Pitney Bowes F601 User manual

Operating Guide
F601
Booklet Feeder

1
Contents
1. Introduction page
1.1 Safety 2
2. Getting to know the Model F601
3. Operation
2.1 Main components 3
2.2 The menus, flow chart 4
2.3 How to read the display 5
2.4 Explanation of the menus 5
4. Diagnostics
3.1 Setting up the Model F601 9
3.2 Adjusting the separation 10
3.3 Loading 10
3.4 Programming the Model F601 12
3.5 Start inserting 12
4.1 The Diagnostics function 13
5. Maintenance
6. Problem solving
5.1 Cleaning the feed belts 13
7. Specifications
6.1 General problems 14
7.1 Model F601 Specifications 16

2
Introduction
This operator manual describes how to operate the Model F601
Booklet feeder.
General
• Know your equipment, especially how to stop it in the event of an
emergency.
• Never reach into the machine while it is on; always wait until the machine
has come to a full stop.
• Never touch moving parts.
• Keep fingers, long hair, jewellery and loose clothing away from moving
parts at all times.
• Use the equipment only for its intended purpose.
• Don’t remove machine covers. Refer servicing to qualified personnel.
1. INTRODUCTION
1.1 Safety

3
rear
right
left
The Feeder
The Model F601 is a microprocessor controlled booklet feeder designed to be
used in a system together with the Model F610 inserter and Model F612/F615
collator or as a stand-alone unit.
Take a few minutes to become familiar with components of the Model F601.
1
6
7
8
2
9
10
3
11
4
12 right
5
rear
front
left
front
16 17 18 19
20
21
The Model F601 is powered from the
Power Pack mounted on the Model F610.
1 Insert side guides
2 Insert front guide
3 Separator adjustment knob
4 Outfeed
sensor
5 Docking plate
6 Length measuring scale
7
Rear guide pusher
8 Insert rear guide adjustment knob
9 Insert rear guide
10 Control panel
11 Insert feed belts
12 Insert sensor
13 Connection cable jack, female
14 Termination plug jack, male
15
Power cord receptacle
16 Display
17 Arrow buttons
18 Escape button
19 OK button
20 Ground fault interrupter
21 Main power switch
2. GETTING TO KNOW THE F601
2.1 Main components
13
14 15

4
On-Line
Off-Line
Sheets/Set= 1
L=210mm BS=70%
Clear
Counter
00075
Counter
00100
Remaining 00025
Sheets/Set:
1
Length: 210mm
SPH: 2800
BS: 70%
Adjustment menus
On-line
The Feeder
Main Menu
Run Mode Menus
STOP 00075
PAUSE
STOP 00075
PAUSE
Pause Mode Menus
STOP 00075
CONTINUE
Option
Menus
PAUSE
ADJUST
CONTINUE
ADJUST
MODE On-line
SINGLE CYCLE
SINGLE CYCLE
CLEAR COUNTER
CLEAR COUNTER
PRESET COUNTER
Run Mode
Option Menus
CLEAR COUNTER
PRESET COUNTER
PRESET COUNTER
SHEETS PER SET
To
Run Mode Menu
or
Pause Mode
SHEETS PER SET
LENGTH
LENGTH
SETS PER HOUR
SETS PER HOUR
BELT SPEED
BELT SPEED
Module Priority (1)
Diagnostics Menu
Run Diagnostics?
SETS PER HOUR
CLEAR COUNTER
1
START
MODE
2.2 The menus, flow chart
SETS PER HOUR
CLEAR COUNTER
Module Priority (1)
LANGUAGE
German
English
LANGUAGE
DIAGNOSTICS
On-line
1
START
MODE
Off-Line
Stand Alone

