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Table of Contents
Related Manuals for Formax 7100 Series
Summary of Contents for Formax 7100 Series
- Page 1 7100 Series High-Volume Modular Inserter OPERATOR MANUAL 7/2009...
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Page 2: Table Of Contents
Main Menu Table of Contents Inroduction ............... 3 1.1 Pictograms ..............3 1.2 Notes on Use of this Handbook ........4 Safety Notes ..............4 2.1 General Safety Notes..........5 2.2 End of Life ..............6 Technical Specifications ............ 8 3.1 Machine Rating Sheet ..........8 Machine Layout Guide ............ - Page 3 Operator Maintenance ............37 7.1 Clearing Paper Crashes ..........37 7.2 Cleaning Rollers & Sensors ..........39 7.3 Maintaining the Wetting System ........43 Document Orientation Tables ..........44...
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Page 4: Inroduction
1 INTrOdUCTION With this inserter you have an advanced, medium-volume folding and inserting machine. Its modular construction allows up to 8 feed units to be fitted, with a maximum of 17 feed trays. Sophisticated software control optimises the order and flow of documents for collating at the insert head before insertion into the envelope. All fold and adjustments take place automatically according to the requirements programmed in by the operator. ... -
Page 5: Notes On Use Of This Handbook
1.2 Notes on the Use of this Handbook This document contains all general information and explanatory text necessary in order to be able to carry out the operation of the machine. When some action is expected from the operator, this will always be explicitly stated, and where relevant, accompanied by an illustration or graphic. Always read through each step, so that you will obtain all of the necessary information. Do not anticipate what you believe will follow in the handbook: It will prevent you from making mistakes! Chronology and reference... -
Page 6: General Safety Notes
General safety notes Caution! Please, read these notes with care. Save these instructions for later use. All notes and warnings found on the machine are to be followed. Installing Important! The machine must be installed only by an authorised Service engineer. A safe, level position is necessary, when installing the machine machine, with sufficient space all round to operate it. The machine is to be protected from moisture. -
Page 7: End Of Life
allow In the following cases, the mains plug must be unplugged and the device machine to left for the authorized Service Agents: be checked • When the mains cable or plug is worn or damaged. by the • When water or other liquid has entered the device. Service • When the device does not function properly, in spite of Agent following the instructions provided. • When the device has fallen down or the housing is damaged. - Page 8 In order to facilitate collection and treatment separated from normal domestic waste, elec- trical and electronic equipment is marked with the following logo: Not only are you by law not allowed to dispose of the waste equipment via other waste- streams, but we encourage you to actively contribute to the success of such collection and to the common good and better quality of life of present and future generations.
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Page 9: Technical Specifications
CAUTION: For continued protection against risk of fire, replace with same type and rating of fuse. The fuse rating/type for this machine is : T 10 A Amps 115Volts (Part No. 135-110). Model details: Model Name: 7100 series Input Voltage: 115 Volts @ 60 Hz Input current: 7 Amps Sound Reading: 75dBA (measured at a distance of 1 meter from the nearest cover and a height of 1.6 meters... -
Page 10: Machine Layout Guide
MaCHINe LayOUT GUIde description of machine The function of the machine is to feed forms from a number of hoppers, fold them in either ‘C’, ‘Z’, ‘V’ or double forward fold and insert them into an envelope which is then sealed and ejected. Further form(s) may optionally be collated with the first form, either by folding together or collating on the track. -
Page 11: Control Panel Layout
Control panel layout Enter/Select Help Scroll up button button button button Exit Scroll down Display Stop button button button eXPLaNaTION Of BUTTONS Help button: Provides context-sensitive Help at any time. Help information displayed will match what you are do- ing when you press the button. Scroll up/down buttons: Scrolls display up or down on the screen, and adjusts speed when running. -
Page 12: Parts Identification
4.3 Parts identification Daily post tray Tower folder Insert (see below) feeders Control panel Insert/collate area Envelope hopper Note: Station 1 is the first feed unit after the insert/ collate area. Filled envelope tray Storage cupboards Feed trays (either 3 or 1) Accumulator (optional) Tower folder... -
Page 13: Operating The Machine
