Formax DS-40i User manual

Table of Contents
Read this First ...............................................................................................11
Safety...............................................................................................................1
Declaration of Conformity (EU only).................................................................1
About this manual............................................................................................1
Meet your Document System ......................................................................32
Introduction......................................................................................................3
Operating Controls...........................................................................................5
Control Panel...................................................................................................6
Power Up..........................................................................................................7
Home screen....................................................................................................8
What is a Job?.................................................................................................8
Job overview....................................................................................................9
Settings menu................................................................................................10
Remote assistance (optional)........................................................................10
Tri-Fold option................................................................................................11
Shut Down the System...................................................................................12
Working with Jobs ......................................................................................133
Introduction....................................................................................................13
Use an existing job.........................................................................................13
Create a New Job..........................................................................................14
Job Settings...................................................................................................15
Save a Job.....................................................................................................18
Run a Job.......................................................................................................19
A Daily Mail job..............................................................................................20
A Tri-Fold job..................................................................................................21
Loading the System ...................................................................................244
Installing the Envelope Catch Tray.................................................................24
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Document Orientation....................................................................................25
Document Feed Trays....................................................................................26
Loading Envelopes.........................................................................................29
Filling the Sealing Liquid Reservoir................................................................31
Settings menu .............................................................................................325
Open the Settings Menu................................................................................32
Open the Supervisor menu............................................................................33
Supervisor Settings Menu..............................................................................35
Operator Maintenance ................................................................................416
Maintenance..................................................................................................41
Cleaning or Replacing Moistening Brushes...................................................42
Clean the system...........................................................................................42
Fault finding ................................................................................................437
Fault Finding..................................................................................................43
Clearing Stoppages.......................................................................................44
Operator Troubleshooting...............................................................................46
Specifications .............................................................................................538
Technical Specifications.................................................................................53
Dimensions and weight..................................................................................54
Hopper and Feeder Capacity.........................................................................54
Document Specifications...............................................................................55
Envelope and Insert Specifications................................................................56
Terminology ................................................................................................589
Terminology description.................................................................................58
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Read this First1
Safety
Ensure you have read and fully understood the safety requirements
in the Safety Guide.
Declaration of Conformity (EU only)
The product presented in this guide meets the requirements of applicable directives. For
more details refer to the Declaration of Conformity. Contact your authorized distributor for
availability of this document.
About this manual
Disclaimer
This Guide is published without any warranty. Improvements and changes to the online
Guide necessitated by typographical errors, inaccuracies of current information, or
improvements toprogramsand/orequipment, maybe made atanytime and withoutnotice.
Such changes will, however, be incorporated into new editions of the PDF Guide (if
applicable).
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Symbols
This manual uses the symbols listed below.
Indicates...This symbol...
WARNING: Indicates a human safety hazard.
ATTENTION: A risk to the equipment or mail could result from an action
you may perform.
NOTE: A remark that explains different cases or specificities.
TIP: Advice to help save you time when processing your mail.
SUPERVISOR: Indicates that you have to use the supervisor menu to
perform the procedure.
Languages
In the EU the user guide must be available in the national language(s) of the country where
the system is delivered. Therefore, if the User Guide is not available in your country’s
language(s), contact your authorized distributor.
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Meet your Document System2
Introduction
The system feeds, folds and inserts documents into envelopes and then seals and stacks
the envelopes. Automatic monitoring ensures the correct number of inserts per envelope.
The system is a sophisticated folding and inserting system which can process large
quantities of mail rapidly and easily.
You can save the settings of the system (document type, envelope type and fold type) in
so-called jobs.
The figure shows an overview of the systems document and envelope flow.
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Feeder Area (1)
The system has a feeder block with two document feeders. The feeder block is equipped
with feeder swap. This means that you can link both feeders as pairs. When the first feeder
is empty, the system switches to the other feeder. Meanwhile you can refill the other empty
feeder without stopping the system. The front feeder (feeder 1) is equipped with a “daily
mail” function to process documents or sets of documents which cannot be processed
automatically (e.g. stapled).
Double Feed Control (DFC)
Each feeder has double feed control (DFC). In this way the system can detect faulty sets
of documents. When a job is started, the first document taken per feeder is used for a
reference measurement. When a document is exceeding that reference thickness an error
will be displayed.
When Daily mail is selected, the DFC is switched off automatically.
Envelope Hopper (2)
The envelopes are picked up and transported to the insert position inside the system.
Feeder for Business Reply Envelopes (BRE) and Other Enclosures (3)
Small enclosures or BREs are fed from feeder 3 and added to the folded document set.
