Formax 6402 User Manual

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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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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

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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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.

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.

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)

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.

2.2 Operating Controls

I H G

A B D

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

L M N

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

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).

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”.

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.

ENGLISH

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

• 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

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).

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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

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.

• : 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.

3.4 Loading Documents

3.4.1 Document Orientation

Fold type

no fold single fold

Type of documents

hopper swap two documents document + enclosureone document

letter fold

zig-zag fold

double

parallel fold

Address carrier in top feeder. Face up and leading.

Address carrier in bottom feeder. Face down and trailing.

Address carrier in top linked pair feeders. Face up and leading.

Address carrier in bottom linked pair feeders. Face down and trailing.

Address carrier in top feeder. Face up and leading.

Address carrier in bottom feeder. Face down and trailing.

Address carrier in top feeder. Face up and leading.

Address carrier in top feeder. Face down and trailing.

In case the optional extended powerFold® is installed, the following feeding rules apply to documents with bottom address position:

Type of documents

two documents document + enclosureone document

Address carrier in top feeder. Face up and trailing.

Fold type

no fold single fold

zig-zag fold

Address carrier in top feeder. Face up and leading.

hopper swap

Address carrier in top linked pair feeders. Face up and trailing.

3.4.2 Side Guides

To adjust the side guides it is best to remove the document feed tray from the feeder as follows:

1. Push handle

2. Lift the document feed tray upwards to unhook it and then pull it out from the feeder.

downwards.

3. Loosen the knob

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

8. Remove the stack of documents.

9. Replace the document feed tray (3.2.1 ”Document Feed Trays” on page 20).

half a turn.

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3.4.3 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 picking up to much documents from the stack at the same time.

The document separation for the automatic feeders is set automatically. There are no manual adjustments needed.

The document separation for special feeders must be adjusted manually as follows:

1. Push the knob

2. Open the left-hand side guide downwards.

3. Place a document on the feed tray and slide it about 60 mm (2.4 inch) into the system (turn the knob set to narrow).

4. Push the document between the separation rollers, which are behind the rubber paper pullers.

5. Turn the knob resistance or counter clockwise to lower the resistance.

The separation is adjusted correctly when a slight resistance is felt on the document.

6. Pull the knob

7. Close the left-hand side guide.

forward until it clicks.

by turning it

counter clockwise if the separation is

clockwise to get more

back again when ready.

A B

3.4.4 Filling the Document Feed Tray

Fill the document feed 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) as shown in 3.4.1 ”Document Orientation” on page 22.

3.4.5 Adjustment of the Document Stoppers

The document stoppers mark the position at which the documents coming from the feeder turn towards the folding area. The position of the document stoppers is automatically determined by the system during the job programming.

Initially the document stoppers are adjusted for position B. In this position a wide variety of documents can be handled (max. 297 mm; 11.7 inch) and adjustment is not needed.

When a job is selected in which a different stopper position has been programmed, the operator has to put the document stoppers in the correct position as indicated by the display.

To adjust the stopper position:

1. Lift and hold the collator arm

2. Squeeze the stopper and pull the front side tab up.

To replace the stopper:

1. Place the flat back tab into the slotted hole.

2. Push the stopper into position.

Stop position handle documents up to 297 mm (11.7 inch) and stop position up to 356 mm (14 inch).

can handle documents up to 148 mm (5.8 inch), stop position B can

3.5 Loading Envelopes

3.5.1 Adjusting Side Guides

Adjust side guides C by rotating thumb wheel 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

can handle documents

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3.5.2 Envelope Separation

To set the envelope separation:

1. Pull down small lever

2. Insert one envelope up to the stoppers.

3. Return lever

Now the envelope separation is set.

DCA

3.5.3 Feeding Envelopes

1. Place the bottom envelope between the rollers (flap down and trailing - bottom side of envelope pointing to the 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").

4. Turn envelope support B so the weight of the envelopes is distributed evenly on both sides.

3.6 Sealing Envelopes

Note

Refer to 5.1 ”Operator Maintenance” on page 54 as well.

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 envelop sealing.

3. Close the top cover.

When the sealing of the envelopes is enabled, the sealing liquid reservoir must be filled:

1. Open the front cover A.

2. Fill the reservoir B to the “Max” level indication with sealing liquid.

3. Close the front cover A.

Before starting the job, wait approximately 5 minutes for the brushes to moisten.

Insert Position

Note

This adjustment must only be checked in case of problems or when changing the envelope type.

1. Lift the locking lever of the loc and pull the loc into the vertical position.

The flap folding line must be positioned under the green indicator position as follows:

2. Press on the left or right side of to adjust the insert position to the left or t he right. Each button stroke stops the next envelope

0.5 mm (0.02 inc h) to the right (earlier) or to the left (later).

3. Press to load a new envelope into the insert position.

4. Recheck the insert position, and adjust as required. If necessary adjust the envelope insert fingers, see ”Adjust the Envelope Insert

Fingers” on page 28.

. If not, adjust the insert

Adjust the Envelope Insert Fingers

To adjust the envelope insert fingers:

1. Loosen the knurled knob

2. Adjust each finger so that the tip enters about 5 mm (0.2 inch) into the envelope.

3. Re-tighten the knurled knob. The fingers can be moved sideways to the desired position.

Caution

When adjusting the fingers sideways, be sure that finger A is not positioned over sensor

. When an incorrect finger position is adjusted the display shows an error screen.

on top of each finger.

4. Place the outer fingers about 5 to 10 mm (0.2 to 0.4 inch) from the edges of the envelope.

Check the position of the insert fingers when changing to a different type of envelope.

Address Position

When the envelope position and the position of the fingers is correct:

1. Press to load a folded sheet into the envelope. The envelope will be sealed (when enabled, refer to 3.6 ”Sealing Envelopes” on page

26) and ejected to the conveyor stacker.

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 position. Each key stroke brings the address 1 mm (0.04 inch) with a maximum of 12 mm

(0.48 inch) lower or higher. If the required address position is beyond the maximum range of 24 mm (0.96 inch),

the AutoSet function can not be used. Use a programmed job instead.

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 (1)” or press the button to immediately start the job.

Starting the Job

To start a job:

1. Press the button to start the job. During running the display shows the “inserting” menu.

2. Press the button to stop the job. The machine will stop immediately.

3. Press the button to clear the document path to prepare the machine for a new job.

When an AutoSet the copy function in the job menu (see 3.11 ”Copy a Job” on page 40) to store the settings.

job is defined successfully these settings can be stored into a job. Use

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3.7.2 Select Another Job

To select another job:

1. Press to select another predefined job.

2. Press the arrows to select another job number. The screen shows the job options of the relevant job (see 2.4.2 ”Job Info” on page 12).

3. Press to confirm the selected job.

Perform a Test Run

To perform a test run:

1. Press to display the “test run” menu.

A message can appear: “Set manual feeding” or “Set automatic feeding”. In that case:

a Check if the daily mail handle is in the

correct position (see 3.8 ”Run the Daily Mail” on page 30).

b Correct if necessary.

c Press the button. d Press again.

The “test run” menu displays.

2. Press to load a new envelope into the insert positio n . This gives the possibility to check and correct the insert position of the envelope (see ”Insert Position” on page 28).

3. When the envelope position and the position of the fingers is correct, press

to load a folded sheet in the envelope.

The envelope will be sealed (when enabled, refer to 3.6 ”Sealing Envelopes” on page

26) and ejected to the conveyor stacker.

When finished testing start the job (see ”Starting the Job” on page 29).

3.8 Run the Daily Mail

To process documents or sets of documents, which can not be processed automatically (e.g. stapled documents), the top feeder is equipped with a daily mail switch.

