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- Page 1 6204 Series Low-Volume Desktop Inserter MyBinding.com 5500 NE Moore Court Hillsboro, OR 97124 Toll Free: 1-800-944-4573 OPERATOR MANUAL 7/2012 Local: 503-640-5920...
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Page 2: Table Of Contents
Table of Contents Read this First ....................1 Warning......................1 About this manual.....................1 Safety.......................2 Country Specific Conditions................4 End of Life......................5 Meet your Document System ..............6 Overview......................6 Operating Controls...................8 Control Panel....................9 Installing the Document Feed Trays...............10 Installing the Slide and Catch tray..............11 Power Up......................12 Home Menu....................12 Job Info......................13 Side Guides....................15... - Page 3 Processing a Mail Set with BRE or Inserts.............24 Document Separation..................25 Processing Daily Mail..................25 Test Run......................26 Adjusting the Address Position...............26 Adjusting the Envelope Insert Fingers............27 Verifying the Insert Position................28 Working with Jobs ..................29 What is a job....................29 Creating a new job..................29 Performing a test run..................31 Adjusting the Envelope Position..............32 Using a job.....................33...
- Page 4 Running diagnostics..................51 Reading .......................52 Introduction.....................52 Adjusting the reading head position...............53 Document Orientation..................54 OMR Code Description..................55 Running an OMR test..................58 Operator Maintenance ................60 Maintenance Schedule...................60 Clean and replace brushes................61 Clean the sensors on the envelope or document path........61 Clean the exit sensors..................62 Resetting Photocells..................62 Fault Finding ....................63 Error Messages....................63...
- Page 5 MyBinding.com 5500 NE Moore Court Hillsboro, OR 97124 Toll Free: 1-800-944-4573 Local: 503-640-5920...
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Page 6: Read This First
Read this First Warning Ensure you have read and fully understood the safety requirements in this section. About this manual Languages According to the EC (European Commission) declaration following the Low Voltage Directive (2006/95/EC), this operator manual must be available in the national language(s) of the country where the system is delivered. -
Page 7: Safety
Symbols This manual uses the symbols listed below. WARNING : Indicates a human safety hazard. ATTENTION : A risk to the equipment or mail could result from an action you may perform. NOTE : A remark that explains different cases or specificities. TIP : Advice to help save you time when processing your mail. - Page 8 Safety Precautions • Only competent, trained personnel should operate this system. If non-trained personnel do operate this system, the manufacturer will not accept responsibility for any resulting accidents or injuries. • Only skilled persons, who are aware of the risks involved, may open the protective covers.
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Page 9: Country Specific Conditions
Country Specific Conditions Denmark In Denmark, certain types of Class 1 appliances may be provided with a plug that does not provide an adequate earth (ground) connection when inserted into a Danish socket outlet. Make sure the system has a good functioning connection that has protective earthing (the plug and socket outlet must match). -
Page 10: End Of Life
End of Life The objectives of the European Community's environment policy are, in particular, to preserve, protect and improve the quality of the environment, protect human health and utilize natural resources prudently and rationally. That policy is based on the precautionary principle and principles that preventive action should be taken, that environmental damage should as a priority be rectified at source. -
Page 11: Meet Your Document System
Meet your Document System Overview Introduction The system is a folding and inserting system for processing mail easily. The system: • Feeds documents • Folds the documents • Inserts the documents into envelopes • Seals the envelopes • Stacks the envelopes Automatic monitoring ensures the correct number of documents per envelope. - Page 12 MyBinding.com 5500 NE Moore Court Hillsboro, OR 97124 Toll Free: 1-800-944-4573 Local: 503-640-5920 The figure shows an overview of the system. Document Feeders (flexFeed) (1) The flexFeed is the feeding part of the system. There are two types of feeders: the automatic and the special feeder.
