FP FPI 8100 (01) PDF DOCUMENT

When using your FP FPI 8100 inserting system, always follow these precautions:

• Read all instructions before you attempt to operate the system.

• Use this equipment only for its intended purpose.

• Place the system close to an easily accessible wall outlet.

• Place the system in an accessible location to allow for proper venting of the equipment and to facilitate servicing.

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

• Plug the AC adapter directly into a properly grounded wall outlet located near the equipment and easily accessible. Failure to properly ground the machine can result in severe personal injury and/or fire.

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

• DO NOT use a wall outlet controlled by a wall switch or one that is 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 AC adapter power cord over sharp edges or trap it between furniture. Make sure there is no strain on the power cord.

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

• 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, be sure machine mechanisms come to a complete stop.

• Remove jammed material gently and carefully.

• DO NOT remove covers. Covers enclose hazardous parts that should only be accessed by properly 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.

• Improper storage and use of aerosol dusters or flammable aerosol dusters can cause an explosive-like condition that could result in personal injury and/or property damage.

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

• Operation of this equipment without periodic maintenance will inhibit optimum operating performance and could cause the equipment to malfunction.

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

• To reduce the risk of fire or electrical shock, DO NOT attempt to remove covers or disassemble the control panel or its base. There are hazardous parts in this cabinet.

• Before operating the main inserting machine with this device, make sure the machine has been properly prepared and that any other personnel in the area are standing clear of the inserter.

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

If your stacker has an AC Adapter:

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

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

• DO NOT route the power cord for the AC adapter over sharp edges or trap it between pieces of furniture. Make sure there is no strain on the power cord.

The warning labels on the FP FPI 8100 system alert you to potential injury that could occur with careless operating procedures. They typically include:

• A CAUTION label with a graphic of moving gears, stating “Moving mechanism can result in personal injury. Keep hands, long hair, ties, jewelry and loose clothing away from moving parts.”

• A NOTICE label with a graphic indicating a pinch point.

The main components of the FP FPI 8100 are:

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

2. **Feeder Tower:** A two-sided tray holder/material feeder. The lower left tray may be used for envelopes 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. Inserts/sheets from other trays can be added.

4. **Pre-fold Accumulator:** A staging area for material that needs to be collated before being sent to the folder.

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

6. **Post-fold Accumulator:** A staging area for folded sheets to meet any inserts that are to be included.

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 an opening on the front right, it provides sealing solution to the envelope sealing system.

10. **Control Panel:** Allows you to run the machine, configure job settings, 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 8100 is divided into several key areas:

• **LED Status Indicator (1):** Shows the machine’s status.

• **Screen Option Keys (2):** Eight keys that correspond to options on the screen, used to define settings for up to 24 jobs and edit them.

• **Fixed Function Keys (3):** Access the system’s built-in tools like the help file. These include Reset Counter, Help, Cancel, and Home.

• **Screen Navigation Keys (4):** A two-tiered circular button to move UP/DOWN and LEFT/RIGHT in the display and an inner OK button to apply selections.

• **Machine Action Keys (5):** Control hardware components. These include Start, Trial Piece, Clear Deck, and Stop.

Each of the four fixed function keys has an assigned function that is enabled or disabled based on the current screen:

• **Reset Counter:**
– *Piece Counter* is a cumulative counter for each completed mail piece.
– *Batch Counter* counts up to a set number and stops the system when it reaches that count.
– *Mark Piece Count* (if a flats sealer is present) resets the counter for the envelope edge mark.
– *Reset Both* resets both the piece and batch counters to zero.

• **Help:** Select to get information about the current screen or access the entire Help file.

• **Cancel:** Select to return to the previous screen.

• **Home:** Returns you to the Home screen for the current job. Changes are not saved until you choose “Save Job”. Unsaved changes are indicated by an asterisk (*) next to the job name.