To switch to the daily mail function:

1. Select a job where the daily mail function has been set to on:

a From the “main menu (1)”, press . b Search for a job with the daily mail function using the arrows. The daily mail

function can be recognized by the icon in the “job info” screen.

c Press to select the job and return to the “main menu (1)”

2. Turn left side guide A of the upper tray down. The Daily Mail handle B will become visible.

3. 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 (see

3.4.2 ”Side Guides” on page 23).

6. Press the button to start the job. The document or document set will be folded and inserted in the envelope as

described in the selected job.

7. Place the following document or document set in the feeder. The machine will keep running to process the inserted document or document set.

8. When finished with Daily Mail, press the button to stop the job.

9. Turn left side guide A down.

10. Move the Daily Mail handle to the ‘AUTO’ position to disable the Daily Mail and to enable the automatic document separation.

3.9 Create a Job

To create a new job:

1. Press from “main menu (2)” (see 2.4.1 ”Main Menu” on page 10).

2. Enter the pin code. The “job menu” opens (see 2.4.5 ”Job Menu” on

page 14).

3. Press . The “create job” menu appears. The new job

must be stored under a job number. The screen will show the lowest free job number.

Press the arrows to select a higher or lower free job number (if available).

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4. Press to confirm the selected free job number. The “job settings” screen opens. The meaning of all buttons and settings will be

explained in 3.9.1 ”Job Settings” on page 32.

5. Press to save the job with the entered settings under the sp ecified job number and name.

To name a job, see 3.9.7 ”Job Name” on page 38.

6. Press to perform a test run with the new job settings (see ”Perform a Test Run” on page 30).

Note

A new selected job number starts with default settings.

3.9.1 Job Settings

From the “job settings” menu the followin g settings are available:

Envelope settings (see 3.9.2 ”Envelope Settings” on page 32)

Document settings (see 3.9.3 ”Document Settings” on page 33)

Fold settings (see 3.9.4 ”Fold Settings” on page 34)

Optical Mark Recognition (OMR) settings (if installed) (see 3.9.5 ”Optical Mark Recognition Settings (Option)” on page 36)

Double feed control settings (see

3.9.6 ”Double Feed Control Settings” on page 37) Job name settings (see 3.9.7 ”Job Name” on page 38)

Mailing/Franking settings (if installed) (see

3.9.8 ”Mailing/Franking Settings (Option)” on page 39)

3.9.2 Envelope Settings

In this screen the properties of the used envelopes must be entered.

In the top of the screen, two selection buttons are displayed, from which one can be selected. The selected settings button will be highlighted yellow.

• Press to select an envelope size . Use the

button to enter the applicable dimensions.

It is also possible to select ISO standard envelopes or dimensions in inches (depends on the installation settings).

The envelope height can be set between 90 mm (3.5 inch) and 162 mm (6.38 inch).

• Press to set a job without inserting the documents in envelopes (no envelope mode). This can be useful for jobs, where documents only have to be sorted and/or folded.

3.9.3 Document Settings

This screen enables the setting of the document formats and the number of documents that must be picked from the different feeders.

• Press to set the number of sheets for the different feeders.

- Press to select a feeder. The selected

feeder will be highlighted.

- Press the arrows to change the number of

sheets that must be picked from the highlighted feeder.

When the number of documents is 0, the relevant feeder will be deselected.

Note

When a feeder is set to daily mail the number of documents is always 1 and can not be set in this screen.

Note

The maximum number of sheets per feeder is 25. When folding is used the maximum set thickness is 8 sheets in letter fold and 10 sheets (80 gr./m2) in single fold. When using

powerFold sheets is limited further.

and bottom address (see 3.9.4 ”Fold Settings” on page 34) the number of

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• Press to enter the document height. The height or the ISO format of the document will be displayed next to the relevant feeder.

- Press to select a feeder. The selected feeder will be highlighted.

- Press to display a numeric keypad to enter the exact dimension of the

document. Dimensions can be entered in mm, inches or as standard ISO paper dimensions

(depending on installation settings). The machine will not allow entering dimensions outer technica l ranges. The document siz e can be set betw een 90 mm (3.54 inch) and 356 mm (14 inch). The default document size setting of a new job is 297 mm (11.7 inch).

• Press to link two feeders. This function enables to fill two adjacent feeders with the same documents. When the first feeder is empty, the system automatically swaps to the other feeder.

- Press to select two adjacent feeders. The selected feeders will be

highlighted.

- Press to link two highlighted feeders.

The will be displayed between the selected feeders.

Note

When linking two feeders, the program will automatically apply the number and format of the documents of the lowest feeder to the other feeder.

• Press to enter the setting of the Daily Mail function. This function enables to process documents or sets of documents, which can not be

processed automatically (see 3.8 ”Run the Daily Mail” on page 30). The feeder that is fit for the Daily Mail function will automatically be selected.

- Press to enable the Daily Mail function. The icon appears behind the

daily mail feeder. If you press again the Daily Mail function will be disabled.

3.9.4 Fold Settings

This screen enables the adjustment of the folding dimensions and the address type.

If the system is equipped with a third fold table and turning unit (‘extended powerFold

settings” menu consists of two parts:

• In the first part you can set the Address type. You can switch between Top and Bottom using

’) the “fold

the button. If you choose Address type Bottom you only have three possible fold settings left.

After pressing the button the second fold setting screen opens.

• In the second fold setting screen you can select the fold type.

The following choices are available:

No fold (no settings required)

Single fold

Letter fold

Double parallel fold

Zig-zag fold

Except when no fold is required, the display shows a simple diagram of the docume nt with the fold positions. To change the fold positions press next to a fold. Enter the

required position of the relevant fold. The next table shows possible fold positions:

Fold type Minimum position Maximum position

Single fold 75 mm (2.95")

25 mm (0.98") (extended

powerFold

)

Letter fold First fold 75 mm (2.95")

25 mm (0.98") (extended

powerFold

)

Second fold Position first fold plus

25 mm (0.98")

Zig-zag fold First fold 75 mm (2.95")

25 mm (0.98") (extended

powerFold

)

Second fold Position first fold plus

25 mm (0.98")

Double parallel fold

First fold 75 mm (2.95")

25 mm (0.98") (extended

powerFold

)

Second fold Position first fold plus

25 mm (0.98")

Longest document length minus 25 mm (0.98")

Longest document length minus 50 mm (1.97")

Longest document length minus 25 mm (0.98")

Longest document length minus 100 mm (3.94")

Longest document length minus 75 mm (2.95")

Longest document length minus 50 mm (1.97")

Longest document length minus 25 mm (0.98")

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Note

The display will indicate when entered positions are out of range.

3.9.5 Optical Mark Recognition Settings (Option)

For a full function description of Optical Mark Recognition (OMR), see 4.2 ”Optical Mark Recognition (OMR)” on page 42. Flex-OMR is also optional. Flex-OMR can read non-Formax codes.

In the “OMR settings” menu it is possible to enable or disable the OMR function and to adjust the basic settings for OMR.

The first “OMR settings” menu covers the following settings:

• Code type: default is the setting “n one”: OMR i s disabled.

Change the setting using the button. The following codes are possible:

- 1-track OMR for reading Formax codes

- Flex 1-9 for reading non-Formax codes

• Read from feeder: press the button to select a feeder to activate OMR on.

• Reverse reading: reverse reading means that the insert mark is on the first page of the set. The system will detect the end of a set by detecting the first page of the next set. Because of the feeding and collating principal reverse reading has the following limitations:

- The last mark of the code should be pri nted maximally 85 mm ( 3.3 inch) from the

top.

