Muller 6609d, 6611/12, 6609/10, 6609, 6611 Operating Instructions Manual

Braillo Cut

Operating Instructions

Automatic Forms Cutter

Model 6609d-6612d
Release: 12.12.2006

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List of Contents

EC Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1. Setting up the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1 Selecting a location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.2 Unpacking the machine and checking the parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.3 Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.4 Installing the stacker tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.5 Testing the forms cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.6 Subassemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2. Starting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.1 Switching the machine on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.2 Selecting the program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.3 Loading paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.3.1 Inserting the paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.3.2 Adjusting the edge blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.3.3 Automatic positioning of the forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.3.4 Paper adjustment with reader from above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.3.5 Paper adjustment with reader from below . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.4 Starting the forms cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.4.1 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.4.2 Test cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3. Operating the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.1 The operating terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.1.1 Introduction to the operation of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.1.2 Panel keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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3.1.3 Display messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.1.4 Further display functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.1.5 Information to the INFO-button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.2 The operator level (level 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.2.1 Entering parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.2.1.1 Parameter b) Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.2.1.2 Parameter i) Special Length and j) Program Sequence . . . . . . . . . . . . . . . . . . 17

3.2.1.3 Parameter c) Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.2.1.4 Parameter d) Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.2.1.5 Parameter e) Counter Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.2.1.6 Parameter m) Programming the fold length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.3 The programming level (level 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.3.1 Selecting and altering parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.3.1.1 Parameter a) Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.3.1.2 Parameter f) Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.3.1.3 Parameter g) Pause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.3.1.4 Parameter h) Fine Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.3.1.5 Parameter k) Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.3.1.6 Parameter l) Copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.3.2 Programming the OMR routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.3.2.1 Explanation of terms relating to optical mark recognition (OMR) . . . . . . . . . . . . . . 29

3.3.2.2 Entering the 5-digit number for the pattern of marks (code) . . . . . . . . . . . . . . . . . . 32

3.3.2.3 Entering the 5-digit number for the functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.3.3 Counter function ONLINE # 00 / # 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.4 The technician level (level 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

3.4.1 Service routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

3.4.2 Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

4. Important notes and information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

4.1 Cleaning and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

4.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

4.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4.4 Technical change of the main PCB·s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

4.4.1 Connections and electrical settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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Safety Instructions

Before operating this machine please read carefully the following instructions for your own
safety and for safe operation of the machine.

This machine may only be operated by trained staff .The manufacturer disclaims liability for
injuries occurring during unauthorized operation.

This equipment must not be installed or altered, and the housing must not be opened, by
anyone other than a trained service technician.

Make sure that the electricity supply conforms with the voltages given on the machine.

This machine may only be operated using the cable supplied.

Do not connect and disconnect the interface connector while the power is switched on. Wait
at least 10 seconds after switching the machine off and on.

Except for the service routines given in the operat ing instructions you should never attempt to
repair the machine yourself. If problems arise call the service technician at your customer
service centre.

Keep long hair, fingers and jewellery well away from rotating machine parts.

1. Setting up the machine

1.1 Selecting a location

The following factors are important in selecting a location for the machine:

- Avoid direct sunlight, heat and damp.

- Always use an earthed socket with no adapter plug.

1.2 Unpacking the machine and checking the parts

Unpack the machine and check that no damage has occurred during transport.

Two persons are required to set up the machine. Hold the automatic forms cutter on the
bars of the base rack and stand it on its feet. Never hold the machine e.g. at the display or
the cover.
Risk of breakage! Remove all PU parts (transport protection).

For your information: You will find the stacker plate (optional) in the waste container.

Fix the machine in position by unscrewing the adjustable feet!

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1.3 Parts list

1 Automatic Forms Cutter
1 Abfallbehälter

1 Stacker tray (optional):

1 Tray
1 Left side piece
1 Right side piece
2 Knurled screw
2 Washer
2 Screw
8 Disc spring
2 Washer
4 Paper stop
2 Paper holder

Items , , are fixed to the side pieces , with a nut. The nut is for transport protection only and is not required
for installation.

1.4. Installing the stacker tray

1. Unpack all parts. Unscrew the fasteners , , on the side pieces , . These parts are fixed to the side
pieces with a nut. The nut is only for protection during transport. Make sure that the disc springs are fitted
in the correct position.

2. Screw the side pieces to the stacker tray and hang in position on the back of the machine.

3. Fit the paper holder . To do this, unscrew the clamps on the rod at th e back of the machine and
fasten the paper holder with the screws .

4. Position the 4 paper stops .

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Before switching the machine on, test the action of the upper blade as it moves to meet the lower
blade. This is vitally important, as otherwise the cross cutter may be damaged.

1.5 Testing the forms cutter

Before beginning to operate the forms cutter remove the protective covering from the feed plate. If it is not
removed, the paper will become statically charged and will affect the cutting process.

This check is absolutely essential as the machine may have become maladjusted during transport.

Proceed as follows:

1. Unscrew the housing from the right side wall of the forms cutter.

2. Slowly turn by hand the large belt pulley to which the connecting rod is fastened. No strong resistance should

be felt.

3. Raise the upper blade to its maximum position by turning the pulley. From the back of the forms cutter

insert a sheet of paper on the far left between the upper and lower blades and perform a cross cut by
turning the pulley slowly. The cross cutter should begin cutting approx. 10 mm from the left edge.

4. If necessary adjust the engagement of the blades by turning the adjusting screw .

5. Screw the housing in position.

6. Before connecting the power supply check the voltage again.

7. Connect the power supply. The forms cutter is now ready for operation.

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1.6 Subassemblies

Subassemblies Illustration

(=Pos.)

Housing and cover sheets 1
Chassis 2
Driving shafts for Randschneider 3
Driving shafts for Tractor 4
Chassis and Platine 5
Safety cover 6
Cross cutter - blade bar 7
Cross cutter - ejector 8
Cross cutter - driving unit 9
Tractor unit 10
Tractor left and right 11
Edge cutter unit 12
Edge cutter left and right 13
Terminal 14
Electronic 15
Stand 16
Fan 17

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2. Starting up

2.1 Switching the machine on

The machine is switched on by the power switch. The
display then shows a message for about 3 seconds
(display version, serial no., model no.), which can be held
in the display by pressing the stop button.
When the button is pressed again the current counter
position appears. When the button is released, the
program last used is shown. If any other equipment is
connected, it will return to its starting position (e.g.
lowering stacker).

2.2 Selecting the program

The display shows the program last used. If you wan t to use a different program, you can select it with buttons F1-F4.
New programs can be entered in program slot 00 only, and stored in slots 01-83 (see also Section 3.3 "The
programming level”). Every time the machine is switched on, fixed programs from the EPROM memory overwrite

program slots 84-99.

2.3 Loading paper

2.3.1 Inserting the paper

Open both tractor covers and release the tractor
screws . Set the tractors at approximately the width of
the paper but do not lock them. Insert the paper. Make
sure that the leading edge is cleanly torn off, as
otherwise the paper will not be cut on the cross­perforation. Now close the tractor covers and position
the paper in the centre of the machine. Use the centre
paper guide as an aid. Fix the screws on one of the
tractors and adjust the tension of the paper by moving
the second tractor. The paper should be neither ver y
tight nor very loose. Then fix the screws on the
secound tractor.
Fine adjustment: This device can be used to fine adjust
the tractor to a certain position using the adjusti ng wheel
(position the tractor first).

2.3.2 Adjusting the edge blades

Release the screws of the edge blades and fix then after setting to the desired width. T he maximum width is 28
mm (option available: extra wide edge cutter max. 60 mm). The red arrow indicates the cutting position of the edge
blade. After setting the required width, lock both edge blade blocks again.
Fine adjustment: This device can be used to fine adjust the edge cu tter to a certain cutting position using the
adjusting wheel (position the edge cutter first).

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2.3.3 Automatic positioning of the forms

After the paper has ben inserted, series 6600 forms cutters position the forms automatically at the bl ade edge on
starting or on changing programs. The central paper guide contains a light-guide fibre optics system, which has two
functions:

1. Recognising end-of-paper

2. Automatic positioning of paper on the cutting edge

If the paper is inserted in the tractors in such a way that it does not reach the optical scanner, the tractors will
transport the paper automatically forwards to the scanner after the Start button has been pressed, and then under
the cross blade for the first cut.

If the paper is inserted in such a way that it already covers the optical scanner, the tractors will m ove in reverse
direction to the scanner after the Start button has been pressed and then forwards under the cross blade.

Due to this automatic positioning the paper can be inserted without any need to position it accurately. Before paper
is inserted in the machine, it is important to chec k that the leading edge of the paper has been clean ly torn off at the
cross-perforation. This is necessary because, due to the automatic positioning of the paper on the cutting edge, the
forms will otherwise not be cut exactly on the cross-perforation.

The machine automatically recognizes the leading edge of the paper and transports it immediately to the cutting
edge. If the leading edge is damaged or if a piece has already been cut off, the machine will not position the paper
correctly with the cross-perforation on the blade e dge. Any correction made using the fine adjustment control will be
automatically applied each time paper is inserted.
We recommend that you tear off one sheet of paper before every new start. This also helps to prevent j amming due
to the cuts made by the edge blades.

Caution!

