Plockmatic FeederPro 1000 User manual
April 2005
Part no. 18364
Air Feed Collator and Feeder Model 1000
and
High Capacity Stacker Model 1010
Operator Manual
FeederPro Model 1000/1010 Operator Manual 3
T10160
Table of contents
1. Introduction 5
1.1 Operational safety 5
2. Getting to know the Model 1000 and 1010 6
2.1 Main Components Model 1000 6
2.2 Main Components Model 1010 8
3. Operator instructions 9
3.1 Adjusting the LCD display contrast 9
3.2 Clear memory 9
3.3 Using the Menus 9
3.4 One, two or three towers 10
3.5 Loading sheets 10
3.6.1 Paper size adjustment 10
3.6 Setting up the Model 1000 11
3.6.3 Bin height adjustment 11
3.6.2 Paper weight adjustment 11
3.6.4 Air flow adjustment 12
3.7 Integral stacker 12
3.8 Docking the Lift 13
3.9 Using the fan 13
3.10 Running a job using Model 1000 as a Collator 14
3.11 Running a job using Model 1000 as a Feeder 16
3.12 Storing a job 18
3.13 Retrieving a job 18
3.14 Clearing a job 19
4. The Menus 20
4.1 Collator Mode / Feeder Mode 20
4.2 Programs 20
4.2.1 Insert Sheet Mode 21
4.2.2 Alternate Bin Mode 21
4.2.3 Alternate Cover Mode 21
4.2.5 Manual Bin Selection Mode 22
4.2.4 Block Mode 22
4.3 Statistics 23
4.4 Stored Jobs 23
4.5 Preset Counter 23
4.6 Added Features 24
4.7 Calibrate Mode 24
4.7.3 Learn Feed Sequence (Feeder mode only) 24
4.7.1 Feeder Function (Feeder mode only) 25
4.7.2 Current Sequence (Feeder mode only) 25
4.7.4 Finishing (Collator and Feeder mode) 26
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4.7.6 After calibration 27
4.7.5 Setup Paper Size (Collator and Feeder mode) 27
4.8 Error screens 28
4.8.2 Integral Stacker 28
4.8.1 Collator/Feeder 29
4.8.3 External Stacker 29
4.8.4 Booklet Maker 29
5. Troubleshooting 30
5.1 Troubleshooting 30
6. Technical Specification 31
6.1 Technical Specification 31
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Always connecttheequipmenttoaproperly
groundedpowersourcereceptacle.In doubt,
havethe receptacle checked by a qualified
electrician.
WARNING: Improperconnectionof the
equipmentgroundingconductorcan resultin
electricalshock.
Always followall warnings marked on,or
suppliedwith, theequipment.
Always locatetheequipment on a solid
supportsurface withadequate strength for
theweight ofthe machine.
Always exercisecareinmovingorrelocat-
ingthe equipment.
Always keepmagnetsandalldeviceswith
strongmagnetic fields away fromthema-
chine.
Never usea ground adapter plug to connect
theequipment to a power source receptacle
thatlacks aground connectionterminal.
Neverattemptany maintenancefunction that
isnotspecifically described in this documen-
tation.
Never removethe covers or guards that are
fastenedwith screws.
Never installthe unit near a radiator orany
otherheat source.
Never overrideor “cheat” electrical or me-
chanicalinterlock devices.
Never operatethe equipment if you notice
unusualnoises orodors.Disconnect the
powercord from the power source recepta-
cleand call yourcustomerservice engineer
tocorrect the problem.
Attentionto thefollowingnotes ensuresthecontinued safeoperationof yourequipment.
1. Introduction
NOTE: Machine must be connected to 230 VAC 10Amps or 100/115 VAC 20Amps dedicated circuit
breaker for one outlet.
1.1 Operational safety
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2. Getting to know the Model 1000 and 1010
1 Conveyordoor
2 Controlpanel (notpresent on
secondor third tower)
3 Outfeedarea
4 Base(optional)
5 Dockinglatch
6 Heightadjustment
2.1 Main Components Model 1000
1
2
3
4
5
6
7
8
10
9
7 LCD display
8 Multifunctionbuttons
9 Setup guide button
10 Start/stopbutton
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2.1 Main Components Model 1000, cont.
