1.1 Overview of machine................................................................. 3

2.1 Safety Notes............................................................................ 3

2.2 Safety Symbols....................................................................... 4

2.3 Ratings and Specifications......................................................... 5

2.4 End of Life.............................................................................. 6

3 Description of machine......................................................................... 7

3.1 Description of operation............................................................. 7

3.2 Identification of parts................................................................ 8

4 Control Panel...................................................................................... 10

4.1 The Job Screen........................................................................10

4.2 The Run Screen.......................................................................11

4.2.1 The Run Screen displayed..............................................11

4.2.2 Testing the mailset........................................................12

4.2.3 Present at exit..............................................................13

4.2.5 Envelope Stop Position...................................................15

4.2.8 To adjust Envelope Inserter settings................................18

4.2.9 To adjust Document Unit settings....................................20

4.3 The Menu Screen.....................................................................21

5 Running an existing job...................................................................... 22

6 Switching the user.............................................................................. 23

6.1 How to switch the user............................................................23

6.2 User Access Rights..................................................................24

7 Creating a job..................................................................................... 25

7.1 Creating the Job Settings..........................................................25

7.1.1 Defining the mailset.....................................................26

7.1.2 Defining the document placement settings.......................30

7.1.3 Defining the fold..........................................................31

7.1.4 Defining the output settings..........................................34

7.1.5 Defining the output placement settings...........................36

7.1.6 Saving the job.............................................................37

7.2 Creating an envelope...............................................................38

7.3 Creating a document................................................................40

7.4 Creating an enclosure..............................................................42

9 Setting up the machine....................................................................... 43

9.1 Loading the envelope hopper.....................................................43

9.2 Loading the versatile feeder hopper...........................................44

9.3 Loading the flex folder hoppers..................................................46

9.4 Paper Control Lever.................................................................51

9.5 Daily Mail (Versatile Feeder)......................................................52

9.5.2 Using Daily Mail............................................................52

9.5.3 Setting the Separator Gap..............................................53

9.6 Daily Mail (Flex Folder).............................................................54

9.6.2 Using Daily Mail............................................................54

9.7 Adjusting the catch tray...........................................................56

10 Operator Maintenance...................................................................... 57

10.1 Cleaning the sensors..............................................................57

10.2 Clearing paper jams...............................................................63

10.3 Changing the feed tyres..........................................................65

10.4 Adjusting the CIS reader.........................................................66

10.5 Maintaining the wetter system.................................................67

11 Technical Specification..................................................................... 68

11.4 Mechanical & Electrical...........................................................76

12 Glossary of Terms............................................................................. 79

1.1 Overview of machine

The 7500/7202 Series are advanced, medium-volume folding and inserting machines. Its modular construction allows up to 8 feed units to be fitted, with a maximum of 11 feed trays. The software control optimises the order and flow of documents for collating at the insert head before insertion into the envelope. All fold and adjustments take tplace automatically according to the requirements programmed in by the operator.

In order to ensure the correct and safe usage of this machine and its components, you must read and adhere to the operating instructions and safety notes. Always be aware of all warnings and notes that are mounted or noted on the machine itself.

The 7500/7202 Series must only be serviced by a Certified Engineer. All cleaning and servicing maintenance the equipment to be isolated from the power source and disconnected. The 7500/7202 Series is very heavy and manual lifting should not be attempted.

Should a fault occur with the 7500/7202 Series, immediately isolate and disconnect the incoming power. When the machine is being transported it should be sat firmly on its feet. The machine should be strapped upright to a flat pallet during transport. If moving the machine, push on the furniture - not the machine itself. Ensure the furniture brakes are on when stationary. When the machine is not in use, it should be disconnected from the electrical supply.

Ensure the equipment is installed, operated and maintained by trained and authorised personnel. Keep hands and loose clothing away from the machine when in operation. Always ensure the machine is level when in use. The machine should be used as provided and should not be tampered with or altered, as the machine contains inbuilt safety systems which could be compromised by any interference. If any external cover is damaged, it must be replaced by a Certified Engineer. Ensure safe storage/positioning of electrical cabling when not in use. Should the electrical cable become damaged do not operate the 7500/7202 Series.

In the event of an emergency, open any cover.

The following safety symbols may be used upon the product and throughout the product documentation:

MEANING / DESCRIPTION

SYMBOL

P rotective E arth (G round )

To identify any terminal which is intended for connection to an external conductor for protection against electric shock in case of a fault, or the terminal of a protective earth (ground) electrode.

D angerous V oltage

To indicate hazards arising from dangerous voltages.

W arning /C aution

An appropriate safety instruction should be followed or caution to a potential hazard exists.

R efer T o M anual

Refer to the relevant instructions detailed within the product manual

H ot S urface

To indicate that the marked item can be hot and should not be touched without taking care.

This product is heavy and reference should be made to the safety instructions for provisions of lifting and moving.

2.3 Ratings and Specifications

Model No. Regions

US, Canada & ROW

E lectrical specifications .

The 7500/7202 Series is configured for the appropriate electrical supply and supplied with a fixed cordset as detailed below.

115/230 VAC

Modular machine: see Technical Specifications for current/power ratings

Input Supply requirements

115/230V, 50/60 Hz 13 Amps (max.)

This machine is supplied with an IEC mains cable terminated with a UK, Euro or US plug, according to country of destination.

or continued protection against risk of fire, replace with same type and F rating of fuse. The fuse rating/type for this machine is : T 6.3 Amps (Part No. 135-106) - 230V Machines Input Protection T 10 Amps (Part No. 135-110UL) - 115V Machines

THIS MACHINE MUST BE GROUNDED/EARTHED.

Operating Temperature: Humidity:

18°C to 28°C (64°F to 82°F)

30 - 80% RH

75db(A) (3 x Versatile Feeders, 1 x Flex Folder, measured at 1.6m height, 1m from nearest cover)

Noise:

Dimensions:

Modular machine: see Technical Specifications for dimensions

Weight (Approx):

400 kg (880 lbs) - based on a configuration of Insert Head, 3 x Feeders, Cut Sheet Collator with Diverter & Conveyor

Caution:

I n order to ensure correct safety and operation, this machine must only be installed and maintained by an authorized Service Engineer.

Caution:

hould any cover or safety interlock be damaged, the machine must not S be used until service repairs have been completed.

Caution:

This machine is not intended to be used in a domestic environment.

2.4 End of Life

The objectives of the European Community’s environment policy are to preserve, protect and improve the quality of the environment, protect human health and utilise natural resources prudently and rationally. That policy is based on the precautionary principle and principles that preventive action should be taken, that environmental damage should as a priority be rectified at source.

Separate collection of waste is the precondition to ensure reuse and recycling of waste that is generated at the disposal of electrical or electronic equipment and is necessary to achieve the chosen level of protection of human health and the environment in the EC.