The end-of-paper light barrier must not be covered by the paper-holder as this means the
paper cannot be detected.
On starting, the machine would run in reverse direction and would eject the paper in reverse
direction into the tractor.
If the paper-holder becomes twisted during continuous operation so that it covers the light
barrier, the forms cutter will not stop at the end of the paper.

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2.3.4 Paper adjustment with reader from above

(See also 3.3.1.5, parameter k)

If the operator starts an OMR program, the paper will not be
aligned on the cutting edge. The optical mark reader
evaluates the OMR marks printed on the paper. When the
Start button is pressed the first mark is positioned at a reading
head.
Please note: There are two different positions of ht e reading
head!

1/6" processing:

The adjustment line (AL) m ust be visible in the groove of
the reading head (see scetch).

1/8" processing:

The adjustment line (AL) must have 0,6 mm distance to the
reading head. Measure the distance always from the middle
of the reading mark.
Adjusting the reading head: The reading head can be moved
in the feeding direction and sideways by loosen the set screws

.

If the adjustment at the reading head is not suffic ent to bring
the reading mark in the position as described above, the
reading area of the adjustment line must be entered one line
before or below under parameter k), .

2.3.5 Paper adjustment with reader from below

(See also 3.3.1.5, parameter k)

With reading from below the OMR mark cannot be detected
when positioning the paper. So you have to make a p unch in
the paper as below.

The adjustment line should be
marked by means of punch pliers before
inserting the paper.

The hole must be punched in the
center of the reading mark.

Please note: There are two different positions of the reading
head!

1/6" processing:

The adjustment line (AL) must be visible in the groove of
the reading head (see scetch).

1/8" processing:

The adjustment line (AL) must have 0,6 mm distancet o the
reading head. Measure the distance always from the middle
of the reading mark or from the middle of the hole.

After pressing the Start - button the first reading mark is
positioned at the reading head.
Adjusting the reading head: The reading head can be moved
sideways by the set screw and in the direction of feed by
moving the plate . If the adjustment at the reading head is

not sufficent to bring the reading mark in the position as
described above, the reading area of the adjustment line must
be entered one line before or below under parameter k), .

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2.4 Starting the forms cutter

When the paper has been positioned by pressing the Start button (Section 2.3.3), the word READY !!! appears in the
displ ay, or if an OMR program is being used the word ADJUST. To start the machine, press the Start button again
to begin continuous operation.

2.4.1 Display

The starting speed increases continuously during cutting of the first sheets, until the set maximum sp eed is reached.
During continuous operation the fine position (cutting edge), the feed rate and the pause between two forms can be
altered. The preset counter, the actual counter and the group counter are also shown.

F1 - Fine position 1/192" reverse

F2 - Fine position 1/192" forward

F3 - Alter feed rate

(Level 1 to 7= maximum speed)

F4 - Alter pause
(Level 7 to 0, 7= longest pause)

All these changes will be automatically saved in the current program.

2.4.2 Test cut

By pressing the Start and Stop buttons simultaneously it is possible to cut single sheets as a test. When the Stop
button is pressed, the form s cutter always stops at the end of the current cycle. The paper is positioned with the
perforation at the blade edge.

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Operator Level

Technician LevelProgramming Level

New programs are always entered in PROG 00

3. Operating the machine

The operation of the machine is divided into three levels:

Areas which are not intended for the operator are protected by special access options.
On the programming level all function parameters of the paper cutting machine can be accessed and programs can
be set up and saved.
The technician level operates in an additionally protected area. Service routines can be started. Info rmation about the
condition of the machine can be read.

3.1 The operating terminal

The operating terminal is on the right-hand side of the machine.
On this terminal are:
4 large buttons PROG, INFO, START and STOP, two LEDs each containing 2 lines for 20 character s, and 4 small
multifunction buttons F1-F4. The functions of these buttons are always shown in the lower display.

3.1.1 Introduction to the operation of the machine

Explanation of terms

Parameter Before forms can be cut, a num ber of different values have to be set, such as sheet length,

type of cut or speed. These values are called parameters.The parameters are entered via
the terminal.

program A program consists of several parameters. The progr ams are saved in the terminal. Up to

100 programs can be saved. The programs saved are numbered continuously from 00 - 99.

Program structure Imagine the arangement of the programs, each with its individual parameters, like a card file.

Each program represents one index card. The individual parameters are recorded on the
index card.

Program In program selection mode, any program that has been saved can be selected.
selection mode To do this the "function buttons” F1, F2, F3, und F 4 are used. When the desired program

appears on the upper left display, the machine can be started by pressing the Start button.
The slots for working programs are numbered from >01< to >99<.

Parameter mode Parameter m ode can be called from program selection mode by pressing the Prog button.

In parameter mode two basic functions can be selected:

1. Parameter selection mode

2. Parameter input mode

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The PROG and INFO buttons have no function during continuous operation.

3.1.2 Panel keys

The 4 panel keys have the following functions:

PROG The PROG button switches between the functions program selection and parameter selection.

INFO The INFO button gives information referring to this instruction manual.

If the OMR system is used during STOP the code is d isplayed.
(For service functions see Section 3.1.5).

START This button starts the machine.

STOP When the STOP button is pressed, the machine will stop at the end of the current cycle.

3.1.3 Display messages

The following messages can appear on the display:

PAPER ??? If there is no paper in the forms cutter the word P APER ??? will appear in the lower display and

the machine will stop. The forms cutter also stops at the end of the paper.

COVER ??? If the transparent cover is opened or even just sl ightly lifted during operation, the lower display

will show COVER ??? and the machine will stop at the end of the current cycle.

READY !!! This message appears after the paper has been positioned at the blade edge before starting

the machine. When the Start button is then pressed, continuous operation begins.

CALL SERVICE If a 3-digit number (e.g. 031) is shown, this is a sign of malfunction. Make a note of the 3-digit

number and inform the service technician. (For service messages see Section 3.4.2),

INTERFACE The interface connection on the machine or on an additional machine is defective. The service

technician should be informed.

ID-CHIP The ID-chip on the main board is missing or is defective - inform service technician.

COOLING FAN The filter needs cleaning.

Additional fan defective (applies to model 6611/6612 only) - inform service technician.

ADJUST When using the OMR system (the adjustment line is within the groove of the reading head) the

reading head can now be adjusted. For further information see Section Reader.

READ ERROR The code that has been detected is shown in the lower window on the display

(e.g. 0000000001001001). For further information see Section Reader/Read errors.

STOP Appears when the Stop button is pressed.

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3.1.4 Further display functions

SLOW FLASHING of numbers indicates that input is possible. The set values can be altered or new

values can be entered or selected.

FAST FLASHING of numbers indicates that the next working step must now be carried out, e.g.

pressing a function key to carry out or end an operation.

DISPLAY TEXTS All texts in the display are available in various languages which can be obtained by

starting the appropriate service number (see Sectio n 3.4.1 SERVICE ROUTINES).

(R) The sign (R) in the operating instructions stands for "rotating function", i. e. after the

last value or position has been reached, the first value or position will reappear.

In addition all keys which display several responsi ve values have a repeat function, i.e. by holding t he button down
it repeats its function.

..... Panels with a grey background in the operating instructions indicate a flashing display.

See above for notes on the flashing speed.

3.1.5 Information to the INFO-button

After pressing the INFO-button a number appears on the display. This number represents sections

- as the table shows - in the operating manual.

INFO-Nr. section contents

1 2.2

Selecting the program

2 3.3.1.1

Parameter a) Label

3 3.2.1.1 Parameter b) Length

4 3.2.1.3

Parameter c) Cut

5 3.2.1.4 Parameter d) Counter

6 3.2.1.5

Parameter e) Counter Function

7 3.3.1.2 Parameter f) Speed

8 3.3.1.3

Parameter g) Pause

9 3.3.1.4 Parameter h) Fine Position

10 3.2.1.2

Parameter i) Special Length

11 3.2.1.2 Parameter j) Program Sequence

12 3.3.1.5 Parameter k) Reader

13 3.3.1.6

Parameter l) Copy

14 3.3.1.7 Parameter m) Programming the fold length

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3.2 The operator level (level 1)

After switching the machine on the operator can carry out various functions. He can:

- select and start programs (00 - 99).

- browse through parameters b) - e) and possibly also i) and j), if parameter b) = 000, in all programs.

- alter parameter d) COUNTER in all programs.

- Change parameter m) fold length in all programs.

- alter parameters b) - e) (possibly also i) and j))in program slot 00.

3.2.1 Entering parameters

After the machine is switched on, the message PROGRAM - SELECT appears on the display. The desired pro gram
can be selected by pressing buttons F1-F4. The program selected then appears in the left upper display.
Press the Prog button to obtain PARAMETER - SELECT. Use buttons F1 and F2 to browse through the
parameters.

3.2.1.1 Parameter b) Length

In the Length parameter you can set the FORM LENGTH . The form length is measured in 1/6" (1 inch = 25.4mm)
or 1/8" line space. Measure the form first on the plexiglass cover. Give the full length from perforat ion to perforation
(including double cuts where necessary). The 1/6" o r 1/8" step also applies when using the OMR system. If a form
is to be cut into several pieces, this can be enter ed with the Special Length program i), j).

F4 - Press Input

Select length:

F1 - Select number (0-9) (R)
F2 - Current write position =_ (R)
F3 - 1/6" or 1/8" length step

F4 - Exit

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3.2.1.2 Parameters i) Special Length and j) Program Sequence

Before parameters i) and j) can be shown at the operator level, you must input the following information.

