Formax 6204 User Manual
6204 Series
Low-Volume Desktop Inserter
7/2012
OPERATOR MANUAL
Table of Contents
1 Read this First ...............................................................................................1
Warning............................................................................................................1
About this manual.............................................................................................1
Safety...............................................................................................................2
Country Specific Conditions.............................................................................4
End of Life........................................................................................................5
2 Meet your Document System ......................................................................6
Overview..........................................................................................................6
Operating Controls...........................................................................................8
Control Panel....................................................................................................9
Installing the Document Feed Trays...............................................................10
Installing the Slide and Catch tray..................................................................11
Power Up........................................................................................................12
Home Menu....................................................................................................12
Job Info...........................................................................................................13
Side Guides....................................................................................................15
Document Orientation....................................................................................16
Filling the Document Feeder Tray..................................................................16
Loading Envelopes.........................................................................................17
Sealing Envelopes..........................................................................................18
Filling the Sealing Liquid Reservoir................................................................19
Shut Down the System...................................................................................20
3 Options ........................................................................................................21
Side Exit.........................................................................................................21
insert'n Frank / insert'n Mail ...........................................................................21
4 Processing Mail Sets ..................................................................................22
Introduction.....................................................................................................22
Processing a Basic Mail Set...........................................................................23
Processing a Mail Set with BRE or Inserts.....................................................24
Document Separation.....................................................................................25
Processing Daily Mail.....................................................................................25
Test Run.........................................................................................................26
Adjusting the Address Position.......................................................................26
Adjusting the Envelope Insert Fingers............................................................27
Verifying the Insert Position............................................................................28
5 Working with Jobs ......................................................................................29
What is a job...................................................................................................29
Creating a new job.........................................................................................29
Performing a test run......................................................................................31
Adjusting the Envelope Position.....................................................................32
Using a job.....................................................................................................33
Editing a job....................................................................................................34
Copying a job.................................................................................................35
Deleting a job.................................................................................................36
Job settings....................................................................................................37
Envelope settings...........................................................................................38
Document settings..........................................................................................39
Fold settings...................................................................................................41
Reading settings (option)...............................................................................43
Double feed control settings...........................................................................44
Job name........................................................................................................45
Mailing/Franking settings (option)..................................................................45
6 Advanced Settings .....................................................................................46
What are Advanced Settings?........................................................................46
Opening the Advanced Settings.....................................................................47
Changing the Display Settings.......................................................................47
Viewing System info and Software versions..................................................48
What are licensed options?............................................................................49
Activating an option........................................................................................49
Test Menu.......................................................................................................50
Running diagnostics.......................................................................................51
7 Reading .......................................................................................................52
Introduction.....................................................................................................52
Adjusting the reading head position...............................................................53
Document Orientation....................................................................................54
OMR Code Description..................................................................................55
Running an OMR test.....................................................................................58
8 Operator Maintenance ................................................................................60
Maintenance Schedule...................................................................................60
Clean and replace brushes............................................................................61
Clean the sensors on the envelope or document path...................................61
Clean the exit sensors....................................................................................62
Resetting Photocells.......................................................................................62
9 Fault Finding ...............................................................................................63
Error Messages..............................................................................................63
Clearing Stoppages........................................................................................64
Lower Envelope Track....................................................................................65
FlexFeed........................................................................................................66
Collating Area.................................................................................................66
PowerFold......................................................................................................67
Operator Troubleshooting...............................................................................67
Trouble Shooting Table...................................................................................68
10 Specifications .............................................................................................72
Technical Specifications.................................................................................72
Hopper and feeder capacity...........................................................................73
Configuration Dimensions..............................................................................73
Document and Insert Specifications...............................................................73
Envelope and Document Set Specifications..................................................75
11 Terminology ................................................................................................76
Terminology....................................................................................................76
12 EC Declaration of Conformity ...................................................................82
EC Declaration of Conformity DS-63, M3300, FD6204..................................82
13 Index ............................................................................................................84
Read this First1
Warning
Ensure you have read and fully understood the safety requirements
in this section.
About this manual
Languages
According to the EC (European Commission) declaration following the Low Voltage Directive
(2006/95/EC), this operator manual must be available in the national language(s) of the
country where the system is delivered. Therefore, if you do not have an operator manual
in your country’s language(s), contact your authorized distributor.
Software
The software used for the reading option is based in part on the work of the Independent
JPEG Group.
Audience
1
English
This manual is meant for operators of the document system.
Trademarks
maxiFeeder™, insert'n Frank™, powerFold™, intelliDeck™, flexFeed™ and versaFeeder™
are trademarks of Neopost however the affix ™ will not be used further in this manual.
1
1
Symbols
This manual uses the symbols listed below.
