IMS FPi4000 User manual

1
ENGLISH
TABLE OF CONTENTS
1 Health, Safety and Environment ..................................................... 3
1.1 Precautions and Safety Issues ................................................... 3
1.2 Country specific conditions ....................................................... 4
1.3 End of life ............................................................................... 5
2 General ........................................................................................... 6
2.1 Denominations ........................................................................ 6
2.2 Function Description ................................................................ 7
2.3 Display .................................................................................. 8
3 Operating Instructions ................................................................... 9
3.1 Installation ............................................................................. 9
3.2 Preparation ............................................................................ 9
3.3 Starting Up ............................................................................ 10
3.4 Loading Documents ................................................................ 11
3.5 Loading Envelopes .................................................................. 13
3.6 Sealing Envelopes .................................................................. 14
3.7 Fill & Start ............................................................................. 14
3.8 Daily Mail .............................................................................. 16
3.9 Other Menu Options ................................................................ 17
4 Job Programming ......................................................................... 21
4.1 Job Menu .............................................................................. 21
4.2 Job Information ...................................................................... 22
4.3 Create Job ............................................................................. 23
4.4 Edit Job ................................................................................ 30
4.5 Copy Job ............................................................................... 30
4.6 Delete Job ............................................................................. 31
5 Supervisor Menu ........................................................................... 32
5.1 System Info ........................................................................... 32
5.2 Options ................................................................................. 33
5.3 Online Services (Option*) ........................................................ 33
6 Optical Mark Recognition OMR (option) ........................................ 34
6.1 General ................................................................................. 34
6.2 Adjustments .......................................................................... 34
6.3 Document Orientation ............................................................. 35
6.4 OMR Codes ............................................................................ 35
7 Options ......................................................................................... 39
7.1 MaxiFeederTM ........................................................................ 39
7.2 Intermediate Transport ........................................................... 40
8 Maintenance ................................................................................. 41
8.1 Operator Maintenance ............................................................. 41
9 Fault finding ................................................................................. 42
9.1 Error Messages ...................................................................... 42
9.2 Clearing Stoppages ................................................................. 43
9.3 Operator Troubleshooting ........................................................ 44
10 Specifications ............................................................................... 48
10.1 Technical specifications ........................................................... 48
10.2 Configuration dimensions ........................................................ 48
10.3 Other general specifications ..................................................... 49
10.4 Document specifications .......................................................... 49
10.5 Insert specifications ................................................................ 50
10.6 Terminology .......................................................................... 51

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ENGLISH
1. HEALTH, SAFETY AND ENVIRONMENT
1.1 Precautions and Safety Issues
Thoroughly read this operator manual, before using this machine.
According to the European Guideline for machine safety (EC98-37), this operator manual
must be available in the national language(s) of the country where the machine is
delivered.
Therefore, if you do not have an operator manual in your country’s language(s), contact
your authorized distributor.
Safety Precautions
• Only competent personnel should operate this machine.
If incompetent personnel do operate this machine, the manufacturer does not accept
responsibility for any resulting accidents or injuries.
• Only skilled persons, who are aware of the risks involved, may open the protective
covers.
For safety reasons, the machine will not function when the covers are open.
• Keep long hair, fingers, jewelry, etc. away from rotating and moving parts.
• The power connection must be easily accessible, preferably close to the machine.
• For safety reasons, it is essential that the machine is connected to a socket outlet that
has a protective earth connection.
• The machine has an over-current protection of 20 Amps. However, it is assumed that
the main power supply also has a circuit protection.
• Remove the plug of the power supply cord from the socket outlet to disconnect the
machine from the power supply.
Conventions
Note
A note gives additional relevant information.
Warning
This symbol:
- identifies situations where improper use of the machine can result in
personal injury or permanent/catastrophic damage to the machine.
- indicates that the operator manual should be consulted.
Warning
This symbol indicates a danger caused by high voltage.

4
1.2 Country specific conditions
Denmark
In Denmark, certain types of Class 1 appliances may be provided with a plug that does not
provide an adequate earth connection when inserted into a Danish socket outlet.
Make sure the machine has a good functioning connection that has protective earthing.
(the Plug and socket outlet must match).
Japan
• Establish an earth connection before connecting the mains plug to the power supply.
• First disconnect the power supply before removing the earth connection.
Languages
This manual is also available in other languages. For more information, please contact
your local supplier.