Select parameter b) and set Length to 000.
Special Length is only possible with Length 000. Sp ecial
Length can not be used together with the OMR system.

Select parameter c) and enter the length step for Special
Length (1/6", 1/8" or 1/24").
The length step in parameter b) is not applicable!

Parameter i) Special Length

Here you can enter up to 4 different lengths. The order is not important at this point.
The sequence of lengths is set in parameter j).

F4 - Press Input

Enter length:

F1 - Select number (0-9) e.g. 10x1/6" (R)
(1/6" is set in parameter c) )

F2 - Current write position =_ (R)

F3 - Length no. 1-4 (i.e. up to 4 different lengths can be

entered) (R)

F4 - Exit

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Parameter j) Program Sequence

The lengths in parameter i) can now be entered in the desired sequence under the numbers 1-9. The machine
passes through all positions from 1-9 in every cycle. When length 0 is entered, this position is passed over without
action in the program sequence.

F4 - Press Input

F1 - Sequence (1-9) (R)
F2 - Length 1-4 or 0 from parameter i) (R)
F3 - Form will be chopped
Form will not not be chopped

F4 - Exit

Multiple distribution of lengths 1-4 from parameter i) among positions 1-9 is also possible. In additi on, it is possible
to decide at each position (1-9) whether the length 1-4 displayed here is to be performed completely or whether the
form is to be chopped.

Chopping witdh: 3/6" means that a feed length of 2" will be cut with 4 cycles (1 cycle = 3/6").

When using counter function ONLINE #00/#01 (see section 3.3.3) note the following:
The function entered under line #01 is carried out until the section before the last section is reached.
The function entered under line #00 is carried out when the last section is reached.

Possible cuts with Special Length:

The following example is stored in the machine under program slot 99 (fixed program):
Parameter i) Special Length (1/6" is set in Length c)):
No. 1 - 002 x 1/6"
No. 2 - 004 x 1/6"
No. 3 - 020 x 1/6"

Parameter j)
Program sequence:

1.) Length 2

2.) Length 3

3.) Length 1

4.) Length 3

5.) Length 1

6.) Length 3

7.) Length 2

8.) Length 0

9.) Length 0

The type of cut in our example is ‘do not chop’.
But it could also be ‘chop’, e.g. in program sequence i), point 6.), length 3.

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3.2.1.3 Parameter c) Cut

Here you can set the type of cut (single cut, double cut or only edge cut without cross cut), the width of cut
and the cut width step (1/6", 1/8" or 1/24") for double cuts.

Single cut is obtained by entering e.g. 0 * 1/6" or 0 * 1/8" for the width

(0 = multiplier).

For Double cut the desired waste area is set by entering a multiplier > 0;

e.g width: 2 * 1/6" (2 = multiplier). Thus in this case the waste area would be 2 * 1/6"
long. Any leftovers longer than this will automatically be chopped.

Edge cut can be set by entering cut width step = NO CUT.

F4 - Press Input

F1 and F2 - Multiplier for cut width step (0-9)

F3 - Cut width step (NO CUT, 1/6", 1/8" or 1/24") (R)

z.B.: 0 x NO CUT = No cross cut

0 x 1/6" = Single cut
2 x 1/8" = Double cut (at the upper and the

lower edge of the form 1/8" will be
cut away)

Possible cuts:

No cross cut -

only the margins will be cut away ­Parameter c) 0 x NO CUT

Single cut

Parameter c) 0 x 1/6"

or 0 x 1/8"
or 0 x 1/24"

Double cut

The piece cut away can be min. 1/24", max.
1 1/2" wide and is distributed symmetr cally
on both sides of the perforation. Wider
double cuts can be programmed using
parametersi) and j).

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3.2.1.4 Parameter d) Counter

In this parameter a programmable counter can be preset. It is used if on reaching a given number of fo rms
a function must be carried out which has been set i n parameter e) Counter Function. In addition the SUB-counter
(= group counter) and the ACT-counter (= actual) can be set at 00000.

F4 - Press Input

F1 - Select number (0-9) (R)

F2 - Current write position =_ (R)

F3 - Set SUB-counter at 00000

(first time F3 is pressed)

The SUB-counter is used for all operations with counter
functions (except NONE).

F3 - Set ACT-counter at 00000

(second time F3 is pressed)

The ACT-counter can be used as a daily counter (or for
a particular job).

F4 - Exit

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3.2.1.5 Parameter e) Counter Function

The machine can carry out a counter function after reaching the number of forms preset in param eter d)

Counter. Available functions are "NONE" - "STOP" - "CUT" - "ONLINE #00/#01" und "PAUSE".

F4 - Press Input

F1 - Select a function (R)

F4 - Exit

NONE: None of the functions listed below (the preset counter is not in use)

STOP: The machine stops on reaching the preset number (SUB-counter returns to 00000).

CUT: Edge cut only - a cross cut is carried out on reaching the preset number (SUB-counter

returns to 00000).

ONLINE #00/#01: The preset counter can be programmed to output any online functions. No OMR system

is required (i.e. no reading head). If this function is selected the reading head will be
automatically dead. A maximum of 2 functions (3 wit h new software) can be performed,
one function several times, the other once only (e.g. collecting and enveloping or
selecting and enveloping). See Section 3.3.4.

PAUSE: Pause (~3 sec) after reaching the preset number (the SUB-counter returns to 00000).

For manual removal or group separation with conveying belts.

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3.2.1.6 Parameter m) Programming the fold length

Button F4 - push enter

F1 - Select Folder 1-4 (R)
(The sequence 1-4 is equal to the set-up of the Folders
in paperflow direction). Max. you can connect up to four
Folders in line.

F2 - Digit selection (0-9) (R)
F3 - actuall writte position =_ (R)
F4 - End

The fold-length input is in mm (i.e. 100 mm).
Fold length: min 50 mm, max. 231 mm

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.3 The programming level (level 2)

Access to the programming level is only possible wh en the machine is switched off. Press and hold down buttons
F1-F4 and switch on the machine. Buttons F1-F4 can be released when the m essage OK appears on the lower

display.

After the machine has been switched on the programmer can peform various functions.
He can:

- perform all operator functions.

- enter all parameters in program slot 00 and save the program in slots 01-83.

- browse through all parameters a) - m) in all programs (00 - 99).

A limited number of service functions are available:

SERVICE 000 Return to program
008 Input OMR routines
078/079 Adjust brightness of display

080-089 Select language
104-107 For OMR precess

3.3.1 Selecting and altering parameters

3.3.1.1 Parameter a) Label

The Label parameter can be used to input program labels or names (e.g. test program). The
labels can be up to twenty characters long and have no effect on the function of the machine.
They are intended only as an aid to finding programs. The label always appears during PROGRAM-SELECT.

Taste F4 - Press Input

F1 and F2 - Select letters, numbers or special
characters (turn page up or down) (R)

F3 - Current write position =_ (R)

F4 - Exit

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3.3.1.2 Parameter f) Speed

In the Speed parameter the feed rate can be altered from level 1-7
(level 7 = maximum speed).

F4 - Press Input

The speed can also be changed during continous
operation. The change will automatically be saved in
the current programm.

F1 and F2 - Select level 1-7

F4 - Exit

3.3.1.3 Parameter g) Pause

In the Pause parameter seven different pause intervals (after cutting) can be preset.
The shortest interval is level 1 = 0,03 sec; longest interval is level 7 = 0.21 sec.

F4 - Press Input

The pause interval can also be changed during
continous operation. The change will automatically be
saved in the current program.

F1 and F2 - Select level 0-7

F4 - Exit

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3.3.1.4 Parameter h) Fine Position

This parameter can be used for fine adjustment of the cross cut position. This is done in steps of
1/192". The cutting position can be adjusted to a maximum of 31/192" forward or reverse.

F4 - Press Input

The fine position can also be changed during continous

operation. The change will autom atically be saved i n the

current program.

F1 - 1/192" reverse

F2 - 1/192" forward

F4 - Exit

The paper is moved forwards in relation to the blade.

The paper is moved backwards in relation to the blade.

F1 and F2 can be used to adust the cutting position

during continous operation.

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3.3.1.5 Parameter k) Reader

Parameter k) is used to set whether or not an optical mark recognition (OMR) system is to be used, or whether
the machine is to operate online-equipment. The OMR system reads marks (the code) on the form, each of which
indicates a special function (e.g. collecting or en veloping). There are 6 OMR program slots. In each of these slots
a complete OMR program can be entered. In addition the OMR routine for the function ONLINE #00/#01 can be
set.

Key to numbers:

0 No OMR (neither the preset counter nor the reading head is active; no interface dialog will be carried out

with on-line equipment)

1 Standard OMR routine (fixed program)

2-6 OMR programs which can be written by the user

7 Routine for cut at adjustment line

8 Reserved for special jobs

9 OMR routine for direct channel. The marks read by the forms cutter will be evaluated in some other system,

e.g. the enveloping machine or the black box. All information detected is transmitted to the evaluating
system without being processed.

If the OMR system is to be used, the adjustment line position (AL) should now be entered. The mark in the
adjustment line is the first to pass under a reading head during scanning. As a rule this mark has no special
function. When the marks are evaluated it serves only to enhance reading reliability.

