FP FPI 7100 (01) PDF DOCUMENT

When using your FP FPI 7100 inserting system, please follow these precautions:

General Use:

Read all instructions before operating the system.

Use this equipment only for its intended purpose.

Place the system in an accessible location with proper venting to facilitate servicing.

Power and Electrical:

Place the system close to an easily accessible wall outlet.

Use the AC power adapter included with this device. Third-party adapters may cause damage.

Plug the AC adapter directly into a properly grounded wall outlet. Failure to ground the machine can result in severe personal injury or fire.

The AC adapter/power cord is the primary means to disconnect the device from the AC supply.

DO NOT use a wall outlet controlled by a wall switch or one shared with other equipment.

DO NOT use an adapter plug on the line cord or wall outlet.

DO NOT remove the ground pin from the line cord.

DO NOT route the power cord over sharp edges or trap it between furniture. Ensure there is no strain on the power cord.

If the unit becomes damaged, unplug it from the wall.

Operational Safety:

Keep fingers, long hair, jewelry, and loose clothing away from moving parts at all times.

Avoid touching moving parts or materials while the machine is in use. Before clearing a jam, ensure machine mechanisms come to a complete stop.

Remove jammed material gently and carefully.

DO NOT remove covers, as they enclose hazardous parts that should only be accessed by trained service personnel.

DO NOT place lighted candles, cigarettes, cigars, etc., on the system.

To prevent overheating, do not cover vent openings.

Use only approved supplies.

Never use aerosol dusters labeled flammable. Always read instructions and safety precautions on the duster container label.

Always follow specific occupational safety and health standards for your workplace.

Before operating, ensure the machine has been properly prepared and other personnel are standing clear.

Immediately report any damaged or non-functioning components that render the unit unsafe to service.

Stacker with AC Adapter:

Use the AC power adapter included with the stacker.

To protect against electrical shock, plug the AC adapter power cord into a properly grounded wall outlet.

DO NOT route the power cord over sharp edges or trap it. Ensure there is no strain on the power cord.

The warning labels on the FP FPI 7100 alert you to potential injury from careless operating procedures. The labels include:

CAUTION: Moving mechanism can result in personal injury. Keep hands, long hair, ties, jewelry and loose clothing away from moving parts. (This warning is depicted with an icon of a hand near gears).

CAUTION: Moving mechanism can result in personal injury. Keep hands, long hair, ties, jewelry and loose clothing away from moving parts. (This warning is depicted with an icon of a hand near rollers).

NOTICE: This label, with an icon of a hand being pinched by rollers, indicates a potential pinch point.

The FP FPI 7100 is a high throughput, mail creation system with the following features:

Folds up to a maximum of 10 sheets of 20 lb. (80 gsm) paper with a single fold.

Supports inserting multiple items into flat envelopes.

Is configurable with four flexible feeder trays, which come in two types:

– Sheet trays: Capable of feeding sheets.

– Insert trays: Capable of feeding slip/insert materials, pre-folded inserts, thin booklets, and envelopes.

The FP FPI 7100 system is equipped with a High Capacity Envelope Feeder (HCEF) for greater speed and throughput.

The system can accept material from optional upstream input devices.

The FP FPI 7100 is comprised of several key components that work together to create mail pieces. The main components are:

1. Feeder Tower Trays: Feed sheets or inserts into the feeder tower.

2. Feeder Tower: A two-sided tray holder and material feeder. The lower left tray can be used as the primary envelope feeder if a High Capacity Envelope Feeder is not present.

3. Manual Feeder: Allows manual feeding of stapled or unstapled sets of up to 5 sheets. The machine waits for each set to be fed before folding and inserting.

4. Pre-fold Accumulator: A staging area where material is collated before being sent to the folder.

5. Folder: Applies one of the available fold types to the collated sheets.

6. Post-fold Accumulator: A staging area where folded sheets are combined with any inserts.

7. Insertion Area: The part of the transport where the collated contents are inserted into an outer envelope.

8. Moistener, Closer, Sealer: Wets the envelope flap, then moves it through the closer and sealer areas to complete the mail piece.

