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FP FPi 4800 Operator's Manual

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FPi 4800
Operator Manual
Betriebsanleitung
Gebruikershandleiding
English
Deutsch
Nederlands

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Summary of Contents for FP FPi 4800

  • Page 1 FPi 4800 Operator Manual English Betriebsanleitung Deutsch Gebruikershandleiding Nederlands...

  • Page 2: 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)................4 Meet your Document System ..............6 Introduction......................6 System Overview.....................7 Operating Controls...................8 Control Panel....................10 Power Up......................11 How to Operate the Touch Screen..............12 What is a Job?....................16...
  • Page 3 Use an Existing Job..................27 Create a New Job..................28 About Automatic Jobs..................29 Create an Automatic Job................29 Create a Manual Job..................30 Create a test mail set..................42 Mail Sets......................48 Change to Another Feeder Tray..............53 Link Feeder Trays...................54 Edit a Job.......................55 Save a Job.....................55 Delete or Move an Enclosure.................56 Copy a Job.....................57 Delete a Job....................57...
  • Page 4 Ping test.......................105 Preferences....................106 AIMS settings....................106 Reading .....................108 Introduction....................108 BCR Code Description.................109 OMR Code Description................115 Flex Reading Code Description..............118 Create Jobs with Reading................118 Reading Settings..................122 Operator Maintenance ................124 Maintenance Schedule................124 Clean and Replace Brushes................125 Replace or Clean Moistening Cloth.............126 Calibrate Photocells..................127 Fault Finding .....................130 Messages.....................130 Clearing stoppages..................133...

  • Page 6: 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 7 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 8: 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 9: User Guide

    User Guide You can use this guide as follows (see example English User Guide): Use the contents overview to browse the contents. To search for topics; enter a keyword in the Search bar and press the Search button. When you are finished you can close the User Guide with the Close button (X). To navigate through the User Guide: •...
  • Page 10 (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 11: 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 12: System Overview

    System Overview The figure shows an overview of the system. Document Feeders (1) The Feeder is 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 fold unit folds the documents. The following fold types are possible (see Terminology on page 147): • No fold • V-fold • C-fold • Z-fold • Double V-fold Envelope feeder (4) Envelopes that are placed on a stack by the user, are fed one by one into the system by the envelope feeder.
  • Page 14 A - Envelope catch tray (optional) K - Sensors B - Envelope slide (optional) L - Bellows C - Display with operating buttons M - Handle for clearing stoppages D - Upper unit N - Sealing liquid reservoir E - Locking hand grip upper unit O - Front cover (ruler at inner side) F - Document feeders P - Thumb wheel for side guide adjustment...

  • Page 15: Control Panel

    Control Panel On/Off (B): The touch sensitive button in the upper right corner of the display switches the system on or off. If the system is not used for one hour, the system switches off to safe power. 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.

  • Page 16: Power Up

    Power Up To start up the system: Connect the system to the mains power supply. You can severely damage the machine if it is connected to the incorrect mains voltage. Before plugging in the machine, check if the local voltage is the same as the voltage mentioned on the type plate.

  • Page 17: How To Operate The Touch Screen

    The touch screen shows the Job list screen. How to Operate the Touch Screen You can operate the touch screen like a tablet: • Tap : touch and release the screen with your finger. • Swipe: touch the screen, hold it and move your finger(s) left, right, up or down. •...
  • Page 19 Swipe...
  • Page 20 Tap and hold...

  • Page 21: What Is A Job

    Pinch out / pinch in (only available in help/content 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'. The next time you just select the job and immediately start without defining any settings.

  • Page 22: Job List

    The following settings are saved in a job: • Envelope type/size; • Sealing on/off; • Which document feeders should be used, how many documents should be fed from each feeder and document height for each feeder; • Feeder linking on/off; •...

  • Page 23: Job Overview

    If you want more information on a job, select the job. With the [Job list] button you get back to the home menu. See also: Working with Jobs on page 27. Job Overview If you want more information on a job, select the job in the Job List. The touch screen shows the following information of the selected job: •...
  • Page 24 If you tap "(i) Details" a summary of all information of the job is listed.
  • Page 25 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 26 Feeder linking Change feeder trays Linking means that when one Possibility to change from feeder is empty, the system one feeder tray to another. automatically starts feeding documents from the other feeder. This symbol at the feeders shows if the feeders are linked.

