Plockmatic 45 User manual

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Mailer/inserter Model 45
Operator Manual
Mar 2000
Part No. 45866

T10113 Mar2000
Mailer/inserter Model 45 Operator Manual i
Table of contents
1. Introduction page
1.1 Operational safety 1-1
2. Getting to know the Model 45
2.1 Main components 2-1
2.2 The menus, flow chart 2-4
2.3 Explanation of the menus 2-5
3. Operator instructions
3.1 Setting up the Model 45 for different insert sizes 3-1
3.2Adjusting theenvelope feeder 3-3
3.3Loading envelopes 3-4
3.4 Filling water 3-4
3.5 Setup a new job 3-5
3.6 Start inserting 3-6
4. Added features
4.1 How to adjust the amount of sealing water 4-1
4.2 How to select language 4-1
4.3 Diagnosis 4-2
5. Maintenance
5.1 Cleaning the water tray 5-1
5.2 Cleaning the envelope sealing flap 5-2
5.3 Cleaning the envelope feed belts 5-3
5.4 GFI function test and resetting 5-3
6. Problem solving
6.1 Problem solving 6-1
7. Specifications
7.1 Specifications 7-1
7.2 Insert and envelope specifications 7-2

T10113 Mar2000
Mailer/inserter Model 45 Operator Manual 1-1
1. Introduction
The Model 45 is a mailer/inserter that can be
used on-line with the collators Model 306/310
and/or booklet feeder Model 46 or for hand-
feeding. This operator manual covers the
operation of the Model 45 both as a stand-
alone unit or connected to the above men-
tioned collators. For on-line operation with
Model 46, also see Model 46 operator manual.
1.1 Operational safety
Always connect the equipment to a properly
groundedpower sourcereceptacle.In doubt,
have the receptacle checked by a qualified
electrician.
WARNING: Improperconnectionof the equip-
mentgrounding conductorcan resultin electri-
calshock.
Always follow all warnings marked on, or
suppliedwith, the equipment.
Always locate the equipment on a solid sup-
port surface with adequate strength for the
weightof themachine.
Always exercise care in moving or relocating
theequipment.
Always keep magnets and all devices with
strongmagnetic fieldawayfrom themachine.
Never use a ground adapter plug to connect
the equipment to a power source receptacle
thatlacks aground connection terminal.
Never attempt any maintenance function that
isnot specificallydescribed inthis documenta-
tion.
Never remove the covers or guards that are
fastenedwith screws.
Never install the unit near a radiator or any
other heat source.
Never override or “cheat” electrical or me-
chanical interlock devices.
Never operate the equipment if you notice
unusual noises or odours. Disconnect the
power cord from the power source receptacle
and call your customer service engineer to
correctthe problem.
Attention to the following notes ensures the continued safe operation of your equipment.

T10113 Mar2000
Mailer/inserter Model 45 Operator Manual 2-1
2. Getting to know the Model 45
The Model 45 is easy to use thanks to a fully micro-
processor 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 compo-
nents of the Model 45.
2.1 Main components
1
2
1 Outfeed area
2 Outfeed cover
3 Receiving tray
4 Water bottle
3
4
rearside
frontside
rightside
leftside

T10113 Mar2000
Mailer/inserter Model 45 Operator Manual 2-2
2.1 Main components, continues
2
3
5
1
4
1 Envelopefeeding cover
2 Plastic cover
3 Document table side guides
4 Document table
5 Insert feed belts
6 Oversize envelope (B4) adjustment knobs
7 Groundfault interrupter(GFI)
8 Main power switch, power cord receptacle
and main fuse
6
7
8

T10113 Mar2000
Mailer/inserter Model 45 Operator Manual 2-3
2.1 Main components, continues
1 Studs
2 Connection cable jacks
3 Envelope side guides
4 Enveloperear guide
5 Envelope feed belts
6 Envelopefeeding table
1
2
37
8
11
4
6
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
510
9
12
13

