Neopost INSERTER IN-3 SI-92 User manual

1/40SI-92
INSERTER IN-3 (SI-92)
OPERATOR MANUAL
Fig. 1
1. GENERAL
The SI-92 is a modular mailing system. For each stage within
the mailing process, such as feeding, folding, collating of
documents and inserting and sorting of filled envelopes a
module is available. In this way SI-92 adapts to the
customers' needs.
The whole system is operated and programmed via the
central operator panel of the base module, the inserter
(IN-3).

2/40 SI-92
Before using this system thoroughly read the operating
instructions. In the European Union an operator manual
printed in the national language(s) is supplied with the
system. If it is not, contact your authorized distributor.
Warning
• Before connecting check whether the system is suitable for
the local mains voltage; refer to the type plate.
Safety precautions
• This system is only to be operated by fully trained
personnel. The manufacturer accepts no responsibility for
injuries caused by unauthorized operation.
•The opening of covers must be carried out only by a
skilled and authorized person who is aware of the hazard
involved. The system will not operate with the covers
opened.
• Keep long hair, fingers, jewellery, etc. away from turning
parts of the system.
• The socket outlet shall be installed near the equipment
and shall be easily accessible.
• The mains plug shall be connected only to a socket outlet
provided with a protective earth contact.
• Over-current protection in the equipment also relies on the
branch circuit protection (max. 20 A).
• The following part(s) is (are) considered the equipment
disconnect device(s):
-powersupplycordplug.
Used symbols
On this module and 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
system.
This symbol also means: Read your operator
instruction.
Warning, this symbol indicates a hazard to life
because of high voltage.
Italic text Additional information (Italic)
CONTENTS
Section Page
1. GENERAL 1
2. HOW TO USE THE OPERATOR MANUALS 3
3. ACCESSORIES 3
4. UNDERSTANDING THE MACHINE 4
4.1 Function 4
4.2 Overview 4
4.3 User interface 4
4.4 Operating controls 5
4.5 Power inlet 5
4.6 Display keys 6
5. OPERATING THE SYSTEM 6
5.1 Preparations inserter module 6
5.2 Switching on 7
5.3 Entering the personal pin code 7
5.4 The main menu 7
5.4.1 Job info screen overview 8
5.4.2 Schematic view 10
5.4.3 Selecting a job 11
5.4.4 Test run menu 11
5.4.5 Counters menu 14
5.4.6 Settings menu 14
5.5 Entry to job menu 15
5.6 Operator menu structure 16
5.7 Envelope hopper adjustment 17
5.7.1 Side guides adjustment hopper A 17
5.7.2 Envelope separation hopper A 17
5.7.3 Side guides hopper B 18
5.7.4 Envelope separation hopper B 18
6. PERFORMING A JOB 19
6.1 Setting up the system 19
6.2 Running a job 22
6.3 Changing settings of a module 23
6.4 Additional functions 23
Section Pa
ge
7. FAULT FINDING 24
7.1 General 24
7.1.1 The error screen 24
7.1.2 The information screen 25
7.1.3 The warning screen 25
7.1.4 The call screen 26
7.2 Clearing stoppages 26
7.2.1 Removing documents 26
7.2.2 Stoppage in the document end feed 26
7.2.3 Stoppage at the document feed 26
7.2.4 Removing documents from the hopper 27
7.2.5 Removing envelopes from the insert or sealing table 27
7.2.6 Stoppage on the insert table or sealing table 27
7.2.7 Stoppage in the envelope track 28
8. ERROR CODES 29
8.1 General 29
8.2 Additions to the error lists of other modules 30
9. MAINTENANCE 31
9.1 General 31
9.2 General cleaning 31
9.3 Cleaning the brushes 31
9.4 Cleaning the sealing roller 31
9.5 Cleaning the moistening cloth 31
10. OPTIONS 32
10.1 General 32
10.2 More options 32
10.3 SI 92 options 35
11. SPECIFICATIONS 38

3/40SI-92
Fig. 2
2. HOW TO USE THE OPERATOR MANUALS
This SI-92 manual, existing of two parts, describes the
inserter (IN-3) module and operating (part 1: operator
manual) and programming of the system (part 2: guide for
job menu).
Use the SI-92 manual as the main guide. In the text of this
manual we will refer to the other operator manuals if
required.
3. ACCESSORIES
The IN-3 is delivered with the accessories shown in Fig. 2.
bottle
dust brush mains supply cable press bracket
envelop slide set brushes (3 pcs.)

