Francotyp-Postalia KS 4000 OL User manual

Operator Manual
Inserting system KS 4000 OL / OLC
About your new inserting system
2
This operator manual is designed for users who have been instructed in
the operation of the Inserting System KS 4000 OL/OLC.
This operator manual is one part of the complete documentation available
for the Inserting System KS 4000 OL/OLC. It describes typical operating
procedures for configurations
– with a single-sheet feeder
– with a single-sheet feeder and supplement feeder
– with automatic cutter (for processing continuous-feed paper)
– with automatic cutter and supplement feeder
– with automatic cutter and cross-fold function (for processing
continueous-feed A3 and broadsheet formats)
– with automatic cutter, cross-fold function and supplement feeder.
Detailed descriptions (about functions, technical data, installation,
maintenance, programming) of individual components can be found in the
“Instruction Manual Inserting System 4000” and in the for “Operating
Instructions Cut-Sheet-Feeder” and/or “Operating Instructions Automatic
Forms Cutter” (depending on the configuration of your system).
Keep this operator manual readily available and near the machine.
The following symbols and cautions represent important safety warnings
in this manual:
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.
Tips marked in this way offer advice and suggestions on the effi-
cient and troublefree use of the inserting system.

4
The control panel
Single-sheet feeder / automatic cutter
Control panel
Inserter type A
Control panel
Inserter type VA
Inse r tonce
E rr o r
Inse r te r
OFF Inse r ting speed
Powe r O N / OFF
S top auto m atic-ope r ation
E rr o r inseale r
S electfold
O N
Auto m atic ( lightba rr ie r )
( Keys co rr espond tofunctions shownin
D isplay 2 )
Multi-function keys
S ta r tfeede r
S top feede r
( m achine stops afte r
co m pleting the
cu rr enthandling
cycle )
Togglebetween
p r og r a m selection
and pa r a m ete r
D isplay info r m ation
aboutcu rr entp r og r a m
settings
D isplay 1 D isplay 2
KS 4000 OL (with automatic cutter)
KS 4000 OL (with single-sheet feeder)
Catcht r ay
Inse r te r
D ive r te r
Cont r olpanel
Auto m aticcutte r
S eale r
Conveyo r
D elive r ydevice
Black Box *
3
Inse r te r
Cont r olpanel
S ingle-sheetfeede r
Conveyo r
* location may vary depending on configuration
D elive r ydevice
Feede r / Folding feede r
Black Box *
S eale r
Catcht r ay

5
Contents
1 Safety information ____________________________________________________________________________________________________________ 9
2 Useful information about the KS 4000 Online __________________________________________________ 11
3 Inserting System KS 4000 OL with single-sheet feeder_______________________________ 13
3.1 Insert stacked material ___________________________________________________________________________________ 13
3.1.1 Starting operation ________________________________________________________________________________________________ 13
3.1.2 Stop automatic operation __________________________________________________________________________________ 17
3.1.3 Reload paper _________________________________________________________________________________________________________ 18
3.1.4 Conclude job and shut system down ___________________________________________________________ 18
3.2 Insert stacked material with supplement ______________________________________________ 19
3.2.1 Starting operation ________________________________________________________________________________________________ 19
3.2.2 Stop automatic operation __________________________________________________________________________________ 24
3.2.3 Replenish paper supply _____________________________________________________________________________________ 25
3.2.4 Conclude job and shut system down ___________________________________________________________ 26
4 Inserting System KS 4000 OL with automatic cutter ____________________________________ 27
4.1 Cut and insert continuous-feed paper ___________________________________________________ 27
4.1.1 Starting operation ________________________________________________________________________________________________ 27
4.1.2 Stop automatic operation __________________________________________________________________________________ 32
4.1.3 Conclude job and shut system down ___________________________________________________________ 33
4.2 Process continuous-feed paper and add supplement ___________________ 34
4.2.1 Starting operation ________________________________________________________________________________________________ 34
4.2.2 Stop automatic operation __________________________________________________________________________________ 40
4.2.3 Conclude job and shut system down ___________________________________________________________ 41
4.3 Reload paper _______________________________________________________________________________________________________ 42
4.3.1 Continuous-feed paper ______________________________________________________________________________________ 42
4.3.2 Supplement ____________________________________________________________________________________________________________ 43
5 Inserting system KS 4000 OLC with automatic cutter __________________________________ 45
5.1 Cut and insert continuous-feed paper ___________________________________________________ 45
5.1.1 Starting operation ________________________________________________________________________________________________ 45
5.1.2 Stop automatic operation __________________________________________________________________________________ 50
5.1.3 Conclude job and shut system down ___________________________________________________________ 51