F4 - Press Input

F1 - Select routine 0-9 (R)
F2 - Select number (0-9) (R)
F3 - Current write position =_ (R)

F4 - Exit

AL - Adjustment line in this case is line 12
(line distance 1/6" or 1/8" is given in
parameter b) Length)

For OMR programming see Section 3.3.2

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Programs can only be entered or altered in program slot 00.

3.3.1.6 Parameter l) Copy

Here you can copy programs from other program slots into the current program slot and save them.

F4 - Press Input

F1 - Always goes to program slot 00
F2 - Advances 10 program slots (R)
F3 - Advances 1 program slot (R)

F4 - Exit

Example:

A program that has been entered or altered in program slot 00 is to be stored in slot 30.

F4 - Select program slot 30

Press PROG and select parameter l) Copy with F1

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F1 - Select program slot 00

F4 - Exit

When F4 is pressed, the program is copied from
program slot 00 into slot 30.

Example:

A program with the number 30 is to be altered. To do this, it has to be loaded in slot 00.

Before a program with a number between 01 and 83 ca n be altered, its parameters must first be copied into slot

00. The altered program is then recopied into its original slot. It is not possible to copy programs i nto slots 84-99.
Every time the machine is switched on, fixed progra ms from the EPROM memory overwrite program slots 84 -99.

F1 - Select program slot

Press PROG

F1 - Select parameter l) Copy

F4 - Input

F2 - At “from” enter 30

F4 - Exit

When F4 is pressed the program is copied from 30
to 00.

The alterations can now be carried out.

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1. Select and start service no. 008.

2. Select an OMR routine (1-6).

3. Select the running function allocation number (#00-#32)

4. Reading the OMR marks:
You must enter a 5-digit decimal number for the pattern of marks (code).

5. Allocating functions:
Enter a 5-digit decimal number for the desired online output (equipment to be
activated).

3.3.2 Programming the OMR routines

In Section 3.3.1.5, parameter k) Reader you were able to select and execute the desired OMR program. If you wish
to enter or compile your own programs, you can use OMR programs 2-6.
Before you can enter a program, the adjustment line must be entered under parameter k).

After accessing the programming level, press INFO and then PROG to get into the service routines. Here you can
program the reader. Carry out the following steps in the given order:

3.3.2.1 Explanation of terms relating to optical mark recognition (OMR)

There are a number of terms relating to the OMR system which should be known to the user and which will be
frequently used.

Form length: Form length always refers to the uncut form. This "real" length must be entered in

parameter b) to avoid producing form length errors.

Print lines: Line feed in the computer printer can be in steps of 1/8" or 1/6". The normal step is 1/6".

The print lines are counted from the top of the form downwards in the direction of feed.
Thus the top line is line 1 (with 12" forms the bottom line is 72). For technical reasons
OMR marks may not be printed in the following lines: (see illustration page 30)

- in lines 1 and 2 (begin at 3/6")

Notice: From software release ...10/96 onwards OMR marks can also be printed in

line 30-33 (= 30/6" - 33/6"). This was not possibl e with former software.

Reading marks: The reading marks are printed by the computer printer and should consist of two

underlines next to each other . The underline gives the most reliable results. Two directly
joined underlines are best, since in most cases the tractors of the printer are moved
sideways by the computer operator during printing. If only one underline is used, there
is a risk that the reading head will not be able to detect it. The mark passes to the side of
the reading head and a reading error occurs.

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Adjustment line (AL): The adjustment line contains the first mark to pass under the reading head. As a rule no

function is allocated to this mark. It serves to enhance reliabilty in evaluating the marks
(codes), and also in adjusting the position of the reading head. The position of the
adjustment line should be given in parameter k).

Read area: The read area is the area on the paper within which the reader is active. The adjustment

line contains the first mark to be processed by the reading program. Sixteen lines are
evaluated including the adjustment line - adjustment line plus 15. Through the allocation
of codes the machine knows in which lines the marks are to be evaluated. Other marks
are ignored by the machine.

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In other words: as soon as lines (except the adjustment line) are linked to a function
(through the programming of the OMR routine), marks which are printed on these lines
will be evalued. All other lines, e.g. text lines, will be treated as not belonging to the
reading code system.

Direct channel: Routine 9, parameter k) is intended for applications in which marks read by the feeder

are evaluated in the enveloping machine or some other system (black box). In this direct
channel routine, the whole code from the adjustment line onwards is transmitted via the
interface data line to the evaluating system (black box). The code is transmitted in its
entirety without any further processing (code = functions).

Code: A 5-digit decimal number which corresponds to the pattern of marks.

Function: A 5-digit decimal number which is transmitted to online equipment via the interface. It

contains (binary) information which triggers a particular function, e.g. collecting or
selecting.

Read errors:

Read error: the code that has been detected is shown in the lower window on the display. The first rea d mark
(always the AL) is shown on the display on the righ t (beside the arrow). The reading code is shown on the display
from the right to the left. For example 00000000010 01001 (together 16 reading lines) means that in lin e 1 (=AL),
4 and 7 a reading mark was detected. No reading marks are printed in the remaining lines.

Read errors can have a variety of causes:

a) The reading head and the mark are not on the same track.

b) The reading head has not been correctly adjusted to the adjustment line in the direction
of feed of the form.

c) During printing the operator has moved the paper in the printer sideways or
lengthways.

d) Read errors may occur if the marks are printed with a coloured ribbon that uses a
black which the infrared reading head cannot recognise as black (aniline dyes).

e) Sensitivity level not correctly set. Can be altered under service routines 060-063.

060 OMR sensitivity level 0 000 low sensitivity
061 OMR sensitivity level 1 001
062 OMR sensitivity level 2 002
063 OMR sensitivity level 3 003 high sensitivity

000 = low sensitivity (recommended for 90% of all applications)
Can be rechecked in service routine 009 (2/F). The new sensitivity level will be
transferred only when the machine is switched on again.

f) The pattern of marks (code) does not exist in the list of routines selected under
parameter k). Either the code is wrong or there may be dirt on the paper.

g) The marks are too faint. The ribbon should have been changed earlier.

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The 5-digit code number is always made up of the adjustment line plus
one or more other marks.

3.3.2.2. Entering the 5-digit number for the position of marks (code)

A 5-digit code number is entered which indicates exactly in which lines the reading head is to search for the
marks.
Table 1 can be used to convert the position of marks (code), which consists of the adjustment line (AL) plus a
number of OMR marks, into a 5-digit number (code). Each code number represents a complete informatio n unit.

Here is an example to show how to enter the 5-digit number:

Example 1: In the equipment illustrated on page 33, six forms are to perform six different functions

(this program is stored as a fixed program in OMR routine 1):
deflector unit 1, 2, 3, collector, enveloping and stop.

Each form (see page 37) must contain the relevant code which gives the commands. The code always consists
of the adjustment line (AL) and one or more other marks. The reading head detects the marks and passes on
the functions information. In example 1, the form will now be sent to deflector unit 1 if the mark is printed in the
third line. The equipment will stop if the mark is printed in the seventh line after the AL, and so on.

Conversion Table 1: Convert code into 5-digit number

Mark in
read area

5-digit number

1 00001 = is always the AL

2 00002

3 00004

4 00008

5 00016

6 00032

7 00064

8 00128

9 00256

10 00512

11 01024

12 02048

13 04096

14 08192

15 16384

16 32768

Mark in

Example 1 Example 2

1 Adjustment line Adjustment

2 Deflector unit 2 Deflector unit Marks in lines 2+3

3 Deflector unit 1 Deflector unit 1 =Deflector unit 3

4 Collector Collector Marks in lines 4+5

5 Enveloping Enveloping = Stop

6 Deflector unit 3

7 Stop

8

9

10

11

12

13

14

15

16

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Unoccupied positions in a list should be filled using the command Fill up.

The 5-digit code number for enveloping and AL is thus 00017.
Let us now consider the whole block of marks as a com plete
unit. The adjustment line contains the first mark, since it is the
first to pass the reading head. Deflector unit 2 is thus the
second mark, and so on. We can use Table 1 to find the
appropriate 5-digit code number for any combinatio n of marks.
In example 1 these are:

1. AL + Collector = 00009

2. AL + Enveloping = 00017

3. AL + Deflector unit 1 = 00005

4. AL + Deflector unit 2 = 00003

5. AL + Deflector unit 3 = 00033

6. AL + Stop = 00065

When entering the above code numbers make sure that the
positions are entered in the OMR routine in ascendi ng order. A
maximum of 33 positions can be entered.
In our example six positions have been filled by en tering all the
combinations that occur. In order for the machine to work
correctly, the remaining positions in this routine must also be
filled with the command Fill up (from #06 - #31).

The 5-digit code numbers worked out using this method are
entered under “Code” when programming the reader. In
example 1 input should be carried out as follows (input for the
function is described below):

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Example 2: The same 6 functions as in example 1 are to be carried out: deflector unit 1,2,3,

collector, enveloping and stop.

