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Formax 6204 Series Maintenance Manual

Low-volume inserter
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See also: Operator's Manual
6204 Series
Low-Volume Inserter
MAINTENANCE MANUAL
6/2012

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Summary of Contents for Formax 6204 Series

  • Page 1 6204 Series Low-Volume Inserter MAINTENANCE MANUAL 6/2012...

  • Page 2: Table Of Contents

    Table of Contents Introduction ..........................1 Health, safety and environment ....................5 General description ........................8 User interface ...........................27 Transport, storage and installation ..................42 Mechanical description ......................51 Electrical description ......................138 Preventive maintenance .......................156 Fault Finding ..........................161 10 Upgrading and installing accessories ................196 11 Technical specifications .......................199 12 Parts lists ..........................208 13 Appendix ..........................289...

  • Page 4: Introduction

    Introduction Introduction ......................1 About this manual ................2 Abbreviations ..................2 Terminology ..................3...

  • Page 5: About This Manual

    About this manual Audience This manual is meant for service engineers. Symbols This manual uses the symbols listed below. WARNING : indicates a human safety hazard. ATTENTION : brings to your attention a risk for equipment or mail that could result froman action you may perform.

  • Page 6: Terminology

    Terminology Term Description Double Feed Control (DFC) Double Feed Control is the sensor that measures the thickness of a sheet to check if the inserting system does not accidentally take more sheets than intended. DFC sensors exist on Feeders (double sheet de- tection).

  • Page 8: Health, Safety And Environment

    Health, safety and environment Health, safety and environment ................5 Safety ....................6 Symbols on the system ..............6 End of Life ..................7...

  • Page 9: Safety

    Safety Warnings • Disconnect the power supply before performing any maintenance. • Before connecting the system to the electrical supply, Ensure that the system is suitable for the local mains voltage. Refer to the serial plate on your system for voltage requirements. Safety Precautions •...
  • Page 10 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: General Description

    General description General description ...................8 The system ..................9 Denominations ..................9 Paper flow ..................10 Process description .................11 Electronics ..................20 Optional features ................25...

  • Page 12: The System

    The system The system feeds, folds and inserts documents into envelopes and then seals and stacks the envelopes. The system is equipped with a variety of special features as programmable jobs, Automatic jobs, flexFeed, double feed control, hopper swap, multifeed, daily mail and powerFold. Denominations A - Envelope catch tray K - Sensors...

  • Page 13: Paper Flow

    Paper flow The figure shows an overview of the system. The documents are vertically transported from the document feeder(s) (1) to the collator (2). When the required documents are collected, the document pile is transported horizontally to the document folder (3). After folding, the documents are inserted into an envelope by the inserter (5).

  • Page 14: Process Description

    Process description The processing of documents by the system can be divided into a number of distinct sequential partial processes. These processes will be discussed in some more detail: • Document feeding • Document transport • Collating the document set •...
  • Page 15 General Description Main motor. Provides the primary mechanical drive for the feeder clutches CL1 – CL3, the folder clutches CL4 – CL7 and the envelope track clutch CL8. Directly drives the vertical track transport (75, 68, 61, 45) and the inserter main drive (15, 17, 19, 20, 22, 23). If the upper unit is in place, items 14, 16, 24 and 26) are driven as well.
  • Page 16 Feeders Description Lower feeder (1) Feeder photocell. Driven output rollers. Counter rollers for 63. Lower separation roller. Feed axle with upper separation roller. Paper puller axle with two rubber rollers. DFC1 Document thickness measuring unit. Middle feeder (2) Feeder photocell. Driven output rollers.
  • Page 17 Vertical track Description Counter roller of 45 (in the upper unit). Driven vertical transport axle. On this axle the folding reverse clutch CL5 is mounted (at the RH side of the machine). This clutch drives 42, 43, 35, 36, 27 and 28 in the reverse direction during the second stage of a long shunt.
  • Page 18 Fold unit Description Folder input photocell. Lower fold input roller. On this axle on the RH side the folding forward clutch CL4 is mounted. This clutch drives 42, 43, 35, 36, 27 and 28. Operational during the fold process and during the first stage of a long shunt.
  • Page 19 Envelope feeding Description Envelope track clutch. Mounted on clutch shaft, at the RH side of the machine. On this shaft two gears take care for the mechanical interface between the permanently M2 driven sub- system and the envelope track subsystem. CL8 drives 1, 4, 6, 8, 10 and 11. Feed roller.
  • Page 20 Drive rollers for future use. PH10 Exit photocell. Document feeding The system has feeders with automatic separation. For the documents to be fed the following rules apply: • Documents with the fold types single fold, letter fold, and double parallel fold must be fed with the orientation face up and leading.
  • Page 21 The collating area • The collating area consists of a set of rollers (46, 50, 53, 56 and 60) that can be driven in both directions by the collator motor (M1), and a set of counter rollers (47, 48, 49, 52, 54, 55 and 58). •...
  • Page 22 Second fold • After leaving the fold rollers (35 and 36), the paper enters the second fold table. The flap (34) moves up. Paper that enters the second fold table will be directed in upward direction. • The paper guide (33) also moves up. This guide is necessary in the second fold table to retain the fold that has been made in the first fold table.

