Formax 6900 User Manual

6900 Series

Folder/Inserter

OPERATOR MANUAL FIRST EDITION

INSERTER IN-3 6900 Series

OPERATOR MANUAL

OPERATOR MANUAL

OPERATOR MANUALOPERATOR MANUAL

1.

1. GENERAL

GENERAL

1.1.

GENERALGENERAL

The

6900

within the mailing process, such as feeding, folding,
collating of documents and inserting and sorting of filled

envelopes a module is available. In this way the 6900 Series adapts

to the customers' needs.
The whole system is operated and programmed via the

central operator panel of the base module, the inserter
(IN-3).

Ser

ies

is a modular mailing system. For each stage

Fig. 1

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Before using this system thoroughly read the operating
instructions. In the European Union an operator manual
printed in the national language(s) is supplied with the
system. If it is not, contact your authorized distributor.

Wa rn i n gs

Wa rn i n gs

Wa rn i n gs Wa rn i n gs

• Before connecting check whether the system is suitable for
the local mains voltage; refer to the type plate. The mains
plug shall be connected only to a socket outlet provided
with a protective earth contact.

• The socket outlet shall be installed near the equipment
and shall be easily accessible.

• The following part is considered the equipment
disconnect device: power supply cord plug.

Safety precautions

Safety precautions

Safety precautions Safety precautions

•This system is only to be operated by fully trained
personnel. The manufacturer accepts no responsibility for
injuries caused by unauthorized operation.

• The opening of covers (except the top and side cover)
must be carried out only by a skilled and authorized
person who is aware of the hazard involved. The system
will not operate with the covers opened.

• Keep long hair, fingers, jewelry, etc. away from turning
parts of the system.

Used symbols

Used symbols

Used symbols Used symbols

In this manual the following symbols are used.

Warning, this symbol indicates a wrong action
which can cause a hazard to health or
damage the system.

Warning, this symbol indicates a hazard to life
because of high voltage.

NOTE

Additional information (Italic)

CONTENTS

CONTENTS

CONTENTSCONTENTS

Section

Section Page

SectionSection

1.

1. GENERAL

GENERAL 1

1.1.

GENERALGENERAL

2.

2. HOW TO USE THE OPERATOR MANUALS

HOW TO USE THE OPERATOR MANUALS 3333

2.2.

HOW TO USE THE OPERATOR MANUALS HOW TO USE THE OPERATOR MANUALS

3.

3. ACCESSORIES

ACCESSORIES 3333

3.3.

ACCESSORIESACCESSORIES

4.

4. UNDERSTANDING THE MACHINE

UNDERSTANDING THE MACHINE 4444

4.4.

UNDERSTANDING THE MACHINE UNDERSTANDING THE MACHINE

4.1 Function 4

4.2 Overview 4

4.3 User interface 4

4.4 Operating controls 5

4.5 Power inlet 5

4.6 Display keys 6

5.

5. OPERATING THE SYSTEM

OPERATING THE SYSTEM 6666

5.5.

OPERATING THE SYSTEM OPERATING THE SYSTEM

5.1 Preparations inserter module 6

5.2 Switching on 7

5.3 Entering the personal pin code 7

5.4 The main menu 7

5.4.1 Job info screen overview 8

5.4.2 Schematic view 10

5.4.3 Selecting a job 11

5.4.4 Test run menu 11

5.4.5 Counters menu 14

5.4.6 Settings menu 14

5.5 Entry to job menu 15

5.6 Operator menu structure 16

5.7 Envelope hopper adjustment 17

5.7.1 Side guides adjustment hopper A 17

5.7.2 Envelope separation hopper A 17

5.7.3 Side guides hopper B 18

5.7.4 Envelope separation hopper B 18

6.

6. PERFORMING A JOB

PERFORMING A JOB 19

6.6.