In order to limit the number of lines to be read, it is also possible to allocate one function
to several marks.
E.g. If there is a mark in lines 2 and 3 at the same time, the form should be sent to
deflector unit 3 (see illustration p. 38)

Where several marks are to be used, the 5-digit code number is worked out by adding them together. Thus the
number for deflector unit 2 + deflector unit 1 + AL = 2 + 4 + 1 = 7.
The 5-digit code number for enveloping and AL is thus 00017. Let us now consider the whole block of marks as a
complete unit. The adjustm ent line contains the first mark, since it is the first to pass the reading head. Deflector
unit 2 is thus the second mark, and so on. We can use Table 1 to find the appropriate 5-digit code number for any
combination of marks. In our exam ple these are:

1. AL + collector = 00009

2. AL + enveloping = 00017

3. AL + deflector unit 1 = 00005

4. AL + deflector unit 2 = 00003

5. AL + deflector unit 3 = 00007

6. AL + stop = 00025

In example 2 input should be carried out as follows
(input for the function is described below):

In posiiton #32 it is possible to output one or more functions for forms which have caused ar eading error. The

function “select” is recomm ended, if there is a def lector unit available. The "Code" column in line 32 is here always

00000. In the "Function" column one or more functions can now be entered (as in numbers #00 - #31). See also
the function tables. If a read error occurs, i.e. none of the codes in #00 - #31 is recognised as valid, then the
function given in line #32 will be output for the form which caused the reading error. The machine will be stopped
and “read error” will appear in the display.

Suggestion for function in line #32: Deflector unit 1 = 5-digit number 00004
The 5-digit number for the code remains 00000

3.3.2.3 Entering the 5-digit number for the functions

We shall now allocate a function to the marks on the form which are to be detected by the reading head.
Table 2 (page 35) for converting functions (Fnc) into 5-digit numbers is used in the same way as Table 1.
Each combination of marks represents one or more functions. To go back to our examples, we have here s ix
different functions (enveloping, collector, deflector unit 1, deflector unit 2, deflector unit 3 and s top). Müller online

machines have fixed functions!

Input for the function is described in the examples above.

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OMR data list

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Conversion Table 2: Convert function into 5-digit number

Function (Fnc)

5-digit number

Müller online equipment to be activated

00001 End of group, enveloping, stapling, eject

00002 Collect (Accumulator)

00004 Deflect (Deflector Unit 1), see a)

00008 Deflect (Deflector Unit 2), see a)

00016 Deflect (Deflector Unit 3), see a)

00032 Deflect (Deflector Unit 4), see a)

00064 Free (e.g. selective)

00128 Free (e.g. selective)

00256 Change direction (cross transport)

00513 Change direction (Transversal Accumulator), see b)

01024 Dual action (cross transport)

02048 Group will be stapled if digi-switch for staple reverse in staple

module 6760/6766 is set at position 5,6,7.

04096 Free

08192 Free

16384 Block Deflection, see a)

32768 Stop

a) Block Deflect:
Block Deflection can be performed by any Müller 6630 deflector unit. The hinged cover of the first def lector unit after
the cutting machine is opened by function 16384 and stays open until function 00001 = End of group is recognised.
In the same way, cross transport 6691 and block Deflection (function 16384) are activated until End of group (function

00001).

b)Transversal Accumulator:
For the Transversal Accumulator, function 00513 is: Eject group from machine.
(00512 for Change direction + 00001 for Eject).

c) Stream stacking:
Lengthwise group separation is obtained with function 00003 (00002 + 00001).

d) Cut at mark:
If you wish the machine to make a cut at a particular mark, first select OMR routine 7 and enter the definition for the
adjustment line "AL" (the "AL" triggers cutting).

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To program the OMR routine you must:

1. be in the programming level (Section 3.3).

2. program parameter k) Reader.

3. change into the service routine by pressing INFO and then PROG.

3. select and start service no. 008.

F1 - Select a routine 1-6 (R)

1 Standard OMR routine (fixed program)
2-6 OMR programs which can be written by the user

F4 - Exit

F1 and F2 - Select a position #00-#32 (R)

F3 - Fill up the remaining positions.

(Code 00000 is not permitted in the OMR routine. This is
so that if, for example, the machine does not recognise a
mark it will stop and show a reading error.)

F4 - Input

F1 - Select number (0-9) (R)
F2 - Current write position = (R)

F3 - Select CODE or FNC.

F4 - Exit

To return to program press the Prog-button twice and call Service Nr. 000.

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Example 1:

——— Adjustment line
——— Deflector unit 2

Deflector unit 1
Collector
Enveloping
Deflector unit 3
Stop
Free
Free
Free
Free
Free
Free
Free

Free
Free

List 1: Deflector unit 2

——— Adjustment line

Deflector unit 2
Deflector unit 1

——— Collector

Enveloping
Deflector unit 3
Stop
Free
Free
Free
Free
Free
Free
Free
Free
Free

List 3: Collector

——— Adjustment line

Deflector unit 2
Deflector unit 1
Collector
Enveloping

——— Deflector unit 3

Stop
Free
Free
Free
Free
Free
Free
Free
Free
Free

List 5: Deflector unit 3

——— Adjustment line

Deflector unit 2

——— Deflector unit 1

Collector
Enveloping
Deflector unit 3
Stop
Free
Free
Free
Free
Free
Free
Free
Free
Free

List 2: Deflector unit 1

——— Adjustment line

Deflector unit 2
Deflector unit 1
Collector

——— Enveloping

Deflector unit 3
Stop
Free
Free
Free
Free
Free
Free
Free
Free
Free

List 4: Enveloping

——— Adjustment line

Deflector unit 2
Deflector unit 1
Collector
Enveloping
Deflector unit 3

——— Stop

Free
Free
Free
Free
Free
Free
Free
Free
Free

List 6: Stop

Mod. 6609d-6612d: Automatic Forms Cutter 13.12.2006

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Example 2:

——— Adjustment line
——— Deflector unit 2

Deflector unit 1
Collector
Enveloping
Free
Free
Free
Free
Free
Free
Free
Free
Free
Free
Free

List 1: Deflector unit 2

——— Adjustment line

Deflector unit 2
Deflector unit 1

——— Collector

Enveloping
Free
Free
Free
Free
Free
Free
Free
Free
Free
Free
Free

List 3: Collector

——— Adjustment line

Deflector unit 2

Deflector unit 1
——— Collector
——— Enveloping

Free

Free

Free

Free

Free

Free

Free

Free

Free

Free

Free

List 5: Deflector unit 3

——— Adjustment line

Deflector unit 2

——— Deflector unit 1

Collector
Enveloping
Free
Free
Free
Free
Free
Free
Free
Free
Free
Free
Free

List 2: Deflector unit 1

——— Adjustment line

Deflector unit 2
Deflector unit 1
Collector

——— Eveloping

Free
Free
Free
Free
Free
Free
Free
Free
Free
Free
Free

List 4: Enveloping

——— Adjustment line

Deflector unit 2
Deflector unit 1

Collector
——— Enveloping
——— Free

Free

Free

Free

Free

Free

Free

Free

Free

Free

Free

List 6: Stop

Mod. 6609d-6612d: Automatic Forms Cutter 13.12.2006

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OMR data list

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3.3.3 Counter function ONLINE # 00 / # 01

The preset counter can be programmed to output any online functions. No OMR system is required (i.e. no reading
head). The reading head is automatically dead. Two or three functions can be carried out, one function several times,
the other(s) only once.

First the following information must be entered in the programming level:

1. Set the preset counter under parameter d) Counter.

2. Enter the function ONLINE #00/#01 under parameter e) Counter function.

3. Change into the service routine by pressing INFO and then PROG:

Service nr. 096: 2 Online functions (installed).
Service nr. 097: 3 Online functions (select when needed).

4. Select service nr. 008 and program the routine.

In an OMR routine desired functions are programmed in the first two lines # 00 / # 01 of the list (input in the CODE
column is of no significance).

2 ONLINE functions

The machine carries out the function entered under line #01 until the number before the preset number on the counter
is reached. On reaching the preset number, the mach ine carries out the function entered under line #00 . At the same
time the actual counter returns to 00000.

Example:

Example: In OMR program 2, three forms are to be collected and enveloped.

1. Select service no. 008 and enter OMR routine 2.

2. Press F4.

3. In line # 00 enter 00001 (enveloping) for the function.

4. Use F3 to switch between Code and Fnc.

5. In line # 01 enter 00002 (collect) for the function.

To return to program press the Prog-button twice and call service nr. 000.

Routine 2 Code Function

# 00 00000 00001 (enveloping) Sheet 00003

# 01 00000 00002 (collect) Sheets 00001 to 00002

The program can be saved in any program slot from 01-84. The counter (PRESET + ACTUAL) can be changed from
programs 00-84.

Special cases: Preset 00001 - the function in # 00 will always be output.
Preset 00000 - the function in # 01 will always be output.

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Access to the technician level should be restricted to trained service technicians only.

3 ONLINE functions

The machine carries out the function entered under line #01 until two numbers before the preset num ber on the
counter is reached. Then the machine once carries out the function entered under line # 02. On reaching the preset
number, the machine once carries out the function e ntered under line #00. At the same time the actual counter returns
to 00000.

Example: In OMR program 2, four forms are to be collected and enveloped, one form will be deflected.

Routine 2 Code Function

# 00 00000 00004 (deflect) Sheet 00005

# 01 00000 00002 (collect) Sheets 00001 to 00003

# 02 00000 00001 (enveloping) Sheet 00004

3.4 The technician level (level 3)

In order to access the technician level the machine must first be switched off. Then switch the machine on while
holding down buttons F1-F4. When OK appears in the display, press INFO once. Then release F1-F4.

To get into the service routines press INFO and then PROG.

The technician has all the service facilities at his disposal.

When the machine is switched off, it returns automatically to the operator level.