  • Page 27: 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 28: 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 156mm (6.1") 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 29: High Capacity Vertical Stacker

    High Capacity Vertical Stacker 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, adjust the side guides as follows: Adjust the side guides with wheel A until a margin of 3 to 5 mm is left between the envelopes and the side guides.

  • Page 30: Side Exit

    Side Exit The system can be equipped with a side exit and catch 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 (see picture). The catch tray is delivered with the side exit.

  • Page 31: 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 32: 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 27.

  • Page 33: Create A New Job

    If the Test mail set is OK: tap [Start]. If the Test 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 on page 38.

  • Page 34: 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 35: Create A Manual Job

    Make sure that the address position and the envelope stop position are correct. If not, adjust the address position on page 46 and envelope stop position on page 43. If necessary, tap the counter symbol to set the counters. See Counter settings page 38.

  • Page 36: Mail Settings

    Mail Settings Select Envelope Tap [Envelope]. Select a predefined envelope or create a custom envelope on page 50. 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.
  • Page 37 Select Main document Tap [Main document]. Select a predefined document or create a custom document on page 52. 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' (see also Daily Mail on page 49) or tap [Advanced] to set the DFC settings (refer to...
  • Page 38 Tap [Advanced]. Tap Double Feed Control to switch it on or off. Confirm the settings by tapping [Select] and continue with the document settings. Select an Enclosure Tap [Add enclosure]. Select a predefined document or create a custom document as your enclosure (see Create a custom document) on page 52.

  • Page 39: Fold Settings

    Continue with the fold settings (see Fold settings on page 34). Fold Settings Default the system 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. If necessary, tap [Settings] to change the fold settings.
  • Page 40 Optionally tap the [Advanced] button to set the Advanced settings per job. Tap [>]. Finish the job defenition and start the job (see Finish the job definition and start the job page 40) or set the Counters (see counter settings on page 38).
  • Page 41 g/m2 or less, a document length of 12 inch (305 mm) or higher, and for situations where Mode 2 is not functioning properly. In all other cases use Mode 2. • Document offset (A in the figure): the extend to which documents are not overlapping in the vertical transport.
  • Page 42 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 43 Change the Counter Settings The counter settings are job related.
  • Page 44 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 45 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 46 Tap [1x] to create a test mail set (see Test mail set on page 42). If desired, you can save the job (see Save a job on page 55). Tap [Start] to start the job.

  • Page 47: 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 Document System: •...
  • Page 48 Verify the Insert Position This adjustment must only be checked in case of problems or when changing the envelope type. For the right Insert Position a correct alignment of the envelope flap fold line has to be applied. Proceed as follows: Choose a job and tap [1x] (envelope only).
  • Page 49 Align the envelope flap fold line with the blue indicator by tapping the arrows. Tap the button [Retry test] to fetch another envelope (Note: the upper unit has to be closed). Check the alignment again. Tap the arrow in the bottom right corner if the alignment is OK.
  • Page 50 Adjust the envelope insert fingers position If the Insert fingers position is not correct, adjust the fingers as follows: Loosen the knurled knob C on top of each finger. Adjust each finger A so that the tip enters about 5 mm (0.2 inch) into the envelope. Re-tighten the knurled knob.
  • Page 51 Adjust the Address Position If the address on your mail is not correctly positioned behind the envelope window, change the address position as follows: Adjusting the address position is only possible after creating an example mail set (by using the [1x] button). Choose a job and tap [1x].
  • Page 52 Tap Address position not correct. Change the address position: slide the position indicator to the correct position. Tap the button [Retry test] to create another example mail set or tap [√] to confirm the setting.

