Formax 6404 Series Operator's Manual
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Formax 6404 Series Operator's Manual

Mid-volume inserter
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  • Page 1 Formax 6404 Series Folder and Inserter Instruction Manual...
  • Page 2 6404 Series Mid-Volume Inserter MyBinding.com 5500 NE Moore Court OPERATOR MANUAL Hillsboro, OR 97124 Toll Free: 1-800-944-4573 Local: 503-640-5920 2/2012...

  • Page 3: Table Of Contents

    Table of Contents Read this Fir st ....................1 Warning......................1 About this man ual....................1 Safety.......................2 Country Specific Conditions................3 End of Life......................4 Meet your Document System ..............5 Overview......................5 Operating Controls...................8 Control Panel....................9 Installing the Document Feed Trays...............10 High Capacity Vertical Stacker...............11 Power Up......................11 Home Menu....................12 Job Info......................13 Side Guides....................15...
  • Page 4 Installing the HCDF..................25 Adjusting the HCDF Side Guides..............25 Document Separation for the HCDF..............26 Feeding documents (HCDF)................26 Conveyor Stacker...................27 Side Exit......................27 insert'n Frank / insert'n Mail ................28 Mail Piece Production Control................28 Processing Mail Sets .................29 Introduction....................29 Processing a Basic Mail Set ................30 Processing a Mail Set with BRE or Inser ts............31 Document Separation..................32 Adjustment of the Document Stoppers ............33...
  • Page 5 Reading settings (option)................52 Double feed control settings................55 Job name.......................56 Mailing/Franking settings (option) ..............57 Mail Piece Production Control settings (option) ..........58 Advanced Settings ..................59 What are Advanced Setting?.................59 Opening the Advanced Settings..............60 Changing the Display Settings...............60 Viewing System info and Software versions..........61 What are licensed options?................62 Activating an option..................62 Test Menu.......................63...
  • Page 6 Connecting to the server................83 Viewing the history..................83 Viewing messages..................84 Installing a new job or new software..............85 Configuration Menu..................86 Changing the telephone number..............87 Changing the prefix..................87 Selecting the countr y..................88 Entering date and time...................88 Setting the dial tone detection................89 Setting the modem v olume................89 Operator Maintenance ................90 Maintenance Schedule..................90 Clean and replace br ushes................91...
  • Page 7 Configuration Dimensions................106 Document and Inser t Specifications............106 Envelope and Document Set Specifications ..........107 maxiFeeder Specifications................108 High Capacity Vertical Stacker Specifications..........109 12 Terminology ....................110 Terminology....................110 13 EC Declaration of Conformity ..............116 EC Declaration of Conformity DS-85, M8500, FPi 5600, FD6404....116 EC Declaration of Conformity HCVS-1............117 EC Declaration of Conformity MF-1.............118 MyBinding.com 5500 NE Moore Court...
  • Page 8 MyBinding.com 5500 NE Moore Court Hillsboro, OR 97124 Toll Free: 1-800-944-4573 Local: 503-640-5920...

  • Page 9: Read This First

    Read this First Warning Ensure you have read and fully understood the saf e ty requirements in this section. About this manual Languages According to the EC (European Commission) declar a tion 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 10: 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 11: Country Specific Conditions

    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.

  • Page 12: 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 13: 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 14 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 (Tower) (1) This is the feeding part of the system.There are two types of feeders: the automatic and the special feeder.
  • Page 15 Folding unit (4) The fold unit folds the documents. The following fold types are possible (see Terminology on page 110): • No fold • V-fold • C-fold • Z-fold • Double V-fold Envelope feeder (5) Envelopes that are placed on a stack by the user, are fed one by one into the system by the envelope feeder.

  • Page 16: Operating Controls

    Operating Controls A - High Capacity Vertical Stacker M - locking handle Folding unit B - loc cover N - handle for manual transport of the enve- lope C - unlocking lever for loc O - air plugs for cleaning the sensors D - power inlet, power switch P - handle for manual transport of the mail E - inserter cover...

  • Page 17: Control Panel

    Control Panel The control panel consists of the touch screen and the following buttons: A: On/Off ( ): Switches the system on or off. If the system is not used for one hour, the system switches to the power save mode. Press the On/Off button to switch back to the user mode.

  • Page 18: 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 black rollers. Move the document feed tray upwards (lifting the black rollers), until it is possible to ‘hook’...

