Pitney Bowes F610 User manual

Operating Guide
F610
Inserter

1
Contents
1. Introduction page
1.1 Safety 2
2. Getting to know the F610
3. Operation
2.1 Main components 3
2.2 The menus, flow chart 6
2.3 Explanation of the menus 7
4. Added features
3.1 Setting up the F610 for different insert sizes 11
3.2 Adjusting the envelope feeder 12
3.3 Loading envelopes 13
3.4 Filling water 13
3.5 Setup a new job 14
3.6 Start inserting 15
5. Maintenance
4.1 How to adjust the amount of sealing water 16
4.2 How to select language 16
4.3 Diagnostics 17
6. Problem solving
5.1 Cleaning the water tray 19
5.2 Cleaning the envelope sealing flap 20
5.3 Cleaning the envelope feed belts 21
5.4 GFI function test and resetting 21
7. Specifications
6.1 General problems 22
7.1 Model F610 Specifications 26
7.2 Insert and envelope specifications 26

2
Introduction
The Model F610 is an inserter that can be used on-line with the Model
F612/F615 collator and/or Model F601 booklet feeder or for handfeeding.
This User Guide covers the operation of the Model F610 both as a stand-
alone unit or connected to the above mentioned collator. For on-line
operation with Model F601, also see the Model F601 User Guide.
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 F610 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
The Inserter
The Model F610 is easy to use thanks to a fully microprocessor controlled
operation. With the 4 buttons on the control panel you can choose between the
different menus shown on the LCD display and do your settings. Take a few
minutes to become familiar with components of the F610.
1
2
3
4
rear side right side
1 Outfeed area
2 Outfeed cover
3 Receiving tray
4 Water bottle
left side
front side
2. GETTING TO KNOW THE F610
2.1 Main components

4
The Inserter
1
2
3
4
5
6
7
8
1 Envelope feeding cover
2
Plastic cover
3 Document table side guides
4 Document table
5 Insert feed belts
6 Oversize envelope (B4) adjustment knobs
7
Ground fault interrupter (GFI)
8 Main power switch, power cord receptacle
and main fuse
2.1 Main components (continued)

5
The Inserter
1
2
3 7
8
4
9
5
10
11
12
6
13
1 Docking Studs
2 Connection cable jacks
3
Envelope side guides
4 Envelope rear guide
5 Envelope feed belts
6 Envelope feeding table
7 Envelope separator pads adjustment knobs
8
Control Panel
9 LCD display
10 Control buttons, multi function
11 Maximum load mark (red)
12 Envelope separator pads
13
Out of envelope sensor
2.1 Main components (continued)

6
The Inserter
1 BOOKLET FEEDER
2 COLLATOR
3 INSERTER
Module Priority Menu
AUTO
SEALING
SETUP
Main Menu
FEED MODE
MACHINE MODE
CLEAR COUNTER
ADDED FEATURES
OK? ESC
Run Mode Setup Menu
AUTO
SEALING
SEALING
MANUAL NO SELAING
BY PASS
CLEAR COUNTER LANGUAGE
DIAGNOSTICS
OK? ESC OK? ESC OK? ESC OK? ESC
Feed Mode Menu
Machine Mode Menu
Clear Counter Menu Added
Features Menu
1 BOOKLET FEEDER
2 COLLATOR
3 INSERTER
AMOUNT WATER
– +
OK? ESC
GERMAN
ENGLISH
FRENCH
SWEDISH
OK? ESC
DIAGNOSTICS
TESTING EEPROM
MEASUR. VOLTAGES
READING INPUTS
TESTING MOTORS
Module Priority Menu Sealing
Menu
Language Menu
Diagnostics Menu
12345 6
2.2 The menus, flow chart
12345 6

7
The Inserter
The Module Priority Menu appears after
switching on the power. This menu shows how
the units are electrically connected. Press the
right button (“SETUP”) once to enter the Setup
Menu, and once again (“ESC”) to enter the
Main Menu.
The Main Menu is where you return before
starting the job after changing any settings.
Use the left button (below the start symbol) to
initialize Run Mode. The next button is the
reset button which allows you to reset the
machine i.e. clear the machine from envelopes
and inserts. With the right button you can enter
the Setup Menu.
The Run Mode indicates that the Model F610
is ready for use. Press the stop button to stop
inserting and to return to the Main Menu. If
manual mode is chosen from the Feed Mode
Menu, and no inserts are fed to the document
table within 15 seconds, the Model F610 will
automatically return to the Main Menu.
In the Setup Menu you can scroll up and down
with the buttons below the arrow symbols. The
chosen submenu will be shown with the text
inverted. Confirm your choice by pressing the
“OK?” button.
To return to the Main Menu press the “ESC”
button.
2.3 Explanation of the menus
FEED MODE
MACHINE
MODE
CLEAR
COUNTER
ADDED FEATURES
OK? ESC
Stop
123456
AUTO
MANUAL
SETUP
Start Reset
1 BOOKLET FEEDER
2
COLLATOR
3 INSERTER
SETUP