9. Sealing Solution Bottle: Located inside a cover on the front right, it supplies sealing solution to the system.

10. Control Panel: Allows you to run the machine, configure jobs, and view machine status.

11. High Capacity Envelope Feeder (FPi 7100/8100 only): Holds at least 500 letter-sized envelopes and feeds them directly to the insertion area.

The control panel on the FP FPI 7100 is used to operate the machine, define jobs, and view status. It consists of the following keys and indicators:

1. LED Status Indicator: Shows the current machine status.

2. Screen Option Keys: Eight keys that correspond to options displayed on the screen. They allow you to define settings for up to 24 stored jobs and edit them.

3. Fixed Function Keys: Four keys with assigned functions displayed on the screen.

– Reset Counter: Resets the Piece Counter, Batch Counter, or both.

– Help: Provides information about the current screen or access to the entire Help file.

– Cancel: Returns to the previous screen.

– Home: Returns to the Home screen for the current job. Changes are not saved until you select “Save Job.”

4. Screen Navigation Keys: A two-tiered circular button for moving around the display.

– UP/DOWN and LEFT/RIGHT Arrows: On the outer tier, these keys move the cursor on the screen.

– OK Button: On the inner tier, this button applies the selection you have made.

5. Machine Action Keys: Four keys to control hardware and mechanical movements.

– Start (Green): Begins running the selected job.

– Trial Piece: Runs a test cycle for your job, preparing one complete mail piece for inspection.

– Clear Deck: Clears materials currently in process in the paper paths. Only press when prompted.

– Stop (Red): Finishes in-process mail and stops the job.

To change the language on the FP FPI 7100 display, follow these steps:

1. From the Home screen, select Menu.

2. From the Menu screen, select Change Language. A list of available languages will be displayed.

3. If needed, use the Next and Previous options to view additional languages. Select the language you want to use.

4. Select Finished.

5. Press the HOME key to return to the Home screen.

The FP FPI 7100 follows a specific path to assemble a mail piece. Here is a brief description of how the system works:

Transport Deck: This is the main path where material moves from the feeder tower through various modules to produce a finished mail piece.

Mail Piece Path:

1. Pre-fold Accumulator: This is the first stop. Material that needs to be folded is stacked and collated here. Once all components for a single mail piece are gathered, they move to the folder.

2. Folder: The collated stack of sheets enters the folder where a fold (C Fold, Z Fold, Single, or Double Fold) is applied. It then moves to the post-fold accumulator.

3. Post-fold Accumulator: The folded sheets arrive here. Other components that do not require folding, like a reply envelope or a pre-folded insert, are added to the stack. When all components are present, the complete stack moves to the insertion area.

4. Folder Bypass Path: The outer envelope is fed from its designated feeder and travels along the bottom part of the transport deck, bypassing the folder, to meet the contents at the insertion area.

5. Insertion Area: The contents of the mail piece meet the outer envelope. The envelope arrives face down with its flap open, and envelope openers widen it for the contents to be slid inside.

6. Moistener, Closer, Sealer: As the envelope passes over the moistener, brushes wet the glued area of the flap. The envelope is then inverted and slid through the closer and sealer portion of the system to complete the sealing process. From there, the finished mail piece is dropped onto a stacker.

The FP FPI 7100 has several covers that provide access to the internal rollers and paper path for clearing stoppages.

Open the Covers:

Main Transport Deck Cover:

1. Place your fingers into the slot on the top of the cover.

2. Pull down gently. A security tie will keep the cover within its recommended range of movement. IMPORTANT: Do not lean on the open cover.

Main Tower Base Cover:

NOTE: The main transport deck cover is interlocked with the tower base cover and must be opened first.

1. Open the main transport deck cover.

2. Pull down on the tower base cover handle.

Close the Covers:

To close the lower tower base cover and/or the main transport deck cover, push the cover up until it is seated firmly in place on the system deck.

The FP FPI 7100 system has two security modes and three levels of user access.

Security Modes:

Login Not Required Mode: Requires a four-digit access code only for supervisor and manager functions.

Login Required Mode: Requires a user ID and password for all system operator, supervisor, and manager functions.