4/40 SI-92
Fig. 3
4. UNDERSTANDING THE MACHINE
4.1 Function
The inserter inserts documents into envelopes and then seals
the envelopes (or not). Via the central operator panel the SI-
92 system can be operated and programmed. Settings of all
modules are stored centrally at the inserter.
4.2 Overview
See Fig. 3.
Envelopes are fed from a stack to the insert position. During
this transport the flap is opened. After the envelope has
arrived at the insert position a document is fed to the inserter
and then inserted into the envelope. After insertion, the
envelope flap is moistened (or not) and closed. Then the
envelope is exited.
4.3 User interface
The user interface of the inserter exists of two menus; the
"main menu" and the "job" menu. These menus are
accessible via a personal pin code.
• The "main" menu is accessible for all operating personnel
and the supervisor. In the main menu jobs can be selected
and performed. After selecting a particular job, all
modules will be set automatically according the job data.
• The "job" menu is only accessible by an authorized user,
the "supervisor", via the supervisor pin code. In the job
menu jobs can be programmed, deleted etc. In a job the
settings of the modules within the system (type of
envelopes, type of documents, type of fold and way to
sort) are recorded. There are more functions in the job
menu. For a description of the job menu see the “Guide
for job menu”.
The service engineer has access to all menus.
The system can be started, stopped or cleared by pressing
the concerned key located below the display of the inserter,
see section 4.6 page 6.
When a stoppage occurs, the IN-3 operator panel
automatically signals the operator and gives a suggestion
about solving the problem. See chapter 7 and 8.
envelop hopper insert position
sealing area exit
user interface

5/40SI-92
Fig. 4
4.4 Operating controls
A:Topcover
B:Loc
C:Bottle
D : Release handle sealing table
E : Sealing table
F : Release handle loc
G: Hopper side guide adjustment wheel
H : Separation adjustment wheel
Fig. 5
I:Envelophopper
J : Release handle hopper
K : Release handle sealing table rollers
Fig. 6
4.5 Power inlet
See Fig. 6. The power inlet B is located at the rear side of the
machine. It contains the power on/off switch and the main
fuse.
See "Warnings", page 2. Connect the main supply cable A
to the power inlet then connect the mains plug to the wall
socket.

6/40 SI-92
Fig. 7
4.6 Display keys
Key 1 through 6
See Fig. 7. These keys correspond with the function in the
display.
Start key
The system will start to operate.
For more details see 6.2 on page 22.
Stop key
The system will stop operating.
Clear key
The system will first finish all documents sets that have
already been fed (e.g. to the transport track) by the feed
units, then it stops.
Esc. key
Use this key to exit a (sub) menu without saving any
(altered) settings.
Fig. 8
5. OPERATING THE SYSTEM
5.1 Preparations inserter module
The bottle A (Fig. 8) must always be filled with water and the
brushes must be moistened. An extra set of brushes is
provided so that one set can be soaked in water whilst the
other set is used. This means there is always a clean set of
brushes ready for usage.
Before moving the system, the bottle and watertray
must be removed.
Refer to the other operator manuals of the used modules for
the required preparations.
If the system is switched off after, for example, a paper
stoppage, the brushes will not rest on the watertray. This
causes the brushes to dry if usage is interrupted for a longer
period.
Always take care that the brushes rest on the watertray.
Therefore the system must be switched on again so that the
brushes will rest on the watertray. The system can then be
switched off.
Key
1
2
3
4
5
6
job number
job name
job counter
preset counter
counter

