Formax 6304 Series User manual

6304 Series

Inserter

OPERATOR MANUAL

Rev. 1

/2010

1

ENGLISH

TABLE OF CONTENTS

1 Health, Safety and Environment ...................................................... 2

1.1 Precautions and Safety Issues ................................................... 2

2 Functional description ..................................................................... 5

2.1 Overview ................................................................................ 5

2.2 Operating Controls .................................................................. 7

2.3 Control Panel .......................................................................... 8

2.4 Software Description ................................................................ 8

3 Operating Instructions .................................................................. 12

3.1 Installation .. .......................................................................... 12

3.2 Preparation .. ......................................................................... 12

3.3 Starting Up ............................................................................ 13

3.4 Loading Documents ................................................................ 14

3.5 Loading Envelopes .................................................................. 16

3.6 Filling the Sealing Liquid Reservoir ............................................ 17

3.7 Run a Job .............................................................................. 17

3.8 Using an Automatic Job ........................................................... 18

3.9 Daily Mail .............................................................................. 18

3.10 Stopping the system ............................................................... 19

4 Job Programming .......................................................................... 20

4.1 Create a Job .......................................................................... 20

4.2 Job Settings .......................................................................... 21

4.3 Edit a Job .............................................................................. 27

4.4 Copy a Job ............................................................................ 28

4.5 Delete a Job .......................................................................... 28

5 Options .......................................................................................... 29

5.1 Activate an Option .................................................................. 29

5.2 Reading .. .............................................................................. 29

5.3 Online Services ...................................................................... 36

5.4 Production Feeder (MF-2) ......................................................... 39

5.5 High Capacity Feeder .............................................................. 41

5.6 High Capacity Vertical Stacker (HCVS-1) ................................... 42

5.7 Side exit ............................................................................... 42

5.8 Mail Piece Production Control (MPPC) (Option) ............................ 42

5.9 Mailing/Franking .................................................................... 42

6 Operator Maintenance ................................................................... 43

7 Fault finding .................................................................................. 44

7.1 Error Messages ...................................................................... 44

7.2 Clearing Stoppages ................................................................. 45

7.3 Operator Troubleshooting ........................................................ 46

8 Specifications ................................................................................ 50

8.1 Technical Specifications ........................................................... 50

8.2 Configuration Dimensions ........................................................ 50

8.3 Other Specifications ................................................................ 50

8.4 Document Specifications ......................................................... 51

8.5 Envelope and Insert Specifications ............................................ 51

8.6 Specifications High Capacity Vertical Stacker .............................. 52

8.7 Specifications Production Feeder ............................................... 53

9 Terminology .................................................................................. 54

Index.............................................................................................. 60

2

1. HEALTH, SAFETY AND ENVIRONMENT

1.1 Precautions and Safety Issues

Thoroughly read this operator manual, before using this system.

According to the EC declaration (European Commission) following the Low Voltage

Directive (2006/95/EC), this operator manual must be available in the national

language(s) of the country where the system is delivered. Therefore, if you do not have an

operator manual in your country’s language(s), contact your authorized distributor.

Warnings

• Disconnect the mains supply before performing any maintenance.

• Before connecting check if the system is suitable for the local mains voltage. Refer to

the type plate.

Safety Precautions

• Only competent personnel should operate this system.

If incompetent personnel do operate this system, the manufacturer does not accept

responsibility for any resulting accidents or injuries.

• Only skilled persons, who are aware of the risks involved, may open the protective

covers.

For safety reasons, the system will not function when the covers are open.

• Keep long hair, fingers, jewelry, etc. away from rotating and moving parts.

• The power connection must be easily accessible, preferably close to the system.

• For safety reasons, it is essential that the system is connected to a socket outlet that

has a protective earth connection.

• Over-current protection in the equipment also relies on the branch circuit protection

(max. 20 A).

• The following part(s) is (are) considered the equipment disconnect device(s):

- Power supply cord plug

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Conventions

Note

A note gives additional relevant information.

Caution

Indicates the presence of a hazard that can cause personal injury or property damage, if

the hazard is not avoided.