- Enclosures and selective enclosures cannot be handled. In case the feeder runs empty the last set is still on the collator because the beginning

of the next set could not be detected. In this case the feeder empty message contains

an function. By pressing the button the set on the collator will be inserted.

Note

Reverse reading is not available in OMR level 0, 1, 2 and 3.

By pressing the button the next “OMR settings” menu appears. This menu covers the following settings:

• 1st mark from top: press to set the position of the first optical mark, measured from top of the sheet. The value can be varied between 15 mm (0.6 inch) and 277 mm (10.9 inch).

• Max. sheets: select the maximum amount of sheets in the set of documents using the arrow buttons.

Note

The maximum number of sheets in a set is 25. When the number of sheets exceeds 8 or 10, depending on the fold, the document can not be folded anymore. In this case, the maximum length of sheets is 156 mm (6.1 inch) for a C5 envelope. Also make sure that the fold is set to No fold. Ignoring this will certainly lead to stoppages.

When the maximum number of sheets exceeds the programmed maximum number of sheets in a set, the machine stops and error VS:110 will be displa yed. After r emoving t he

set and pressing the button, the machine will start and repeat the proces s until an insert or divert mark is encountered, error VS:135 (final set part) will be displayed.

By pressing the button the next “OMR settings” menu appears. This menu covers the following setting:

• Stop on misread: press to set if the machine should stop or not on misreading an optical mark.

When “stop on misread” is set to “yes”, the machine stops after detecting an OMR misreading. The incorrect set is diverted. After resetting the machine, the final part of the set is also diverted and the system starts processing again. The diverted set(s) should be checked by the operator.

When “stop on misread” is set to “no” the machine does not stop after detecting an OMR misreading. The incorrect set is diverted. The final part of th e set is also diverted and th en the machine starts processing again. After detecting 5 OMR mi sreadings in a row, the system stops and an error code is generated.

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3.9.6 Double Feed Control Settings

This screen enables to set the Double Feed Control (DFC) settings for the different feeders on or off and to set the thickness measurement.

To set the DFC for the different feeders:

1. Press the button to select a feeder.

2. Press the button to switch the DFC on - or off - .

If the DFC is on you can set Continue on double on or off using the button. If Continue on double is on (“yes”), the machine will not stop if two sheets are feeded instead of one. The document-set containing the double sheets will be diverted.

When a job is started, the first document taken per feeder is used for a reference measurement. When a document is exceeding that reference thickness an error will be displayed.

Note

When Daily mail is selected, the DFC will be switched off automatically.

To set the thickness measurement:

1. Press the button to select the inserter area.

2. Press the button to switch the thickness measurement on - or off - . If the thickness measurement is on you can set the measurement area:

3. Press the button.

4. Set the measurement area using the arrow buttons.

The standard position of the measurement area is sufficient for a great variety of documents. Only when using special types of documents, for example small cards, the position of the measurement area might be adjusted.

When the set thickness is not corresponding the refere nce v alue an error will be display ed.

3.9.7 Job Name

It is possible to store the job with a meaningful job name, to easily recognize the job. This name will be displayed in the Main screen during job selection.

1. Enter a job name using the alpha-numeric keypad.

2. Press to clear a char ac ter le ft of the cu rso r position (backspace).

3. Press to clear all entered characters and start again.

3.9.8 Mailing/Franking Settings (Option1)

If this machine is connected to a mailing/franking machine, this option allows you to select the franking mode.

Press the button to select:

•Pass through The mailing (franking) machine will let the

envelopes pass through without printing/

franking. Press the button to return to the “job menu”.

•Franking machine The mailing (franking) machine will print/frank the envelopes according to the local

mailing (franking) machines settings.

If you press the button a screen appears in which it is possible to link a mailing (franking) job to the inserter job. Use the arro w buttons to select a job. If no link is required, select

“Current job” . Press the button to return to the “job menu”.

• Inserter data The mailing (franking) machine will print/frank

the envelopes according to the weight and size data communicated by the inserter.

If you press the button a screen appears via which the weight of single documents and envelopes and the envelope width can be entered. Use the

and buttons to enter these data. Press the

button to return to the previous screen. To link a mailing (franking) job to the inserter job, use the arrow buttons to select a

job. If no link is required, select “Current job”. Press the button to return to the “job menu”.

Refer to the appendix for an extensive description of this option.

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3.10 Edit a Job

To edit an existing job:

1. Press from “main menu (2)” (see 2.4.1 ”Main Menu” on page 10).

2. Enter the pin code. The “job menu” opens (see 2.4.5 ”Job Menu” on

page 14).

3. Press . The “edit job” menu appears.

4. Press the arrows if you want to select an other job number.

5. Press to confirm the selected job number.

The “job settings” screen opens. Refer to 3.9.1 ”Job Settings” on page 32 for the meaning of all buttons and settings.

6. Press to save the job with the entered settings under the sp ecified job number and name.

To name a job, see 3.9.7 ”Job Name” on page 38.

7. Press to perform a test run with the new job settings (see ”Perform a Test Run” on page 30).

3.11 Copy a Job

To copy existing job settings or AutoSet jobs to a new job:

1. Press from “main menu (2)” (see 2.4.1 ”Main Menu” on page 10).

2. Enter the pin code. The “job menu” opens (see 2.4.5 ”Job Menu” on

page 14).

3. Press . The “copy job” menu appears.

4. Press the arrows if you want to select an other job number to copy from or to copy to.

Note

You can only copy job settings to new jobs.

5. Press for details of the job to copy from.

6. Press to copy the job settings. If all jobs are programmed the display shows “No more free jobs”.

It is possible to copy a AutoSet job into a job. Before a AutoSet job can be copied AutoSet has to be defined successfully (see 3.7.1 ”Using AutoSet” on page 27).

3.12 Delete a Job

To delete an existing job:

1. Press from “main menu (2)” (see 2.4.1 ”Main Menu” on page 10).

2. Enter the pin code. The “job menu” opens (see 2.4.5 ”Job Menu” on

page 14).

3. Press . The “delete job” menu appears.

4. Press the arrows if you want to select an other job number.

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5. Press for job details.

6. Press . The job will be deleted without a warning.

4. OPTIONS

4.1 Activate an Option

To activate a new option:

1. From the “supervisor menu” choose . Software options are enabled using license codes. These license codes, together with

the identification number of the machine enable the relevant options. The enabled and available software options are displayed in this screen. Contact your dealer for information about these license codes.

2. Press to activate other software options.

3. Enter the license key code that you received from the supplier to activate the relevant option on this machine.

Use the arrow keys to navigate through the entered characters.

4. Press to confirm the license key and to return to the “options” menu.

5. Switch the system off and on.

4.2 Optical Mark Recognition (OMR)

4.2.1 General

The folding and inserting system can be equipped with Optical Mark Recognition (OMR) or Flex-OMR. This allows the system to read special codes that have been printed on the documents. These codes contain information about the processing of the sheets. With Flex-OMR, the system can also ‘read’ non-Formax codes.

The sheets with the printed code are placed in a feeder. Depending on the programmed code, the other feeders can be used as selective feeders to add enclosures.

In case of a zig-zag fold, the address has to be printed on the last page of the set. With the other fold types, the first sheet of a set always contains the address. A full length code is printed on every sheet of a set.

The code on the last sheet of the set contains the insert instruction. The other sheets carry the accumulate instruction. If a parity check is used, this is checked on each sheet. If the set contains only one sheet, it is the ‘last’ sheet. The code must appear in the same location on every page regardless of the actual code length.