T10113 Mar2000
Mailer/inserter Model 45 Operator Manual 2-4
2.2 The menus, flow chart
DiagnosisMenu
Feed Mode Menu
Setup Menu
ClearCounterMenu
Main Menu
Machine Mode Menu AddedFeatures Menu
Language MenuWater Amount Adjustment Menu
Run Mode

T10113 Mar2000
The Main Menu appears after switching on the power.
This is also 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.
In the Setup Menu you can scroll up and down with the
buttons below the arrow symbols. The chosen sub-
menu 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
Mailer/inserter Model 45 Operator Manual 2-5
Start Reset
The Run Mode indicates that the Model 45 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 45 will
automatically return to the Main Menu.
Stop

T10113 Mar2000
Mailer/inserter Model 45 Operator Manual 2-6
2.3 Explanation of the menus, continues
In the Machine Mode Menu you can choose between
inserting with sealing, inserting and no sealing or just to
let the Model 45 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.
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.

T10113 Mar2000
Mailer/inserter Model 45 Operator Manual 2-7
2.3 Explanation of the menus, continues
In the Added Features Menu you can access the
Water Amount Adjustment Menu, the Language
Menu or start the self test program, Diagnosis. The
chosen item will be shown with the text inverted. Con-
firm your choice by pressing the “OK?” button or cancel
with the “ESC” button to return to the Setup Menu.
NOTE: Choosing “DIAGNOSIS” will immediately start
the built in self test program. Before performing
a diagnosis it is very important to read “4.3
Diagnosis” in the section “4 Added Features”.
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.
In the Water Amount Adjustment Menu you can
adjust the amount of sealing water in the wetting sys-
tem 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.

T10113 Mar2000
2.3 Explanation of the menus, continues
After choosing “DIAGNOSIS” the display will show what
type of self test that is currently performed. During the
test you will hear sounds when components are tested.
NOTE: Before performing a diagnosis it is very impor-
tant to read “4.3 Diagnosis” in the section “4
Added Features”.
Mailer/inserter Model 45 Operator Manual 2-8
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 would find any errors the dis-
play will show the faulty component, its actual status
and a fault code. In case of 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.

T10113 Mar2000
Mailer/inserter Model 45 Operator Manual 3-1
3. Operator instructions
3.1 Setting up the Model 45 for different insert sizes
The holes in the docking plate allows you to move the
Model 45 to the front or to the rear depending on the
size of the inserts.
Adjust the document table side guides by sliding them
towards or from each other by gripping the side guides
by the green dots. Adjust them to the scale mark corre-
sponding the insert size. Normal setting is a 2-3 mm
play between the inserts and the side guides. If meas-
urement “C” (see section 7.2) is large, a larger play has
to be accepted, otherwise the envelopes will not be
opened for insertion.
CAUTION • Beforeadjustingtheside guidespress
the reset button from the Main Menu to
avoid damages on the inserting tools.
Move the Model 45 to the front for portrait A4 size
inserts and to the rear for landscape A4 or portrait A5
size inserts.
A5Landscape
A4Portrait A4Landscape

T10113 Mar2000
Mailer/inserter Model 45 Operator Manual 3-2
3.1 Setting up the Model 45 for different insert sizes, contin-
ues
oversizeenvelopeadjustment knobs
shownintheir outermost position
When B4 envelopes (extra wide) is used to
accomodate a large packing thickness, the oversize
envelope adjustment knobs should be set to their
outermost positions to aviod damages to the enve-
lopes. Loosen the knobs to adjust.
CAUTION • Only perform the adjustment when the
document table side guides are in their
outermostposition.
NOTE • If B4 envelopes (extra wide) not is used,
theoversize envelope adjustmentknobs
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 re-
quired position as shown in the figure.

