FPi3030 OpManual

Operator Manual
FPi 3030 Inserting Machine
Contents
Please read this operator manual before using your FPi 3030 folderinserter. Keep this manual near the folder-inserter for easy
reference.
The following symbols and cautions represent important warnings in
this manual:
Contents
1
Safety tips ________________________________________________________________________________________________ 6
About the FPi 3030 folder-inserter _________________________________________________________ 7
General _____________________________________________________________________________________________________ 8
3.1 Understanding the machine ______________________________________________________________ 8
3.2 Operating controls __________________________________________________________________________ 11
3.3 Display buttons _______________________________________________________________________________ 12
3.4 Optical Mark Reading/OMR (option) ______________________________________________ 13
Preparations __________________________________________________________________________________________ 15
4.1 Moistening the brushes __________________________________________________________________ 15
4.2 Power supply __________________________________________________________________________________ 15
Operating the machine __________________________________________________________________________

5.1 Switching on ___________________________________________________________________________________
5.2 The main menu ______________________________________________________________________________
5.3 JOB INFO screen ___________________________________________________________________________
5.4 OTHER JOB menu _________________________________________________________________________
5.5 Adjustment of the document hopper _______________________________________________
5.5.1 Document separation _________________________________________________________
5.5.2 Side guides ________________________________________________________________________
5.5.3 Filling the document hopper _______________________________________________
5.6 Adjustment of the document stoppers ____________________________________________
5.7 Feeding documents ________________________________________________________________________
5.7.1 Feeding documents (without OMR) ____________________________________
5.7.2 Feeding documents with OMR (option) ______________________________
5.8 Adjustment of the envelope feed ____________________________________________________
5.8.1 Envelope separation ___________________________________________________________
5.8.2 Side guides ________________________________________________________________________
5.8.3 Envelope support _______________________________________________________________
5.8.4 Envelope receiving tray ______________________________________________________
5.8.5 Envelope sealing ________________________________________________________________
Warning! indicates a potential hazard which may result in injury.
Caution! indicates a potential hazard that may result in damage to

your inserting system or which may impair the processing of
documents.
Typography
Please note the following typographic features:

Chapter headings, keys and information of particular importance are
printed in semi-bold type.
Words or phrases that appear in the display are written in CAPITAL
LETTERS.
Tips marked in this way offer advice and suggestions on the

efficient use of the FPi 3030 folder-inserter.
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FPi 3030 Operator manual
5.9
5.10
5.11
5.12
5.13
5.14
5.15
5.16
6
Contents
TEST RUN menu ___________________________________________________________________________

Insert position _________________________________________________________________________________
Envelope insert fingers ___________________________________________________________________
COUNTERS menu _________________________________________________________________________
INSERTING menu __________________________________________________________________________
FILL & START menu _______________________________________________________________________
Daily mail ________________________________________________________________________________________
Reading head position (machines with OMR option only) _______________
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Jobs ________________________________________________________________________________________________________
6.1 JOB MENU _____________________________________________________________________________________
6.2 CREATE JOB menu _______________________________________________________________________
6.3 EDIT JOB menu _____________________________________________________________________________
6.4 COPY JOB menu ___________________________________________________________________________
6.5 DELETE JOB menu _______________________________________________________________________
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Job settings ___________________________________________________________________________________________

7.1 ENVELOPE SETTINGS menu _______________________________________________________
7.1.1 Envelope with closed flap ___________________________________________________
7.1.2 Envelope with open flap _____________________________________________________
7.1.3 No envelopes _____________________________________________________________________
7.2 DOCUMENT SETTINGS menu ______________________________________________________
7.2.1 Number of sheets _______________________________________________________________
7.2.2 Document size ___________________________________________________________________
7.2.3 Hopper swap ______________________________________________________________________
7.2.4 Daily mail ___________________________________________________________________________
7.3 FOLD SETTINGS menu _________________________________________________________________
7.3.1 No fold ________________________________________________________________________________
7.3.2 Single fold __________________________________________________________________________
7.3.3 Letter fold ___________________________________________________________________________
7.3.4 Zig-zag fold ________________________________________________________________________
7.3.5 Double parallel fold _____________________________________________________________
7.4 DFC (Real Sheet Control) SETTINGS menu __________________________________
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7.5
OMR SETTINGS menu (machines with OMR option only) _____________

7.5.1 Select OMR settings screen _______________________________________________
7.5.2 OMR position settings screen ____________________________________________
JOBNAME menu ____________________________________________________________________________
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Fault finding ___________________________________________________________________________________________

8.1 General __________________________________________________________________________________________
8.2 Clearing stoppages ________________________________________________________________________
8.3 Error codes _____________________________________________________________________________________
8.4 Operator troubleshooting ________________________________________________________________
8.5 OMR error codes ____________________________________________________________________________
8.5.1 General OMR error codes __________________________________________________
8.5.2 Flexible reading error codes (Flex code) ____________________________
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Maintenance ___________________________________________________________________________________________
9.1 Servicing ________________________________________________________________________________________
9.2 General cleaning ____________________________________________________________________________
9.3 Cleaning the brushes _____________________________________________________________________
9.4 Cleaning the moistening felt ___________________________________________________________
9.5 Cleaning the fold rollers __________________________________________________________________
9.6 Cleaning the sensors ______________________________________________________________________
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Options ___________________________________________________________________________________________________ 80
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Specifications ________________________________________________________________________________________ 81
7.6
Appendix
FPi 3030 operator menu structure (without OMR) ___________________________________ 85
FPi 3030 operator menu structure with Optical Mark Reading (OMR) _____ 86
FPi 3030 job edit menu structure (without OMR) _____________________________________ 87
FPi 3030 job edit menu structure with Optical Mark reading (OMR) ________ 88
Service ____________________________________________________________________________________________________ 89
About the FPi 3030 folder-inserter
Safety tips
Your FPi 3030 inserting machine complies with standard safety regulations for office equipment of this type. Before operating your FPi 3030,
read the following tips to assure safe operation.
The FPi 3030 is a compact fold and inserting system which can process
large quantities of mail rapidly and easily. The system can be operated by
means of a user friendly interface.
FPi 3030 feeds, folds and inserts documents into envelopes and then
seals and stacks the envelopes. Automatic monitoring ensures the correct number of inserts per envelope.
About the FPi 3030 folder-inserter
The folder-inserter should be unpacked, installed and taken into initial

service only by qualified service technicians authorized by FrancotypPostalia.
Never remove or disable safety devices or guards.
Use only the power cable supplied with the machine or ones that are
approved by Francotyp-Postalia. Make sure that connecting cables
are in flawless condition. Make sure your office power supply conforms to power requirements shown on the systems serial number
plate.
Never extend hands into areas or spaces marked as danger zones.
Never place hands on or near any moving parts and keep long hair,
loose clothing or scarves and jewelry safely away from moving parts.
The opening of covers (except the top and side cover) must be
carried out only by a skilled and authorized person who is aware of
the hazard involved. The machine will not operate with the covers
opened.
Switch off the FPi 3030 before cleaning the machine or moving to a
new location.
Ensure that no liquids or objects enter the interior of the machine.
Disconnect the power cable from the outlet immediately if such an
accident occurs. Have the FPi 3030 checked by your local servicing
dealer before use.
All maintenance and repair must be done by an authorized
FP-technician. Non-observance of this rule will void your warranty.
For your own safety, please follow the special advises when moving
the FPi 3030 to a different location.
FPi 3030 is equipped with a variety of special features as
programmable jobs (machine parameters that can be set by authorized staff only)
Fill & Start (automatic recognition of document and envelope size)
Vario Feed (automatic and special feeder)
Real Sheet Control (double feed control / DFC; detects faulty sets of
documents)
Hopper swap (Two feeders can be linked as pairs. When the first
feeder is empty, the system switches to the other feeder. Meanwhile
the other empty feeder can be refilled without stopping.)
Multifeed (feeding of multiple documents from one station)
Daily mail (processing documents or sets of documents which cannot
be processed automatically)
Five in ONE (one folding unit for different folding types).
The system can be equipped with Optical mark reading (OMR). With
this reading the system reads optical marks that have been specially
printed on the documents. This code contains information about the
processing of the documents.
General
General
3.1
The system consist of the following parts (fig. 2):