4.2.2 Alignment Reading Head Position

The horizontal position of the reading head must be aligned to the same position of the printed marks on the documents. To align the reading head, proceed as follows:

1. Open the “OMR test” menu from the “Test menu” (refer to 2.4.6 ”Supervisor Menu” on page 14).

2. Press to start the alignment procedure.

3. Put a document with reading marks in the feeder (either feeder 1 or 2, depending on the selected job).

4. Press . The document will be transported to the reading

head position.

5. Open the special OMR reading head cover in the feeder.

6. Shift the reading head until the red pointer is positioned exactly above the middle of the reading marks.

7. Open the vertical transport cover and remove the document.

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8. Press to determine the alignment.

9. Press to finish the alignment procedure.

Note

When the reading head is aligned it is possible that paper guides have to be removed and placed on the other side of the reading head.

4.2.3 Document Orientation

Switch on the OMR-function and set the position of the reading marks as described in “Optical Mark Recognition Settings (Option)” on page 36.

Document orientation:

Fold type

direction

Type of documents

no fold single fold

letter fold

double

parallel fold

address

OMR start reading

OMR stop reading

(duplex printed)

direction

first page

Address carrier, face up and leading.

address

zig-zag fold

OMR stop reading

OMR start reading

last page

Address carrier, face down and trailing.

4.2.4 OMR Codes Printing Quality

• Marks should be printed in black.

• Marks on the same sheet must have equal intensity.

• Marks must be printed on the same position on every sheet.

• For matrix printers near letter quality (NLQ ) printed characters are preferred to obtain maximum blackness (double strike).

• Be aware of background ‘noise’. Color changes on the form, background design, a logo or copy on the opposite side of the sheet that will bleed through can be read by the reading head causing disturbances of the OMR function.

• The ribbon or toner quality must be checked before printing.

Minimum Code / Basic Commands

The minimum code is one mark in one line (insert). However for reliability it is advised to use at least 2 marks.

The first line is the start mark. A mark printed on the second line means insert. No

mark on the second line means accumulate.

Start mark Insert/accumulate

Note

In some cases, on request of the customer, the reading of the basic commands can be reversed by the service organization. This means that no mark is interpreted as an insert command and that for the accumulate command a mark has to be printed.

Length

Above the first mark and below the last mark a space of 8.5 mm (0.33") must be kept without printing. This means that the minimum code area consists of 6 lines:

• 2 lines to print the (basic) commands

8,5 mm

6,3 mm

• 4 lines free space Line distance may be 2.54 mm (0.1") to 6.35 mm

(0.4").

8,5 mm

Code Width, Character Spacing and Pitch

The minimum width of the code area is 7 character spaces. From left to right:

• 2 characters space not printed (4.2 mm; 0.17")

• Track mark (3 characters or 6.3 mm; 0.24")

• 2 character spaces not printed Pitch 10 or 12 is accepted.

The track mark can be printed using the underline sign (_), which must have a thickness of at least 0.2 mm (0.08").

Line 1 Line 2

Line 3 Line 4

Line 5 Line 6

4,2 mm4,2 mm

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Additional Marks

When it is required to control more functions in the inserter system, the use of more marks is needed.

The following additional functions are possible via software options:

• Divert mark (divert & continue)

• Stop mark (divert & stop)

• 1 mark: selective feed from station x (max. 6 depending on configuration)

• 1, 2 or 3 marks: respectively sequence c heck 4, 2 and 1

• 1 mark: parity check mark (even)

• 1 mark: safety mark

General remarks:

• The marks must always be used in the above sequence.

• If a function is suppressed the following function will move upwards one line.

• The chosen code must always be used on all material which must be processed by the Optical Mark Recognition.

• The length of the code and the mark definition is a service setting.

• Other marks/functions are possible via special codes (Flex codes).

Start mark

Insert/accumulate

Divert mark Stop mark

Selective feed 1 Selective feed 2 Selective feed 3 Selective feed 4

Selective feed 5 Selective feed 6

Sequence check 4 Sequence check 2 Sequence check 1 Parity (even parity) Safety mark

Divert Mark (Divert & Continue)

The set will be diverted and the system continues.

Stop Mark (Divert & Stop)

The set will be diverted and the system stops indicating error VS:113 (stop mark read).

Selective Feed Mark

The machine will selectively feed an enclosure when commanded so.

Sequence Check

Sheets in a stack can accidentally get out of sequence or can be missing. This can be detected by the sequence check.

Each sheet has a binary code that is a part of the reading code.

Parity Mark

By adding a parity mark the reading code can be checked. When the OMR-2 code is used the sum of the marks has to be even.

Safety Mark

The safety mark is used as an extra security. With skewed paper the reading head can miss part of the reading code. In these situations the safety mark is not read, and the system will give an error.

The safety mark also indicates the end of the reading code.

This mark must always be present on the document if it has been activated as an OMR code.

Examples of OMR Code

In the figure the legend for the following example is shown. In this example feeder station 1 is the reading feeder. The feeder stations 2 through 6 are selected for selective feeding.

Example Code

In this example a set of 8 sheets with three selectiv e feeds (station 2, 3 and 4) and three sequence check marks is shown.

• The first position is used for the start mark which must be printed on every sheet.

• The second mark position is used for the insert/ accumulate command. The mark is printed on the last sheet of the set (inserting is required).

• Position 3, 4 and 5 are reserved for selective feeding from station 2, 3 and 4. Print a mark on position 3 when a selective feed from station 2 is required. Print a mark on position 4 when a selective feed from station 3 is required. Print a mark on position 5 when a selective feed from station 4 is required.

• Position 6, 7 and 8 are used for the sequence check marks.

Normal paper flow Skewed paper flow

Start mark Start mark

Safety mark Safety mark

reading direction reading direction

mark printed no mark printed accumalate insert

no selective feed wanted, mark not printed selective feed wanted, mark printed

Sheet 1 Sheet 2 Sheet 3 Sheet 4 Sheet 5 Sheet 6 Sheet 7 Sheet 8

selective feeder 6 selective feeder 5 selective feeder 4 selective feeder 3

selective feeder 2

reading feeder 1

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4.3 Online Services

4.3.1 General

The folding and inserting system can be equipped with Online Services. This option enables the machine to connect to a central server. During the connection data is downloaded to and uploaded from the machine. The machine always initiates the connection, it is not possible to make a connection from outside to the machine. Ask your supplier if this option is available.

4.3.2 Start-Up Online Services

To start-up Online Services:

1. Select from the “main menu (2)”.

2. Enter the PIN-code 2546 to access the supervisor menu.

3. Press .

The “Online Services” menu shows the following functions:

• : opens the “connection” menu to create a connection to a central server and to view the connection history (see

4.3.3 ”Connection” on page 48).

• : opens the “messages” menu to view received messages (see

4.3.4 ”Messages” on page 49).

• : opens the “configuration” menus to change Online Services settings (see 4.3.5 ”Configuration Menu” on page 50).

4.3.3 Connection

The machine makes a connection on fixed times. It is possible that you manually connect the ma chine to the server. To connect to the server:

1. Press in the “Online Services” menu.

The display shows the “connection” menu.

2. Press to manually connect the machine to the OLS server.

You can view the status of the connection on the screen. The text on the button changes to .

Press to terminate connection with the server.

The “connection” menu shows the following functions:

• : opens the “history” menu to view the connection history (see ”History” on page 49).

• : this button appears when the machine received new messages and

opens the “messages” menu (see 4.3.4 ”Messages” on page 49).

History

The “history” menu shows previous connections of the machine to the server.

1. Press or to select a previous

connection.

2. Press to view details on selected

previous connection.

4.3.4 Messages

After pressing in the “On line Services” menu the display will show messages received from the server. A message has content like new software or a new job.

1. Press or to select a message.

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2. Press for more information over a

selected message.

