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6404
User Manual
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Formax 6404 User Manual

6404 Series Mid-Volume Inserter
2/2012
OPERATOR MANUAL

Table of Contents

1 Read this First ..............................................................................................1
About this manual............................................................................................1
Safety...............................................................................................................2
2 Meet your Document System ......................................................................5
Overview..........................................................................................................5
Operating Controls...........................................................................................8
Control Panel...................................................................................................9
Installing the Document Feed Trays...............................................................10
High Capacity Vertical Stacker.......................................................................11
Power Up........................................................................................................11
Home Menu....................................................................................................12
Job Info..........................................................................................................13
Side Guides...................................................................................................15
Document Orientation....................................................................................16
Filling the Document Feeder Tray...................................................................17
Loading Envelopes.........................................................................................17
Sealing Envelopes.........................................................................................19
Filling the Sealing Liquid Reservoir................................................................20
3 Options ........................................................................................................21
Production Feeder.........................................................................................21
Installing the Production Feeder....................................................................21
Adjusting the Side Guides..............................................................................22
Adjusting the Document Separation...............................................................23
Feeding documents with Production Feeder..................................................24
High Capacity Document Feeder (HCDF)......................................................24
Adjusting the HCDF Side Guides...................................................................25
Document Separation for the HCDF..............................................................26
Conveyor Stacker...........................................................................................27
Side Exit.........................................................................................................27
insert'n Frank / insert'n Mail ..........................................................................28
Mail Piece Production Control........................................................................28
4 Processing Mail Sets .................................................................................29
Introduction....................................................................................................29
Processing a Basic Mail Set ..........................................................................30
Processing a Mail Set with BRE or Inser ts....................................................31
Document Separation....................................................................................32
Adjustment of the Document Stoppers..........................................................33
Test Run.........................................................................................................35
Verifying the Insert Position............................................................................37
5 Working with Jobs .....................................................................................38
What is a job..................................................................................................38
Creating a new job.........................................................................................38
Performing a test run......................................................................................40
Adjusting the Envelope Position.....................................................................41
Job settings....................................................................................................46
Envelope settings...........................................................................................46
Document settings.........................................................................................48
Fold settings...................................................................................................50
Double feed control settings...........................................................................55
Job name.......................................................................................................56
Mail Piece Production Control settings (option).............................................58
6 Advanced Settings .....................................................................................59
What are Advanced Setting?.........................................................................59
Changing the Display Settings.......................................................................60
Viewing System info and Software versions..................................................61
What are licensed options?............................................................................62
Test Menu.......................................................................................................63
Running diagnostics.......................................................................................64
Job Settings (Supervisor)...............................................................................65
Envelope Clearing..........................................................................................66
System Output...............................................................................................67
7 Reading .......................................................................................................70
Introduction....................................................................................................70
Reverse reading.............................................................................................71
Document Orientation....................................................................................72
Reading a configuration sheet (BCR only).....................................................74
Running an OMR test ....................................................................................80
8 Online Ser vices ..........................................................................................82
Online Services..............................................................................................82
Connecting to the server................................................................................83
Viewing the histor y.........................................................................................83
Viewing messages.........................................................................................84
Installing a new job or new software..............................................................85
Configuration Menu........................................................................................86
Changing the telephone number....................................................................87
Selecting the countr y.....................................................................................88
Entering date and time...................................................................................88
Setting the dial tone detection........................................................................89
Setting the modem volume............................................................................89
9 Operator Maintenance ...............................................................................90
Maintenance Schedule..................................................................................90
Clean and replace br ushes............................................................................91
Clean the sensors on the envelope or document path...................................92
Clean the exit sensors....................................................................................92
Resetting Photocells......................................................................................93
10 Fault Finding ...............................................................................................94
Error Messages..............................................................................................94
Clearing Stoppages.......................................................................................95
Exit, Sealing and Inserting Area.....................................................................97
Envelope Hopper...........................................................................................98
Lower Envelope Track....................................................................................98
PowerFold......................................................................................................99
FlexFeed......................................................................................................100
Collating Area..............................................................................................100
Operator Troubleshooting.............................................................................101
Trouble Shooting Table.................................................................................101
11 Specifications ...........................................................................................105
Technical Specifications...............................................................................105
Hopper and feeder capacity.........................................................................106
Configuration Dimensions............................................................................106
Envelope and Document Set Specifications ................................................107
maxiFeeder Specifications...........................................................................108
High Capacity Vertical Stacker Specifications..............................................109
12 Terminology ..............................................................................................110
Terminology..................................................................................................110
13 EC Declaration of Conformity .................................................................116
EC Declaration of Conformity DS-85, M8500, FPi 5600, FD6404...............116
EC Declaration of Conformity HCVS-1........................................................117
EC Declaration of Conformity MF-1.............................................................118

Read this First1

Warning

Ensure you have read and fully understood the safety requirements in this section.

