Francotyp-Postalia FPI 5000 C User manual

FPi 5000
Inserting System
ILLUSTRATED PARTS LIST
SERVICE MANUAL
FPI 5000 I
FPI 5000 C
1

service manual FPI 5000 C
rev. 01.0 - 01/2002
FPI 5000 Collator

service manual FPI 5000 C
rev. 01.0 - 01/2002
Contents
Section Page
General 520.00-1
Process description 520.01-1
Mechanical description 520.02-1
Electrical description 520.03-1
Parts list 520.04-1
Fault finding 520.05-1

service manual FPI 5000 C
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General

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Contents
Section Page
1 Function 6
2 Specifications 7
2.1 Machine specifications 7
2.2 Paper insert specifications 8
2.3 Envelope insert specifications 8
3 Preparing the machine for use 9
3.1 Unpacking 9
3.2 Unpacking instruction 10
4 Preventive maintenance 11

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Used symbols
In this manual the following symbols are used.
Warning, this symbol indicates a wrong action which can cause a hazard to health or
damage the machine.
Warning, this symbol indicates a hazard to life because of high voltage.

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1Function
The FPI 5000 C is a document processing device thattransports, collates and aligns documents from one or
two feed stations (each equipped with two feeding devices) and feeds the documents with or without folding
to the inserter (FPI 5000 C).
General note. This documents describes the feed- and folding device FPI 5000 C. No specific part number is
given to the FPI 5000 C as this device can be configured in several ways.

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2 Specifications
2.1 Machine specifications
Model:FPI 5000 C
Type : document processing device for medium office use.
Overall Dimensions 2-station module 4-station module 6-station module
height : 735 mm (22.4 inch) 735 mm (29.3 inch) 920 mm (36.2 inch)
width : 460mm (16.5 inch)
length : 750 mm (29.5 inch)
Weight : 2-station module approx. 54 kg (119 lbs)
4-station module approx. 63 kg (138.8 lbs)
6-station module approx. 74.0 kg (163 lbs)
Noise level:refer to FPI 5000 I Inserter noise level.
Theoretical max.speed :refer to FPI 5000 I Inserter theoretical max. speed.
Operating temperature : 10 - 40°C (50 - 104°F)
Humidity : 10 - 80%
Power consumption : low voltage supplied by the inserter.
Approvals : conforms to IEC 950 and derivatives.
UL listed ITE, File E153801
BS EN60950, File KM11322

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2.2 Paper insert specifications
Paper sizes minimum maximum
width* : 130 mm (5.1 inch) 236 mm (9.5 inch)
length : 90 mm (3.5 inch) 356 mm (14.0 inch)
Booklets depending on envelope size (inserter)
Quality** : 60 gr/m²250 gr/m²
(15 lb bond) (62.5 lb bond)
Booklets up to approximately 2 mm (0.08 inch) thickness,
depending on stiffness.
* When folded max. 230 mm (9.1 inch)
** When folded max. 170 gr/m
2
.
Folding capacity : 8 sheets (max. 80 gr/m²)
2.3 Envelope insert specifications
Envelope sizes : Standard BRE (Business Reply Envelopes)
Quality : 80 gr/m²120 gr/m²
(20 lb bond) (30 lb bond)
Remarks
•Self-copying paper may cause rubber parts to wear quicker. The rubber used in this machine has the best
resistance to Wiggins Teape material.
•The specification of the paper handling equipment is often wider than that of the envelopes and docu-
ments 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 20°C (68°F) with a relative
humidity factor of 50%. If difference in temperature occurs between store room and
mailing area, the material has to be stored near the machine at least 24 hours before use.

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3 Preparing the machine for use
First the machine must be unpacked. Then it must be mechanically and electrically hooked up with the FPI
5000 I Inserter of which the paper processing configuration as a whole exists. After unpacking and installing, the
machine is ready for use.
3.1 Unpacking

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3.2 Unpacking instruction

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4 Preventive maintenance
Recommended preventive maintenance checkpoints
In the following it is assumed that if any unscheduled service call is less than a month prior to a
preventive maintenance call, it will replace that latter.
1 Ask how the machine has worked and use that information as a guide for checking the equipment.
2 Ask if there has been change in use of the machine, such as high production or change of material.
3 Check the machine adjustments and check materials and, if necessary, instruct the operator(s) again.
(Many service calls are caused by wrong adjustments or wrong material, and sometimes there is a quick
succession of operators. Here a five or ten minutes refresher course would save unnecessary and
embarrassing service calls in the future).
4 Test the proper functioning of the safety switches of the vertical transport track and the folder.
5 Check condition of the separation rollers, adjust or replace if necessary.
6 Check the tension and condition of the belts, adjust or replace if necessary
7 Check the condition of the rubber rollers, clean or replace if worn.
8 Check the condition of the pulleys and gears, replace if necessary.
9 Remove paper dust from photocells (LEDs and receivers).
10 Test the system hardware and software using the service software.
If available make a test run with “users”material; if not, use own material for the test run.

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service manual FPI 5000 C
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Process description

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Contents
Section Page
1Overview 5
2 Legend 7
2.1 Feeding documents (the Vario Feed concept) 10
2.2 Vertical document transport 10
2.3 Transport to and from the collator 10
2.4 The Divert & Go divert process 10
2.5 The multifeed shunt process 11
2.6 The Eight in One folding process, including exit to the
FPI 5000 I 11

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service manual FPI 5000 Collator
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1 Overview
The processing ofdocumentsby the FPI 5000 C and itsattached feeders can be divided into a number of
distinct sequential partial processes. These processes will be discussed in some more detail:
• Feeding documents (the Vario Feed concept).
• Vertical document transport.
• Transport to and from the collator area.
• The Divert & Go divert process (only if the optional divert subsystem is present).
• The multifeed shunt process (only if the optional divert subsystem is present).
•The Eight in One folding process, including exitto the FPI 5000 I.
The figure on the foldout page 520.01-6 shows a schematic overview of the process. All mechanical items that
are strictly necessary to explain the process are projected on the LH side of the machine. This implies that not
all auxiliary mechanical items (such as gears, belts et cetera) are shown; using the concept of LH projection,
this would make this figure pretty unreadable. However, some global information on the main mechanical
drive systems is included in this process description. Refer to the FPI 5000 C mechanical description
(document 520.02) for full detailson the FPI 5000 C mechanics.