F1 and F2 - Move one service no. up or down (R)

F1 and F2 together - Move fast through the service nos.

F3 - Select service no. 000

F4 - Start the selected service routine

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3.4.1 Service routines

The service routines can only be called from the following software version onwards:

Central computer chip "H ..... 46/92" ("H 133") and display chip "D ..... 05/93"

Service
routine
no.

Function Display when a

service routine is
started

Comments

000 Return to user program

008 OMR routines program program own routine

009 1) ID chip data

0,1,2,3,4,5 = running numbers of levels (use the - + buttons to move one level
up or down). ). A = control no., B + C = serial no. (e.g. B = 00001, C = 04465,
serial no. = 14465), D = model no., E = fine correc tion, F = reading sensitivity,
G = calendar week, H = year, I = DA value 1, J = DA value 2, K = DA value 3,
L = DA value 4, M = cutting cycles, see table N+O below, P=Doublecut
Increase. DA values are correcting variables output by the computer to
correct deviations in the electronic system. After automatic adjustment
(service 10) the DA values must not be greater than 200.(for further
information see pt. 4.4.). An error message (31,32,33,34) will appear in the
display for values above 250. The machine can only be started after the error
has been corrected. Examples of possible errors are: distance between
scanner head and encoder disk, fibre-optic plug not plugged in, dirt on the
encoder disk. DA value 1,2 = scanner head - cross cutter, DA value 3,4 =
scanner head - tractor.
The display valves N+O will show ID-valves from 000 to 255 (=1 Byte)
consisting of 8 Bits. The valve results in the bina ry addition of selected service
numbers. Example: All service routines of the left side are set: result = 000.
If service 69,67,65,75 is set (right side ID valves 1+2+4+8) and service
76,96,38 is set, the result = 015.

Table for display N:

Table for display O:

1) The DA values (IJKL) are only shown in forms cutters with a new main board (no pots.)

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Service
routine
no.

Function Display when a

service routine is
started

Comments

010 2) Automatic adjustment

Opto 1-4

A:B =

50:50
Set value = 050 (045-055 tolerance range)
Caution: Do not start the machine before carrying out the following
precautionary measures:
Check the distance between the heads and the encoder disk (0,3mm). Make
sure the fibre-optic is correctly plugged in. Lower blade test run: Upper blade
must move freely to meet lower blade (fix the cable clamp between blade bar
and adjusting screw).
If service routine 10 is finished, the display changes into service no 9 level 3
and shows the DA values. The DA-values should not be over 200. (for further
information see pt. 4.4, S.52). Press the "Prog"-button two times and start
service routine no 000 to return to the program.

011 Opto 1 Adjust cross cutter 000-100

display range

012 Opto 2 Adjust cross cutter 000-100

display range

013 Opto 3 Adjust tractor 000-100

display range

014 Opto 4 Adjust tractor 000-100

display range

015 Opto 5 000, 002 Not in use at present

016 Opto 6 OMR Like service 17 for head 6

017 Opto 7 OMR

Test routine
(machine must be
switched off ­unplug online machines)

000-015
display range

Binary addition of the OMR marks recognized. In this test a maximum of four
marks are read (in four successive lines, AL + 3 li nes). Before the test routine
is started, the adjustment line (AL) of the test form must be positioned in the
groove on the reading head. Caution! The machine must be switched off ­unplug all online machines. Then start the test routine. 001 = first OMR mark
(AL), 002 = second mark, 004 = third mark and 008 = fourth mark. Altogether

015. In a correct reading operation the result shown in the display must be
stable.

018 Opto 8 End of paper 000

001

No paper
Paper present

019 Hall sensor cover 000

001

Plexiglass cover closed
Plexiglass cover open

020 Hall sensor pressure-

switch

000
008

008 pressure ok

021 Opto 1-2 Phase position

cross cutter

000-100
display range

Set value = 040
(030-065 tolerance range )
Caution: Service routine 10
must be started first!

022 Cross cutter - motor 001-255

display range

Motor test, together with test of electric drive circuits.

023 Opto 3-4 Phase position

tractor

display range 6609/10: Set value = 040

(030-055 tolerance range)
6611/12: Set value = 040
(030-050 tolerance range)
Attention: You will have to
START with Service Routine
10 first!

024 Tractor motor 001-255

display range

Motor test, together with test of electric drive circuits.

025 Edge knife and

ejector motor

001-255
display range

Motor test, together with test of electric drive circuits.

026 3) Motor test 8V 001-255

display range

Motor test: Use extension to plug motor into ejector socket, and with your
hand hold the belt pulley still. If the pulley makes jerky movements this is an
indication of faulty winding.

2) Only for forms cutters with new main board (no pots.)

3) Only for forms cutters with central computer chip "H..... 42/94"

Mod. 6609d-6612d: Automatic Forms Cutter 13.12.2006

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Service
routine
no.

Function Display when a

service routine is
started

Comments

027 3) Motor test 12V 001-255

display range

Motor test: use the extension to plug motor into ejector socket, and with your
hand hold the pulley still. If the pulley makes jerky movements this is an
indication of faulty winding.

028 4) Temperature sensor 001-255

display range

The numbers in the display correspond to the following room temperatures:
145 20 C; 150 30 C; 160 40 C; 170 50 C;
From number 154 (corresponds to 35 C) onward, the feed rate will
automatically be reduced in steps.

030 Clear display RAM OK

Caution: When this service no. is started, all programs are erased.

031 Erase OMR routines 2-6 OK

Caution: When this service no. is started, all OMR routines (2-6) are erased.
OMR routine 1 is a fixed progr am and will be reloaded when the machine is
switched on (even after erasing).

032
to
036

Erase one OMR routine OK E.g. Service no. 032 erases OMR routine 2.

Service no. 033 erases OMR routine 3, etc.
OMR routine = service no. minus 30

038 Find beginning of paper

after program change

see service routine 9
table N

The paper is repositioned automatically on the blade edge when the program
is changed.

039 Do not search for

beginning of paper after
program change

see service routine 9
table N

The paper is not repositioned automatically on the blade edge when the
program is changed.

040
to
043

Dsplay OMR code
Current cycle

000-255
display range

040 = the first 8 OMR marks, 041 = the next 8 OMR marks , etc. The same
applies to service nos. 044-047, 048-051, etc.

Example: Service no. 040 and display 017
017 is composed of 001 + 016. Thus OMR marks have been detected in line
1 (1) and line 5 (16) (binary addition of the marks). The adjustment line (AL)
contains the first mark.

044
to
047

Display OMR code
1 sheet before

000-255
display range

048
to
051

Display OMR code
2 sheets before

000-255
display range

052
to
055

Display OMR code
3 sheets before

000-255
display range

056
to
059

Display OMR code
4 sheets before

000-255
display range

060 2)

061 2)

062 2)

063 2)

OMR sensitivity level 0

OMR sensitivity level 1

OMR sensitivity level 2

OMR sensitivity level 3

000

001

002

003

000 = low sensitivity (recommended for 90% of all applications ).

Can be checked again in service routine 009 (2/F). The new sensitivity level
will be transferred only after the machine is switched on again.

003 = high sensitivity

064 4)

065 4)

Match code

Match code

see service routine 9
table N

The group match code must be programmed, it will not be output directly.

The group match code will be read in lines 4-16 without programming and
will be output directly.

066 4)

067 4)

Eject last sheet (>8")

Not eject last sheet

see service routine 9
table N

The last cut sheet (> 8") is transported off the Automatic Forms Cutter and
put to the ONLINE-Systems. Sheets < 8" remain in the Automatic Forms
Cutter - they were not ejected.

The last cut sheet (< oder > 8") is not ejected - remains in the Automatic
Forms Cutter.

2) Only for forms cutters with new main board (no pots.)

3) Only for forms cutters with central computer chip "H..... 42/94"

4) Only for forms cutters with central computer chip "H.....47/95"

Mod. 6609d-6612d: Automatic Forms Cutter 13.12.2006

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Service
routine
no.

Function Display when a

service routine is
started

Comments

068 4)

069 4)

Start/Stop

Start/Stop

see service routine 9
table N

The Start/Stop button can be used during online operation.

The Start/Stop button cannot be used during online operation.

070 Find beginning of paper

automatically

OK

071 Position beginning of

paper manually

OK

074 4)

075 4)

Fine position normal

Fine position x2

see service routine 9
table N

In parameter h) Fine Position, the values entered will be used unaltered.

In parameter h) Fine Position, the values entered will be multiplied
by factor 2.

076 4)

077 4)

OMR intermediate
adjustment off

OMR intermediate
adjustment on

see service routine 9
table N

No intermediate stroke to adjust position of OMR marks.

After every 1024 strokes, one intermediate stroke to adjust position of OMR
marks when reader is being used.

078 5) Display darker 244-004

The language in the display can be changed by activating the appropriate
service routine.

079 5) Display brighter 004-244

080 5) Language: German 000

081 5) Language: English 001

082 5) Language: French 002

083 5) Language: Italian 003

084 5) Language: Dutch 004

085 5) Language: Portuguese 005

086 5) Language: Spanish 006

087 5) Language: Norwegian 007

088 5) Language: Japanese 008

089 5) Language: Swedish 009

090 5) Language: Czech 010

096

097

ONLINE function

ONLINE function

see service routine 9
table N

A maximum of two online functions can be performed with the counter.

maximum of three online functions can be performed with the counter.