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Page 13: Operating Controls
• Double V-fold Envelope feeder (4) Envelopes that are placed on a stack by the user, are fed one by one into the system by the envelope feeder. Inserter (5) After the documents are folded, the documents are transported to the inserter. The inserter inserts the documents into a waiting envelope. -
Page 14: Control Panel
A - Envelope catch tray K - Sensors B - Envelope slide L - Bellows C - Display with operating buttons M - Handle for clearing stoppages D - Upper unit N - Sealing liquid reservoir E - Locking hand grip upper unit O - Side cover (opened) F - Document feeders P - Ruler... -
Page 15: Installing The Document Feed Trays
Installing the Document Feed Trays Place the document feed trays in position: Hold the document feeder slightly inclined as shown in the figure. Place the front end of the document feed tray underneath the two rollers. Move the document feed tray upwards (lifting the two rollers), until it is possible to ‘hook’... -
Page 16: Installing The Slide And Catch Tray
Installing the Slide and Catch tray To install the slide and the catch tray: Attach the slide as shown in the figure. 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. MyBinding.com 5500 NE Moore Court Hillsboro, OR 97124... -
Page 17: Power Up
Power Up To start up the system: You can severely damage the machine if it is connected to the incorrect power supply. Before plugging in the machine, check if the local voltage is the same as the voltage mentioned on the type plate. -
Page 18: Job Info
Job Info If you want more information on a job, select the job in the ‘home’ menu. The ‘current job’ menu shows the following information of the selected job: • Job number and Job name • Total: total number of envelopes that have been processed using this job •... - Page 19 • A picture of the system with symbols for the selected features. The following symbols can be used: Shows the feeders selected to pick documents from (black is selected). Every selected feeder shows how many sheets will be fed from the feeder and the length of the sheets. This sign indicates that the relevant feeders are linked.
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Page 20: Side Guides
Side Guides To adjust the side guides it is best to remove the document feed tray from the feeder as follows: Push handle A downwards. Lift the document feed tray upwards to unhook it and then pull it out from the feeder. Loosen the knob B half a turn. -
Page 21: Document Orientation
Document Orientation Filling the Document Feeder Tray Fill the document feeder tray as follows: Open the left-hand side guide A by turning it downwards. The feed rollers will automatically be lifted. Place a stack of documents between the side guides. Turn the left side guide upwards again. -
Page 22: Loading Envelopes
Loading Envelopes Before you load the envelopes, make sure the envelope separation and side guides are correctly set. Proceed as follows: Rotate thumb wheel D to move the side guides C apart. If the distance between the side guides is too large, the envelopes will twist sidewards, when transported into the machine. -
Page 23: Sealing Envelopes
Place the bottom envelope between the rollers (flap down and trailing - bottom side of the envelope pointing to the machine). Loosen the stack of envelopes, and place the stack on top of the bottom envelope. Shift envelope support B in or out, so that the flap side of the envelope is lifted approximately 20 mm (0.8”). -
Page 24: Filling The Sealing Liquid Reservoir
Shift the blue handle A towards to disable the envelope sealing or towards to enable the envelop sealing. Close the top cover. Before you start a job with sealing, wait approximately 5 minutes for the brushes to moisten or use moistened brushes. For instructions on the installation of brushes, see Clean and replace brushes on page 61. -
Page 25: Shut Down The System
Fill the reservoir B to the "Max" lip C with sealing liquid. Close the front cover A. Before starting the job, wait approximately 5 minutes for the brushes to moisten. Before starting the job, wait approximately 5 minutes for the brushes to moisten or use moistened brushes. -
Page 26: Options
Options Side Exit The system can be equipped with a side exit and catch tray. The side exit can be fitted instead of the standard envelope receiving tray. The side exit allows a conveyor or a franking system to be fitted in line with the system. The side exit can also be used with a catch tray to achieve vertical stacking. -
Page 27: Processing Mail Sets
Processing Mail Sets Introduction With the system you can process mail sets in the following ways: • Automatic job: The system automatically picks one sheet from each filled feeder and processes them into mail sets. The automatic feature is described in this chapter. •... -
Page 28: Processing A Basic Mail Set
Processing a Basic Mail Set A basic mail set consists of documents from one or more document feeders. This set is inserted into an envelope. Before you start, make sure you have read the Introduction on processing mail sets page 22. From the home menu, press the [New job] button. -
Page 29: Processing A Mail Set With Bre Or Inserts
