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Operator Manual

Inserting system KS 4000 OL / OLC

About your new inserting system

2

This operator manual is designed for users who have been instructed in
the operation of the Inserting System KS 4000 OL/OLC.

This operator manual

 

is one part of the complete documentation available

for the Inserting System KS 4000 OL/OLC. It describes 

typical operating

procedures 

for configurations

– with a single-sheet feeder
– with a single-sheet feeder and supplement feeder
– with automatic cutter (for processing continuous-feed paper)
– with automatic cutter and supplement feeder
– with automatic cutter and cross-fold function (for processing

continueous-feed A3 and broadsheet formats)

– with automatic cutter, cross-fold function and supplement feeder.

Detailed descriptions (about functions, technical data, installation,
maintenance, programming) of individual components can be found in the
“Instruction Manual Inserting System 4000” and in the for “Operating
Instructions Cut-Sheet-Feeder” and/or “Operating Instructions Automatic
Forms Cutter” (depending on the configuration of your system).

Keep this operator manual readily available and near the machine.

The following symbols and cautions represent important safety warnings
in this manual:

Warning!

 indicates a potential hazard which may result in injury.

Caution!

 indicates a potential hazard that may result in damage to

your inserting system or which may impair the processing of
documents.

Tips marked in this way offer advice and suggestions on the effi-
cient and troublefree use of the inserting system.

Содержание KS 4000 OL

Страница 1: ...s with automatic cutter cross fold function and supplement feeder Detailed descriptions about functions technical data installation maintenance programming of individual components can be found in the...

Страница 2: ...feeder Stop feeder machine stops after completing the current handling cycle Toggle between program selection and parameter Display information about current program settings Display 1 Display 2 KS 4...

Страница 3: ...27 4 1 Cut and insert continuous feed paper ___________________________________________________ 27 4 1 1 Starting operation ____________________________________________________________________________...

Страница 4: ...ng head____________________________________________________________________________________________ 72 7 2 Automatic cutter ____________________________________________________________________________...

Страница 5: ..._________________________________________ 99 7 10 Sealer ___________________________________________________________________________________________________________________ 100 8 Trouble shooting tips...

Страница 6: ...8 Operator Manual KS 4000 OL OLC...

Страница 7: ...the machine is in operation Never place hands on any moving parts and keep long hair loose clothing or scarves and jewelry safely away from moving parts Never reach hands into areas or spaces marked...

Страница 8: ...10 Operator Manual KS 4000 OL OLC...

Страница 9: ...ignals errors and empty feeder stations Program memory All parameters that govern the system s operations e g document length transport speed marks recognition routines are stored in program memories...

Страница 10: ...Fold oversized or broadsheet material in the crossfold unit lateral transport unit and folder before inserting Three common system configurations are shown on the fold out pages 3 and 124 For process...

Страница 11: ...n each side Begin making settings at the inserter and then move upstream Load envelopes Switch inserter power to ON Press button on the inserter The inserter ON button lights up The inserting system t...

Страница 12: ...e red mark on the reading head should be aligned to the center of the printed marks Make sure the separator pre sluice is lowered Fan out a stack of sheets c 20 to 30 mm high so that the leading edges...

Страница 13: ...el The single sheet feeder will draw separate from stack the first sheet The lower display Display 2 will show READY If more than one sheet is drawn by the sepa rator the display will show an error me...

Страница 14: ...rt pro cessing the following sets Press the button on the inserter machine The first document set will be folded and inserted into an envelope The following set enters the inserter and the system stop...

Страница 15: ...e sheet feeder Resuming automatic operation after interruption To continue automatic operation press the stop button that was used to stop operation If the button on the inserter has been pressed the...

Страница 16: ...been fed from the single sheet feeder and the last complete document set is on the conveyor the system stops Check that the last set is complete and correct Turn OFF the single sheet feeder The inser...

Страница 17: ...2 mm gap on each side Begin making settings at the inserter and then move upstream Load envelopes Switch inserter power to ON Press button on the inserter The inserter ON button lights up The insertin...

Страница 18: ...ark on the reading head should be aligned to the center of the printed marks Make sure the separator pre sluice is lowered Fan out a stack of sheets c 20 to 30 mm high so that the leading edges form a...