WARNING : Indicates a human safety hazard.
English
Safety
Warnings
ATTENTION : A risk to the equipment or mail could result from an
action you may perform.
NOTE : A remark that explains different cases or specificities.
TIP : Advice to help save you time when processing your mail.
SUPERVISOR : Indicates that you have to use the supervisor
menu to perform the procedure.
• Disconnect the power supply before performing any maintenance.
• Before connecting the system to the electrical supply, Ensure that the system is
suitable for the local mains voltage. Refer to the serial plate on your system for voltage
requirements.
2
Safety Precautions
• Only competent, trained personnel should operate this system. If non-trained
personnel do operate this system, the manufacturer will not accept responsibility
for any resulting accidents or injuries.
• Only skilled persons, who are aware of the risks involved, may open the protective
covers.
For safety reasons, the system will not function when the covers are open.
• Keep long hair, fingers, jewelry, etc. away from rotating and moving parts.
• The power connection must be easily accessible, preferably close to the system.
For safety reasons, it is essential that the system is connected to a socket outlet that
has a protective earth (ground) connection.
• Overcurrent protection in the equipment also relies on the branch circuit protection
(max. 20 A).
• The following part(s) is (are) considered the equipment disconnect device(s):
- Power supply cord plug or appliance coupler.
CAUTION: DOUBLE POLE / NEUTRAL FUSING
(this means that after operating of the fuse, parts of the equipment
that remain energized, might represent a hazard during servicing.)
Precaution
The general process of automated document handling can sometimes create a build up of
static electricity. Therefore we recommend that the following measures are taken to reduce
the side effects of any electrostatic charge.
• Make sure that you operate the system within the recommended temperature and
humidity conditions.
• Make use of antistatic mats where appropriate.
• If necessary, make use of an ionizer to reduce static charge build up in the room
where the system is located.
Please contact your supplier for further information.
1
English
3
Country Specific Conditions
1
Denmark
In Denmark, certain types of Class 1 appliances may be provided with a plug that does not
provide an adequate earth (ground) connection when inserted into a Danish socket outlet.
English
Make sure the system has a good functioning connection that has protective earthing (the
plug and socket outlet must match).
Japan
• Establish an earth (ground) connection before connecting the mains plug to the power
supply.
• First disconnect the power supply before removing the earth (ground) connection.
4
End of Life
The objectives of the European Community's environment policy are, in particular, to
preserve, protect and improve the quality of the environment, protect human health and
utilize 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.
Separating waste during collection is the precondition to ensure reuse and recycling of waste.
The proper disposal of electrical or electronic equipment is necessary to achieve the chosen
level of protection of human health and the environment in the European Community.
More particularly, certain materials and components of waste electrical and electronic
equipment need special treatment as improper handling or disposal on or into land, water
or air would represent a major threat to the environment and human health.
In order to facilitate collection and treatment separated from normal domestic waste,
electrical and electronical equipment is marked with the following logo:
1
English
By law, not only are you not allowed to dispose of the waste equipment via other waste
channels, 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 service
organization.
5
Meet your Document
2
System
2
Overview
Introduction
English
The system is a folding and inserting system for processing mail easily. The system:
Automatic monitoring ensures the correct number of documents per envelope. The system
can be operated by means of a user friendly interface. The settings of the system (types
of documents, type of envelopes and the type of fold) is recorded in so called jobs. These
jobs can be programmed by an authorized user.
The system is equipped with a variety of special features, such as:
• Feeds documents
• Folds the documents
• Inserts the documents into envelopes
• Seals the envelopes
• Stacks the envelopes
• Document thickness detection
• Programmable jobs
• Automatic jobs
• flexFeed
• Double feed control
• Hopper swap
• Multifeed
• Daily mail
• powerFold.
6
The figure shows an overview of the system.
Document Feeders (flexFeed) (1)
The flexFeed is the feeding part of the system. There are two types of feeders: the automatic
and the special feeder. The automatic feeder does not require any adjustments for the
separation. From a feeder you can feed one or more documents (multi feed). The feeders
have a double feed control (DFC). DFC detects if more documents are fed instead of one.
You can link feeders. This means that two feeders can be linked as pairs. When the first
feeder is empty, the system switches to the other feeder. Meanwhile the empty feeder can
be refilled without stopping the system.
The upper automatic feeder is equipped with a 'daily mail' function. You can use this feeder
to process sets of documents that you cannot process automatically (stapled documents
and sets with varying thickness).
Collating Area (2)
All documents of a document set are collated and aligned in the collating area.
powerFold(3)
The fold unit folds the documents. The following fold types are possible (see Terminology):
• No fold
• V-fold
• C-fold
• Z-fold
2
English
7
Envelope feeder (4)
Envelopes that are placed on a stack by the user, are fed one by one into the system by
the envelope feeder.