  • Page 53: 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 54 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 55 Turn down the left side guide A of the upper tray. 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. Place the document or document set in the feeder tray. The document or document set will be folded and inserted into the envelope as described in the selected job.
  • Page 56 Tap on [Settings] in Custom (envelope). 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 [√] to save and close the custom envelope settings and tap [Select]. Complete the Fold Settings and Exit Settings to complete the job settings.
  • Page 57 Create a Job with Custom Documents Makes sure that your custom documents fit within the specifications (see Document Specifications on page 143). Create a manual job as explained in Create a Manual job on page 30 and select a custom document as your main document or enclosure. Tap [Settings] in Custom (document) to create a custom document.

  • Page 58: Change To Another Feeder Tray

    Change to Another Feeder Tray You cannot change the order of the documents in the mail set by changing feeders. If you want to change the order of the mail set, Delete or move an enclosure on page 56. If you want to move the main document or enclosures to another feeder tray: Select a job from the Job list.

  • Page 59: Link Feeder Trays

    Link Feeder Trays Link feeder trays as follows: Select a job from the Job list. Tap the feeder tray that you want to link to another feeder tray. The link symbol appears. Tap the link symbol. The figure shows an example of linked feeders. Tap [Save] to save the link to the job.

  • Page 60: Edit A Job

    Edit a Job To edit an existing job: From the Job list, select a job you want to edit. 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.

  • Page 61: Delete Or Move An Enclosure

    If necessary, add a description to the job. The description is visible in the job list. Tap [√] 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, select a job you want to edit.

  • Page 62: Copy A Job

    Tap the arrow buttons [>] to pass the other job definition steps and close the job editor. 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 on page 43 and Adjusting the Address Position page 46).

  • Page 63: Rename A Job

    Tap [Delete]. Tap [√] to confirm. Rename a Job To rename a job: Tap and hold the job in the Job list. Tab [Rename]. Enter the name of the new job and tab [√].

  • Page 64: Lock A Job

    Lock a Job To lock an existing job: Log on as supervisor. Tap and hold the job in the Job list. Tap [Lock]. Tap [√] 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.

  • Page 65: 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 down and trailing (top address) Enclosure face up Enclosure face down...

  • Page 66: 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 67 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 68 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 69: Load Documents

    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 70: Document Separation

    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 71 Adjust the side guides by turning the thumb wheel A such that the documents/BREs just fit and can move without resistance. Too much play causes skewing. Item Description Thumbwheel for adjusting side guides Handle for unlocking the feeding plate E (use in combination with Handle for unlocking the feeding plate E (use in combination with (Manual) Separation adjustment knob Feeding plate...
  • Page 72 Adjust the maxiFeeder Document Separation Item Description Thumbwheel for adjusting side guides Handle for unlocking the feeding plate E (use in combination with C) Handle for unlocking the feeding plate E (use in combination with B) (Manual) Separation adjustment knob Feeding plate...
  • Page 73 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 74 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 F to support the documents.
  • Page 75 Handle for unlocking the feeding plate E (use in combination with C) Handle for unlocking the feeding plate E (use in combination with B) (Manual) Separation adjustment knob Feeding plate Squeeze the two blue handles B and C. Shift the feeding plate assembly E to the rear position. Loosen the stack of documents and place them in the feeder tray.
  • Page 76 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 77: Loading Envelopes

    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 on page 60 how to place the documents in the feeder tray. Release lever A.
  • Page 78 Item Description Side guide adjustment lock (to prevent unintentonal misadjustments). Thumbwheel for side guide adjustment. Envelope support to ensure correct feed angle. Lever to set/reset envelope separation. Loading envelopes correctly will help to prevent jams and mis-feeds. Make sure the envelope separation and side guides are correctly set.
  • Page 79 Shift the envelope support C in the correct position, according to the printed scale and matching the envelope size (height). Pull down lever D and insert one envelope up to the stoppers. The position of the envelope is flap down and trailing (bottom side of the envelope pointing to the system). 10.

  • Page 80: Fill The Sealing Liquid Reservoir

    11. Loosen a stack of envelopes and place the stack on top of the bottom envelope between the side guides. If envelopes are warped the envelope support can be set at an angle to better guide the flow of envelopes. Fill the Sealing Liquid Reservoir Open the front cover B.
  • Page 81 Before starting the job, wait approximately 5 minutes for the brushes to moisten or use moistened brushes. For instructions on the installation of brushes, see the User Guide, section Clean and replace brushes on page 125.