5
The Feeder
The arrow on the left side of the display shows which
option is currently selected.
Pressing the OK button on the control panel confirms
your selection and the corresponding submenu will
appear in the display.
On the right side of the display, up and/or down arrows
appear if there are more options that can be selected.
These arrows are also displayed when the value of
the selected option can be increased/decreased using
the arrow buttons. Use the up/down buttons on the
control panel for selecting, scrolling or adjustment.
Main Menu
Run Mode Menu
The ”Main Menu” is displayed with the option ”START”
selected when the Model F601 is switched on. The
information in the display shows that the Model F601
is ready to start, it is (in this case) on-line with the
system and the ID number in the system is one. See
table below.
Press the OK button on the control panel to confirm
your selection and the Model F601 will start. If the
F601 is installed in a system with a Model F610 Inserter
and a Model F612/F615 Collator, the complete system
can be started from any unit’s start button. The “Main
Menu” will be replaced with the “Run Mode Menu”
when the Model F601 system is started.
Units in the system
ID number
*
**
* If “Module Priority” in F601 is changed to ID no.2.
** If the power is off to the Model F612/F615, a “Comm
Error” is created. Turn on the power to the Model
F612/F615 and select OFF-line or ON-line.
2.4 Explanation of the menus
2.3 How to read the display
MODE On-line
SINGLE CYCLE
Sheets/Set= 1
L=210mm BS=70%
Length: 210mm
SHEETS PER SET
LENGTH
START
MODE
1
On-line
STOP 00075
PAUSE
Model F610
Model F601
Model F612/F615
2
1
not installed
3
1
2
3
2
1
1
2
No power

6
The Feeder
Run Mode Menu
Pause Mode Menu
Adjustment Menu
Adjustment Menu
Adjustment Menu
The “Run Mode Menu” is displayed when the Model
F601 is started. In the “Run Mode Menu” there are
three options: “STOP”, “PAUSE” and “ADJUST”. Scroll/
select an option with the arrow buttons and confirm
with the OK button.
“STOP”: The Model F601 (and attached units)
completes the set being processed and then stops.
You will be returned to the “Main Menu”.
“PAUSE”: The Model F601 (and attached units) is
paused immediately. The text “PAUSE” will be replaced
with the text “CONTINUE”. Select “CONTINUE” and
confirm with the OK button when you want to leave
the pause mode and start the system. Or, select
“STOP” and confirm with the OK button when you
want to leave the pause mode and stop the system.
“ADJUST”: The “Run Mode Option Menus” can be
reached both when the Model F601 is paused and
while it is running. In the “Run Mode Option” menu
there are three options: “SETS PER HOUR”, “CLEAR
COUNTER” and “PRESET COUNTER”. Scroll/select
an option with the arrow buttons and confirm with the
OK button.
“SETS PER HOUR”: Change the number of sets per
hour using the arrow buttons. The range is 1000 to
3600 sets per hour. Default value is 1800. The speed
will however be limited to match units attached.
“CLEAR COUNTER”: Clears the set counter when the
OK button is pressed.
“PRESET COUNTER”: Change the value of the preset
counter using the arrow buttons. Default value is 0.
This menu can also be used to check the setting of
the preset counter and the number of sets to go before
the job is completed.
NOTE: When checking, use the “ESC” button to
leave the menu without changing the settings.
2.4 Explanation of the menus (continued)
Counter 00100
Remaining 00025
Clear Counter
00075
STOP 00075
PAUSE
PAUSE
ADJUST
STOP 00075
CONTINUE
SPH: 2800

7
Sheets/Set= 1
L=210mm BS=70%
MODE On-line
SINGLE CYCLE
The Feeder
Option Menu
Adjustment Menu
Scrolling down from the “Start Menu”, using the arrow
buttons, you will find several options. Press the OK
button at the desired option to enter the corresponding
“Adjustment Menu” as illustrated in the figure to the
left. How each adjustment menu works in detail will be
described later in this text. After adjustment, press the
OK button to confirm changes or the ESC button to
cancel. In either case you will be returned to the “Option
Menus”.
Decide whether the Model F601 should be on-line or
off-line with the system or function as a stand alone
unit (not applicable to Pitney Bowes models).
This menu provides information on basic settings,
number of sheets per set, insert length and belt speed.
No changes can be made here.
Clears the set counter when the OK button is pressed.
Enter the number of sets for the preset counter using
the arrow buttons. Default value is 0. This menu can
also be used to check the setting of the preset counter
and the number of sets to go before the job is
completed.
NOTE: When checking, use the “ESC” button to
leave the menu without changing the settings.
START 00075
MODE On-line
CLEAR COUNTER
PRESET COUNTER
2.4 Explanation of the menus (continued)
Clear Counter
00075
SINGLE CYCLE
CLEAR COUNTER
CLEAR COUNTER
PRESET COUNTER
Counter 00100
Remaining 00025
Counter 00100
Remaining 00025
On-Line
Off-Line
Off-Line
Stand Alone