OPeraTING THe MaCHINe Operating overview Shown below is a brief summary of the operating procedure of the machine. Full details of the functions referred to can be found in the section numbers indicated. 1. Load document and/or insert hoppers (page 33). 2. -
Page 14: Main Menu
Read this first: Throughout this section, selections are made using the button after using the Scroll Up/ Down buttons to reach the option. Options that have a scroll box are changed by first press- to highlight the box, then using the Scroll Up/Down buttons to change the setting. Press again to finish. The x button aborts the changes in any menu and returns you back one step. Main menu When the machine first starts, the Main Menu is displayed as shown* For full details of each menu option, see the following sections: Select &... -
Page 15: Select & Go
Select & Go Select & Go is a rapid method of setting up a job without the need for full programming. You as the user decide which hoppers to load - the machine’s software then automatically cre- ates a simplified programme. First select the fold type and press . Load the hoppers and ... -
Page 16: Running A Job
running a job The Run Job menu shows the currently available jobs that have previously been pro- grammed (or you can run the last job from the Main menu). The graphic indi- cates which hop- pers are active, and whether a folded document or an insert. -
Page 17: Other Run Job Menu Functions
Other run Job menu functions From the Run Job menu, select the job you wish to edit and press . This displays the Run screen, as shown below, which will be in ‘Ready’ mode. Now press x and a list of options will be shown, described below: edit: Enters the same edit mode as described on page 21. advanced: Allows adjustments to various machine functions as described on page 19. -
Page 18: Batching
5.5.1 Batching Batching allows a preset number of filled envelopes to be processed before the machine automatically stops. From the Run Job menu, select the job you wish to set a batch for, and press . This displays the Status screen, which will be in ‘Ready’ mode. Now press x and a list of options will be shown. Select ‘Batch Count’, and you will enter the batch screen, as shown below. -
Page 19: Count
5.5.2 Count The ‘Count’ function allows the global or job counts shown on the display to be set to zero. The global count continues to accrue even if you switch to another job; the job count applies only to the job you are running. To zero either count, stop the job you are running by press- ing the Stop button. -
Page 20: Advanced Settings
5.5.3 advanced settings Advanced settings allow adjustments to be made to various machine functions. It is specific only to the job you are in when you make changes, and will be saved with the job, even when the machine is switched off. Note that this function is password protected. Warning: Changes made in this function may adversely affect the machine. Use it only if you know what you are doing! Collate Pocket adj. - Page 21 Maximum folds Adjusts up or down the maximum number of forms that can be folded together in a tower folder. If multiples are set to greater than this number, the multiple will be split into sections. Default for C, Z or V = 5, max. = 8. Default for double-V = 4. max. = addr. on every page Gives software greater flexibility by allowing, for example, a group to be split over more than one envelope, or swapping prime document.
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Page 22: Creating A New Job
Creating a new job Select ‘New Job’ from the main menu to display the Create screen as shown: The graphic indi- cates where the inserts and folded documents should be placed. Note that it may be different to that shown, depend- ing upon machine configuration... -
Page 23: Envelopes
5.6.1 envelopes When you enter the edit screen, the first ‘Edit Item’ shown will be #1 which is the enve- lope - higher numbers will be documents (folded sheets or inserts). Press to highlight the scroll box, then press it again to display the envelope settings. Select the envelope from the standard range, or ‘Custom’ (this allows depth and width to be set). Choose whether flap is to be sealed always, by OMR select, no seal with flap closed or no seal with flap open. Select required deskew level (high slows machine more). Select ‘Done when finished to return to the Edit screen. Note: If you wish these settings to be de- fault, see ‘Supervisor Mode’... -
Page 24: Documents
5.6.2 Documents Press to highlight ‘Edit item’ scroll box, then use the scroll-up button to select #2 (this is usually the prime, or address document). Options are explained below. The settings that appear may be fewer than those described below, depending upon wheth- er the item is a folded form or an insert. - Page 25 doubles det. Detects for double documents. On by default. Deselect only if you are using unusual stationery that may cause spurious errors (eg. some sheets heavy, dark text and some almost none). deskew Straightens a document if it is skewed. Options are Off/ Low / Me- dium / High. If deskew is selected, note that the operating speed is slowed;...