  • Page 82: Settings Menu

    Settings menu Changing screen display In all settings menus (operator as well as supervisor) information shown might not be visible at a glance. You will notice that the following icon is available: ; this icon will enlarge the view of your screen. For example in the Display settings the 'normal' view will show: Tapping the icon will enlarge the view.

  • Page 83: Open The Operator Settings Menu

    In the enlarged view you will find the icon. Tapping this icon will reduce the view of your screen again (back to ‘normal’ view). Double tapping anywhere on the touch screen, in one of the settings menus, will also result in enlarging (or reducing) the view. Open the Operator Settings Menu In the settings menu for the operator it is possible to edit the display settings, to set the localisation and to view license information.
  • Page 84 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. Tap [License information] if you want more information on Open source licenses.

  • Page 85: The Supervisor Settings Menu

    The Supervisor Settings Menu Supervisor Settings are all settings that can be found under the Settings Menu when logged in as supervisor (pin code 2546). The following flowchart shows which subjects are available via the Supervisor settings menu. It is possible to view or edit any of the Supervisor Settings. Supervisor Settings Menu Open the Supervisor Settings Menu If you want to view or edit any of the Supervisor settings proceed as follows:...

  • Page 86: System Info

    Tab [Settings] at the top of the touch screen. Configuration Configuration The Configuration menu contains information and settings about the configuration of the system. System Info The System info part of the Configuration menu shows the following information: • Serial number of the system •...

  • Page 87: Software Overview

    Software Overview The Software overview part of the Configuration menu shows the versions of the software that is present in the total system.

  • Page 88: Licensed Options

    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 89 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/licenses have become available. New licenses will be installed automatically. Add a Licensed Option manually To add a licensed option manually: In the Configuration, Licensed options screen, enter the license code.
  • Page 90 Settings Settings The Settings menu contains specific configuration settings for the system. 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.

  • Page 91: Display Settings

    Display Settings Refer to the the Operator Settings Menu on page 78 for the operator. 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 •...

  • Page 92: Production Settings

    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 93 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 94: Job Settings

    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 95 The Job settings part of the Settings menu covers settings that improve the processing of jobs: • Flap closer offset: To delay or advance the moment of flap closing, you can enter a number between -20 and 20 to fine tune the closing of the envelope. •...
  • Page 96 • 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 97: License Information

    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 98: System Test

    Connectivity Connect the system to the internet on page 100. 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 99 Tap [System test]. 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 the status of all tested items. If the tests fail, contact your service organization.
  • Page 100 Photocells When too much paper dust is built up at the sensors a warning message will be displayed. To check the conditions of the photocells or to calibrate them follow the instructions as described in Calibrate photocells on page 127. Reading Reading In the reading menu it is possible to view and to add new code definitions.
  • Page 101 Select a code definition. The [View] button will become active. Tap [View]. Information about the code definition will be displayed. Adding a new code definition From the (main) Reading menu window tap [+ New].
  • Page 102 Select new code type; BCR 1D or BCR 2D. Contact your local distributor for more information about available reading licenses.

  • Page 103: Last Image

    Set configuration. When logged on as Supervisor the only way to set the configuration is via a configuration sheet. Follow the instructions displayed on screen to finalize the settings of the code definition. 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 a reading code.

  • Page 104: Job History

    Job history The Job history screen shows an overview of the jobs run. Tap on the [Job history] tab to view the Job history. Tap either on [Today], [Last week] or [All] if you want to view the jobs that are run 'Today', 'Last week' or 'All'.

  • Page 105: 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 106: Set Up A Wireless Connection

    Open the supervisor settings menu. Tap the tab [Connectivity]. Tap [LAN settings] and 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.
  • Page 107 Open the supervisor settings menu. Tap the tab [Connectivity]. Tap [LAN settings] and select Wireless from the Connection type pulldown menu. Tap [List] if you want to connect to one of the available networks from the SSID pull down menu. The system will automatically refresh the list and will show all available networks.
  • Page 108 Tap [Apply]. When the system connected successfully to the network, the screen shows connected.