Warning

This symbol:

• Identifies situations where improper use of the system can result in

personal injury or permanent/catastrophic damage to the system.

• Indicates that the operator manual should be consulted.

4

Please use the subjoined return or

5

ENGLISH

2. FUNCTIONAL DESCRIPTION

The system feeds, folds and inserts documents into envelopes and then seals and stacks

the envelopes. Automatic monitoring ensures the correct number of inserts per envelope.

The system is a sophisticated folding and inserting system which can process large

quantities of mail rapidly and easily. The system can be operated by means of a user

friendly interface.

The settings of the system (document type, envelope type and fold type) is recorded in

jobs. These jobs can be programmed by an authorized user.

The system is equipped with a variety of special features as programmable jobs, including

double feed control, hopper swap, multifeed, and daily mail

.

2.1 Overview

The system consists of the following areas:

1

2

3

4

6

5

6

2.1.1 Feeder (1)

The feeder is the feeding part of the system. There are two types of feeders available: the

automatic and the special feeder. The automatic feeder does not require any adjustments

for the separation. The feeder is equipped with double feed control. In this way the system

can detect faulty sets of documents. The feeder is equipped with hopper swap. This means

that two feeders can be linked as pairs. When the first feeder is empty, the system

switches to the other feeder. Meanwhile the other empty feeder can be refilled without

stopping the system. It’s also possible to feed multiple documents from one feeder. In this

way more documents can be fed from one station, for example an original and a copy of a

document.

The upper automatic feeder is equipped with a “daily mail” function for processing

documents or sets of documents which cannot be processed automatically (e.g. stapled).

2.1.2 Collating Area (2)

After feeding, the documents are gathered and aligned in the collating area.

2.1.3 Folder (3)

The folder unit folds the documents. The following fold types are possible (see

“Terminology” on page 54).

• No fold

• Single fold

• Letter fold

• Zig-zag fold

• Double parallel fold

2.1.4 Envelope Feeder (4)

The envelopes are picked up and transported to the insert position inside the system.

2.1.5 Inserter (5)

After folding the documents are transported to the inserter unit where the documents are

inserted into a waiting envelope. The inserter then seals the envelope.

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2.2 Operating Controls

A catch tray K sensors

Benvelope slide L bellows

C control panel with touch screen M unlocking handle for rollers envelope

track

D upper unit N sealing liquid reservoir

E locking hand grip upper unit O side cover (opened)

F document feeder tray P ruler

G collator arm Q thumb wheel for side guide adjustment

H collating area R side guides envelope hopper

I power inlet, power switch,

RS232 connector / USB / modem

S handle for separation adjustment

J handles for clearing jams T Envelope support bracket

Q OPRST JKL

N

JM

A B C

F

G

H

I

D

E

8

2.3 Control Panel

The system has a graphical touch screen.

There are two buttons next to the touch screen:

• : the start key

When the start key is pressed the system starts

processing

: the stop key

When the stop key is pressed, the system completes the current set and stops.

Caution

The touch screen is covered with a thin pressure-sensitive layer. To avoid permanent

damage of the touch screen, do not use sharp objects to press on the touch screen.

2.4 Software Description

2.4.1 Home

When you start up the system, the ‘home’ menu

appears. With the arrows you can scroll through the

jobs. If you want more information on a job, select

the job (see 2.4.2 ”Job Description” below).

If you just want to start without job definition, press

New job and select Automatic (see 3.8 ”Using an

Automatic Job” on page 18).

With the home button you get back to the

‘home’ menu.

The MENU button opens the main menu (see

2.4.3 ”Main Menu” on page 10).

2.4.2 Job Description

If you want more information on a job, select the job

in the ‘home’ menu.

The ‘current job’ menu shows the following

information of the selected job:

• Job number and Job name

• Total: total number of envelopes that have been

processed using this job

• To do: number of envelopes to do. Only

indicated if a ‘stop at’ value is set.

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• Stop at: number of processed envelopes at which the system stops. You can set this

number with the Counters button. You can set it between 0 (switched off) and 9999.