7/40SI-92
Fig. 9
5.2 Switching on
Switch on the inserter using the power switch A, see Fig. 9.
If the AS-1A, PS-3 or franking machine etc. are part of the
system switch these on. Refer to the operator manuals of the
used modules if necessary.
After switching on the pin code screen or the main menu will
appear. In case the pin code screen appears, see section
5.3 for further instructions. In case the main menu screen
appears, see section 5.4 for further instructions.
Fig. 10
5.3 Entering the personal pin code
In Fig. 10 the pin code screen is shown.
Enter your pincode using the keys 1 to 6. If the code is not
correct, a warning “wrong code, try again” will be
displayed. This warning disappears immediately when a
key is pressed.
The pincode screen is not displayed if only the supervisor
code is defined. In this case the main menu as shown in Fig.
11 will be displayed after switching on the system.
Fig. 11
5.4 The main menu
The main menu is shown in Fig. 11.
The "main menu" shows 6 different functions:
• go to job info screen (key 1).
• go to the "select job" menu (key 2).
• go to the "test run" menu (key 3).
• go to the "change counters" menu (key 4).
• go to the "settings"menu (key 5).
• go to the "entry to the job menu" (key 6).
Key
1
2
3
4
5
6
Key
1
2
3
4
5
6

8/40 SI-92
Fig. 12
5.4.1 Job info screen overview
When key 1 is pressed in the “main menu”, the job info
screen will be displayed (see Fig. 12). The job info screen
shows the following functions:
• select a higher job number (key 1).
• select a lower job number (key 2).
• go to the job data of the upstream (VersaFeeder 1, 2 or
transport) module (key 3).
• go to the job data of the downstream (sorting) module
(key 4) (the job data of the downstream (sorting) module
is shown in Fig. 15).
Press the escape key to go back to the main menu.
Because of the modularity of the system, different
configurations are possible. So take in account that the job
data can differ from which is shown in this job info screen
overview.
Fig. 13
When key 3 is pressed in the “job data” menu the upstream
(transport) module screen is displayed (see Fig. 13). The
screen shows the following functions:
• select a higher job number (key 1).
• select a lower job number (key 2).
• go back to the inserting module (key 4).
• go to next job data screen of the upstream (VersaFeeder
1, 2 or transport) module (key 6).
Press the escape key to go back to the main menu.
Fig. 14
When key 6 is pressed in the upstream (transport) module
screen, the screen in Fig. 14 is displayed. The screen shows
the following functions:
• select a higher job number (key 1).
• select a lower job number (key 2).
• go back to the inserting module (key 4).
• go to previous job data screen of the upstream
(VersaFeeder 1, 2 or transport) module (key 6).
Press the escape key to go back to the main menu.
Key
1
2
3
4
5
6
Key
1
2
3
4
5
6
Key
1
2
3
4
5
6

9/40SI-92
Fig. 15
When key 4 is pressed in the “job data” menu the
downstream (sorting) module screen is displayed (see Fig.
15). The screen shows the following functions:
• select a higher job number (key 1).
• select a lower job number (key 2).
• go back to the inserter module (key 3).
Press the escape key to go back to the main menu.
Key
1
2
3
4
5
6

10/40 SI-92
5.4.2 Schematic view

11/40SI-92
Fig. 16
5.4.3 Selecting a job
After pressing key 2 in the "main menu", the display shows
the "select job" menu (see Fig. 16). The "select job" menu
shows the following functions:
•jobdata(key1).
• select a higher job number (key 3).
• select a lower job number (key 4).
• confirm with "OK" (key 6) which will get you back to the
"main menu".
Only programmed jobs can be selected (maximum of 9
jobs).
Fig. 17
5.4.4 Test run menu
After pressing key 3 in the "main menu" a test run screen will
be displayed. In case an FO-2A is used the screen as shown
in fig. 17 will appear. The purpose of the test run menu is to
check proper envelope feed and to make adjustments to the
envelope stop settings.
The "test run" menu shows the following functions:
• feed one envelope (key 2).
• insert one document (key 3).
• envelope stop position to the right (key 4).
• envelope stop position to the left (key 5).
• confirm settings and return to the main menu (key 6).
In case an FO-3 is used, a screen as shown in fig. 18 will be
displayed. The envelope position keys 4 and 5 of figure 17
have moved to a new submenu (see fig. 18, key 4): after
pressing key 4 this submenu will be entered and the
possibility of adjusting the envelope stop position to the left
or right is available again.
After pressing key 5 a submenu will be entered for fine
tuning the folder settings. For more information see "Fine
tuning the folder settings".
In case the inserter is equipped with a second envelope
hopper (EF-3) the test run menu has been extended and the
following functions for key 1 and 2 have become available
(see fig. 18 for an example):
• feed one envelope from the standard hopper (key 1).
• feed one envelope from the second hopper EF-3 (key 2).
Key
1
2
3
4
5
6
Key
1
2
3
4
5
6