In order to facilitate collection and treatment separated from normal domestic waste, electrical and electronic equipment is marked with the following logo:

Do not mix with normal domestic waste. Please use the subjoined return or collection system dedicated to electrical and electronic waste.

Equipment produced after August 13 2005

Not only are you by law not allowed to dispose of the waste equipment via other wastestreams, but we encourage you to actively contribute to the success of such collection and to the common good and better quality of life of present and future generations.

For more information on the correct disposal of this product please contact your local dealer.

3 Description of machine

3.1 Description of operation

The function of the machine is to fold forms to ‘C’, ‘Z’, ‘V’ or double forward fold, either singly, in fixed multiples or in varying groups. Enclosures such as inserts, BR envelopes etc. may be added. Folded forms and enclosures are collated in the collation area in the inserter head before insertion into the envelope. Forms may be inserted without sealing the envelope for subsequent checking or hand insertion.

There is a batch processing facility, allowing a preset number of cycles to be completed before the machine automatically stops.

The machine is equipped with PC controlled operating software from where jobs can be programmed and run. The number of jobs that can be programmed is limited only by the capacity of the PC. Input is via touchscreen monitor or keyboard/mouse.

The machine is Barcode/2D/OMR compatible for use with a mark-reading feeder or tower folder, allowing a group of forms to be collated on the track prior to folding. A number of barcode symbologies may be read.

The machine consists of a number of modules, depending upon the build ordered these modules are briefly described below:

Inserter head - Collates all documents in a pocket before insertion, feeds the envelope, inserts the pack and seals the flap.

Versatile Feeder - Feeds shortform inserts (cards, BR envelopes, booklets etc.) onto the track for subsequent insertion. Available with single feed hopper only. An OMR/Barcode version is also available (top read only).

Flex Folder - Mounts at the end of the machine. Folds documents either separately or in groups, using an accumulator if required. Fitted with either one or two feed pods, each consisting of either 2 x 500 sheet trays or 1 x 1000 sheet tray. Uses a 3-plate folding mechanism. An OMR/Barcode version is also available (top or bottom read).

A daily mail function can be used as an optional feature on a flex folder or versatile feeder. This allows groups of documents, stapled or loose, to be hand-fed; they will then be folded and inserted into an envelope (flex folder only). If other hoppers are loaded, further forms can be collated.

No manual setting of the fold plates or envelope closer is required, these being adjusted automatically according to the settings in the selected program, except for fold plate 2 which is manually adjusted.

An optional output conveyor can be specified, to replace the standard receiving tray. This can be fitted in two possible orientations.

3.2 Identification of parts

The main parts of the machine are shown below.

Holds up to 800 envelopes (DL). Fitted with a sensing conveyor that operates on demand to move the envelope stack forward.

Runs the IMOS operating software and responds to button pushes. A keyboard and mouse are also fitted.

Collation and insertion area

Folded forms, either singly or in groups, are collated here into one pack, along with enclosures. The pack in then inserted into the envelope.

Note: Items 1, 2, 3 & 8 are all part of the Insertion Head Unit.

This is a track mounted unit, with an end-station variant also available. Up to 8 may EHfitted (7 if a Flex Folder unit is fitted - see below).

The Versatile Feeder feeds enclosures such as inserts, flyers, BR envelopes etc. The hopper holds up to 1000 80gsm A4 inserts. A mark reading variant for OMR/Barcode/2D is also available.

This is a folder unit and is only available as an end module. It can be fitted to the insertion head on its own, or in conjunction with Versatile Feeders. It is fitted with various options of feed pods and an accumulator (see following page).

Fitted to the Flex Folder. Either a 1-Pod or a 2-Pod Flex Folder is available. Each one is fitted with either 2 x 500-sheet trays, or 1 x 1000-sheet tray; both variants can be mark reading as an option.

Fitted to the Flex Folder and allows groups of forms to be collated together before folding as a group. It is also fitted with a diverter tray.

This is where the envelope flap is closed and sealed before ejected the filled envelope into a receiving tray or onto a conveyor.

Receives filled envelopes from the Inserter and stacks them ready for hand removal.

4.1 The Job Screen

This is the screen displayed when the machine starts up.

Run Screen

Menus (see below)

Job screen

See section 7

Users (sect. 6)

Online help

Graphic shows machine configuration

Menus (including Engineer & Admin screens) are only available if logged in as Supervisor or Engineer.

See section 5 for running an existing job directly from this screen.

4.2 The Run Screen

4.2.1 The Run Screen displayed

This is the screen you will see after an existing job has been selected in the Job Menu, or after pressing the Run screen button.

Paper load indicators

Speed controls & indicator

Count indicators See 4.2.7

• Close down IMOS and PC - does not switch the machine off.

†Autoend stops the machine after processing all documents in paper path. Press Run to resume. Pause stops the machine after processing the current envelope only. Press Run to resume.

Press F4 to display the counts at all available exits. (Supervisor or Engineer only).

4.2.2 Testing the mailset

This allows various adjustments to be made before beginning the job, in order to minimise insertion crashes.

Press the Single Cycle button

to open the following options:

See following page for explanation of each button.

4.2.3 Present at exit

After pressing Present at exit, the first piece will be processed and the machine will stop to allow you to adjust the vertical alignment of the address, if required.

Remove the filled envelope and adjust as necessary, as shown below:

Sets the order of insertion of the fingers in the envelope, whether inner or outer fingers first, or both together.

Press Finger Sequence – the machine will feed an envelope into position and present the following screen:

Open side cover to view fingers. Press button to operate.

Select required sequence. Press Revert to restore machine default.

4.2.5 Envelope Stop Position

Allows the stop position of the envelope at insert to be adjusted.

Press Envelope Stop Position – the machine will feed an envelope into position and present the following screen:

+ Moves envelope further into insert position.

Adjust as required. Press Revert to restore machine default.

Allows the width of the outer fingers to be adjusted.

Press Finger Adjust – the machine will feed an envelope into position and present the following screen:

Use + Or - buttons to adjust finger width.

Press the Job Count button on the Run screen

Current job until changed, even if switch-off/back on. Press Reset to zero.

Set total for job. If zero, machine runs without stopping.

Press the Batch Count button on the Run screen

Exit for batching (if required). Note: Exits 2 & 3 appear only if Sorters are fitted.

Options:

Batch and Continue: Machine will pause for specified pause time (see 7.1.3), then resume. Note: conveyor continues during pause time.

Batch and Stop: Press Run to resume after stop.

Total batch quantity. Note: Applies to Exit above.

Exit used for Batch Count displayed on Run Screen.

Reset at any time.

OK when all complete.

4.2.8 To adjust Envelope Inserter settings

Fine adjustments apply only to current job. Settings available depend upon user access rights (see 6.2).