Folding area (4)
In the folding area the documents are folded. The following fold types are possible (see
“Terminology” on page 29):
• No fold
• V-fold (single fold)
• C-fold (letter fold)
• Double V-fold (double parallel fold)
Inserter (5)
The folded document set is transported to the inserter unit and inserted into a waiting
envelope. The inserter can seal the envelope.
Exit (6)
The mail set leaves the system from the exit.
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Operating Controls
thumb wheel to adjust side
guides feeder 3
Jbutton to open the systemA
power inletKcontrol panel with touch
screen
B
power switchLOn/Off buttonC
side guides envelope hopperMpaper guidesD
thumb wheel for adjusting
side guides envelope hopper
Ndocument feeder 1E
locking levers for side guides
(document feeder trays)
Odocument feeder 2F
thumb wheels for adjusting
sideguides (document feeder
trays)
Pflap, for access to document
path of feeder 3
G
sealing liquid reservoirQsupport feeder 3H
catch trayRside guides feeder 3I
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Control Panel
On/Off (B): The touch sensitive button in the upper right corner of the display switches the
system on or off. If after operation the system is not used for 15 minutes, the system
switches to sleep mode. If you touch the screen the system will switch to operation mode
again. If the system is not used for one hour, the system switches off to safe power.
Status LED (C): A status LED indicates the state of the machine: a green LED indicates
that the system is switched on. An orange LED (and a black screen) indicates that the
system is in sleep mode. No colored LED (togehter with a black screen) indicates that the
system is switched off.
The display is a capacitive touch screen. To avoid permanent
damage of the display, do not use sharp objects to operate the
display.
To clean the display use a dry lint-free or microfiber cloth. If water
is necessary to clean the screen, you should make your microfiber
cloth slightly damp instead of putting the water directly on your
screen. Never use large amounts of water, harsh chemicals,
abrasive cloths or paper towels to clean the display.
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Power Up
To start up the system:
Connect the system to the mains power supply.1.
You can severely damage the machine if it is connected to the
incorrect mains voltage. Before plugging in the machine, check if
the local voltage is the same as the voltage mentioned on the type
plate.
2. Use the power switch to switch on the system. The power switch is located at the back
of the system.
3. Press the on/off button next to the display.
The touch screen shows the "Home screen".
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Home screen
When you start up the system, the ‘Home screen’ appears. The LH side of the screen
shows the job list. The RH side of the screen shows the selected/current job. Other things
you can do here are:
1. Create a new job
2. Edit the selected/current job
3. Start the selected/current job
4. Open the settings menu bar *)
5. Select another job
*) From the settings menu bar you can get access to the following:
- the "main" settings menu
- the Remote Assistance screen
What is a Job?
If you have to process a lot of mail sets of the same type (for example bills), you can save
the settings to a 'job'. The next time you just select the job and immediately start without
defining any settings.
The following settings are saved in a job:
• Envelope type/size;
• Sealing on/off;
• Which document feeders should be used, how many documents should be fed from
each feeder and document height for each feeder;
• Feeder linking on/off;
• If BREs or insert cards should be included;
• Address position;
• Double feed control settings;
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Job overview
The job overview of the selected/current job is part of the 'home screen' and shown on the
RH side.
This job overview shows the following information of the selected job:
• A picture of the system with symbols for the selected features. The following symbols
can be used:
Feeder is set for daily mail
Envelope size and whether sealing is on/off
Document size and if the document has to be fed face
up/down
BRE size
As part of the home screen also the Job Counter is shown of the selected job. The Job
counter shows the total number of mail sets that have been processed with this job.
The counter settings are job related.
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Settings menu
When you open the settings menu bar, tap on the [Settings] symbol button to open the
"Settings menu". This Settings menu shows the following possibilities:
•Language settings: change the language of the user interface.
•Supervisor Settings menu: For authorized personnel only. Via this menu it is a.o.
possible to customize the envelope height, adjust the stop position etc. (see “Open
the Supervisor menu on page 33” for more information).
•Key click: if you tap this button you can choose if you want to turn the key click sound
on or off.
Remote assistance (optional)
Ask your authorized distributor if this feature is available for your
system/organization.
It is necessary that the system is connected to the internet.
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(Online) Remote Assistance is a tool for help desk guidance. Add the support key supplied
by the support assistant and follow the instructions as indicated by the support assistant.
The remote assistance screen can be entered by tapping the second symbol in the settings
bar.
Tri-Fold option
Some applications require a fold setting where all three “panels” have the same dimensions,
the so called “Perfect Fold”. In order to have those documents correctly transported to the
exit an extra pair of transportation rollers have to be fitted in the system. By replacing the
sealing liquid reservoir with the “Tri-Fold" transportation unit correct transportation to the
exit is ensured.