- Page 26 Select the named sheet you wish to replace, then ‘Done’. When the New Name screen appears, use the Scroll Up/Down buttons to select the first character, then press . This moves to the second character, and so on, up to the maximum 10 characters. When finished, press x to exit the screen. Confirm your changes, and your new template is now saved. repeat the edit process for all the remaining document or insert items. When finished, select ‘Done’ to move to the Save screen, as described on the following page.
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Page 27: Saving The Job
5.6.3 Saving the job When all documents and inserts have been edited, you move to the Save screen, which al- lows you ‘Save As’ to a new jobname (for a new job), or ‘Save’ (if editing an existing job). To enter a new jobname, select ‘Save As’, as shown below: Use the Scroll Up/Down buttons to select the first character, then press . This moves to the second character, and so on, up to the maximum 10 characters. When finished, press x to exit the screen. Confirm your changes, and your new job is now saved and will appear on the Run Job menu. -
Page 28: Omr Reading
OMR Reading If ‘Mark read’ was set to OMR when editing a document or insert, the following screen will appear when all other settings have been made. Note: OMR definitions can only be created by authorised personnel. Explanation of settings OMR definition This is the name of the setup that defines the function of each of the marks. - Page 29 divert blank sheets Diverts sheet with no gate mark without stopping machine. Sheet must be be- tween groups; if a mid-group sheet is diverted, then machine will stop with ‘no gate mark’ error - operator must then intervene. Only one consecutive blank sheet allowed - more will cause same error as above.
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Page 30: Barcode Reading
Barcode reading If ‘Mark read’ was set to Barcode when editing a document or insert, the following screen will appear when all other settings have been made. Note: Barcode definitions can only be created by authorised personnel. explanation of settings BCR definition This is the name of the setup that defines the function of each of the marks. It can only be created by authorised personnel and must already exist in order to be used. Up to 9 definitions can be created. read head Id This stipulates the location of the read head on the machine, ie. which hopper and whether LH or RH side. -
Page 31: Supervisor Mode
Supervisor mode Supervisor mode can only be accessed by input of the correct PIN. It allows a variety of ma- chine functions, as described below. Language Select required operating language from available list. firmware version Read-only display of firmware for each module fitted. Machine Count Read-only display of the total cycle count to date (this count cannot be reset). enable Supervisor PIN Enables/disables the need to enter a PIN for Supervisor access. - Page 32 analogue Sensors (only available if this option is set in Engineer mode) A read-only display of analogue sensor settings, as described below: Settings are shown in the format: abc d.d C or B The meaning of the numbers is as follows: a = emitter current value (0 - 9).
