Formax 6402 User Manual
6402 Series
Inserters
5/2007
OPERATOR MANUAL
FIRST EDITION
TABLE OF CONTENTS
1 Health, Safety and Environment ...................................................... 3
1.1 Precautions and Safety Issues ................................................... 3
2 Functional Description..................................................................... 6
2.1 Overview ............ .......................... .......................................... 7
2.1.1 FlexFeed
2.1.2 Collating Area (2) ...................................................... .. .. 8
2.1.3 IntelliDeck
2.1.4 PowerFold
®
(1) ................................................................ 7
®
(3) ............................................................. 8
®
(4) .............................................................. 8
2.1.5 Inserter (6) .................................................................. 8
2.2 Operating Controls .................................................................. 9
2.3 Display Buttons ...................................................................... 10
2.4 Software Description ....................... .. ... .. ................................. 10
2.4.1 Main Menu ................................................................... 10
2.4.2 Job Info ...................................................................... 12
2.4.3 Counters ..................................................................... 13
2.4.4 Display Settings ........................................................... 13
2.4.5 Job Menu ..................................................................... 14
2.4.6 Supervisor Menu ............................. ...................... .. ..... 14
3 Operating Instructions .................................................................. 20
3.1 Installation ............................................................................ 20
3.2 Preparation ........................................................................... 20
3.2.1 Document Feed Trays ................................................... 20
3.2.2 Conveyor Stacker ......................................................... 21
3.3 Starting Up ............................................................................ 21
3.4 Loading Documents ................................................................ 22
3.4.1 Document Orientation ................................................... 22
3.4.2 Side Guides ................................................................. 23
3.4.3 Document Separation .................................................... 23
3.4.4 Filling the Document Feed Tray ...................................... 24
3.4.5 Adjustment of the Document Stoppers ............................ 24
3.5 Loading Envelopes .................................................................. 25
3.5.1 Adjusting Side Guides ................................................... 25
3.5.2 Envelope Separation ..................................................... 25
3.5.3 Feeding Envelopes ........................................................ 26
3.6 Sealing Envelopes .................................................................. 26
3.7 Job Selection or AutoSet
...................................................... 27
3.7.1 Using AutoSet .............................................................. 27
3.7.2 Select Another Job ........................................................ 29
3.8 Run the Daily Mail .................................................................. 30
3.9 Create a Job .......................................................................... 31
3.9.1 Job Settings ................................................................. 32
3.9.2 Envelope Settings ......................................................... 32
3.9.3 Document Settings ....................................................... 33
3.9.4 Fold Settings ................................................................ 34
3.9.5 Optical Mark Recognition Settings (Option) ...................... 36
3.9.6 Double Feed Control Settings ......................................... 37
3.9.7 Job Name .................................................................... 38
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1
3.9.8 Mailing/Franking Settings (Option) .................................. 39
3.10 Edit a Job .............................................................................. 40
3.11 Copy a Job ............................................................................ 40
3.12 Delete a Job .......................................................................... 41
4 Options..................................................................... ......... ............ 42
4.1 Activate an Option .................................................................. 42
4.2 Optical Mark Recognition (OMR) ............................................... 42
4.2.1 General ................ ........................... ............................ 42
4.2.2 Alignment .................................................................... 43
4.2.3 Document Orientation ................................................... 44
4.2.4 OMR Codes .................................................................. 44
4.3 Online Services ...................................................................... 48
4.3.1 General ................ ........................... ............................ 48
4.3.2 Start-Up Online Services ............................................... 48
4.3.3 Connection .................................................................. 48
4.3.4 Messages ................................................................... 49
4.3.5 Configuration Menu ....................................................... 50
4.4 Production Feeder................................................................... 51
4.4.1 Function ...................................................................... 51
4.4.2 Preparations ................................................................ 51
4.4.3 Adjust Side Guides ....................................................... 52
4.4.4 Document Separation .................................................... 52
4.4.5 Feeding Documents ...................................................... 52
4.5 insert’n Frank™ (insert’n Mail) ................................................. 53
5 Maintenance .................................................................................. 54
5.1 Operator Maintenance ............................................................. 54
6 Fault Finding.................................................................................. 55
6.1 Error Messages ...................................................................... 55
6.2 Clearing Stoppages ................................................................ 56
6.2.1 Exit, Sealing and Inserting Area ..................................... 56
6.2.2 Envelope Hopper .......................................................... 57
6.2.3 Lower Envelope Track ................................................... 57
6.2.4 PowerFold
6.2.5 FlexFeed
® ............................................................................................................................ 58
® ............................................................................................................................... 58
6.2.6 Collating Area .......................... ....................... .. ........... 58
6.3 Operator Troubleshooting ........................................................ 58
7 Specifications .............................................................................. .. 62
7.1 Technical Specifications ........................................................... 62
7.2 Configuration Dimensions ........................................................ 62
7.3 Other Specifications ................................................................ 62
7.4 Document Specifications ......................................................... 62
7.5 Envelope and Insert Specifications ............................................ 63
8 Terminology .................................................................................. 65
Index.............................................................................................. 72
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1. HEALTH, SAFETY AND ENVIRONMENT
1.1 Precautions and Safety Issues
Thoroughly read this operator manual, before using this machine.