8
The Inserter
In the Feed Mode Menu you can choose
between manual feeding or automatic feeding
from a collator and/or booklet feeder. The
chosen item will be shown with the text inverted.
Confirm your choice by pressing the “OK?”
button or cancel with the “ESC” button to return
to the Setup Menu.
In the Machine Mode Menu you can choose
between inserting with sealing, inserting and
no sealing or just to let the Model F610 feed
your inserts through the machine (without any
envelopes as a bypass function). The chosen
mode will be shown with the text inverted.
Confirm your choice by pressing the “OK?”
button or cancel with the “ESC” button to return
to the Setup Menu.
In the Clear Counter Menu you can reset the
counter. Confirm your choice by pressing the
“OK?” button or cancel with the “ESC” button
to return to the Setup Menu.
2.3 Explanation of the menus (continued)
SEALING
NO
SEALING
BY PASS
OK?
ESC
AUTO
MANUAL
OK?
ESC
CLEAR COUNTER
OK?
ESC
123456

9
The Inserter
In the Added Features Menu you can access
the Water Amount Adjustment Menu, the
Language Menu or start the self test program,
Diagnostics. The chosen item will be shown
with the text inverted. Confirm your choice by
pressing the “OK?” button or cancel with the
“ESC” button to return to the Setup Menu.
NOTE: Choosing “DIAGNOSTICS” will
immediately start the built in self test
program. Before performing Diagnostics it
is very important to read “4.3 Diagnostics”
in the section “4 Added Features”.
In the Water Amount Adjustment Menu you
can adjust the amount of sealing water in the
wetting system by pressing the corresponding
arrow button. The previous setting is indicated
by an arrow. Confirm your choice by pressing
the “OK?” button or cancel with the “ESC”
button to return to the Added Features Menu.
In the Language Menu you can scroll/select
which language you want to be displayed using
the arrow buttons. The chosen language will
be shown with the text inverted. Confirm your
choice by pressing the “OK?” button or cancel
with the “ESC ” button to return to the Added
Features Menu.
2.3 Explanation of the menus (continued)
GERMAN
ENGLISH
FRENCH
SWEDISH
OK?
ESC
SEALING
LANGUAGE
DIAGNOSTICS
OK?
ESC
AMOUNT WATER
–
+
OK?
ESC

10
The Inserter
After choosing “DIAGNOSTICS” the display will
show what type of self test is currently being
performed. During the test you will hear sounds
when components are tested.
NOTE: Before performing a Diagnostics it
is very important to read “4.3 Diagnostics”
in the section “4 Added Features”.
Normally the message “NO FAULTS FOUND”
should be displayed. Press the reset button
( ) to return to the Added Features Menu.
If the self test program finds any errors, the
display will show the faulty component, its
actual status and a fault code. If there are
multiple errors, there will be an arrow button
and a cancel button visible. Scroll with the arrow
button and press the “ESC” button to return to
the Added Features Menu.
2.3 Explanation of the menus (continued)
DIAGNOSTICS
TESTING EEPROM
MEASUR. VOLTAGES
READING INPUTS
TESTING MOTORS
NO FAULTS FOUND

11
Operation
CAUTION: Before adjusting the side guides
press the reset button from the Main Menu
to avoid damaging the envelope opener.
oversize envelope adjustment knobs
shown in their outermost position
The side guide position determines the position
of the envelope openers engaging the
envelope. Adjust the document table side
guides by sliding them towards or away from
each other by gripping the side guides by the
blue dots. Adjust them to the scale mark
corresponding the insert size. A normal setting
allows a 2 to 3mm gap between the inserts
and the side guides. If measurement “C” (see
section 7.2) is large, a larger gap has to be
allowed, otherwise the envelopes will not be
opened for insertion.
When B4 envelopes (extra wide) are used to
accommodate a large packing thickness, the
oversize envelope adjustment knobs should be
set to their outermost positions to avoid damage
to the envelopes. Loosen the knobs to adjust.
CAUTION: Only perform the adjustment
when the document table side guides are
in their outermost position.
NOTE: If B4 envelopes (extra wide) are not
being used, the oversize envelope
adjustment knobs should be set to their
innermost positions.
0 - 7 mm position 5 - 12 mm position
Depending on the actual packing thickness, the
outfeed rollers need to be adjusted. Open the
outfeed cover and position the two levers, one
on each side, to the required position as shown
in the figure. The position also depends on
how compressible the envelope with the inserts
is, and the envelope texture.
3. OPERATION
3.1 Setting up the F610 for different insert sizes