Vario Feed
Understanding the machine
The settings of the system (types of documents, types of envelopes and

the type of fold) is recorded in so called jobs. These jobs can be programmed by an authorized user.
As a special feature the system is equipped with a Fill & start function.
The purpose of this function is to go to work as quick as possible without
doing extensive adjustments.
When a stoppage occurs, the system automatically signals the operator
and gives a suggestion about solving the Problem.
Collating area
Five in ONE
Inserter
Vario Feed
The Vario Feed is the feeding part of the system. The Vario Feed can be
equipped with two types of feeders. The automatic and the special feeder.
The automatic feeder does not require any adjustments for the separation.
The Vario Feed is equipped with Real Sheet Control. In this way the system can detect faulty sets of documents.
The FPi 3030 is equipped with hopper swap. This means that two feeders
can be linked as pairs. When the first feeder is empty, the system
switches to the other feeder. Meanwhile the other empty feeder can be
refilled without stopping. To use hopper swap it must be selected in a job.
It is also possible to feed multiple documents from one feeder. In this way
more documents of the same can be fed from one station, for example an
original and a copy of a document.
The automatic feeder can be equipped with a daily mail function for
processing documents or sets of documents which cannot be processed
automatically (e.g. stapled).
Fig. 2
Collating area
After feeding, the documents are gathered in the collating area.
General
3.2
Five in ONE
The following fold types are possible:
no fold.
single fold.
letter fold.
zig-zag fold.
double parallel fold.
Inserter
After folding the documents are transported to the inserter unit where the
documents are inserted into a waiting envelope. The inserter then seals
the envelope (or not) and stacks them on the rear receiving tray.
E
A
Operating controls
A:
B:
C:
D:
E:
F:
G:
H:
I:
J:
K:
L:
M:
N:
O:
P:
Q:
R:
letter receiving tray

letter slide
display
upper unit
locking hand grip upper unit
document hopper
collator arm
collator area
power inlet, power switch
knobs for cleaning stoppages
bellows
handle for cleaning stoppages
water tray
side cover (opened)
side guides envelope hopper
knob for separation adjustment
envelopes support bracket
thumbwheel for side guide adjustment
Fig. 3
Fig. 4
N
G F
I (rear side)
10
P Q
O
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General
3.3
3.4
Display buttons
The keys below the display are used for the functions: START, STOP,
CLEAR and ESC.
Optical Mark Reading/OMR (option)
The FPi 3030 fold and inserting machine can be OMR equipped with Optical Mark Reading (OMR). With documents can be processed according
to the printed code on the documents.
Using Optical Mark Reading (OMR), these levels are available:
Low Level
Level A
Level B
Level C (other suppliers reading code)
Flex Code (freely programmable reading code).
For more information please refer to the OMR Programmers guide.
Fig. 5
The 6 keys on the right of the display are used for the corresponding
functions shown in the display. When the START key is pressed the machine starts processing.
After pressing the STOP key the machine does not stop immediately, but
on the first opportunity while processing. Because of this there can be
incomplete sets in some Parts of the machine.
When the CLEAR key is pressed the machine stops feeding after competing the Set. It is possible that there are still documents left in the document feeder (for example a small card). Remove all these documents
from the feeder before restarting in another job. There can also be envelopes left in the envelope track. These envelopes must be removed when
another type of envelopes is required. See also section 8.2.
The ESC (escape) key can be used to exit a menu without saving any
(altered) settings.
The documents with the printed reading code are placed in the reading
feeder 3. Depending on the programmed code the other feeders can be
used as selective feeders. This means documents can be fed selectively.
In this way different sets can be processed.
At first the documents (incl. the address carrier) with the printed codes
are accumulated. The selective enclosures are accumulated after the last
document of a set, with a reading code, is fed.
Feeder:
3 (reading)
2 (selective)
1 (selective)
Fig. 6
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Preparations
Preparations
4.1
Moistening the brushes
The water tray B (fig. 7) must always be filled with water and the brushes
must be moistened. An extra set of brushes is provided so that one set
can be soaked in water whilst the other set is used. For this a special
section is available in the water tray. In that way there is always one set
ready for usage.
Fig. 7
A
Open the side cover N (fig. 3). Remove the water tray A and fill it to the
max. level. Replace the water tray.
Caution! Before moving the machine, the watertray must be
empty. Take in account the weight of the machine when moving it.
4.2
Power supply
Warning! Connect the FPi 3030 only to a grounded socket outlet.
Connect the power supply cable B (fig. 8) with the socket outlet.
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Operating the machine
5.2

5.1
Switching on
The machine can be switched on or off with the power switch A (fig. 8) on
the back of the machine. After starting up, the display shows the MAIN
MENU (1) (see fig 9).
The main menu
The main menu consists of two menus, MAIN MENU (1) and MAIN
MENU (2). After pressing key 6 in the in the MAIN MENU (1) the display
will show the MAIN MENU (2) as shown in fig. 10.
Fig. 9
Fig. 8
A
For operating the machine the following steps have to be taken (also see
the appendix for a schematic view):
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check the job by means of the JOB INFO screen.

when needed, select another job in the OTHER JOB menu.
when needed, make adjustments to the document hoppers.
when needed, make adjustments to the envelope feed.
when needed, adjust the document stopper position in the collator
area.
when needed, adjust the insert position of the envelope.
when needed, adjust the envelope insert fingers.
make a test run to check all settings.
if desired set the counters in the COUNTERS menu.
The MAIN MENU (1) shows 6 different functions:
job information (key 1), press key 6 to go back to the MAIN MENU (1)
(the job information function is available in all the menus where the
symbol
is shown).
go to ANOTHER JOB menu (key 2).
go to the TEST RUN menu (key 3).
go to the COUNTERS menu (key 4).
go to the FILL & START menu (key 5).
go to the MAIN MENU (2) (key 6).
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The MAIN MENU (2), as shown in fig. 10 shows 5 different functions:
The JOB INFO screen shows the following job settings :
job information (key 1).

display contrast lighter (key 2).
display contrast darker (key 3).
go to the JOB MENU (key 4) (only for authorized personnel).
back to the MAIN MENU (1) (key 6).
Fig. 10
5.3
inserting of the envelopes:

- envelope with closed flap (
- envelope with open flap (
- no envelopes (
)
black is selected)
which feeders are selected (
which feeders are linked (
the feed stations Real Sheet Control are on (
the number of documents processed by the feeder (
the length of the document in the feeder (
daily mail on or off (
hopper swap)
)
)
When the system is equipped with OMR, the JOB INFO screen also
shows if OMR is activated. A similar screen is shown in fig. 12.
JOB INFO screen
When key 1 is pressed in a menu, the JOB INFO screen will be

displayed. Press key 6 to go back to the MAIN MENU (1).
Fig. 12
The OMR function, activated for feeder 3 (upper feeder), is indicated by a
symbol in the
collumn.
Fig. 11
18
The
symbol indicates that the feeders no. 1 (lower feeder) and/or
no. 2 (middle feeder) are selected as a supplement selective feeding
station.
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5.4
OTHER JOB menu
5.5
Adjustment of the document hopper
5.5.1
Document separation
The document separation for the automatic feeders is set automatically.

There are no manual adjustments needed.
Fig. 13
After pressing key 2 in the MAIN MENU (1) display shows the OTHER
JOB menu (see fig. 13). The OTHER JOB menu shows the following
functions:
job information (key 1) (see section 5.3).

select a higher job number (key 3).
select a lower job number (key 4).
select the desired job and confirm with OK (key 6) which will get you
back to the MAIN MENU (1).
Only programmed jobs can be selected (maximum of 9 jobs).
Via the SERVICE SETTINGS menu, which is accessible by service personnel only, either mode 1 or mode 2 can be programmed per job, depending on the document sizes to be processed.
Fig. 14
B
The document separation for special feeders must be adjusted manually

as follows:
push the knob A (fig. 14) forward until it clicks.

open the left side guide B (fig. 14) by turning it downwards.
place a document on the feeding tray and slide it about 60 mm
(2.4 inch) into the machine (turn the knob A counter clockwise if the
separation is set to narrow).
push the document between the separation rollers, which are behind
the rubber paper pullers.
turn the knob A clockwise to get more resistance or counter clockwise to lower the resistance.
Mode 2 is considered to be the default mode with which a wide variety of

documents can be processed.
For documents with length > 304,8 mm (12 inch) or documents with
weight > 65 gr/m (16.25 lb bond), mode 1 is recommended. In this case
the maximal output of the system will be lower than when mode 2 has
been programmed.
The separation is adjusted correctly when a slight resistance is felt on the

document.
Pull the knob A (fig. 14) back again when ready. Close the left side guide.
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5.5.2
Side guides
To adjust the side guides it is best to remove the document feeding tray
from the feeder as follows:
push handle A (fig. 15) downwards.
The space between the side guides and the documents should be such
that the documents have just enough play to move freely.
re-tighten knob B.
remove the stack of documents.
Replace the document feeding tray as follows:
place the document feeding tray under guide B (as shown in fig. 17).
push the document feeding tray up and then lower it into position.
5.5.3
Filling the document hopper
Open the left side guide A (fig. 17) by turning it downwards. The feed rollers will automatically be lifted.
Fig. 15
A
lift the document feeding tray upwards to unhook it and then pull it out
from the feeder.
loosen the knob B half a turn (fig. 16).
Fig. 17
Fig. 16
A
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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.
Place a stack of documents between the side guides. Turn the left side
guide upwards again.
Feed the documents (depending on the documents and the types of fold)
as shown in section 5.7.
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24
Address carrier in top

feeder.
Face down and trailing.
Address carrier in
Address carrier in
bottom linked pair
bottom feeder.
feeders.

