Formax 6302 User Manual
6302 Series
Inserter
7/2006
OPERATOR MANUAL
FIRST EDITION
TABLE OF CONTENTS
1 Health, Safety and Environment ..................................................... 3
1.1 Precautions and Safety Issues ................................................... 3
1.2 blank ..................................................................................... 4
1.3 blank...... ............................................................................... 5
2 General ........................................................................................... 6
2.1 Denominations ........................................................................ 6
2.2 Function Description ................................................................ 7
2.3 Display .................................................................................. 8
3 Operating Instructions ................................................................... 9
3.1 Installation ............................................................................. 9
3.2 Preparation ............................................................................ 9
3.3 Starting Up ............................................................................ 10
3.4 Loading Documents ................................................................ 11
3.5 Loading Envelopes .................................................................. 13
3.6 Sealing Envelopes .................................................................. 14
3.7 AutoSet ................................................................................. 14
3.8 Daily Mail .............................................................................. 16
3.9 Other Menu Options ................................................................ 17
4 Job Programming ......................................................................... 21
4.1 Job Menu .............................................................................. 21
4.2 Job Information ...................................................................... 22
4.3 Create Job ................................................................... .......... 23
4.4 Edit Job ................................................................................ 30
4.5 Copy Job .......................... ..................................................... 30
4.6 Delete Job .................... ......................................................... 31
5 Supervisor Menu ........................................................................... 32
5.1 System Info ................................ ........................................... 32
5.2 Options .......... ................................ ............................. .......... 33
5.3 Online Services (Option*) ........................................................ 33
6 Optical Mark Recognition OMR (option) ........................................ 34
6.1 General .............. ................ ............... ................ .............. ...... 34
6.2 Adjustments .......................................................................... 34
6.3 Document Orientation ............................................................. 35
6.4 OMR Codes ............................................................................ 35
7 Options ......................................................................................... 39
7.1 Production Feeder.................................................................... 39
7.2 Intermediate Transport ..................... ... ................................... 40
8 Maintenance ................................................................................. 41
8.1 Operator Maintenance ............................................................. 41
9 Fault detection ............................................................................... 42
9.1 Error Messages ...................................................................... 42
9.2 Clearing Jams ...................................................... ............................. 43
9.3 Operator Troubleshooting ........................................................ 44
10 Specifications ............................................................................... 48
10.1 Technical specifications ........................................................... 48
10.2 Configuration dimensions ........................................................ 48
10.3 Other general specifications ..................................................... 49
10.4 Document specifications .......................................................... 49
10.5 Insert specifications ................................................................ 50
10.6 Terminology .......................................................................... 51
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1. HEALTH, SAFETY AND ENVIRONMENT
1.1 Precautions and Safety Issues
Thoroughly read this operator manual, before using this machine.
According to the European Guideline for machine safety (EC98-37), this operator manual
must be available in the national language(s) of the country where th e machine is
delivered.
Therefore, if you do not have an operator manual in your country’s language(s), contact
your authorized distributor.
Safety Precautions
• Only competent personnel should operate this machine.
If incompetent personnel do operate this machine, the manufacturer does 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 machine 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 machine.
• For safety reasons, it is essential that the machine is connected to a socket outlet that
has a protective earth connection.
• The machine has an over-current protection of 20 Amps. However, it is assumed that
the main power supply also has a circuit protection.
• Remove the plug of the power supply cord from the socket outlet to disconnect the
machine from the power supply.
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Conventions
Warning
This symbol:
- identifies situations where improper use of the machine can result in
personal injury or permanent/catastrophic damage to the machine.
- indicates that the operator manual should be consulted.
Warning
This symbol indicates a danger caused by high voltage.
Note
A note gives additional relevant information.
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4
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5
2. GENERAL
2.1 Denominations
E
A B C
D
F
G
H
I
N
Q OPRST
A Envelope catch tray K Sensors
B Envelope slide L Bellows
CDisplay with operating buttons M Handle for clearing stoppages
D Upper unit N Water reservoir
E Locking hand grip upper unit O Side cover (opened)
F Document feeders P Ruler
GCollator arm Q Thumb wheel for side guide
H Collator area adjustment
I Power inlet, power switch R Side guides envelope hopper
J Knobs for clearing stoppages S Knob for separation adjustment
T Envelope support bracket
6
JM
JKL
2.2 Function Description
The system consists of the following areas:
1
2
5
3
6
4
1 Document Feeders The machine selects documents from the feeders according to
the applicable job options.
2 Collating area The documents are collected in the collating ar ea before they
are transported to the folding area.
3 Folding area In the folding area, the document(s) are folded according to
the job specifications.