Inserter (5)
2
After the documents are folded, the documents are transported to the inserter. The inserter
inserts the documents into a waiting envelope. The inserter seals the envelope or not,
depending on the settings. Automatic monitoring ensures the correct number of inserts per
envelope.
English
Operating panel (6)
The machine is programmed and operated from the operating panel.
Operating Controls
• Double V-fold
8
A - Envelope catch tray
B - Envelope slide
C - Display with operating buttons
D - Upper unit
E - Locking hand grip upper unit
F - Document feeders
G - Collator arm
H - Collator area
I - Power inlet, power switch, RS232
connector / USB / modem
J - Knobs for clearing stoppages
Control Panel
K - Sensors
L - Bellows
M - Handle for clearing stoppages
N - Sealing liquid reservoir
O - Side cover (opened)
P - Ruler
Q - Thumb wheel for side guide adjustment
R - Side guides envelope hopper
S - Knob for separation adjustment
T - Envelope support bracket
2
English
The control panel consists of the touch screen and the following buttons:
Stop ( ): The system completes the current mail set and stops, leaving the system
empty and ready for a new set.
Start ( ): The system starts to process mail sets.
The display is covered with a thin pressure-sensitive layer. To avoid
permanent damage of the display, do not use sharp objects to press
on the display.
9
Installing the Document Feed Trays
Place the document feed trays in position:
1. Hold the document feeder slightly inclined as shown in the figure.
2
English
2. Place the front end of the document feed tray underneath the two rollers.
3. Move the document feed tray upwards (lifting the two rollers), until it is possible to
‘hook’ the feeder into place.
4. Move the document feed tray towards the machine and move the hooks over the
mounting points (on both sides).
5. Let the document feed tray rest on the machine.
10
Installing the Slide and Catch tray
To install the slide and the catch tray:
1. Attach the slide as shown in the figure.
2. Position the envelope catch tray into the holes underneath the envelope hopper as
shown in the figure.The distance A should be approximately 1.5 x the envelope height.
2
English
11
Power Up
To start up the system:
2
English
1. Connect the system to the mains power supply.
2. Use the power switch to switch the system on. The power switch is located on the
The touch screen shows the home menu.
Home Menu
You can severely damage the machine if it is connected to the
incorrect power supply. Before plugging in the machine, check if
the local voltage is the same as the voltage mentioned on the type
plate.
right-hand side of the system.
When you start up the system, the ‘home’ menu appears. With the arrows you can scroll
through the jobs. If you want more information on a job, select the job.
If you just want to start without job definition, press [New job] and select [Automatic] (see
Processing mail sets on page 23).
With the home button you get back to the home menu. The [Menu] button opens
the advanced settings menu (see Opening the Advanced Settings on page 47).
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Job Info
If you want more information on a job, select the job in the ‘home’ menu.
The ‘current job’ menu shows the following information of the selected job:
• Job number and Job name
• Total: total number of envelopes that have been processed using this job
• To do: number of envelopes to do. Only indicated if a ‘stop at’ value is set.
• Stop at: number of processed envelopes at which the system stops. You can set this
number with the [Counters] button.
You can set it between 0 (switched off) and 9999. The system will continue until the
job counter reaches the stop counter value. The system stops and can be restarted.
The stop counter is switched off when it is set to zero.
If you want to reset the daily job counter and the stop counter, press the [Reset TOTAL
Counter] button in the ‘counters’ menu.
2
English
The counter settings are job related.
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2
English
• A picture of the system with symbols for the selected features. The following
symbols can be used:
Shows the feeders selected to pick documents from (black
is selected). Every selected feeder shows how many sheets
will be fed from the feeder and the length of the sheets.
This sign indicates that the relevant feeders are linked. This
means that when one feeder is empty, the system
automatically starts picking documents from the other feeder.
This sign indicates that for the selected feeder OMR is
switched on (optional).
This sign indicates that the relevant feeder is set for daily
mail.
Gives information about the envelope size (ISO format or
height in mm). An envelope with a cross means that no
envelopes are used.
Shows the type of fold, in this case C-fold.
The sign indicates that for the relevant feeder the double
feed detection is switched on.
• [Edit]: use this button to edit the job (see Editing a job on page 34).
• [Info]: if you press the [Info] button, the screen shows how to position the envelope
and documents in the feeders. From this menu you can press a button to view the
reading settings and insert'n Frank / insert'n Mail settings.