feeder.
Face up and leading.
Address carrier in
bottom feeder

linked pair feeders.
zig-zag fold
double
parallel fold
letter fold
5.7
For use of longer documents, maximal 356 mm (14 inch), the document
stoppers have to be set in last position (position C).

feeder.
For use of small documents of about 148 mm (5.8 inch) or smaller, the
document stoppers can be set in the first position (position A).
single fold
To adjust the stopper position pull down the collator plate D, squeeze the
stopper and pull the front side tab up. To replace the stopper, first place
the flat back tab into the slotted hole and then push the stopper into position. Replace the collator plate back into position.
Feeding documents
When a job is selected in which a different stopper position has been

programmed, the operator has to put the document stoppers in the correct position indicated by the display.
5.7.1 Feeding documents (without OMR)
Initially the document stoppers are adjusted and programmed for

position B (fig. 18). In this position a wide variety of documents can be
handled (max. 297 mm; 11.7 inch) and adjustment is not needed.
no fold
The position of the document stoppers has been programmed in the jobs
by service personnel according to the document sizes.
two documents
hopper swap
A B C
Type of documents
Fig. 18

feeder.
document + enclosure
Adjustment of the document stoppers
one document
5.6
Fold type
25
5.8
Adjustment of the envelope feed
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double
parallel fold
letter fold
Selective supplements can be placed on feeder 1 (lower feeder) or on feeder 2 (middle feeder).
The selective supplements feature is not possible with all reading code levels. For information
see the OMR Programmers Guide.
first
OMR
page
stop reading
OMR start
reading
address
single fold
no fold
direction
Type of documents
Fold type
Feed the documents with the OMR codes as shown below:
5.7.2
Feeding documents with OMR (option)
2
3
Address carrier, face up and leading.
5.8.1
Envelope separation
Fig. 19
C
Adjust the envelope Separation by turning knob A (fig. 19) counter clockwise until two envelopes (flap down and trailing), one on top of the
other, can be moved backward and forward between the rollers without
resistance. Turn knob A clockwise until one envelope will pass between
the rollers.
After starting the machine it may occur that more than one envelope at a
time is pulled in. In that case rotate knob A a quarter turn clockwise. Repeat if necessary to obtain correct operation.
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5.8.2
Side guides
5.8.4
Envelope receiving tray
Take a stack of about 20 envelopes. Fan the envelopes a bit (see fig. 20)
and place the envelopes in the hopper with the flap down and trailing on
the envelope support B (fig. 19).
Fig. 21
A
Fig. 20
The bottom envelope must enter the separator first. Adjust the side
guides C (fig. 19) by turning the thumbwheel D (fig. 19) to provide enough
space to move freely. Too much play causes skewing.
5.8.3
Envelope support
Shift the envelope support B (fig. 19) in or out so that the flap side of the
envelope is lifted about 20 mm (0.8 inch).
The FPi 3030 standard configuration is equipped with a rear envelope

receiving tray A (see fig. 21). This can be adjusted according to the envelope height, by shifting it in or out.
5.8.5
Envelope sealing
Envelopes can be sealed or not.

To switch sealing on or off, pull the hand grip of the upper unit upward
(E fig. 3) and pull the upper unit into the vertical position.
Envelopes may skew on the insert table. The envelope support B can be
rotated compensate this. Turn the envelope support so that the weight of
the envelopes is distributed evenly on both sides.
Top up the envelope hopper with more envelopes.
Fig. 22
A
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Shift the blue handle A (fig. 22) towards (

Shift the handle towards (
) switch sealing off.
) to switch sealing on.
Push the upper unit down until it locks. This should be done in the middle
off the locking hand grip.
5.9
TEST RUN menu
5.10 Insert position

Press key 1 in the TEST RUN menu to bring one envelope onto the insert
table. Pull the hand grip of the upper unit upward and pull the up er unit
into the vertical position.
The flap folding line must be positioned under the green indicator B
(fig. 24). If necessary adjust the flap folding line position by pressing key
4 or 5 in the TEST RUN menu. Each key stroke stops the next envelope
0,5 mm (0.02 inch) to the right (earlier) or to the left (later). Check the
settings by pressing key 1 again.
Fig. 23
Fig. 24
Press key 3 in the MAIN MENU (1) to enter the TEST RUN menu
(fig. 23). The test run menu shows the following functions:
feed one envelope onto the insert table (key 1).

make one insert (key 2).
set the insert position (= envelope stop position) to the right (key 4).
set the insert position to the left (key 5).
save the insert position setting with OK (key 6) which will get you to
the MAIN MENU (1).
First the insert position must be set. Then the insert fingers must be adjusted. To check all settings a test run can be made.
CD
5.11 Envelope insert fingers

To adjust the insert fingers A (fig. 24) (2 in total) loosen the knurled knob
C (fig. 24) on top of each finger.
Then adjust each finger so that the tip enters about 5 mm (0.2 inch) into
the envelope. Re-tighten the knurled knob. The fingers can be moved
sideways to the desired position. Place the outer fingers D about 5 to 10
mm (0.2 to 0.4 inch) from the edges of the envelope.
Check the position of the insert fingers when changing to a different type
of envelope.
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5.12 COUNTERS menu
5.13 INSERTING menu

When the start key is pressed the machine starts inserting in automatic
mode. The display shows the INSERTING menu.
Fig. 25
After pressing key 4 in the MAIN MENU (1), the display shows the
COUNTERS menu (fig. 25). The COUNTERS menu shows the following
functions:
reset the daily counter and stop counter to zero (key 2).
increase the preset counter (key 3).
decrease the preset counter (key 4).
save the counter settings with OK (key 6) which will get you back to
the MAIN MENU (1).
The stop counter is switched off when it is set to zero. The display will
show Stop at off.
Fig. 26
Press key 1 (and keep it pressed) for job information. Release key 1 for
returning to the INSERTING menu by pressing key 6.
5.14 FILL & START menu
After pressing key 5 in the MAIN MENU (1) the FILL & START menu is
displayed (fig. 27).
The stop counter can be set between 0 (switched off) and 9999.
Fig. 27
32
33
The Fill & Start function can be used for creating simple jobs. The machine automatically selects the document hoppers and recognizes the
document size, envelope size and necessary fold settings.
Before starting the Fill & Start function the adjustment of the envelope
feed must be made manually to obtain correct operation
(see section 5.8.2).
Testset run
Press key 3 to start a testset run (fig. 27). The settings of the testset run
will be saved. The machine prepares a job 0 which is named Fill & Start.
Only the feeders that feed successfully will be selected.
When special feeder are present, the adjustment of the document hoppers must be made manually (see section 5.5).
The document will be folded and inserted in the envelope. Only the insert
and address position can be adjusted if needed.
The address carrier must be put in the upper feeder.
The FILL & START menu shows the following functions:
FILL & START HELP (key 1). The screen in fig. 29 is shown and gives
suggestions for the Fill & Start usage.
feed one envelope onto the insert table (key 2). This function is used
for checking the insert position (= envelope start position).
make a testset run (key 3). After pressing this key the setting of the
insert position will be saved. The screen as shown in fig. 26 will be
displayed.
set the insert position to the right (key 5).
set the insert position to the left (key 6).
Caution! In the Fill & Start function only the DFC of the upper
feeder is selected automatically (see section 7.4).
Before starting FILL & START be sure that no documents or
envelopes are left in the machine.
Fig. 28
When the testset run is started the display shows the FILL & START
menu (fig. 28), extended with the possibility of adjusting the address position as follows:
press key 4 to set the address higher. Each key stroke brings the
address up 1,2 mm (0.05 inch) (maximum 12 m; 0.5 inch higher).
press key 5 to set the address lower. Each key stroke brings the
address down 1,2 mm (0.05 inch) (maximum 12 m; 0.5 inch lower).
If the requested address position is beyond the maximum range of 12
mm (0.5 inch) up and 12 mm (0.5 inch) down, the Fill & Start function can
not be used. Use a programmed job instead.
In the Fill & Start job the following options cannot be used:
34
hopper swap (for more informations see section 3.1).

multifeed (for more informations see section 3.1).
35
The usage of Fill & Start function is not possible in the no envelopes mode, or with usage of envelopes with open flap.
The Fill & Start job can not be saved. When the machine is
switched off the settings will be lost.
5.15 Daily mail