1 Paperweight adjustmentlever
2 Paperweight adjustment scale
3 Papersize adjustment scale
4 Papersize adjustmentlever
5 Binheight switch scale
6 Binheight switchlever
7 Paperdeflector
8 Suctionbelt
9 Airseparation adjustment scale
10 Air separationadjustmentknob
11 Paper stop guide
12 Bin
13 Main Power Switch
14 Integralstackerlengthadjustment
1
15 Integral stackerwidth adjustment
16 Secondary unitconnector
(i.e.secondary unittower)
NOTE: If no secondary unit is used, terminator
plug part No. 141026 (female) has to be
connected.
17 Third partydeviceconnector
(i.e.stacker,stapler/folder)
18 Power cord receptacle
19 Fuse, 3.15A
16
17
18
19
5
6
7
8
2
3
4
11
10
9
12
14
13
15
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2.2 Main Components Model 1010
1 Collatorconnector
2 Thirdparty deviceconnector
(i.e.stapler/folder)
NOTE: If no third party device unit is used,
terminator plug part No. 141096 (male)
has to be connected.
3 Power cord receptacle
4 Fuse
5 Dockinglatch
6 Bypasspaperpath
7 Bar
8 Mainpower switch
14
16
9
810 11
13
6
132 4
9 Idlerrollerbar
10 Openinghandle
11 Topcover
12 Paper guide(man.adjust.)
13 Lift, documenttableincluding
14 Heightadjustment
15 Maximum loadsign
16 Docking instruction sign
17 BatteryIndicator
18 Lowering Liftbutton
19 Elevating Liftbutton
7
12
17
15
18
5
19
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3. Operator instructions
Mostsettings andadjustmentsare operatedfromthe controlpanelusing themultifunction
buttons.The actual functionineach menu willbe indicated by anicon above thecorrespond-
ingbutton.
Switchon the powerwiththe main powerswitch.The Main
Menuwill appearinthe screen. Increase/decreasethe
contrastof the LCD display bypressingthe buttons below
thecontrastadjustmentbuttons.
3.1 Adjusting the LCD display contrast
Contrast adjustment buttons
3.3 Using the Menus
Toselect an itemona menu, usethe”Up/Down” arrow
buttons.
Toalter asetting,use the”Right/Left”arrowbuttons.
Somemenu itemshavesubmenus. In thosecases press the
”OK”buttontoreach thecorresponding submenu.Then use
the”Up/Down” arrowbuttonsto reach thedifferent items in
thatsubmenuandthe”Right/Left”arrow buttonsto alterthe
settings.
Right/Left Up/Down
arrowbuttons arrow buttons
3.2 Clear memory
Toclear memory press the“CM”button.Thiswill erase a
programmedjob.
Clearmemory
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3.6.1 Paper size adjustment
Dependingon paper size, the suction belt assemblyneeds
tobe adjusted to achieve proper feeding of the sheets. The
scaleshows different number of dotsfordifferent paper
sizes.The number ofdotscorresponds to thenumberof
visibleholes in thepapersizeadjustment lever. Followthis
suggestionand pullorpush thepapersize adjustmentlever
untilthe correctnumberof holes arevisible on thelever.
Adjustmentsdue to paper sizecanbedone individually for
eachbin.
NOTE: It is important to adjust the paper size adjustment lever
properly in order not to loose feeding power.
Papersizeadjustment lever
3.6 Setting up the Model 1000
Belowyou will findinstructionshow to set uptheModel 1000, and inwhatorder the different
settingsand adjustments shouldbeapplied.These instructions areguidelines how to
achieveoptimum performance.Finaladjustments and finetuningmay stillhaveto be done
sincefactors like paperquality,print quality,airhumidityetc. affectsperformance.
3.4 One, two or three towers
Severalmenus show that there areapossibility to use two
orthree towers. Until additionaltowersare installed in the
system,these options will be displayedingrey to show that
theyare not accessible.
3.5 Loading sheets
Beforeloading the bins, make sure thatthesheets are well
fanned,aligned and that the inkhasdried out. Load the
sheetsinto the bins sothatall the sheets are incontactwith
themainframeatthe left side and at the rear side. Place the
paperstop guides as shown in the figure.
sheets bin paper stop guides
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3.6.2 Paper weight adjustment
Paperweight adjustmentlever
Dependingon paper weight, thesuctionbelt assembly
needsto be adjusted mechanically to achieve propersepa-
rationof the sheets.The scale showsdifferentnumber of
dotsfor different paper weights. Thenumberof dots corre-
spondsto the number of visible holes in the paper weight
adjustmentlever.Followthissuggestionand pullor pushthe
paperweight adjustmentlever untilthecorrect numberof
holesare visible on thelever.Adjustmentsduetopaper
weightcan be done individuallyforeach bin.