Страница 19: ...panel The single sheet feeder will draw separate the first sheet The lower display Display 2 will show READY If more than one sheet is drawn by the sepa rator the display will show an error message P...

Страница 20: ...e first set to the first active supplement feeder station At the station first supplement Press button Set up station and load with supplement material Press button Press button One supplement will be...

Страница 21: ...tton The first set will be folded and inserted into an envelope The system then stops Start automatic operation only after making sure that each handling step is performed correctly You can use the bu...

Страница 22: ...stop automatic operation Press the button on the inserter or Press the button on the supplement feeder station or Press the button on the control panel of the single sheet feeder Resuming automatic op...

Страница 23: ...gle sheet feeder indicates that the stacked supply of single sheets has been exhausted Prepare a stack of material and load it into the single sheet feeder Press the button on the control panel The sy...

Страница 24: ...nserting system will automatically finish all sets that remain along the material handling path and then stop Press the last envelope button on the sealer The sealer delivers the last sealed envelope...

Страница 25: ...anual Inserting System 4000 Caution Make sure that no material from the previously run job remains in the machine Set all paper guides according to the width of the material being handled c 2 mm gap o...

Страница 26: ...e knurled set screws The paper should lay flat without being under tension or sagging in the middle Adjust edge blades Loosen edge blade locks Set edge blades left and right by sliding the trimmer hou...

Страница 27: ...the desired program number F1 Set program 00 F2 To reduce by 1 the shown program number F3 To increase by 1 the shown program number F4 To increase by 10 the shown program number Please read the Inst...

Страница 28: ...optical marks reading are to be run the lower display will show the message READY after the program has been selected Press the button to start the job The first sheet to be inserted will be cut and t...

Страница 29: ...nd inserted The following set enters the inserter and the system stops Start automatic operation only after making sure that the entire process is performed correctly You can use the button to start a...

Страница 30: ...cutter Resuming automatic operation after interruption To continue automatic operation press the stop button that was used to stop operation If the button on the inserter has been pressed the red butt...

Страница 31: ...heck that the last document set is com plete and correct corrections can be made manually if necessary Turn OFF the automatic cutter The inserting system will automatically finish all sets that remain...

Страница 32: ...s according to the width of the material being handled c 2 mm gap on each side Begin making settings at the inserter and then move upstream Load envelopes Switch inserter power to ON Press button on t...

Страница 33: ...trimmer housing to the desired position The blue marks on each edge blade housing show where the edge will be cut Lock edge blades into the desired position by tightening the set screws If necessary...

Страница 34: ...F2 To reduce by 1 the shown program number F3 To increase by 1 the shown program number F4 To increase by 10 the shown program number Please read the Instruction Manual Inserting System 4000 and the O...

Страница 35: ...is complete and correct Additional stations feeder folding feeder may be present on the conveyor These can add supplementary sheets to each set How you use any supplement station depends on how the sy...

Страница 36: ...nveyor control to move the set into position for receiving the next supplement Repeat the procedure described above for feeding a supplement to the set When the first set is complete on the con veyor...

Страница 37: ...peration Press the button button will light up If necessary Switch material format to match material A4 2 3 A4 is not pressed 1 3 A4 is pressed lights up Press button button lights up and automatic op...

Страница 38: ...ter interruption To continue automatic operation press the stop button that was used to stop operation If the button on the inserter has been pressed the button is lit up in red Press the button on th...

Страница 39: ...tter s control panel The last cut sheet will be delivered to the conveyor Check that the last document set is com plete and correct corrections can be made manually if necessary Turn OFF the automatic...

Страница 40: ...the automatic cutter control panel The last cut page remains in the cutter Press the button on the cutter control panel the last page will be transported to the conveyor Check that the last set is co...

Страница 41: ...n to resume automatic operation If necessary press the black button on the hand held conveyor control repeatedly until the system starts automatic operation 4 3 2 Supplement The system stops The feede...

Страница 42: ...44 Operator Manual KS 4000 OL OLC...

Страница 43: ...no material from the previously run job remains in the machine Set all paper guides according to the width of the material being handled c 2 mm gap on each side Adjust paper guides in the inserter fir...