  • Page 19: High Capacity Vertical Stacker

    High Capacity Vertical Stacker The High Capacity Vertical Stacker can be used to stack filled envelopes. The vertical stacker can store up to 325 filled envelopes. The vertical stacker can be equipped with Mail Piece Production Control (MPPC). In case you have a High Capacity Vertical Stacker, install it as follows on your system: Move the stacker as indicated by the arrow.

  • Page 20: Home Menu

    Use the power switch to switch the system on. The power switch is located on the back of the system. Press the on/off button next to the display. (Only necessary when the system is in standby mode.) The touch screen shows the home menu. Home Menu When you start up the system, the ‘home’...

  • Page 21: 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 22 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.

  • Page 23: 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 24: Document Orientation

    Document Orientation In case the optional extended powerFold is installed, the following feeding rules apply to documents with bottom address position:...

  • Page 25: Filling The Document Feeder Tray

    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. Feed the documents (depending on the type of documents and the type of fold) (see Document Orientation on page 16).
  • Page 26 Move the side guides towards the envelopes. The space between the side guides and the envelopes should be such that the envelopes have just enough play to move freely. If the distance between the side guides is too large, the envelopes will twist sidewards, when transported into the machine.

  • Page 27: Sealing Envelopes

    Sealing Envelopes Switch the envelope sealing on or off: Lift the handgrip to open the top cover. 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, w ait approximately 5 minutes for the brushes to moisten or use moistened brushes.

  • Page 28: Filling The Sealing Liquid Reservoir

    Filling the Sealing Liquid Reservoir Open the front cover A. Fill the reservoir B to the "Max" lip with sealing liquid. Close the front cover A. Before starting the job, wait approximately 5 minutes for the brushes to moisten or use moistened brushes.

  • Page 29: Options

    Options Production Feeder The production feeder is a feeder that can be loaded with a high number of documents. This feeder is intended to be used for Business Reply Envelopes (BRE), but also 'standard' documents up to 356 mm (14") length can be processed with it. Installing the Production Feeder The production feeder should be installed at the position of feeder no.

  • Page 30: Adjusting The Side Guides

    Adjusting the Production Feeder Side Guides Adjust the side guides: Take a stack of documents/BREs and place them in the feeder tray. BREs with flap down and leading (top side pointing to system). Adjust the side guides by turning the thumb wheel A so the documents/BREs just fit and can move without resistance.

  • Page 31: Adjusting The Document Separation

    Adjusting the Production Feeder Document Separation When the production feeder is used at an automatic separation feeder, the separation is set automatically. It can also be used on a feeder position with a manually adjusted separation. To adjust, proceed as follows: Remove the document feeder trays 2 and 3.

  • Page 32: Feeding Documents With Production Feeder

    Feeding documents (Production Feeder) To feed documents: When filling the production feeder, make sure that the document/BREs are positioned parallel in relation to the feed plate to ensure correct feeding. The feeding plate assembly will be shifted up automatically (when the system starts processing) until documents/BREs are underneath the rubber paper pullers.

  • Page 33: Installing The Hcdf

    Installing the HCDF To install the feeder tray of the HCDF: Pull down lever A. Hook in the feeder tray. Release lever A. Adjusting the HCDF Side Guides To adjust the side guides B: Loosen the knob D half a turn. Put a small stack of documents between the side guides.

  • Page 34: Document Separation For The Hcdf

    Rotate wheel E. The space between the side guides and the documents should be such that the documents have just enough play to move freely. Re-tighten knob D. Document Separation for the HCDF The document separation is set automatically. There are no manual adjustments needed. Feeding documents (HCDF) To fill the document feeder tray: Pull down lever A.

  • Page 35: Conveyor Stacker

    Conveyor Stacker In case you have a conveyor stacker, install it as follows on your system: Position the fork in a forward direction. Move the conveyor as indicated by the arrows. Lift the conveyor with the suspension hooks over the two rods (upper and lower) and lower it.

  • Page 36: Insert'n Frank / Insert'n Mail

    insert'n Frank / insert'n Mail If this system is connected to a mailing/fr a nking system, insert'n Frank / insert'n Mail allows you to: • Switch automatic mailing/franking on or off • Remotely select a mailing/franking job • Set the printing/franking value (option) •...

  • Page 37: 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 38: 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 29. From the home menu, press the [New job] button.

  • Page 39: 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 29.

  • Page 40: 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 pulling 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.

  • Page 41: Adjustment Of The Document Stoppers

    Adjustment of the Document Stoppers The document stoppers mark the position at which the documents coming from the f e eder turn towards the folding area. The position of the document stoppers is automatically determined by the system during the job programming. Initially the document stoppers are adjusted for position B.