On the Run screen, select:

Note that each heading expands.

Press ‘Advanced’ to show all the settings described below.

You can change:

Collate Pkt. Adj: Width of collate pocket guides.

Adjust pawl pause pos: Pause time after insertion. Increase if pawls start before previous pack has cleared.

Collate Slowdown: Select ‘Not on Last Form’ for thick packs if final document in the pack does not feed fully into collate pocket.

Fingers Adj: Overall width of insert fingers.

Adjust envelope stop (mm): Stop position for insertion. + = towards exit.

Finger Sequence: Change if envelopes not opening properly.

Insert in env position (mm): Pack insertion into envelope. + = past flap crease.

Envelope Blower: Increase opens envelope more. High for thick packs, low for single sheets/thin packs.

Seal Time: Envelope ejects after.

Adjust wetter start: When wetter beam drops.

+ = start point towards insertion area.

Adjust env seal pos: Envelope into seal rollers. + = further in.

Adjust env reverse pos: Envelope foward travel after wetting, before reversing into sealing rollers. + = into output rollers, towards exit. Note: High-window envelopes, set to 20 - 50mm +.

Env Conveyor Drive Delay: Number of envelopes on the conveyor before conveyor switches back on. Increase if envelopes ‘bunching’.

Linear Speed: Inserter head speed. Set lower speed if pack is not being fully inserted, eg. long packs.

On the Run screen, select:

You can change:

Seal Mode: Eg. select ‘Off’ for later hand insertion of insert etc.

Deskew: Use High settings only when necessary – machine operates faster on low.

Note: Advanced button is not currently enabled.

Important: Fine adjustments apply only to current job.

4.2.9 To adjust Document Unit settings

Options available depend upon whether a Versatile Feeder or Flex Folder is fitted, and also whether a reading unit is fitted.

On the Run screen, select:

You can change:

Feed Control Mode: If Off, unit is disused until turned back on.

Doubles Detect: Turn Off if booklets/thick inserts used (Flex Folder only). If On, select Optical, Mechanical, or Auto (software decides - Versatile Feeder only).

Optical Doubles Sensitivity: (Optical only). Low is more tolerant of high contrast printing.

Only for Reading units

Reset Seq. Count: If Sequence OMR marks are in use and job is disrupted, select to reset the sequence.

Calibrate Reader: follow the on-screen instructions to calibrate the CIS reader.

CIS Reader Diagnostics: Displays the label of all documents in the group (up to 10), as seen by the CIS reader. Confirms that whole label was read, for example, or compare the images. Contact IPSS department for further diagnostic options.

Important: Fine adjustments apply only to the current job.

4.3 The Menu Screen

Note: Menu screen available only with Engineer or Supervisor access rights.

Menu functions are described in detail further in this document.

5 Running an existing job

This describes running an existing job. To create a new job, see section 7.

Note: paper hoppers must be loaded with stationery - see section 8.

Select Jobs button at the top and select required job from the list. Select Accept. You will switch to the Run screen with that job.

Current will switch to the Run screen for the current

Load paper and envelopes in hoppers indicated.

For Flex Folder: faceup and feet-first if nonreading, face down and head-first if reading. This may vary: see also appendix A.

See also section 4.2 for a full description of the controls.

Important: If using Cascade, Press Run while machine is still running, after reloading the empty hopper. Paper is then fed to pre-load.

Otherwise, machine will stop with full hopper: Press Run to continue.

6 Switching the user

6.1 How to switch the user

Each user has password and access rights allocated by Supervisor. To switch user, the password must be known.

Select User button in Job or Run screen.

Enter the password with keyboard or onscreen keypad.

The user has now changed.

Press the Login button.

6.2 User Access Rights

4 levels of access rights can be allocated to each user. Note: You must be logged on as Supervisor to modify.

Standard Operator

Expert Operator

Programme Jobs with Wizard

Add items to Libraries from Wizard

Add to Libraries from Outside Wizard

Mechanical Fine tuning

PC shutdown on exit?

Additionally, ‘System Security Level’ can be set in the Menu screen/Admin. This is the level where no password is needed to perform certain operations.

Effective role of ‘Operator’

On Startup

Operator can run/edit/ Job screen create jobs but cannot ac- displayed cess the main menu.

Standard Operator

Operator can only run jobs.

Job screen displayed

Operator’ has no access to the system. All users have to logon.

User screen displayed

7 Creating a job

Creating a job involves:

Defining the Mailset (Envelope, document & enclosures)

Defining the Fold Settings

Setting required Output Options

Saving the Job to a Jobname

When defining the Document, OMR or Barcode definitions can be optinally enabled.

Note: to use an OMR or Barcode definition, it must exist - see 7.3.

7.1 Creating the Job Settings

Press New in the Job screen to start defining the mailset.

7.1.1 Defining the mailset

Press Select to choose envelope from the library.

Select the required envelope and press OK.

To create envelopes in the library, see 7.3.

If required, define envelope usage (sealing mode and deskew).

Select Sealing mode (usually Always. Other options:

No-seal Label Select: reads no-seal character in label.

Off, flap open: envelope left unsealed with flap open.

No Envelopes: envelope feeding disabled to allow forms only.

Press Edit advanced to change deskew setting or set document order in the envelope.

Change the order that enclosures are inserted into the envelope (default is Automatic). If set to Manual, enclosures are inserted in the order created in the job (see Selecting the enclosure at step 12).

Note: Document Order is not available when reading.

Press Select to choose document from the library.

Select the required document and press OK.

To create documents in the library, see 7.4.

Now either select enclosures, or see step 10 to define the document usage, (form count, cascading etc). When this is complete, you will return here.

Set form count for multiples, and if required, select cascading (automatically feed from another hopper when this one runs out), or Daily Mail (hand-feed) or External feed (FFPD).

See 9.5 & 9.6 for details of Daily Mail.

Press OK when done.

Press Edit Advanced for further settings.

Press Auto to choose orientation other than the default.

Deskew: Set low if possible; high slows machine down. Turn off if skewing is not occurring.

Thickness doubles: mechanical on Versatile Feeder only. Optical on Flex Folder and Versatile Feeder. Change default setting only if needed.

Feed control mode: Set to ‘Selective Feed’ for reading-enabled units. Works in conjunction with ‘Select ID’ - see below.

Select ID: Defines an ID number for document to accord with the Select mark in the label. This will then feed the document when that mark is read.

Sequence handling mode: how sequence marks (if used) are handled when a document set is broken up (eg. to change a job in the middle of a document set). Set to ‘Full’ for the first pass, then change to ‘Mailset’ for the second pass after the job has been changed. The machine will not then expect an unbroken sequence.

Press Select, choose an enclosure and pres OK.