Страница 44: ...knurled set screws The paper should lay flat without being under tension or sagging in the middle Adjust edge blades Loosen edge blade locks Set edge blades left and right by sliding the trimmer housi...

Страница 45: ...the desired program number F1 Set program 0 F2 To reduce by 1 the shown program number F3 To increase by 1 the shown program number F4 To increase by 10 the shown program number Please read the Instr...

Страница 46: ...ow the message READY after the program has been selected Press the button to start the job The cutter delivers the first set of documents to the lateral conveyor or sequencer which moves the material...

Страница 47: ...ded and inserted The following set enters the inserter and the system stops Start automatic operation only after making sure that the entire process is performed correctly You can use the button to st...

Страница 48: ...o continue automatic operation press the stop button that was used to stop operation If the button on the inserter has been pressed the button is lit up in red Press the button on the inserter If the...

Страница 49: ...orrections can be made manually if necessary Caution If the last set is incomplete remove and finish it by hand to avoid inserting errors Wait until the lateral conveyor transport motors shut down The...

Страница 50: ...ctions on configuring the inserting system for a job loading paper setting paper guides adjusting reading head etc can be found in Chapter 7 in descriptions of individual modules and in the Instructio...

Страница 51: ...in the paper s side strips with the pins on the transport belt Close tractor covers Align paper to the middle the of the machine Paper center line Centered to paper center paper guide Tighten set scr...

Страница 52: ...switch ON The red signal buttons on the individual modules will light up briefly The conveyor will move to its starting position The red signal button on the Black Box blinks The upper display Displa...

Страница 53: ...g head The reading head is positioned correctly when the adjustment line the first printed optical mark can be seen in the reading head s notch If programs without optical marks reading are to be run...

Страница 54: ...ore than one station move the first set to the first active supplement feeder station At the station first supplement Press button Set up station and load with supplement material Press button Press b...

Страница 55: ...ration only after making sure that each handling step is performed correctly You can use the button to start a single insertion cycle Starting automatic operation Press the button button will light up...

Страница 56: ...blink To resume automatic operation press the stop button that was used to interrupt operation If the button on the inserter has been pressed the button is lit up in red Press the button on the insert...

Страница 57: ...the last set of documents is complete and correct corrections can be made manually if necessary Caution If the last set is incomplete remove and finish it by hand to avoid inserting errors Wait until...

Страница 58: ...ither at the automatic cutter or one of the supplement feeder stations the system will stop and show an error message Detailed instruction on reloading paper and resuming a job that has been started c...

Страница 59: ...erter Set the orange coloured button on the hand held conveyor control to I the con veyor is now turned ON The on line exten sion of the inserting system is now deacti vated Press the button to turn O...

Страница 60: ...t set enters the inserter and automatic operation begins The first set has reached the inserter Start automatic operation Press the button the button will light up If necessary Switch material format...

Страница 61: ...r Set the orange coloured button on the hand held conveyor control to I the con veyor is now turned ON The on line exten sion of the inserting system is now deacti vated Press the button to turn ON St...

Страница 62: ...ess button One sheet page will be drawn from the stack to generate a reference value Verify that only a single sheet was drawn Press the button to confirm Use the black button on the hand held conveyo...

Страница 63: ...ration Press the button the button light will come one If necessary Switch material format to match material A4 2 3 A4 is not pressed 1 3 A4 is pressed lights up Press button button lights up and auto...

Страница 64: ...ure the last set is complete and correct When the last set has been inserted Press the last envelope button on the sealer The sealer delivers the last sealed envelope Press the button on the inserter...

Страница 65: ...in the Instruction Manual Inserting System 4000 Operating Instructions Cut Sheet Feeder and in the Operating Instructions Automatic Forms Cutter 7 Inserting system KS 4000 OL OLC modules Inserting Sys...

Страница 66: ...68 Operator Manual KS 4000 OL OLC 7 1 Single sheet feeder 7 1 1 Operating and adjustment controls 1 2 5 3 7 6 8 9 10 4...

