear side of the separation rollers.

  • Page 139: Troubleshooting Table

    Troubleshooting Table Symptom Possible cause Remedy Reference The system cannot System not connec- Connect the system be started after ted to mains. to the mains. switching on. Fuse is blown. Replace fuse below power switch. A cover is opened. Close the covers. System stops with Envelopes stacked Check envelope feed...
  • Page 140 Flap is wrinkled and Envelope not within Check specifications Envelope Specifica- sometimes not specifications. and change envel- tions on page 142 opened. opes if needed. Flap sticks. Store envelopes ac- Envelope Specifica- cording to specifica- tions on page 142 tions. Flap curled.
  • Page 141 Flap not sufficiently Water level low. Check water level, Filling the Sealing Li- moistened. refill if needed. quid Reservoir page 70 Brushes dry. Check brushes, re- Clean and replace place if needed by the brushes on page 121 extra soaked set. Brushes dirty.
  • Page 142 No document fed. Feeder tray empty. Refill feeder tray. Loading documents standard feeder trays on page 58 Loading documents maxiFeeder Loading documents High Capacity Docu- ment Feeder page 65 Loading documents versaFeeder Separation set too Adjust the separation. Adjusting the Separa- wide / too tight.
  • Page 143 Skewed documents Side guides set too Adjust the side Adjusting the side fed. wide. guides. guides standard feeder trays on page Adjusting the side guides maxiFeeder on page 59 Adjusting the side guides High Capacity Document Feeder on page 64 Adjusting the side guides versaFeeder on page 66...

  • Page 144: Specifications

    Specifications Technical Specifications Model DS-85i, FPi 5700, FD6406 Type Inserter system for medium office use. Theoretical max. speed 4000 inserts per hour, depending on applic- ation. Power consumption 100V AC/50Hz/3.0 Amps. 115V AC/50/60Hz/3.0 Amps. 230V AC/50Hz/1.5 Amps. Voltage tolerance 100V: +6% / -10%...

  • Page 145: Hopper And Feeder Capacity

    Noise Level 67,9 dBA (with side exit) 69,6 dBA (with HCVS) Measurements based on 1 sheet A4 in C5/6 envelope C-fold application (US equivalent: 1 sheet letter size in #10 envelope) (accord- ing to ISO 11202) Note: Noise level may vary depending on application.

  • Page 146: Document And Insert Specifications

    Document and Insert Specifications Paper quality Minimum 60 g/m (15 lb bond) Maximum 250 g/m (62.5 lb bond), when folded max. 170 g/m (42.5 lb bond) Booklets up to approximately 2 mm (0.08 inch)thickness, depending on stiffness Paper size Minimum width: 130 mm (5.1") Maximum width: 242 mm (9.5"), when fol- ded 230 mm (9.1") Minimum length: 90 mm (3.5")
  • Page 147 Minimum 60 g/m2 160 mm 90 mm 32 mm 10 mm 130mm 84 mm size 6.3” 3.5” 1.25” 0.4” 5.1” 3.3” Maximum 248 mm 162 mm B-32 75 mm A-12* 2.5 mm size 9.7” 6.38” B-1.25 2.9” A-0.47** B-0.2 0.1” * Booklets up to approximately 2 mm (0.08 inch) thickness, depending on stiffness ** When insert is more than 1 mm (0.04 inch): A-15 mm / A-0.6 inch Envelope quality...

  • Page 148: Maxifeeder Specifications

    • Self-copying paper may cause rubber parts to wear quicker. The rubber used in this machine has the best resistance to Wiggins Teape material. maxiFeeder Specifications Model Model MF-4 Type High capacity feeder Theoretical see Technical Specifications max. speed Power con- Low voltage supplied by the inserter system.

  • Page 149: High Capacity Vertical Stacker Specifications

    High Capacity Vertical Stacker Specifications Model HCVS-1 Type High Capacity Vertical Stacker. Suitable for all kinds of mail sets that consist of at least one 80 grams envelope and one folded document (80 gram). Power con- Low voltage supplied by the inserter system. sumption Approvals EMC Certificate conform EMC-Directive.

  • Page 150: Versafeeder Specifications

    versaFeeder Specifications Model VF-4 Type Booklet feeding device for medium office use Theoretical 4300 inserts per hour, depending on application. max. speed Power con- 100V AC/50Hz/2.0 A sumption 115V AC/50/60Hz/2.0 A 230V AC/50Hz/1 A Approvals EMC Certificate conform EMC-Directive. FCC Certificate conform 47CFR, part 15. CB Certificate conform IEC 62368-1.
  • Page 151 Document size Minimum width: 120 mm (4.7") Maximum width: 243 mm (9.6") Minimum length: 90 mm (3.5") Maximum length: 162 mm (6.4") Hopper tray ca- Booklets with a tough cover: maximum height 250 mm pacity Booklets with a weak cover: maximum height 150 mm Single sheets (80 gr/m ): maximum height 50 mm...

  • Page 152: Terminology

    Terminology 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 must remain visible while enclosures are added and the document-set is folded. The fold type and selected envelope must ensure that the address is visible be- hind the window in the envelope.
  • Page 153 C-fold Fold type in which a document-set is folded twice in which the folded flaps are on top of each other. This fold is illustrated in the picture below. The position of both folds is adjustable. Synonym: Letter fold. Clear The function of an inserting system in which all mail-sets in progress are finished and the document path is left empty.
  • Page 154 Double V-fold The double V-fold is a type of fold where the document is first folded halfway and the resulting folded set is again folded halfway. This fold is illustrated in the picture below. The position of both folds is adjustable. Synonym: double parallel fold. Envelope The envelope is the packaging of a mail set.
  • Page 155 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 pro- grammed in a dedicated way for a specific customer. This is normally used to support the OMR codes from other suppliers.
  • Page 156 Maxifeeder Feeder with high capacity feed tray (e.g. 1200 sheets A4 80gr). 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).
  • Page 157 Tray Contains a stack of paper for a printer or inserter. This paper is supplied to the machine for further processing. V-fold A V-fold implies the document/set is folded once. The fold-position is adjustable. This fold is illustrated in the picture below: Synonym: Single fold.

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