Warnings
• If the feed/fold unit and inserter unit have to be physically separated, the operator
should pay attention to the heavy weight of the unit during separation.
• Before connecting check whether the system is suitable for the local mains voltage.
Refer to the type plate.
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.
• Over-current 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
- 12-pole connector, located on the right-hand side
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3
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.
.
4
5
2. FUNCTIONAL DESCRIPTION
The 6402 Series feeds, folds and inserts documents into envelopes and then seals and stacks
the envelopes. Automatic monitoring ensures the correct number of inserts per envelope.
The machine is a sophisticated folding and inserting system which can process large
quantities of mail rapidly and easily. 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 6402 Series is equipped with a variety of special features as document thickness detection,
programmable jobs,
AutoSet, double feed control, hopper swap, multifeed, and daily mail.
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2.1 Overview
The system consists of the following parts:
1. FlexFeed®
2. Collating area
3. Divert Deck
4. Folding area
5. Envelope feeder
6. Inserter
7. Envelope exit (including conveyor
stacker)
1
3
2
6
4
7
5
2.1.1 FlexFeed® (1)
The flexFeed® is the feeding part of the system. There are two types of feeders available:
the automatic and the special feeder. The automatic feeder does not require any
adjustments for the separation. The flexFeed
this way the system can detect faulty sets o f documents. The flexFeed
hopper swap. 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 other empty feeder can be
refilled without stopping. It’s also possible to feed multiple documents from one feeder. In
this way more documents can be fed from one station, for example an original and a copy
of a document.
®
is equipped with double feed control. In
®
is equipped with
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The upper automatic feeder is equipped with a “daily mail” function for processing
documents or sets of documents which cannot be processed automatically (e.g. stapled).
2.1.2 Collating Area (2)
After feeding, the documents are gathered and aligned in the collating area.
2.1.3 Divert Deck (3)
The Divert Deck automatically throws out incorrect sets of documents. In this way the
system does not need to stop. Correct sets will be transported to the Folding area.
2.1.4 Folding area (4)
The Folding area folds the documents. The following fold types are possible:
•No fold
•Single fold
• Letter fold
• Zig-zag fold
• Double parallel fold
2.1.5 Inserter (6)
After folding the documents are transported to the inserter unit where the documents are
inserted into a waiting envelope. The inserter then seals the envelope (or not) and stacks
them on the conveyor stacker. Automatic monitoring ensures the correct number of
inserts per envelope.
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2.2 Operating Controls
I
H
G
A B D
C
F
E
U TVWX
A conveyor stacker
Bloc cover
C unlocking lever for loc
D power inlet, power switch
Einserter cover
F RS232 connector / USB / modem
G display (operator panel)
H OMR reading head cover
I hand grip vertical transport cover
J document feed tray
Kcollator arm
L operator manual storage space
M folding area
J
K
L
M
N
S
N locking handle
O air plugs for cle aning the sensors
P handle for manual envelope transport
Q unlocking handle for rollers envelope
track
R water reservoir
S bellows for cleaning sensors
T side cover (opened)
U thumb wheel for side guide adjustment
V side guides envelope feed tray
W lever for envelope separation
adjustment
X envelopes support
OPQR
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2.4.2 Job Info
To enter the “job info” menu, press .
This menu displays all relevant information about
the selected job.
If the optional OMR is used the "1 track OMR info"
menu is also available using the button.
To return to the “main menu (1/2)”, press .
The “job info” menu contains the following information:
Gives information about the envelope size (ISO format or height in mm).
Shows the type of fold.
3
2
1
Shows the feeders selected to pick documents from (black is selected).