For processing documents or sets of documents which can not be
processed automatically (e.g. stapled documents) the daily mail function
can be used.
The automatic (upper) feeder can be equipped with a daily mail switch.
Contact your dealer when further information is wanted.
B
Fig. 29
Fig. 30
A
Switch the daily mail in the following way:
select or change a job where the daily mail function has been set to
on (see section 7.2.4).
turn to the left side guide A downwards (fig. 30).
the daily mail handle B will be visible and can be set. Push the handle
to the right to switch to the daily mail function. Push the handle to the
left to switch back to the automatic function.
turn to the left side guide upwards again.
Be sure the daily mail function is switched off when switching to normal
use again (see section 7.2.4).
When using the OMR feature, the daily mail function is deactivated.
36
37
5.16 Reading head position (machines with OMR option only)

When the system is equipped with OMR, the reading head must be
placed according to the (horizontal) position of the printed marks on the
documents. To adjust the reading head, proceed as follows:
adjust the reading head A (fig. 33) according to the measured width.
divide the paper guides B (fig. 33) along the width of the document.
take a template document with a reading code.

fold the document double on the middle line as shown in fig. 31.
Fig. 33
A
When the reading head is adjusted it is possible that some paper guides
have to be removed and replaced on the other side of the reading head.
Remove a paper guide as follows:
Fig. 31
measure the width from the middle of the document to the middle of
the marks.
pull the hand grip B (fig. 32) upward to open the upper unit A (fig. 32).
turn the paper guide until it comes free from the axles.
pull the paper guide out of the machine.

B
The replacement procedure is the reversal of the removal procedures.
In the appendix, you can find a summary of the menus described

in chapter 5.
For more information about OMR features please refer to the
OMR Programmers guide.
Fig. 32
38
39
Jobs
Jobs
6.1
JOB MENU
After pressing key 4 in the MAIN MENU (2) (fig. 10) the display shows
the JOB ACCESS screen and asks for a pin code to enter (fig. 34).
Fig. 34
Enter the pin code with the keys 1 through 6.
When a wrong pin code is entered, the cursor is set to the first number to
try again.
After 3 times entering a wrong pin code the display shows the MAIN
MENU (1) again.
When the correct pin code is entered, the display shows the JOB MENU
as shown in fig. 35. The JOB MENU shows the following functions:
40

create a job (key 2).
edit a job (key 3).
copy a job (key 4).
delete a job (key 5).
exit and go back to the MAIN MENU (1) (key 6).
41
Jobs
The display will start with the lowest free job number available. Job numbers already programmed or job numbers locked by service personnel
will not be shown.
select the desired job and confirm with OK (key 6) which will get you
to the JOB SETTINGS menu.
All job settings are described in chapter 7.
A new selected job number starts with default settings.

Fig. 35
The escape key will get you back to the previous menu.
6.2
6.3
EDIT JOB menu
When key 3 in the JOB MENU is pressed, the display shows the EDIT
JOB menu as shown in fig 37. The initially selected job will be displayed.
CREATE JOB menu
After pressing key 2 in the JOB MENU the display will show the CREATE
JOB menu as shown in fig. 36. If all jobs are programmed the display
shows No more free jobs.
Fig. 37
The EDIT JOB menu shows the following functions:
Fig. 36
The CREATE JOB menu shows the following functions:
42
choose a higher free job number (key 3).

choose a lower free job number (key 4).

choose a higher job number to edit (key 3).
choose a lower job number to edit (key 4).
select the job to edit and confirm with OK (key 6) which will get you to
the JOB SETTINGS menu.
All job settings are described in chapter 7.
43
Jobs
6.4
COPY JOB menu
6.5
Fig. 38
DELETE JOB menu
Fig. 39
After pressing key 4 in the JOB MENU, the display shows the COPY JOB
menu as shown in fig. 38. The COPY JOB menu shows the following
functions:
After pressing key 5 in the JOB MENU, the display shows the DELETE
JOB menu, as shown in fig. 39. The DELETE JOB menu shows the
following functions:

choose a higher job number to copy from (key 2).
choose a lower job number to copy from (key 3).
choose a higher job number to copy to (key 4).
choose a lower job number to copy to (key 5).
copy the job with OK (key 6) which will get you to the JOB MENU.

select a higher job number to delete (key 3).
select a lower job number to delete (key 4).
delete job with OK (key 6) which will get you to the JOB MENU.
If all jobs are programmed the display shows No more free jobs.
44
45
Job settings
Job settings
Fig. 40
After confirmation (key 6) in the CREATE JOB or EDIT JOB menu, the
display shows the JOB SETTINGS menu as shown in fig. 40. The JOB
SETTINGS menu shows the following functions:
select a setting menu by pressing key 1 or 2.

To program a job use the following order of settings:
1. ENVELOPE SETTINGS menu (
2. DOCUMENT SETTINGS menu (
3. FOLD SETTINGS menu (
).
).
).
4. DFC (Real Sheet Control) SETTINGS menu (
46
).
select the chosen settings menu to edit (key 3).

go to the JOB NAME menu (key 5).
save the job settings by pressing key 6 which will automatically get
you back to the JOB MENU.
47
Job settings
When the system is equipped with OMR option, the JOB SETTINGS
menu is provided with an additional settings menu indicated by the
symbol as shown in fig. 41.
7.1
ENVELOPE SETTINGS menu
When the ENVELOPE SETTINGS menu is selected and key 3 is

pressed in the JOB SETTINGS menu, the display shows the screen as
shown in fig. 42. In this menu, the following choices are available by
pressing key 1:
1. Envelope with closed flap (
).
2. Envelope with open flap (
).
3. No envelopes (
).
Fig. 41
When OMR is selected, the amount of documents in the DOCUMENT
SETTINGS menu is not displayed anymore. Instead the
is displayed.
The amount of documents of the reading feeder is set to 1 and can only
be altered in the OMR SETTINGS menu. See also section 7.5.
A selective feeder will be activated when the amount of documents is set
to one or higher and the sheet length is set in the DOCUMENT SETTINGS menu. See also section 7.2.
Fig. 42
7.1.1
Envelope with closed flap
When envelope with closed flap is selected the display shows the
screen as shown in fig. 42. The following choices are available:
go to the envelope with open flap screen (key 1).

increase the envelope height (key 2).
decrease the envelope height (key 3).
confirm the setting by pressing OK (key 6) which will get you back to
The envelope height can be set between 90 mm (3.5 inch) and 162 mm
(6.38 inch).
Default the envelope size is set to 162 mm (6.38 inch).
48
49
Job settings
7.1.2
Envelope with open flap
7.1.3
No envelopes
Fig. 43
When envelope with open flap is selected the display shows the screen
as shown in fig. 43. The following choices are available:
When no envelopes is selected, the display shows the screen as shown

in fig. 44. The following choices are available:
go to no envelopes screen (key 1).

increase the envelope height (key 2).
decrease the envelope height (key 3).
increase the flap height (key 4).
decrease the flap height (key 5).
confirm the settings by pressing OK (key 6) which will get you back to
The envelope height can be set between 90 mm (3.54 inch) and 162 mm
(6.38 inch).
The flap height can be set between 32 mm and the envelope height minus 32 mm (1.26 inch).
Default the envelope height is set to 162 mm (6.38 inch) and the envelope flap size is set to 44 mm (1.73 inch).
50
Fig. 44
7.2
go to the envelope with closed flap screen (key 1).

DOCUMENT SETTINGS menu
When the DOCUMENTS SETTINGS menu is selected and key 3 is

pressed in the JOB SETTINGS menu, the display shows the screen as
shown in fig. 44. The following choices are available, by pressing key 1:
set number of documents (
set document size (
set hopper swap ( ).
set daily mail on or off (
).
).
).
51
Job settings
7.2.2
Document size
Fig. 45
Fig. 46
7.2.1 Number of sheets
When number of sheets is selected the following choices are available
(see fig. 45):
go to document size screen (key 1).

select a higher feeder number (key 2) (The lowermost feeder is
feeder number one).
select a lower feeder number (key 3).
increase the number of documents of the selected feeder (key 4).
decrease the number of documents of the selected feeder (key 5).
A feeder can be de-selected when the amount of documents is set to

Zero. The default setting is 1 document per feeder.
When a feeder is set to daily mail the number of documents is always 1
and can not be set in this screen.
52
When document size is selected, the display shows the screen as shown
go to the hopper swap screen (key 1).