User Access Levels:

User	Access Rights
Operator	Access to selecting and running a job, limited scanning activities, and running a Swift Start job. System operators may be required to log in and out of the system if a security mode has been enabled.
Supervisor	Access to all operator functions as well as programming a job, saving a job, and deleting a job (with the correct access code or user ID and password).
Manager	Access to all of the above functions plus exclusive rights to manage other users (i.e. assign/restrict functions and selecting the account mode).

NOTE: The supervisor and manager access levels require entry of an access code or a user ID and password, which are assigned by the system manager.

The login procedure depends on the security mode enabled on your FP FPI 7100.

Login Required Mode:

If this mode is enabled, you need a user ID and password to access the system.

1. At the Select User screen, select your user ID. If necessary, select Next to view additional user IDs.

2. Enter your password. Passwords are four-digit numeric codes. The numbers 1, 2, 3, 4, and 5 are on the first screen; press “Next” to access numbers 6, 7, 8, 9, and 0.

3. Select Accept. The Home screen will display.

Login Not Required Mode:

If this mode is enabled, user IDs and passwords may still be set up by a manager. The “Log In” option will display on the Home screen to access restricted functions.

Log Out:

To log out, select Log Out on the Home screen. You must log out of the system for the next operator to be able to log in.

WARNING! Read the safety information in the front of the operator guide before connecting the system to power.

To power up your FP FPI 7100, follow these steps:

1. Connect the power cord to the socket on the back of the inserter.

2. Plug the power cord into a suitable power outlet. Verify the power outlet is near the inserter and is easily accessible.

3. Press the ON/OFF switch, located below the control panel, to start the power-up process.

NOTE: If you have a High Capacity Sheet Feeder (HCSF), power it on before you power on the base inserter. When power cycling the system, be sure to power cycle any optional add-on equipment as well.

The system will automatically conduct checks to verify its operational integrity. If any problems are detected, the system will display information to help you find a solution.

Running a job on the FP FPI 7100 involves five major steps, which must be followed in order. This guide assumes the job has already been created and saved in the system.

Step 1: Select a Job

– If the job you want is already on the Home screen, proceed to Step 3.

– Otherwise, from the Home screen, select Another Job or go to Menu > Jobs > Select Job.

– Choose from Saved Jobs, Recently Run Jobs, or Library Jobs.

– Select the desired job from the list. The Mail Piece Icon Tree for that job will appear.

Step 2: Set Up Feeders and Load Material

– If prompted, attach the necessary trays to the Feeder Tower.

– Load material into the trays as directed by the on-screen loading instructions and the Mail Piece Icon Tree.

– Load the High Capacity Envelope Feeder (HCEF), if necessary for the job.

Step 3: Make Pre-Run Adjustments (if necessary)

– If using a different envelope size than the previous job, you may need to adjust the envelope openers to ensure accuracy.

– Follow the on-screen prompts for any required adjustments.

Step 4: Run a Trial Piece

– Press the TRIAL PIECE key. The system will assemble one complete mail piece and feed it to the upper divert area for inspection without sealing it.

– Examine the trial piece for correct collation, address visibility, and to check for doubles.

– If it is correct, select Trial Piece OK or press START.

– If adjustments are needed (e.g., address position), select Adjust Address or Edit Job.

Step 5: Start the Job

– Once the trial piece is verified and you are on the Home screen, press the green START key. The system will begin running the job.

Properly setting up the feeders and loading material is crucial for running a job on the FP FPI 7100.

Attach Trays to the Feeder Tower:

1. Align the back end of the tray with the tray mounts in the feeder tower.

2. Lift the separator by pushing up on the separator lift lever (located on the side of the feeder tower).

3. Slide the tray into the mounts until you feel it seat into place. The notch on the bottom of the tray should be seated in the groove on the tray mount.

4. Pull back on the tray slightly to ensure it is secure.

Load Material into the Trays:

1. Loosen (fan) the stack of material to prevent items from sticking together.

2. Use the side guide adjustor (blue knob) to open the side guides wider than the material.

3. Place the fanned material into the tray according to the orientation shown on the Home screen’s Mail Piece Icon Tree.

4. Use the side guide adjustor to move the guides in until they lightly touch the material. When released, they will spring back slightly to allow for proper feeding.