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Page 33: Daily Post
5.10 daily post Daily post allows a group of forms to be hand-fed, folded and inserted. Up to 8 forms of 80gsm (20lbs bond) may be fed, and they may be stapled or not, as required. To use daily post, you must first create a new job using Handfeed. Select ‘New Job’ from the Main Menu and ensure that the Handfeed box is ticked. Note that other sheets and inserts can also be collated with the hand-fed daily post if required, up to the limits shown in ‘Spec- ifications’. Select ‘Done’ and edit the envelope and mail items in the same way as any other new job (‘Creating a New Job’ on page 21). When finished, save the job to a suitable name. -
Page 34: Setting Up The Machine
SeTTING UP THe MaCHINe Loading the paper hoppers Insert feeder Pull the weighted roller back and load the inserts, ensuring they are fully down. Release the weighted roller so that it ‘tips’ the inserts into the pickup roller. An alternative heavier roller is also available Slacken the lock- le- (part no. -
Page 35: Loading The Envelope Hopper
Tower folder - curled forms stop Documents that are slightly curled may not feed properly, as the leading edge may become snagged at the infeed. To help overcome this, each hopper tray is fitted with a 2-position stop that can be raised or lowered. Withdraw the hopper and pull both of the spring-loaded knobs outwards. 2. For flat forms or forms curling upwards, select the upper (default) position. -
Page 36: Setting The Separator Gap
Setting the separator gap The feeder separator has 4 settings, marked A to C on the slide. Before running the job, the gap must be set to suit the thickness of material being processed - this prevents more than one item being fed at a time. Note that there is an intermediate setting between each marked position, allowing finer adjustment. -
Page 37: Operator Settable Separator
Operator settable separator (optional) The standard separator on the tower folder is spring-loaded and operates with a preset gap for 80gsm (20lbs bond) paper. Under certain circumstances (eg. extra thick material) it may be necessary to open the gap, or in some cases to close it. As standard, this can only be carried out by a Service Engineer, but with some stationery, this may not provide a suffi- ciently sensitive adjustment. -
Page 38: Operator Maintenance
SeCTION 7 OPeraTOr MaINTeNaNCe Clearing paper crashes If a paper crash occurs, the machine will stop and indicate the position of the crash on the screen. Clear the crash as shown below, then press the Run button to resume operating. Insert head and feeder Raise the top perspex cover and small feeder cover. - Page 39 Tower folder Open the side cover and operate the two green latches to raise the roller platten and open the daily-post hop- per. Also open the top cover to access the upper part of the feed hopper. Carefully withdraw any jammed pa- per, taking care not to tear it - turn the green knobs to help wind jammed paper out of the rollers.
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Page 40: Cleaning Rollers & Sensors
Cleaning rollers and sensors Periodically, all rollers, feed wheels and sensors should be cleaned, especially if a long run is envisaged. Use only Rubber Roller Restorer, except for the pick-up rollers on the feed and envelope hoppers - these must be cleaned using only a cloth dampened with water. - Page 41 Cleaning sensors (contd.) Note: in most places the sensor or access hole is indicated with an arrow punched into the sheet metal. Spray the air jet liberally into holes to ensure thorough cleaning. Insert and collate area For all positions shown, direct the jet of air onto the sensors, indicated by arrows in the fol- lowing views.
- Page 42 Tower feeder Open the cover in front of the feeder trays and direct a jet of air onto the sensors shown by the arrows in the diagram below. Ensure that all sensors, including those inside the pivoting cover are thoroughly cleaned as some sensors are located deep behind the apertures. Closer area Open the closer cover below the envelope hopper and direct the jet of air onto the sensors, indicated by arrows in the following view.
- Page 43 Tower folder There are sensors in three locations. Open the side cover and swing the lower green latch upwards to raise the roller platten. Clean both halves as shown. With the side cover open, swing the upper green latch forwards to open the daily post hopper.
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Page 44: Maintaining The Wetting System
Maintaining the wetting system The wetter tank supplies the fluid for wetting the envelope flaps and needs topping up from time to time. It is located on the left hand side of the machine, below the closer area at the output. To gain access, lower the side cover on the insert head. Fill the tank through the spout until the level reaches the indicator visible inside - be careful not to overfill. -
Page 45: Document Orientation Tables
8. dOCUMeNT OrIeNTaTION TaBLeS Paper orientation on the feed hoppers will depend on fold type, accumulation tray, OMR/Bar- code and feed sequence. The example below shows how to reference the required orienta- tion from the tables. Note that for most applications, the LEDs on the rear edge of the tower folder will indicate the required orientation. example Fold Chosen is top address ‘C’... - Page 47 Page intentionally left blank...