6
Operator Manual KS 4000 OL / OLC
5.2 Process continuous-feed paper and add supplement ___________________ 52
5.2.1 Starting operation ________________________________________________________________________________________________ 52
5.2.2 Stop automatic operation __________________________________________________________________________________ 58
5.2.3 Conclude job and shut system down ___________________________________________________________ 59
5.3 Reload paper _______________________________________________________________________________________________________ 60
6 Inserting from Stations (feeder/folding feeder) _______________________________________________ 61
6.1 Inserting from a single station _________________________________________________________________________ 61
6.2 Inserting from multiple stations _______________________________________________________________________ 63
6.3 Conclude job and shut system down ___________________________________________________________ 66
7 Inserting system KS 4000 OL / OLC modules ___________________________________________________ 67
7.1 Single-sheet feeder __________________________________________________________________________________________ 68
7.1.1 Operating and adjustment controls _______________________________________________________________ 68
7.1.2 Adjust paper guides ____________________________________________________________________________________________ 70
7.1.3 Adjust separator sluice ______________________________________________________________________________________ 70
7.1.4 Load paper _____________________________________________________________________________________________________________ 71
7.1.5 Adjust reading head ____________________________________________________________________________________________ 72
7.2 Automatic cutter ________________________________________________________________________________________________ 74
7.2.1 Operator controls _________________________________________________________________________________________________ 74
7.2.2 Load continuous-feed paper ____________________________________________________________________________ 76
7.2.3 Adjust edge cut position ____________________________________________________________________________________ 77
7.2.4 Adjust reading head ____________________________________________________________________________________________ 78
7.3 Lateral conveyor ________________________________________________________________________________________________ 80
7.3.1 Controls ___________________________________________________________________________________________________________________ 80
7.3.2 Adjust paper transport guides _________________________________________________________________________ 81
7.4 Sequencer and Delivery device _________________________________________________________________ 82
7.4.1 Controls ___________________________________________________________________________________________________________________ 82
7.4.2 Adjust paper guide ______________________________________________________________________________________________ 83
7.5 Folder ______________________________________________________________________________________________________________________ 84
7.6 Diverter unit _________________________________________________________________________________________________________ 86
7.6.1 Diverter for KS 4000 OL ____________________________________________________________________________________ 86
7.6.2 The catch tray (KS 4000 OLC) _______________________________________________________________________ 87

7
7.7 Conveyor _______________________________________________________________________________________________________________ 88
7.7.1 Adjust paper guides ____________________________________________________________________________________________ 90
7.7.2 Adjust paper stops
(only on KS 4000 OL-systems) ______________________________________________________________________ 91
7.8 Feeder / folding feeder ___________________________________________________________________________________ 92
7.8.1 Controls ___________________________________________________________________________________________________________________ 92
7.8.2 Adjust paper guides ____________________________________________________________________________________________ 94
7.8.3 Adjust separator gate _________________________________________________________________________________________ 94
7.8.4 Load paper _____________________________________________________________________________________________________________ 95
7.9 Inserter ___________________________________________________________________________________________________________________ 96
7.9.1 Controls - type A inserter __________________________________________________________________________________ 96
7.9.2 Controls - type VA inserter _______________________________________________________________________________ 96
7.9.3 Adjust paper guides ____________________________________________________________________________________________ 98
7.9.4 Load envelopes ____________________________________________________________________________________________________ 99
7.10 Sealer ___________________________________________________________________________________________________________________ 100
8 Trouble-shooting tips _________________________________________________________________________________________________ 103
8.1 General notes_____________________________________________________________________________________________________ 103
8.2 Single-sheet feeder faults ______________________________________________________________________________ 105
8.3 Automatic cutter faults ____________________________________________________________________________________ 107
8.4 Lateral conveyor faults ___________________________________________________________________________________ 109
8.5 Delivery device faults _______________________________________________________________________________________ 110
8.6 Sequencer faults ________________________________________________________________________________________________ 111
8.7 Folding machine faults _____________________________________________________________________________________ 112
8.8 Diverter unit faults ______________________________________________________________________________________________ 116
8.9 Feeder / folding feeder faults_________________________________________________________________________ 117
8.10 Inserter faults _____________________________________________________________________________________________________ 120
8.11 Sealing unit faults _____________________________________________________________________________________________ 122
9Service_______________________________________________________________________________________________________________________________ 125
Contents