  • Page 42: Processing Daily Mail

    Processing Daily Mail The daily mail function is only available when reading is not activated. When daily mail is set, the links to the daily mail feeder will be deselected automatically. When the daily mail function is selected DFC is not available. To process documents or sets of documents, which can not be processed automatically (e.g.

  • Page 43: Test Run

    When finished with Daily Mail, press the [stop] button to stop the job. Set the Daily Mail handle B to the ‘AUTO’ position to disable the Daily Mail and enab le the automatic document separation. Test Run Before starting an Automatic job, it is possible to perform a single test run. This test run is intended to validate the settings of the Inserting System: •...

  • Page 44: Adjusting The Envelope Insert Fingers

    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 45: 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 C. To verify the insert position: This adjustment must only be checked in case of prob lems or when changing the envelope type.

  • Page 46: 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 47 Press [Manual] to create a new job. For [Automatic], see Processing a basic mail set on page 30. Enter the pin code 2546. Press [OK] to confirm the selected free job number. A new selected job number starts with default settings. The job settings menu opens.

  • Page 48: Performing A Test Run

    Press [Save] to save the job with the entered settings under the specified job n umber and name. To name a job, see Job name settings on page 56. Press the [1x] button to verify that the insert position and address position are correct (see Verifying the Insert Position on page 37 and...

  • Page 49: Adjusting The Envelope Position

    Press the button if you want to adjust the envelope position before running the test run (see Adjusting the Envelope Position on page 41). Press the [1x] button to perform the test run. 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 50: Using A Job

    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. If you want to change the counter for this job: Press the [Counters] button to make changes to the amount of mail sets that the job produces.

  • Page 51: Copying A Job

    Enter the pin code 2546. The job settings menu opens. See Job settings on page 46 for the meaning of all buttons and settings. Press [Save] to save the job with the entered settings under the specified job n umber and name.
  • Page 52 Press the [Job] menu button. The job menu opens. Press the [Copy job] button. The copy job menu appears. 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.

  • Page 53: Deleting A Job

    Deleting a job To delete an existing 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 [Delete job] button. The delete job menu appears. When you press [OK], the job is deleted without a warning.

  • Page 54: Job Settings

    Select a job number and press [OK]. Job settings From the job settings menu the following settings are available: • Envelope settings (see Envelope settings on page 46); • Document settings (see Document settings on page 48); • Fold settings (see Fold settings on page 50);...
  • Page 55 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. This means that the envelopes are fed with closed flap. Use the button to enter the applicable dimensions.

  • Page 56: 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 57 • 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.

  • Page 58: Fold Settings

    When a feeder is selected for reading, the feeder below can not be linked to this reading feeder. The reading feeder can be linked to a feeder above when it is not selected for selective feeding. • 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...
  • Page 59 Select the fold type. The following choices are available for top address: • No fold (no settings required) • V-fold • C-fold • Double V-fold • Z-fold For Bottom address only three fold types are possible. Except when no fold is required, the touch screen sho ws a simple diagram of the document with the fold positions.

  • Page 60: Reading Settings (Option)

    The touch screen will indicate when entered positions are out of range. Reading settings (option) For a full function description of reading, see Reading Introduction on page 70. In the ‘reading settings’ menu it is possible to enable or disable the Optical Mark Recognition (OMR) or Barcode Reading (BCR) function and to adjust the basic settings .
  • Page 61 Code type: default is the setting ‘none’: reading is disabled. • Change the setting with the button. The following codes are possible: - 1-track OMR - BCR for reading barcodes - Flex 1-9 for reading customer specific codes (only if flex dongle is installed) •...
  • Page 62 • Stop on misread: define if the system should stop or not when a code is misread. In case of “yes”, the system stops after a misread. The incorrect set is diverted. After resetting the system, the final part of the set is also diverted and the system starts processing again.

  • Page 63: 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 64: 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 65: Mailing/Franking Settings (Option)

    Mailing/Franking settings (option) If this machine is connected to a mailing/franking machine, this option allows you to select the franking mode. Use the button to choose between: • Pass through: franking off • Franking: the mailing (franking) system will print/frank the envelopes according to the local mailing (franking) system settings.

  • Page 66: Mail Piece Production Control Settings (Option)

    Mail Piece Production Control settings (option) For Mail Piece Production Control settings, see the appendix operator manual Mail Piece Production Control.