The four machine action keys on the FP FPI 8100 run the system:

• **Start:** Press this green-colored key to begin running the selected job.

• **Trial Piece:** Press to do a test run on your job. One complete mail piece will be prepared.

• **Clear Deck:** Press to rid the system of materials currently in process in the paper paths. Only press this when prompted by the system to minimize lost material.

• **Stop:** Press to finish in-process mail.

1. From the Home screen, select Menu.

2. From the Menu screen, select Change Language, a list of available languages displays.

3. If necessary, use the Next and Previous options to view additional languages on the list, and select the appropriate language.

4. Select Finished.

5. Press HOME to return to the Home screen.

The FP FPI 8100 processes mail through a series of steps along its transport deck:

• **Mail Piece Path:** Material from feeder trays moves down the feeder tower in a pre-defined order to the transport deck.

• **Pre-fold Accumulator:** This is the first stop, where materials that need to be folded are collated together.

• **Folder:** The collated stack of sheets moves from the pre-fold accumulator into the folder, where a fold is applied. The system offers C Fold, Z Fold, Single Fold, Double Fold, and No Fold options.

• **Post-fold Accumulator:** The folded sheets exit the folder and land here. Other components, like a reply envelope or pre-folded insert, are added to the accumulation.

• **Insertion Area:** The complete contents of the mail piece meet the outer envelope. The envelope arrives face down with the flap open, and envelope openers widen it for the contents to be inserted.

• **Folder Bypass Path:** The outer envelope travels along the bottom part of the transport deck, bypassing the folder, to reach the insertion area.

• **Moistener, Closer, Sealer:** As the envelope passes over the moistener, brushes wet the glued flap. The envelope is then inverted and passed through the closer and sealer to complete the mail piece before being dropped onto a stacker.

The FP FPI 8100 has several covers that open to provide access to the paper path and release knobs.

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 keeps the cover within the recommended range of movement. IMPORTANT! Do not lean on the open cover.

Main Tower Base Cover:

1. Open the main transport deck cover first.

2. Pull down on the tower base cover handle.

Close the Covers

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

The FP FPI 8100 system has three levels of user access, each with different rights:

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: Depending on the security mode, the supervisor and manager access levels require entry of an access code or user ID and password. These are assigned by the system manager.

The login procedure depends on the security mode enabled on your FP FPI 8100.

Login Required Mode

If Login Required Mode is enabled:

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

2. Enter your password. Passwords are four-digit numeric codes. Numbers 1-5 display on the first screen; press “Next” to access numbers 6-9 and 0.

3. Select Accept and the Home screen displays.

Login Not Required Mode

If this mode is enabled and user profiles are set up, a “Log In” option displays on the Home screen. This requires an access code for restricted functions.

Log Out

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

The Mail Piece Icon Tree on the FP FPI 8100 provides a visual guide for how a mail piece is assembled. Here’s how to read it:

• **Order of Collation:** Icons are arranged in the order components are collated. The outer envelope is at the top of the tree.

• **Item Orientation:** Each icon has a darker edge (top or bottom) indicating the leading edge of the material, which is the edge that feeds into the machine first.

• **Feeder Assignment:** A letter (e.g., A, B, C) next to an icon indicates which feeder tray to use. Linked trays are shown with multiple letters (e.g., B and D).

• **Sealing:** A small blue droplet icon indicates the seal feature is enabled for that envelope.

• **Special Conditions:**
– A Double Detect icon appears to the left of an item if that feature is active.
– For multiple sheets from one feeder, the icon shows multiple pages with a number indicating the count.
– For scanning jobs, a small letter “n” indicates a variable number of sheets.

Lines connecting the icons show the assembly path. Be sure to check the Icon Tree any time you change job settings, as feeder assignments may change.

The FP FPI 8100 uses various icons to represent materials and actions. Here are some common ones:

Fold Icons:

• Icons exist for No Fold, C Fold, Z Fold, Single Fold, and Double Fold.