098

099

Fine offset +1

Fine offset -1

After changing or replacement of the cross-cutter subassembly (comlete
block) the new cut-position has to be fine-adjusted again. The form is
positioned on the blade edge. When service routines 98 or 99 are started, the
distance between light barrier (paper recognition) and cut position is adjusted.
In parameter h) the fine position is correctly set at factor 00 atfer fine off set.
Fine offset +1: The distance from light barrier to cut position is increased by
factor 1 (corresponds to 1/192").
Fine offset -1: the distance from light barrier to cut position is decreased by
factor 1 (corresponds to 1/192").

100

101

Set board (PCB)
Set board without
temperature and
pressure sensor.

Set board (PCB)
Set latest board version
with temperature and
pressure sensor.

see service routine 9
table O

PCB version installed previously without control,
(for machines without fan for the motors, but with NEW PCB)

Newest board version with temperature and pressure sensor.

4) Only for Automatic Forms Cutter with central computer chip "H.....47/95"

5) From new display board 16060 onward.

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Service

routine
no.

Function Display when a

service routine is
started

Comments

102 Standard see service

routine 9 table O

For standard uses - sheet does not hang so far out of the forms cutter (lies
over both rollers in the cross cutter)

103 Paper hangs further out

of the forms cutter

Sheet hangs further out of the forms cutter (is only held by the last roller).
In order to avoid paper jams at the entry to the conveyor stacker 6624,
6625 or drop stacker 6650, 6651 when operating at high speed, a greater
distance between sheets is required.
This adjustment will be transferred only when the Forms Cutter is switched
on again.

104
105

Standard
2-up special

see service
routine 9 table O

OMR Standard
2-up-16+16 special

106
107

Standard
48+48 marks

8+8 / 16+16 Service 134/135 apply
48+48 lines (OCB)

108

109

Paper lead-edge +
presence sensor active
Paper lead-edge +
presence sensor shut
off

see service
routine 9 table O

Standard: checks for lead-edge and end-of-paper

The sensor is switched off during continuous run. A fter the paper has been
positioned to the blade or read-head(Display shows ’READY’) the sensor
will be inoperative.
Notice: The cutter will NOT stop at the end of paper / end-of-web!
Use this feature for: paper backside with solid black printing or holes in
the paper web.

114
115

Doublecut
Increase

see service
routine 9 / P

Doublecut - Offset adjustable - 1/24"
+1/ 24"

130

131

Standard 6-7 not
crossed

head 6-7 swapped over

see service
routine 9 table O

The right hand OMR head is connected to LED-block input 7, the left head to
input 6. Head 7 is read first.

The two head 6-7 are swapped over, so 6 becomes 7 and 7 becomes 6 in the
Software.

132
133

Standard 1head
2 heads

see service
routine 9 table O

1-head OMR heads 6-7
2-head OMR, (see service 134/135) may be swapped serv. 130/131

134
135

Standard 8+8
16+16 marks

see service
routine 9 table O

with 2-head OMR: 8+8 marks (Sequencer Digi "0")
with 2-head OMR: 16+16 marks (Sequencer Digi "1")

201
to
215

Interface
Transmit equipment
address

201-215
display range

interface diagnostic: continuous
emission of adress # = service # - 200

255 Show connected

interface participants

001-015
display range

Equipment addresses: 001 - master terminal, 002 - main board, 003 ­terminal, 004 - remote control, 005 - remote control, 008 - drop stacker, 010 ­loop control, 013 - group separation, 014 - drop stacker conveyor, 015 -online
equipment.

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3.4.2 Messages

The messages appear from the following software version onwards:

Central computer chip "H ..... 46/92" ("H 133")

and display chip "D ..... 05/93"

Display after
switching on or
during
operation

Function Comments

007 ID chip ID chip missing or interface blocked

011 Opto 1 - Cross cutter Start service no. 011 (adjust opto 1)

012 Opto 2 - Cross cutter Start service no. 012 (adjust opto 2)

013 Opto 3 - Tractor Start service no. 013 (adjust opto 3)

014 Opto 4 - Tractor Start service no. 014 (adjust opto 4)

021 Opto 1-2 Phase position Start service no. 021 (opto 1-2, phase position: adjust distance between the

two scanner heads)

022 2) Overcurrent at cross cutter motor Cause: Cross cutter is too stiff, motor is blocked, winding or final stage

is defective

023 Opto 3-4 Phase position Start service no. 023 (opto 3-4, phase position: adjust distance between the

two scanner heads)

024 2) Overcurrent at tractor motor Cause: Motor is blocked, winding or final stage is defective

025 2) Overcurrent at ejector motor Cause: Motor is blocked, winding or final stage is defective

026 Overcurrent at edge blade turbine motor Cause: Motor is blocked, winding or final stage is defective

031 2)

Opto 1 - Cross cutter

DA value outside permissible range
Cause: Dirt on encoder disk or fibre-optic

Distance at scanner head not correct
Fibre-optic not plugged in
Power supply interrupted

After correcting the problem, start service routine 10.

032 2)

Opto 2 - Cross cutter

033 2) Opto 3 - Tractor

034 2) Opto 4 - Tractor

040 8) Revolution - Controll Cause: Cross cutter is too stiff, motor is blocked, winding or final stage

is defective

099 7) Supplementary cooling fan defective The supplementary cooling fan for models 6611, 6612 and 6613 is tested with

a pressure sensor to check whether it is functioning correctly. If the pressure is
not sufficient, the interface to the terminal will be blocked. The message 099
Call Service!" will appear in the display. Operation cannot be continued, The
forms cutter must be switched off.
Cause: Defective motor, air distribution channel no t correctly installed, or motor
not plugged in.

2) Only for forms cutters with new main board (without pots.)

7) Only forms cutters 6611/6612, from display chip "D 16061 39/94" onward

8) Only for forms cutters with cross-cutter chip "Q .....08/00"

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4. Important notes and information

4.1 Cleaning and maintenance

The maintenance periods given here are based on a d aily use of approx. 4 hours. If the system is in operation longer,
you will need to maintenance it more frequently.
For example:
If used for four hours a day for DIN A4 format with two cuts, this adds up to approx. 60,000 machine cycles (mod.

6611) and approx. 120,000 cutting cycles. Over a period of one month (20 working days), this is equal to over two
million cutting cycles.
The following maintenance plan is appropriate for this amount of use:

Every month: replace or turn around the blades (cross cutter and edge cutter).
Approx. every 4 months: replace the rear cutter guide bar.
Approx. every 12 months (approx. 20 millionen cuts): replace motors.

To ensure trouble-free operation, replace parts subjected to high loads before they fail!

We recommend that the operator perform the following
maintenance work after every 500,000 cuts.

1. Clean all areas accessible from outside with a vacuum
cleaner. Do not use compressed air.

2. Apply two drops of oil to each edge cutter unit and to the
centre cutter 6875 (if present) .

The following maintenance work should be performed by a service
technician every 2 million cutting cycles:

If necessary, replace or turn around the edge and cross cutter blades
(see Service Instructions). Clean the sliding surfaces of the cross blade,
inspect for wear and grease lightly (if necessary, replace the rear cutter
guide bar). Apply one drop of oil to the upper pivo t pins of the
connecting rod on the cross cutter drive. Wipe away any excess oil
which drips onto the connecting rod.

The following maintenance work should be performed by a service
technician every 3 months (every 5-6 million cutting cycles):

1. All maintenance work peformed by the operator.

2. Use a vacuum cleaner to clean the machine inside and outside. Do

not use compressed air.

3. Clean both encoder disks and the scanning heads on the cross
cutter and tractor (see Service Instructions).

4. Inspect the flat belts and make sure they are still centered.
Remove any dirt which may have accumulated on the running
surfaces.

5. Begin service routine 10 and adjust the machine automatically.

If service routine 10 is finished, the display chan ges into service no
9 level 3 and shows the DA values. The DA-values sh ould not be
over 200. (for further information see pt. 4.4, S.52). Press the
"Prog"-button two times and start service routine n o 000 to return to
the program.

6. Check that the tractors and edge cutter units stop correctly. Adjust
them if necessary.

7. Grease hexagonal shafts and both shafts .

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4.2 Troubleshooting

Problem Causes and Solution

Machine always runs in reverse on
starting
Forms cutter does not stop at end
of paper

End-of-paper light barrier is covered by paper-holder.
End of paper cannot be detected, Adjust the paper-holder vertically
downwards. The light barrier must not be covered.

Light barrier is covered with paper dust and end of paper cannot be
detected. Clean the light barrier.

The height of the light barrier has been altered. End of paper cannot be
detected. Inform the service technician.

Forms are not cut straight Inform the service technician.

Forms are not cut Check the cut width factor (NO CUT means edge cut only)

Programs cannot be copied You are not in the programming level (see Section 3.3)

Service routines cannot be called Check whether you are in the technician level. For further information,

see Section 3.4.

Machine stops without any
message

Form is not being called by other equipment connected to the form
cutter.
The equipment is out of order, is not properly connected or is set at
Stop.
Check the equipment.

Display messages:
see Section 3.1.3, page 14

Read errors:
see Section 3.3.2, page 29

Mod. 6609d-6612d: Automatic Forms Cutter 13.12.2006

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4.3 Technical Data

Number of cuts per hour

Model: 6609 6610 6611 6612

Type of cut: Single Double Single Double Single Double Single Double

Form length:

4" 17000 13000 20000 15000 23000 17000 27000 20500

8" 11000 9500 15000 12000 18000 14000 24000 17500

12" 8000 7500 12000 10000 15000 12000 18000 14500

These performance figures may vary by – 5% and represent machine cycle performance only (without paper).