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ENGLISH
1.3 End of life
The objectives of the European Community's environment policy are, in particular, to
preserve, protect and improve the quality of the environment, protect human health and
utilise natural resources prudently and rationally. That policy is based on the
precautionary principle and principles that preventive action should be taken, that
environmental damage should as a priority be rectified at source.
Separate collection of waste is the precondition to ensure reuse and recycling of waste
that is generated at the disposal of electrical or electronical equipment and is necessary to
achieve the chosen level of protection of human health and the environment in the
European Community.
More particularly, certain materials and components of waste electrical and electronical
equipment needs selective treatment as their injudicious handling or disposing of on or
into land, water or air would represent a major threat to the environment and human
health.
In order to facilitate collection and treatment separated from normal domestic waste,
electrical and electronical equipment is marked with the following logo:
Not only are you by law not allowed to dispose of the waste equipment via other waste-
streams, but we encourage you to actively contribute to the success of such collection and
to the common good and better quality of life of present and future generations.
For more information on the correct disposal of this product please contact your local
dealer.
Do not mix with normal domestic waste
collection system dedicated to electrical
and electronical waste.
Please use the subjoined return or
Equipment produced after August 13,
2005.

6
2. GENERAL
2.1 Denominations
A Envelope catch tray K Sensors
B Envelope slide L Bellows
CDisplaywithoperating buttons M Handle for clearing stoppages
D Upper unit N Water reservoir
E Locking hand grip upper unit O Side cover (opened)
F Document feeders P Ruler
G Collator arm Q Thumb wheel for side guide adjustment
H Collator area R Side guides envelope hopper
I Power inlet, power switch S Knob for separation adjustment
J Knobs for clearing stoppages T Envelope support bracket
Q OPRST JKL
N
JM
A B C
F
G
H
I
D
E

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ENGLISH
2.2 Function Description
The system consists of the following area’s:
1 Document Feeders The machine selects documents from the feeders according to
the applicable job options.
2 Collating area The documents are collected in the collating area before they
are transported to the folding area.
3 Folding area In the folding area, the document(s) are folded according to
the job specifications.
4 Envelope feeder The envelopes are picked up and transported to the insert
position inside the machine.
5 Inserter After the folded package of documents is inserted into the
envelope, the glue of the envelope is moistened and the
envelope is closed.
6 Operating panel The machine is programmed and operated from the operating
panel. This panel consists of a touch screen and a separate
Start, Stop and Clear button.
1
2
3
4
6
5

8
2.3 Display
The machine has a graphical touch screen.
A touch screen sensor is a clear glass panel with a touch responsive surface. The touch
sensor/panel is placed over a display screen so that the responsive area of the panel
covers the viewable area of the display.
This display shows functions and/or buttons, which can be operated by pressing a finger
directly on the touch screen on the relevant function or button. The interface recognizes
the location of the pressure point and when this is located within the defined area of a
button, the user interface reacts with ‘pressing’ this button.
In this way, the user can simply operate the machine by pressing on the displayed buttons
and/or functions.
Caution
The display is covered with a thin pressure-sensitive layer. To avoid permanent damage of
the display, do not use sharp objects to press on the display.

9
ENGLISH
3. OPERATING INSTRUCTIONS
3.1 Installation
Warning
You can severely damage the machine if it is connected to the incorrect power supply.
Before plugging in the machine, check if the local voltage is the same as the voltage
mentioned on the type plate.
Incidence of light can cause disturbing reflections in the display, resulting in reduced
readability. If necessary, change the position of the machine to improve the readability for
the operator.
3.2 Preparation
Document Feeder Trays
Note
The machine can be delivered with a tray to manually adjust the separation. However, this
tray fits in all positions, this adjustment is only possible when fitted on the lowest position
(position one).
Place the document feeder trays in position.
1. Hold the document feeder slightly inclined as
shown in the figure.
2. Place the front end of the document feeder tray
underneath the two black rollers.
3. Move the document feeder tray upwards (lifting
the black rollers), until it is possible to “hook”
the feeder into place.
4. Move the document feeder tray towards the
machine and move the hooks over the mounting
points (on both sides).
5. Let the document feeder tray rest on the
machine.

