quadient Full Format Inserter (FFI) User guide

Brand: quadient

Model: Full Format Inserter (FFI)

Type: User guide

Full Format Inserter User Guide Issue 3 July 2014

Table Of Contents

1 Health, Safety & Environment ............................................................. 2

1.1 Precautions and Safety Issues .................................................. 2

1.2 Country Specic Conditions ...................................................... 3

1.3 End of life ............................................................................... 3

2 Description of Machine ........................................................................ 5

2.1 Machine Options ...................................................................... 5

2.2 Description of Machine ............................................................. 5

3 Operating the Machine ......................................................................... 7

3.1 Setting the paper guides ........................................................... 7

3.2 DS-1000/1200 Operation .......................................................... 9

3.3 Full Format Inserter ................................................................11

4 Operator Maintenance ....................................................................... 13

4.1 Clearing paper jams ................................................................13

4.2 Cleaning the sensors ...............................................................15

5 Troubleshooting Guide ....................................................................... 16

6 Technical Specication ...................................................................... 17

6.1 Product requirement ...............................................................17

6.2 Functional specication ............................................................17

6.3 Electrical specication .............................................................18

6.4 Physical sizes and weights .......................................................21

2Full Format Inserter User Guide Issue 3 July 2014

1 Health, Safety & Environment

1.1 Precautions and Safety Issues

Thoroughly read this operator manual, before using this system.

According to the EC declaration (European Commission) following the Low Voltage Directive

(2006/95/EC), this operator manual must be available in the national language(s) of the

country where the system is delivered. Therefore, if you do not have an operator manual in

your country’s language(s), contact your authorized distributor.

Warnings

• Disconnect the mains supply before performing any maintenance. The machine

operates on low voltage so no general electrical hazard is present. However, the

inserter to which it connects operates at mains voltage, hence a hazard exists if

any electrical parts remain uncovered.

• Before connecting, check if the system is suitable for the local mains voltage.

Refer to the rating plate located near the mains inlet.

Safety Precautions

• Only competent personnel should operate this system.

If incompetent personnel do operate this system, the manufacturer does not

accept responsibility for any resulting accidents or injuries.

• Only authorised personnel, who are aware of the risks involved, may remove the

permanent protective covers: the operator has access only to opening covers. For

safety reasons, the system will not function when the covers are open.

• Keep long hair, ngers, jewelry, etc. away from rotating and moving parts.

• The mains power connection must be easily accessible, preferably close to the

system.

• For safety reasons, it is essential that the system is connected to a socket outlet

that has a protective earth connection.

• Over-current protection in the equipment also relies on the mains branch circuit

protection (max. 16 A).

• The following part(s) is (are) considered the equipment disconnect device(s):

- Power supply cord plug

Full Format Inserter User Guide Issue 3 July 2014

Conventions

General Warnings

• This symbol identies situations where improper use of the

system could result in personal injury or damage to the machine.

Warning of danger from electricity or electrical shock

Information / Note indicating important information regarding the handling of

the machine.

1.2 Country Specic Conditions

Denmark

In Denmark, certain types of Class 1 appliances may be provided with a plug that does not

provide an adequate earth connection when inserted into a Danish socket outlet.

Make sure the system has a good functioning connection that has protective earthing (the

plug and socket outlet must match).

Japan

• Establish an earth connection before connecting the mains plug to the power supply.

• First disconnect the power supply before removing the earth connection.

Languages

This manual is also available in other languages; please contact your local supplier.

1.3 End of life

The objectives of the European Community’s environment policy are, in particular, to

preserve, protect and improve the quality of the environment, protect human health and

utilise natural resources prudently and rationally. That policy is based on the precautionary

principle and principles that preventive action should be taken, that environmental damage

should as a priority be rectied at source.

Separate collection of waste is the precondition to ensure reuse and recycling of waste that

is generated at the disposal of electrical or electronic equipment and is necessary to achieve

the chosen level of protection of human health and the environment in the European

Community.

More particularly, certain materials and components of waste electrical and electronic

equipment needs selective treatment as their injudicious handling or disposing of on or into

land, water or air would represent a major threat to the environment and human health.