The remainder of the process is the same for enclosures as documents see steps 9 to 11.

The mailset is now defined, and the screen will show that this is ticked.

7.1.2 Defining the document placement settings

Only do this if you want to assign documents/enclosures to specific hoppers, otherwise press Next.

Select document to move, then the hopper to assign it to.

To revert to default, press Auto place documents.

The document placement is now defined, and the screen will show that this is ticked.

Now define the fold settings.

7.1.3 Defining the fold

The machine automatically selects the optimum fold type. To change this, deselect Fold Type and set as required. Use with caution.

To adjust or check fold lengths, press Adjust fold.

Adjust as required and press OK. Affects current job only.

To see fold plate lengths, press Advanced. To adjust, Custom-Fold must be enabled in System Options in the Service screen.

Note: Custom-Fold disables Address Adjust when job is run (see 4.2.2).

See ‘Technical Specifications’ for Max. & Min. fold plate lengths.

For further adjustments, press Edit Advanced.

Collate Mode: ‘Singly’ folds sheets one by one. ‘Together’ collates forms and folds them together. ‘Together via Accumulator’ is as above, but feeds into accumulator before folding. Maximum in accumulator: Up to 25 depending upon the paper type.

Maximum Fold (Forms): Number of forms that can be folded together. Groups bigger will split into a) max number, followed by b) remainder.

Multi-envelope mode: Allows two separate jobs to be run in succession using the same document set. If set to Split Oversized, this splits, folds and inserts as for ‘Maximum Fold’ described above. If set to Divert Oversized. all groups more than number set in Divert/Split Threshold will be diverted. For Divert Undersized, the same applies for groups below the threshold. Machine is then stopped, job is changed and forms in divert tray are replaced into the document set, and the new job is run. See also Table 1.

Note: If Divert Oversized/Undersized is selected, Divert/Split Threshold must be set to the same as Maximum Fold (Forms).

Error handling: Action of machine after bad reads.

Oversize/Undersize handling: Action of machine after diverting as above. Note: not available if Split Oversized is set.

Fold settings are now complete and the screen will show that this is ticked.

Press Next to define the Output settings.

Handling of folded forms

Shown below are handling of oversized/undersized groups under different circumstances.

Multi envelope mode

Maximum in accumulator

When folding, the group or sub-group is folded on reaching this limit

When not folding Not used or diverting, the group or subgroup is ejected towards divert or head unit on reaching this limit

Mechanical limits of folder and accumulator for given stationery

Not used (As for Split Oversize if oversize not yet detected).

Not used (As for Split Oversize).

The complete group is assembled in the accumulator and then diverted if prime document count is equal or greater than this limit

Typically used for diverting large groups for re-processing into a larger envelope

Divert undersized

Not used (As for Split Oversize if undersize not yet detected).

Not used (As for Split Oversize).

The complete group is assembled in the accumulator and then diverted if prime document count is less than this limit

Typically used for diverting small groups for re-processing into a smaller envelope

Divert/Split threshold

7.1.4 Defining the output settings

Set Batching to Batch On if required and set required quantity in Batch Quantity.

Set Batch Mode as follows:

Batch and Continue: Machine pauses for specified Batch complete pause time, then resumes. Note: conveyor will continue to run.

Batch and Stop: Machine will stop. Press Run to resume.

When settings are complete, press Save.

If a conveyor is fitted, select Conveyor Settings to adjust the Jog function:

Single Jog Adjust: Adjusts default jog step (gap) between mailpieces. Steps are unitless.

Batch Complete Jog Step: Adjusts gap before machine performs action described in ‘Batch Mode’.

Mark Reading Jog Step: Adjusts gap created after Jog mark is read.

Autoend Jog Step: Adjusts gap created before machine autoends.

When settings are complete, press Save.

Output Settings for unsorted mail are now complete. If using Mail Sorting or Franking, refer to the INF Output Sorter Operator Manual.

However, if an INF Turner is fitted without a dedicated franker, the envelope can be turned independently.

Set Turning to Unsorted Mail (or a Mailsort) and press the Settings.

With no franker fitted, no settings will be shown. Press Edit Advanced and set the envelope rotation to Auto, Yes or No.

When settings are complete, press Save.

Output settings are now defined, and the screen will show that this is ticked.

Press Next to define the output placement settings.

7.1.5 Defining the output placement settings

Allows you to select a different exit instead of the default (if other exits are fitted). An exit may be an ouput conveyor, INF conveyor or catch bin.

Select the mailpiece in Exit 1, then select the required exit.

To revert to default, press Auto place mail sorts.

Output placement is now defined and the screen will show that this is ticked.

Press Next to save the job.

7.1.6 Saving the job

Press the keyboard button and enter a job name using virtual or physical keyboard.

Repeat for a brief job description for the job. This will appear in the job list.

Set the Job number control mode. Options are Auto generated; Manual entry (Internal or External); Read from prime; Read on output; Externally supplied.

Enter a Job number if manual entry control mode is being used. Disabled for all other modes.

Set the AIMS Mode. Options are Off; Statistics; Audit; Verification; Lookup (FBM).

Set the Datalogging Mode. Options are Off; Standard; AIMS Statistics Compatible.

See also AIMS User Reference Guide for full details.

You have now successfully created a new job

and it will appear in the job list.

Any of the Job Creation screens can be edited by pressing Edit for the selected job in the Job screen. Note that the Save button will then be enabled on each screen.

7.2 Creating an envelope

Begin creating a job (see section 7.1)

In the Envelope selection box, press New.

Select envelope size. If you change default dimensions, size will change to ‘Custom’.

Note: measure envelope carefully before changing sizes.

For further settings, press Edit Advanced.

Enter the paper weight and envelope weight will automatically calculate, or press Computed and enter actual weight.

Wetting rate number shown is quantity of envelopes sealed before wetter tank is topped up. Default is 25.

Press Save when done.

The envelope is now fully defined and is available for use.

Envelopes can also be created from the Menu screen. The procedure is the same as described above.

7.3 Creating a document

Begin creating a job (see section 7.1).

In the Document selection box, press Create new.

Select document size. If you change default dimensions, size will change to ‘Custom’.

For further settings, press Edit Advanced.

Make selections and enter sizes as required.

Enter the paper weight and document weight will automatically calculate, or press Computed and enter actual weight.

If using OMR or BCR, select a reading definition. Note: this is obtained under licence as an option and must already exist on the machine.

If the document does not use an OMR or BCR label, press Save, otherwise, proceed as follows.

Press Region of Interest to specify label position.

Enter label size and position. Turn Off edge detection if coloured or densely printed paper is giving false readings.

Press Save when done.

For Doc ID mode see ‘7500 Series Reading Specification’.

The document is now fully defined and is available for use.

Documents can also be created from the Menu screen. The procedure is the same as described above.