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Side Guides
To adjust the side guides it is best to remove the document feed tray from the feeder as
follows:
1. Push handle A downwards.
2. Lift the document feed tray upwards to unhook it and then pull it out from the feeder.
3. Loosen the knob B half a turn.
2
English
4. Grab the side guides in the middle and push them apart as far as possible.
5. Put a small stack of documents between the side guides.
6. Grab the side guides in the middle and push them towards the documents.The space
between the side guides and the documents should be such that the documents have
just enough play to move freely.
7. Re-tighten knob B.
8. Remove the stack of documents.
9. Replace the document feed tray (see Installing document feeders on page 10).
15
Document Orientation
2
English
Filling the Document Feeder Tray
Fill the document feeder tray as follows:
1. Open the left-hand side guide A by turning it downwards.
The feed rollers will automatically be lifted.
2. Place a stack of documents between the side guides.
3. Turn the left side guide upwards again.
4. Feed the documents (depending on the type of documents and the type of fold) (see
Document Orientation on page 16).
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Loading Envelopes
Before you load the envelopes, make sure the envelope separation and side guides are
correctly set. Proceed as follows:
1. Rotate thumb wheel D to move the side guides C apart.
If the distance between the side guides is too large, the envelopes
will twist sidewards, when transported into the machine.
2. Turn knob A counter-clockwise as far as possible.
2
English
3. Slide an envelope (with closed flap) between the rollers in the machine and turn knob
A clockwise until a slight resistance is felt when moving the envelope in and out of
the machine.
4. When the resistance is too high, turn knob A counter-clockwise, until only a slight
resistance is felt.
17
5. Place the bottom envelope between the rollers (flap down and trailing - bottom side
2
English
6. Loosen the stack of envelopes, and place the stack on top of the bottom envelope.
7. Shift envelope support B in or out, so that the flap side of the envelope is lifted
8. Turn envelope support B so the weight of the envelopes is evenly distributed on both
Sealing Envelopes
of the envelope pointing to the machine).
approximately 20 mm (0.8”).
sides.
Switch the envelope sealing on or off:
1. Lift the handgrip to open the top cover.
18
2. Shift the blue handle A towards
to disable the envelope sealing or towards
to enable the envelop sealing.
3. Close the top cover.
Before you start a job with sealing, wait approximately 5 minutes for the brushes to moisten
or use moistened brushes. For instructions on the installation of brushes, see Clean and
replace brushes on page 61.
Filling the Sealing Liquid Reservoir
1. Open the front cover A.
2
English
19
2. Fill the reservoir B to the "Max" lip C with sealing liquid.
3. Close the front cover A.
Before starting the job, wait approximately 5 minutes for the brushes to moisten or use
moistened brushes. For instructions on the installation of brushes, see Clean and replace
2
brushes on page 61.
For good moistening, regularly check that the sealing liquid reservoir is filled.
English
Shut Down the System
1. Use the power switch to switch off the system. The power switch is located on the
Before starting the job, wait approximately 5 minutes for the brushes to moisten.
right-hand side of the system.
20
Options3
Side Exit
The system can be equipped with a side exit and catch tray. The side exit can be fitted
instead of the standard envelope receiving tray. The side exit allows a conveyor or a franking
system to be fitted in line with the system.
The side exit can also be used with a catch tray to achieve vertical stacking. The catch tray
is delivered with the side exit.
insert'n Frank / insert'n Mail
If this system is connected to a mailing/franking system, insert'n Frank / insert'n Mail allows
you to:
• Switch automatic mailing/franking on or off
• Remotely select a mailing/franking job
For programming this option, see Mailing and Franking settings on page 45. Refer to the
appendix for an extensive description of the mailing (franking) option.
3
English
21
Introduction
With the system you can process mail sets in the following ways:
4
English
Automatic job processes mail sets according to the following rules:
The following features are not supported with Automatic job processing:
If you want to use any of these features, you have to use Manual jobs to process the mail
set (see What is a job on page 29).
Processing Mail Sets4
• Automatic job: The system automatically picks one sheet from each filled feeder
and processes them into mail sets.
The automatic feature is described in this chapter.
• Manual job: various settings, not available in an Automatic job, can be stored for
re-use in user-programmable jobs (Manual jobs). This includes the use of daily mail.
Working with manual jobs is described in What is a job on page 29.
• The machine picks one sheet from each filled feeder;
• The picked documents will be folded (if necessary) and inserted into an envelope;
• Only the feeders that feed successfully will be selected;
• Only the Double Feed Control (DFC) of the upper feeder will be selected (this is done
automatically).
• Linked feeders (the option where, if one feeder is empty, the system automatically
continues using another feeder);
• Multifeed (picking more than one sheet from a certain feeder);
• Daily mail (see Processing Daily Mail on page 25);
• Reading functionality (see Reading Introduction on page 52);
• No envelope mode (see Envelope settings on page 38);
• Envelopes with open flap (see Envelope settings on page 38).
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