PERFORMING A JOBPERFORMING A JOB

6.1 Setting up the system 19

6.2 Running a job 22

6.3 Changing settings of a module 23

6.4 Additional functions 23

Page

PagePage

1

1 1

19

19 19

Section

Section Page

SectionSection

7.

7. FAULT FINDING

FAULT FINDING 24

7.7.

FAULT FINDING FAULT FINDING

7.1 General 24

7.1.1 The error screen 24

7.1.2 The information screen 25

7.1.3 The warning screen 25

7.1.4 The call screen 26

7.2 Clearing stoppages 26

7.2.1 Removing documents 26

7.2.2 Stoppage in the document end feed 26

7.2.3 Stoppage at the document feed 26

7.2.4 Removing documents from the hopper 27

7.2.5 Removing envelopes from the insert or sealing table 27

7.2.6 Stoppage on the insert table or sealing table 27

7.2.7 Stoppage in the envelope track 28

8.

8. ERROR CODES

ERROR CODES 29

8.8.

ERROR CODESERROR CODES

8.1 General 29

8.2 Additions to the error lists of other modules 30

9.

9. MAINTENANCE

MAINTENANCE 31

9.9.

MAINTENANCE MAINTENANCE

9.1 General 31

9.2 General cleaning 31

9.3 Cleaning the brushes 31

9.4 Cleaning the sealing roller 31

9.5 Cleaning the moistening cloth 31

10.

10. OPTIONS

OPTIONS 32

10.10.

OPTIONS OPTIONS

10.1 General 32

10.2 More options 32

690 Options 35

10.3

11.

11. SPECIFICATIONS

SPECIFICATIONS 38

11.11.

SPECIFICATIONSSPECIFICATIONS

Page

PagePage

24

2424

29

29 29

31

3131

32

3232

38

38 38

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bottle

dust brush mains supply cable press bracket

envelope slide set brushes (3 pcs.)

Fig. 2

2.

2. HOW TO USE THE OPERATOR MANUALS

HOW TO USE THE OPERATOR MANUALS

2.2.

HOW TO USE THE OPERATOR MANUALSHOW TO USE THE OPERATOR MANUALS

This manual, existing of two parts, describes the
inserter (IN-3) module and operating (part 1: operator
manual) and programming of the system (part 2: guide for
job menu).

Use the 6900 Series manual as the main guide. In the text of this

manual we will refer to the other operator manuals if
required.

3.

3. ACCESSORIES

ACCESSORIES

3.3.

ACCESSORIESACCESSORIES

The IN-3 is delivered with the accessories shown in Fig. 2.

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envelope hopper insert position user interface

sealing area exit

4.

4. UNDERSTANDING THE MACHINE

UNDERSTANDING THE MACHINE

4.4.

UNDERSTANDING THE MACHINEUNDERSTANDING THE MACHINE

4.1

4.1 Function

Function

4.14.1

Function Function

4.3

4.3 User interface

User interface

4.34.3

User interface User interface

The user interface of the inserter exists of two menus; the
"main menu" and the "job" menu. These menus are

The inserter inserts documents into envelopes and then seals
the envelopes (or not). Via the central operator panel the

6900 Series system can be operated and programmed.
Settings of a

4.2

4.2 Overview

4.24.2

ll modules are stored centrally at the inserter.

Overview

Overview Overview

See Fig. 3 .
Envelopes are fed from a stack to the insert position. During
this transport the flap is opened. After the envelope has
arrived at the insert position a document is fed to the inserter
and then inserted into the envelope. After insertion, the
envelope flap is moistened (or not) and closed. Then the
envelope is exited.

accessible via a personal pin code.

• The "main" menu is accessible for all operating personnel
and the supervisor. In the main menu jobs can be selected
and performed. After selecting a particular job, all
modules will be set automatically according the job data.

• The "job" menu is only accessible by an authorized user,
the "supervisor", via the supervisor pin code. In the job
menu jobs can be programmed, deleted etc. In a job the
settings of the modules within the system (type of
envelopes, type of documents, type of fold and way to
sort) are recorded. There are more functions in the job
menu. For a description of the job menu see the “Guide
for job menu”.