Processing a Mail Set with BRE or Inserts A mail set with BRE consists of documents from one or more document feeders and an insert/BRE from the BRE feeder. This set is inserted into an envelope. Before you start, make sure you have read the Introduction on processing mail sets page 22. -
Page 30: Document Separation
Document Separation The term ‘Document separation’ refers to the adjustment required for separating the upper document from the rest of the documents in the stack. This prevents documents being picked up from the stack at the same time. This machine has automatic feeders only; all document separation is automatically adjusted. -
Page 31: Test Run
Place the document or document set in the feeder (see Filling the Document Feeder Tray on page 16). The document or document set will be folded and inserted into the envelope as described in the selected job. Place the next document or document set in the feeder. The system will keep running to process the inserted document or document set. -
Page 32: Adjusting The Envelope Insert Fingers
Press No if asked if the address is readable. Follow the steps in the wizard. Adjusting the Envelope Insert Fingers To make a good insert of the document set into the envelope, the insert fingers A should be about 5 mm (0.2 inch) inside the envelope. The outer fingers should be about 5 to 10 mm (0.2 to 0.4 inch) from the edges of the envelope. -
Page 33: Verifying The Insert Position
Verifying the Insert Position To make a good insert of the document set into the envelope, the envelope should be positioned correctly. The document set is inserted correctly if the flap folding line of the envelope is positioned underneath the green roller B. To verify the insert position: This adjustment must only be checked in case of problems or when changing the envelope type. -
Page 34: Working With Jobs
Working with Jobs What is a job If you have to process a lot of mail sets of the same type (for example bills), you can save the settings to a 'job'. The next time you just select the job and immediately start without defining any settings. - Page 35 Press [Manual] to create a new job. For [Automatic], see Processing a basic mail set. Enter the pin code 2546. Press the [Job wizard] button to create a new job with the job creation wizard or press the [Advanced] button (experienced users only) to define the settings of the new job. If you use the job creation wizard, follow the steps on screen.
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Page 36: Performing A Test Run
Press [OK] to confirm the selected free job number. A new selected job number starts with default settings. The job settings menu opens. The meaning of all buttons and settings is explained in settings. Press [Save] to save the job with the entered settings under the specified job number and name. -
Page 37: Adjusting The Envelope Position
Select the job you want to use. Click the [1x] button. Follow the steps in the wizard. Adjusting the Envelope Position Before performing a test run, it is possible to adjust the envelope position. To adjust the envelope position: Press the button to start adjusting the envelope position. -
Page 38: Using A Job
Press the to check the new alignment. Press the [OK] button to accept the new alignment. Using a job If you want to use an existing job: From the home menu, select the job you want to use. If you want to perform a test run: Press the [1x] button to do a test run. -
Page 39: Editing A Job
Editing a job To edit an existing job: From the home menu, select a job you want to edit. Press the [Edit] button. Enter the pin code 2546. The job settings menu opens. See Job settings on page 37 for the meaning of all buttons and settings. -
Page 40: Copying A Job
Copying a job To copy existing job settings to a new job: Press the [Supervisor] menu button from the main menu. Enter the pin code 2546. Press the [Job] menu button. The job menu opens. Press the [Copy job] button. The copy job menu appears. -
Page 41: Deleting A Job
Press the arrows if you want to select another job number to copy from or to copy to. You can only copy job settings to new jobs. Press the button for details of the job to copy from. Press [OK] to copy the job settings. If all jobs are programmed the touch screen shows “No more free jobs”. -
Page 42: Job Settings
Press the [Delete job] button. The delete job menu appears. When you press [OK], the job is deleted without a warning. Select a job number and press [OK]. Job settings From the job settings menu the following settings are available: •... -
Page 43: Envelope Settings
Envelope settings In the ‘envelope settings’ menu you can define the envelope properties. In the top of the screen, three selection buttons are displayed, from which one can be selected. The selected settings button will be highlighted. • Press the button to select an envelope with closed flap. -
Page 44: Document Settings
Document settings In the ‘document settings’ menu you define the document formats and the number of documents that must be picked from the different feeders. • Press the button to set the number of sheets for the different feeders. • Press the button to select a feeder. - Page 45 • Press the button to enter the document height. The height or the ISO format of the document will be displayed next to the relevant feeder. • Press the button to select a feeder. The selected feeder is highlighted. • Press the button to show a numeric keypad to enter the exact dimension of the document.
