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 I
rev. 01.0 - 01/2002
FPI 5000 Inserter

service manual FPI 5000 I
rev. 01.0 - 01/2002
Contents
Section Page
General 510.00-1
Process description 510.01-1
Mechanical description 510.02-1
Electrical description 510.03-1
Parts list 510.04-1
Fault finding 510.05-1

service manual FPI 5000 I
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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 Envelope and paper 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 I inserts documents from the upstream feeding device FPI 5000 C into envelopes and the seals
and stacks the envelopes.
General note. This document describesthe inserter FPI 5000 I, the 110 V/60 Hz version,
the 230 V/50 Hz version and the 100 V/50 Hz version.

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2 Specifications
2.1 Machine specifications
Model:FPI 5000 I
Type : inserter module for medium office use.
Overall Dimensions height : 405 mm (15.9 inch)
width : 455 mm (17.9 inch)
with side catch tray; depends on envelope size
length : 650 mm (25.6 inch)
+ conveyor 1050 mm (41.3 inch)
+ side exit 780 mm (30.7 inch)
+ catch tray: depends on envelope size
Weight : approx. 48 kg (105.8 lbs)
Noise level : < 70 dB(A) (following DIN 45635 part 19)
Theoretical max. speed : 3500 inserts p/h, depending on configuration.
Operating temperature : 10 - 40°C (50 - 104°F)
Humidity : 10 - 80%
Power consumption : 100-120V AC / 50/60Hz / 3 Amps
220-240V AC / 50Hz / 1.4 - 1.5 Amps
Approvals : conforms to IEC 950 and derivatives.
UL listed ITE, File E153801
BS EN60950, File KM11322

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2.2 Envelope and paper insert specifications
Maximum insert specifications are based on single sheets. When multiples are handled, more room inside the
envelope is needed depending on application.
figure 2.1
* Booklets up to approximately 2 mm (0.08 inch) thickness, depending on stiffness.
** When insert is more than 1 mm thickness: A-15 mm/A-0.6 inch.
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.
AB C D E F G
minimum size mm 140 90 32 10 - 80 60 g/m
2
inches 5.5 3.5 1.25 0.4 - 3.14 60 g/m
2
maximum size mm 242 162 B - 32 - A - 12** B - 5 2.5*
inches 9.5 6.38 B - 1.25 - A - 0.47** B - 0.2 0.1

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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 FV-2A
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 transparent cover and the hinged cover.
5 Check condition of the separation roller, adjust or replace if necessary.
6 Check the adjustment of the joggers, adjust if necessary.
7 Check the envelope stop position on the insert table. (About ± 2 mm/0.08 inch) maximum
variation accepted). If more, clean lower track photocell, check clutch functioning, check
flapscraper adjustment and friction break adjustment and functioning.
8 Check if the envelope flap is correctly held at the insert place.
9 Check the pressure of the upper insert rollers on the documents, adjust if necessary.
10 Check the moistening brushes and moistening cloth. Wash out the brushes and, if necessary,
instruct the operator to wash out the brushes regularly. Check the moistening cloth and replace if more
than 120,000 inserts have been made.
11 Check the tension and the adjustment of the chains and the main drive belt, adjust or replace if necessary
12 Check the condition of the rubber rollers and the freewheel clutch, clean or replace if worn.
13 Check the condition of the sprockets, pulleys and gears, replace if necessary.
14 Check the adjustment of the solenoids, adjust if necessary.
15 Remove paper dust from photocells (LEDs and receivers).
16 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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Process description

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Contents
Section Page
1Overview 5
2Somedetails 7
2.1 Envelope transport 7
2.2 Document input and insert 7
2.3 Envelope ejecting, sealing and exiting 8

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1 Overview
The FPI 5000 I inserter performs the following tasks:
1 Transport an empty envelope from the hopper to the insert position.
2 Transport a single documentor document set fromthe FPI 5000 C to and in
the opened envelope.
3 Eject and seal the filled envelope and transport it to the rear exit (or side exit).
The simplest diagram of this process consists of just three arrows:
These three tasks make up just one cycle of the machine operating in the automatic mode. The operator can
choose the execution of a single cycle or a two-stage cycle as well.
E+D D
E