The sign below this icon shows if the document double feed detection for the
relevant feeder is switched on - or off - .
The number under this icon indicates the number of sheets that must be
picked from the relevant feeder.
This sign indicates that the rele vant feeder is set for daily mail.
Below this icon, the format of the document in the relevant feeder is
3
2
indicated (ISO standard or height in mm).
This sign indicates that the relevant feed ers are linked. This means that
when one feeder is empty, the system automatically starts picking
documents from the other feeder.
The sign indicates that for the relevant feeder the Optical Mark Recognition
(OMR) is switched on (optional).
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2.4.3 Counters
T o enter the “counters” menu, press
from the “main menu (1)”.
The “counters” menu shows the following functions:
• : press this button to reset the
daily job counter and stop counter to zero.
• : press this button to enter a
stop value.
The stop counter is switched off when it is set to
zero. The display will show “Stop at off”.
The stop counter can be set 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.
Note
The counter settings are job related.
2.4.4 Display Settings
To enter the “display settings” menu, press
from the “main menu (2)”.
The “display settings” menu shows the following
functions:
• : enables to change the contrast of the
display. The graphic shows the contrast setting.
• : enables to adjust the volume of the
acoustic signals. The graphic shows the volume setting.
• Rotate display: press the button to rotate the display 180 °.
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2.4.5 Job Menu
After pressing the button a login
menu opens.
To prevent jobs being edited or deleted without
informing the ‘job owner’, this menu is protected by
a PIN-code. The PIN-code is
When a wrong pin code is entered, the cursor is set
to the first number to try again.
After 3 times entering a wrong pin code the display
shows the “main menu (1)” again.
After entering the correct pin code the “job menu”
appears.
This menu enables the creation, deletion and/or
editing of jobs.
The “job menu” shows the following functions:
• : job information (see 2.4.2 ”Job
Info” on page 12).
• : create a job (see 3.9 ”Create a
Job” on page 31.)
• : edit a job (see 3.10 ”Edit a Job” on page 40).
2546
.
• : copy a job (see 3.11 ”Copy a Job” on page 40).
• : delete a job (see 3.12 ”Delete a Job” on page 41).
• : exit and return to the “main menu (1)”.
2.4.6 Supervisor Menu
After pressing the button a login
menu opens.
Enter the PIN-code 2546 to access the “supervisor
menu”.
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After entering the correct pin code the “supervisor
menu” appears.
This menu enables checking and configuring the
system.
The “supervisor menu” shows the following
functions:
• : shows system information,
like:
- The flex certificate, used for OMR
- The counter since last visit: the counter value since the last service visit
- The last error generated by the system
The screen shows a button : this shows the software versions that are
present in the total system.
• : shows option information and system information:
-The chip ID
-The system ID
- The installed options
For installing new options, see 4.1 ”Activate an Option” on page 42.
• : opens the “job settings” supervisor menu (see ”Job Settings
(Supervisor)” on page 16). From this menu system parameters can be set.
• : opens the “test menu” (see ”Test” on page 18). Use this menu to
test the system.
• : opens the “Online Services” menu ( option, see 4. 3 ”Online Services”
on page 48). This screen enables to connect the system to a server and receive
messages.
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Job Settings (Supervisor)
Caution
Job settings normally will be changed by a service engineer only. Therefore first consult
the supplier’s Helpdesk before changing any settings. Changes to the job settings can
result in malfunctioning of jobs.
The “job settings” menu (supervis or) can be o pened
from the “supervisor menu”. From this menu system
parameters can be set. The “job settings” menu
shows the following functions:
• : opens the “mode menu” to set
the output mode for a job (see ”Mode Menu” on
page 16).
• : opens the “document offset”
menu to set the document offset in a set of
documents for a job (see ”Document Offset” on page 17).
• : opens the “BRE offset” menu to set the BRE offset on or off (see
”BRE Offset” on page 17).
• : opens the “flap closer” menu (see ”Flap Closer” on page 18). Use
this function to improve the envelope sealing process.
Mode Menu
When selecting from the “supervisor menu”
, , the “mode menu”
appears.
In this menu for each of the jobs 1 through 25 and
AutoSet a choice can be made between output
Mode 1 and Mode 2 using the button. Mode 2 is
the default setting.
Mode 1 focuses on the versatility of paper
parameters (paper thickness; document length), i.e.
correct operation under even extreme paper conditions.