5. For a sheet tray, lift the separator before loading material into the tray. Do not load material above the maximum fill line.

6. For an insert tray, stand the material up against the front end of the tray, adjust the guides, and then slide the sled forward until it contacts the material.

If you are using a different size envelope than the previous job, you may need to adjust the envelope openers to ensure proper insertion.

1. Feed a Test Envelope:

– Load the outer envelopes into the appropriate feeder.

– From the Home screen, select Loading Instructions > Pre-Run Adjustments > Envelope Opener Settings.

– Press TRIAL PIECE to feed one envelope to the insertion area.

– Open the insertion area cover to observe the envelope’s position.

2. Perform Width Adjustments (Outer Envelope Openers):

– Loosen the thumbscrews on the top of the two outer envelope openers.

– Slide the openers so their pointers align with the outer edges of the envelope.

– For windowed envelopes, ensure the openers do not touch the edges of the window.

– Tighten the thumbscrews.

3. Perform Length Adjustments (Inner Envelope Openers):

– Loosen the thumbscrews on the three inner envelope openers.

– Position the openers so they do not touch the edge of the window (if applicable).

– Press down and pull one of the knobs on the top of the frame to check how far the opener goes into the envelope. Adjust if necessary so it goes at least 5 mm into the top panel of the envelope.

– Tighten the thumbscrews for all adjusted openers.

4. Verify Settings:

– Close the insertion area cover.

– Press CLEAR DECK, then press TRIAL PIECE again.

– If the openers are positioned correctly, select OK. If not, repeat the adjustment steps.

Properly adjusting the scan heads is key to maximizing barcode or OMR performance on the FP FPI 7100. The side guides must be set correctly and material loaded evenly for marks to align with the scan head.

Adjusting for Ladder or 2D Orientation Marks:

1. Fold a sheet to be scanned in half vertically (mark side up).

2. Fold the sheet horizontally, so the barcode appears on either side of the fold line.

3. Open the main transport deck cover. Use a ruler to measure the distance from the center of the sheet (vertical fold) to the center of the mark.

4. Refer to the loading instructions to determine if the sheet is loaded top or bottom first, and which scan head (left or right) is used.

5. Open the feeder tower cover or HCSF tower cover where the scanner is located.

6. Determine which way the scan head needs to move. Align the center of the sheet (vertical fold) with the 0 on the ruler in the inserter. If the sheet is loaded top first, the mark should be below the horizontal fold; if bottom first, it should be above.

7. Use the blue thumbwheel to move the scan head. Move the thumbwheel until the pointer on the scan head lines up with the measurement you took in step 3.

Adjusting for Picket Orientation Marks (HCSF Only):

The process is the same as above, but you will use a picket-style barcode for your test sheet.

Verify the Adjustment:

1. From the home screen, select Loading Instructions > Pre-Run Adjustments > Scanner Setup.

2. Use the UP/DOWN keys to select the feeder to test.

3. Press TRIAL PIECE to feed one piece from that feeder.

4. Select Finish.

If a material stoppage occurs, the FP FPI 7100 will immediately stop the job and display an error message. Follow these steps to clear it:

Clear the Stoppage:

1. Use the information in the error message on the display screen to locate where the problem occurred.

2. Open the necessary cover(s) to access the material stoppage.

3. Gently and carefully clear only the material in the area indicated.

4. If the screen prompts you to clear the deck, press the CLEAR DECK key.

5. Follow any further instructions on the display screen.

6. Once the stoppage is fully cleared, close all open covers.

Resume the Job:

1. Verify that there are no error messages on the screen and all system covers are closed.

2. Press the green START key.

– If the error message instructed you to remove material from the trays to start a new collation, pressing START will begin a new collation.

– Otherwise, the job will resume counting from the last successfully completed mail piece.

Outsorted Material:

During a jam recovery, any partially assembled pieces are not counted and are transported to the upper divert area. These items should be discarded or manually assembled.

Problem	Cause	Action
System won’t power up	System power cord is not plugged into the wall outlet.	Plug power cord into wall outlet.
	No power at outlet.	Check outlet. Verify that wall outlet has power.
	Faulty Power Supply, circuit board wiring, or Power Switch.	Call your system supplier.