  • Page 67: Advanced Settings

    Advanced Settings What are Advanced Settings? 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 60);...

  • Page 68: Opening The Advanced Settings

    • System info (see Viewing System info and Software versions); • Options (see Activating an option on page 62); • Test (see Test menu on page 63); • Online Services (see Start-up Online Services on page 82); • Job menu (see What is a job on page 38);...

  • Page 69: Viewing System Info And Software Versions

    Use the arrows next to the volume symbol to increase or decrease the interface volume. Press the button to toggle the orientation of the display screen. This function is useful in case of applications when the operator is working on the backside of the system.

  • Page 70: 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 71: 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 72: 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 73: Job Settings (Supervisor)

    Job Settings (Supervisor) Job settings normally will be changed by a service engineer only. Therefore first consult the supplier’ s Helpdesk before changing any settings. Changes to the job settings can result in malfunctioning of jobs. The "job settings" menu (supervisor) can be opened from the "super visor menu". From this menu system parameters can be set.

  • Page 74: Flap Closer Offset

    Flap Closer Offset To change the flap closer offset for a selected job: Use the arrows next to "Select job" to select f o r which job (Job 1-25 or A uto) you want to make the changes. Use the arrows next to "Flap Closer offset" to change the Flap closer offset for the selected job.

  • Page 75: System Output

    System Output To change the output mode for a selected job: Use the arrows next to "Select job" to select f o r which job (Job 1-25 or A uto) you want to make the changes. Use the next to Output to change the Output mode for the selected job. Mode 1 focuses on the versatility of paper parameters (paper thickness;...

  • Page 76: Changing Document Offset

    Changing Document Offset To change the document offset for a selected job: Use the arrows next to "Select job" to select f o r which job (Job 1-25 or A uto) you want to make the changes. Use the arrows next to "Document offset" to change the Document offset for the selected job.
  • Page 77 Use the button next to BRE with window to set the BRE offset to On of Off. If a document is longer than the set address f old but shorter than the envelope height, this document sometimes will be unnecessarily folded. Under certain conditions this document can be prevented from being folded.

  • Page 78: 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. Three types of codes are available: •...

  • Page 79: Reverse Reading

    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. • Codes on the same sheet must have equal intensity. • Print the code at the same position on every sheet. •...

  • Page 80: Document Orientation

    Document Orientation Switch on the reading function and set the position of the reading marks as described in BCR Code Description on page 73 and OMR Code Description on page 77. Document orientation:...

  • Page 81: Bcr Code Description

    BCR Code Description Position of the code on the document. Minimum line thickness of a bar: 0.25 mm (0.01 inch) The thickness ratio of thick bars versus thin bars: 2.2 The white area in the picture shows the limits where the code can be printed. BCR license types There are two BCR license types: •...

  • Page 82: Reading A Configuration Sheet (Bcr Only)

    BCR basic license For the BCR basic license the following functions are available: • Page N of M: as long as N is below M, the document set is not complete. As soon as N=M, the set is complete and will be inserted into an envelope. •...
  • Page 83 Press the [Run sheet] button.The BCR settings screen appears. In the BCR settings screen, confirm that all settings are read correctly. Note that this screen consists of tw o parts. Use the arrows at the bottom of the screen to navigate between the two parts of this screen. Press the [Back] button to leave the BCR settings menu.

  • Page 84: Running A Bcr Test

    Running a BCR test To run a BCR test: Before running a BCR test, select a job that uses BCR reading. In the Test menu, press the [BCR test] button. The BCR test menu appears. Press the [Test] button to start the BCR test. After the test is finished, the Result screen appears.

  • Page 85: 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 86 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 87 OMR advanced license For the OMR advanced license the following functions are available: • The basic functions (Start, Insert, Parity, Safety) • Divert (Divert & Continue) - The set will be diverted and the system continues. • Stop (Divert & Stop) - The set will be diverted and the system stops indicating error (VS:113 - Reading stop - Stop mark read).

  • Page 88: Running An Omr Test

    An Example of OMR Code In the figure the legend for the following example is shown. In this example, a set of 8 sheets with one selective feed and three sequence check marks is shown. • The first position is used for the start mark which must be printed on every sheet. •...
  • Page 89 Press the [Test] button to start the OMR test. After the test is finished, the Result screen appears. 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.

  • Page 90: Online Services

    Online Services Online Services The folding and inserting system can be equipped with Online Ser v ices. This option enables the system to connect to a central server. During the connection data is downloaded to and uploaded from the system.The system always initiates the connection, it is not possib le to make a connection from outside to the system.