4 Envelope feeder The envelopes are picked up and transported to the insert
position inside the machine.
5 Inserter After the folded package of documents is inserted into the
envelope, the glue of the envelope is moistened and the
envelope is closed.
6 Operating panel The machine is programmed and operated from the operating
panel. This panel consists of a touch screen and a separate
Start, Stop and Clear button.
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2.3 Display
The machine has a graphical touch screen.
A touch screen sensor is a clear glass panel with a touch responsive surface. The touch
sensor/panel is placed over a display screen so that the responsive area of the panel
covers the viewable area of the display.
This display shows functions and/or buttons, which can be operated by pressing a finger
directly on the touch screen on the relevant function or button. The interface recognizes
the location of the pressure point and when this is located within the defined area of a
button, the user interface reacts with ‘pressing’ this button.
In this way , the user can simply operate the machine by pressing on the displayed buttons
and/or functions.
Caution
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.
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3. OPERATING INSTRUCTIONS
3.1 Installation
Warning
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.
Incidence of light can cause disturbing reflections in the display, resulting in reduced
readability . If necessary, change the position of the machine to improve the readability for
the operator.
3.2 Preparation Document Feeder Trays
Note
The machine can be delivered with a tray to manually adjust the separation. However, this
tray fits in all positions, this adjustment is only possible when fitted on the lowest position
(position one).
Place the document feeder trays in position.
1. Hold the document feeder slightly inclined as
shown in the figure.
2. Place the front end of the document feeder tray
underneath the two black rollers.
3. Move the document feeder tray upwards (lifting
the black rollers), until it is possible to “hook”
the feeder into place.
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4. Move the document feeder tray towards the
machine and move the hooks over the mounting
points (on both sides).
5. Let the document feeder tray rest on the
machine.
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Slide and Envelope 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.
3.3 Starting Up
1. Connect the machine to the main power
supply.
2. Use the power switch to switch the machine ON.
The software will ask you to select the required
language.
3. Select the required language for the display.
4. The software will ask you i f you w ant the “ select
language option” to be displayed every time the
machine is switched on. Select either Yes or
No.
5. Press .
OK
The Main Menu screen 1/2 will be displayed.
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MAIN MENU 1/2
JOB 1
Total:
0
A
other job
Test run
Counters
AutoSet
3.4 Loading Documents Document Orientation
feeder swap
Address carrier in upper
linked pair feeders.
Face up and leading.
Address carrier in lower
linked pair feeders.
Face down and trailing.
no fold
single fold
letter fold
double
parallel fold
zig-zag fold
one document
Address carrier in
upper feeder.
Face up and leading.
Address carrier face
down and trailing.
Adjusting Side Guides
1. Loosen knob B half a turn.
2. Move the side guides outwards.
3. Place a small stack of documents between the
side guides.
4. Move the side guides A and C to the document,
so the documents have just enough space to
slide between the side guides.
5. Tighten knob B.
two documents
Address carrier in
upper feeder.
Face up and leading.
Address carrier in lower
feeder.
Face down and trailing.
document + enclosure
Address carrier in upper
feeder.
Face up and leading.
Address carrier in upper
feeder.
Face down and trailing.
CA
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B
Document Separation
The term ‘Document separation’ refers to the
adjustment required for separating the upper
document from the rest of the documents in the
stack. This prevents documents being picked up from the stack at the same time.
The document separation for the automatic feeders is set automatically.
The special feeder (fitted in the lowest, first position) can be manually adjusted.
Adjust the manual document separation as follows:
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1. Remove trays 2 and 3:
- Push the handle on the left side of the tray
down.
- Lift the tray to unhook it, and th en pull it from
the feeder.
2. Push knob B until it clicks and stays in place,
and then turn it counterclockwise as far as
possible.
3. Lower the left side guide A. The feed rollers will
move up.
4. Place a document on the feeding tray.
5. Push the document, as far as possible into the
machine, without damaging it.
6. Raise the left side guide A until it clicks into place. The feed rollers will move down.
7. Slide the document further into the machine until it stops.
8. Turn knob B clockwise until a slight resistance is felt when moving the document in
and out the machine.
If you feel too much resistance, turn knob B counterclockwise.
9. Remove the document.
10. Pull back knob B.
11. Place a stack of documents in the document feeding tray.
12. Fit the removed feeder trays 2 and 3 (refer to “Document Feeder Trays” on page 9).
A B
Feeding Documents
1. Turn the left side guide A downwards
The feed roller will be lifted.