Fig. 3

The service engineer has access to all menus.

The system can be started, stopped or cleared by pressing
the concerned key located below the display of the inserter,
see section 4.6 page 6.

When a stoppage occurs, the IN-3 operator panel
automatically signals the operator and gives a suggestion
about solving the problem. See chapter 7 and 8.

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Fig. 4

Fig. 5

Fig. 6

4.4

4.4 Operating controls

Operating controls

4.44.4

Operating controls Operating controls

A: Top cover
B: Loc
C: Bottle
D : Release handle sealing table
E : Sealing table
F : Release handle loc
G: Hopper side guide adjustment wheel
H : Separation adjustment wheel

I : Envelope hopper

J : Release handle hopper
K : Release handle sealing table rollers

4.5

4.5 Power inlet

Power inlet

4.54.5

Power inlet Power inlet

See Fig. 6 . The power inlet B is located at the rear side of
the machine. It contains the power on/off switch and the
main fuse.

See "Warnings", page 2. Connect the main supply cable A
to the power inlet then connect the mains plug to the wall
socket.

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job number
job name

job counter

preset counter
counter

Key

1
2
3
4

5
6

Fig. 7

4.6

4.6 Display keys

Display keys

4.64.6

Display keys Display keys

Key 1 through 6

Key 1 through 6

Key 1 through 6Key 1 through 6

See Fig. 7 . These keys correspond with the function in the
display.

Start key

Start key

Start keyStart key

The system will start to operate.

For more details see 6.2 on page 22.

Stop key

Stop key

Stop keyStop key

The system will stop operating.

Clear key

Clear key

Clear keyClear key

The system will first finish all documents sets that have
already been fed (e.g. to the transport track) by the feed
units, then it stops.

Esc. key

Esc. key

Esc. keyEsc. key

Use this key to exit a (sub) menu without saving any
(altered) settings.

Fig. 8

5.

5. OPERATING THE SYSTEM

OPERATING THE SYSTEM

5.5.

OPERATING THE SYSTEMOPERATING THE SYSTEM

5.1

5.1 Preparations inserter module

Preparations inserter module

5.15.1

Preparations inserter module Preparations inserter module

The bottle A (Fig. 8) must always be filled with water and
the brushes must be moistened. An extra set of brushes is
provided so that one set can be soaked in water whilst the
other set is used. This means there is always a clean set of
brushes ready for usage.

Before moving the system, the bottle and
watertray must be removed.

Refer to the other operator manuals of the used modules for
the required preparations.

If the system is switched off after, for example, a paper
stoppage, the brushes will not rest on the watertray. This
causes the brushes to dry if usage is interrupted for a longer
period.
Always take care that the brushes rest on the watertray.
Therefore the system must be switched on again so that the
brushes will rest on the watertray. The system can then be
switched off.

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Key

1
2
3
4

5
6

Key

1
2
3
4

5
6

Fig. 9

5.2

5.2 Switching on

Switching on

5.25.2

Switching on Switching on

Switch on the inserter using the power switch A, see Fig. 9.

If the AS-1A, PS-3 or franking machine etc. are part of the
system switch these on. Refer to the operator manuals of the
used modules if necessary.

After switching on the pin code screen or the main menu will
appear. In case the pin code screen appears, see section

5.3 for further instructions. In case the main menu screen
appears, see section 5.4 for further instructions.

Fig. 10

5.3

5.3 Entering the personal pin code

Entering the personal pin code

5.35.3

Entering the personal pin code Entering the personal pin code

In Fig. 10 the pin code screen is shown.
Enter your pincode using the keys 1 to 6. If the code is not

correct, a warning “wrong code, try again” will be
displayed. This warning disappears immediately when a
key is pressed.

The pincode screen is not displayed if only the supervisor
code is defined. In this case the main menu as shown in Fig.
11 will be displayed after switching on the system.