8
Operator Manual KS 4000 OL / OLC

9
1 Safety information
The Inserting System KS 4000 OL/OLC is constructed to comply with all
standard safety regulations for office equipment of this type. The following
safety information is important. To prevent injury or damage to the system
this information should be familiar to all persons that may use the machine.
• The system may be installed and moved only by service technicians who
have been trained and authorized by Francotyp-Postalia.
• The Inserting System KS 4000 OL/OLC may be used only by staff who
have been instructed in the system’s operation.
• Never remove or disable safety devices or guards.
• Make sure the mains supply conforms to power requirements shown on
the machine’s serial number plate.
• Never connect or disconnect cables between components while the
machine is in operation.
• Never place hands on any moving parts and keep long hair, loose
clothing or scarves and jewelry safely away from moving parts.
• Never reach hands into areas or spaces marked as danger zones.
• Use caution and care when closing the sequencer. Never reach between
the roller mounting and the sequencer’s upper part. Fingers may be
crushed if the top slams closed.
• Make sure other people stay at a safe distance when remedying errors in
the folding unit.
• Ensure that no liquids or objects enter the interior of any component.
Disconnect all power cables if such an accident occurs and have the
inserting system checked by your local servicing dealer before resuming
operation.
• All repairs and maintenance work should be carried out only by service
technicians who have been trained and authorized by Francotyp-Postalia.
Work performed by unauthorized persons may void the warranty.
FP will not be held liable for any resulting damages.
Safety information

10
Operator Manual KS 4000 OL / OLC

11
Useful information about the KS 4000 OL / OLC
The KS 4000 OL/OLC is a sophisticated mail
processing system for finishing computer-
generated mass mailings. The system can
collect material, divert office duplicates, fold,
insert and seal material in a finished
envelope.
Each KS 4000 OL/OLC inserting system
consists of modular components configured
according to the customer’s requirements,
and can be easily expanded at any time.
Important performance characteristics are:
– Simple and sure operation using fully-
electronic document controls. The inserting
system signals errors and empty feeder
stations.
– Program memory. All parameters that
govern the system’s operations (e.g.
document length, transport speed, marks
recognition routines) are stored in program
memories.
– Feeds EDP-generated documents reliably
and quickly from the single-sheet feeder
(laser printed, stacked single sheets) or
from the automatic cutter (continuous-feed
paper).
– FP-folding flap principle. The folding-flap in
the inserter makes it possible to fold and
insert various kinds of material in a single
handling cycle. Material that is stapled or
paperclipped or has a rigid plastic card
affixed can be processed safely and
reliably.
–Sealsenvelopesanddepositsfinished
letters in a catch tray or stacking tray.
2 Useful information about the KS 4000 OL / OLC

12
Operator Manual KS 4000 OL / OLC
Available options include:
– Optical marks recognition (OMR). Code
marks printed on each sheet being
processed instruct the system to collect
and check material addressed to a single
address and / or to divert material that
should not be mailed.
– Feed unfolded or folded supplementary
materials from a feeder/folding feeder
placed on the conveyor.
– Fold oversized or broadsheet material in
the crossfold unit (lateral transport unit and
folder) before inserting.
Three common system configurations are
shown on the fold-out pages 3 and 124.
– For processing online continuous-feed
material (e.g. invoices, circulars, account
statements)
– For processing laser-printed single-sheet
material
– For processing oversized online
continuous-feed material with a crossfold
unit.
Feeder/Folding feeder
Crossfold unit
KS 4000 OL with automaticcutter
KS 4000 OL with single-sheetfeeder
KS 4000 OLC with automaticcutter and
crossfold unit
OMR

13
Inserting System KS 4000 OL with single-sheet feeder
3.1 Insert stacked material
3.1.1 Starting operation
Detailed instructions on configuring the
inserting system for a job can be found in
Chapter 7 in descriptions of individual
modules and in the “Instruction Manual
Inserting System 4000”.
Caution! Make sure that no material from the
previously run job remains in the machine.
• Set all paper guides according to the width
of the material being handled (c. 2 mm gap
on each side). Begin making settings at the
inserter and then move upstream.
•Loadenvelopes.
• Switch inserter power to ON.
• Press button on the inserter.
The inserter ON button lights up. The inserting
system tests all interfaces.
• Switch single-sheet feeder power ON.
The red signal buttons on the individual
modules will light up briefly. The conveyor will
move to its starting position. The red signal
button on the Black Box blinks.
The upper display field (Display 1) on the opera-
tor panel shows the last program to have
been run. The program number blinks.
3 Inserting System KS 4000 OL with single-sheet feeder
S ingle-sheetfeede r powe r O N / OFF
Inse r te r powe r O N / OFF
Inse r te r O N