  • Page 91: Connecting To The Server

    Connecting to the server The system makes a connection on fixed times. It is possible that you manually connect the system to the server. To connect to the server: Press [Connection] in the Online Services menu. The touch screen shows the connection menu.

  • Page 92: Viewing Messages

    Press the button to view details on selected previous connection. Viewing messages After pressing Messages in the ‘Online Services’ menu the touch screen will sho w messages received from the server. A message has content like a new job or new software. To view the messages: Press the arrows to select a message.

  • Page 93: Installing A New Job Or New Software

    Installing a new job or new software After pressing Messages in the ‘Online Services’ menu the touch screen will sho w messages received from the server. In case a new job or new software can be installed the Continue button appears. To install a new job or new software: Press [Continue].The new job available menu or new software menu appears.

  • Page 94: Configuration Menu

    In case of a new job: Press the arrows to select a free job number (see Creating a new job on page 38). Press [OK] to confirm the selected job number or press Cancel to return to the ‘new job available’ menu. In case of new software: Press [OK] to confirm the installation or [Cancel] to return to the new software menu.

  • Page 95: Changing The Telephone Number

    Changing the telephone number To change the number: Press the button next to the telephone number. Enter the correct number using the numeric keypad. Press [OK] to confirm the new number. Press [OK] to confirm the modified settings and leave the Configuration Menu. Changing the prefix To change the prefix: Press the...

  • Page 96: Selecting The Country

    Selecting the country To select a country from where you are dialing: Use the up and down arrows to select the country from where you are dialing. Press [OK] to confirm the modified settings and leave the Configuration Menu. Entering date and time To enter the current date and time: Press the button next to the date/time.

  • Page 97: Setting The Dial Tone Detection

    Setting the dial tone detection To toggle the dial tone detection: Press the button next to dialtone detection to toggle the dial tone detection on/off . Press [OK] to confirm the modified settings and leave the Configuration Menu. Setting the modem volume To set the modem volume: Press the button next to the volume symbol to increase/decrease the modem...

  • Page 98: 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 99: 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 100: Clean The Sensors On The Envelope Or Document Path

    Clean the sensors on the envelope or document path When the display warns about dusty sensors in the en velope or document path, clean them as follows: Open side cover A. Place bellows B in the upper air plug C and firmly squeeze a few times to blow the dust from the document path sensor.

  • Page 101: Resetting Photocells

    Rotate a slightly moistened cotton swab in the upper hole, to clean the upper exit sensor. Calibrate the photocells (see Resetting photocells on page 93). Resetting Photocells To calibrate all photocells: In the Test menu, press the [Reset photocells] button.The Calibrate photocells menu appears.

  • Page 102: 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 103: Clearing Stoppages

    Clearing Stoppages Stoppages can occur in the following areas: Feeding area Collating area Folding area Lower envelope track Moistening and inserting area Sealing and exit area Envelope hopper MyBinding.com 5500 NE Moore Court Hillsboro, OR 97124 Toll Free: 1-800-944-4573 Local: 503-640-5920...
  • Page 104 For clearing of stoppages, six system sections can be opened: A - loc cover, to reach the sealing and exit area B - inserter cover, to reach the moistening and inserting area C - collator arm, to reach the collating area D - vertical transport cover, to reach the vertical transport and feeding area E - Folding aread cover, to reach the folding area F - side cover, to reach the lower envelope track...

  • Page 105: Exit, Sealing And Inserting Area

    Exit, Sealing and Inserting Area When a stoppage occurs in this area, remove the material as follows: Open the side cover F. Lift the locking lever of the loc and pull the loc up into the vertical position. Remove all material. Close the side cover.

  • Page 106: Envelope Hopper

    Envelope Hopper When an envelope gets stuck in this area, remove the envelope as follows: Pull down small lever B. Pins C will come down. Push lever A to the right and hold it. Pins C will go up. Remove the stuck envelope. Release lever A.

  • Page 107: Powerfold

    Remove the envelope(s) from the lower envelope track. Close the side cover. Press the [Reset] button to reset the error and restart the job. Folding Area When a stoppage occurs in the Folding area, remove the documents as follows: Push the lower end of the locking handle A to open the powerFold cover B. Remove the documents from the Folding area.