In case new software or a new job can be installed the button appears. To install new software or a new job:

1. Press .

The “new software” menu or the “new job” menu appears. Press for more information on the software or the job.

2. Press to install the new software or the new job or press

to reject the new software or new job.

After pressing a confirmation menu opens:

• In case of new software, press to confirm installation or press to return

to “installation” menu.

• In case of a new job press or to select a free job number (see 3.9 ”Create a Job” on page 31).

Press to confirm the selected job number or press to return to message menu.

After conforming the installation of the new software or new job the “message” menu appears.

4.3.5 Configuration Menu

After pressing in the “On line Services” menu the “configuration” menu opens. Use this menu to modify the OLS settings.

The menu consists of two screens containing the following functions:

• Dial tone detection on / off This setting is required if no dial tone is heard

during establishing a connection. The default value is on. This setting is relevant to some PABX telephone switch systems.

Press to switch the dial tone detection on or off.

• Telephone number of server: contact your supplier for the telephone number of the OLS server.

To change the number:

aPress . b Enter the corre ct number using the numeric keypad.

c Press to confirm the new number.

• Prefix: use this function in case you need to dial a certain number or string to access an outside line.

aPress . b Enter the corre ct prefix using the numeric keypad.

c Press to confirm the new number.

• Country: enter the country from where you are dialing. Select the correct country from a list by pressing or .

• Date and time: enter the current date and time.

aPress . b Enter the correct date and time using the numeric keypad.

c Press to confirm the new number.

• Volume of modem: set the modem volume. a Press or to change the volume of the speaker.

Do not set the volume to zero as the sound of the modem is helpful during remote assistance.

b Press to confirm modified settings.

4.4 Production Feeder

4.4.1 Function

The Production Feeder can be loaded with a high number of documents. This feeder is intended to be used for Business Reply Envelopes (BRE), but also ‘standard’ documents up to 356 mm (14") length can be processed with it.

4.4.2 Preparations

The Production Feeder should be installed at the position of feeder no. 1.

It can be placed into position in the same way as the other document feeders are fitted.

Proceed as follows:

1. Lift the paper feed rollers with the front edge of the Production Feeder.

2. Move the Production Feeder forward until it hooks behind the frame axle.

3. Connect the connector A to the socket B.

The Production Feeder is auto-detected by the system when it is switched on. This makes

it easy to switch over from the standard document feed tray to the Production Feeder and vice versa.

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Note

To allow easier hooking on of the Production Feeder it is advised to put the feeding plate in the rear position (see 4.4.4 ”Document Separation” on page 52).

To make use of a Production Feeder it is not necessary to (re-)program the jobs.

4.4.3 Adjust Side Guides

Adjust the side guides:

1. T ake a stack of documents/BREs and place them in the feed tray.

BREs with flap down and leading (top side pointing to machine).

2. Adjust the side guides by turning the thumb wheel A so the documents/BREs just fit and can move without resistance.

Too much play causes skewing.

4.4.4 Document Separation

When the Production Feeder is used at an automatic separation feeder, the separation is set automatically.

The Production Feeder can also be used on a feeder position with a manually adjusted separation.

To adjust, proceed as follows:

1. Remove feeders 2 and 3.

Note

The lowest feeder is feeder 1.

2. Squeeze the two blue h andles A and B and shift the feeding plate C as far as possible to the front.

3. Push knob D forward until it clicks.

4. Place a document/BRE on the feed tray and slide it in the machine till the leading edge is not visible anymore. T urn knob the separation is set to narrow.

5. Push the document/BRE between the rollers.

6. Turn knob and counterclockwise if the separation is set to narrow.

The separation is adjusted correctly when a slight resistance is felt on the document/BRE.

7. Pull knob D back when ready.

8. Remount feeders 2 and 3.

clockwise to get more resistance

counterclockwise if

A B C

4.4.5 Feeding Documents

To feed documents:

1. Squeeze the two blue handles A and B.

2. Shift the feeding plate C to the rear position.

3. Loosen the stack of documents and place them in the feeder . BREs with flap down and leading (top side pointing to machine).

The feeding plate assembly will be shifted up automatically (when the system starts processing) until documents/BREs are underneath the rubber paper pullers.

Note

When filling the Production Feeder, make sure that the document/BREs are positioned parallel in relation to the feed plate to ensure correct feeding.

Note

When longer documents are used, plate C can be extended by pulling out the adjustable feed plate extension.

ENGLISH

5. MAINTENANCE

Disconnect the mains power supply before performing any maintenance.

The user must not attempt to service the appliance beyond that described in this operator manual. All other servicing must be carried out by qualified service personnel only. Please contact your authorized distributor.

5.1 Operator Maintenance

Maintenance frequency

Daily • Check the system functions.

Weekly • When dirty or saturated, clean the brushes of the envelope

When necessary • When the display warns about dusty sensors, the sensors on the

Maintenance

• Keep the system in proper condition by removing dust, paper remains, etc.

• When dirty, clean the sealing table and rubber rollers with a slightly wetted cloth, soaked in warm water.

sealing. The machine is delivered with an extra set of brushes. To always

have one clean set available, it is recommended to soak one set in water and use the other set.

Remove the brushes one by one by pulling them down from the brush holder.

Replace the brushes and make sure that the studs on the brushes are fitted in the corresponding holes in the brush holder.

• Check moistening cloth and replace if necessary. When dirty or saturated, clean the moistenin g cloth and the

reservoir.

• Clean feed and insert rollers as instructed by the Service Engineer.

envelope or document path must be cleaned using the bellows that is located behind the side cover.

Place the bellows in the upper air plug and firmly squeeze a few times to blow the dust from the document path sensor.

Repeat this procedure for the lower air plug to clean the envelope path sensor.

Calibrate the photocells (see ”Test” on page 18).

6. FAULT FINDING

6.1 Error Messages

When an error occurs the display shows a screen showing the following information:

•An indication of the area in which the error occurred

• An error description

• A suggested solution behind the pointing hand

Press to view more information about the occurred error and about the possible actions to avoid the error from re-occurring.

After solving the problem, press to reset the error (the error screen will disappear).

Special Errors

• Reading errors (when Optical Mark Recognition is enabled) The document set is diverted. The operator must remove the document set and has to

complete the set manually!

• Technical errors The display shows a message. The error cannot be solv ed by operating personnel and

assistance of the service support is needed.

ENGLISH

Warning Screen

When a cover is opened, the display shows a warning screen with the message "Cover Open" and a suggested solution “Close cover”.

6.2 Clearing Stoppages

Stoppages can occur in the following areas:

1. FlexFeed

2. Collating area

3. PowerFold

4. Lower envelope track

5. Sealing and inserting area

6. Exit area

7. Envelope hopper

area

For clearing of stoppages, six system sections can be opened:

A loc cover, to reach the exit area B inserter cover, to reach the sealing and inserter

area C collator arm, to reach the collating area D feeder cover, to reach the feeding area

EpowerFold F side cover, to reach the lower envelope track

cover, to reach the folding area

6.2.1 Exit, Sealing and Inserting Area

When a stoppage occurs in this area, remove the material as follows:

1. Open the side cover

2. Lift the locking lever of the loc and pull the loc up into the vertical position.

3. Lift the inserter cover.

4. Remove all material.

5. Lower the loc and the inserter cover.

6. Close the side cover.

7. Press to reset the error and restart the job.

6.2.2 Envelope Hopper

When an envelope gets stuck in this area, remove the envelope as follows:

1. Pull down small lever Pins C will come down.

2. Push lever A to the right and hold it. Pins C will go up.

3. Remove the stuck envelope.

4. Release lever A.

5. Return lever

6. Press to reset the error and restart the job.

6.2.3 Lower Envelope Track

When a stoppage occurs in the lower envelope track, remove the envelopes as follows:

1. Open the side cover

2. Squeeze handles

3. Remove the envelopes.

4. Release handles

5. Close the side cover.

6. Press to reset the error and restart the job.

If needed, envelopes and documents can be transported manually by means of handle transport envelopes manually to the insert table or to the lower envelope track, joggle the handle. To transport a document manually push handle inwards and then joggle.

to unlock the rollers.