select a higher feeder number (key 2).
select a lower feeder number (key 3).
increase the document size of the documents in the selected feeder
(key 4).
decrease the document size of the documents in the selected feeder
(key 5).
confirm the settings by pressing (key 6) which will get you back to the
JOB SETTINGS menu.
The document size can be set between 90 mm (3.54 inch) and 356 mm
(14 inch) in steps of 1 mm (0. 64 inch). The minimum document size for
the upper feeder is 115 mm (4.5 inch).
The maximum document size is depending on the document stopper
position in the collator area. If the stopper is set to position a (see section
5.6) the max. size is 148 mm (5.8 inch). For the position b: 297 mm
(11.7 inch). For the position c: 356 mm (14 inch).
53
Job settings
7.2.3
Hopper swap
7.2.4
Fig. 47
Daily mail
Fig. 48
When hopper swap is selected, the display shows the screen as shown
When daily mail is selected, the display shows the screen as shown in
fig. 48. The following choices are available:
go to the daily mail screen or when this is not available to the

number of sheets screen (key 1).
select the pair of feeders which must be linked (key 2 or 3).
select linked or unlinked for a pair of feeders (key 4).
go to the number of sheets screen (key 1).

set the daily mail function on or off (key 3).
When a pair of feeders is linked, the settings of the lowermost feeder will
be used and shown in the display.
54
55
Job settings
7.3
FOLD SETTINGS menu
7.3.2
Single fold
When the FOLD SETTINGS menu is selected and key 3 is pressed in

the JOB SETTINGS menu, the display shows the screen as shown in fig.
49. The following choices are available by pressing key 1:
1. No fold (
).
2. Single fold (
).
3. Letter fold (
).
4. Zig-zag fold (
).
Fig. 50
When single fold is selected, the display shows the screen as shown in
Fig. 49
7.3.1
go to the letter fold menu (key 1).

increase the fold position to the right (key 3).
decrease the fold position to the left (key 4).
The fold length can be minimally 75 mm (2.95 inch) and maximally the
length of the longest document used minus 25 mm (1.0 inch).
No fold
When no fold is selected, the display shows the screen as shown in

56
go to the single fold menu (key 1).

57
Job settings
7.3.3
Letter fold
7.3.4
Fig. 51
Zig-zag fold
Fig. 52
When letter fold is selected, the display shows the screen as shown in
When zig-zag fold is selected, the display shows the screen as shown in
go to the zig-zag fold menu (key 1).

increase the position of the first fold to the right (key 2).
decrease the position of the first fold to the left (key 3).
increase the position of the second fold to the right (key 4).
decrease the position of the second fold to the left (key 5).
go to the no fold menu (key 1).

increase the position of the first fold to the right (key 2).
decrease the position of the first fold to the left (key 3).
increase the position of the second fold to the right (key 4).
decrease the position of the second fold to the left (key 5).
The fold length of the first fold can be minimally 75 mm (2.95 inch) and
maximally the length of the longest document used minus 50 mm
(2.0 inch).
The fold length of the first fold can be minimally 75 mm (2.95 inch) and
maximally the length of the longest document used minus 100 mm
(3.9 inch).
The fold length of the second fold can be minimally the length of the first
fold plus 25 mm (1.0 inch) and maximally the length of the longest document used minus 2.0 mm (1.0 inch).
The fold length of the second fold can be minimally the length of the first
fold plus 25 mm (1.0 inch) and maximally the length of the longest document used minus 75 mm (2.95 inch).
When using the OMR feature, zig-zag folding is not possible.
58
59
Job settings
7.3.5
Double parallel fold
7.5
By using the letter fold settings, it is possible to create a double parallel

fold.
OMR SETTINGS menu (machines with OMR option only)
7.5.1
Select OMR settings screen
When a document is to large to be inserted (letter folded) in the desired

envelope the double parallel fold can be used.
ExampIe: a document of 356 mm (14 inch) must be parallel folded for an
envelope of 104 mm (4.1 inch). To insert the document properly, the size
of the folded document must be maximally 8 mm (3.9 inch).
The first fold is set to 98 mm (3.9 inch) and the second fold is set to
196 mm (7.7 inch). When processed a parallel fold is automatically created. The document will now be inserted correctly.
7.4
Fig. 54
DFC (Real Sheet Control) SETTINGS menu
When the OMR SETTINGS menu is selected (with key 1 or 2 and key 3
to edit, fig. 41) the screen as shown in fig. 54 is displayed. The following
choices are available:
Fig. 53
go to the OMR position settings screen (key 1).

set reading on or off (key 3).
select the needed reading code (key 5).
The daily mail of the upper feeder is switched off and the number of
documents is set to 1.
When the DFC SETTINGS menu is selected and key 3 is pressed in the
JOB SETTINGS menu, the display shows the screen as shown in fig. 53.
This menu shows the following functions:
60
select the required feeder (key 2 or 3).

set the DFC (Real Sheet Control) on or off (key 4).
61
Job settings
7.5.2
OMR position settings screen
7.6
Fig. 55
JOBNAME menu
Fig. 56
When the OMR position is selected the display shows the screen as
shown in fig. 55. The following choices are available:
After pressing key 5 in the JOB SETTINGS menu the display shows the
screen as shown in fig. 56. The following choices are available:
go to the Select OMR settings screen (key 1).

select the position of the first optical mark, measured from the top of
the sheet (key 2 and 3).
select the maximum amount of sheets in the set of documents (key 4
and 5).
change the selected character (key 1 or 2).

select the character position (key 3).
insert the selected character (key 4)
delete the selected character (key 5)
The maximum amount of sheets in a set is 25. When the amount of

sheets is above 5 the documents can not be folded. Therefore the maximum length of the documents can be 148 mm (5.8 inch). Be sure that in
the used job the fold is set to no fold (see section 7.3.1). Otherwise
document stoppages will occur and the system stops.
When the max. sheets counter is exceeded the machine will accumulate
until it reads an insert mark, divert mark or a number of 26 sheets. This
set or part of a set will be diverted and error code 3:130 is generated. By
pressing the reset key the machine will start and will repeat this process
until an insert or divert mark is found.
62
63
Fault finding
When there is a technical problem the display shows the message as

shown in fig. 58.
Fault finding
8.1
General
In the system the following error types are possible:
paperflow errors.
technical errors.
double thickness measurement errors.
reading errors (machines with OMR option only).
This error cannot be solved by operating personnel and assistance of the

service support is needed.
First write down the error code, than switch the inserter off and on again,
to verify machine operation. When the error still occurs contact your service organization.
If an error occurs the display shows a screen with an error description

and a suggested solution.
Fig. 58
Fig. 57
When a paperflow error occurs the display shows a screen as in fig. 57
(for example). The menu shows the following functions:
Show more information (key 1).

reset the error after solving the Problem (key 6) (the error screen will
disappear).
The black arrow or a black feeder indicates where the problem occurs.
For a complete description of error codes see sections 8.3, 8.4 and 8.5.
64
65
Fault finding
8.2
Clearing stoppages
Lower envelope track

When a stoppage occurs in the lower envelope track, remove the envelopes as follows:
Exit and sealing area

When a stoppage occurs in the exit and sealing area, remove the material as follows:
pull the hand grip A up (fig. 59) and pull the upper unit into vertical
position.
open the side cover B (fig. 59).
remove all material.
lower the upper unit until it clicks
close the side cover.
open the side cover A (fig. 60).

lower and hold the handle B and remove the envelope(s) (fig. 52) to
the left from the lower envelope track.
release the handle B.
close the side cover.
C
Reset the error after solving the problem with key 6 (see fig. 57).
A
Fig. 60
A
Reset the error after solving the problem with key 6.

Fig. 59
66
If needed envelopes and documents can be transported manually by

turning knob C clockwise (fig. 60). To transport envelopes manually to the
insert table or to the lower envelope track, turn knob D clockwise. Pull the
hand grip A up (fig. 59) and pull the upper unit into vertical position. The
envelopes and documents can be removed.
67
Fault finding
Five in ONE
Collating area
When a stoppage occurs in the Five in ONE, remove the documents as

follows:
When a stoppage occurs in the collating area, remove the documents as

follows:
position.
remove the documents from the Five in ONE.
lower the upper unit until it clicks.
pull down the collator plate B (fig. 61).

remove the documents.
push the collator plate into position.