Страница 67: ...e K 5 F F O N O r e w o P F F O N O r e d e e f t e e h s e l g n i s s e h c t i w S 6 e c i u l s h c t a l d e s o l C e g d i r b l a m r o n d e r e w o l s t i o t n i e g d i r b e c i u l s s...

Страница 68: ...ne meets the center markings of the single sheet feeder Move the two paper guides one after the other up to the sample sheet so that a gap of about 2 mm remains between the guide and the sample sheet...

Страница 69: ...red markings should be visible during automatic operation 7 1 4 Load paper A stack of paper about 20 to 30 mm tall should be neatly fanned with the leading side forming a wedge The wedge should be ev...

Страница 70: ...he prepared stack of paper into the paper tray Make sure the address location is correct 7 1 5 Adjust reading head Open clamps that hold the separator bridge assembly into position Raise the entire sl...

Страница 71: ...ign with the middle of the optical marks on the sheet of paper Now tighten the reading head down with the locking screws Release the sluice bridge assembly and lower the bridge back into its normal wo...

Страница 72: ...74 Operator Manual KS 4000 OL OLC 1 2 3 4 7 2 Automatic cutter 7 2 1 Operator controls 11 12 13 8 7 5 6 10 7 8 9 14 15 10 9 11 12 13 14...

Страница 73: ...p g n i t t u c e d a l b e g d e s e t a c i d n I 8 g n i s u o h d n a s e d a l b e g d E s e d i s r e p a p s m i r T 9 e d a l b e g d e r o f w e r c s d e l r u n K n o i t i s o p e d a l b...

Страница 74: ...e sure guide holes mesh correctly with the transport pins on the transport tractor belts Close tractor covers Move both tractors to correctly position the sheet of paper to the middle of the automatic...

Страница 75: ...using so that the blue mark is aligned to the desired cutting position Tighten the blade housing locking screw This locks the edge blade into position If necessary use the knurled screw to make fine a...

Страница 76: ...the first printed mark that passes under the reading head during an optical marks recognition cycle This adjustment line must be exactly aligned with the notch in the reading head If necessary adjust...

Страница 77: ...Reading from below Before loading the piece of continuous feed paper use a punch pliers to mark the location of the adjustment line Adjust the reading head as described above The marking hole must be...

Страница 78: ...s s e r p s r o r r e d n a s u t a t s s w o h S e g d e l w o n k c a 2 e c a r b r e l l o r t r o p s n a r T t r o p s n a r t r e p a P 3 r o t c e l f e D t r o p s n a r t r e p a p t c e r r...

Страница 79: ...position Use a screwdriver to loosen the screw on the deflector Move the deflector to a position that safely guides the paper Retighten deflector screw Adjust the other deflector in the same manner O...

Страница 80: ...t s s e r p s r o r r e d n a s u t a t s g n i t a r e p o s w o h S s r o r r e e g d e l w o n k c a 3 d n a h t n e m t s u j d a l a u n a M k n a r c h t g n e l l a i r e t a m o t t s u j d A...

Страница 81: ...t the back stop 2 to 3 mm from the sample s lower edge Remove sample sheet Warning Danger of injury Use caution when closing the sequencer s upper body and do not reach between the roller brace and th...

Страница 82: ...84 Betriebsanleitung KS 4000 OL OLC 7 5 Folder 1 2 3 4 4 5 7 6...

Страница 83: ...t u b l a n g i S o t s s e r p s r o r r e d n a s u t a t s s w o h S s r o r r e e g d e l w o n k c a 2 n o t t u B t e k c o p g n i d l o f e h t l l a t s n i e r d n a e v o m e r o T g n i c...

Страница 84: ...etween the sheet s leading edge and the paper stop Adjust paper length 1 3 4 2 on rear side s l o r t n o C n o i t c n u F 1 p o t s r e p a P r e p a p d e t r e v i d r o f e d i u G 2 r e d i l S...

Страница 85: ...st the pressure with which the depressor springs hold paper down Test settings and correct if necessary Pages should be neatly caught to form an even stack Adjust catch tray Modules Diverter 1 3 2 2 2...

Страница 86: ...88 Operator Manual KS 4000 OL OLC 7 7 Conveyor 1 4 5 2 3 6 7...