12/40 SI-92
Fig. 18
Feed one envelope
With this function the proper feed of envelopes can be
tested. First carry out the envelope hopper adjustments, see
section 5.7 on page 17. Then put a stack of envelopes in the
hopper. Use key 1 or key 2 to feed one envelope onto the
insert table. Each time the key is pressed a new envelope
will be fed. No insertion will take place.
The “feed one envelope” function can be used when
adjusting the envelope stop position, see “Envelope stop
position adjustment” on the next page.
Insert one document
With this function the proper functioning of the whole
document and envelope transport will be tested. First carry
out all adjustments, see section 5.7 on page 17. Then load
the system with documents and envelopes.
Use key 3 to make one insert cycle. Each time the key is
pressed another insert cycle will be made. When there is no
envelope waiting on the insert table, the machine feeds one
envelope waiting on the insert table. The document will be
inserted and filled envelope is ejected.
If there are documents on the collating area, these
documents will be inserted and the filled envelope is ejected
(and counted). If there is an empty envelope in the inserter,
this envelope will be ejected.
See notes mentioned in section 6.2 on page 22.
Fig. 19
Envelope stop position adjustment
The flap folding line must be positioned under the green
indicator B (Fig. 19). This indicator can be seen after
opening the transparent cover and releasing and lifting the
loc by pulling the release handle of the loc (see page 5).
If necessary, adjust the folding line position by pressing “to
the right” (key 4) or the “to the left” (key 5). Each press
stops the next envelope 1 mm (0,04 inch) to the right (later)
or left (earlier).
Adjustments to the envelope stop position can be made with
the system operating.
Key
1
2
3
4
5
6
(5x)

13/40SI-92
Envelope fingers adjustment
When the envelope stop position is correct the insert fingers
A (Fig. 19) can be adjusted. Adjust the fingers by loosening
the thumb screw on top of each finger (5 in total). Slide the
finger until the tip has entered about 5 mm (0,2 inch) into the
envelope. Re- tighten the screw. The fingers on either side of
the loc can be moved sideways to the desired position.
Place the outer fingers about 10 mm (0,4 inch) from the
edges of the envelope.
Check the finger positions when changing to a different type
of envelope.
Fig. 20
Fine tuning the folder settings
In SI 92, if and when the electronic folder FO-3 is used, the
operator has the possibility to adjust the (mechanic) folder
settings during the execution of a specific job. This might be
neccesary for instance when adapting the fold settings to the
current mechanic paper parameters (thickness, sturdiness et
cetera).
After pressing key 5 in figure 18 the menu of figure 20
appears.
The following functions are available:
•test for a folded document 1x (key 1). It makes sense to
do this in the same menu screen.
• Increase/ decrease value of fold setting A (keys 2 and 3).
Basically there is no limitation in the values. The
possibilities are same as in the equivalent settings of the
job menu (FO settings).
• as keys 2 and 3, for fold setting B, if relevant (keys 4 and
5). This depends on the fold type. Setting B is relevant for
all fold types except single fold. Note that you cannot
change the fold type in this menu.
• enter and effectuate the settings (key 6). Back to the menu
"test run" menu of figure 18.
• discard the settings (Esc). Back to the "test run" menu of
figure 18.
Key
1
2
3
4
5
6

14/40 SI-92
Fig. 21
5.4.5 Counters menu
After pressing key 4 in the "main menu", the display shows
the "change counters" menu (Fig. 21). The "change
counters" menu shows the following functions:
• increase the counters (key 1).
• decrease the counters (key 2).
• reset counters to zero (key 3).
• increase the preset counters (key 4).
• decrease the preset counters (key 5).
• save the counter settings with "OK" (key 6) which will get
you back to the "main menu".
Increase/decrease counters
The following counters will be increased or decreased:
•jobcounter.
•counter.
Reset counters to zero
The following counters will be set to zero:
•jobcounter.
•counter.
Increase and decrease preset counter
By pressing key 4 or key 5 the preset counter will be
increased or decreased.
The counter will only be displayed when the preset counter
is set higher than zero.
When pressing key 4 or key 5, the stop counter will initially
be increased or decreased with one unit at a time. When
the key is pressed longer the counter will be raised with ten
units at a time.
Fig. 22
5.4.6 Settings menu
After pressing key 5 in the “main menu”, the screen as
shown in Fig. 22 will be displayed. The “settings” menu
shows the following functions:
•jobdata(key1).
• decrease contrast of the display (key 2).
• increase contrast of the display (key 3).
• thickness detection on or off (key 4).
• reset thickness detection (key 5).
• save the counter settings with "OK" (key 6) which will get
you back to the "main menu".
In case the system contains a VersaFeeder, via the settings
menu its double document detector can be switched on/off
and can be reset as well.
Display contrast
By pressing key 2 the display contrast will be decreased. By
pressing key 3 the display contrast will be increased.
Key
1
2
3
4
5
6
Key
1
2
3
4
5
6