Reading and double feed control errors (machines with OMR only)
When a reading or double feed control error occurs, the document stops
in the collator area. The display shows an error screen as shown in
fig. 57.
Caution! The operator must remove the document(s) from the
collator area and must complete the set manually!!
After resetting the machine, it can be started again by pressing the start
key.
Fig. 61
B
Vario Feed
When a stoppage occurs in the Vario Feed, remove the documents as
follows:
position.
remove the documents.
lower the upper unit until it clicks.
Paperflow error with reading on (machines with OMR only)

When a paperflow error with optical mark reading on occurs, the system
stops. The involved documents have to be removed from the machine
manually. The display shows an error screen which indicates the position
of the occurred stoppage position.
After resetting the machine, it can be started again by pressing the start
key.
68
69
8.3
Error codes
error description
Envelope too long.
Document stoppage.
Document stoppage.
Envelope stoppage.
Envelope stoppage.
Document stoppage.
Document stoppage.
Envelope stoppage.
Envelope stoppage.
Envelope stoppage.
Envelope stoppage.
Document stoppage.
Envelope stoppage.
Envelope stoppage.
Document stoppage.
Document stoppage.
70
Fault finding
suggested
solution
Remove envelope.
(see section 8.2)
Remove documents.
(see section 8.2)
Remove documents.
(see section 8.2)
Remove envelope.
(see section 8.2)
Remove envelope.
(see section 8.2)
Remove documents.
(see section 8.2)
Remove documents.
(see section 8.2)
Remove envelope.
(see section 8.2)
Remove envelope.
(see section 8.2)
Remove envelope.
(see section 8.2)
Remove envelope.
(see section 8.2)
Remove documents.
(see section 8.2)
Remove envelope.
(see section 8.2)
Remove envelope.
(see section 8.2)
Remove documents.
(see section 8.2)
Remove documents.
(see section 8.2)
information
Envelope length error.
(Error code 1:10)
Inserting failure.
(Error code 1:11)
Document length error.
(Error code1:12)
Transport failure.
(Error code 1:13)
Flap not opened.
(Error code 1:15)
Document too early.
(Error code 1:17)
Inserting failure.
(Error code 1:18)
Flap sensor covered.
(Error code 1:19)
Envelope lost.
(Error code 1:20)
Wrong envelope size.
(Error code 1:22)
Seal switch active.
(Error code 1:23)
Seal switch active.
(Error code 1:24)
Seal switch not covered.
(Error code 1:25)
Seal switch not covered.
(Error code 1:26)
Document too late.
(Error code 1:27)
Insert area blocked.
(Error code 1:29)
error description
Document stoppage.
Document stoppage.
Envelope to small.
Document stoppage.
Document stoppage.
Document stoppage.
Document stoppage.
Empty feeder.
Feeding failure.
Feeding failure.
Document stoppage.
Document stoppage.
Document stoppage.
suggested
solution
Remove documents.
(see section 8.2)
Remove documents.
(see section 8.2)
Go to the EDIT JOB
menu. (see section 6.3)
Remove documents.
(see section 8.2)
Remove documents.
(see section 8.2)
Remove documents.
(see section 8.2)
Remove documents.
(see section 8.2)
Load documents.
(see section 5.5.3)
Remove documents.
(see section 8.2)
Check previous set.
(see section 8.2)
Remove documents.
(see section 8.2)
Remove documents.
(see section 8.2)
Remove documents.
(see section 8.2)
information
Stoppage at folder.
(Error code 2:11)
Stoppage at folder.
(Error code 2:12)
Fold not possible.
(Error code 2:14)
Stoppage at vert. track.
(Error code 3:10)
Stoppage at collator.
(Error code 3:11)
Stoppage at collator.
(Error code 3:12)
Document stoppage.
(Error code 3:14)
(Error code 4, 5, 6 :00)
Document too thick.
(Error code 4, 5, 6 :10)
Wrong reference.
(Error code 4, 5, 6 :11)
Document too long.
(Error code 4, 5, 6 :12)
Paper jam.
(Error code 4, 5, 6 :13)
Document too short.
(Error code 4, 5, 6 :14)
Caution! Service assistance is needed for the error codes with the
message technical failure.
to verify machine operation. When the error still occurs contact your
service organization.
71
8.4
Fault finding
Operator troubleshooting
Symptom
Possible cause
Remedy
Symptom
Possible cause
Remedy
The machine
cannot be started
after switching on.
Machine not connected

to mains.
Fuse is blown.
Connect the machine to the mains.
Envelope not within

specifications.
Replace fuse below power switch.
Flap is wrinkled
and sometimes not
opened.
A cover is opened.
Close the covers.
Envelopes stacked
reversed in the hopper.
Check envelope feed adjustments.

Place envelopes correctly in
hopper. (see section 5.8.2)
Store envelopes according to
specifications. (see chapter 11)
Change envelopes according to
specifications.
(see chapter 11)
Check separation settings, adjust if
needed.
(see section 5.8.1)
Check and replace if needed.
Check specifications and change

envelopes if needed.
(see chapter 11)
Store envelopes according to
specifications. (see chapter 11)
Envelopes stored or manufactured
improperly. (see chapter 11)
needed. (see section 5.8.1)
Check fingers position, adjust if
needed. (see chapter 5.11)
Check envelope stop position,
adjust if needed.
(see section 5.10)
Check fingers position, adjust if
needed. (see section 5.11)
Check fold settings.
(see section 7.3)
Check envelope specifications.
(see chapter 11)
Eliminate faulty envelopes.
(see chapter 11)
Eliminate faulty envelopes.
Machine stops with

envelope at insert
position (flap not
open).
Envelope flap sticks.

Wrong envelope type
used.
Envelopes are
double fed.
Envelope separation not

correctly adjusted.
Envelope stop
skewed.
Envelopes not placed

properly in the hopper.
Side guides of the
envelope hopper are set
too wide.
Hopper almost empty.
Envelopes are fed

irregulary.
Side guides set too

narrow.
Envelope support not
positioned correctly.
Enveloppe stops too
early.
72
Check side guides and adjust if

needed.
(see section 5.8.2)
Refill hopper.
(see section 5.8.2)
needed. (see section 5.8.1).
Check side guides and adjust if
needed. (see section 5.8.2)
Reposition the envelope support.
(see section 5.8.3)
Flap sticks.
Flap curled.
Fingers are placed

on top of the
envelope.
Machine stops
while inserting
(stoppage at the
inserting point).
Separation set too

narrow.
Fingers adjusted too
deep into the envelope.
Envelope stops too early.
Fingers not correctly

adjusted.
Inserted document too
long for used envelope.
Envelope throat
incorrect.
Envelope glued inside.
Window not glued
properly.
73
Fault finding
Symptom
Possible cause
Remedy
Flap not sufficiently

moistened.
Water level low.
Check water level, refill if needed.

(see section 4.1)
Check brushes, replace if needed
by the extra soaked set.
(see sections 4.1, 9.3)
Check brushes, clean if needed.
(see section 9.3)
Check the moistening felt, refill
water tray if needed.
(see section 4.1)
Check the moistening felt, clean if
Activate the moistening brushes.
(see section 5.8.5)
Check fold settings, adjust if
Check adiustment of envelope stop
position and fingers.
(see section 5.11)
Refill feeder.
(see section 5.5.3)
Adjust the separation.
(see section 5.5.1)
Adjust the side guides.
(see section 5.5.2)
Adjust side guides.
(see section 5.5.2)
Adjust the separation.
(see section 5.5.1)
Adjust stopper position.
(see section 5.6)
Brushes dry.
Brushes dirty.
Moistening felt dry.
Moistening felt dirty.
Envelope not
always ejected from
sealer.
No document fed.
Moistening brushes
inactive.
Inserted document too
big.
Document not inserted
deep enough.
Feeder empty.
Separation set too wide.
Skewed documents
fed.
Double documents
fed.
Documents
stoppage at
collating area.
Side guides set too

narrow.
Side guides set too wide.
Separation set too wide.
Stopper position set
incorrect.
8.5
8.5.1
OMR error codes

General OMR error codes
error description
Too many sheets in set.
Reading error.
Reading stop.
Reading error.
Reading error.
Reading error.
Reading error.
Reading error.
information
Remove the document and
complete the set manually.
Remove the documents and
adjust the 1st mark from the top
position correctly.
(see section 7.5.2)
complete the set manually
adjust the reading head (see
section 5.16). Adjust the 1st
mark from the top position
correctly. When the error still
occurs, contact your service
organisation.
check the used OMR code.
Remove the documents. Check
the set and the used OMR code.
Replace the set in the feeder or
check the used OMR code.
Adjust the reading head.
(see section 5.16)
check the used OMR code's
(mark line distance).
Set size exceeded.

(Error code 3:110)
Wrong window
position.
(Error code 3:112)
Stop mark read.
(Error code 3:113)
No marks on paper.
(Error code 3:120)
Conflicting
commands.
(Error code 3:121)
Wrong sheet
sequence.
(Error code 3:124)
Wrong parity in code.
(Error code 3:126)
Wrong mark distance.