The system will continue until the job counter reaches the stop counter value. The

system stops and can be restarted.The stop counter is switched off when it is set to

zero.

If you want to reset the daily job counter and the stop counter, press the Reset

counters button in the ‘counters’ menu.

Note

The counter settings are job related.

• A picture of the system with symbols for the selected features. The following symbols

can be used:

•Edit button: use this button to edit the job (see

“Edit a Job” on page 27).

•Info button: if you press the Info button, the

screen shows how to position the envelope and

documents in the feeders.

From this menu you can press a button to view

the reading settings.

.

Shows the feeders selected to pick documents from (black is selected).

Every selected feeder shows how many sheets will be fed from that

feeder and the length of the sheets.

This sign indicates that the relevant feeders are linked. This means that

when one feeder is empty, the system automatically starts picking

documents from the other feeder.

This sign indicates that for the selected feeder OMR or BCR is switched

on (optional).

This sign indicates that the relevant feeder is set for daily mail.

Gives information about the envelope size (ISO format or height in mm).

An envelope with a cross means that no envelopes are used.

Shows the type of fold, in this case letter fold.

The sign indicates that for the relevant feeder the double feed detection

is switched on.

2X

3X

OMR

BCR

10

2.4.3 Main Menu

When you press the MENU button the main menu

appears. This menu allows you to change system

settings and define jobs. The screen shows the

following functions:

•Display settings: change touch screen and

volume settings (see “Display Menu” below)

•Supervisor menu: change system settings and

define jobs (see “Supervisor Menu” below),

only for authorized personnel

2.4.4 Display Menu

When you press the Display settings button in the

main menu, the ‘display settings’ menu appears.

Use the arrow buttons to adjust the touch screen

contrast and the volume of acoustic signals. The

figure between the arrow buttons shows the level of

contrast or volume.

2.4.5 Supervisor Menu

When you press the Supervisor menu button in the

main menu, a login menu opens. Enter the PIN-code

2546 to access the ‘supervisor menu’.

If you enter 3 times a wrong pin code the touch screen shows the main menu again.

When you enter the correct pin code the ‘supervisor

menu’ appears. This menu enables you to check and

configure the system and maintain jobs.

The ‘supervisor menu’ shows the following functions:

•System info: shows system information, like:

- The software versions that are present in

the total system

- The flex certificate, used for reading

- The counter value since the last service visit

- The last error generated by the system

•Options: shows option information and system information:

-The chip ID

- The system ID

- The installed options

For installing new options, see 5.1 ”Activate an Option” on page 29.

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•Test: opens the ‘test menu’ (see 2.4.6 ”Test Menu,” below). Use this menu to

test the system.

•Online services: opens the ‘Online Services’ menu (option, see 5.3 ”Online Services”

on page 36). This menu enables to connect the system to a server and receive

messages.

•Job menu: opens the ‘job menu’. In this menu you can create, edit, copy or delete

jobs (see 2.4.7 ”Job Menu,” below).

•Read config sheet: reads Barcode Reading (BCR) settings from a BCR configuration

sheet.

2.4.6 Test Menu

Open the ‘test menu’ from the ‘supervisor menu’.

Use this menu to check the system, reset all

photocells and execute a reading test. The ‘test

menu’ shows the following functions:

•Diagnostics: use this function to verify that all

motors, clutches and sensors are correctly

connected. This test briefly activates the

actuators and then measures the current to

determine the status of the actuators and

clutches.

Note

Remove all paper and close all covers before testing.

•Reset photocells: used for photocell calibration.

•OMR test: use this menu to test the reading head and the quality of the codes on the

sheets. Follow the directions on screen.

•BCR test: use this menu to test the reading head and the quality of the codes on the

sheets. Follow the directions on screen.

2.4.7 Job Menu

When you press the Job menu button in the

‘supervisor menu’, the ‘job menu’ opens. This menu

enables you to create, edit, copy or delete jobs.