15/40SI-92
Thickness detection
The IN-3 is equipped with a document thickness detector.
The thickness detector controls the thickness of the
document. In this way the machine checks if the envelope
will be filled with the correct amount of documents. The
detector will stop the machine if a document is too thick or
too thin and an error message will be displayed.
The thickness detector is self-setting. After switching on (or
after resetting the thickness detection) the thickness of the
first document passing under the detector is memorized and
compared with the following inserts.
If the thickness of the documents can vary, for example
when a small card is used that can shift in place, it is
recommended to switch off the thickness detection or shift it
to a stable section of the document. The thickness detection
measurement area can only be adjusted by the supervisor.
See section 2.4.3 in the “Guide for job menu”.
Reset thickness detection
By pressing key 5 the thickness detection will be reset.
If the thickness detection is switched off, the text “reset
thickness det.....” will not be displayed in the screen.
Fig. 23
5.5 Entry to job menu
When key 6 in the “main menu” is pressed the display
shows the screen in Fig. 23. Only the supervisor can get
access to the job settings after entering the correct code.
Enter your pincode using the keys 1 to 6. If the code is not
correct, a warning “wrong code, try again” will be
displayed. This warning disappears immediately when a
key is pressed.
Key
1
2
3
4
5
6

16/40 SI-92
5.6 Operator menu structure
Key
1
2
3
4
5
6
Start key
Start processing
Stop key
Stop processing
Clear key
Empty the system and stop
Escape key
Exit a menu without saving any
altered settings
Select a job number for job
data, see page 8 Job data, page 8
Select (upstream) VersaFeeder 1, 2
or transport module data Select a job
Confirm selected job and go to main menu
Select (downstream) sorter module data
Feed one envelope from hopper A, page 12
Feed one envelope from hopper B
Insert one document
Envelope stop position to the right
Envelope stop position to the left
Confirm settings and back to main menu
Confirm settings and back to main menu
Increase counters, page 14
Decrease counters
Reset counters to zero
Increase preset counter
Decrease preset counter
Confirm settings and back to main menu
Job data, page 8Enter pincode, page 15
Select thickness detection on or off
Reset thickness detection
Adjust display contrast, page14

17/40SI-92
Fig. 24
5.7 Envelope hopper adjustment
The IN-3 can be equipped with a second hopper, the EF-3
see section 10.2 page 32. This hopper is then called
“hopper B”. The IN-3 standard hopper is called “hopper
A”. Although an operator manual is delivered with the EF-3,
on this page you will also find a description of the hopper
adjustments.
Fig. 25
5.7.1 Side guides adjustment hopper A
Take a stack of about 20 envelopes. Fan the envelopes a bit
(see Fig. 24) and place the envelopes upright in the system
with the flap to the back. Place the press bracket C on the
envelopes.
Adjust the envelope hopper side guides B by turning the
thumbwheel A, to provide just enough space for the
envelopes to move freely. Too much play causes skewing.
When using C4 envelopes check if the blade spring on the
sealing table is up. The spring is visible after lifting the loc.
The purpose of the spring blade is to obtain better support
when using thin A4 sized documents.
5.7.2 Envelope separation hopper A
Adjust the envelope separation by turning thumbwheel D
(see Fig. 25) until one envelope is just about to be pulled in.
After starting the system it may occur that more than one
envelope at a time is pulled in. If this happens, rotate the
thumbwheel slightly until only one envelope at a time is
pulled in. Adjustments can be made with the system
operating.