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Page 46: Fold Settings
When a feeder is selected for reading, the feeder below can not be linked to this reading feeder. • Press the button to enter the setting of the daily mail function. This function enables to process documents or sets of documents, which can not be processed automatically (see Processing Daily Mail on page 25). - Page 47 To change the fold positions press the button next to a fold. Enter the required position of the relevant fold. Fold type Minimum position Maximum position V-fold 75 mm (2.95") Longest document length minus 25 mm (0.98") C-fold First fold 75 mm (2.95") Longest document length minus 50 mm...
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Page 48: Reading Settings (Option)
Reading settings (option) For a full function description of reading, see Reading Introduction on page 52. In the ‘reading settings’ menu it is possible to enable or disable the Optical Mark Recognition (OMR) function and to adjust the basic settings. The first ‘reading settings’ menu covers the following settings: •... -
Page 49: Double Feed Control Settings
Double feed control settings In the ‘DFC settings’ menu you can set Double Feed Control (DFC) for the different feeders on or off. • Press the button to select a feeder. • Press the button to switch the DFC on or off. When switched on, the icon is displayed. -
Page 50: Job Name
Job name It is possible to store the job with a meaningful job name, to easily recognize the job. This name is displayed at job selection. Enter a job name with the alpha-numeric keypad. • Use the button to clear a character left of the cursor position (backspace). •... -
Page 51: Advanced Settings
Advanced Settings What are Advanced Setting? Advanced Settings are all settings that can be found under the Display Settings Menu and the Supervisor Menu. The Display Settings menu contains the following settings: • Set screen brightness (see Changing the Display Settings on page 47);... -
Page 52: Opening The Advanced Settings
• System info (see Viewing System info and Software versions); • Options (see Activating an option on page 49); • Test (see Test menu on page 50); • Online Services (see Start-up Online Services); • Job menu (see What is a job on page 29);... -
Page 53: Viewing System Info And Software Versions
Viewing System info and Software versions From the Supervisor menu, you can view the System info and Software versions. Proceed as follows: From the Supervisor menu, press the [System info] button. The System info menu opens. Here, the following information is shown: - Flex certificate - this option is used for OMR;... -
Page 54: What Are Licensed Options
What are licensed options? The Option menu shows the following information: • Chip ID • System ID • Installed options. These software options are enabled using license codes. These license codes, together with the identification number of the machine enable the relevant options. The enabled and available software options are displayed in this screen. -
Page 55: Test Menu
Use the keypad to enter the license key code that you received from the supplier to activate the relevant option on this machine. If needed, use the arrow keys to navigate through the entered characters. Press the [OK] button to add the licensed option. The system will now verify the license key. -
Page 56: Running Diagnostics
Running diagnostics To run a diagnostics of the system: In the Test menu, press the [Diagnostics] button. The Hardware test screen appears. Remove all documents and envelopes and close all covers before starting the diagnose. In the Hardware test menu, press the [Start diagnose] button. When the test is finished, the Status report is shown, showing a list of all problems found during diagnostics. -
Page 57: Reading
Reading Introduction The folding and inserting system can be equipped with reading. This allows the system to read special codes that have been printed on the documents. These codes contain information about the processing of the sheets. The following code type is available: •... -
Page 58: Adjusting The Reading Head Position
General requirements for printing codes If you print documents for reading: • Make sure the ribbon or toner quality is sufficient. • Print the code in black. • Marks on the same sheet must have equal intensity. • Print the code at the same position on every sheet. •... -
Page 59: Document Orientation
Divide the paper guides B along the width of the document. When the reading head is adjusted it is possible that paper guides have to be removed and placed on the other side of the reading head. Document Orientation Switch on the reading function and set the position of the reading marks as described in OMR Code Description on page 55. -
Page 60: Omr Code Description
OMR Code Description Position of the code on the document: Minimum line thickness of a mark: 0.2 mm (0.008 inch) Default the first mark from the top is set to: 100 mm (3.9 inch). This parameter is set in the job settings. - Page 61 OMR basic license For the OMR basic license the following functions are available: • Start mark: indicates the start of the code. • Insert/Accumulate: defines when a document set is complete and must be inserted into an envelope. • Parity check: by adding a parity mark the reading code can be checked. The sum of the marks must be even.