  • Page 23: Electronics

    Inserting process • Once the envelope is on the insert table, the fingers solenoid (So1) is activated. The fingers are moved forward into the envelope. The envelope stays in place, it is fixed between the two rollers (11 and 12). •...
  • Page 24 ID-tag Contains information (serial number, encrypted machine options, encrypted total counter) See section “Electrical description on page 138” for the location of the PCBs in the system. The regular connection board only provides connection to USB. The expanded connection board also provides connection to RS232 and the phone line.
  • Page 25 Schematic overview The electronics and the wiring between the boards in the 075.1 can be summarized in a schematic overview. For a device without communication board: For a device with communication board:...
  • Page 26 Connection with PC (Concorde application) If you want to upgrade the inserter software or backup information from the inserter, the inserter can be connected to a PC. Special software has to be installed on the PC to enable communication between the USB port of the PC and the machine.
  • Page 27 In this schedule, number 1 to 5 can be described by: Normal situation If either FRAM or TAG has been disconnected, the latest counter can be used. Replacement of PCB or replacement of both the ID-Tag and PCB. PCB replacement (Tag OK). PCB and ID-Tag replacement (new ID-Tag) if incorrect Tag is installed, software controlled options and connectivity will not function correctly.

  • Page 28: Optional Features

    The following information is stored on the ID-tag: • Serial number of the machine. • Encrypted machine options. • Total insert counter (kept up to date when the inserter is running). Software package compatibility check For all systems with (optionally) multiple boards and software versions, NTBV will release packages that contain the supported software versions of each board.
  • Page 29 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 receiving tray which is delivered with the side exit.

  • Page 30: User Interface

    User interface User interface ....................27 Operator menus ................28 Job and supervisor menus ...............28 Service menu ...................28...