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Slide and Envelope Catch Tray
1. Attach the slide as shown in the figure.
2. Position the envelope catch tray into the holes
underneath the envelope hopper as shown in the
figure.
The distance Ashould be approximately 1.5 x
the envelope height.
3.3 Starting Up
1. Connect the machine to the mains power
supply.
2. Use the power switch to switch the machine ON.
The software will ask you to select the required
language.
3. Select the required language for the display.
4. The software will ask you if you want the “select
language option” to be displayed every time the
machine is switched on. Select either Yes or
No.
5. Press .
The Main Menu screen 1/2 will be displayed.
A
Test run
other job
JOB 1
Counters
Fill & Start
Total:
0
MAIN MENU 1/2
OK

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ENGLISH
3.4 Loading Documents
Document Orientation
Adjusting Side Guides
1. Loosen knob Bhalf a turn.
2. Move the side guides outwards.
3. Place a small stack of documents between the
side guides.
4. Move the side guides Aand Cto the document,
so the documents have just enough space to
slide between the side guides.
5. Tighten knob B.
Document Separation
The term ‘Document separation’ refers to the
adjustment required for separating the upper
document from the rest of the documents in the
stack. This prevents documents being picked up from the stack at the same time.
The document separation for the automatic feeders is set automatically.
The special feeder (fitted in the lowest, first position) can be manually adjusted.
Adjust the manual document separation as follows:
feeder swap two documents document + enclosure
one document
no fold
single fold
letter fold
zig-zag fold
Address carrier in
upper feeder.
Face up and leading.
Address carrier in upper
linked pair feeders.
Face up and leading.
Address carrier in
upper feeder.
Face up and leading.
Address carrier in upper
feeder.
Face up and leading.
Address carrier face
down and trailing.
Address carrier in lower
linked pair feeders.
Face down and trailing.
Address carrier in lower
feeder.
Face down and trailing.
Address carrier in upper
feeder.
Face down and trailing.
double
parallel fold
B
CA

12
1. Remove trays 2 and 3:
- Push the handle on the left side of the tray
down.
- Lift the tray to unhook it, and then pull it from
the feeder.
2. Push knob Buntil it clicks and stays in place,
and then turn it counterclockwise as far as
possible.
3. Lower the left side guide A. The feed rollers will
move up.
4. Place a document on the feeding tray.
5. Push the document, as far as possible into the
machine, without damaging it.
6. Raise the left side guide A until it clicks into place. The feed rollers will move down.
7. Slide the document further into the machine until it stops.
8. Turn knob Bclockwise until a slight resistance is felt when moving the document in
and out the machine.
If you feel too much resistance, turn knob Bcounterclockwise.
9. Remove the document.
10. Pull back knob B.
11. Place a stack of documents in the document feeding tray.
12. Fit the removed feeder trays 2 and 3 (refer to “Document Feeder Trays” on page 9).
Feeding Documents
1. Turn the left side guide Adownwards
The feed roller will be lifted.
2. Place a stack of documents between the side guides.
3. Turn the left side guide Aupwards.
A B

13
ENGLISH
3.5 Loading Envelopes
Adjusting Side Guides
Adjust side guides Cby rotating thumbwheel D, so
that the envelopes:
- fit exactly between the side guides.
- can move freely.
NOTE
If the distance between the side guides is too large,
the envelopes will twist sidewards, when transported
into the machine.
Envelope Separation
1. Turn knob Acounterclockwise as far as possible.
2. Slide an envelope (with closed flap) between the rollers in the machine and turn knob
Aclockwise until a slight resistance is felt when moving the envelope in and out of the
machine.
When the resistance is too high, turn knob Acounterclockwise, until only a slight
resistance is felt.
Feeding Envelopes
1. Place the bottom envelope between the rollers
(flap down and trailing - bottom side of envelope
pointing to machine).
2. Loosen the stack of envelopes and place the
stack on top of the bottom envelope.
3. Shift envelope support Bin or out, so that the
flap side of the envelope is lifted approximately
20 mm (0.8”).
Turn envelope support Bso the weight of the
envelopes is distributed evenly on both sides.
DCA
B
C