Problem	Cause	Action
– No display; but system power is on. (LED in upper right corner of the Control Panel is orange or green.) – Display locks up. – Screen Option Keys don’t work. – Machine Keys don’t work.	Faulty circuit boards or power supply, loose wiring, or poor connections.	Press the power button to restart system. If problems persist, call your system supplier.
Display locks up.	Display timeout.	Press the OK key turn on the display.
Display is too light or dark (contrast and/or readability problem).	Poor contrast / brightness adjustment.	Adjust contrast and/or brightness settings.

Problem	Cause	Action
Failure to feed.	Material not within specifications.	Check that all material meets published specifications. Remove curled or warped material and use only properly stored material.
	Improper loading.	Be sure to fan (aerate) material before loading. Follow loading instructions on the display. Check that side guides are not too tight. Ensure material is in the correct feeder and orientation.
	Paper fragments or debris in tray, rollers or tower transport.	Inspect feed rollers and transport path. Remove paper fragments before running a clear deck.
Double or multiple feeds; stream feeding.	Material not within specifications.	Check that all material meets published specifications. NOTE: Some glossy materials can contaminate rollers and cause double feeds.
	Improper loading.	Be sure to fan (aerate) material before loading, especially recently printed material. NOTE: Low humidity can cause static cling.
	Dirty, worn or glazed feed and/or retard rollers.	Clean or replace affected rollers. Contact your system supplier.
	System incorrectly detects double feeds.	– For inserts: If the double detect is seeing the flap or seam of an insert, set the custom double detect window to an area without these features, or turn double detect off. – For sheets: If inserts have thick print or images, set the custom double detect window away from these areas. If the problem persists, turn double detect off. – For mixed thickness paper: Rerun the trial piece. If that fails, turn off double detect.
First piece following trial piece is a false double.	The initial trial piece was likely a real double.	Run the trial piece again.

Problem	Cause	Action
Stoppage in insertion area or flapper area; failure to insert.	Outer envelope is skewed.	Check side guides; incorrect adjustment can cause skewing. Refer to Adjusting Tray Side Guide instructions.
	Envelope openers improperly adjusted.	Perform setup adjustment. Refer to Adjusting the Envelope Openers instructions. The recommended distance between the tip of the outside finger and the edge of the envelope is .5-inch to 1-inch (15 to 25mm). Ensure binding on booklets is parallel or perpendicular to the feed direction as appropriate for size.
	Insufficient edge clearance.	Check clearance: envelope width must be at least .5-inch (13mm) greater than the sum of the width of the widest insert plus the insert pack thickness. For a single piece into a standard business envelope, 9 mm clearance is sufficient.
	Insertion pack or envelopes not centered.	Ensure that Side Guides are set correctly. Too much clearance can cause material to skew.
Contents of insertion pack are thick, catching on the side seam, or difficult to insert.	The aligner custom settings may need adjustment.	Adjust the Aligner custom settings. Go to Menu > Jobs > Edit Current Job > Edit Job Settings > Advanced > Aligner > On with Custom Settings. Set the “Envelope Width” and “Widest Enclosure Width” to the exact dimensions of the insertion pack.

Problem	Cause	Action
No seal, failure to seal, incomplete seals.	Sealing is off in job set up.	Check job definition and make sure sealer is ON.
	Low sealant level.	Add water or sealing solution.
	Poor quality envelopes.	Inspect envelopes. Examine glue lines.
	Worn moistener brushes.	Inspect. Replace if necessary.
	Worn moistener wick.	Inspect. Replace if necessary.
High seal: flap is folded/sealed above crease line.	Outer envelope or content skew.	Check Side Guide adjustment and for proper loading of material in Trays.
	Contents of insertion pack are thick or catching on side seam.	Adjust the Aligner custom settings for “Envelope Width” and “Widest Enclosure Width”.
Stoppage in envelope exit area.	Glue contamination or debris in transport.	Inspect and clean transport.
Box seal: material obstructs envelope fold, causing flat area at crease.	Materials are not inserted deep enough into envelope.	Adjust the Envelope Crease Line upstream so materials are inserted deeper into the envelope. Go to Menu > Tools > Configure System > Set Envelope Crease.
Envelope exit through letter path is unreliable; envelope is damaged.	Collations may be too stiff to exit through the letter exit path.	If the envelope is longer than 6 inches (152 mm), process it through the flat exit path by enabling the “Stiff Media” option in the job’s advanced settings.

