Formax 6606 User Manual
6606 Series Inserters
8/2014
Operator Manual
Table of Contents
How this Help Works ....................................................................................11
Help Menu........................................................................................................1
User Guide.......................................................................................................1
Meet your Document System .......................................................................32
Introduction.......................................................................................................3
System Overview.............................................................................................4
Operating Controls...........................................................................................6
Control Panel....................................................................................................7
Power Up..........................................................................................................7
How to Operate the Touch Screen...................................................................9
Open a Web Browser.....................................................................................11
What is a Job?................................................................................................11
Job List...........................................................................................................12
Job Overview..................................................................................................13
High Capacity Document Feeder (HCDF)......................................................15
Production Feeder (FD 6606-00).................................................................15
Thin Booklet Feeder (FD 6606-15).. .............................................................16
Catch Tray......................................................................................................17
Shut Down the System...................................................................................18
Working with Jobs ......................................................................................193
Introduction.....................................................................................................19
Use an Existing Job........................................................................................19
Create a New Job...........................................................................................20
About Automatic Jobs....................................................................................21
Create an Automatic Job................................................................................21
Create a Manual Job......................................................................................23
Create an Test Mail Set..................................................................................35
Mail Sets.........................................................................................................41
Change to Another Feeder Tray.....................................................................47
Link Feeder Trays...........................................................................................47
Edit a Job.......................................................................................................48
Save a Job.....................................................................................................49
Delete or Move an Enclosure.........................................................................50
Copy a Job.....................................................................................................51
Lock a Job......................................................................................................51
Rename a Job................................................................................................53
Delete a Job...................................................................................................54
Loading the System ....................................................................................554
Document Orientation....................................................................................55
Document Feed Trays....................................................................................56
Load Envelopes..............................................................................................66
Adjust the Side Guides and Envelope Separation.........................................67
Fill the Sealing Liquid Reservoir.....................................................................68
Options ........................................................................................................695
Support for Curved Reply Envelopes (option for Thin Booklet Feeder).........69
Power Stacker Support..................................................................................69
High Capacity Envelope Hopper (FD 6606-30/EF-4).....................................70
High Capacity Conveyor Belt (FD 6606-25)..................................................72
Settings menu .............................................................................................746
Open the Settings Menu.................................................................................74
Open the Settings Menu (Supervisor)............................................................76
Supervisor Settings Menu..............................................................................78
Connect the System to the Internet ..........................................................957
Options for Connection...................................................................................95
Set up a Wired Connection............................................................................95
Set up a Wireless Connection........................................................................97
Test the Connection........................................................................................99
Reading ......................................................................................................1008
Introduction...................................................................................................100
OCR Code Description.................................................................................101
BCR Code Description.................................................................................104
OMR Code Description................................................................................108
Flex Reading Code Description....................................................................112
Create Jobs with Reading............................................................................113
Reading Settings..........................................................................................119
Exit Selection with Reading..........................................................................122
Operator Maintenance ..............................................................................1239
Maintenance Schedule.................................................................................123
Clean and Replace Brushes.........................................................................124
Replace or Clean Moistening Cloth..............................................................125
Calibrate Photocells.....................................................................................126
Fault Finding .............................................................................................12710
Messages.....................................................................................................127
Clear Stoppages...........................................................................................130
Operator Troubleshooting.............................................................................136
Troubleshooting Table..................................................................................137
Specifications ............................................................................................14211
Technical Specifications...............................................................................142
Hopper and Feeder Capacity.......................................................................143
Configuration Dimensions............................................................................143
Document and Insert Specifications.............................................................143
Envelope and Document Set Specifications................................................144
Production Feeder Specifications...............................................................145
Thin Booklet Feeder Specifications.............................................................146
High Capacity Envelope Hopper Specifications...........................................147
High Capacity Conveyor Belt Specifications................................................148
Terminology ...............................................................................................14912
How this Help Works1
Help Menu
The help button [?] gives access to help topics via a pull-down menu.
The contents of the help menu can be different for your situation. The help menu can contain
the following topics:
• Search; use the search engine to find a specific topic.
• User Guide; user instructions describing how to use the system.
• FAQ's (option); when the system is connected to the internet, frequently asked
questions are answered here (option).
• What can I do here; a list with relevant help topics related to the current screen.
• Remote assistance (option); online remote assistance for helpdesk guidance. Call
the phone number that is displayed and follow the instructions of the support assistant.
User Guide
1
English
You can use this guide as follows:
• Use the contents overview to browse the contents.
• Use the keyword search, to enter a keyword for the search. The information button
at the keyword search supplies detailed information on how to optimize the search.
• If necessary, use the advanced search to narrow down your keyword search to better
matching results.