18/40 SI-92
Fig. 26
5.7.3 Side guides hopper B
Take a stack of about 20 envelopes. Fan the envelopes a bit
and place the envelopes in the system with the flap to the
bottom side and trailing.
Adjust the envelope hopper side guides A (Fig. 26) by
turning the thumbwheel C, to provide just enough space for
the envelopes to move freely. Too much play causes
skewing.
5.7.4 Envelope separation hopper B
Adjust the envelope separation by turning knob B (Fig. 26)
counter clockwise until two envelopes, one on top of the
other, can be moved backwards and forwards between the
rollers without resistance. Then turn knob B clockwise until
one envelope will pass between the rollers.
After starting the system it may occur that more than one
envelope at a time is pulled in. If this happens, rotate knob B
clockwise a quarter turn. Repeat if necessary to obtain
correct operation.
Once the envelope separation has been set, a wide variety
of envelopes can be handled.

19/40SI-92
6. PERFORMING A JOB
6.1 Setting up the system
Switch on the inserter IN-3 and, if part of the system, the AS-1A and PS-3 etc.
Refer to the operator manuals of the used modules.
Inserter IN-3
VersaFeeder 1 and 2
Action Refer to..
• Check the waterlevel, refill if necessary Refer to section 5.1 Preparations inserter module on page 6
• If required, enter pincode to gain access to the main menu Refer to section 5.3 Entering the personal pin code on page 7
• Select the required job
To recognize the correct job number, all jobs should have been given names. If so, the name is visible in the
framework under JOB X.
Refer to section 5.4.3 Selecting a job on page 11
• Press the Job info key. Using the job info facility as a guide to put the envelopes at the correct enve-
lope hoppers and the documents at the correct feed stations.
Refer to section 5.4.1 Job info screen overview on page 8
• After the correct job has been selected press the OK key to confirm. Now the job information will
be sent to all modules.
Refer to section 5.4.3 Selecting a job on page 11
• Set the envelope hopper side guides and separation Refer to section 5.7 Envelope hopper adjustment on page 17
• Enter the test menu, press the 1x envelope key to bring an envelope onto the insert table.
• Check the envelope stop position, adjust if necessary.
• Set the envelope fingers
Refer to section 5.4.4 Test run menu on page 11
• If necessary, enter the counters menu to change or reset the counters. Refer to section 5.4.5 Counters menu on page 14
• If necessary, enter the settings menu to check the thickness detector settings. Refer to section 5.4.6 Settings menu on page 14
Action Refer to..
Refer to the operator manual of these modules if required.
• If necessary adjust the VersaFeeders modules 1 and 2. Refer to the chapter “Adjustments” and follow the instructions.

20/40 SI-92
Transport unit TR-7A, TR-1B
Fold unit FO-3, FO-2A
Feed stations FE-1M, FE-8, FE-7, FE-9, ST-1, PF-45A, PF-65A, SF-4/6
Action Refer to..
Refer to the operator manuals of these modules if required.
• If necessary adjust the module TR-7A.
Note 1: With SI-92 selection of a mode at the TR-7A is not applicable.
Note 2: Information about where to put the address carrying documents and the enclosures can be
found in the job info menu of the inserter.
Note 3: It is possible that there is no TR-7A fold/no fold selector available. In that case the TR-7A is
equipped with so called Twin cycle facility that automizes this setting (see options).
Refer to the chapter “Adjustments” and follow the instructions.
• If necessary adjust the module TR-1B. Refer to the chapter “Adjustments” and follow the instructions.
Action Refer to..
Refer to the operator manuals of these modules if required.
• For the FO-3 no adjustments have to be made. -
• The fold unit has to be set such that the folded documents fit in to the envelope. Refer to the chapter “Adjustments” and follow the instructions.
Action Refer to..
Refer to the operator manuals of these modules if required.
• If necessary adjust the modules FE-7, FE-8, ST-1, PF-45A, PF-65A. Refer to the chapter “Adjustments” and follow the instructions.
• If necessary adjust the module FE-9. Refer to the chapter “Settings” and follow the instructions.
• If necessary adjust the module FE-1M. Set the document hopper guides and the separa-
tion.
Refer to the sections “Side guide adjustment” and “Separation
adjustment”.
• Fill the hoppers of the feed units with documents. Refer to the operator manuals of the feed units.