  • Page 109: 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 [Connectivity] tab. 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 110: Ping Test

    Ping test If you want to test the network connection between your system and a specific server you can do a PING test. Proceed as follows: Open the supervisor settings menu. Tap the [Connectivity] tab. Tap [Ping test] and enter the IP address of the server. Tap [Ping] to perform the Ping test.

  • Page 111: Preferences

    Preferences The system optionally can share statistics for online reporting. In case the system is not connected to internet or the server can’t be reached, the statistics are temporary stored on the system. If the storage is full a warning message can be raised that statistic information will be discarded and will not be available for the online reports.

  • Page 113: 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 114: 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 115 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 116 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 117 - 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 118 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 119 BCR license types There are two BCR license types: • Basic • Advanced BCR basic license For the BCR basic license the following functions are available: • Page N of M: defines when a document set is complete and must be inserted into an envelope.

  • Page 120: Omr Code Description

    OMR Code Description Position of the code on the document 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.
  • Page 121 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 122 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 123: 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 124 Load a sample document in the feeder tray as indicated and tap [Verify] to find the barcode(s) on the sheet. • If multiple barcodes are found you can select the correct barcode from the list. 10. Tap [√] and follow the remaining steps to complete the job. 11.
  • Page 125 Select one of the pre-defined OMR code definitions from the pull down menu (code definitions have been programmed by your supervisor or by the service engineer). Load a sample document in the feeder tray as indicated and tap [Verify] to read the OMR code on the sheet.
  • Page 126 Create a Flex Reading Job To create a job with flex reading: From the Job list, tap [New job]. Choose [Manual] to define the job settings. Select an envelope. Tap [Main document]. Tap [Settings] in Custom (document) to create a custom document. Enter the document size or select a standard type.

  • Page 127: Reading Settings

    10. Tap [√] and follow the remaining steps to complete the job. 11. 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 on page 122 for more details on how to change these settings. Reading Settings When you create a reading job for OMR, BCR 1D/2D or Flex reading, the following options can be set:...
  • Page 128 • Maximum number of sheets: use the [-] or [+] button to select the maximum amount of sheets in the set of documents. The maximum number of sheets in a set is 25. When the number of sheets exceeds 5 or 8, depending on the fold, the document can not be folded anymore.

  • Page 129: 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 130: 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. Unlock lever A of the upper unit and pull up the upper unit. Remove the brushes one by one by pulling them down from the brush holder. Replace the brushes.

  • Page 131: Replace Or Clean Moistening Cloth

    Replace or Clean Moistening Cloth When dirty or saturated, clean the moistening cloth or replace if necessary. Proceed as follows: Open the front cover A. Remove the sealing liquid reservoir B from the system. Remove the cover with moistening cloth D. Remove clips C to remove the moistening cloth.

  • Page 132: Calibrate Photocells

    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. In the settings menu, tap the [Diagnostics] tab. Tap [Photocells]. Remove all documents and envelopes.
  • Page 133 Clean the photocells. Place the bellows (item L, section Operating Controls on page 8) in the upper and lower air plug and firmly squeeze a few times to blow the dust from the document path sensor and envelope path sensor.
  • Page 134 To clean the exit sensor place the bellows in the hole for the exit sensor and firmly squeeze a few times to blow the dust from the exit sensor. Close all covers. Tap [Calibrate photocells].

  • Page 135: 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 136 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 (i) Details to view more information about the event.
  • Page 137 Error messages 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 (i) Details to view more information about the occurred error and about the possible actions to avoid the error from re-occurring.

  • Page 138: Clearing Stoppages

    Clearing stoppages Clearing Stoppages For clearing of stoppages, three system sections can be opened: A - Top cover (upper unit) to reach the Folder and Feeder area. B - Collator plate to reach the collator area. C - Front cover to reach the envelope track and inserter area. Lower Envelope Track When a stoppage occurs in the lower envelope track, remove the envelopes as follows: Open the Front cover.
  • Page 139 Lower and hold the handle A to the left and remove the envelope(s) from the lower envelope track. Release the handle A. If necessary, the envelopes and documents can be transported manually by turning the blue knob C clockwise. Turn the blue knob B clockwise to manually transport envelopes through the lower envelope track.