The ‘job menu’ shows the following functions:

•Create job (see 4.1 ”Create a Job” on page 20)

•Edit job (see 4.3 ”Edit a Job” on page 27)

•Copy job (see 4.4 ”Copy a Job” on page 28)

•Delete job (see 4.5 ”Delete a Job” on page 28)

12

3. OPERATING INSTRUCTIONS

3.1 Installation

Warning

You can severely damage the system if it is connected to the incorrect power supply.

Before plugging in the system, check if the local voltage is the same as the voltage

mentioned on the type plate.

3.2 Preparation

3.2.1 Document Feeder Trays

Note

The system can be delivered with a tray to manually adjust the separation (special

feeder). This tray fits in all positions, but the adjustment is only possible when fitted on

the lowest position (position one).

To place the document feeder trays in position:

1. Hold the tray slightly inclined as shown in the

figure.

2. Place the front end of the tray underneath the

two black rollers.

3. Move the tray upwards (lifting the black rollers),

until it is possible to ‘hook’ the tray into place.

4. Move the tray towards the system and move the

hooks over the mounting points (on both sides).

5. Let the tray rest on the system.

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3.2.2 Slide and Envelope Catch Tray

To attach the slide and envelope catch tray:

1. Attach the slide as shown in the figure.

2. Position the envelope catch tray into the holes

underneath the envelope hopper as shown in the

figure.

The distance A should be approximately 1.5 x

the envelope height.

3.3 Starting Up

To start up the system:

1. Connect the system to the mains power supply.

2. Use the power switch to switch the system on.

The power switch is located at the back of the

system.

The software will ask you to select the required

language.

3. Select the required language for the touch

screen.

The software will ask you if you want the “select

language option” to be displayed every time the

system is switched on.

4. Select either Yes or No.

5. Press the OK button.

The touch screen shows the home menu.

A

14

3.4 Loading Documents

3.4.1 Document Orientation

See also the job information on the touch screen.

3.4.2 Adjusting Side Guides

To adjust the side guides of the document feeder trays:

1. Remove the tray from the feeder as follows:

a Push handle

A

downwards.

b Lift the tray upwards to unhook it and then

pull it out from the feeder.

feeder swap two documents document + enclosure

one document

no fold

single fold

letter fold

zig-zag fold

Address carrier in

upper feeder.

Face up and leading.

Address carrier in upper

linked pair feeders.

Face up and leading.

Address carrier in

upper feeder.

Face up and leading.

Address carrier in upper

feeder.

Face up and leading.

Address carrier face

down and trailing. Address carrier in lower

linked pair feeders.

Face down and trailing.

Address carrier in lower

feeder.

Face down and trailing.

Address carrier in upper

feeder.

Face down and trailing.

double

parallel fold

A

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2. Loosen the knob

B

half a turn.

3. Grab the side guides in the middle and push

them apart as far as possible.

4. Put a small stack of documents between the side

guides.

5. Grab the side guides in the middle and push

them towards the documents.

The space between the side guides and the

documents should be such that the documents

have just enough play to move freely.

6. Re-tighten knob

B

.

7. Remove the stack of documents.

8. Replace the document feeder tray (3.2.1 ”Document Feeder Trays” on page 12).

3.4.3 Document Separation

‘Document separation’ means the adjustment that is required to separate the upper

document from the rest of the documents in the stack. This prevents picking up too many

documents from the stack at the same time.

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

manual adjustments needed.

Feeder 1 (the feeder in lowest position) can be a special feeder. You can manually adjust

the separation of special feeders as follows:

1. Remove feeder trays 2 and 3 (the upper trays).

2. Push the knob

B

forward until it clicks.

3. Turn the left-hand side guide

A

downwards.

4. Place a document on the feeder tray and slide it

about 60 mm (2.4 inch) into the system. Turn

the knob

B

counter clockwise if the separation is

set too narrow.

5. Push the document between the separation

rollers, which are behind the rubber paper

pullers.

6. Turn the knob

B

clockwise to increase resistance

or counter clockwise to lower the resistance.

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

7. Pull the knob

B

back again when ready.