Correction of separation errors:
Ifseparation problemsoccure whenrunningsheets witha
higherpaper weight,changethe paper weightadjustment
leverfrom 2 dots (holes)to4 dots (holes). Ifproblemsthe
persist,set the paperweightadjustment lever 3 dots(holes).
NOTE: Also see item 3.6.3 and 3.6.4
3.6.3 Bin height adjustment
Binheightadjustment lever
Dependingon paper weight, the height of the bin needs to
be adjusted in order to achieve a proper separation of the
sheets.Adjustthebin heightadjustmentlever tosuggested
positionon the scale to match the corresponding paper
weight.
Itis possible to adjust binheightindividually for each bin.
Correcting separation errors
Ifseparation problems are experienced,alterbinheight by
raisingor lowering thebinheight adjustment lever fromit’s
original position
NOTE: Also see item 3.6.2 and 3.6.4
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3.7 Integral stacker
Whenthe integral stacker is to be used, slidetheadjustable
guidesto the correct sheet size.
Adjustableguides
3.6.4 Air flow adjustment
Whenthe machine is running, airisblownat the lead edge
ofthepaper stack loaded in the bin. When the air flow is
properlyadjusted, appr. the topten(10) sheetsshould be
liftedfrom the stack at the leadedge.The correct amount of
airflow mustbe fine adjustedwhen themachineis running.It
ispossible to adjust the air flow individually foreachbin.
Recommendedsettings:
Paperweight Air flow adjustmentknobsetting
Less than 90 gsm 9 o´clock
(24 lb Bond)
Morethan 90gsm 12 o´clock
(24 lb Bond)
Correcting separation errors
Checkthat the loaded sheetsarenot curled downwards at
thelead edge.Straighten thematerialwhen necessary.
Adjustthe air flow to obtainthat appr. the top ten (10) sheets
arelifted from the stack at the leadedgewhenthe machine
isrunning. If air flow should be increased or decreased is
dependingon paper weight and paperquality.
NOTE: Also see item 3.6.3.
Air flow adjustment knob
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3.8 Docking the Lift
Whenpushing the lift into the Model 1010 HCS, itisnot
necessaryto openthetop cover.Theliftwillautomatically
lockto the Model 1010 HCS whilepushedin. However,
makesure that the lift is not in the upper most position to
avoid damaging the paper guide in the top cover.Also be
carefulwhile pushing the lift intoavoiddamaging the
electrical connectorlocated on the rightlegof the lift.Topull
outthe lift, first lift the top coveronthe Model 1010 HCS.
Note: When not using the
Model 1010 HCS for a
longer time, leave the Lift
docked to the Model 1010
HCS. Do not disconnect the
power cord, otherwise the
com-pensationcharge does
not work.
3.9 Using the fan
Normallythe fanshould be switchedoff. Switch onthe fanto
facilitatestackingof static sheets. Lift the top cover to
accesstheswitch located on the right side (1) of the Model
1010HCS. The fanonlyoperates when thesystemis
running.
1
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3.10 Running a job using Model 1000 as a Collator
IntheMainMenu, select”Mode” usingthe ”Up/Down”
buttonsand pressthe”OK” button. Select”Collator” and
pressthe ”OK”button.
Selecttype offinishing using the”Up/Down” arrow buttons.
Pressthe ”OK”button.
Selectpapersize. To use any of thepredefined papersizes
select”Format” byusing the”Up/Down”arrow buttons.
Selectformatusingthe ”Left/Right”buttons.
Tousecustom papersizes, select ”Length”and/or”Width”
usingthe ”Up/Down”arrowbuttons and increase/decrease
measurementusingthe ”Left/Right”buttons.
Toalter orientation,select”Orientation”usingthe ”Up/Down”
arrowbuttons andchange orientationusingthe ”Left/Right”
buttons.Press the”OK”button to startcalibration.
Thescreen ”CALIBRATINGJOB”will beshownduring
calibration.At the endofthe calibration, the message:
”Calibrationcompleted. Please check set.” will beshown.
Removethe calibration set and check that it is OK.