4Full Format Inserter User Guide Issue 3 July 2014

In order to facilitate collection and treatment separated from normal domestic waste,

electrical and electronic equipment is marked with the following logo:

Do not mix with normal domestic waste.

Please use the subjoined return or

collection system dedicated to electrical

and electronic waste.

Equipment produced after

August 13 2005

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.

For more information on the correct disposal of this product please contact your local dealer

Full Format Inserter User Guide Issue 3 July 2014

2 Description of Machine

2.1 Machine Options

The Full Format Pack Diverter system can be used with a 1000 or

1200 Series inserter, using either a standard-capacity, high-capacity or

continuously fed collator. The Full Format inserter can include up to 8 feed

stations, with reading option if required. A folding option is not available.

2.2 Description of Machine

The function of the Full Format Pack Diverter is to receive unfolded A4 forms

or groups of forms from the collator of a 1000 or 1200 Series inserter in

portrait orientation and pass them in landscape orientation to a Full Format

Inserter for insertion into a C4 envelope.

The Full Format Inserter can include up to 8 feeders for addition of further

forms.

See following page for explanation.

6Full Format Inserter User Guide Issue 3 July 2014

Description of Machine (cont).

(1) Document Feed: High-Capacity or Standard Capacity feed unit, or

continuously fed from fan-fold stationery in 1-up or 2-up format via a cutter.

Roll feed can also be used.

(2) Collate Area: Documents can be collated as a group, either as

multiples or BCR/OMR reading. Collator includes a built-in reader.

(3) FFPD Diverter: Documents are fed onto a turnover conveyor which

moves them underneath. A transfer conveyor then moves them sideways

into the input of the Full Format Inserter.

(4) Feed Units: Up to 8 feed units can optionally be tted, allowing other

forms to be added to the prime document prior to insertion.

(5) Insertion Area: Document or group of documents is inserted into

the envelope (see Specications for maximum number of sheets and pack

thickness).

(6) Output Conveyor (optional): Accumulates lled envelopes for

subsequent removal. Receiving tray is available if conveyor not specied.

Full Format Inserter User Guide Issue 3 July 2014

3 Operating the Machine

Important: This document describes features applicable only

to the Full Format Pack Divert system. It should be read in

conjunction with standard machine User Guides.

3.1 Setting the paper guides

There are paper guides at both ends of the FFPD which must be set prior to use. They are

factory set for either A4 or Letter size documents and should not normally require changing,

but if they do, the procedure is shown below.

1. Release the latch on the LH side of the

collator stand and move the collator and

FFPD unit backwards.

2. In front of the FFPD unit, lift out the

turnover plate to gain access to the paper

guide adjustment knobs.

8Full Format Inserter User Guide Issue 3 July 2014

3. Slacken the adjustment knobs (1 each

side) and move the guides to either A4 or

Letter size, as indicated on the scale.

Note: A4 or Letter are the only sizes that

can be used.

4. Move the FFPD Unit forward, leaving

the collator moved back. At the rear, lift

up the overguide plate and slacken the

lock levers (1 each side).

Move the guides to either A4 or Letter

size, as indicated on the scale.

5. Move the FFPD Unit and collator back into position, ensuring the latch is fully locked.

The machine is now set up and available for use.

Full Format Inserter User Guide Issue 3 July 2014

3.2 DS-1000/1200 Operation

Select the Menu icon from the Run Screen.

Select Jobs from the Menu Screen (see following page) and New to create

a new job.

You can also use an existing job by selecting Edit, but be

aware that unless you change it back, the job can only be used

in FFPD mode.

10 Full Format Inserter User Guide Issue 3 July 2014

Set Tandem Mode to FFPD, and make all other selections as required.

Save and exit when you are nished.

Important: The Job Name must be exactly the same as the Job Name

on the Full Format Inserter.

FFPD

Full Format Inserter User Guide Issue 3 July 2014

3.3 Full Format Inserter

Select Create Job from the Job screen.