About this manual

Languages
According to the EC (European Commission) declaration following the Low Voltage Directive (2006/95/EC), this operator manual must be available in the national language(s) of the country where the system is delivered. Therefore, if you do not have an operator manual in your country’s language(s), contact your authorized distributor.
Software
The software used for the reading option is based in part on the work of the Independent JPEG Group.
Audience
1
English
This manual is meant for operators of the document system.
Trademarks
maxiFeeder™, insert'n Frank™, powerFold™, intelliDeck™, flexFeed™ and versaFeeder™ are trademarks of Neopost however the affix ™ will not be used further in this manual.
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1
Symbols
This manual uses the symbols listed below.
WARNING : Indicates a human safety hazard.
English
ATTENTION : A risk to the equipment or mail could result from an action you may perform.
NOTE : A remark that explains different cases or specificities.
TIP : Advice to help save you time when processing your mail.
SUPERVISOR : Indicates that you have to use the supervisor
menu to perform the procedure.

Safety

Warnings
• Disconnect the power supply before performing any maintenance.
• Before connecting the system to the electrical supply, Ensure that the system is suitable for the local mains voltage. Refer to the serial plate on your system for voltage requirements.
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Safety Precautions
• Only competent, trained personnel should operate this system. If non-trained personnel do operate this system, the manufacturer will not accept responsibility for any resulting accidents or injuries.
• Only skilled persons, who are aware of the risks involved, may open the protective covers. For safety reasons, the system will not function when the covers are open.
• Keep long hair, fingers, jewelry, etc. away from rotating and moving parts.
• The power connection must be easily accessible, preferably close to the system. For safety reasons, it is essential that the system is connected to a socket outlet that has a protective earth (ground) connection.
• Overcurrent protection in the equipment also relies on the branch circuit protection (max. 20 A).
• The following part(s) is (are) considered the equipment disconnect device(s):
- Power supply cord plug or appliance coupler.
- 12-pole connector, located on the right-hand side.

Country Specific Conditions

Denmark
In Denmark, certain types of Class 1 appliances may be provided with a plug that does not provide an adequate earth (ground) connection when inserted into a Danish socket outlet. Make sure the system has a good functioning connection that has protective earthing (the plug and socket outlet must match).
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English
Japan
• Establish an earth (ground) connection before connecting the mains plug to the power supply.
• First disconnect the power supply before removing the earth (ground) connection.
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End of Life

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English
The objectives of the European Community's environment policy are, in particular, to preserve, protect and improve the quality of the environment, protect human health and utilize natural resources prudently and rationally. That policy is based on the precautionary principle and principles that preventive action should be taken, that environmental damage should as a priority be rectified at source.
Separating waste during collection is the precondition to ensure reuse and recycling of waste. The proper disposal of electrical or electronic equipment is necessary to achieve the chosen level of protection of human health and the environment in the European Community.
More particularly, certain materials and components of waste electrical and electronic equipment need special treatment as improper handling or disposal on or into land, water or air would represent a major threat to the environment and human health.
In order to facilitate collection and treatment separated from normal domestic waste, electrical and electronical equipment is marked with the following logo:
By law, not only are you not allowed to dispose of the waste equipment via other waste channels, but we encourage you to actively contribute to the success of such collection and to the common good and better quality of life of present and future generations. For more information on the correct disposal of this product, please contact your local service organization.
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Meet your Document System2

Overview

Introduction
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The system is a folding and inserting system for processing mail easily. The system:
• Feeds documents
• Folds the documents
• Inserts the documents into envelopes
• Seals the envelopes
• Stacks the envelopes
Automatic monitoring ensures the correct number of documents per envelope. The system can be operated by means of a user friendly interface.The settings of the system (types of documents, type of envelopes and the type of fold) is recorded in so called jobs. These jobs can be programmed by an authorized user.
The system is equipped with a variety of special features, such as:
• Document thickness detection
• Programmable jobs
• Automatic jobs
• flexFeed
• Double feed control
• Hopper swap
• Multifeed
• Daily mail
• intelliDeck
• powerFold.
English
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English
The figure shows an overview of the system.
Document Feeders (Tower) (1)
This is the feeding part of the system.There are two types of feeders: the automatic and the special feeder. The automatic feeder does not require any adjustments for the separation. From a feeder you can feed one or more documents (multi feed). The feeders have a double feed control (DFC). DFC detects if more documents are fed instead of one.
You can link feeders. This means that two feeders can be linked as pairs. When the first feeder is empty, the system switches to the other feeder. Meanwhile the empty feeder can be refilled without stopping the system.
The upper automatic feeder is equipped with a 'daily mail' function.You can use this feeder to process sets of documents that you cannot process automatically (stapled documents and sets with varying thickness).
Collating Area (2)
All documents of a document set are collated and aligned in the collating area.
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 Fold unit.
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Folding unit (4)
The fold unit folds the documents. The following fold types are possible (see Terminology on page 110):
• No fold
• V-fold
• C-fold
• Z-fold
• Double V-fold
Envelope feeder (5)
Envelopes that are placed on a stack by the user, are fed one by one into the system by the envelope feeder.
Inserter (6)
After the documents are folded, the documents are transported to the inserter.The inserter inserts the documents into a waiting envelope. The inserter seals the envelope or not, depending on the settings. Automatic monitoring ensures the correct number of inserts per envelope.
Stacker (7)
If you have a High Capacity Vertical Stacker installed on your system, the envelope is stacked in the stacker, when it leaves the system.The vertical stacker can store up to 325 filled envelopes.
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English
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English