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3.6 Sealing Envelopes
Switch the envelope sealing ON or OFF.
1. Lift the handgrip to open the top cover.
2. Shift the blue handle Atowards to disable
the envelope sealing or towards to enable
the envelop sealing.
3. Close the top cover.
When the sealing of the envelopes is enabled, the
sealing liquid reservoir must be filled.
4. Open the front cover A.
5. Fill the reservoir Bto the “Max” level indication
with sealing liquid.
6. Close the front cover A.
Before starting the job, wait approximately 5
minutes for the brushes to moisten.
3.7 Fill & Start
The Fill & Start feature automatically adjusts all
machine settings.
When Fill & Start is started, the machine will pick one sheet from each filled feeder.
The picked documents will be folded (if necessary) and inserted into an envelope.
Using Fill & Start
1. Load envelopes.
2. Make sure there is sufficient sealing liquid in the
sealing liquid reservoir. If the reservoir has just
been filled, wait approximately 5 minutes for the
brushes to moisten. See “Sealing Envelopes” on
page 14.
3. Load the documents face up and leading.
4. From the Main menu 1/2, press .
A
A
B
Test run
other job
JOB 1
Counters
Fill & Start
Total:
0
MAIN MENU 1/2
Fill & Start

15
ENGLISH
5. After a few seconds, the Fill & Start display will
appear.
6. Press to load one envelope to the
insert position in the machine.
7. The envelope is visible through the window in
the top cover.
Insert Position
Note
This adjustment must only be checked in case of problems or when changing the envelope
type.
Check if the flap folding line is positioned
underneath the green roller B. If not adjust the
Insert position as follows:
1. Press on the left or right side of to
adjust the insert position to the left or the right.
2. Press to load a new envelope into
the insert position
3. Recheck the insert position, and adjust as
required.
4. If necessary adjust the “envelope insert
fingers”:
- Open the top cover.
- Adjust the outer fingers Dapproximately 5 - 10 mm (0.2 till 0.4”) from the edges of
the envelopes.
- Loosen the knurled knobs C.
- Adjust the fingers Aso that the tip is approximately 5 mm (0.2”) inside the
envelope.
- Tighten the knurled knobs C.
1x
1x
FILL & START
Insert position
ESCAPE
1x
A
B
C
D
1x

16
Address Position
1. When the envelope position and the position of the fingers is correct,
press to load a folded sheet into the envelope.
The envelope will be sealed (when enabled, refer to “Sealing Envelopes” on page 14)
and ejected to the envelope tray.
2. Check the position of the address in relation to the address window in the envelope.
3. If necessary, press the Up or Down button to adjust the address.
4. Press to make another test run.
5. Recheck the position of the address, and adjust as required.
6. Press to leave this screen to return to the main menu or press the button
to immediately start the job.
Starting the Job
• Press the button to start the job.
• Press the button to stop the job. The machine will stop immediately.
• Press the button to clear the document path to prepare the machine for a new job.
3.8 Daily Mail
To process documents or sets of documents, which can not be processed automatically,
the top feeder is equipped with a daily mail switch.
Switch to Daily Mail function:
1. Select or change to a job where the Daily Mail
function is set to ON.
The Daily Mail function can be recognized by the
icon in the Job info screen.
2. Turn left side guide Aof the upper tray down.
3. The Daily Mail handle Bwill become visible.
Move the handle to to enable the Daily
Mail function.
4. Turn left side guide Aupwards.
5. Place the document or document set in the
feeder.
If necessary adjust the side guides. Refer to
“Adjusting Side Guides” on page 11.
1x
1x
OK
A
B

17
ENGLISH
6. Press the button to start the job.
The document or document set will be folded and inserted in the envelope as
described in the selected job.
7. Place the following document or document set in the feeder. The machine will keep
running to process the inserted document or document set.
8. When finished with Daily Mail, press the button to stop the job.
9. Turn left side guide A down.
10. Move the Daily Mail handle to the ‘AUTO’ position to disable the Daily Mail and to
enable the automatic document separation.
3.9 Other Menu Options
After starting up, the Main Menu 1/2 screen will
appear.
The screen shows the selected job number and the
total number of envelopes that have been processed
using this job.
• Press the button to start the job.
• Press the button to stop the job. The machine
will stop immediately.
• Press the button to clear the document path
to prepare the machine for a new job.
The Main menu 1/2 will be displayed.
Job Info
• Press to display all relevant
information about the selected job.
Refer to “Job Information” on page 22 for a
detailed explanation of the screen.
• Press to return to the Main menu screen
Test run
other job
JOB 1
Counters
Fill & Start
Total:
0
MAIN MENU 1/2
JOB 1
ESCAPE
1
2
3
114
108/216
b
1 297
JOB INFO
ESCAPE