Страница 87: ...a p s d l o H 4 r o y e v n o c d l e h d n a H r e l l o r t n o c l o r t n o c r o y e v n o C 5 k c a l B n o t t u B p o t S 0 g n i t t e S d r a w r o f d l e i f e n o t r o p s n a r T 1 g n...

Страница 88: ...with 0 corres ponding to the centerline The two guide rails should be centered equally on both left and right scales Adjust the guide rails at both ends of the conveyor Check the setting with a sample...

Страница 89: ...yor The trailing edge of the sheet of paper should be flush to the fixed back stop on the conveyor The leading edge of the sample sheet should be 2 3 mm from the paper stop If necessary adjust the pap...

Страница 90: ...92 Operator Manual KS 4000 OL OLC 7 8 Feeder folding feeder 7 8 1 Controls 1 2 3 5 4 2 6 Control panel 7 8 9 10 11 17 16 15 14 13 12...

Страница 91: ...r P 9 b o n K e t a g r o t a r a p e s s t s u j d A 0 1 y a l p s i D s e d o c r o r r e d n a s n o i t c n u f s y a l p s i D 1 1 s D E L s n o t t u b l a u d i v i d n i f o s u t a t s w o h...

Страница 92: ...s into position 7 8 3 Adjust separator gate Swing the separator sluice upward until it clicks into position Lay a sample sheet onto the tray Turn the knob counterclockwise until the sample sheet can e...

Страница 93: ...is at the point of a wedge Swing the separator head upward until it clicks out of the way Lay the fanned out stack of documents into the tray as shown and push up to the separating head Note that addr...

Страница 94: ...ual KS 4000 OL OLC 7 9 Inserter 7 9 1 Controls type A inserter 20 19 18 17 16 15 12 7 9 2 Controls type VA inserter 20 19 18 17 16 15 12 13 14 1 2 5 4 9 6 3 3 8 11 10 10 interior 7 1 2 5 4 9 3 3 11 10...

Страница 95: ...K h t p e d r e p p o h e p o l e v n e t s u j d A t h g i e h e p o l e v n e o t g n i d r o c c a e i 1 1 r e p p o h e p o l e v n E y l p p u s e p o l e v n E 2 1 d e r n o t t u b p o t S o s...

Страница 96: ...s Swing cover open Place a sample sheet inside the inserter Use the material width knob to set the paper guide rails to the correct setting The rails should leave a 2 mm gap on both sides of the stack...

Страница 97: ...n and flat Unpack envelopes 24 hours earlier for best results Fan the envelopes through your fingers before loading to loosen them up before loading Lay the envelopes into the hopper as shown Be caref...

Страница 98: ...100 Operator Manual KS 4000 OL OLC 7 10 Sealer 2 1 3 4 8 9 10 5 7 6 6 5 1...

Страница 99: ...i l i a r t h g i e h e p o l e v n e k c o L 6 s g n i k r a M l i a r e d i u g e p o l e v n e r o f d i a t n e m t s u j d A 7 l i a r t h g i e h e p o l e v n E e d i u g e p o l e v n E 8 w e...

Страница 100: ...e cover Push the latch as shown to release Raise cover upwards Closing the cover Lower cover to normal position Push the latch as shown with one hand while pressing the cover gently downward Let the l...

Страница 101: ...ps With the assistance of the system s error signaling system you can locate the problem and iden tify causes We recommend the following steps Press the button on the inserter Identify the cause of th...

Страница 102: ...hand and completed manually Resume operation only after the complete document set has been removed and the next addressee is ready to start This will help you avoid incorrectly or incompletely filled...

Страница 103: ...er jam Caution Raise the pre sluice preliminary separator block before attempting to clear a paper jam or when removing loaded material If the separating device draws more than a single sheet the disp...

Страница 104: ...a P t e e h s e v o m e R e z i s k c e h C R E P A P O N t o n n a c r e i r r a b t h g i L e l g n i s e h t n i r e p a p e t a c o l r e d e e f t e e h s s g n i t t e s k c e h C s i r e d e e...

Страница 105: ...e e f s u o u n i t n o c n i h s a r C t r o p s n a r t 2 y a l p s i D R E P A P s i l a i r e t a m t u c n U y l t h g i t o o t d e d n e p s u s o o t r o s r o t c a r t n e e w t e b y l e s...