Operating Controls

A - High Capacity Vertical Stacker B - loc cover C - unlocking lever for loc D - power inlet, power switch E - inserter cover F - RS232 connector / USB / modem G - display (operator panel) H - hand grip vertical transport cover I - document feed tray J - collator arm K - Divert Deck L - Folding unit
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M - locking handle Folding unit N - handle for manual transport of the enve-
lope
O - air plugs for cleaning the sensors P - handle for manual transport of the mail
set Q - unlocking handles for rollers envelope
track
R - sealing liquid 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 adjust-
ment
X - envelopes support

Control Panel

The control panel consists of the touch screen and the following buttons:
A: On/Off ( ): Switches the system on or off. If the system is not used for one hour,
the system switches to the power save mode. Press the On/Off button to switch back to the user mode.
B: Stop ( ): The system completes the current mail set and stops, leaving the system empty and ready for a new set.
C: Start ( ): The system starts to process mail sets.
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English
The display is covered with a thin pressure-sensitive layer.To avoid permanent damage of the display, do not use sharp objects to press on the display.
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English

Installing the Document Feed Trays

Place the document feed trays in position:
1. Hold the document feeder slightly inclined as shown in the figure.
2. Place the front end of the document feed tray underneath the two black rollers.
3. Move the document feed tray upwards (lifting the black rollers), until it is possible to
‘hook’ the feeder into place.
4. Move the document feed tray towards the machine and move the hooks over the
mounting points (on both sides).
5. Let the document feed tray rest on the machine.
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High Capacity Vertical Stacker

The High Capacity Vertical Stacker can be used to stack filled envelopes. The vertical stacker can store up to 325 filled envelopes. The vertical stacker can be equipped with Mail Piece Production Control (MPPC). In case you have a High Capacity Vertical Stacker, install it as follows on your system:
1. Move the stacker as indicated by the arrow.
2. Lift the stacker with the suspension hooks over the two rods (upper and lower) and
lower it.
3. Connect the connector
4. Adjust the side guides with wheel A until a margin of 3 to 5 mm is left between the
envelopes and the side guides.
5. For small envelopes it can be necessary to remove the extensions B from the envelope
support.
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English

Power Up

To start up the system:
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.
1. Connect the system to the mains power supply.
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2. Use the power switch to switch the system on. The power switch is located on the
back of the system.
3.
Press the on/off button next to the display. (Only necessary when the system is in standby mode.)
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English
The touch screen shows the home menu.

Home Menu

When you start up the system, the ‘home’ menu appears. With the arrows you can scroll through the jobs. If you want more information on a job, select the job.
If you just want to start without job definition, press [New job] and select [Automatic] (see
Processing mail sets).
With the home button ( ) you get back to the home menu.The [Menu] button opens the advanced settings menu (see Opening the Advanced Settings on page 60).
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Job Info

If you want more information on a job, select the job in the ‘home’ menu.
The ‘current job’ menu shows the following information of the selected job:
• Job number and Job name
• Total: total number of envelopes that have been processed using this job
• To do: number of envelopes to do. Only indicated if a ‘stop at’ value is set.
• Stop at: number of processed envelopes at which the system stops.You can set this number with the [Counters] button. You can set it between 0 (switched off) and 9999. The system will continue until the job counter reaches the stop counter value. The system stops and can be restarted. The stop counter is switched off when it is set to zero.
If you want to reset the daily job counter and the stop counter, press the [Reset TOTAL Counter] button in the ‘counters’ menu.
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English
The counter settings are job related.
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English
A picture of the system with symbols for the selected features. The following symbols can be used:
• Shows the feeders selected to pick documents from (black
is selected). Every selected feeder shows how many sheets will be fed from the feeder and the length of the sheets.
This sign indicates that the relevant feeders are linked. This means that when one feeder is empty, the system automati­cally starts picking documents from the other feeder.
This sign indicates that for the selected feeder OMR or BCR is switched on (optional).
This sign indicates that the relevant feeder is set for daily mail.
Gives information about the envelope size (ISO format or height in mm). An envelope with a cross means that no en­velopes are used.
Shows the type of fold, in this case C-fold.
The sign indicates that for the relevant feeder the double feed detection is switched on.
• [Edit]: use this button to edit the job (see Editing a job on page 42).
• [Info]: if you press the [Info] button, the screen shows how to position the envelope
and documents in the feeders. From this menu you can press a button to view the reading settings and insert'n Frank / insert'n Mail settings.
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Side Guides