14
Operator Manual KS 4000 OL / OLC
• Check settings of the single-sheet sheet
separator sluice.
The single-sheet separator sluice is adjusted
correctly when both red marks for automatic
operation are visible.
• Adjust the optical marks reading head
when using marks recognition programs
(OMR): The red mark on the reading head
should be aligned to the center of the
printed marks.
• Make sure the separator pre-sluice is
lowered.
•Fanoutastackofsheets(c.20to30mm
high) so that the leading edges form a
wedge to the pre-sluice.
Thin paper = a smaller stack of sheets
Thick paper = a larger stack of sheets
• Push the leading edge of the wedge of
sheets into the pre-sluice (see Chapter
7.1.4).
Ma r kings ( r ed )
P r e-sluice
( lowe r ed )
W edge-shaped
leading edge ofstack
R eading head tightening sc r ew

15
• If you wish to change the program, use the
– function keys to select the
desired program number.
F1 – Set programm “00”.
F2 – To reduce by “1” the shown program
number.
F3 – To increase by “1” the shown program
number.
F4 – To increase by “10” the shown program
number.
Please read the single-sheet feeder operator
manual for instructions on changing a
program or creating a program for a new job.
• Press the button on the control
panel.
The single-sheet feeder will draw (separate
from stack) the first sheet. The lower display
(Display 2) will show READY !!!
If more than one sheet is drawn by the sepa-
rator, the display will show an error message.
Please refer to Chapter 8.2 “Single-sheet
feeder faults” for instructions on remedying
errors.
• Press the button to start the job.
The first complete document set to be
processed will be deposited on the conveyor.
The signal button on the Black Box will turn
off.
• Check to make sure the first set of docu-
ments is complete and correct.
Inserting System KS 4000 OL with single-sheet feeder
P r og r a m nu m be r ( blinking )

16
Operator Manual KS 4000 OL / OLC
If the document set on the conveyor is
complete, you can start automatic operation.
How you do this depends on the inserter
model used in the system.
• Press the black button on the hand-held
conveyor control repeatedly until the first
set enters the inserter and automatic
operation begins.
• Press the black button on the hand-held
conveyor control repeatedly until the first
set has arrived in the inserter. The single-
sheet feeder will automatically start pro-
cessing the following sets.
• Press the button on the inserter
machine. The first document set will be
folded and inserted into an envelope. The
following set enters the inserter and the
system stops.
Start automatic operation only after making
sure that each handling step is performed
correctly. You can use the button to
start a single insertion cycle.
Starting automatic operation:
• Press the button – button lights up.
• If necessary: Switch material format to
match material.
A4, 2/3 A4 = is not pressed
1/3 A4 = is pressed (lights up)
• Press button – Button lights up and
automatic operation begins.
Systems with typeVA inserter
Systems with typeA inserter
Inse r t
Inse r t
Auto m atic
Change
fo r m at

17
Inserting System KS 4000 OL with single-sheet feeder
3.1.2 Stop automatic operation
You can interrupt automatic operation at any
time.
• Press the button on the inserter
or
• Press the button on the control panel
of the single-sheet feeder.
Resuming automatic operation after
interruption
To continue automatic operation press the
stop-button that was used to stop operation.
If the button on the inserter has been
pressed (the red button is lit up):
• Press the button on the inserter.
If the control panel STOP has been pressed
(the lower display shows STOP and SPEED
PAUSE alternately):
• Press the button on the control panel
(single-sheet feeder).
S top syste m