8. Close the left-hand side guide.

B

A B

16

3.4.4 Filling the Document Feeder Tray

To fill the document feeder tray:

1. Turn the left-hand side guide

A

downwards.

The feed rollers are lifted automatically.

2. Place a stack of documents between the side guides.

Feed the documents (depending on the type of documents and the type of fold) as

shown in 3.4.1 ”Document Orientation” on page 14.

3. Turn the left side guide upwards again.

3.5 Loading Envelopes

To load the envelopes:

1. Adjust the side guides C with thumb wheel D so,

that the envelopes:

- Fit exactly between the side guides

- Can move freely

Note

If the distance between the side guides is too

large, the envelopes will twist sidewards, when

transported into the system.

Note

If you use the optional High Capacity Vertical

Stacker, also adjust the side guides of this

stacker (see “Adjusting the Side Guides” on

page 42).

2. Set the envelope separation as follows:

a Pull down small lever

A

.

b Insert one envelope horizontally up to the stoppers.

cReturn lever

A

.

3. Place the bottom envelope between the rollers

(flap down and trailing - bottom side of envelope

pointing to the system).

4. Loosen the stack of envelopes and place the

stack on top of the bottom envelope.

DCA

B

C

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5. Shift envelope support B in or out, so that the

top side of the envelope lies against the dotted

line on the support.

6. Turn envelope support B so the weight of the

envelopes is distributed evenly on both sides.

3.6 Filling the Sealing Liquid

Reservoir

When you want to seal envelopes, the sealing liquid

reservoir must be filled.

1. Open the front cover A.

2. Fill the reservoir B up to lip C with sealing liquid.

3. Close the front cover A.

Before you start the job, wait approximately 5

minutes for the brushes to moisten.

If the liquid reservoir is almost empty the

touchscreen shows a message to warn you that you

should refill the reservoir.

3.7 Run a Job

To run a job:

1. From the ‘home’ menu select a job.

If you press the OK button, the job information

appears (see “Job Description” on page 8).

2. Load envelopes as specified in the job. Press the

Info button for details.

3. Load the documents face up and leading, as

specified in the job. Press the Info button for

details.

Place the address carrier in the upper feeder.

4. Press the 1x button to start a test run or press

the button to start the job.

If you press the 1x test button, the screen shows questions that help you to solve any

problems on mail set quality. If necessary this troubleshooting wizard helps you to:

- adjust envelope position (see 7.3.1 ”Insert Position” on page 49)

- adjust finger position (see 7.3.2 ”Envelope Insert Fingers” on page 49)

- adjust address position (see 7.3.3 ”Address Position” on page 49)

A

C

B

18

3.8 Using AutoSet

If you do not want to define a job and just want to do some inserts, you can let the

system determine the job settings for you.

This ‘automatic’ job determines automatically its job settings by measuring the sizes of

documents and envelope. One sheet will be taken from all feeders that are loaded. Based

on the maximum document length (which is also the length of the document set) and the

length of the envelope, the fold type is determined.

Note

AutoSet cannot be used together with linked feeders, multifeed, daily mail and

reading functionality.

The AutoSet is not possible in the no envelopes mode or with usage of

envelopes with open flap.

In AutoSet only the Double Feed Control (DFC) of the upper feeder is selected.

Note

Before starting an AutoSet job, be sure that no documents or envelopes are left in the

system.

To start an AutoSet job:

1. From the ‘home’ menu, press the New job

button.

2. Press the Automatic button.

3. Load envelopes.

4. Load the documents face up and leading.

Place the address carrier in the upper feeder.

5. Press the 1x button to start a test run (see

3.7 ”Run a Job” on page 17) or press the

button to start the job.

6. If you press the Save button you can copy this job to a job number.

3.9 Daily Mail

To process documents or sets of documents, which can not be processed automatically

(e.g. stapled documents), the top feeder is equipped with a daily mail switch.

To use the Daily Mail function:

1. Select a job where the daily mail function is selected. You can recognize the daily mail

by the icon in the job information menus.

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Formax 6304 Series User manual

Formax 6304 Series User manual

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