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

10
Operation
Step # Description Action Notes
1 Select program
mode.
Press "Selection programming mode"
until the LED indicating the program to
be set is lit (preset counter or sheet
insertion program).
2 View program mode. Press "Counter reset button". The display will show
the value flashing.
3 Program a new
value.
Press "Counter reset button" to
access the last digit.
Press "Selection programming mode"
to change the setting.
Press "Counter reset button" to
confirm the setting and access the
second digit.
Repeat this for the remaining (2) digits
starting with pressing "Selection
programming mode".
After adjusting the last digit, press
"Counter reset button" to confirm the
settings made.
Repeat
these
two
steps
Display shows 000
LED Indication
Description
Notes
Continuous
light
On-line mode selected
Flashing Connected unit stopped
LED indication,
On-line
4.7 Programming preset counter & sheet insertion program
4.8 LED indications, third party device

11
Operation
Step # Description Action Notes
1 Disable stacker
motion.
Press and hold down "Straight/offset
stacking" for more than two (2)
seconds.
For handling of
extreme light weight
papers.
2 Reinstate stacker
motion.
Press and release "Straight/offset
stacking".
Step #
Description
Action
Notes
1 Enter speed
adjustment mode.
Press and hold "Selection
programming mode" for more than two
(2) seconds.
The last bin LED
lights and counter
display shows speed
in sets/h :10
2 Select collating
speed.
Press "Selection programming mode". The counter will
display the speed in
sets/h :10
3 Confirm adjustment. Press and hold "Selection
programming mode" for more than two
(2) seconds (the bin LED will go out).
The counter will now
display the counter
value.
Step # Description Action Notes
1 Isolate defective bin
sensors and
disengage these
bins.
Press and hold "Test and calibration"
for more than five (5) seconds.
The electronics check
all bin sensors and
disengages the bins
with defective sensors.
2 Re-engage bins after
correction of the
problem.
Press and hold "Test and calibration"
for more than five (5) seconds.
* This process can also be used to disengage bins with other problems. In this
case the feed roller shaft is removed and a sheet inserted (80 gsm or heavier) in
the bin to cover the bin sensor (simulating a defective sensor). Pressing “Test/
calibration” for more than five (5) seconds will now disengage this bin.
4.9 Disabling stacker motion
4.10 Collator speed adjustment
4.11 Disengaging bins with defective sensors*

12
Maintenance
If misfeeding starts occuring more frequently, clean the feed rollers.
If double feeding starts occuring more frequently, clean the separator pads.
1 Remove the feed roller assembly shaft by pressing it to the left side.
The right end of the feed roller assembly will now be released and the
assembly can be removed.
2 Clean the feed rollers and the separator pad with an alcohol based liquid.
paper separator pad
Lift out this side
5. MAINTENANCE
5.1 Cleaning feed rollers and paper sensor pad
feed rollers
Press to the left

13
Problems?
Problem Possible causes Action
The machine is
Stacker tray blocked and can not
Switch the machine off. Unblock
inoperative and the
reach home position.
tray and switch machine on.
letters "HEJ" are not
shown in the display
when the machine is
switched on.
The machine is
inoperative as the
start button is
pressed.
Machine in jam condition.
Load lever in lower position.
Clear jam.
Raise load lever to upper position.
Stacker full.
Empty stacker.
Conveyor door open. Close door.
Attached units shut down. Correct problem in third party
device.
Repeated
misfeeds/double
feeds.
Feed rollers need cleaning.
Paper separator pad needs
cleaning.
Check/clean (see section 5.1).
Check/clean (see section 5.1).
Sheets not fanned enough
(ink/powder/cutting burrs etc. will
make this a very important step).
Check/fan sheets.
Paper quality out of
specification.
Check specifications.
Incorrect double
feed/jam indication.
Different paper quality or print
impression in the bins since
previous calibration.
Mixed sheets (mixed paper
qualities).
Perform calibration cycle.
Check the sheets.
Front panel
commands
inoperative.
Machine has accidently entered
service mode.
Switch machine off and then back
on.
6. PROBLEM SOLVING
6.1 General Problems

14
Specifications
Model F612/F615
Number of bins 6 (F612), 10 (F615)
Bin capacity 20 mm
Sheet size Min 139 x 210 mm
Max 320 x 450 mm
Paper weight Min 40* gsm
Max 200* gsm
Adjustable speed
1000/1500/1800/2200/2600/2800/3000/3200/3400/3600
sets per hour
Double feed detection Yes, sensor in each bin
Misfeed detection Yes
Empty bin detection Yes
Paper jam detection Yes
Stacker full detection
Yes
Set counter Yes
Preset counter Yes
Sheet inserting program Yes
Receiving tray Offset/straight stacking
Height 700 mm
Width 575 mm
Depth 525 mm
Weight 65 kg
Voltage
230/240V 50Hz
The machine design and specifications are subject to change without notice
*Depending on paper quality and printing method
7. SPECIFICATIONS
7.1 Model F612/F615 Specifications

15
Notes

16
Notes

3001 Summer Street, Stamford,
Connecticut 06926
www.pitneybowes.com
Form No. SDC489 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.