2. Place a stack of documents between the side guides.
3. Turn the left side guide A upwards.
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3.5 Loading Envelopes Adjusting Side Guides
Adjust side guides C by rotating thumbwheel D, so
that the envelopes:
- fit exactly between the side guides.
- can move freely.
NOTE
If the distance between the side guides is too large,
the envelopes will twist sidewards, when transported
into the machine.
C
B
Envelope Separation
DCA
1. Turn knob A counterclockwise as far as possible.
2. Slide an envelope (with closed flap) between the rollers in th e machine and turn knob
A clockwise until a slight resistance is felt when moving the envelope in and out of the
machine.
When the resistance is too high, turn knob A counterclockwise, until only a slight
resistance is felt.
Feeding Envelopes
1. Place the bottom envelope between the rollers
(flap down and trailing - bottom side of envelope
pointing to machine).
2. Loosen the stack of envelopes and place the
stack on top of the bottom envelope.
3. Shift envelope support B in or out, so that the
flap side of the envelope is lifted approximately
20 mm (0.8”).
Turn envelope support B so the weight of the
envelopes is distributed evenly on both sides.
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3.6 Sealing Envelopes
Switch the envelope sealing ON or OFF.
1. Lift the handgrip to open the top cover.
2. Shift the blue handle A towards to disable
the envelope sealing or towards to enable
the envelope sealing.
3. Close the top cover.
When the sealing of the envelopes is enabled, the
sealing liquid reservoir must be filled.
4. Open the front cover A.
5. Fill the reservoir B to the “Max” level indication
with sealing liquid.
6. Close the front cover A.
Before starting the job, wait approximately 5
minutes for the brushes to moisten.
A
B
3.7 AutoSet
TM
A
The AutoSetTM feature automatically adjusts all
machine settings.
When AutoSet
TM
is started, the machine will pick one sheet from each filled feeder.
The picked documents will be folded (if necessary) and inserted into an envelope.
Using AutoSet
1. Load envelopes.
2. Make sure there is sufficient sealing l iquid in the
sealing liquid reservoir. If the reservoir has just
been filled, wait approximately 5 minutes for the
brushes to moisten. See “Sealing Envelopes” on
page 14.
3. Load the documents face up and leading.
4. From the Main Menu 1/2 press r
TM
AutoSet
MAIN MENU 1/2
JOB 1
Total:
0
other job
Test run
Counters
AutoSet
14
5. After a few seconds, the AutoSet
appear.
6. Press to load one envelope to the
insert position in the machine.
7. The envelope is visible through the window in
the top cover.
1x
TM
display will
AutoSet
1x
1x
Insert position
ESCAPE
Insert Position
Note
This adjustment must only be checked in case of problems or when changing the envelope
type.
Check if the flap folding line is positioned
underneath the green roller B. If not adjust the
Insert position as follows:
1. Press on the left or right side of to
adjust the insert position to the left or the right.
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2. Press to load a new envelope into
the insert position
3. Recheck the insert position, and adjust as
required.
4. If necessary adjust the “envelope insert
fingers”:
- Open the top cover.
- Adjust the outer fingers D approximately 5 - 10 mm (0.2 till 0.4”) from the edges of
the envelopes.
- Loosen the knurled knobs C.
- Adjust the fingers A so that the tip is approximately 5 mm (0.2”) inside the
envelope.
- Tighten the knurled knobs C.
1x
A
B
C
D
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Address Position
1. When the envelope position and the position of the fingers is correct,
press to load a folded sheet into the envelope.
The envelope will be sealed (when enabled, refer to “Sealing Envelopes” on page 14)
and ejected to the envelope tray.
2. Check the position of the address in relation to the address window in the envelope.
3. If necessary, press the Up or Down button to adjust the address.
1x
4. Press to make another test run.
5. Recheck the position of the address, and adjust as required.
6. Press to leave this screen to return to the main menu or press the button
to immediately start the job.
OK
1x
Starting the Job
• Press the button to start the job.
• Press the button to stop the job. The machine will stop immediately.
• Press the button to clear the document path to prepare the machine for a new job.
3.8 Daily Mail
To process documents or sets of documents, which can not be processed automatically,
the top feeder is equipped with a daily mail switch.
Switch to Daily Mail function:
1. Select or change to a job where the Daily Mail
function is set to ON.
The Daily Mail function can be recognized by the
icon in the Job info screen.
2. Turn left side guide A of the upper tray down.
3. The Daily Mail handle B will become visible.
Move the handle to to enable the Daily
Mail function.
4. Turn left side guide A upwards.
5. Place the document or document set in the
feeder.
If necessary adjust the side guides. Refer to
“Adjusting Side Guides” on page 11.
B
A
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