  • Page 31: Operator Menus

    Operator menus For an explanation of the Operator menus, see the Operator Manual. Job and supervisor menus For an explanation of the Job menu and Supervisor menu, see the Operator Manual. Service menu See the following flowchart for an overview of the various menus:...
  • Page 32 System settings Power up In this menu you select if you want to display the language menu after you switch on the system. Folder offset Two timed cams discs are used for the folding process. There is one cam disc for each folding table. The timing is determined by the length of the sheets to be folded.
  • Page 33 Reset data There may be situations in which it is necessary to restore the system settings to their states at the beginning of the system’s operational life. To this purpose the menu item Reset Data is present. Make sure all paper is removed from the machine, before you start Reset data. This is necessary because the data resetting includes readjusting of the photocells.
  • Page 34 BRE offset If a document is longer than the set address fold but shorter than the envelope height, this document sometimes will be unnecessarily folded. Under certain conditions this document can be prevented from being folded. This can be implemented with the menu “BRE offset” (BRE means Business Reply Envelope). For each of the jobs 1 through 15 and Automatic, an offset can be switched on or off using the arrow button.
  • Page 35 Service tests Photocells This machine uses so-called intelligent photocells. The currents of the photocell transmitters are adjusted in such a way that the no-paper output voltage of the photocell receiver is within a certain voltage range of the photocell receiver. In this way, a reasonable amount of dust on the photocell sensors can be compensated for.
  • Page 36 Digital inputs The digital input screens show: • The status of the three safety switches: MS1 (collator switch), MS2 (front switch) and MS3 (loc switch) The status is real time: a change is reflected in the displayed status. This allows you to easily check the correct operation of the three microswitches.
  • Page 37 After pressing the Start/Stop key, the run in test will start/stop. The machine stops automatically if the counter value is zero. If some covers are removed (but not the safety covers!), you can watch the sequence of the various mechanical actions, which reflect the sequence of events during normal operation.
  • Page 38 Service counters This menu allows you to read, set, or reset the service counters: • The "since last visit" counter can be reset to zero. • The "since installation" counter can be displayed. • The "next visit after" counter can be: - incremented in 5000 steps to a maximum value of 6.000.000 steps.
  • Page 39 Marks Value Description License Start mark Start mark Basic, advanced No start mark Basic, advanced Insert on Mark Insert on mark and Accu- Basic, advanced mulate on space Space Accumulate on mark and Basic, advanced Insert on space Parity check Parity check, based on an Basic, advanced even parity mark...
  • Page 40 Marks Value Description License Gate mark Not selectable, always on Basic, Advanced Insert on Not selectable, always on Basic, Advanced (insert on mark) Selective feed insert Selective feed on station 1 Advanced No selective feed on sta- Advanced tion 1 Selective feed 2 Selective feed on station 2 advanced...
  • Page 41 Read direction Reading direction is re- Advanced versed Normal reading direction Advanced Parity check Parity check, based on an Advanced even parity mark No parity check Advanced Unseal Mark is no sealing, space Advanced is sealing No sealing control Advanced...
  • Page 42 OMR code test Use this menu to test the OMR reading head (RH1) and, if necessary, to readjust the relevant OMR electronics. 1. Select “Adjust” to start testing the reading head. The settings of the current job are used for this test. This implies that an OMR job must be selected, otherwise the text “Select a job with OMR”...
  • Page 43 Diagnostics Start test This test checks if all motors, clutches and sensors are correctly connected. The system test derives the status of the actuators and clutches by briefly activating the actuators and then measuring the current. Error counters In the Error counters menu a list is given of the top 40 occurred errors. The errors are sorted based on quantity. That means that the errors occurring most frequent are in the top of the list.
  • Page 44 Remove blockage During system start-up, the serial number stored on the main board is compared to the original serial number in the ID-tag. After a main board or ID-tag has been replaced, the machine may have lost it's identity, backup counter, and enabled features.

  • Page 45: Transport, Storage And Installation

    Transport, storage and installation Transport, storage and installation ..............42 Transport ..................43 Storage ....................43 Unpacking Instructions ..............43 Installation ..................46 Test the System and Define Custom Jobs ........49...

  • Page 46: Transport

    Transport The system, including all accessories, is transported in one box. The box is attached onto a pallet. Handle the package with care. DANGER: • Do not turn the box on its side. • Prevent the box from falling over. •...

  • Page 49: Installation

    Your inserter is unpacked and installed on a stable surface. The following items are delivered with your system: • Operator Manual and this Installation Guide • Power cable, brushes and moistening cloth • A bottle with sealing liquid Make sure that the indicated parts are available. Make sure that the system is suitable for the local mains voltage.
  • Page 50 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. Installing the side exit and the catch tray (option) Remove the envelope catch tray and the slide Hook in the side exit...
  • Page 51 Open the front cover A. 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. For instructions on the installation of brushes, see Clean and replace brushes (User Guide).

  • Page 52: Test The System And Define Custom Jobs

    To connect to the central server: Press [Connection], [Connect] for the initial declaration call. Press the [i] button to follow the status of the connection.The initial declaration call is finished if the System status shows "Pending declaration". Press [Connect] again for declaration. Press the [i] button to follow the status of the connection.
  • Page 53 Make sure that the folds are in the correct position. If not correct, adjust the folder offset (service menu, [System settings], [Folder offset]). Make sure that the flap closer quality is sufficient. If not correct, adjust the flap closer offset (service menu, [System settings], [Flap closer offset]).

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