8
Module Priority (1)
LANGUAGE
German
English
The Feeder
Enter the number of sheets that should be fed from
the Model F601 per set using the arrow buttons. The
range is 1 to 45 sheets per set. Default value is 1.
If running on-line with the Model F610, multiple sheets
per set should only be run portrait.
Enter the length of the inserts (in the feed direction)
using the arrow buttons. The range is 100 to 310 mm.
Default value is 200 mm. Use the scale attached to
the unit to measure the length of the booklet.
Enter the number of sets per hour using the arrow
buttons. The range is 1000 to 3600 sets per hour.
Default value is 1800. The speed will however be
limited to match units attached. When running the
machine do not change speed by more than 1000
SPH at a time, it can create interruption.
Belt speed is how fast each insert will be fed. Adjust
to determine the position of the booklet on the Model
F610. Enter a percentage using the arrow buttons.
The range is 60 to 100%. Default value is 80%. If the
belt speed is too slow the inserts might have problems
to “leaving” the Model F601. If the belt speed is too
high, single sheets might turn over when they are fed
and booklets might bounce back.
Module Priority is similar to the ID number and decides
the order of the inserts in the envelope. Lowest number
feeds first and so on. For example, the table on page
5 shows that the Model F601 feeds first and then the
Model F612/F615.
Select language using the arrow buttons.
Starts the self diagnosis when the OK button is
pressed. Memory, sensors, feed belt motor and the
voltage supplied is checked.
See section 6 for error messages, explanations and
actions to be taken.
2.4 Explanation of the menus (continued)
Length: 210mm
SHEETS PER SET
LENGTH
SPH: 2800
LENGTH
SETS PER HOUR
BS: 70%
SETS PER HOUR
BELT SPEED
LANGUAGE
DIAGNOSTICS
Run Diagnosis?
Sheets/Set: 1
PRESET COUNTER
SHEETS PER SET
BELT SPEED
Module Priority (1)

9
Operation
Model F601 docking plate
Lift the Model F601 docking plate and position the
Model F601 up to the Model F610. Ensure that the
docking plate locks the Model F601 to the Model F610.
If a Model F612/F615 Collator is present in the system,
it should be positioned in the docking plate on Model
F610. While calibrating the collator, adjust the paper
deflector so that the leading edge of the sheets lands
between the insert feed belts on the Model F610
document table.
To exclude the Model F601 from the system, just select
“Off-line” from the “Mode” option.
To reactivate, select “On-line” from the “Mode” option.
To exclude the Model F612/F615 from the system,
just select “Stacking mode” on the control panel.
To reactivate, select “Third party device mode” on the
control panel.
3. OPERATION
3.1 Setting up the Model F601
collator Model F612/
F615
inserter Model F610
booklet feeder Model F601
output module
paper deflector

10
Operation
separator
adjustment knob
separator pads
The illustration to the left shows schematically how
the separation works and the name of the different
parts. Tightening the separator adjustment knob moves
the bearing rollers and the separator pads closer to
the feed belt. Adjust the separation as follows.
rollers feed belt
Booklets over 3 mm thickness
Place the booklet between the bearing rollers and the
feed belt as shown in the illustration. Tighten the
separator adjustment knob until the feed belts move
when the booklet is pulled back and forth.
Single sheets and booklets up to 3 mm thickness
First, place two sheets/booklets between the bearing
rollers and feed belt. Tighten the separator adjustment
knob so the two rollers are parallel. Pull the two sheets/
booklets so they are now between the separator pads
and the feed belts as shown in the illustration. Tighten
the separator adjustment knob. Grab only the top sheet
and keep it streched. Then release until the top sheet
can be pulled out.
Adjustment can be checked from the Module Priority
menu. Press the up arrow button to feed step by step.
To feed an entire set, press the OK button.
Repeat pressing OK while fine turning adjustment if
needed.
side guide adjustment
Slide the insert side guides away from each other.
Load the inserts. Slide the guides towards and up
against the inserts. First place one insert under the
separation, then load the rest of the stack. Make sure
each insert is up against the front guide.
3.3 Loading
3.2 Adjusting the separation