To adjust the side guides it is best to remove the document feed tray from the feeder as follows:
1. Push handle A downwards.
2. Lift the document feed tray upwards to unhook it and then pull it out from the feeder.
3. Loosen the knob B half a turn.
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English
4. Grab the side guides in the middle and push them apart as far as possible.
5. Put a small stack of documents between the side guides.
6. Grab the side guides in the middle and push them towards the documents.The space
between the side guides and the documents should be such that the documents have just enough play to move freely.
7. Re-tighten knob B.
8. Remove the stack of documents.
9. Replace the document feed tray (see Installing document feeders on page 10).
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English

Document Orientation

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

Fill the document feeder tray as follows:
1. Open the left-hand side guide A by turning it downwards.
The feed rollers will automatically be lifted.
2. Place a stack of documents between the side guides.
3. Turn the left side guide upwards again.
4. Feed the documents (depending on the type of documents and the type of fold) (see
Document Orientation on page 16).

Loading Envelopes

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English
Before you load the envelopes, make sure the envelope separation and side guides are correctly set. Proceed as follows:
1. Rotate thumb wheel D to move the side guides C apart.
2. Put a small stack of envelopes between the side guides.
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English
3. Move the side guides towards the envelopes. The space between the side guides and
the envelopes should be such that the envelopes have just enough play to move freely.
If the distance between the side guides is too large, the envelopes will twist sidewards, when transported into the machine.
4. Pull down small lever A to set the separation.
5. Insert one envelope up to the stoppers. The position of the envelope is flap down and
trailing (bottom side of the envelope pointing to the system).
6. Return lever A.
7. Loosen the stack of envelopes and place the stack on top of the bottom envelope.
8. Shift envelope support B in or out. The top side of the envelope must touch the dotted
line on the support.
9. Turn envelope support B to distribute the weight of the envelopes evenly on both
sides.
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Sealing Envelopes

Switch the envelope sealing on or off:
1. Lift the handgrip to open the top cover. Shift the blue handle A towards
2.
2
to disable the envelope sealing or towards
to enable the envelop sealing.
3. Close the top cover.
Before you start a job with sealing, wait approximately 5 minutes for the brushes to moisten or use moistened brushes. For instructions on the installation of brushes, see Clean and
replace brushes on page 91.
English
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2
English

Filling the Sealing Liquid Reservoir

1. Open the front cover A.
2. Fill the reservoir B to the "Max" lip with sealing liquid.
3. Close the front cover A.
Before starting the job, wait approximately 5 minutes for the brushes to moisten or use moistened brushes. For instructions on the installation of brushes, see Clean and replace
brushes on page 91.
If the liquid reservoir is almost empty the touchscreen shows a message to warn you that you should refill the reservoir.

Shut Down the System

1.
Press the [On/Off] button to shut down the system.
When the system is busy, it completes and inserts the current set, stops and will be shut down.
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Options3

Production Feeder
The production feeder is a feeder that 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.
Installing the Production Feeder
The production feeder should be installed at the position of feeder no. 1 and/or 4. If you install it on position 4, you cannot use position 2 and 3 for document feeders.
To install the production feeder 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.
3
The production is auto-detected by the system when the system is switched on. This makes it easy to switch over from the standard document feeder tray to the production feeder and vice versa.
To make use of a production feeder it is not necessary to (re-)program the jobs.
To allow easier hooking on of the production feeder it is advised to put the feeding plate in the rear position.
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3
English
Adjusting the Production Feeder Side Guides
Adjust the side guides:
1. Take a stack of documents/BREs and place them in the feeder tray.
BREs with flap down and leading (top side pointing to system).
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.
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Adjusting the Production Feeder Document Separation
When the production feeder is used at an automatic separation feeder, the separation is set automatically. It can also be used on a feeder position with a manually adjusted separation. To adjust, proceed as follows:
1. Remove the document feeder trays 2 and 3.
The lowest feeder is feeder 1.
2. Squeeze the two blue handles 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 feeder tray and slide it in the system till the leading
edge is not visible anymore. Turn knob D counterclockwise if the separation is set to narrow.
5. Push the document/BRE between the rollers.
6. Turn knob D clockwise to get more resistance 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. Replace the document feeder trays 2 and 3.
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English
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