12
Operation
envelope
feed belt
envelope
separator pad
NOTE: It is important for envelope feeding
that the gap between the envelope separator
pads and the envelope feed belts is correct
and equal!
Default setting
Press the envelope feed belt downwards at
the arrow and tighten the envelope separation
adjustment knob until there is no gap between
the separator pad and the feed belt. Then
loosen the adjustment knob one and a half
turns. To facilitate adjustment, use a flash light
and/or a 0.05 mm feeler gauge.
If double feed occurs: Tighten the adjustment
knobs.
If misfeed occurs: Loosen the adjustment
knobs.
B A NOTE: The friction between the envelopes
and the envelope feed belts is also essential
for proper envelope feeding. Therefore the
rear envelope guide (B) must be adjusted
properly.
Envelopes
Place one envelope on the envelope feeder
with its right edge against the envelope
separator pads (A). Loosen the knob on the
rear envelope guide (B) and slide it so that it is
in line with the left edge of the envelope.
Bags
Place one bag on the envelope feeder so its
right edge is against the envelope separator
pads (A). Loosen the knob on the rear envelope
guide (B) and slide it so that the left edge of
the bag reaches the top of the slope.
3.2 Adjusting the envelope feeder

13
Operation
envelope low symbol
Slide the envelope feeder side guides away
from each other. Load the rest of the envelopes,
no higher than the red mark, with the flaps up
and to the left. Slide the envelope feeder side
guides towards each other against the
envelopes without squeezing.
The right side of the envelope stack should be
straight and make sure the envelope low
symbol disappears from the display.
NOTES:
Before loading the envelopes, fan them
properly to make sure they are not glued
together.
Also bend the envelopes perpendicular to
the feed direction, to make sure the
envelopes have proper contact with the
envelope feed belts.
When running, make sure one or two
envelopes fall down to the feed belts and
the rest of the stack should lay onto the
rear envelope guide. Adjust the rear guide
if necessary.
The water bottle is mounted upside down and
fills the wetting system through holes in the
cap.
Press down the water bottle slightly. Remove
the bottle by turning it over and lifting it out. Fill
the bottle with fresh water and tighten the cap.
Put the bottle back in the same position.
Do not pour water directly into the tray.
3.3 Loading envelopes
3.4 Filling water

14
Operation
Switch on the power and enter the Setup
Menu.
Enter the Feed Mode Menu.
Choose “AUTO” to feed your inserts from a
collator and/or a booklet feeder. Follow
instructions in the collator and/or booklet feeder
operator manual to setup the collator and/or
booklet feeder properly. Choose “MANUAL” to
feed your inserts manually. Confirm your choice
by pressing the “OK?” button.
Enter the Machine Mode Menu.
Choose the desired machine mode; “INSERT”,
“NO SEALING” or “BY PASS”.
Confirm your choice by pressing the “OK?”
button
If you wish to clear the counter, choose “CLEAR
COUNTER” and confirm by pressing the “OK?”
button.
Press the “ESC” button to return to the Main
Menu.
3.5 Setup a new job
AUTO
INSERT
SETUP
FEED MODE
MACHINE
MODE
CLEAR
COUNTER
ADDED FEATURES
OK?
ESC
AUTO
MANUAL
OK?
ESC
FEED MODE
MACHINE MODE
CLEAR
COUNTER
ADDED FEATURES
OK?
ESC
SEALING
NO
SEALING
BY PASS
OK?
ESC
FEED MODE
MACHINE
MODE
CLEAR
COUNTER
ADDED FEATURES
OK?
ESC

15
Operation
“AUTO” mode:
If a collator is connected, press the calibration
test button on the collator. One set will be fed to
the document table and the system will stop.
Check that the inserts fed to the document table
are correct.
If a booklet feeder is connected, select Single
cycle. One insert will be fed from the booklet
feeder. Check that the insert was properly fed.
Start the F610 by pressing the start button.
Attached on-line units will start as well. The
system can also be started by pressing start on
any of the other units.
The Run Mode indicates that the Model F610 is
operating.
“MANUAL” mode:
Set the F610 into stand-by mode by pressing
the Start button.
Begin inserting by feeding your inserts manually
to the document table. Make sure that the inserts
block the infeed sensor.
Inserts can be “married together” by choosing
“AUTO” mode combined with hand feeding.
Reduce the speed on the collator (1000 sets per
hour). Feed the document you want to add
before the inserts are fed from the collator.
To stop inserting, press the stop button on the
Model F610.
CAUTION: The insert feed belts will start to
travel about 0.7 seconds after the insert
sensor is blocked.
NOTE: If the insert sensor is not blocked
within 15 seconds in “MANUAL” mode, the
Model F610 will return from run mode to the
Main Menu.
3.6 Start inserting
Insert
sensor
AUTO
INSERT
MANUAL
INSERT
SETUP
SETUP
123456