11
Operation
rear guide adjustment
front guide in rightmost position
front guide in leftmost position
The adjustment of the rear guide affects the friction
between the inserts and the feed belt. Adjustment
therefore depends on paper weight, structure and
printing method as well as what type of inserts are
being fed. Proper adjustment is more significant when
running single sheets. Loosen the knob and slide the
rear guide to adjust. Tighten after adjustment. Start
with the rear guide to the left and work to the right
until proper feed is obtained.
Adjusting the rear guide too much to the left may
cause inserts not to be fed due to lack of friction. The
error message “Belt overload” will be shown in the
display. Move the rear guide to the right to increase
the friction.
Adjusting the rear guide too much to the right may
cause the next insert to follow directly after the first
one. The error message “Paper jam” will be shown in
the display. Move the rear guide to the left to decrease
the friction.
Proper adjustment of the rear guide demands that the
separation is properly adjusted. Detach the rear guide
pusher when running booklets. When running sigle
sheets, move the rear guide to the left so the trail
edge of the sheets are up on the slop of the pusher.
This increases the feed of the sheets.
The insert front guide should be positioned in its
rightmost position when booklets over 3mm thick are
fed. For single sheets and booklets up to 3mm thick,
position the front guide in its leftmost position. Lift the
front guide to adjust.
Add addition weight for sheets or inserts which are
difficult to feed, or when the stack of paper is low.

12
Operation
Switch on the power. Select “Mode” and press the OK button. Choose “On-line”
if the Model F601 is used together with a Model F612/F615 collator and/or a
Model F610 inserter. Choose “Stand Alone” to use the Model F601 as a stand
alone booklet feeder. To make the Model F601 inactive, choose “Off-line”. Confirm
your choice by pressing the OK button.
Select “Sheets per set” and press the OK button. Enter number of sheets per
set using the arrow buttons. The range is 1 to 45 sheets per set. Default value is
1. Confirm by pressing the OK button. If running on-line with a Model F610,
multiple sheets per set should only be run portrait.
Select “Length” and press the OK button. Enter the length of the inserts (in the
feed direction) using the arrow buttons. The range is 100 to 310 mm. Default
value is 200 mm. Confirm by pressing the OK button. Use the scale attached to
the unit to measure the length of the booklet.
Select “Sets per hour” and press the OK button. Enter the number of sets per
hour using the arrow buttons. The range is 1000 to 3600 sets per hour. Default
value is 1800. The speed will however be limited to match units attached.
Confirm by pressing the OK button.
Select “Belt speed” and press the OK button. Enter a percentage using the
arrow buttons. The range is 60 to 100%. Default value is 80%. Confirm by
pressing the OK button.
Select “Module Priority”. If necessary, change the feeding order (ID number) by
pressing the OK button. Lowest number feeds first and so on. Leave the “Module
Priority” option menu using the ESC button.
If you wish to reset the set counter select “Clear counter” and press the OK
button. The next menu shows the actual value of the set counter. Clear the set
counter by pressing the OK button.
If you wish to program a specific number sets for a job, select “Preset counter”
and press the OK button. The next menu shows the actual value of the preset
counter and how many more sets to go to finish the job. Enter a new value using
the arrow buttons. Default value is 0. Confirm by pressing the OK button.
Pressing ESC anywhere in the option menu, takes you to the top of the menu.
After setting up attached units according to their respective operator instructions,
the system is ready to be started. The system can be started and stopped using
the start and stop buttons on any unit in the system.
3.4 Programming the Model F601
3.5 Start inserting

13
Run Diagnostics?
BELT SPEED
DIAGNOSTICS
Maintenance
MEMORY: PASSED
S1:
Example: Display shows
that the Model F601
passed the memory test
and testing of sensor S1
is in progress.
Note: Before starting the diagnostics, all inserts
must be removed.
Select “DIAGNOSTICS” from the “Options Menu” and
press the OK button at the “Diagnostics Menu” to start
the self test.
The self test will check: memory, insert sensor (S1),
outfeed sensor (S2), voltage supplied from the power
pack and feed belt motor (M1). During the test, the
display will show which part is currently being tested.
After the test, you can scroll with the arrow buttons to
check that all parts diagnosed, passed the test.
If either of the sensors should fail the diagnostics,
check if they are contaminated. If so, clean them and
perform the self test again. If cleaning does not correct
the problem, or if any other of the parts checked fails
the test, have the Model F601 checked by a qualified
technician.
The self test is indicated with a flashing “TEST” until
the test is completed.
Clean the insert feed belts using a mild soap detergent
every 10,000 feeds or when belts lack friction.
insert feed belts
5. MAINTENANCE
4. DIAGNOSTICS
4.1 The Diagnostics function
MEMORY: PASSED
S1: TEST
5.1 Cleaning the feed belts