Envelope, Sheet, and Insert Icons:

• Specific icons represent different types of envelopes (window, non-window, letter, flat), sheets (personalized with top, middle, or bottom address, or not personalized), and inserts (slip, reply envelope, reply card). The icons change based on orientation (face up/down, top/bottom first).

Other Icons:

• **Error Icon (Red X):** Appears in pop-up messages to indicate an error.

• **Warning Icon (Yellow Triangle with !):** Appears in pop-up messages to indicate a warning.

• **Seal On Icon (Blue water drop):** Appears in the Mail Piece Icon Tree if sealing is on.

• **Safe Seal Icon:** Appears if safe seal is on.

• **Double Detect Icon:** Appears if double detect is on.

Feeder Assignment Icons:

A letter in a grey square indicates the assigned feeder. A single square is a single feeder; two stacked squares indicate linked feeders.

Feeder Letter	Location	Position
A	Feeder Tower	Bottom left feeder
B	Feeder Tower	Bottom right feeder
C	Feeder Tower	Top left feeder
D	Feeder Tower	Top right feeder
G	High Capacity Envelope Feeder (HCEF)	N/A
J	High Capacity Sheet Feeder 1 (HCSF)	Bottom feeder
K	High Capacity Sheet Feeder 1 (HCSF)	Top feeder
L	High Capacity Sheet Feeder 2 (HCSF)	Bottom feeder
M	High Capacity Sheet Feeder 2 (HCSF)	Top feeder
X	Custom Feeder	N/A
Z	Attached Printer	N/A

WARNING! Read the safety information before connecting the FP FPI 8100 to power.

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. If any problems are detected, it will display information directing you to a solution.

Running a job on the FP FPI 8100 involves five major steps in order. This assumes the job has already been created and saved.

1. **Select a Job:**

– If the job is already on the Home screen, you can proceed. If not, select “Select Another Job” or go to Menu > Jobs > Select Job.

– You can choose from Saved Jobs, Recently Run Jobs, or Library Jobs (pre-defined).

– Select the desired category and then select the specific job from the list.

2. **Set up the feeders and load material:**

– Attach the required trays to the Feeder Tower if prompted.

– Follow the Mail Piece Icon Tree and loading instructions to load all materials (sheets, inserts, envelopes) into the correct trays with the correct orientation.

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

3. **Make pre-run adjustments (if necessary):**

– Adjust the envelope openers in the insertion area to match the envelope size, especially if it’s different from the previous job.

4. **Run a trial piece:**

– Press the TRIAL PIECE key. The system will collate one mail piece and feed it to the upper divert area for inspection (it will not be sealed).

– Examine the trial piece to ensure contents are correct, in the proper order, and the address is visible in the window. Check for doubles.

– If it passes, select “Trial Piece OK”. If adjustments are needed (e.g., address position), select “Adjust Address” or “Edit Job”.

5. **Start the job:**

– Once the trial piece is verified, press the START key. The system will begin running the job.

Always use both hands when attaching or removing a tray from the FP FPI 8100.

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 tray mounts until you feel it seat into place. The tray is seated properly when the notch on the bottom of each side of the tray is seated in the groove on the tray mount.

4. Pull straight back on the tray slightly to ensure it is attached securely. If not, repeat the process.

Remove Trays from the Feeder Tower

1. Grasp the open end of the tray and lift up.

2. Slide the tray out until it clears the grooves in the tray mount.

Prepare the Material:

Before placing material in a tray, it is important to loosen (fan) any items that may be stuck together. Hold one end of the stack and flip through the opposite end with your other hand. Repeat for the other side.

Load a Sheet Tray:

1. Using the side guide adjustor, open the sides of the tray wide enough to clear the material width.

2. Fan a small stack of material and place it in the tray in the orientation specified on the Home screen.

3. Use the side guide adjustor to move the guides in until they lightly touch the material. When you release the adjustor, the guides automatically spring back slightly to allow for proper clearance.