18
Other Job
Press to select another predefined
job.
1. Press to select another job number.
The screen shows the job options of the relevant
job. (For a description of the items, refer to the
previous page).
2. Press to confirm the selected job.
3. Press to leave this screen without
changing job.
Test Run
Press to display the Test Run screen.
1. Press to load a new envelope into
the insert position. This gives the possibility to
check the insert position of the envelope.
2. Adjust the position by pressing on to
adjust the insert position more to the left or the
right. (Refer to “Insert Position” on page 15).
Press to load a new envelope into
the insert position and check the condition again.
3. Press to confirm the insert position.
4. When the envelope position and the position of the fingers is correct, press
to load a folded sheet in the envelope.
The envelope will be sealed (when enabled, refer to “Sealing Envelopes” on page 14)
and ejected to the envelope tray.
5. Press to leave this screen without changing settings.
- Press the button to start the job.
- Press the button to stop the job. The machine will stop immediately.
- Press the button to clear the document path to prepare the machine for a new
job.
The Main menu 1/2 will be displayed.
JOB 1
1
2
3
114
108/216
b
Select job
1 297
1
ESCAPEOK
OTHER JOB
other job
OK
ESCAPE
1x
1x
JOB 1
Total:
0
OK
TEST RUN
Insert position
ESCAPE
Test run
1x
1x
OK
1x
ESCAPE

19
ENGLISH
Counters
Press to display the Counters screen.
1. Press to reset the counters to 0.
2. Press to confirm possible changed
settings and to return to the Main menu.
3. Press to leave this screen without
changing settings.
- Press the button to start the job.
- Press the button to stop the job. The machine will stop immediately.
- Press the button to clear the document path to prepare the machine for a new
job.
The Main menu 1/2 will be displayed.
4. Press to program the stop counter.
5. Enter the number of envelopes that must be
processed with the numeric keys.
6. Press to confirm possible changed
settings and to return to the previous screen.
7. Press to return to the previous screen
without changing settings.
Main Menu 2/2
• Press will bring you in the second main menu
screen 2/2.
Also this screen shows the selected job number and
the counters, indicating the programmed number of
envelopes to do as well as the total number of
envelopes that have been processed using this job.
Reset counters
JOB 1
Total:
0
OK
OFF Stop at:
COUNTERS
ESCAPE
Counters
Reset counters
OK
ESCAPE
Stop at:
0
COUNTERS
ESCAPE
CE
3
6
9
2
5
8
0
1
4
7
OK
OK
ESCAPE
Job menu
Display setting
JOB 1
Supervisor menu
Total:
0
MAIN MENU 2/2

20
Display Settings
Press to change settings for the touch
screen display.
enables to change the contrast of the
display. The graphic shows the contrast setting.
enables to adjust the volume of the acoustic
signals. The graphic shows the volume setting.
• Press to confirm changed settings.
• Press to return to the previous screen without changing settings.
Job Menu
The starts the job menu.
This menu enables the creation, deletion and/or
editing of jobs. To prevent jobs being edited or
deleted without informing the ‘job owner’, this menu
is protected by a PIN-code.
This job menu will be described in “Job
Programming” on page 21.
• Press to return to the previous screen
without changing settings.
Supervisor Menu
Pressing the gives access to system
settings.
The supervisor menu therefore is restricted and
protected by a PIN-code.
The supervisor menu will be described in “Supervisor
Menu” on page 20.
• Press to return to the previous screen
without changing settings.
• Press to return to the Main Menu 1/2.
OK
DISPLAY SETTINGS
ESCAPE
Display setting
OK
ESCAPE
Enter pin code
_
JOB ACCESS
ESCAPE
CE
3
6
9
2
5
8
0
1
4
7
Job menu
ESCAPE
Enter pin code
_
SUPERVISOR ACCESS
ESCAPE
CE
3
6
9
2
5
8
0
1
4
7
Supervisor menu
ESCAPE