5.4

5.4 The main menu

The main menu

5.45.4

The main menu The main menu

The main menu is shown in Fig. 11.
The "main menu" shows 6 different functions:

• go to job info screen (key 1).

• go to the "select job" menu (key 2).

• go to the "test run" menu (key 3).

• go to the "change counters" menu (key 4).

• go to the "settings"menu (key 5).

• go to the "entry to the job menu" (key 6).

Fig. 11

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Key

1
2
3
4

5
6

Key

1
2
3
4

5
6

Key

1
2
3
4

5
6

Fig. 12

5.4.1

5.4.1 Job info screen overview

5.4.15.4.1

Job info screen overview

Job info screen overview Job info screen overview

When key 1 is pressed in the “main menu”, the job info
screen will be displayed (see Fig. 12). The job info screen
shows the following functions:

• select a higher job number (key 1).

• select a lower job number (key 2).

• go to the job data of the upstream (transport) module (key

3).

• go to the job data of the downstream (sorting) module
(key 4) (the job data of the downstream (sorting) module
is shown in Fig. 15).

Press the escape key to go back to the main menu.
Because of the modularity of the system, different

configurations are possible. So take in account that the job
data can differ from which is shown in this job info screen
overview.

Fig. 13

When key 3 is pressed in the “job data” menu the upstream
(transport) module screen is displayed (see Fig. 13). The
screen shows the following functions:

• select a higher job number (key 1).

• select a lower job number (key 2).

• go back to the inserting module (key 4).

• go to next job data screen of the upstream (transport)
module (key 6).

Press the escape key to go back to the main menu.

Fig. 14

When key 6 is pressed in the upstream (transport) module
screen, the screen in Fig. 14 is displayed. The screen shows
the following functions:

• select a higher job number (key 1).

• select a lower job number (key 2).

• go back to the inserting module (key 4).

• go to previous job data screen of the upstream (transport)
module (key 6).

Press the escape key to go back to the main menu.

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Key

1
2
3
4

5
6

Fig. 15

When key 4 is pressed in the “job data” menu the
downstream (sorting) module screen is displayed (see Fig.

15). The screen shows the following functions:

• select a higher job number (key 1).

• select a lower job number (key 2).

• go back to the inserter module (key 3).

Press the escape key to go back to the main menu.

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5.4.2

5.4.2 Schematic view

5.4.25.4.2

Schematic view

Schematic view Schematic view

Inserting module Folding module Feeding and accumulation module

Transport module

See pages 17, 18, 19 
and the Guide for job menu.

and

Info shown:

Stop at

250

Sorting module

Info shown:

Sorting choice

Exit 1

Exit 2

Stop after
thickness err.

See pages 20 and 32 and
the Guide for job menu.

See page 20 and the
Guide for job menu.

One document is fed.

More documents are fed.

and

Documents with enclosures are fed.

Upstream modules

Job data symbols Job data symbols Job data symbols

means:

The hopper A is selected, envelopes

114

of 114 mm are fed and sealed.

The hopper B is selected.

Both hoppers are selected.

Thickness error detection is activated.

The preset counter is set to
250 document sets.

Job data symbols

means:

Envelopes

The sorting module will sort on
envelopes.

The envelopes fed from hopper A, will
leave the sorter from Exit 1.

The envelopes fed from hopper B, will
leave the sorter from Exit 2.

The system will stop when a thickness

yes

error is detected.

Downstream modules

Info shown:

No fold

means:

No fold

Single fold

Letter fold

Zig-zag fold

Double
parallel fold

Info shown:

means:

The lenght of the fed documents is shown.

297

The number of the fed documents from the

6

feeder station(s) or accumualation station is
set to 6.

Thickness detection is activated.

Optical mark reading is selected (only
available for the accumulation station).

The feeder is selected and used in the job.

The hopper A is linked with the feeder.

The hopper B is linked with the feeder.