Form length: min. 12/6" Paper weight: min. 40 g/m

2

max. 999/6" max. 200 g/m

2

Form width: min. 88 mm max. 500 mm Basis weight for
Edgetrim: 28mm (option 60 mm) multipart forms: max. 350 g/m2

Cuttingtolerance: – 0,3 mm

Standard Option

Input terminal Interface to Inserters
Transp. cover w. auto stop Stacker tray
Rim chopper Automatic lowering stacker
Automatic stop at end of paper OMR reader (programmable)
Self diagnostic center Center Slitter
Electronic fine adjustment Additional Vertical Slitter
High speed interface Group separation
(other forms processing systems can Tension control
be connected to high speed interface - 6610, Rem ote control
6611,6612 and 6613 with online interface)
Multifunction counter
Length steps 1/6",1/8 ", and 1/24"
Stand

Dimensions Weight

Width without/with input terminal: 760/850 mm Form cutter incl.
Height without/with input terminal: 1090/1200 mm Stand: 80,0 kg
Length without/with standard tray: 525/960 mm Stacker tray/standard: 5,0 kg

Finish Two colours

Connected loads:

Single-phase a.c. 50/60 Hz
Voltage: 115V / 230 V
Power consumption during continuous operation: 600W/2160 kJ/h (depending on cycle speed

and number of systems connected)
Stand by: 50 W
Noise level: 68 dB/A

Subject to alteration

Mod. 6609d-6612d: Automatic Forms Cutter 13.12.2006

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4.4 Technical change of the main PCB·s

The actual delivered Automatic Forms Cutter (dated week 43/2000) are with a potentiometer (to adjust the
optical power) on the main PCB.

The reason for this change is the ageing of the light emmiting
diodes (LED·s) used in the LED block. The optical power of the
LED·s decreases faster, ages faster, as specified b y the
manufacturer! As consequence, after several years of using, the
head unit (Mod. 6600 Automatic Forms Cutter , Mod. 6618
Pinless-Cutter , Mod. 6683 Cut-Sheet-Feeder or Mod. 6790
Cutsheet Guillotine shows the error message 31, 32, 33, or 34.
That means the DA-values are not within the allowed range.
(Further reasons for this error message are: dirt on encoder disc,
distance between scanner head and encoder disc is not correct or
encoder disc is scratched.) This also has not change after this
modification. Please really note the technical service manual.
In addition to the above mentioned potentiometer, which is
mounted from now on, we changed software details, which are not
visible from outside. The control range was extende d, so in future
times the space of time the error message 31-34 appears is
widened (caused by deviating DA-values!). In addition the DA­values are now directly shown on the display after running "service
routine 10" (during turn of the Poti). Please note that the displayed
values (for every channel one value) can always be different. By
manufacturing tolerances of the semiconductors and of the fibre
cable, always individual differences result within the 4 channels!
Independant of this, the DA-values should be between 70 and 130

- Total control range up to 250 (Important: Adjust the machine at
room temperature)! This range was settled new!
If the adjusted values are lower than 70 the Poti must be turned to
the left (lower optical power!). More than 130 - tu rn the Poti to the
right (more optical power!). After poti adjustments service "routine
10" must always be restarted in order to adjust the new actuall
DA-values automatically.
If the deviation between the 4 channels (no more in the range 70­130 = approx. 40 DA-points difference) is to high, it is
recommended to change the deviating channel. The fibre cable or
the light emitting diode or the detector diode.
With the technical modifications described above, i t is possible for
the service technician on site to carry out themselves the
corresponding adjustments and as result extend the period
essentially, until the light emitting diodes must be changed.

Mod. 6609d-6612d: Automatic Forms Cutter 13.12.2006

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4.4.1 Connections and electrical settings

Mod. 6609d-6612d: Automatic Forms Cutter 13.12.2006

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No. Description Mod. 6609/10

Part no. for motor
(Ø belt pulley)

Mod. 6611/12
Part no. for motor
(Ø belt pulley)

Motor for Cross-Cutter left 20599

(Ø 16)

15250
(Ø 21)

Motor for Cross-Cutter right 20599

(Ø 16)

15250
(Ø 21)

Motor for ejecter 20599

(Ø 18)

15250
(Ø 24)

Motor for Tractor 20599

(Ø 18)

15250
(Ø 24)

Motor for fan 26199

(Ø 30)

26199
(Ø 30)

Motor for fan and edge cutters 10179

(Ø 9)

10179
(Ø 14)

T Terminal

H Hallsensor

S Interface

N Power supply

Mod. 6609d-6612d: Automatic Forms Cutter 13.12.2006

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Index

Actual counter . . . . . . . . . . . . . . . . . . . . . 20

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 10

Adjustment line . . . . . . . . . . . . . . . . . . . . . 30

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Call service . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Checking parts . . . . . . . . . . . . . . . . . . . . . . . . . 5

Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Connected loads . . . . . . . . . . . . . . . . . . . . 50

Connections and electrical settings . . . . . . . 53

Cooling fan . . . . . . . . . . . . . . . . . . . . . . . . 16

Copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Counter function . . . . . . . . . . . . . . . . . . . . 21

Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Cross blade . . . . . . . . . . . . . . . . . . . . . . . . 10

Cross cut position . . . . . . . . . . . . . . . . . . . 20

Cross perforation . . . . . . . . . . . . . . . . . . . . 10

Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Cutting program . . . . . . . . . . . . . . . . . . . . 13

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 50

Direct channel . . . . . . . . . . . . . . . . . . . . . 30

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Display messages . . . . . . . . . . . . . . . . . . . 16

Double cut . . . . . . . . . . . . . . . . . . . . . . . . 17

EC Declaration of conformity . . . . . . . . . . . . 4

Edge blade . . . . . . . . . . . . . . . . . . . . . . . . 10

Edge cut . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Entering parameters . . . . . . . . . . . . . . . . . 16

Fault location . . . . . . . . . . . . . . . . . . . . . . . 48

Features . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Feed rate . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Fine position . . . . . . . . . . . . . . . . . . . . . . . 27

Flashing . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Form length . . . . . . . . . . . . . . . . . . . . . . . 16

Function . . . . . . . . . . . . . . . . . . . . . . . . . . 30

ID chip . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Info button . . . . . . . . . . . . . . . . . . . . . . . . . 16

Inserting the paper . . . . . . . . . . . . . . . . . . . . 9

Interface . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

List of contents . . . . . . . . . . . . . . . . . . . . . . 2

Loading paper . . . . . . . . . . . . . . . . . . . . . . . 9

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Maintenance . . . . . . . . . . . . . . . . . . . . . . . 48

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Number of cuts . . . . . . . . . . . . . . . . . . . . . 50

OMR code . . . . . . . . . . . . . . . . . . . . . . . . . 32

OMR data list . . . . . . . . . . . . . . . . . . . . . . 39

OMR mark . . . . . . . . . . . . . . . . . . . . . . . . . 32

OMR routines . . . . . . . . . . . . . . . . . . . . . . 29

Online . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Operating terminal . . . . . . . . . . . . . . . . . . . 13

Operation . . . . . . . . . . . . . . . . . . . . . . . . . 13

Operator level . . . . . . . . . . . . . . . . . . . . . . 16

Optical mark recognition . . . . . . . . . . . . . . 29

Optical scanner . . . . . . . . . . . . . . . . . . . . . 10

Panel keys . . . . . . . . . . . . . . . . . . . . . . . . 14

Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Paper adjustment . . . . . . . . . . . . . . . . . . . 10

Paper guide . . . . . . . . . . . . . . . . . . . . . . . . 9

Parameters . . . . . . . . . . . . . . . . . . . . . . . . 13

Pause . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Print lines . . . . . . . . . . . . . . . . . . . . . . . . . 29

Prog button . . . . . . . . . . . . . . . . . . . . . . . . 14

Program selection . . . . . . . . . . . . . . . . . . 13

Program sequence . . . . . . . . . . . . . . . . . . 13

Program structure . . . . . . . . . . . . . . . . . . . 13

Programming level . . . . . . . . . . . . . . . . . . 22

Programm ing the fold length . . . . . . . . . . . . 22

R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Read area . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Read lines . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Reading mark . . . . . . . . . . . . . . . . . . . . . . . . 29

Ready . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Safety instructions . . . . . . . . . . . . . . . . . . . . . . 5

Select program . . . . . . . . . . . . . . . . . . . . . . . . 9

Service routines . . . . . . . . . . . . . . . . . . . . . . . 41

Single cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Special Length . . . . . . . . . . . . . . . . . . . . . . . 17

Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

START button . . . . . . . . . . . . . . . . . . . . . . . . 14

Starting the machine . . . . . . . . . . . . . . . . . 9,12

Starting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

STOP button . . . . . . . . . . . . . . . . . . . . . . . . . 14

Sub counter . . . . . . . . . . . . . . . . . . . . . . . . . 20

Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Technical change . . . . . . . . . . . . . . . . . . . . . 52

Technical Data . . . . . . . . . . . . . . . . . . . . . . . 50

Technician level . . . . . . . . . . . . . . . . . . . . . . 41

Test cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Tractors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50