(Error code 3:128)
When encountering OMR errors please see the OMR Programmers

guide (available separately).
74
75
error description
Too many sheets.
Incomplete set.
8.5.2
Maintenance
suggested solution
the set and complete the set
manually.
the set and complete the set
manually.
information
Max. Accumulate 25
sheets.
(Error code 3:134)
Part of previous set.
(Error code 3:135)
Maintenance
9.1
Warning! Disconnect the mains supply before performing any

maintenance.
Warning! The user must not attempt to service the appliance
beyond that described in this operator manual. All other servicing
must be referred to qualified service personnel only. For service
please contact your authorized distributor.
Flexible reading error codes (Flex code)

error description
Reading error.
Reading stop.
Reading error.
Reading error.
Reading error.
suggested solution
check the used OMR code
(flex code).
Remove the documents, check
the matched number and
replace the set in the feeder or
Remove the documents, check
the matched number and
replace the set in the feeder or
(flex code).
(flex code).
information
No commands in
code.
(Error code 3:122)
Unmatched set.
(Error code 3:123)
9.2
Undefined mark
found.
(Error code 3:127)
Wrong numbers of
marks.
(Error code 3:129)
General cleaning
The machine must be kept in proper condition by regularly removing

dust, paper remains, etc. Clean the sealing table and rubber rollers when
dirty. This can be done by using a slightly wetted cloth soaked in warm
water.
9.3
Wrong set sequence.

(Error code 3:125)
Servicing
Cleaning the brushes
Clean the brushes when dirty or saturated with glue. An extra set of
brushes is provided. The best procedure is to soak one set of brushes
and use the other set. In that way there is always a clean set of brushes
ready for usage.
A
Caution! Service assistance is needed for the OMR error codes with the
message technical failure.
to verify machine operation. When the error still occurs contact your
service organization.
Fig. 62
When encountering OMR errors please see the OMR Programmers

guide (available separately).
76
77
Maintenance
To replace the brushes the upper unit must be lifted. The brushes can be
removed one by one by pulling them straight off the brush holder (see fig.
62). When replacing the brushes, align the studs on each brush with the
respective holes in the brush holder.
It is also possible to remove the brush holder completely. Pull tongue A
(fig. 62) down and the brush holder out of the loc. To replace the brush
holder, slide the tongue on the holder into the loc and press downwards
and inwards to click in.
The brushes should be cleaned once a week.
9.4
Cleaning the moistening felt
9.5
Cleaning the fold rollers
To clean the fold rollers in the folder place the upper unit into vertical position (see section 8.2). Clean the fold rollers in the folder regularly with a
dry duster or a cleaner (dont use chemical products!).
Lower the upper unit until it clicks and close the side cover.
9.6
Cleaning the sensors
When the display shows a message like Track sensor dusty, the sensors on the envelope or document path must be cleaned. The screen on
the display indicates which sensor(s) must be cleaned.
Clean the moistening felt and water tray when dirty or saturated with glue.
To remove the water tray the side cover must be opened. Pull out the
water tray B and clean it under running water. Replace the water tray
lower the upper unit until it clicks and close the side cover.
A B
Fig. 64
C
Fig. 63
A
78
The sensors can be cleaned by using the bellow C (fig. 64) located behind the side cover.
For cleaning the envelope track sensor, put the bellow in hole B (fig. 64).
Squeeze a few times firmly to blow away the dust from the sensor. Repeat this procedure for hole A (fig. 64), for cleaning the flap sensor.
79
Specifications
10
11
Options
The following functions are optional and can be set or fitted by the service organization.
Specifications
Machine specifications
Model
FPi 3030
Type
inserter system for medium office use.
Overall dimensions
- height
- width
- length
3-station system
1670 mm (26.3 inch)
1420 mm (16.5 inch)
1100 mm (43.3 inch)
with side exit
receiving tray
stacker
Optical Mark Reading (OMR)

The system can be equipped with Optical mark reading (OMR). With this
reading the system reads optical marks that have been specially printed
on the documents. This code contains information about the processing
of the documents. There are different levels of OMR features. For more
information see OMR Programmers guide (available separately).
Conveyor stacker
At the rear exit a conveyor stacker (as shown in fig. 65) can be fitted instead of the Standard envelope receiving tray. The conveyor stacker
stacks up filled envelopes from the system in a tiled way.
Fig. 65
Side exit
At the rear exit a side exit as shown in fig. 66 can be fitted by the service
organization. The side exit can be fitted instead of the standard envelope
receiving tray. The side exit allows a conveyor, conveyor/stacker or a
franking machine to be fitted in line with the FPi 3030. When a side exit is
ordered, a receiving tray will be delivered with it. The side exit can be fitted to the left or to the right.
1200 mm/47.2 inch

1350 mm/53.1 inch
1600 mm/43.3 inch
Weight
80 kg
Noise level
< 70 dBA (following DIN 45635 part 19)
Theoretical
max. speed
3000 inserts per hour

depending on configuration
Operating temperature
10C - 40C (50F - 104F)
Humidity
30% - 80%
Power consumption
100 - 120 V AC / 60 Hz / 3 Amps

220 - 240 V AC / 50 Hz / 1,4 - 1,5 Amps
Approvals
conforms to:
- IEC 950 and derivates
- UL Listed ITE, File E153801
- BS EN60950
- KM11322
Fig. 66
80
81
Specifications
Paper insert specifications
Remarks
Paper sizes
width*
length**
minimum
130 mm (5.1 inch)
190 mm (3.5 inch)
maximum
236 mm (19.3 inch)
356 mm (14.0 inch)
Quality***
60 gr/m (15 lb bond)
250 gr/m (62.5 lb bond)
booklets up to approximately 1mm (0.04 inch)

thickness, depending on stiffness
5 sheets (max. 80 gr/m)
Folding capacity
*
**
***
When folded max. 230 mm (9.1 inch).

The min. document size used for the upper feeder is 115 mm (4.5 inch).
When folded max. 170 gr/m.
Envelope and insert specifications
minimum size
maximum size
*
**
82
mm
160
90
32
10
84
60 g/m
inches
6.3
3.5
1.25
0.4
3.3
60 g/m
mm
inches
248 162
B - 32
35 A - 12** B - 6
9,7 6.38 B-1.25 1.4 A-0.47** B - 0.2
The specifications of the paper handling equipment is often wider than that of
the envelopes and documents handled. The condition of material handled will
limit the specified environmental conditions.
We recommend that materials to be handled are stored at a temperature of
20C (68F) with a relative humidity factor of 50%. If difference in temperature occurs between storage room and mailing area, the material has to be
stored near the machine at least 24 hours before use.
Selfcopying paper may cause rubber parts to wear quicker. The rubber used
in this machine has the best resistance to Wiggins Teape material.
For machines with OMR option only:
- The maximum amount of sheets in a set is 25.
- The following fold types are available: single fold, letter fold and double
parallel fold
- The daily mail feature of the upper feeder is deactivated.
- For more informations refer to the OMR Programmers guide (available
separately).
2.5*
160
booklets up to approx. 1 mm (0.04 inch) thickness, depending on stiffness.

when insert is more than 1 mm: thickness A - 15/A - 0.6 inch.
83
Notes
84
FPi 3030 operator menu structure

(without OMR)
JOB INFO
OTHER JOB
JOB 1
invoice
12
JOB
2
2
1
3
2
114
i ................
297
297
297
Select job....
OK
start
stop
clear
OK
esc.
start
Mechanical adjustments
separation (section 5.5.1)
side guides (section 5.5.2)
filling the hopper
key
MAIN MENU (1)
i .......................
Other job................
Total:
0
Test run..................
Counters.................
Fill & Start..............
start
stop
clear
esc.
stop
clear
TEST RUN
1x................
+
1x........
Insert position
...........
OK
start
stop
Confirm settings
esc.
JOB 1
invoice
Total:
0
Select higher job number (section 5.4)

Select lower job number (section 5.4)
clear
esc.
Feed one envelope (section 5.9)

Insert one document (section 5.9)
Stop position to the right (section 5.9)
Stop position to the left (section 5.9)
Confirm settings
(section 5.5.3)
daily mail (section 5.15)
JOB 1
invoice
JOB INFO (section 5.3)
document stoppers (section 5.6)

envelope support (section 5.8.3)
receiving tray (section 5.8.4)
envelope sealing (section 5.8.5)
envelope insert fingers
(section 5.11)
start: Start key

Start processing
COUNTERS
JOB 1
invoice
Reset counters.........
Total:
0
Stop at
750
OK
start
stop
clear
esc.
Reset counter (section 5.12)

Increase stop counter (section 5.12)
Decrease counter (section 5.12)
Confirm settings
stop: Stop key

Stop processing
clear: Clear key
Empty the system and stop
MAIN MENU (2)
esc.: Escape key

Exit a menu without saving
any altered jobs
JOB
i .......................
1
Display contrast
Total:
0
start
Job menu...............
stop
clear
esc.