Using the Tri-Fold option is only possible if this option has been set
by the Service organization.
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Shut Down the System
Press the [On/Off] button. The system completes and inserts the current set and
stops, this results in a cleared system. After that the system switches off.
1.
In case the system is unresponsive or fails to switch off, press and
hold the touch sensitive power button for 10 seconds to switch off
the system.
2. Press the Power switch to shut down the system.
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Working with Jobs3
Introduction
With the system you can process mail sets in the following ways:
•Using an existing (saved) job: Existing jobs are shown in the Job list. These jobs
have been saved via the job creation process.
•Using a new, unsaved job: after tapping the [New Job] button and finishing the Job
Wizard just tap the start button. It is not needed to save the job first.
Use an existing job
Before you use an existing job where sealing is required, make
sure the sealing liquid reservoir is filled.
To use an existing job:
1. From the home screen choose a job. The job information appears, see “Job overview
on page 9".
2. Load envelopes as specified in the job.
3. Load the documents face up and trailing, as specified in the job. Place the address
carrier in feeder 1.
4. Tap the [1x] button to start a test run or tap the [Start] button to start the job. If you
tap the [1x] button, the system helps you to adjust the address position (see ”Address
Position” on page 20).
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Create a New Job
To create a new job:
1. In the home screen, tap [New job]. The New job Wizard starts and helps you to choose;
• Envelope type (size). Custom is only available if defined by the supervisor (see
“Supervisor Menu on page 33”).
• Closing type; if the envelopes should be sealed or not.
• Document size for feeder 1.
• Feeding type: Automatic feeding or Daily mail (manual).
• Document size for feeder 2. If you choose None, you can use feeder 2 as a
linked feeder. This means that when one feeder is empty, the system
automatically starts picking documents from the other feeder.
• Enclosure type (size) from feeder 3.
• Fold type.
2. Tap the [1x] button to make sure that the address position is correct (see “Address
Position on page 20”).
3. Tap the [Start] button to start the job or tap the [Save] (disk symbol) button to save
the job.
4. If you tap the [Save] button:
• Enter a name for the job. Use the backspace button to clear a character left of
the cursor position.
• Tap [OK] to confirm the job name.
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Job Settings
Job Settings menu
When you tap in the Home screen on the [Edit job] button, the "Job Settings" menu opens.
This menu enables you to:
• Edit a job (see ”Edit a Job” on page 15).
• Delete a job (see ”Delete a Job” on page 16).
• Reset the job counter: sets the counter to zero (see "Reset job counter on page 16").
• Switch per feeder the double feed control (DFC) on or off (see "Feeder options on
page 17").
Edit a Job
To edit an existing job:
1. From the home screen choose a job.
2. Tap the [Edit job] button. The "Job Settings" menu opens.
3. In the "Job settings" menu tap the [Edit job] button. The Job Wizard starts and helps
you to change job settings.
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4. Tap [Save] to save the job with the changed settings.
5. Press the [1x] button to make sure that the address position is correct (see “Address
Position”).
Delete a Job
To delete an existing job:
From the home screen choose a job.1.
2. Tap the [Edit job] button. The "Job Settings" menu opens.
3. Tap [Delete job].
4. Tap [Yes] to confirm. The job will be deleted without a warning.
Reset the job counter
Counter settings are job related.
The job counter shows the total number of mail sets that have been processed with the
selected job. If you want to set the job counter of the job to zero proceed as follows:
From the home screen tap the [Edit job] button. The "Job Settings" menu opens.1.
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2. In the "Job Settings" screen tap the [Reset job counter] button.
3. You will be asked if you want to reset the job counter. Tap [Yes] to reset the job
counter.
4. The job counter will be reset to zero. The "Job Settings" screens appears again.
Feeder options
For some applications it is preferred to switch the double feed control (DFC) off per feeder.
For example, if you have a document with an address sticker on it, the DFC may see the
sticker as a double feed; an error message will be generated. To prevent this you can
switch the DFC off per feeder. Proceed as follows:
From the home screen tap the [Edit job] button. The "Job Settings" menu opens.1.
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2. Tap the [Feeder options] button.
3. Select per feeder if you want to have the double feed control switched on or off.
4. Tap the [Disk] button to save the settings.
Save a Job
When you have created a new job or edited a job, save the job as follows:
After you have completed the job definition, tap the [Save] button.1.
2. Enter the job name.
Note: It is possible to delete the existing name at once by using the [clear] button.
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