When the Main Document has been chosen, select Settings and set the

Hopper Feed Mode to External. Save the settings. This will then direct the

document to the FFPD.

12 Full Format Inserter User Guide Issue 3 July 2014

If required, create Enclosures and select output settings as described in the

standard User Guide.

When all settings are complete, save the job to your required name. It will

now be available for use in the Job list.

Important: The Job Name must be exactly the same as the Job Name

on the DS-1000/1200.

If an Insert Feeder is tted and an insert is specied in the job, this will be

indicated in the icons on the Run screen.

Added insert from

Insert Feeder

Main document

from FFPD

Full Format Inserter User Guide Issue 3 July 2014

4 Operator Maintenance

This section describes jam clearance for the FFPD Unit - see

also jam clearance for Full Format Inserter & 1000/1200 Units

in each of their Operator Manuals.

4.1 Clearing paper jams

If the paper jams inside the FFPD unit, it can be moved rearwards to provide access for

clearance.

1. Release the latch on the LH side of the

collator stand and move the collator and

FFPD unit backwards.

2. In front of the FFPD unit, remove any

jammed paper from the cavity at the end

of the conveyor.

14 Full Format Inserter User Guide Issue 3 July 2014

3. Better access may be gained by

lifting the Turnover Plate out of the

cavity. Remember to replace it when

the jam is cleared.

4. Move the FFPD Unit forward to

remove jammed paper from behind.

Lift the overguide plate up to check

for paper beneath.

5. When you are satised the unit is clear of jammed paper, move the

FFPD and collator back into home position. Ensure the latch is locked.

6. If the jam is in the output to

the Full Format Inserter, lift up the

handle of the cover on the output

conveyor and raise the cover to ac-

cess the paper.

Note: the cover is not supported on

gas springs.

Full Format Inserter User Guide Issue 3 July 2014

4.2 Cleaning the sensors

There are a number of optical sensors on the FFPD Unit which detect and monitor the paper

as it passes through the machine. These sensors can become obscured with paper dust, so

they should periodically be cleaned with an airduster.

Use a non-ammable airduster (part number 9103707C), spraying liberally onto each lens.

Two sensors are visible to operators, as described below.

1. Move the FFPD Unit rearwards, as

described in section 4.1.

Spray the airduster onto the sensor

indicated left.

2. Open the FFPD output cover, as

described in section 4.1.

Spray the airduster onto the sensor

indicated left.

Whenever running problems develop, the sensors should always

be cleaned rst. If this does not resolve the issue, your local

Service Department will need to be alerted.

16 Full Format Inserter User Guide Issue 3 July 2014

5 Troubleshooting Guide

If operating problems occur when using the FFPD Unit, refer to the following guide before

contacting your local Service Department.

Problem Suggested Solution

Documents failing to feed from

1000/1200 machine, or into Full

Format Inserter.

1. Check Tandem Mode is set to FFPD

on both machines (sections 3.2 & 3.3).

2. Check hardware is correctly cong-

ured for FFPD (appendix 1).

3. Ensure paper size is A4 or Letter only.

Error “no matching job found;

Tandem Mode requires the job

names to be common” appears.

Ensure job name on 1000/1200 machine

is the same as for Full Format Inserter

(sections 3.2 & 3.3).

Documents consistently crashing

in FFPD Unit.

1. Ensure paper guides are correctly set

(section 3.1).

2. Check that turnover plate is properly

located on its spigots (sections 3.1 &

4.1).

Documents feeding through FFPD

Unit but not appearing at Full

Format Inserter.

Check for paper jam in output to Full

Format Inserter (section 4.1).

Documents not feeding from

1000/1200 machine.

Check collator is properly latched in

place.

Paper jams or misfeeds occurring

erratically.

Clean sensors (section 4.2).

Full Format Inserter User Guide Issue 3 July 2014

6 Technical Specication

6.1 Product requirement

DS-1000 & DS-1200, tted with accumulator unit and

folder, end station only. Diverted output generally to Full

Format Inserter, but output to conveyor option is available.

IMOS on DS-1xxx plus IMOS on Full Format Inserter.