  • Page 108: Flexfeed

    Feed Tower When a stoppage occurs in the Feed Tower, remove the documents as follows: Pull the vertical transport hand grip A upward to open the vertical transport cover B. Remove the documents. Close the vertical transport cover B. Press the [Reset] button to reset the error and restart the job. Collating Area When a stoppage occurs in the collating area, remove the documents from the collating area as follows:...

  • Page 109: Operator Troubleshooting

    Lower the collator arm. Press the [Reset] button to reset the error and restart the job. Operator Troubleshooting To resolve problems: Write down the error. Try to solve the problem by consulting the troubleshooting table. Switch the inserter off and on again, to verify system operation. When the error still occurs contact your service organization.
  • Page 110 Envelopes are double Envelope separation Adjust envelope sepa- Loading Envelopes fed. not correctly set. ration. on page 17 Envelopes not placed Check and replace if Loading Envelopes properly in the hop- needed. on page 17 per. Envelope stops Side guides of the Check side guides Loading Envelopes skewed.
  • Page 111 System stops while Fingers not correctly Check fingers posi- Adjusting the enve- inserting (stoppage at adjusted. tion, adjust if needed. lope insert fingers the inserting point). on page 36 Inserted document Check fold settings. Fold settings too long for used en- page 50 velope.
  • Page 112 No document fed. Feeder empty. Refill feeder. Filling the document feeder tray on page Separation set too Adjust the separation. Adjusting Document wide / too tight. Separation on page Side guides set too Adjust the side Adjusting the side narrow. guides.

  • Page 113: Specifications

    Specifications Technical Specifications Model DS-85, M8500, FPi 5600, FD6404 Type Inserter system for medium office use. Theoretical max. speed 4000 inserts per hour, depending on appli- cation. Power consumption 100V AC/50Hz/3.0 Amps. 115V AC/50/60Hz/3.0 Amps. 230V AC/50Hz/1.5 Amps. Voltage tolerance 100V: +6% / -10% 115V: +6% / -10% 230V: +10% / -10%...

  • Page 114: Hopper And Feeder Capacity

    Hopper and feeder capacity Envelope hopper 325 envelopes (80 g/m²) Document feeder tray 325 sheets (80 g/m²) High Capacity Document Feeder tray 725 sheets (80 g/m²) Configuration Dimensions 2 stations 3/4 stations 5/6 stations Height 570 mm (22.4 inch) 745 mm (29.3 inch) 920 mm (36.2 inch) Width 420 mm (16.5 inch)

  • Page 115: Envelope And Document Set Specifications

    Folding capacity V-fold - 10 sheets (max. 80 g/m²) C-fold/Z-fold - 8 sheets (max. 80 g/m²) Double V-fold - 4 sheets (max. 80 g/m²) Envelope sizes Standard BRE (Business Reply En velopes) Envelope quality Minimum 80 g/m² (20 lb bond) Maximum 120 g/m²...

  • Page 116: Maxifeeder Specifications

    Remarks: • The specification of the paper handling equipment is often wider than that of the envelopes and documents handled. The condition of material handled will limit the specified environmental conditions. • We recommend that materials to be handled are stored at a temperature of 20°C (68°F) with a relative humidity factor of 50%.

  • Page 117: High Capacity Vertical Stacker Specifications

    Document / BRE insert specifications Document Specifications on page 106 and Envelope Specifications on page 107. High Capacity Vertical Stacker Specifications Model HCVS-1 Type High Capacity Vertical Stacker. Suitable for all kinds of mail sets that consist of at least one 80 grams envelope and one folded document (80 gram).

  • Page 118: 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 be- hind the window in the envelope.
  • Page 119 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 120 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 121 Flexcode OMR An OMR code for which the meaning of the OMR marks can be pro- grammed in a dedicated way for a specific customer. This is normally used to support the OMR codes from other suppliers. The feeding part of the system.eeding area High Capacity Optional feeder with a capacity for up to 725 sheets.
  • Page 122 Optical Mark Recognition OMR code Standard 1-track OMR code definition. Specifies the amount of reading definition marks used and the functionality linked to each of them (how each should be interpreted). Online Services The ability to connect the system to a central server for updates and (OLS) other communication.
  • Page 123 V-fold A V-fold implies the document/set is folded once. The fold-position is adjustable. This fold is illustrated in the picture below: Synonym: Single fold. versaFeeder Booklet feeding device. Vertical transport The vertical transport section between feeders and collator. Z-fold A Z-fold means that a document is f o lded twice in such a way that each folded flap is on a different size of the folded document, resulting in a Z-shape.

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