7.4 Creating an enclosure

Begin creating a job (see section 7.1).

In the Document selection box, press Create new.

Definition of enclosure is the same as for documents, (see 7.3).

Note: Documents and enclosures use the same library.

See section 7.3 for the remainder of the settings.

The enclosure is now fully defined and is available for use.

Enclosures can also be created from the Menu screen. The procedure is as for document creation. (see 7.3).

9 Setting up the machine

9.1 Loading the envelope hopper

Adjust side guides to 1-1.5mm clearance each side of envelope.

Adjust backrest angle (see below) and load envelopes, flaps forward. Move backrest forward (see below) so envelopes are fully forward, but not tightly packed.

Squeezing handle upwards to release. Slacken knob each side to adjust angle. C4: Fully raised DL/DL+: Fully lowered

Note: If envelopes feed erratically, try a backrest angle in-between.

Adjusting the envelope separator

The separator prevents more than one envelope being fed at a time.

Open on the inserter side cover; blue knob is below envelope conveyor. Clockwise decreases gap, anticlockwise increases it. Slide an envelope into the gap and turn the knob until the separator just grips it. Close side cover when finished.

9.2 Loading the versatile feeder hopper

Slacken side-guide knob and adjust guides to 1-1.5mm clearance each side. Tighten knob.

Slacken knob under backrest and move it forwards to support the enclosures as shown. Tighten knob.

The separator prevents more than one enclosure being fed at a time.

Adjustment knob is behind feed hopper. Clockwise decreases gap, anti-clockwise increases it. Slide an enclosure into the gap and turn the knob until the separator just grips it. See also 9.5.3.

Note setting gauge on knob.

For problem enclosures, optional feed rollers are available; see 10.3

9.3 Loading the flex folder hoppers

The Flex Folder may be fitted with one or two 500 or 1000-sheet hoppers. Example shown has 2 x 500 and 1 x 1000.

500-sheet hoppers: Slacken knob and adjust guides to 1-1.5mm clearance each side. Tighten knob. Press down and load paper fully forward and under the pick-up roller.

1000-sheet hoppers: slacken knob and use tabs to adjust guides to 1-1.5mm clearance each side.

Push tray firmly downwards all the way. Load paper stack fully forward.

Paper orientation in the hoppers depends upon the job requirement - see Tables 2 & 3.

Slacken knob and adjust side guides to preset size markings.

To clear paper, raise the overguide until it locks. Press latch to release.

The separator prevents more than one document being fed at a time.

Open side cover and turn knob to open or close the gap. The markings indicate direction.

To set: For single sheets (up to 100gsm), the separator roller should just contact the pad below. Increase the gap slightly if it feeds erratically.

For thicker forms, slide a form into the gap and turn the knob until the separator just grips it.

If using fold-plate 2, adjust as shown (see also Tables 2 & 3).

Most applications do not use fold plate 2.

Open side cover. Slacken knob and set to length on scale.

Raise transport assemblies and slide latch inwards to open fold plate 2 for use.

Lower transport assemblies, ensuring they are latched.

Remember to slide the latch back when you no longer need fold plate 2.

Tables 2 & 3

Paper orientations for various applications (Euro & US) are shown below.

European Sizes:

9.4 Paper Control Lever

Lower this lever for single documents or packs with lightweight prime document.

Raise the perspex top cover and move lever forward for single sheets, lightweight prime documents etc.

Note: Lever may also be set halfway.

9.5 Daily Mail (Versatile Feeder)

For Flex Folder Daily Mail, see 9.6.

Hand feed forms or packs up to 6mm, stapled or not (see below). observe folding capacity of 8 forms of 80gsm (20lbs bond).

No staples in area shown

9.5.2 Using Daily Mail

Define a new mailset (see 7.1.1) or edit document settings for existing job.

Set ‘Hopper Feed Mode’ to Daily Mail.

Save settings, then press Next until you reach Save to save the job.

9.5.3 Setting the Separator Gap

Open gap wide and insert pack into it, corner first.

Close gap until it lightly grips, then open by 1 turn (1mm).

If document is an 80gsm sheet, set to 1mm

To operate, press Run and feed post into hopper tray inside 30 seconds. After this, press Run again.

To turn the function off, switch ‘Daily Mail’ back to No in Document Settings.

9.6 Daily Mail (Flex Folder)

For Versatile Feeder Daily Mail, see 9.5.

Hand feed forms or packs up to 6mm, stapled or not (see below). observe folding capacity of 8 forms of 80gsm (20lbs bond).

No staples in area shown

9.6.2 Using Daily Mail

Define a new mailset (see 7.1.1) or edit document settings for existing job.

Set ‘Daily Mail’ to Yes. Press Next until the job is saved.

Set the accumulator as follows.

Raise overguide until it latches

Hook divert tray into slots on top surface

Adjust side guides to suit paper width

Press the Run button, then select Auto or Manual feed.

• Auto feed pauses 1 or 2 seconds before feeding.
• Manual feed will feed immediately.

To operate, press Run and feed post fully into accumulator inside 30 seconds. After this, press Run again.

To turn the function off, switch ‘Daily Mail’ back to No in Document Settings.

9.7 Adjusting the catch tray

If a Catch Tray is being used for ejected envelopes, it should be adjusted to suit the ejected envelopes.

Slacken knob under side guides, and adjust to 2mm clearance each side. Tighten knobs.

Lift and pull backstop, adjust to suit ‘bounce’ of ejected envelopes.

10.1 Cleaning the sensors

Optical sensors consist of two halves: emitter and receiver. These can become obstructed with paper dust and should regularly be cleaned using a non-flammable airduster (Part No. 9103707C). Both halves must be cleaned.

Sensor locations are shown below. For most sensors, an arrow is pierced in the chassis to show where the jet of the airduster should be directed.

Ensure you clean the sensor lens, not the retaining bush next to it.

Open perspex top cover and raise collate clamshell (closest to envelope hopper) so it locks in place.

Picture is viewed looking inside collation area towards envelope hopper.

Picture is viewed looking inside collation area away from envelope hopper.

Lower collate clamshell and open upper conveyor (furthest from the envelope hopper) so it locks in place.

Picture is viewed looking inside collation area away from envelope hopper.

Lower side cover and raise overguide inside closer cavity, latching it in place.

Picture is viewed on front of envelope hopper.

Open side cover and lower front output cover below envelope feeder.

Open the feeder front top covers for first station. For subsequent stations, open side cover and approach from the side.

Picture is viewed looking down feed hopper.

Push nozzle forward about 20mm and spray liberally.

Open side cover and lower the conveyor.

Sensors are located in the centre of track.

Open folder top cover to locate the sensors.

Insert the airduster nozzle under the chassis bridges to reach the sensors.