4. Lift the separator and load the material into the tray. Do not load material above the maximum fill line.

Load an Insert Tray (for pre-folded items, cards, envelopes, etc.):

1. Use the sled locking lever to slide the sled to the end of the tray, where it will lock.

2. Open the side guides wider than the material.

3. Stand a stack of material upright against the front end of the tray in the correct orientation.

4. Use the side guide adjustor to bring the guides lightly against the material, then release.

5. Finish loading the tray to the appropriate fill line.

6. Tilt the material slightly toward the back of the tray.

7. While holding the material, gently pull up on the sled lock release to unlock it, and allow the sled to move forward until it contacts the material.

Before running a job with a new envelope size, you must adjust the envelope openers.

1. Load the outer envelopes into the feeder.

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

3. Press TRIAL PIECE to feed one envelope into the insertion area.

4. Open the insertion area cover to observe the envelope.

Perform Width Adjustments (Outer Envelope Openers):

1. Loosen the thumbscrews on top of the outer envelope openers.

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

– For small envelopes (less than 7.5 inches wide), move the openers away from the outer edges.

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

3. Tighten the thumbscrews.

Perform Length Adjustments (Inner Envelope Openers):

1. Loosen the thumbscrews that secure each of the three inner envelope openers.

– Position them so they do not touch the window edge.

– Tighten the thumbscrews.

2. Press down and pull one of the knobs on the top of the frame to check how far the opener’s insertion edge goes into the envelope.

3. If necessary, loosen the knob and adjust until the edge goes at least 5 mm into the top panel of the envelope.

4. Tighten the knob and repeat for the other inner openers.

Verify Settings:

1. Close the insertion area cover.

2. Press CLEAR DECK, then press TRIAL PIECE.

3. If alignment is correct, select OK. If not, repeat the adjustment steps.

SwiftStart mode on the FP FPI 8100 allows you to run a simple job without entering setup information, as the system automatically senses the material and sets the parameters.

1. Select SwiftStart from the Home screen.

2. Attach and load Feeder Trays:

a. Load outer envelopes in insert tray A or the HCEF (G).

b. Load sheets and then inserts, starting with the feeder farthest to the left on the bottom.

c. Load remaining items clockwise and to the right of the first item.

3. Press TRIAL PIECE.

• The system feeds and measures the envelope, then each sheet and insert, to determine the fold type and create a Mail Piece Icon Tree for the job.

• After all items are measured, a sample mail piece is produced.

4. Check the trial piece and make any needed adjustments.

5. Repeat the trial piece process until the mail piece meets your specifications.

6. Press START to run the job.

7. To save the job for future use, you need supervisor or manager access to enter a name in the save job screen.

A warning message will appear on the display when it is time to replenish the sealing solution. To refill the bottle:

1. Open the Sealer bottle cover, remove the bottle from its holder, and place it on a flat surface.

2. Unscrew the pressure-sensitive top and remove it from the bottle.

3. Pour sealing solution into the bottle until it reaches the fill line. (NOTE: While water is acceptable, it is not recommended as it can lead to bacterial growth that inhibits sealer performance.)

4. Screw the pressure-sensitive top securely back onto the bottle.

5. Wipe off any excess fluid that may have spilled.

6. Put the bottle back into the holder and close the Sealer cover.

NOTE: On first-time use or if the wick has become dry, a brief waiting period is required to allow the wick to get moist.

Proper adjustment of the scan heads on your FP FPI 8100 is key to maximizing barcode or OMR performance. The side guides must be set properly and material loaded evenly.

For Ladder or 2D Orientation Marks:

1. Take one of the sheets to be scanned and fold it in half vertically (with the mark facing up).

2. Draw two arrows, one at the top and one at the bottom of the mark, both pointing towards the top of the sheet.

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

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

5. Refer to the loading instructions to determine if the scan head is on the left or right, and if the sheet loads top or bottom first.