Adjust contrast
(section 5.2)
Enter JOB MENU
(section 5.2)
To MAIN MENU (1)
FILL & START
? .......................
Fill & Start help (section 5.14)
1x.........
+
1x.........
Testset run (section 5.14)
Insert position
...........
start
stop
clear
esc.
85
FPi 3030 operator menu structure

with Optical Mark Reading (OMR)

JOB INFO
JOB
OTHER JOB
12
3
2
114
JOB
i ................
297
297
297
Select job....
OK
start
stop
clear
OK
esc.
start
stop
TEST RUN
JOB
key
i .......................
Other job................
Test run..................
Counters.................
Fill & Start..............
JOB
start
stop
clear
esc.
start: Start key

Start processing
...........
OK
stop
clear
esc.
Feed one envelope (section 5.9)

Insert one document (section 5.9)
Stop position to the right (section 5.9)
Stop position to the left (section 5.9)
Confirm settings
(section 5.5.3)
reading head position
(section 5.15)
document stoppers (section 5.6)
MAIN MENU (1)
1x........
Insert position
start
Confirm settings
esc.
1x................
Mechanical adjustments
filling the hopper
clear
Select higher job number (section 5.4)

Select lower job number (section 5.4)

envelope support (section 5.8.3)
receiving tray (section 5.8.4)
envelope sealing (section 5.8.5)
envelope insert fingers
(section 5.11)
COUNTER without any function for OME
stop: Stop key

Stop processing
clear: Clear key
Empty the system and stop
Fill & Start not available for OME
MAIN MENU (2)
esc.: Escape key

Exit a menu without saving
any altered jobs
JOB
i .......................
1
Display contrast
Job menu...............
start
stop
clear
esc.

Adjust contrast
(section 5.2)
Enter JOB MENU
(section 5.2)
To MAIN MENU (1)
86
FPi 3030 job edit menu structure

(without OMR)
JOB MENU
JOB INFO
i .......................
JOB 1
invoice
Select settings menu (chapter 6)
JOB SETTINGS
select job to create/edit page (sec. 6.2/6.3)
Create job...............
JOB
ABC
Select....
Edit..........
Edit job..................
Copy job (section 6.4)

Delete job (section 6.5)
Exit JOB MENU and go to
MAIN MENU (2) (section 6.1)
Copy job.................
Delete job...............
Exit.......................
start
stop
clear
esc.
ENVELOPE SETTINGS
DOCUMENT SETTINGS
JOB 1
invoice
JOB
12
114
Feeder
3
2
1
0
1
1
Save job....
start
DFC SETTINGS
Number of
sheets
FOLD SETTINGS
JOB
99
OK
OK
Single fold (section 7.3.2)
ENVELOPE SETTINGS
DOCUMENT SETTINGS
FOLD SETTINGS
JOB 1
invoice
JOB
12
1+2
No envelopes
2
1
JOB 1
invoice
216
OK
OK
Hopper swap (section 7.2.3)

DOCUMENT SETTINGS
JOB
2
3
108
Link/unlink..
OK
No envelopes (section 7.1.3)
OK
Double feed control (DFC)

on/off (section 7.4)
JOB 1
invoice
Document size (section 7.2.2)
1
OFF
108
297
99 Size
OK
Envelope with open flap (section 7.1.2)
Feeder
Detection
OK
DOCUMENT SETTINGS
12
JOB 1
invoice
Feeder
3
ENVELOPE SETTINGS
Enter JOB NAME menu (section 6.5)

Save job settings and return to JOB MENU
(chapter 6)
JOB 1
invoice
No fold (section 7.3.1)
50
esc.
FOLD SETTINGS
OK
114
clear
JOB 1
invoice
Number of sheets (section 7.2.1)
stop
No fold
OK
Envelope with closed flap (section 7.1.1)
Job name..
Documents
Edit select settings menu (chapter 6)
12
Letter fold (section 7.3.3)

FOLD SETTINGS
JOB 1
invoice
108
Daily mail ON
2
1
216
OK
OK
Daily mail (section 7.2.4)
Zig-zag fold (section 7.3.4)
87
FPi 3030 job edit menu structure

with Optical Mark Reading (OMR)
JOB MENU
JOB INFO
i .......................
JOB 1
invoice
Select settings menu (chapter 6)
JOB SETTINGS
select job to create/edit page (sec. 6.2/6.3)
Create job...............
JOB
Select......
Edit.........
Edit job..................
Copy job (section 6.4)

Delete job (section 6.5)
Exit JOB MENU and go to
MAIN MENU (2) (section 6.1)
Copy job.................
Delete job...............
Exit.......................
start
clear
esc.
DOCUMENT SETTINGS
ENVELOPE SETTINGS
JOB
stop
JOB
12
114
Job name..
OMR
Save job...
start
stop
FOLD SETTINGS
JOB
clear
esc.
Edit select settings menu (chapter 6)

Enter JOB NAME menu (section 6.5)
Save job settings and return to JOB MENU
(chapter 6)
DFC SETTINGS
JOB
Feeder
No fold
2
1
Number of
sheets
OK
Envelope with closed flap (section 7.1.1)
DOCUMENT SETTINGS
JOB
12
JOB
108
2
1
50
OK
Envelope with open flap (section 7.1.2)

ENVELOPE SETTINGS
JOB
99
Size
99
OK
OK
Adjust document size (section 7.2.2)
Single fold (section 7.3.2)

FOLD SETTINGS
Results:
JOB
OMR SETTINGS
JOB
108
216
Code
type
OK
OK
Feeder 3 = reading
Feeder 2 = inactive
Feeder 1 = selective supplements
ON
Reading ON/OFF
No envelopes
No envelopes (section 7.1.3)
Double feed control (DFC)

on/off (section 7.4)
FOLD SETTINGS
Feeder
114
OK
OK
No fold (section 7.3.1)
OFF
Detection
OK
JOB
Activate selective supplements
ENVELOPE SETTINGS
Feeder
Letter fold (section 7.3.3)

(Zig-zag fold not recommended.)
OMR-2
OK
OMR settings (section 7.5)

OMR SETTINGS
JOB
2
1st mark
from top
200
2
1
Max. sheets
9
OK
OMR position + number of sheets (section 7.5)
88
Service
Service
Sach-Nr. 51.0062.1000.00
Special release for Service Manual 07.2001/ivh helbig Berlin
Every FPi 3030 is thoroughly checked

before leaving the factory. Should any
faults occur in spite of our extensive
quality control, please contact your
local servicing dealer. Our main office
will be pleased to tell you the address
of your local servicing dealer.
FP authorized dealer
Francotyp-Postalia AG & Co.

Postfach
16542 Birkenwerder/Germany
Phone:
Telefax:
+49 33 03 / 525 - 0
+49 33 03 / 525 - 799
Internet:
www.francotyp.com
89

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Operator Manual

FPi 3030 Inserting Machine

Safety tips ________________________________________________________________________________________________ 6

About the FPi 3030 folder-inserter _________________________________________________________ 7

Operating the machine __________________________________________________________________________

Warning! indicates a potential hazard which may result in injury.

Caution! indicates a potential hazard that may result in damage to

Please note the following typographic features:

Tips marked in this way offer advice and suggestions on the

FPi 3030 Operator manual

TEST RUN menu ___________________________________________________________________________

Job settings ___________________________________________________________________________________________

OMR SETTINGS menu (machines with OMR option only) _____________

Fault finding ___________________________________________________________________________________________

FPi 3030 Operator manual

About the FPi 3030 folder-inserter

About the FPi 3030 folder-inserter

The folder-inserter should be unpacked, installed and taken into initial

FPi 3030 is equipped with a variety of special features as

FPi 3030 Operator manual

The system consist of the following parts (fig. 2):

Understanding the machine

The settings of the system (types of documents, types of envelopes and

FPi 3030 Operator manual

double parallel fold.

letter receiving tray

FPi 3030 Operator manual

Optical Mark Reading/OMR (option)

FPi 3030 Operator manual

Moistening the brushes

Operating the machine

FPi 3030 Operator manual

Operating the machine

The main menu

check the job by means of the JOB INFO screen.

The MAIN MENU (1) shows 6 different functions:

FPi 3030 Operator manual

Operating the machine

The MAIN MENU (2), as shown in fig. 10 shows 5 different functions:

The JOB INFO screen shows the following job settings :

job information (key 1).

inserting of the envelopes:

- envelope with open flap (

which feeders are selected (

which feeders are linked (

the feed stations Real Sheet Control are on (

the number of documents processed by the feeder (

the length of the document in the feeder (

daily mail on or off (

JOB INFO screen

When key 1 is pressed in a menu, the JOB INFO screen will be

Operating the machine

FPi 3030 Operator manual

OTHER JOB menu

Adjustment of the document hopper

The document separation for the automatic feeders is set automatically.

job information (key 1) (see section 5.3).

The document separation for special feeders must be adjusted manually

push the knob A (fig. 14) forward until it clicks.

Mode 2 is considered to be the default mode with which a wide variety of

The separation is adjusted correctly when a slight resistance is felt on the

Operating the machine

FPi 3030 Operator manual