1
To navigate through the User Guide:
• Tap to select
• Swipe up/down to scroll
• Double tap to zoom
1
English
• Pinch in/out to zoom in/out
See also How to operate the touchscreen on page 9.
When you use the User Guide, you can minimize it, to operate the system. Use the minimize
button to minimize the User Guide.
The help button shows a purple color when the User Guide is minimized. When you click
the help button, the User Guide is restored.
2
Meet your Document System2
Introduction
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 (type of
documents, type of envelopes and the type of fold) are recorded in so called jobs. These
jobs can be created by the operator.
The system is equipped with a variety of special features, such as:
• mail set thickness detection
• job wizard for creating jobs
• Double Feed Control
• feeder tray linking
• feeder tray swapping
• daily mail
• Flexible Feeders on page 4
• Divert Deck on page 4
• Folding Power on page 4
Operator and supervisor
2
English
You can use the system as operator and as supervisor. The supervisor has access to more
settings than the operator. You can switch from operator to supervisor in every screen.
When you switch to supervisor, you see immediately the result: extra tabs appear for the
advanced settings. Also the side menu contains extra functions.
3
System Overview
2
English
The figure shows an overview of the system.
Document Feeders (1)
The Document Feeders are 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.
feeding part of the system. There are two types of feeders: the
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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 folding unit.
Folding Unit (4)
The fold unit folds the documents. The following fold types are possible (see Terminology
on page 149):
• No fold
• V-fold
• C-fold
• Z-fold
• Double V-fold
Inserter (5)
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.
Present on Deck (6)
The documents inserted (or not) can leave the inserter from the upper unit (present on
deck). This can occur when:
• Clearing the machine;
• Making a test set;
• Depending on the reading code.
Stacker (7)
The documents inserted (or not) are transported to the stacker depending on the
programmed job. The stacker automatically stacks inserted documents.
Side exit (8)
The documents inserted are transported to the side exit depending on the programmed
job. The side exit can be used for sorting and stacking of documents into the catch tray as
well as transporting to the optional conveyor belt or franking/mailing machine.
Envelope Hopper (9)
Envelopes that are placed on a stack by the user, are fed one by one into the system by
the envelope hopper.
2
English
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Operating Controls
2
English
A - catch tray (optional)
B - side exit / stacker unit
C - side guides stacker
D - power inlet, power switch
E - USB (service only)
F - unlocking lever for upper unit
G - USB (2x), RS232 and ethernet
H - control panel
I - vertical transport
J - hand grip vertical transport cover
K - document feed tray
L - collator arm
M - Divert Deck
N - Folding unit
O - locking handle Folding unit
P - handle for manual transport of the envel-
ope
Q - handle for manual transport of the mail
set
R - unlocking handle for rollers envelope
track
S - sealing liquid reservoir
T - side cover (opened)
U - thumb wheel for side guide adjustment
V - side guides envelope feed tray
W - flap for envelope separation adjustment
X - envelope support
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Control Panel
The touch screen is covered with a thin pressure-sensitive layer.
To avoid permanent damage of the touch screen, do not use sharp
objects to press on the touch screen.
2
The control panel consists of the touch screen and the following buttons:
A: On/Off button. 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 button. The system completes the
current mail set and stops, leaving the system empty and ready for a new set. The Stop
button and [Stop] on the touch screen have
the same functionallity.
C: Start button. The system starts to process
mail sets. The Start button and [Start] on
the touch screen have the same functionallity.
Power Up
To start up the system:
You can severely damage the machine if it is connected to the
incorrect mains voltage. Before plugging in the machine, check if
the local voltage is the same as the voltage mentioned on the type
plate.
English
1. Connect the system to the mains power supply.
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2. Use the power switch A to switch the system on. The power switch is located on the
back of the system.
2
English
3.
Press the on/off button next to the display B.
The touch screen shows the Job list screen.
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How to Operate the Touch Screen
You can operate the touch screen like a tablet:
• Tap: touch and release the screen with your finger
2
English
• Swipe: touch the screen, hold it and move your finger(s) left or right
• Tap and hold: touch the screen with your finger and hold it for two seconds
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2
English
Some screens have a side menu. Which functions the side menu contains, depends on
the screen you are working in, and on authorization on page 3.
To open the side menu, tap the icon on the left.
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Open a Web Browser
You can open a web browser in the user interface of the system. Open the web browser
as follows:
Tap on the logo in the upper left corner of the screen.1.
2. Tap the cross in the upper left corner of the screen to close the web browser.
If you work with a special keyboard for your language, you can switch the keyboard back
to the English version on page 82 to type e.g. a web address.
What is a Job?
If you have to process a lot of mail sets of the same type (for example bills), you can save
the settings to a 'job'. The next time you just select the job and immediately start without
defining any settings.