Страница 106: ...i d a e r d e m m a r g o r P t o n o d s e n i t u o r d e t n i r p o t d n o p s e r r o c s k r a m m a r g o r p g n i d a e r k c e h C s i d a e h g n i d a e r R M O d e t n i r p h t i w d e...

Страница 107: ...The system is ready to resume operation To clear a paper jam Push the sheet of paper which is jammed in the lateral conveyor into the folding device by hand until you notice resistance Press the sign...

Страница 108: ...delivery device t l u a F e s u a C y d e m e R n o n o t t u b l a n g i s d e R r o y e v n o c l a r e t a l e h t s k n i l b t o n o d s r e i r r a b t h g i L t n e m u c o d a t c e t e d r o...

Страница 109: ...also blink After eliminating the cause of the fault clear the error message First press the sequencer signal button for about 1 second The button will stop blinking If the Black Box signal button is...

Страница 110: ...nce when working on the folding device or clearing jammed paper Mov ing parts can cause injury Remove all materials from the delivery device and the lateral conveyor sequencer Paper jam in the folder...

Страница 111: ...ally stops Releasing the two buttons stops the folding pocket drive motors The next time the but tons are pressed the pocket will move in the opposite direction Whenever the buttons are pressed the fo...

Страница 112: ...black folding device buttons and hold them pressed until the folding pocket reaches its bottom position and stops Before resuming operation Check all paper involved in the paper jam and make sure the...

Страница 113: ...l u d o m m a e r t s p u h t a p r e p a p k c e h C t o n s e o d r e d l o f e h T d n a s t n e m u c o d t c e j e n o t t u b l a n g i s d e r e h t m a e r t s n w o d e h t n o s k n i l b e...

Страница 114: ...t a c s s e r P e g a p e v o m e R 1 t u o b a n o t t u b l a n g i s d n o c e s l l u f s i y a r t h c t a c r e t r e v i D y t p m E l a n g i s s s e r P 1 t u o b a n o t t u b d n o c e s t...

Страница 115: ...i D e s n e l e h t n a e l C r e i r r a b t h g i l s k c o l b r e p a P r e p a p k c a b l l u P g n i k n i l b a e r a r o t c e j e n i m a j r e p a P m a j r e p a p r a e l C r o s n e s e...

Страница 116: ...o d e e f e l b u o D r e h t o e h t n e e w t e b p a g h t i w s t e e h s t e e h s d n o c e s e v o m e R h t a p r e p a p k c e h C r o r r e f I y l d e t a e p e r s r u c c o r o t a r a p...

Страница 117: ...e s r o s n e s e v i t c e f e D e c i v r e s r e m o t s u c t c a t n o C e h t n o t f e l n e e b s a h e g a p A n o i t a t s e h t r e d n u r o y e v n o c s s e r P e g a p e h t e v o m e...

Страница 118: ...n o r o t i n o m d e l i a f A V l e d o m 0 0 0 5 e t e l p m o c e v o m e R s t n e m u c o d d n a t e e u n i t n o c o t s s e r p n o i t a r e p o r e l a e s n i m a j e p o l e v n E m a e...

Страница 119: ...e S g n i e b s t n e m u c o d d e s s e c o r p d n a d e s s e r p s i t i l d n a n i a g a n o t t u b s s e r P t u o s e o g t h g i l y t p m e s i r e t r e s n I m o r f s t e s t n e m u c...

Страница 120: ...e d r o t i n o m t h g i e h e p o l e v n e k c e h C g n i t t e s e c i v r e s y b t n e m t s u j d A e b y a m n a i c i n h c e t y r a s s e c e n t o n s e o d r e l a e S e p o l e v n e t...

Страница 121: ...rossfold configuration with automatic cutter Location may very depending on configuration Catch tray Inserter Catch tray diverter Control panel Automatic cutter Sealing unit Conveyor Sequencer Folder...

Страница 122: ...In the event of a fault becoming apparent despite our best quality control measures please contact your customer service representative FP authorized dealer Francotyp Postalia AG Co Postfach D 16542 B...

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