Ifyou wanttouse any ofthe programs, select”Programs”
usingthe ”Up/Down”buttons and pressthe ”OK” button.For
detailedprogramming description, see chapter 4.
Whetheryou decided touseany program ornot, continue by
pressingthe yellowSetup guide button.
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3.10 Running a job using Model 1000 as a Collator, cont
Ifyou are satisfiedwithyour programmed settings, pressthe
greenStart/Stop button tostartthejob.
Thisscreen willbeshown whilethejob isrunning.
Aftera successfully completedcalibration, the screen
”CURRENTJOB” willbeshown. From thisscreen you can
alsochoose to clear the counterbypressing the ”CLR”
button,to save thejobby pressing the”MEM”button or to
changesettings made by pressingthe”ADJ” button.
Safe mode is that only one set is processed. Next set does
notstart until the firstsetis finished. Unsafe modeisthat the
machinewill feed next set assoonas possible. It means that
more than one set can be processed at the same time.
Safe/Unsafe
mode
Note: In Unsafe mode the machine can never run faster than the
slowestmachine connected.
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3.11 Running a job using Model 1000 as a Feeder
Selecthow youwantto program theFeederfunction using
the”Up/Down” arrowbuttons andpressthe”OK”button.
Fordetailed description how to program the feederfunction,
seechapter4.
Selectpapersize. To use any of thepredefined papersizes
select”Format” byusing the”Up/Down”arrow buttons.
Selectpaper sizeusingthe ”Left/Right” buttons.
Touse custom papersizes,select ”Length” and/or”Width”
usingthe ”Up/Down”arrowbuttons and increase/decrease
measurementusingthe ”Left/Right”buttons.
Toalter orientation,select”Orientation”usingthe ”Up/Down”
arrowbuttons andchange orientationusingthe ”Left/Right”
buttons.Pressthe”OK”button.
Selecttype offinishingusing the”Up/Down” arrow buttons.
Pressthe ”OK”button.
IntheMainMenu, select”Mode” usingthe ”Up/Down”
buttonsand press the”OK”button. Select ”Feeder”and
pressthe ”OK”button.
NOTE: “Programs” are not available in ”Feeder Mode”.
Pressthe yellowSetupguide button.
Thescreen ”CALIBRATINGJOB”will beshownduring
calibration.At the endofthe calibration, the message:
”Calibrationcompleted. Please check set.” will beshown.
Removethe calibration set and check that it is OK.
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Aftera successfully completedcalibration, the screen
”CURRENTJOB” willbeshown. From thisscreen you can
alsochoose to clear the counterbypressing the ”CLR”
button,to save thejobby pressing the”MEM”button or to
changesettings made by pressingthe”ADJ” button.
3.11 Running a job using Model 1000 as a Feeder, cont.
Ifyou are satisfiedwithyour programmed settings, pressthe
greenStart/Stop button tostartthejob.
Thisscreen willbeshown whilethejob isrunning.
Whenstopping a jobpressthe ”softstop” button.This
functionwill feed the completepresetsequence before
stopping.Next time the greenStart/Stop buttonispressed,
themachine startsfeedingnext preset sequence.
Ifstopping a job withgreenStart/Stopbutton, the job stops
immediately.PressgreenStart/Stop button and the
sequencecontinous where itwasstopped.
NOTE: If a jam occurs, when pressing green Start/Stop button it
always starts with the first sheet in the sequence. Therefore it is
important to reload/unload bins in use to correct sequence limit.
Soft stop
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3.12 Storing a job
Jobscan be stored after a succesful calibration.To store the
job,press the”MEM” button.
Selecta storage position withthe”Up/Down” arrow buttons
andpress the ”OK” button.Ifthe selected storage position
alreadyis occupied, previously stored job will be deleted.
3.13 Retrieving a job
To retrieve astoredjob,select”Stored Jobs” from the Main
Menuandpressthe ”OK”button.
Selectthe storedjobyou want toretrievewith the”Up/Down”
arrowbuttons andpressthe ”OK” button.To see information
abouta certain job, pressthe”?” button.
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3.14 Clearing a job
To clear a stored job,select”Stored Jobs” from the Main
Menuandpressthe ”OK”button.
Selectthe stored jobyouwant toclearwith the ”Up/Down”
arrowbuttons and press the”CLR”button. Press the ”ESC”
buttonto go back orthe”OK” button to confirm.
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