. To

A B

ENGLISH

C B

6.2.4 PowerFold

When a stoppage occurs in the powerFold®, remove the documents from the powerFold

1. Push the lower end of the locking handle open the powerFold

2. Remove the documents from the powerFold

3. Close the powerFold

cover B.

cover.

as follows:

4. Press to reset the error and restart the job.

6.2.5 FlexFeed

When a stoppage occurs in the flexFeed®, remove the documents from the flexFeed® as follows:

1. Pull the vertical transport hand grip upward to open the vertical transport cover.

2. Remove the documents.

3. Close the vertical transport cover.

4. Press to reset the error and restart the job.

6.2.6 Collating Area

When a stoppage occurs in the collating area, remove the documents from the collating area as follows:

1. Lift and hold the collator arm

2. Remove the documents.

3. Lower the collator arm.

4. Press to reset the error and restart the job.

6.3 Operator Troubleshooting

To resolve problems:

1. Write down the error.

2. Try to solve the problem by consulting the troubleshooting table.

3. Switch the inserter off and on again, to verify system operation.

4. When the error still occurs contact your service organization.

Note

When contacting the service organization, you will also be asked for the last error message and the software version of the installed software. To determine the software version, refer to 2.4.6 ”Supervisor Menu” on page 14.

Symptom Possible cause Remedy Reference

The system cannot be started after switching on.

System stops with envelope at insert position (flap not open).

Envelopes are double fed.

Envelope stop skewed.

Envelopes are fed irregularly.

System not connected to mains.

Fuse is blown. Replace fuse below

A cover is opened. Close the covers. Envelopes stacked

reversed in the feed tray.

Envelope flap sticks. Store envelopes

Wrong envelope type used (not according specifications or job settings).

Envelope separation not correctly set.

Envelopes not placed properly in the feed tray.

Side guides of the envelope feed tray are set too wide.

Feed tray almost empty.

Separation set too narrow.

Side guides set too narrow.

Envelope support not positioned correctly.

Connect the system to the mains.

power switch.

Check envelope feed adjustments. Place envelopes correctly in feed tray.

according to specifications.

Change envelopes according to specifications.

Adjust envelope separation.

Check and replace if needed.

Check side guides and adjust if needed.

Refill feed tray. “Loading Envelopes” on

Adjust envelope separation.

Check side guides and adjust if needed.

Reposition the envelope support.

“Loading Envelopes” on page 25

“Envelope Settings” on page 32

“Envelope Separation” on page 25

“Loading Envelopes” on page 25

page 25 “Envelope Separation”

on page 25 “Loading Envelopes” on

page 25 “Loading Envelopes” on

page 25

ENGLISH

Symptom Possible cause Remedy Reference

Flap is wrinkled and sometimes not opened.

Fingers are placed on top of the envelope.

System stops while inserting (stoppage at the inserting point).

Envelope not within specifications.

Flap sticks. Store envelopes

Flap curled. Envelopes stored or

Separation set too narrow.

Fingers adjusted too deep into the envelope.

Envelope stops too early.

Fingers not correctly adjusted.

Inserted document too long for used envelope.

Envelope throat incorrect.

Envelope glued inside.

Window not glued properly.

Check specifications and change envelopes if needed.

according to specifications.

manufactured improperly.

Adjust envelope separation.

Check fingers position, adjust if needed.

Check envelope stop position, adjust if needed.

Check fingers position, adjust if needed.

Check fold settings. “Fold Settings” on

Check envelope specifications.

Eliminate faulty envelopes.

“Document Specifications” on page 62

“Envelope Separation” on page 25

“Insert Position” on page 28

page 34

“Envelope Settings” on page 32

Symptom Possible cause Remedy Reference

Flap not sufficiently moistened.

Envelope not always ejected from sealer.

No document fed. Feeder empty. Refill feeder. “Filling the Document

Skewed documents fed.

Double documents fed.

Document stoppage at collating area.

Water level low. Check water level,

refill if needed.

Brushes dry. Check brushes,

replace if needed by the extra soaked set.

Brushes dirty. Check brushes, clean

if needed.

Moistening felt dry. Check the moistening

felt, refill water tray if needed.

Moistening felt dirty. Check the moistening

felt, clean if needed.

Moistening brushes inactive.

Brushes worn out. Replace brushes. “Operator Maintenance”

Moistening felt worn out.

Inserted document too big.

Document not inserted deep enough.

Sealing area dirty. Clean sealing area. “Operator Maintenance”

Separation set too wide / too tight.

Side guides set too narrow.

Side guides set too wide.

Separation set too wide.

Stopper position set incorrect.

Activate the moistening brushes.

Replace moistening felt.

Check fold settings, adjust if needed.

Check adjustment of envelope stop position and fingers.

Adjust the separation.

Adjust the side guides.

Adjust side guides. “Side Guides” on

Adjust the separation.

Adjust stopper position.

“Sealing Envelopes” on page 26

“Operator Maintenance” on page 54

“Sealing Envelopes” on page 26

“Operator Maintenance” on page 54

“Sealing Envelopes” on page 26

on page 54 “Operator Maintenance”

on page 54 “Fold Settings” on

page 34 “Insert Position” on

page 28

on page 54

Feed Tray” on page 24 “Document Separation”

on page 23 “Side Guides” on

page 23

page 23 “Document Separation”

on page 23 “Adjustment of the

Document Stoppers” on page 24

ENGLISH

7. SPECIFICATIONS

7.1 Technical Specifications

Model 6402 Series Type inserter system for medium office use. Theoretical max.

speed Power consumption 100V AC/50Hz/3.0 Amps.

Fuse 100/115 Vac: T 5.0 A, 125 V

Approvals EMC Certificate conform EMC-Directive.

4000 inserts per hour, depending on application.

115V AC/50/60Hz/3.0 Amps. 230V AC/50Hz/1.5 Amps.

Time lag, 5.0 Amps. rated current, 125 V. 230 Vac: T 2.5 A H, 250 V Time lag, 2.5 Amps. rated current, high breaking capacity, 250 V

FCC Certificate conform 47CFR, part 15. CB Certificate conform IEC 60950-1. UL Listed I.T.E. (Information Technology Equipment), conform UL-IEC 60950-1, file: E153801. Conform NEN-EN-IEC 60950-1 and derivatives.

