Pitney Bowes F612 User manual

Operating Guide
F612/F615
Collator

1
Contents
1. Introduction page
1.1 Safety 2
2. Installation
2.1 Connect Power 3
3. Getting to know the collator
3.1 Main components 4
3.2 The control panel 5
3.3 Output module 6
4. Operation
4.1 Load paper 7
4.2 Operating the collator 7
4.3 Adjusting the output module 8
4.4 Bin indicators 9
4.5 Correcting counter and stacker position 9
4.6 Setting the total counter to zero 9
4.7 Programming preset counter 10
and sheet insertion program
4.8 LED indications, third party device 10
4.9 Disabling stacker motion 11
4.10 Collator speed adjustment 11
4.11 Disengaging bin´s with defective sensors 11
5. Maintenance
5.1 Cleaning feed rollers and paper separator pad 12
6. Problem solving
6.1 General problems 13
7. Specifications
7.1 Model F612/F615 Specifications 14

2
Introduction
This operator manual describes how to operate the Model F612/F615
Collator as a stand alone unit.
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.
Mains Electrical Connection
In some countries the F612/F615 is supplied with a moulded mains lead.
In other countries, or if the supplied lead is not used, the following information
applies:
1. An approved mains lead for the country concerned must be used.
2. The wires in the supplied mains lead are coloured in accordance with
the following code: Green and Yellow -
Earth
Blue - Neutral
Brown - Live
3. As the colours of the wires in the mains lead of this equipment may not
correspond with the coloured markings identifying the terminals in your
plug, proceed as follows:
The wire which is coloured green and yellow must be connected to the
terminal in the plug which is marked with the letter “E” or by the earth
symbol or coloured green or green and yellow.
The wire which is coloured blue must be connected to the terminal
which is marked with the letter “N” or coloured black.
The wire which is coloured brown must be connected to the terminal
which is marked with the letter “L” or coloured red.
1. INTRODUCTION
1.1 Safety

3
Installation
Plug the collator into a suitable power source. Make sure that the collator is
plugged in securely.
2. INSTALLATION
2.1 Connect Power
WARNING:
This equipment must be earthed.
The socket outlet should be near to the equipment
and should be easily accessible.

4
left side
rear
The Collator
1
5
2 6
7
8
9
3
10
4 11
front right side
1 Control panel
2 Adjustable side guide (in each bin)
3 Load lever
4 Power switch
5 Rear side guide (in each bin)
6 Bin extension tray
7 Power cord receptacle
8 Third party receptacle
9 Conveyor door
10 Adjustable stacker guide (side)
11 Adjustable stacker guide (length)
3. GETTING TO KNOW THE COLLATOR
3.1 Main components

5
The Collator
1 8
9
2
10
11
3
4
12
5 13
6 14
7 15
16
1 Double feed or paper jam mode
(Shown by bin indicators - firm light)
2 Door open indicator
3 On-line or Off-line/stacking mode
4 Straight/offset stacking in stacking
mode
Module priority change in On-line
mode
5 Counter display
6 Counter reset button
7 Test calibration button
8 Misfeed or bin empty
(Shown by bin indicators flashing)
9 Clear button conveyor belt transport &
connected unit
10 Bin indicators
11 Stacker full or load lever out of
position
12 Set counter
13 Selection programming mode
14 Preset counter
15 Sheet insertion program (only in
stacking mode)
16 Start & stop button
3.2 The control panel

6
The Collator
1
5
2 6
3 7
4
1 Output module top cover
2 Paper deflector
3 Output module adjustment lever
4 Docking studs
5 Top cover release device (on each side)
6 Output module
7 Output module bracket
3.3 Output Module

7
Operation
1 Make sure that the sheets are well fanned to avoid misfeeds or double
feeds.
2 Align the sheets well to achieve a reliable collating operation and good
stacking result.
3 Make sure that the ink has dried out well.
4 Press the load lever downwards to release the bins.
5 Load the sheets into the bins against the rear side guide.
6 Move the adjustable side guides up against the sheets until there is no
clearance.
7 Raise the load lever to actuate the feed rollers.
1 Set the on/off switch to on position. The counter display will show ”HEJ”
to confirm that the collator is OK.
2 Select output mode:
- Offset/straight stacking mode.
- On-line mode.
3 Select stacking mode if set to stacking:
- Straight stacking.
- Offset stacking.
4 Set the adjustable stacker guide (side) to the selected paper size.
5 Set the adjustable stacker guide (length) to the paper size.
6 Press test/calibration button. The collator will adjust the number of bins
used and the paper quality in each bin and is now ready for operation.
Check the result to make sure that it is OK and press start.
If not correct, repeat the test/calibration.
4. OPERATION
4.1 Load paper
4.2 Operating the Collator

8
Operation
paper
deflector
paper
guide
adjustment
lever output module
bracket
output module locked in the
innermost position
output module in the outermost
position (adjustment lever in pos. 1)
The purpose of the output module is to ensure that
the set from the collator is fed correctly to the inserter
document table. To achieve this, the position of the
output module is adjustable to match different paper
sizes and how the set is orientated.
On the output module bracket there is an adjustment
lever and a scale. The adjustment lever can be
placed in five different positions, where a higher
number places the output module closer to the
collator. To change position of the adjustment lever,
first push the output module towards the collator
until it locks in the innermost position.
The recommendations in the table below are
guidelines. The adjustments can vary depending on
paper quality, paper weight etc.
Paper size Feed direction Adjustment lever position
A4 Portrait Output module in innermost
position.
A4 Landscape 3
8.5" x 11" Portrait 5
8.5" x 11" Landscape 3
Note: Before moving the adjustment lever, push
the output module towards the collator
until it locks and the adjustment lever
moves freely.
The leading edge of the set should land between
the feeding belts on the inserter document table.
When necessary, adjust the paper deflector.
Change the position of the adjustment lever if:
• The set bounces back, up on the inserter
document table side guide - move the adjustment
lever to a higher number.
• The set stays on the paper guide - move the
adjustment lever to a lower number.
4.3 Adjusting the output module

9
Operation
LED Status Description Notes
Continuous
light
Double sheet/Jam detect Can be caused by:
Double sheets
Paper jam
Different paper quality or print
compared to the calibrated set
Reduced paper feeding
capability
Incorrect paper length
(compared to the calibrated
length)
Flashing slow Misfeed indication Load/check paper.
If continuous misfeed, clean the
feed rollers (see section 5.1)
Flashing fast Comes on after the calibration cycle. The
bin sensor that is flashing is incapable of
sensing double sheets but is operational
and still capable of detecting misfeeds.
The other bins are OK and calibrated.
Step # Description Action Notes
1 Reduce the total
counter value by 1
set.
Press and release "Counter
reset button".
In offset stacking mode
the stacker will cycle
once.
Step # Description Action Notes
1
To zero the total
counter.
Press "Counter reset button" and hold
down for more than one (1) second.
4.4 Bin Indicators
4.5 Correcting counter and stacker position
4.6 Setting the Total Counter to Zero