Problem	Cause	Action
Failure to feed. OR Skew of envelopes.	Envelopes not advancing down Tail Prop. – Separator Gap too tight. – Side Guides too loose or too tight. – Incorrect Tail Prop position.	Push or tap the bottom of the stack of envelopes. Check the separator gap, side guide, and tail prop settings.
	Debris in area below HCEF.	Remove debris.
Double feeds (envelopes fail to separate), stream feeds.	Separator Gap adjustment too wide.	Adjust the separator gap.
	Incorrect Tail Prop position.	Adjust the tail prop.
	Envelopes nested, stuck or glued together.	Remove unsatisfactory envelopes.
System incorrectly detects double feeds.	Double detect is seeing flap or seam of insert envelope.	Set the custom double detect window where there is no flap, seam or window on the envelope. OR Turn double detect off.
Envelopes stop in flapper. OR Envelopes stop in the transport beyond the flapper and are not flapped or partially flapped.	Incorrect loading of envelopes.	Ensure envelopes are properly oriented per the loading instructions on the display screen.
	Envelopes stuck or glued together.	Ensure envelope flaps are not bonded to the body of the envelope. Remove unsatisfactory envelopes.
	Side Guides set too loose or too tight.	Perform Side Guide adjustment.

Problem	Cause	Action
Two or more collations are inserted in a single envelope. OR A single collation is broken in two and inserted into two envelopes. OR System stops and declares an error.	Scanner head position improperly adjusted.	Check position adjustment of scanner head.
	Selected scan definition is incorrect for job.	Select correct scan definition.
	Adverse paper motion (skew, slippage, offset).	Make sure material is properly loaded. In particular, check the feeder side guides. Check the transport is free of obstructions.
	Poor OMR / barcode printing (insufficient contrast, poor print quality, inadequate clear zones).	Check the mark specifications to make sure OMR or barcodes are fully compliant. Low toner in printers or rough paper can cause problems.
	Scanner inoperative.	Contact your system supplier.

To keep your FP FPI 7100 running smoothly, perform these daily tasks:

Remove any excess paper dust that has accumulated on or around the system modules.

Use a damp cloth to wipe unwanted soil marks from the covers.

Report any system malfunctions and/or noticeable wear on system parts to your supervisor.

Replace the moistener wick when it becomes dry. It is recommended to replace the wick and brushes together around 250,000 machine cycles.

1. Open the insertion area cover.

2. Place paper towels on the Sealer deck to the left of the reservoir to catch any water drips.

3. Release the plastic latches on each side of the reservoir by sliding them away from each other.

4. Pull the old wick cartridge straight up and out of the reservoir and place it on the paper towels.

5. Wrap the old wick cartridge in the paper towel and discard it.

6. Slide the new wick cartridge into the reservoir, with the open side of the cartridge facing the exit (rear) of the machine.

7. Press down on the ends of the new cartridge until the two bump features sit below the top edges of the reservoir.

8. Slide the plastic latches toward each other and over the new wick cartridge until they snap into place.

9. Close the insertion area cover.

Replace the moistener brushes when they show signs of wear to ensure proper sealing.

1. Open the insertion area cover.

2. Remove the old brushes:

a. Hold the blue brush holder in place with one hand.

b. Use your other hand to push the bristles of one old brush completely free from the holder. You will be pushing the bristles toward yourself.

c. Repeat for all three brushes and discard them.

3. Install the new brushes:

NOTE: Avoid bending or deforming the brush bristles.

a. Hold the blue brush holder in place with one hand.

b. Insert the metal edge of a new brush into the channel opening in front of the brush holder.

c. Push the brush slightly into the channel to start it.

d. Slide the new brush completely into the holder by its bristles until it stops. The brush is fully inserted when no more visible metal edge is extending from the front of the holder.

e. Repeat for the remaining two brushes.