14
Problems?
Displayed message Possible causes Explanation/action
WARNING
Comm. Error
1. Model F601 started in
off-line or on-line mode
when Model F610 is
powered off.
2. Communication cable
between Model F610 and
Model F601 not connected
or defective.
3. Communication box
defective.
4. The Model F612/F615
is switched off or the
Comm-Box is not
connected.
Communication between the units in the
system could not be established.
1. Switch the Model F610 on.
2. Check/replace communication cable.
3. Have the communication box/system
checked by a qualified technician.
4. Turn on the Model F612/F615 and set the
machine ON-line or OFF-line. Connect the
Comm-Box
ERROR Reset
Paper Jam
1. Incorrect insert length
entered.
2. Double feed because of
incorrectly adjusted
separation.
3. Double feed because
rear guide is adjusted too
much to the right.
4. Insert length incorrectly
set.
5. Outfeed sensor
defective or dirty.
Insert/s not reported fed properly to the
Model F610 document table.
1. Enter the correct insert length, in
millimeters (see section 2.4).
2. Adjust separation (see section 3.2).
3. Adjust the rear guide (see section 3.3).
4. Sensor may be contaminated with dust.
Check/clean the outfeed sensor. Run
"Diagnostics" to verify status of sensor. If the
self test verifies that the sensor is defective,
have the Model F601 checked by a qualified
technician.
Press the up arrow button to reset the
insert/s. Press the Esc button once to enter
the single cycle menu. Check what insert
length is entered. Press the Esc button once
more to enter the start menu.
ERROR Reset
Belt over load
1. No inserts fed because
of incorrectly adjusted
separation.
2. Misfeed because rear
guide is adjusted too
much to the right.
3. Misfeed because of
improper use of the rear
guide pusher.
4. Outfeed sensor
defective.
5. Feed motor defective.
The outfeed sensor has not sensed any
inserts reaching it.
1. Adjust separation (see section 2.4).
2. Run "Diagnostics" to verify status of
sensor. If the self test verifies that the sensor
is defective, have the Model F601 checked
by a qualified technician.
3. Run "Diagnostics" to verify status of feed
motor. If the self test verifies that the motor is
defective, have the Model F601 checked by a
qualified technician.
Press the up arrow button to purge the
insert/s. Press the Esc button once to enter
the single cycle menu. Press the Esc button
once more to enter the start menu.
6. PROBLEM SOLVING
6.1 General Problems

15
Problems?
Displayed message Possible causes Explanation/action
WARNING Reset
Feeder is empty
1. No inserts.
2. Inserts do not cover the
sensor on the insert table.
3. Insert sensor defective.
It is not registered that there are any inserts
on the insert table.
1. Reload.
2. Check that the inserts are loaded properly
(see section 3.3).
3. Run "Diagnostics" to verify status of
sensor. If the self test verifies that the sensor
is defective, have the Model F601 checked
by a qualified technician.
System ERROR
Interlock at (X)
1. Interlock switch at unit
with ID number "X" is
actuated.
See section 2.4 to identify which unit is
causing the problem.
1. Check that the interlock switches are not
actuated. If problem cannot be corrected,
have the system/unit checked by a qualified
technician.
System ERROR
Jam at (X)
1. Jam at unit with ID
number "X" is sensed.
1. Clear jam at unit "X". If necessary, see
section 2.4 to identify which unit is causing
the problem.
6.1 General Problems (continued)

16
Specifications
Model F601
Paper size Min 140 x 210 mm
Max 310 x 310 mm
Paper weight Min 60 gsm
Max
Up to 600g total weight of insert
Speed Up to 3600 sets per hour
Max insert thickness 8 mm
Misfeed detection Yes
Jam detection Yes
Height 1020 mm
Width 510 mm
Depth 480 mm
Weight 36 kg
Voltage 36VDC supplied from Power Pack in Model F610
The machine design and specifications are subject to change without notice
7. SPECIFICATIONS
7.1 Model F601 Specifications

3001 Summer Street, Stamford,
Connecticut 06926
www.pitneybowes.com
Form No. SDC490 RevB (9-22) © Pitney Bowes Limited, 2022 Printed in England
FOR SERVICE AND SUPPLIES:
We have made every reasonable effort to assure the accuracy and usefulness
of this guide, however we cannot assume responsibility for errors or omissions
or liability for the misuse or misapplication of our products.