The following settings are saved in a job:
• Envelope type/size;
• Sealing on/off;
• Which document feeders should be used, how many documents should be fed from
each feeder and document height for each feeder;
• Feeder linking on/off;
• If BREs or insert cards should be included;
• Address position;
• Fold settings;
• Double feed control settings;
• Reading settings (option);
• Exit select settings;
• Batch Counter, defining the number of mail sets that the job must process. The job
will automatically stop processing when this number is reached.
2
English
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Job List
2
English
When you start up the system, the ‘Job list’ menu appears.
1. Open a web browser on page 11
2. Help menu on page 1
3. Login, see Introduction on page 3
4. Side menu
The side menu contains the settings menu (see Settings menu operator on page 74). When
you are logged in as supervisor, the settings menu is extended with advanced settings
(see Settings menu supervisor on page 76).
If you want more information on a job, select the job. With the [Job list] button you get
back to the home menu.
See also: Working with Jobs on page 19.
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Job Overview
If you want more information on a job, select the job in the Job List menu.
The touch screen shows the following information of the selected job:
• Job name
• Job settings (for example the document and envelope type)
• How to load envelopes and documents for this job
• The number of envelopes that have been processed with this job
In this screen you can change the following settings:
• Counter settings (see Change the counter settings on page 31)
• Job settings (see Editing a job on page 48)
• Move documents between feeders (see Change to an other feeder tray on page 47)
• Link feeders (see Link feeder trays on page 47)
• Start the job or run a test run (see Performing a test run)
2
English
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The following is a list of symbols or icons and their descriptions.
2
English
Main document.
Shows the correct document
orientation; A is the address.
ally insert mail-sets one by
one into the system.
NotificationNext to this symbol, a message appears, e.g.
Sealing liquid low, empty
feeder.
Envelope, sealing onEnvelopes will be sealed. The
symbol shows the correct
envelope orientation.
Feeder linkingLinking means
that when one feeder is
empty, the system automatically starts feeding documents
from the other feeder. This
symbol at the feeders shows
if the feeders are linked.
DFC/mail set thickness detectionDouble feed control
and/or mail set thickness detection has been set to 'off'.
By default the dfc/mail set
thickness detection will be set
to 'on' and the icon will not be
shown.
Exit settingThis icon shows
what kind of exit setting has
been set.
1x buttonAfter tapping this
button the system will create
an example mail set.
Document with reading
Shows the correct document
orientation; A is the address.
EnclosureDaily mailFeature to manu-
Envelope sealing offEnvel-
opes will not be sealed. The
symbol shows the correct
envelope orientation.
When sealing is off, the flap
of the envelope is closed but
not moistened.
Change feeder traysPossibility to change from one feeder tray to another.
Fold type
This icon shows what kind of
fold type has been set.
Counter settingShows on
what number the counter has
been set.
Start button
Tapping this button runs the
job.
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Job list buttonAfter tapping
this button the job list screen
will be shown.
Edit buttonGives access for
editing a job.
Stop buttonButton to stop
the system The current mail
set will be completed and the
system stops, being empty
and ready for a new set.
Save buttonSave the job or
changes that have been
made to a job.
High Capacity Document Feeder (HCDF)
The High Capacity Document Feeder (HCDF) is an option that can be delivered from factory,
or added to a 2 or 4 station version by a service engineer. The High Capacity Document
Feeder has a capacity for up to 725 sheets. The normal document feeder tray has a capacity
of 325 sheets.
For more information on the operation of the HCDF, refer to the topic on loading documents
for the HCDF on page 63.
2
English
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.
For more information on the operation of the Production Feeder, refer to the topic on
loading documents for the Production Feeder on page 59.
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2
English
Thin Booklet Feeder (FD 6606-15)
The Thin Booklet Feeder is used to feed booklets, regardless of the thickness of the
cover, to the document flow from the feeder to the inserter. Because of the location of the
Thin Booklet Feeder (downstream the feeder module) documents feeded by the Thin
Booklet Feeder will not be folded.
When the Thin Booklet Feeder is added to the configuration, this is shown in the
screens at the operator panel.
For more information on the operation of the Thin Booklet Feeder, refer to the topic on
loading documents for the Thin Booklet Feeder.
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Catch Tray
2
English
For stacking envelopes leaving from the side exit a catch tray can be mounted. You can
select the catch tray in the Output settings tab of the job definition (see Exit settings on
page 29).
Instead of a catch tray at the right hand (RH) side of the system it is also possible to install
a catch tray on the left hand (LH) side. To achieve this it is necessary to reverse the side
exit of the Stacker from RH to LH.
Contact your supplier for more information about this option.
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Shut Down the System
1.
Press the [On/Off] button next to display B to shut down the system.
2
English
When the system is busy, it completes and inserts the current set, stops and will be shut
down.