7.2 Configuration Dimensions

2 stations 4 stations 6 stations Height Width

Length

Weight 88.5 kg (195 lbs) 96.2 kg (212 lbs) 110 kg (242 lbs)

570 mm (22.4 inch)

420 mm (16.5 inch)

1340 mm (52.8 inch)

(with receiving tray 1590 mm/

62.6 inch, with side exit 1440

mm/56.7 inch, with stacker 1840

mm/72.4 inch)

745 mm (29.3 inch) 920 mm (36.2 inch)

7.3 Other Specifications

Noise level <66 dBA (according to ISO 11202) Operating temperature 10°C - 40°C (50°F-104°F) Humidity 30%-80%

7.4 Document Specifications

Paper quality minimum 60 g/m² (15 lb bond)

maximum 250 g/m² (62.5 lb bond), when folded max. 170 g/ m² (42.5 lb bond)

Booklets up to approximately 2 mm (0.08 inch) thickness, depending on stiffness

Paper size Minimum width: 130 mm (5.1")

Maximum width: 242 mm (9.5"), when folded 230 mm (9.1") Minimum length: 90 mm (3.5") Maximum length: 356 mm (14")

Folding capacity Single fold - 10 sheets (max. 80 g/m²)

Letter fold / Z-fold - 8 sheets (max. 80 g/m²) Double parallel fold - 4 sheets (max. 80 g/m²)

Envelope sizes Standard BRE (Business Reply Envelopes)

Envelope quality minimum 80 g/m² (20 lb bond)

maximum 120 g/m² (30 lb bond)

7.5 Envelope and Insert Specifications

ENGLISH

A B C D E F G

Minimum size mm 160 90 32 10 - 84

inches 6.3 3.5 1.25 0.4 - 3.3

Maximum size* mm 248 162 B-32 75 A-12** B-6 2.5*

inches 9.7 6.38 B-1.25 2.9 A-0.47** B-0.2 0.1

* Booklets up to approximately 2 mm (0.08 inch) thickness, depending on stiffness ** When insert is more than 1 mm (0.04 inch): A-15 mm / A-0.6 inch

Remarks:

• The specification of the paper handling equipment is often wider than that of the envelopes and documents handled. The condition of material handled will limit the specified environmental conditions.

60 g/m 60 g/m

2 2

• We recommend that materials to be handled are stored at a temperature of 20°C (68°F) with a relative humidity factor of 50%. If difference in temperature occurs between store room and mailing area, the material has to be stored near the machine at least 24 hours before use.

• Self-copying paper may cause rubber parts to wear quicker. The rubber used in this machine has the best resistance to Wiggins Teape material.

8. TERMINOLOGY

Term Description

Address carrier The address carrier is the document that carries the address of the

person for who the mail-set is meant. The address carrier can consist of one or more sheets, from which at least the first sheet must contain the address. The address must remain visible while enclosures are added and the document-set is folded. The fold type and selected envelope must ensure that th e address is v isible be hind th e window in the envelope. For personalized mailings there is always an address carrier present as long as envelope printing is not supported. Normally there is one address carrier.

Address position Position of the address on the address carrier,

measured from the upper left corner. The address position consists of a horizontal x coordinate, a vertical y coordinate, a horizontal width w and a vertical height h.

ENGLISH

Business Reply Envelope (BRE)

C-fold See “Letter fold” on page 67. Clear The function of an inser ting system in which all mail-sets in progress

Conveyor stacker Stacks up filled envelopes from the syste m. Daily Mail Capability of an inserting system to manually insert mail-sets one by

Document A document is one of the components of a mail-set. A document can

Document-set The document-set is the physical collection of address carrier and

Envelope included in outgoing mail-sets for addressee response purposes.

are finished and the document path is left empty.

one into the system, which are then inserted into an envelope. Optionally, depending on settings, additional enclosures can be added and the mail-set can be folded. This function is intended for small amounts of mail that each can have a different build-up.

consist of one or more sheets. Documents can be divided into address carriers and enclosures. For personalized mailings there is always one address carrier and an optional number of enclosures.

enclosure(s) that is under production in the Inserting System. The document-set is completed during production and is to be inserted in the envelope. The number of enclosures can range from 0 to the limit opposed by the number of available Feeders. Once the document set has been inserted into an envelope it is called mail set.

Term Description

Double Feed Control (DFC)

Double Feed Control is the sensor that measures the thickness of a sheet to check if the inserting system does not accidentally take more sheets than intended. DFC sensors exist on Feeders (double sheet detection). Currently DFCs on Formax inserting systems perform relative measurements, which means that they need a cycle to 'learn' the thickness of a sheet. Also the length of the document is measured so partly overlapping sheets will be detected.

Double parallel fold

The double parallel fold is a type of fold where the document is first folded halfway and the resulting folded set is again folded halfway. This fold is illustrated in the picture below. The position of both folds is adjustable.

Envelope The envelope is the packaging of a mail set. Window envelopes are

envelopes that have a transparent section through which the address on the address carrier can be read. Besides the normal top-closing

window envelopes there are also bottom-closing envelopes. Extended powerFold

Option, makes bottom address applications and short folds possible.

Face down Situation in which the front of a sheet is facing downwards when

placed in a document feeder. Face down

leading Face down

trailing

Situation in which the front of a sheet is facing downwards and the top

of the sheet is closest to the separation unit in a document feeder.

Situation in which the front of a sheet is facing downwards and the

bottom of the sheet is closest to the separation unit in a document

feeder. Face up Situation in which the front of a sheet is facing upwards when placed

in a document feeder. Face up leading Situation in which the front of a sheet is facing u pwards and the top of

the sheet is closest to the separation unit in a document feeder. Face up trailing Situation in which the front of a sheet is facing upwards and the

bottom of the sheet is closest to the separation unit in a document

feeder. Feeder A Feeder is a Module for the input of documents to the inserting

system. The Feeder separates documents sheet by sheet from the

stack of documents in the feed tray.

Term Description

Feeder linking The ability to load two feeders with the same document type where

the Inserting System automatically switches to a second feeder when the first feeder is empty and vice versa. In the mean time the first feeder can be refilled, so the inserting system can keep running

without having to stop for refilling the feeders. Feed tray Part of the feeder that contains the stack of documents. Flexcode OMR An OMR code for which the meaning of the OMR marks can be

programmed in a dedicated way for a specific customer. This is

normally used to support the OMR codes from other suppliers. FlexFeed

Insert • An insert is the action of inserting a document-set into an

Inserter An Inserter is the Module where the document-set is inserted into the

Inserting system The system of all the Modules that cooperate to perform the inserting

The flexFeed® is the feeding part of the system.

envelope.

• For native English speaking customers an insert is also a short, not to be folded document, usually an enclosure.

envelope, the envelope is closed and if necessary sealed.

function (accumulate docume nt -set, fo ld and insert) and have a single point of control.

ENGLISH

IntelliDeck

Job A job is an actually produced collection of mail-sets based on a certain

Job counter The counter that registers the number of mail-sets that is produced as

Letter fold Fold type in which a document-set is folded twice in which the folded

Linking See Feeder Linking.

To avoid stoppages the IntelliDeck® diverts duplicate on faulty documents before folding them while the system is still running.

Job Definition at a certain point in time for a specific purpose. It consists of:

• The Job definition used for the production

• Information about the batch size

part of a specific job.

flaps are on top of each other. This fold is illustrated in the picture below. The position of both folds is adjustable.

Synonym: C-fold.

Term Description

AutoSet

The feature of an Inserting System to automatically determine its Job settings by measuring the sizes of documents and envelope. From all Feeders that are loaded one sheet will be taken. Based on the maximum document length (which is also the length of the documentset) and the length of the envelope the fold type is determined.

AutoSet

job A job that is created with the AutoSet functionality.

Prod. Feeder Feeder with high capacity feed tray (e.g. 2000 sheets A4 80gr). Multifeed The feature of an Inserting System in which more than one sheet is

taken from a Feeder. OMR Optical Mark Recognition OMR code

definition

Standard 1-track OMR code definition. Specifies the amount of reading

marks used and the functionality linked to each of them (how each

should be interpreted). Operator The person operating an Inserting System. Optical Mark

Recognition (OMR)

Optical Mark Recognition is intended for reading and interpreting

printed codes. These codes are one or more black marks which are

read from a document. These marks give information to the Inserting

system about how to build-up and handle a set. PowerFold

The powerFold® can fold up tot 10 pages. Reading error Condition in which the system could not reliably read or interpret the

OMR reading marks from a sheet. Reading marks Marks added to documents containing finishing instructions that can

be identified by an OMR head and interpreted according to the used

OMR code definition. Remote

diagnostics

The feature that makes it is possible to analyze a problem on an

Inserting System from a remote location. Service engineer Technical engineer whose task it is to resolve problems with systems

in the field. Besides dealing with problems, service engineers are also

responsible for preventive maintenance. Single fold A single fold implies the document/set is folded once. The fold-p osition

is adjustable. This fold is illustrated in the picture below:

Stacker Used as storage for filled envelopes. Stop counter Counter which sets the amount of envelopes to be filled. After filling

this amount of envelopes the system will stop (even during a clear). Supervisor Person who is responsible for the technical state of the machine.