6.2 Functional specication

Pass-through mode: Up to 12,000 forms/hour

Diverted mode (FFI): Up to 3,000 forms/hour

Pass-through mode: 750,000/month typical

Diverted mode (FFI): Up to 200,000/month

Pass-through mode:

Width: 149mm Min.

216mm Max.

Depth: 89mm Min.

406mm Max.

Diverted mode:

Width: 210mm Min.

216mm Max.

Depth: 280mm Min.

306mm Max.

Product

compatibility

Software

required

Cycling speed

Volume

Paper sizes

18 Full Format Inserter User Guide Issue 3 July 2014

Full Format Sizes: Factory set to either European A4 or US letter

297 x 210 or 279 x 217.

Note that the unit can be set for continuous

stationery up to 12”

Maximum collation: 72 sheets of 80gsm (or 20lb bond)

Note that the maximum number of pages is

automatically reduced relative to paper weight.

Sub groups of 8 pages or less are recommended

from the accumulator.

Env. Pack thickness 10mm

Independent operation The DS-1200 G3 and FFI can run independently

as two separate machines or in ‘Tandem’.

Tandem modes: FFI always/DS-1200 G3 always or Divert to

FFI by page count/label select

Connectivity: AIMS compatible in all operating modes

Power input: 220V, 50 or 60 Hz

Full Format Inserter User Guide Issue 3 July 2014

Horizontal portion of throat

Max. = Envelope Width - 75mm(3")

Flap Shoulder Angle

Min.70mm (234")

Minimum open

throat area

50°Min. 90°Max.

Min.

(1332")

10mm Throat angle

5°Min. 20°Max.

(1332")

Min. 10mm

Max. = Envelope Width - 75mm(3")

Envelope Width Max. 330mm(13") Min. 225.5mm(8 7/8")

Min.70mm (234")

Horizontal portion of throat

Flap Shoulder Angle

Body Depth

Max. 254mm(10")

Min. 98.5mm(3 7/8")

Minimum open

throat area

Min.

50°Min. 90°Max. (1332")

10mm Throat angle

5°Min. 20°Max.

Min. 10mm

(1332") Flap Length

Max. 65mm (2½")

Min. 32mm (114")

Side Seam style envelope

Commercial style envelope

Body Depth

Max. 254mm(10")

Min. 98.5mm(3 7/8 ")

Flap Length

Max. 65mm (2½")

Min. 32mm (114")

Min. 10mm (13 32")

Max. 25mm (1")

Throat Depth

Envelope Width Max. 330mm(13") Min. 225.5mm(8 7/8")

Throat Depth

Max. 25mm (1")

Min. 10mm (13 32")

20 Full Format Inserter User Guide Issue 3 July 2014

6.3 Electrical specication

115v @ 60Hz or 230v @ 50Hz (± 10% maximum)

Machine tted with BS4343 32A IP44 industrial free plug

connector, conforming to EN60309 1 & 2 and CEE17.

Mating socket required at supply source.

Notes:

1. For 115v supplies with rated current greater than 15A it is acceptable to replace

the supplied plug with a NEMA L14-30 (4-pin device), or a 3-pin higher current

rated device, wired to achieve 230V (X and Y, or Live and Neutral pins are ‘hot’ with

respect to ground). The connector used must comply with UL requirements and

have a UL reference number. Note that both Live and Neutral are fused in the ma-

chine.

2. For countries using 230V who wish to change away from the supplied plug please

note that the replacement device used must have a rated current carrying capabil-

ity greater than 30A and meet all safety requirements for that country.

3. Changing the supplied plug negates any responsibility of the Company for the

safety integrity of the machine.

4. Changing the supplied plug must be carried out by a qualied electrician.

5. If 2 x Hi-Cap Feeder Folders, a Hi-Cap and a Lo-Cap Feeder Folder or an OMR/

Barcode Feeder Reader Folder with any other unit are located next to each other on

the same track pair, it is necessary to order and t an additional power supply kit

184-156 to ensure correct operation.

See following page for details of current ratings.

Voltage

Power

connector

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quadient Full Format Inserter (FFI) User guide

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