T10113 Mar2000
3.2 Adjusting the envelope feeder
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 so the right
edge stops 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 enve-
lope.
Bags
Place one bag on the envelope feeder so the right edge
stops 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.
NOTE: It is important for the envelope feeding that the
gap between the envelope separator pads and the
envelope feed belts is correct and equal!
A
B
envelope
feed belt envelope separatorpad
Default setting:
Press the envelope feed belt downwards at the arrow
and thighten 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 turn. To facilitate adjustment, use a flash light and/
or a 0.05 mm feeler gauge.
If double feed occurs: Thighten the adjustment knobs.
If miss feed occurs: Loosen the adjustment knobs.
Mailer/inserter Model 45 Operator Manual 3-3

T10113 Mar2000
Mailer/inserter Model 45 Operator Manual 3-4
3.3 Loading envelopes
The water bottle is mounted upside down and fills water
into 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.
Slide the envelope feeder side guides away from each
other. Load the rest of the envelopes, not higher than up
to the red mark, with the flap 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.
NOTE: •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
envelopefeed belts.
•When running, make sure one or two
envelopes falls down to the feed belts and
the rest of the stack should lay onto the
rear envelope guide. Adjust the rear guide
ifnecessary.
3.4 Filling water
envelopelow symbol

T10113 Mar2000
3.5 Setup a new job
Switch on the power and enter the Setup Menu.
Enter the Feed Mode Menu.
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.
Enter the Machine Mode Menu.
Choose the desired machine mode; “INSERT”, “NO
SEALING”or “BYPASS”.
Confirm your choice by pressing the “OK?” button
Choose “AUTO” to feed your inserts from a collator or a
booklet feeder. Follow instructions in the collator and/or
booklet feeder operator manual to setup the collator
and/orbooklet feederproperly.Choose “MANUAL”to
feed your inserts manually. Confirm your choice by
pressing the “OK?” button.
Mailer/inserter Model 45 Operator Manual 3-5

T10113 Mar2000
Mailer/inserter Model 45 Operator Manual 3-6
Start the Model 45 by pressing the start button.
3.6 Start inserting
“AUTO” mode: 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
and put them back. Make sure that
the inserts blocks the infeed sensor.
Press the start button on the Model
45 and then the start button on the
collator.
“MANUAL”mode: Begin inserting by feeding your
inserts manually to the document
table. Make sure that the inserts
blocks 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 docu-
ment you want to add before the inserts are fed from
the collator.
To stop inserting press the stop button on the Model 45.
CAUTION: The insert feed belts will start to travel in
about0.7 secondsafter theinsert sensor is
blocked.
NOTE: If the insert sensor is not blocked within 15
seconds in “MANUAL” mode the Model 45
will return from run mode to the Main Menu.
Insert
sensor
The Run Mode indicates that the Model 45 is ready for
use. Depending of the chosen machine mode continue
as follows:

T10113 Mar2000
4. Added features
4.1 How to adjust the amount of sealing water
Mailer/inserter Model 45 Operator Manual 4-1
4.2 How to select language
•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 in-
verted. Confirm your choice by pressing the “OK?”
button or cancel with the “CANCEL” button to return to
the Added Features Menu.
•Press the “CANCEL” 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 Water Amount Adjustment 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 “CANCEL” button to
return to the Added Features Menu.
•Press the “CANCEL” button to return to the Setup
Menu.
•Press the “ESC” button to return to the Main Menu.

T10113 Mar2000
4.3 Diagnosis
Mailer/inserter Model 45 Operator Manual 4-2
The diagnosis is a self test program the operator can
run in order to verify the status of the Model 45 if some
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 “DIAGNOSIS” will immediately start
the self test program. Before performing a
diagnosis 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 45 from envelopes and in
sertsinside.
•Empty the receiving tray
CAUTION: Do not attempt to stop the self test program
before it is finished.
To start the self test program from the Main Menu:
•Enter the Setup Menu.
•Enter the Added Features Menu.
•Choose “DIAGNOSIS” and press the “OK” button.
After choosing “DIAGNOSIS” the display will show what
type of self test that is currently 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 would find any
errors the display will show the faulty component, its
actual status and a fault code. In case of multiple errors
you can scroll with the arrow button.
•Press the “CANCEL” button to return to the Added
Features Menu.
•Press the “CANCEL” button to return to the Setup
Menu.
•Press the “ESC” button to return to the Main Menu.
Reset