Normally a supervisor has access to programming functions, which are

restricted for standard users.

Term Description

Test run A test run is intended to validate the settings of the Inserting System:

• Inspect and adjust the stop position of the envelope.

• Check the fold settings for one set.

• Check whether the address is correctly positioned behind the envelope window.

Thickness detection

Tray Contains a stack of paper for a printer or inserter. This paper is

Vertical transport The vertical transport section between feeders and collator. Z-fold A Z-fold means that a document is folded twice in such a way that

Checks the thickness of the document set. If the thickness is less or more than the set value an error message is displayed.

supplied to the machine for further processing.

each folded flap is on a different size of the folded document, resulting in a Z-shape. This fold is illustrated in the picture below. The position of both folds is adjustable.

Synonyms: zigzag fold

ENGLISH

his is a class A product. In a domestic environment this product may cause radio interference in

which case the

Not

e: this equipment has been tested and found to comply with the limits for class A digital device,

rsuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interfe equipment g accordance with this instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.

user may be required to take adequate measures.

rence when the equipment is operated in a commercial environment. This

enerates, uses, and can radiate radio frequency energy and, if not installed and used in

Index

address carrier 65 address position 28, 65

bellows 9, 54 BRE offset 17 brush 26 brush replacement 54 business reply envelope 65 button 10

calibrate photocell 19 cleaning 54 clear button 10, 29 collating area 8 collator arm 9 configuration 50 configuration dimensions 62 connection 48 connection history 49 contrast 13 conveyor stacker 9, 21, 65 counter 13 counters menu 13 cover

inserter 9 side 9

daily mail 30, 65 daily mail handle 31 daily mail settings 34 date online services 50 DFC

continue on double 38

settings 37 diagnostics 18 dial tone detection 50 display 9

contrast 13

rotate 11, 13

settings 13 document 65

feed tray 9

height 33

offset 17

orientation 22 separation 23 settings 33 specifications 62 stopper 24

document orientation

extended powerFold normal 22 OMR 44

document stoppage

see stoppage document-set 65 double feed control 7, 66 double feed control settings 37 double feeding 59, 61 double parallel fold 66

envelope 66

feed 26

insert position 28

load 25

no envelope mode 33

quality 63

sealing 26

separation 25

settings 32

size 32, 63

specifications 63 envelope feeder

side guides 25 error messages 55 errors

reading errors 55

technical errors 55 extended powerFold

face down 66 face down leading 66 face down trailing 66 face up 66 face up leading 66 face up trailing 66 feed

document 24

envelopes 26 feed tray 67

installation 20 feeder 66

automatic 7, 23

install 20 link 34 load 24 remove 23 side guides 23

special 7, 24 feeder linking 67 fill water reservoir 26 flap closer 18 flex certificate 15 flexFeed Flex-OMR 42 fold

fold settings 34 franking

fuse 62

C 65

double parallel 35

letter 35

none 35

single 35

zig-zag 35

settings 39

insert 67 insert position 28 insert specifications 63

inserter 8 inserter cover 9 installation 20 intelliDeck

8, 67

job 67

copy 40

counter 67

create 31

delete 41

edit 40

info 12

job menu 14

name 38

new 31

selection 29

settings 32

settings (supervisor) 16

start 29

letter fold 67

AutoSet 27, 68

loading envelopes 25 loc 9

main menu 10 maintenance 54 Production Feeder 51, 68

document separation 52 feed documents 52 installation 51

side guides 52 message 49 mode menu 16 modem volume 51 multifeed 68

noise level 62 number of sheets 33

offset

BRE 17

document 17, 18 OMR 68

adjustments 43

align heads 43

codes 44

description 42

document orientation 44

reading head position 43

reverse reading 36

settings 36

test 19 OMR reading head cover 9 Online Services 15, 48 online services 48 operating controls 9 operating instructions 20 Optical Mark Recognition

see OMR option

activate 42

information 15

license code 42 other job 29 overview 7

ENGLISH

paper quality 62 paper size 63 photocell calibration 19 power consumption 62 power switch 9 powerFold

reading head position 43 RS232 connection 9

safety 3 seal envelopes 26 sensor 9 sensor dusty 54 set automatic feeding 30 set manual feeding 30 side cover 9 single fold 68 software description 10 software version 15 speed 16 stacker 68 start button 10, 29 starting the job 29 stop button 10, 29 stop counter 68 stoppage 56

collating area 58 envelope hopper 57 exit 56 flexFeed inserting area 56 lower envelope track 57 powerFold

sealing area 56 stoppage at inserting point 60 supervisor menu 14 system ID 15 system info 15

technical specifications 62 telephone number 50 test menu 18 test run 30, 69 thickness detection 37, 69 touch screen 10

tray 69 troubleshooting 58

volume acoustic signals 13

water reservoir 9

Z-fold 69

Formax 6402 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1. HEALTH, SAFETY AND ENVIRONMENT

1.1 Precautions and Safety Issues

Warnings

Safety Precautions

Conventions

2. FUNCTIONAL DESCRIPTION

2.1 Overview

2.1.1 FlexFeed® (1)

2.1.2 Collating Area (2)

2.1.5 Inserter (6)

2.2 Operating Controls

2.4.2 Job Info

2.4.3 Counters

2.4.4 Display Settings

2.4.5 Job Menu

2.4.6 Supervisor Menu

Job Settings (Supervisor)

Mode Menu

Document Offset

BRE Offset

Flap Closer

Test

OMR Test

3. OPERATING INSTRUCTIONS

3.1 Installation

3.2 Preparation

3.2.1 Document Feed Trays

3.4 Loading Documents

3.4.1 Document Orientation

3.4.2 Side Guides

3.4.3 Document Separation

3.4.4 Filling the Document Feed Tray

3.4.5 Adjustment of the Document Stoppers

3.5 Loading Envelopes

3.5.1 Adjusting Side Guides

3.5.2 Envelope Separation

3.5.3 Feeding Envelopes

3.6 Sealing Envelopes

Insert Position

Adjust the Envelope Insert Fingers

Address Position

Starting the Job

3.7.2 Select Another Job

Perform a Test Run

3.8 Run the Daily Mail

3.9 Create a Job

3.9.1 Job Settings

3.9.2 Envelope Settings

3.9.3 Document Settings

3.9.4 Fold Settings

3.9.5 Optical Mark Recognition Settings (Option)

3.9.6 Double Feed Control Settings

3.9.7 Job Name

3.10 Edit a Job

3.11 Copy a Job

3.12 Delete a Job

4. OPTIONS

4.1 Activate an Option

4.2 Optical Mark Recognition (OMR)

4.2.1 General

4.2.2 Alignment Reading Head Position

4.2.3 Document Orientation

4.2.4 OMR Codes Printing Quality

Minimum Code / Basic Commands

Length

Code Width, Character Spacing and Pitch

Additional Marks

Divert Mark (Divert & Continue)

Stop Mark (Divert & Stop)

Selective Feed Mark

Sequence Check

Parity Mark

Safety Mark

Examples of OMR Code

Example Code

4.3 Online Services