Mode 2 focuses on high speed and is achieved as follows:
• During multi feed (more than one page from one feeder) the movement on the
collator is minimal. In mode 1 the divert unit will be used for completing the collating
process (less paper on paper transport).
• During the transportation of a set from the co ll ator into the powerFold
is going into the collator already. This results in temporary overlapping sets with two
different transport directions. In mode 1 the set has left the collator completely before
the next set enters the collator.
®
, the next set
16
• Anticipation call for the envelope is used. That means that a (folded) set is leaving the
flexFeed
envelope is on the insert position already before the set leaves the flexFeed
It is advised to use Mode 1 with a paper thickness of 65 g/m
of 12 inch (305 mm) or higher, and for situations where Mode 2 is not functioning
properly. In all other cases Mode 2 is advised.
If you select Mode 2, select if the reply envelope has a window or not.
®
already before the envelope is ready on the insert position. In mode 1 the
2
or less, a document length
®
.
Document Offset
When selecting from the “supervisor menu”
, , the “document
offset” menu appears.
The vertical transport of documents fed by the
various feeders is arranged in such a way that the
documents are partially overlapping each other. This
overlapping scheme ensures that the documents are
properly aligned in the collator area.
In the “document offset” menu you can set the
extend to which the documents are not overlapping
each other, i.e. the document offset value. The default value is 50 mm (2.0 inch). The
document offset can be varied between 20 mm (0.8 inch) and 75 mm (3.0 inch).
BRE Offset
When selecting from the “supervisor menu”
, , the “BRE offset”
menu appears.
If a document is longer than the set address fold but
shorter than the envelope height, this document
sometimes will be unnecessarily folded. Under
certain conditions this document can be prevented
from being folded. This can be implemented with the
menu “BRE offset” (BRE means Business Reply
Envelope).
ENGLISH
For each of the jobs 1 through 25 and AutoSet
using the button.
In the case of offset “on” the last docume nt that was added to the set will be shifted from
the rest of the set (offsetting). This document will be held back during a certain distance.
This means that the trailing edge of this upper document leaves the collator at last. This
document will not be folded. During the insertion into the envelope the documents of the
set will be realigned.
an offset can be switched on or off
17
The conditions are:
• The feeder that supplies this upper document (BRE) is set to one document per set
(no multi feeding).
• The document directly beneath this document must be at least 60 mm (2.4 inch)
longer than the BRE.
• The upper document must be longer than the set address fold.
• The folding mode is either single fold or letter fold (no Z-fold).
• The upper document must be shorter than the envelope height.
Note
It is possible to use the BRE offset for a BRE and an enclosure (card) in one set. The extra
condition is that this enclosure is equal to or smaller than the set address fold and should
be placed direct underneath the BRE in the set.
The whole BRE offset is based on friction between documents within a set. Therefore it is
necessary to make use of these conditions to reduce the risk of bad transporting, folding
and inserting.
Flap Closer
When selecting from the “supervisor menu”
, , the “flap closer”
menu appears. Use this function to improve the
envelope sealing process for a job. The offset can be
varied between -20 and 20. If for example the offset
is set to +10 the sealing process will be activated 10
pulses later than initially.
For each of the jobs 1 through 25 and AutoSet
an offset can be set.
Test
The “test menu” menu can be opened from the
“supervisor menu”. Use this menu to check the
system, reset all photocells and execute an OMR
test. The menu consists of the following functions:
• : use this function to check if all
motors, clutches and sensors are correctly
connected. This test derives the status of the
actuators and clutches by briefly activating the
actuators and then measuring the current.
Note
Remove all paper and close all covers before testing.
18
• : use this function to calibrate all photocells.
Note
Remove all paper and close all covers before calibration.
• : use this function to align and test t he OMR readi ng he ad (see ”OMR
Test” on page 19).
OMR Test
The “OMR test” menu can be opened from the “test
menu”. Use this menu to align and test the OMR
reading head (see ”Reading Head Position” on page
43). The menu consists of the following functions:
• : align the OMR reading head.
Put a document with reading marks in the
feeder and press this button.
• : shows the mark quality and the
number of read marks from the last processed document. Also the gain of the OMR
amplifier is shown.
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3. OPERATING INSTRUCTIONS
3.1 Installation
Caution
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.
3.2 Preparation
3.2.1 Document Feed Trays
Place the document feed trays in position:
1. Hold the document feeder slightly inclined as
shown in the figure.
2. Place the front end of the document feed tray
underneath the two black rollers.
3. Move the document feed tray upwards (lifting
the black 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.
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