Thissymbolisshownunde
accumulation station if the address carrying
document is fed from it.

Refer to operator manuals:
FE 7, FE 8, FE 9, AS 1A, BB 1
and the Guide for job menu.

rthe

feederorthe

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Key

1
2
3
4

5
6

Key

1
2
3
4

5
6

Fig. 16

5.4.3

5.4.3 Selecting a job

5.4.35.4.3

Selecting a job

Selecting a job Selecting a job

After pressing key 2 in the "main menu", the display shows
the "select job" menu (see Fig. 16). The "select job" menu
shows the following functions:

• job data (key 1).

• select a higher job number (key 3).

• select a lower job number (key 4).

• confirm with "OK" (key 6) which will get you back to the
"main menu".

Only programmed jobs can be selected (maximum of 9
jobs).

Fig. 17

5.4.4

5.4.4 Test run menu

5.4.45.4.4

Test run menu

Test run menu Test run menu

After pressing key 3 in the "main menu" a test run screen will
be displayed. In case an FO-2A is used the screen as
shown in fig. 17 will appear. The purpose of the test run
menu is to check proper envelope feed and to make
adjustments to the envelope stop settings.

The "test run" menu shows the following functions:

• feed one envelope (key 2).

• insert one document (key 3).

• envelope stop position to the right (key 4).

• envelope stop position to the left (key 5).

• confirm settings and return to the main menu (key 6).

In case an FO-3 is used, a screen as shown in fig. 18 will be
displayed. The envelope position keys 4 and 5 of figure 17
have moved to a new submenu (see fig. 18, key 4): after
pressing key 4 this submenu will be entered and the
possibility of adjusting the envelope stop position to the left
or right is available again.
After pressing key 5 a submenu will be entered for fine
tuning the folder settings. For more information see "Fine
tuning the folder settings".

In case the inserter is equipped with a second envelope
hopper (EF-3) the test run menu has been extended and the
following functions for key 1 and 2 have become available
(see fig. 18 for an example):

•

feed one envelope from the standard hopper (key 1).

•

feed one envelope from the second hopper EF-3 (key 2).

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Feed one envelope

Feed one envelope

Feed one envelope Feed one envelope

Key

1
2
3
4

5
6

Fig. 18

Insert one document

Insert one document

Insert one document Insert one document

(5x)

Envelope stop position adjustment

Envelope stop position adjustment

Envelope stop position adjustment Envelope stop position adjustment

Fig. 19

With this function the proper feed of envelopes can be
tested. First carry out the envelope hopper adjustments, see
section 5.7 on page 17. Then put a stack of envelopes in
the hopper. Use key 1 or key 2 to feed one envelope onto
the insert table. Each time the key is pressed a new
envelope will be fed. No insertion will take place.

The “feed one envelope” function can be used when
adjusting the envelope stop position, see “Envelope stop
position adjustment” on the next page.

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With this function the proper functioning of the whole
document and envelope transport will be tested. First carry
out all adjustments, see section 5.7 on page 17. Then load
the system with documents and envelopes.

Use key 3 to make one insert cycle. Each time the key is
pressed another insert cycle will be made. When there is no
envelope waiting on the insert table, the machine feeds one
envelope waiting on the insert table. The document will be
inserted and filled envelope is ejected.
If there are documents on the collating area, these
documents will be inserted and the filled envelope is ejected
(and counted). If there is an empty envelope in the inserter,
this envelope will be ejected.

See notes mentioned in section 6.2 on page 22.

The flap folding line must be positioned under the green
indicator B (Fig. 19). This indicator can be seen after
opening the transparent cover and releasing and lifting the
loc by pulling the release handle of the loc (see page 5).

If necessary, adjust the folding line position by pressing “to
the right” (key 4) or the “to the left” (key 5). Each press
stops the next envelope 1 mm (0,04 inch) to the right (later)
or left (earlier).

Adjustments to the envelope stop position can be made with
the system operating.