10.2 Clearing paper jams

If paper jams occur, area affected is indicated in the error message on screen. Clear the paper jam as shown below.

Open side cover on the operator side, and lower front sealer cover.

If paper is not fully visible, turn blue knobs to wind into view.

Open side cover on the versatile feeder.

Push levers indicated to access jammed paper.

If paper is not fully visible, turn the blue knobs to wind into view.

Open the side cover on the flex folder.

Raise and latch transport assemblies #1, 2 & 3.

If paper is not fully visible, turn blue knobs to wind into view.

Raise and latch transport assembly #4, and raise roller assembly #5 below it.

If paper is not fully visible, turn blue knobs to wind into view.

10.3 Changing the feed tyres

Certain documents (eg. glossy materials) may not not feed properly with standard feed rollers. Optional feed tyres are available to assist feeding and are fitted as follows.

Remove 3 knobs indicated and open side guides to their widest.

Lift the feed bed out of the chassis to access feed shafts beneath.

Slide spring-loaded collars inboard and lift feed shafts out of their bearing hubs. The feed tyres can be prised off the rollers and replaced with alternative items.

When replacing shafts, ensure drive pins are properly located in hubs.

10.4 Adjusting the CIS reader

If a CIS reader is fitted to a Flex Folder, it must be adjusted to align with the barcode label.

Open side cover and using blue tab, slide CIS reader over to the side of the paper that the label is printed.

Note: Move the CIS reader fully to one side or the other. Do not position it in-between.

TOP READ

BOTTOM READ

10.5 Maintaining the wetter system

The wetter system comprises a tank to damp the wetter beam, replenished by a pump-driven reservoir bottle located in the stand.

At regular intervals, the tank should be removed to clean it.

Cleaning the wetter tank

Open the side cover on the insert head. Using the blue tab, lift the end of the wetter tank slightly and withdraw it.

Empty the tank and clean it by running clear water over its length for 2 or 3 minutes.

Replace the tank. It will automatically replenish.

Changing the reservoir bottle

Open the door of the stand below the insert head. Lift the pipes with attached weight out of the bottle.

Remove the empty bottle, uncap a new one and replace the pipes.

Important: For optimum sealing, use only approved sealing fluid (Part No. A0275A 9101264H for 10 litre bottle).

Maximum pack thickness is defined as the internal dimension of a rigid opening that a filled envelope will fall through under its own weight.

All envelopes sizes:

up to 10mm (25/64”)

The minimum clearances required between the inserts and envelopes are dependent on insert pack thickness.

Clearance is the total clearance and is defined as the difference between the largest overall dimensions of the pack and the internal dimensions of the envelope (see below). The required clearances are summarised as follows:

Pack <3mm: Depth 6mm (¼”) Width 16mm (5/8”) Pack >3mm <6mm: Depth 12mm (½”) Width 19mm (¾”)

Depth Clearance

Up to 6000 envelopes per hour (based on 1 or 2 x A4 single-folded sheets into a C5/6 or #10 envelope).

Up to 5300 envelopes per hour (based on 1 x A4 folded sheet with 1 x BRE into a C65 or #10 envelope).

Speeds for other conditions available on request.

Up to 300,000 filled envelopes per month.

MAILPIECE

Max. speed per hour/ Max doc speed per hour Accumulation speed (A4) C 65 (114mm), 1 x A4/Letter in C-fold via Accumulator C 65 (114mm), 2 x A4 in C-fold via Accumulator C 65 (114mm), 4 x A4 in C-fold C 65 (114mm), 1 x A4 in C-fold + BRE Nr#10 (105mm), 1 x Letter in C-Fold via Accumulator Nr#10 (105mm), 2 x Letter in C-Fold via Accumulator Nr#10 (105mm), 4 x Letter-20 in C-Fold C5 (162mm), 1 x A4 single fold via Accumulator C5 (162mm), 2 x A4 single fold via Accumulator C5 (162mm), 4 x A4 single fold C4 (324mm), 1 x A4 unfolded C4 (324mm), 10 x A4 unfolded C4 (324mm), 15 x A4 unfolded

SPEED

6,000

Envelope Hopper capacity

C5 or below - up to 800 of 90gsm (24lbs bond) C4 (flat type) - up to 500 of 100gsm (28lbs bond) Loading whilst running - Yes

Minimum: C5 or below - 70gsm (18lbs bond) Minimum: Above C5 - 90gsm (24lbs bond) Maximum: 110gsm (28lbs bond)

General envelope requirements

Receiving tray capacity (optional)

Envelope to be good quality machine-fill type. Dimensions and quality to be consistent across manufactured batches. Side seams must be securely glued to the top of the seam. Flap crease must be pre-scored to enable the envelope flap to open flat. no glue seepage must be evident on interior or exterior of envelope.

215 filled envelopes* 300 filled envelopes*

• assumes 1 document inserted.

Envelope details

Flap Shoulder Angle 50° Min. 90° Max.

Body Depth Max. 254mm (10") Min. 98.5mm (3 7 8 ")

Min. 10mm ( 13 32 ")

Minimum open throat area

Min. 10mm ( 13 32 ")

Throat angle 5° Min. 20° Max.

Min. 70mm (2 3 4 ")

Flap Length Max. 65mm (2½") Min. 32mm (1 1 4 ")

Throat Depth Max. 25mm (1") Min.10mm ( 13 32 ")

Horizontal portion of throat Max. = Envelope Width - 75mm (3")

Side Seam style envelope

Envelope Width Max. 330mm (13") Min. 225.5mm (8 ")

Flap Shoulder Angle 50° Min. 90° Max.

Body Depth Max.254mm (10") Min. 98.5mm (3 7 8 ")

Min. 10mm ( 13 32 ")

Minimum open throat area

Min. 10mm ( 13 32 ")

Throat angle 5° Min. 20° Max.

Min. 70mm (2 3 4 ")

Horizontal portion of throat

Max. = Envelope Width - 75mm (3")

Flap Length Max. 65mm (2½") Min. 32mm (1 1 4 ")

Throat Depth Max. 25mm (1") Min.10mm ( 13 32 ")

Commercial style envelope

Envelope Width Max. 330mm (13") Min. 225.5mm (8 ")

7500 Series Operator Manual

14mm minimum to edge

of address carrier

20mm minimum

Position of internal side seams to give a minimum of 5mm 3 ( 16 ") clearance or overlap to the edge of any insert

Flap crease to be scored sufficiently to prevent distortion of envelope between window and flap crease when closing and sealing.

Top edge of window to be flat and free from puckering

Windows to be securely affixed to within 1.5mm ( 116 ") of top and side edges.

Window width to be less than 40% of envelope width.