6. Open the appropriate tower cover (Feeder Tower or HCSF Tower).

7. Align the folded sheet’s center fold with the 0 mark on the inserter’s ruler. If the sheet loads top first, the arrows you drew should point DOWN. If it loads bottom first, they should point UP.

8. Use the blue thumbwheel to move the scan head until its pointer lines up with the measurement you took in step 4.

9. To verify, go to Loading Instructions > Pre-Run Adjustments > Scanner Setup, select the feeder, press TRIAL PIECE, and then select Finish.

If a material stoppage occurs on your FP FPI 8100, the system will immediately stop the job and display an error message. Follow these guidelines to clear it:

1. Use the error message on the display screen to locate the problem area.

2. Open any covers necessary to access the stoppage.

3. Clear only the indicated area gently and carefully.

4. If prompted to clear the deck, press the CLEAR DECK key.

5. Follow any further instructions on the display screen.

6. Once the stoppage is cleared, close all open covers. The error message should clear and the Home screen will display.

To Resume the Job:

1. Verify there are no error messages and all covers are closed.

2. Press START. The job will resume counting from the last complete mail piece it produced, unless the error message instructed you to start a new collation.

Outsorted Material:

During recovery from a jam, any partially assembled pieces are not counted and are transported to the upper divert area. You should discard these items and manually assemble the piece.

Here are solutions for common issues with the FP FPI 8100. You can also press the HELP key on the control panel for more information.

Startup Problems

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.

Control Panel Problems

Problem	Cause	Action
No display, but system power is on; Display locks up; Screen/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 to turn on the display.
Display is too light or dark.	Poor contrast / brightness adjustment.	Adjust contrast and/or brightness settings.

Mail Piece Problems

Problem	Cause	Action
Wrong fold type.	Job is set up incorrectly.	Check job definition and make appropriate adjustments to meet job specifications.
Fold panel length incorrect.	Job is set up incorrectly.	Select auto-measure, or make manual adjustments, then rerun a trial piece.
Address not showing in envelope window.	Item loaded incorrectly; Lead edge is not in the lead position; Job is set up incorrectly.	Reload item in correct position as per loading instructions. Ensure job is set up correctly (item personalized, correct address location, window envelope type selected). Use “Adjust Address” on the Trial Piece Complete screen if needed.

You can perform several routine maintenance tasks on your FP FPI 8100.

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.

Periodic Replacement (recommended at 250,000 machine cycles):

• **Replace the Moistener Wick:** When the wick becomes dry, replace the cartridge.

• **Replace the Moistener Brushes:** Replace brushes when they show wear.

• **Replace the Envelope Edge Marker Roller (if applicable):** Replace when needed.

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

1. Open the insertion area cover.

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

3. Release the plastic latches on each side of the reservoir: place one thumb on the rear latch and the index finger of your other hand on the front latch, then slide the latches away from each other.

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

5. Wrap the paper towel around the old cartridge 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 so its 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 wear, typically around 250,000 cycles.

1. Open the insertion area cover.

2. **Remove old brushes:**

a. Hold the blue brush holder in place with one hand. With your other hand, push the bristles of the old brush completely free from the holder (pushing toward yourself).

b. Repeat for all three brushes and discard them.

3. **Install the new brushes:**

NOTE: Avoid bending or deforming the bristles.

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

b. Insert the metal edge of the 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 of its metal edge is visible.

e. Repeat for the remaining two brushes.

For reliable operation, avoid using the following materials in your FP FPI 8100:

Contaminants:

• Materials with visible material loss (like loose powder, ink, surface glaze, etc.) when hung free over a clean surface and struck sharply with a standard wood ruler should not be used.

Special Materials:

• Do not use materials that are sensitive to heat (such as thermal papers).

• Do not use materials that are sensitive to minor magnetic fields.

• Do not use pressure-sensitive materials.