- Page 62 OMR advanced license For the OMR advanced license the following functions are available: • The basic functions (Start, Insert, Parity, Safety) • Divert - The machine stops, manually remove the set from the collator. Reset and start again. • Stop - The machine stops, manually remove the set from the collator. Reset and start again.
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Page 63: Running An Omr Test
An Example of OMR Code In the figure the legend for the following example is shown. In this example feeder station 3 is the reading feeder. The feeder stations 1 and 2 are selected for selective feeding. In this example, a set of 4 sheets with two selective feeds (station 2 and 1) and three sequence check marks is shown. - Page 64 In the Results screen, evaluate the test results. Use the button to see the OMR info. Press the [Back] button to return to the OMR test menu.
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Page 65: Operator Maintenance
Operator Maintenance Maintenance Schedule Disconnect the mains power supply before performing any maintenance. The user must not attempt to service the appliance beyond that described in this operator manual. All other servicing must be carried out by qualified service personnel only. Please contact your authorized distributor. -
Page 66: Clean And Replace Brushes
Clean and replace brushes When dirty or saturated, clean the brushes of the envelope sealing or replace them as follows: Moisten the new brushes in water. Remove the brushes one by one by pulling them down from the brush holder. Replace the brushes. -
Page 67: Clean The Exit Sensors
Clean the exit sensors To clean the exit sensors: Rotate a slightly moistened cotton swab in the lower hole, to clean the lower exit sensor. Rotate a slightly moistened cotton swab in the upper hole, to clean the upper exit sensor. -
Page 68: Fault Finding
Fault Finding Error Messages When an error occurs the display shows a screen showing the following information: • An indication of the area in which the error occurred • An error description • A suggested solution behind the pointing hand Press the button to view more information about the occurred error and about the possible actions to avoid the error from re-occurring. -
Page 69: Clearing Stoppages
Clearing Stoppages Stoppages can occur in the following areas: 1.Feed area Collating area 3.Fold area Lower envelope track... -
Page 70: Lower Envelope Track
For clearing of stoppages, three system sections can be opened: A - Top cover to reach the Fold and Feed area. B - Collator plate to reach the collator area. C - Front cover to reach the envelope track and inserter area. Lower Envelope Track When a stoppage occurs in the lower envelope track, remove the envelopes as follows: If needed, envelopes can be transported manually to the insert table or lower envelope... -
Page 71: Flexfeed
Close the side cover. Press the [Reset] button to reset the error and restart the job. FlexFeed When a stoppage occurs in the flexFeed, remove the documents from the flexFeed as follows: Open the top cover A by pulling up the handle. Remove the documents from the flexFeed area. -
Page 72: Powerfold
Remove the documents from the collator area. Move the collator plate B up in position. Press the [Reset] button to reset the error and restart the job. Fold When a stoppage occurs in the Fold area, remove the documents from the area as follows: Open the top cover A by pulling up the handle. -
Page 73: Trouble Shooting Table
Trouble Shooting Table Symptom Possible cause Remedy Reference The system cannot System not Connect the system be started after connected to mains. to the mains. switching on. Fuse is blown. Replace fuse below power switch. A cover is opened. Close the covers. System stops with Envelopes stacked Check envelope feed... - Page 74 Flap is wrinkled and Envelope not within Check specifications Verifying the Insert sometimes not specifications. and change Position on page 28 opened. envelopes if needed. Flap sticks. Store envelopes Verifying the Insert according to Position on page 28 specifications. Flap curled. Envelopes stored or Verifying the Insert manufactured...
- Page 75 Flap not sufficiently Water level low. Check water level, Filling the Sealing moistened. refill if needed. Liquid Reservoir page 19 Brushes dry. Check brushes, Maintenance replace if needed by Schedule on page the extra soaked set. Brushes dirty. Check brushes, clean Maintenance if needed.
- Page 76 Document set not Insert position not Check insert position. Verifying the Insert correctly inserted. correct. Position on page 28 Insert fingers not Check insert finger Adjusting the correctly positioned. position. envelope insert fingers on page 27 Address not readable Address position not Check address Adjusting the address from window...