The bottom flap of the envelope should be in-line or below the top of the seam shoulders

Bad example - Out of Specification

Maximum distortion allowable on a twisted envelope to be 10mm ( 3 8 ") when envelope measured sitting flat on a table

Envelope

sealing fluid

Built-in wetter tank, automatically pump-fed by 10-litre wetter container located in stand. Optional low-level float switch available.

Minimum width: 148mm (5¾”)* Maximum width: 305mm (12”)† Minimum length: 93mm (3⅝”) (140mm (5½”) when reading and using acumulator) Maximum length: 406mm (16”)

• For individual items. Min. pack width: 210mm (8¼”) †Maximum width when folding: 229mm (9”) Note: The maximum suggested width difference between inserts is 32mm (1¼”): this may be increased subject to test. If this difference is exceeded, the insertion fingers will not cover the edges of the narrow insert and may cause insertion problems. Sandwiching a narrow insert between two wider ones may resolve this.

Minimum 70gsm (18lbs bond) Maximum 120gsm (32lbs bond) for folded documents Maximum 2mm thick for unfolded inserts (subject to test)

C, Z or V-fold: 8 sheets 80gsm (20lbs bond)* Double-forward fold: 4 sheets 80gsm (20lbs bond)*

• Multiple folded sets dependent upon pack thickness.

Fold Plate 1: 237mm Max, 50mm Min. Fold Plate 2: 232mm Max, 85mm Min. Fold Plate 3: 135mm Max, 50mm Min.

Tower can be ordered with 1 or 2 pods, each fitted with 1 or 2 hoppers as follows:

2 x 500 sheets of 80gsm (20lbs bond) 1 x 1000 sheets of 80gsm (20lbs bond)

Examples shown above are for illustration only. Other configurations are available.

Up to 8 sheets of 80gsm (20lbs bond) for C, Z or V fold, up to 4 sheets of 80gsm (20lbs bond) for double forward fold, up tp 25 sheets of 80gsm (20lbs bond) unfolded. May be stapled or not. Max. thickness of staple 3mm. Allowable staple positions are shown below.

No staples in area shown

Minimum width: 148mm (5¾”)* Maximum width: 305mm (12”) Minimum length: 76mm (3”) for non-reading unit 93mm (3 ⅝”) for reading unit Maximum length: 216mm (8½”)

• For individual items, min. pack width is 210mm (8¼”) Note: The maximum suggested width difference between inserts is 32mm (1¼”): this may be increased subject to test. If this difference is exceeded, the insertion fingers will not cover the edges of the narrow insert and may cause insertion problems. Sandwiching a narrow insert between two wider ones may resolve this.

Minimum 70gsm (20lbs bond) Maximum 6mm (¼”) thickness

1000 sheets of A4 80gsm (20lbs bond) 500 sheets of A4 Z-folded 80gsm (20lbs bond) 250 x 2.4mm booklets 500 x C65 envelopes

Note: Quantities shown above are maxima. Depending upon other conditions, actual quantities may be lower than those shown.

Enclosures must be flexible enough to suit path constraints. Some enclosures may require special tyres.

Up to 25 sheets of 80gsm (20lbs bond) unfolded. May be stapled or not. Max. thickness of staple 3mm. Allowable staple positions are shown below.

No staples in area shown

11.4 Mechanical & Electrical

Noise level:

75dbA (3 x Versatile feeders, 1 x Flex tower, measured at 1.6m height, 1m from nearest cover).

Heat Output (BTU/Hour):

Rated current x rated volts x 3.412 (eg. 2464 BTU/Hour for typical configuration of 3 x versa feeders + flex tower folder).

Heat Output (Watts):

Rated current x rated volts (eg. 722W for typical configuration of 3 x Versatile feeders + Flex tower folder).

Electrical:

230VAC 115VAC

Input Current Head: 0.85A Head: 1.6A

Versa Feeder: 0.58A Versa Feeder: 1A

CIS Feeder: 0.58A CIS Feeder: 1A

Flex Tower: 0.55A Flex Tower: 1.4A

PC & Monitor: 1.2A PC & Monitor: 2.4A

Fuse Rating T6.3A T10A (Insert Head)

Operating Temperature:

18 - 28 deg C (64 - 82 deg F)

Operating humidity:

30 - 80% RH

Weights:

Inserter Head 101Kg 119Kg

Flex Tower* 114Kg 130Kg

Furniture Units 23Kg 24Kg (short)

PC, Arm & Fluid

• 2-pod version (each with 2 x 500 sheet-trays), and including accumulator with diverter tray.

Sizes:

Insert Head

Flex Folder

Versatile Feeder

Divert Tray

Heights (incl. furniture): Inserter head 1200 Versatile Feeder 1400 Flex Folder* 1500

• Fitted with 4 x 500-sheet trays

Ambient light:

Although the machine may operate in sunlight, it is not designed for use in direct sunlight, or where sunlight is exposed to the machine through windows or skylights. The light-sensitive sensors can be affected in these conditions. It is therefore recommended to:

Locate the machine out of direct sunlight Protect the machine from direct sunlight using blinds or similar blocking devices.

If the machine can only be located where it may be exposed to direct sunlight, then please contact Technical Support department, who may be able to advise on the use of blocking material on the inside of the Perspex cover where necessary.

Important Notes:

1. All stationery should be allowed to acclimatise near the machine for at least 24 hours before use to prevent rapid absorption of moisture in the material, or condensation forming on the machine. Failure to acclimatise the material may cause pre-gumming of envelopes or otherwise impair machine performance.
2. The machine will function with humidity levels lower than 30% RH, but high levels of static may be generated, impairing machine performance.
3. The machine will function with humidity levels higher than 80% RH, but moisture absorption into the material may impair machine performance.
4. Condensation must not be present under any circumstances.
5. The machine will function at temperature levels above 28 deg C (82 deg F) and below 18 deg C (64 deg F). However, temperature levels outside these limits may impair the machine performance.
6. Material processed directly from laser printers may have high levels of static causing material to stick together. If double feeding occurs, then Hi-Grip separators may be required - contact IPSS department.

12 Glossary of Terms

Term Description Address carrier The address carrier is the document that carries the address of the person for who the mail set is meant. The address carrier can consist of one or more sheets, from which at least the first sheet must contain the address. The address must remain visible while enclosures are added and the document set is folded. The fold type and selected envelope must ensure that the address is visible behind the window in the envelope. For personalized mailings there is always an address carrier present as long as envelope printing is not supported. Normally there is one address carrier. Address Position of the address on the address carrier, position measured from the upper left corner. The address position consists of a horizontal x coordinate, a vertical y coordinate, a horizontal width w and a vertical height h.