  • Page 140: Collating Area

    Collating Area When a stoppage occurs in the collating area, remove the documents from the collating area as follows: Move the collator plate B down. Remove the documents from the collator area. Move the collator plate B up in position. Press the [Reset] button to reset the error and restart the job.

  • Page 141: Operator Troubleshooting

    Close the top cover A. Press the [Reset] button to reset the error and restart the job. Operator Troubleshooting To resolve problems: Write down the event message number that is shown in the message on the screen. Try to solve the problem by consulting the Troubleshooting Table. Switch the inserter off and on again, to verify system operation.
  • Page 142 Envelopes are double Envelope separation Adjust envelope sep- Loading Envelopes fed. not correctly set. aration. on page 72 Envelopes not placed Check and replace if Loading Envelopes properly in the hop- needed. on page 72 per. Envelope stops Side guides of the Check side guides Loading Envelopes skewed.
  • Page 143 System stops while Fingers not correctly Check fingers posi- Adjust the envelope inserting (stoppage at adjusted. tion, adjust if needed. insert fingers position the inserting point). on page 45 Inserted document Check fold settings. Editing a job too long for used en- page 55 velope.
  • Page 144 Envelope not always Inserted document Check fold settings, Editing a job ejected from sealer. too big. adjust if needed. page 55 Document not inser- Check adjustment of Verify the Insert Posi- ted deep enough. envelope stop posi- tion on page 43 tion and fingers.
  • Page 145 Document set not Insert position not Check insert position. Verify the Insert Posi- correctly inserted. correct. tion on page 43 Insert fingers not cor- Check insert finger Adjust the envelope rectly positioned. position. insert fingers position on page 45 Address not readable Address position not Check address posi- Adjusting the address...

  • Page 146: Specifications

    Specifications System Specifications Model DS-77iQ, FPi 4800, FD6308, TSI-5S, C777iQ Type Folder and inserter system for medium office use. Theoretical max. speed 3800 inserts per hour, depending on application. Power consumption Standby: 0.33 W Idle: 15.5 W Run mode: 160 W...

  • Page 147: Hopper And Feeder Capacity

    Hopper and Feeder Capacity Envelope hopper 325 envelopes (80 g/m ) Document feeder tray 325 sheets (80 g/m ) High Capacity Document Feeder tray 725 sheets (80 g/m ) Configuration Dimensions and Weight 2/3 stations Height 720 mm (28.3 inch) 780 mm (30.7 inch) including High Capacity Vertical Stacker Width...

  • Page 148: Document And Enclosure Specifications

    Document and Enclosure Specifications Paper quality Minimum 60 g/m² (15 lb bond) Maximum 250 g/m² (62.5 lb bond), when folded max. 170 g/m² (42.5 lb bond) Booklets up to approximately 1 mm (0.04 inch) thickness, depend-ing on stiffness 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")
  • Page 149 Minimum 60 g/m2 160 mm 90 mm 32 mm 10 mm 130 mm 84 mm size 6.3” 3.5” 1.25” 0.4” 5.1” 3.3” Maximum 248 mm 162 mm B-32 35 mm A-12* 2.5 mm size 9.7” 6.38” B-1.25 1.38” A-0.47** B-0.2 0.1”...

  • Page 150: 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 151: 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 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 Flexcode An OMR/BCR code for which the meaning of the marks can be pro- OMR/BCR grammed in a dedicated way for a specific customer. This is normally used to support the OMR/BCR codes from other suppliers. High Capacity Optional stacker that is mounted on the exit of the system, to stack filled Vertical Stacker envelopes.
  • Page 156 Operator The person operating a document system. Optical Mark Re- Optical Mark Recognition is intended for reading and interpreting printed cognition (OMR) codes. These codes are one or more black marks which are read from a document. These marks give information to the Inserting system about how to build-up and handle a set.
  • Page 157 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 in a Z-shape.