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Page 77: Specifications
Specifications Technical Specifications 6204 eries Type Inserter system for medium office use. Theoretical max. speed 2000 inserts per hour, depending on application. Power consumption 100V AC / 50 Hz / 5.0 Amps. 115V AC / 60 Hz / 5.0 Amps. 230V AC / 50 Hz / 2.5 Amps. -
Page 78: Hopper And Feeder Capacity
Hopper and feeder capacity Envelope hopper 325 envelopes (80 g/m²) Document feeder tray 325 sheets (80 g/m²) Configuration Dimensions 1 station 1.5 stations 2 stations 2.5 stations Height 527 mm (20.7 527 mm (20.7 527 mm (20.7 637 mm (25.1 inch) inch) inch) - Page 79 Paper size Minimum width: 130 mm (5.1") Maximum width: 236 mm (9.3"), when folded max. 230 mm (9.1") Minimum length: 90 mm (3.5"), the minimum document length used for the upper feeder is 115 mm (4.5") Maximum length: 356 mm (14") Folding capacity max.
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Page 80: Envelope And Document Set Specifications
Envelope and Document Set Specifications Minimum 60 g/m2 160 mm 90 mm 32 mm 10 mm 130 mm 84 mm size 6.3” 3.5” 1.25” 0.4” 5.1" 3.3” Maximum 248 mm 162 mm B-32 35 mm A-12 ** 2.5 mm size* 9.7”... -
Page 81: Terminology
Terminology Terminology Term Description Address carrier The address carrier is the document that carries the address of the person for who the mail-set is meant. The address must remain visible while enclosures are added and the document-set is folded. The fold type and selected envelope must ensure that the address is visible behind the window in the envelope. - Page 82 C-fold Fold type in which a document-set is folded twice in which the folded flaps are on top of each other. This fold is illustrated in the picture below. The position of both folds is adjustable. Synonym: Letter fold. Clear The function of an inserting system in which all mail-sets in progress are finished and the document path is left empty.
- Page 83 Double V-fold The double V-fold is a type of fold where the document is first folded halfway and the resulting folded set is again folded halfway. This fold is illustrated in the picture below. The position of both folds is adjustable. Synonym: double parallel fold. Envelope The envelope is the packaging of a mail set.
- Page 84 Insert • An insert is the action of inserting a document-set into an envelope. • For native English speaking customers an insert is also a short, not to be folded document, usually an enclosure. Inserter An Inserter is the Module where the document-set is inserted into the envelope, the envelope is closed and if necessary sealed.
- Page 85 Reading error Condition in which the system could not reliably read or interpret the OMR reading marks or barcode from a sheet. Reading marks Marks added to documents containing finishing instructions that can be identified by a reading head and interpreted according to the used OMR code definition.
- Page 86 Z-fold A Z-fold means that a document is folded twice in such a way that each folded flap is on a different size of the folded document, resulting in a Z-shape. This fold is illustrated in the picture below. The position of both folds is adjustable. Synonyms: zigzag fold MyBinding.com 5500 NE Moore Court Hillsboro, OR 97124...
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Page 87: Ec Declaration Of Conformity
EC Declaration of Conformity EC Declaration of Conformity DS-63, M3300, FD6204 (According to Annex III B of the Low Voltage Directive) Manufacturer: Neopost Technologies BV Address: De Tijen 3, 9201 BX Drachten, The Netherlands, herewith declares that the: DS-63, M3300, FD6204 which this declaration refers to, is in accordance with: •... - Page 88 Note: this equipment has been tested and found to comply with the limits for class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment.
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Page 89: Index
Index MyBinding.com 5500 NE Moore Court Hillsboro, OR 97124 Toll Free: 1-800-944-4573 Local: 503-640-5920... - Page 90 Index Power 2, 4, 8, 60, 68, 72 Processing Mail 6, 12, 23, 24 Brushes 18, 19, 60, 61, 68 Rollers 60 Can 2, 6, 12, 13, 21, 22, 25, 29, 38, 39, 43, 46, 47, 52, 55, 64, 76, 82 Catch Tray 8, 11 Sensors 8, 60, 61, 62 Control Panel 9...
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