16
Features
• Enter the Setup Menu.
• Enter the Added Features Menu.
• Enter the Sealing Menu.
Adjust the amount of sealing water by pressing
the corresponding arrow button. The previous
setting is indicated by an arrow. Confirm your
choice by pressing the “OK?” button or cancel
with the “ESC” button to return to the Added
Features Menu.
• Press the “ESC” button to return to the
Setup Menu.
• Press the “ESC” button to return to the Main
Menu.
• Enter the Setup Menu.
• Enter the Added Features Menu.
• Enter the Language Menu.
Select language by scrolling with the arrow
buttons. The chosen language will be shown
with the text inverted. Confirm your choice by
pressing the “OK?” button or cancel with the
“ESC” button to return to the Added Features
Menu.
• Press the “ESC” button to return to the
Setup Menu.
• Press the “ESC” button again to return to
the Main Menu.
4. ADDED FEATURES
4.1 How to adjust the amount of sealing water
4.2 How to select language
DEUTSCH
ENGLISH
FRANCAIS
SVENSKA
OK?
ESC
AMOUNT WATER
–
+
OK?
ESC

17
Features
The Diagnostics is a self test program the operator can run in order to verify the status
of the Model F610 if problems are experienced. The self test program will perform a
test of the EEPROM, sensors, motors and circuits as well as checking of different
voltages.
NOTE: Choosing “DIAGNOSTICS” will immediately start the self test program.
Before performing a Diagnostics it is very important to:
• Remove all envelopes from the envelope feeding table.
• Remove all inserts from the document table.
• Press the reset button from the Main Menu to clear the Model F610 from
envelopes and inserts inside.
• Empty the receiving tray.
CAUTION: Do not attempt to stop the self
test program before it is finished.
To start Diagnostics from the Main Menu:
• Enter the Setup Menu.
• Enter the Added Features Menu.
• Choose “DIAGNOSTICS” and press the
“OK” button.
After choosing “DIAGNOSTICS” the display will
show what type of self test is currently being
performed. During the test you will hear sounds
when components are tested.
Normally the message “NO FAULTS FOUND”
should be displayed. If the self test program
finds any errors, the display will show the faulty
component, its actual status and a fault code. If
there are multiple errors, you can scroll with the
arrow button.
• Press the “ESC” button to return to the
Added Features Menu.
• Press the “ESC” button to return to the
Setup Menu.
• Press “ESC” to return to the Main Menu.
4.3 Diagnostics
NO FAULTS
FOUND
SENSOR S2
ACTUATED
FAULT CODE:7
CANCEL
DIAGNOSTICS
TESTING
EEPROM
MEASUR.
VOLTAGES
READING
INPUTS
TESTING
MOTORS
OK?
ESC
Reset

18
Features
Fault code Error message Explanation
1 EEPROM ERROR The EEPROM is defective.
2 UNR. VOLTAGE LOW
The unregulated voltage supplied to the
Model F610 is too low and/or the
transformer is defective.
3 UNR. VOLTAGE HIGH
The unregulated voltage supplied to the
Model F610 is too high and/or the
transformer is defective.
4 REG. VOLTAGE LOW The regulated voltage is too low.
5 REG. VOLTAGE HIGH The regulated voltage is too high.
6 - 19 SENSOR S# ACTUATED Foreign object is covering the
mentioned sensor.
20 COVER OPEN The envelope feeding table is open.
21 INTERLOCK The interlock switch in the envelope
feeding cover is actuated.
22 SENSOR S17 ACTUATED Water level low.
31 - 49
(odd Nos only)
MOTOR M# OPEN CIRCUIT Interruption in the specified motor
circuit.
32 - 50
(even Nos only)
MOTOR M# SHORT CIRCUIT Short circuit in the specified motor
circuit.
51 - 56 SENSOR S# NOT
RESPONDING
Interruption in the specified sensor
circuit.
57 INTERLOCK RELAY Interlock relay defective.
4.3 Diagnostics (continued)

19
Maintenance
The water tray should be cleaned at least every
other week.
• Remove the water bottle.
• Pull out and remove the receiving tray.
• Open and remove the outfeed cover.
• Pull out the hose, open the tap and empty
the water tray.
• Close the tap and put the hose back in
position.
• Unlock the water tray by pushing it to the
left and fold it downwards.
• Clean the water tray.
• Hold the guide plate in the correct position
(see picture on next page) while folding the
water tray upwards until it snaps into locked
position.
Caution: Check that the guide plate behind
the water tray is in the correct position.
Incorrect position causes sealing jam.
5. MAINTENANCE
5.1 Cleaning the water tray
open
closed