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Working with Jobs3
Introduction
With the system you can process mail sets in the following ways:
• Using an existing job. Existing jobs are shown in the Job list and saved via the
'automatic' or 'manual' job creation process. How to use an existing job is described
in Using an existing job on page 19.
• Automatic job: The system automatically picks one sheet from each filled feeder
and processes them into mail sets.
The automatic feature is described in About Automatic jobs on page 21.
• Manual job: various settings, not available in an Automatic job, can be set in a
'manual job. This includes the use of daily mail. Working with manual jobs is described
in Create a manual job on page 23.
Use an Existing Job
If you want to use an existing job:
3
English
Open the job list.1.
2. Tap the icon of the job you want to use.
3. Load the feeders as shown on the display.
4. Tap [1x] to create an example mail set, see Example mail set on page 35.
5. Select an exit for the example mail set.
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6. Check the example mail set.
7. If example mail set is OK: tap [Start].If the example mail set is not OK: adjust the
address position or envelope stop position or check and re-adjust the job settings.
If desired tap the counter button to set the counters. See Counter
settings on page 31.
3
8. Tap [Start] to start the job.
9. Press the [Stop] button to finish the job.
English
10. Tap [Job list] to return to the job list.
Create a New Job
To create a new job:
From the Job list menu, tap [New job].1.
2. Choose [Automatic] or [Manual] to create a new job.
3. If you choose 'Automatic' follow the description as can be found in Create an Automatic
job on page 21.
4. If you choose 'manual' follow the description as can be found in Create a manual job.
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About Automatic Jobs
You can save every automatically created job and edit it like any job.
An Automatic job processes mail sets according to the following rules:
• The machine picks one sheet from each filled feeder;
• The picked documents will be folded (if necessary) and inserted into an envelope;
• Only the feeders that feed successfully will be selected;
• Only the Double Feed Control (DFC) of the upper feeder will be selected (this is done
automatically).
The following features are not supported with Automatic job processing.
• Linked feeders (the option where, if one feeder is empty, the system automatically
continues using another feeder)
• Multiple sheet feeding (picking more than one sheet from a certain feeder)
• Daily mail
• Reading functionality
• No envelopes (use envelopes yes/no)
• Exit select
If you want to use any of these features, you have to use Manual jobs to process the mail
set.
3
English
Create an Automatic Job
Proceed as follows if you want to create an automatic job:
From the Job list menu, tap [New job].1.
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2. Tap [Automatic] to start an Automatic job.
3
English
3. Fill the envelope hopper, load your documents and tap [1x] to create an example mail
set.
4. Make sure that the address position and the envelope stop position is correct. If
not, adjust the address position on page 36 and envelope stop position on page 39.
5. If necessary, tap the counter symbol to set the counters. See counter settings on page
31.
6. Tap [Start] to start the job.
7. Tap [Stop] to finish the job.
Tap [Save] if you want to save the settings of the Automatic job to a new job.
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Create a Manual Job
Introduction
Creating jobs manually is easy: the user interface guides you through the job definition with
clear steps.
These steps are:
• Define the mail set: envelope type, main document and optional enclosures.
• Define how to fold the document set.
• Define the exit of the system that should be used for this job.
Create a Job Manually
To create a job manually:
1. From the Job list menu, tap [New job].
2. Choose [Manual] to define the job settings.
3
English
Continue with the envelope settings (see Envelope on page 24).
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Mail Settings
Envelope
3
1. Tap [Envelope].
English
2. Select a predefined envelope or create a custom envelope on page 45.Optionally tap
[Use envelope] to set the use of envelopes to 'off' if you want to Create a job without
the use of envelopes.
3. Tap [Sealing] to switch it on or off.
By default the envelopes will be sealed.
4. Confirm the envelope settings with [OK].
Continue with the main document settings (see Main Document on page 25).
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Main Document
1. Tap [Main document].
3
English
2. Select a predefined document or create a custom document on page 46.
3. Change the [Count] to add more than one document from a feeder (multiple sheet
feeding).
4. Optionally tap Daily Mail on page 43 to set Daily Mail to 'on' or tap [Advanced] to set
the DFC Settings on page 26.
5. Confirm the document settings with [OK].
Continue with the enlosure settings (see Enclosure on page 27).
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Switch DFC on or off for feeders
For every feeder you can switch the double feed control (DFC) on or off.
To change the DFC settings:
Tap the job that you want the change the DFC settings for.1.
2. Tap [Edit].
3
3. Tap the document that you want to change the DFC for.
4. Tap [Advanced].
English
5. Tap Double Feed Control to switch it on or off.
6. Tap Continue on double to switch it on or off. If Continue on double is on, the machine
will not stop if two sheets are fed instead of one. The document-set that contains the
double sheets will be diverted.
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