18
Operator Manual KS 4000 OL / OLC
3.1.3 Reload paper
The system stops. An error message at the
single-sheet feeder indicates that stacked
supply of single sheets has been exhausted.
• Fan out a stack of material and load it into
the single-sheet feeder.
• Press the button on the control panel
(single-sheet feeder).
The system will resume automatic operation.
3.1.4 Conclude job and shut system down
When the last sheet has been fed from the
single-sheet feeder and the last complete
document set is on the conveyor, the system
stops.
• Check that the last set is complete and
correct.
• Turn OFF the single-sheet feeder.
The inserting system will automatically finish
all sets that remain along the material
handling path and then stop.
• Press the “last envelope” button on the
sealer.
The sealer delivers the last sealed envelope.
• Press the button on the inserter.
• Turn OFF the power switch on the inserter
machine.
The system is now completely shut down.
S ingle-sheetfeede r powe r switch
Inse r te r powe r O N / OFF
Inse r te r OFF button
“ L astenvelope ” button

19
3.2 Insert stacked material with
supplement
3.2.1 Starting operation
Detailed instructions on configuring the
inserting system for a job (loading paper,
setting paper guides, adjusting reading head,
etc.) can be found in Chapter 7 in descriptions
of individual modules and in the “Instruction
Manual Inserting System 4000”.
Caution! Make sure that no material from the
previously run job remains in the machine.
• Set all paper guides according to the width
of the material being handled (c. 2 mm gap
on each side).
Begin making settings at the inserter and
then move upstream.
•Loadenvelopes.
• Switch inserter power to ON.
• Press button on the inserter.
The inserter ON button lights up. The inserting
system tests all interfaces.
• Switch single-sheet feeder power ON.
The red signal buttons on the individual
modules will light up briefly. The conveyor will
move to its starting position. The red signal
button on the Black Box blinks.
The upper display field (Display 1) on the
operator panel shows the last program to
have been run. The program number blinks.
Inserting System KS 4000 OL with single-sheet feeder
S ingle-sheetfeede r powe r switch
Inse r te r powe r O N / OFF
Inse r te r O N button

20
Operator Manual KS 4000 OL / OLC
• Check settings of the single-sheet
separator.
The single-sheet separator sluice is adjusted
correctly when both red marks for automatic
operation are visible.
• Adjust the optical reading head when using
marks recognition programs (OMR): The
red mark on the reading head should be
aligned to the center of the printed marks.
• Make sure the separator pre-sluice is
lowered.
•Fanoutastackofsheets(c.20to30mm
high) so that the leading edges form a
wedge to the separator.
Thin paper = a smaller stack of sheets
Thick paper = a larger stack of sheets
• Push the leading edge of the wedge of
sheets into the pre-sluice (see Chapter
7.1.4).
Ma r ks ( r ed )
P r e-sluice
( lowe r ed )
W edge-shaped
leading edge ofstack
R eading head tightening sc r ew

21
• If you wish to change the program, use the
– function keys to select the
desired program number.
F1 – Set program “00”.
F2 – To reduce by “1” the shown program
number.
F3 – To increase by “1” the shown program
number.
F4 – To increase by “10” the shown program
number.
Please read the “Operating Instructions Cut-
Sheet-Feeder” for instructions on changing a
program or creating a program for a new job.
• Press the button on the control
panel.
The single-sheet feeder will draw (separate)
the first sheet. The lower display (Display 2) will
show READY.
If more than one sheet is drawn by the sepa-
rator, the display will show an error message.
Please refer to Chapter 8.2 “Single-sheet
feeder faults” for instruction on remedying
errors.
• Press the button to start the job.
The first complete set to be processed will be
deposited on the conveyor. The signal button
on the Black Box will turn off.
• Check to make sure the first set of docu-
ments on the conveyor is complete and
correct.
Inserting System KS 4000 OL with single-sheet feeder
P r og r a m nu m be r ( blinking )

22
Operator Manual KS 4000 OL / OLC
Additional stations (feeder / folding feeder)
may be present on the conveyor. These can
add supplementary sheets to each set.
How you use any supplement station depends
on how the system is configured and the job
being processed.
• Use the black button on the hand-held
conveyor control to move the set into
position for receiving the supplement.
If adding supplements from more than
one station move the first set to the first
active supplement feeder station.
At the station (first supplement):
• Press button.
• Set up station and load with supplement
material.
• Press button.
• Press button. One supplement will
be fed to determine reference value.
• If the station feeds the supplement cor-
rectly, press the to confirm.
If additional supplements are to be fed:
• Use the black button on the hand-held
conveyor control to move the set into
position for receiving the next supplement.
• Repeat the procedure described above for
feeding a supplement to the set.
S tation O N
S ta r t
Occupied field
Exa m ple:Twosupple m entspe r set
S tation / S upp.2
S tation / S upp.1