The feature of an inserting system to automatically determine its job settings by measuring the sizes of documents and envelope. From all feeders that are loaded one sheet will be taken. Based on the maximum document length (which is also the length of the document set) and the length of the envelope the fold type is determined. Automatic job A job that is created with the Automatic job functionality. Barcode Barcode Reading is intended for reading and interpreting printed Reading (BCR) barcodes. The codes give information to the inserting system about how to build-up and handle a set. Business Reply Envelope included in outgoing mail sets for addressee response Envelope (BRE) purposes. Cascading See Feeder linking. C-fold See Letter fold. Daily Mail Capability of an inserting system to manually insert mail sets one by one into the system, which are then inserted into an envelope. Optionally, depending on settings, additional enclosures can be added and the mail set can be folded. This function is intended for small amounts of mail that each can have a different build-up. Deskew A system of straightening a skewed document or enclosure by driving it into a set of drive rollers that have been briefly stopped. This removes the skew, and after a set period of time, the rollers restart. Deskew slows the machine down and can be disabled or adjusted for amount of deskew for forms that are not prone to skewing.

Term Document

Double Document Detection

Double parallel fold

Description A document is one of the components of a mail set. A document can consist of one or more sheets. Documents can be divided into address carriers and enclosures. For personalized mailings there is always one address carrier and an optional number of enclosures. The document set is the physical collection of address carrier and enclosure(s) that is under production in the inserting system. The document set is completed during production and is to be inserted into the envelope. The number of enclosures can range from 0 to the limit imposed by the number of available feeders, whilst observing the overall pack thickness. Once the document set has been inserted into an envelope it is called mail set. Double Document Detection is the sensor that measures the thickness of a sheet to check if the inserting system does not accidentally take more sheets than intended. DD sensors exist on feeders (double sheet detection). Currently DD detection on Neopost inserting systems perform relative measurements, which means that they need a cycle to ‘learn' the thickness of a sheet. Also the length of the document is measured so partly overlapping sheets will be detected. The double parallel fold is a type of fold where the document is first folded halfway and the resulting folded set is again folded halfway. This fold is illustrated in the picture below. The position of both folds is adjustable.

The envelope is the packaging of a mail set. Window envelopes are envelopes that have a transparent section through which the address on the address carrier can be read. Besides the normal top closing window envelopes there are also bottom closing envelopes. Face down Situation in which the front of a sheet is facing downwards when placed in a document feeder. Face down Situation in which the front of a sheet is facing downwards leading and the top of the sheet is closest to the separation unit in a document feeder, ie. the front end of the tray. Face down Situation in which the front of a sheet is facing downwards and trailing the bottom of the sheet is closest to the separation unit in a document feeder, ie. the front end of the tray. Face up Situation in which the front of a sheet is facing upwards when placed in a document feeder. Face up leading Situation in which the front of a sheet is facing upwards and the top of the sheet is closest to the separation unit in a document feeder, ie. the front end of the tray.

Term Description Face up trailing Situation in which the front of a sheet is facing upwards and the bottom of the sheet is closest to the separation unit in a document feeder, ie. the front end of the tray. Feeder A feeder is a module for the input of documents to the inserting system. The feeder separates documents sheet by sheet from the stack of documents in the feeder tray. Feeder linking The ability to load two feeders with the same document type (Cascading) where the inserting system automatically switches to a second feeder when the first feeder is empty and vice versa. In the mean time the first feeder can be refilled, so the inserting system can keep running without having to stop for refilling the feeders. Feeder tray Part of the feeder that contains the stack of documents or envelopes. Flexcode OMR An OMR code for which the meaning of the OMR marks can be programmed in a dedicated way for a specific customer. This is normally used to support the OMR codes from other suppliers. FlexFeed® The flexFeed® is the feeding part of the system. High Capacity Feeder that has a capacity up to 1000 sheets (on a Tower unit). Feeder High Capacity Optional stacker that is mounted on the exit of the system, to Vertical Stacker stack filled envelopes. Insert

• To insert is the action of inserting a document set into an envelope.
• For native English speaking customers an insert is also a short document, not to be folded, usually an enclosure.

Inserter An inserter is the module where the document set is inserted into the envelope, the envelope is closed and if necessary sealed. Inserting The system of all the modules that cooperate to perform the system inserting function (accumulate document set, fold and insert) and have a single point of control.

A job is an actually produced collection of mail sets based on a certain job definition at a certain point in time for a specific purpose. It consists of:

• The job definition used for the production
• Information about the batch size The counter that registers the number of mail sets that is produced as part of a specific job.

Description Fold type in which a document set is folded twice in which the folded flaps are on top of each other. This fold is illustrated below. The position of both folds is adjustable.

Term Letter fold (also known as C-fold)

Linking MaxiFeeder™ Multiples

OMR OMR code definition

Operator Optical Mark Recognition (OMR)

Output Conveyor

Remote diagnostics Service engineer

See Cascade. Feeder with high capacity feeder tray. The feature of an inserting system in which more than one sheet is taken from a feeder. Optical Mark Recognition (see further table entry). Standard 1-track OMR code definition. Specifies the amount of reading marks used and the functionality linked to each of them (how each should be interpreted). A definition is a licenced option. The person operating an inserting system. Optical Mark Recognition is intended for reading and interpreting printed codes. These codes are one or more black marks which are read from a document. These marks give information to the inserting system about how to build-up and handle a set. Fitted at the output for filled envelopes to be ejected onto. Higher capacity alternative to a receiving tray. 2 lengths are available. The feed hopper unit fitted to a Tower. A Tower is available with either 1 or 2 pods, each one consisting of either 2 x 500-sheet trays or 1 x 1000-sheet tray. Condition in which the system could not reliably read or interpret the OMR reading marks or barcode from a sheet. Marks added to documents containing finishing instructions that can be identified by an reading head and interpreted according to the used OMR code definition. Fitted at the output for filled envelopes to be ejected into. Basic alternative to an Output Conveyor. The feature that makes it is possible to analyze a problem on an inserting system from a remote location. Technical engineer whose task it is to resolve problems with systems in the field. Besides dealing with problems, service engineers are also responsible for preventive maintenance.

Term Single fold

Description A single fold implies the document set is folded once. The fold position is adjustable. This fold is illustrated below:

Counter which sets the amount of envelopes to be filled. After filling this amount of envelopes the system will stop. Person who is responsible for the technical state of the system. Normally a supervisor has access to programming functions, which are restricted for standard users. A test run is intended to validate the settings of the inserting system:

• Inspect and adjust the stop position of the envelope.
• Check the fold settings for one set.
• Check whether the address is correctly positioned behind the envelope window.

Contains a stack of paper for a printer or inserter. This paper is supplied to the system for further processing. The vertical transport section between hoppers and folder/ collator below . A Z-fold means that a document is folded twice in such a way that each folded flap is on a different size of the folded document, resulting in a Z-shape. This fold is illustrated below. The position of both folds is adjustable.

Tray (or hopper) Vertical transport Z-fold (also known as zigzag fold)