1. Manuals
  2. Brands
  3. Formax Manuals
  4. Folding Machines
  5. 6600 Series
  6. Operator's manual

Formax 6600 Series Operator's Manual

Folder/inserters
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
6600 Series
Folder/Inserters
FORMAX
OPERATOR MANUAL
FIRST EDITION
1-800-658-8788
www.abcoffice.com

Advertisement

Table of Contents
loading

Related Manuals for Formax 6600 Series

Summary of Contents for Formax 6600 Series

  • Page 1 1-800-658-8788 www.abcoffice.com FORMAX 6600 Series Folder/Inserters OPERATOR MANUAL FIRST EDITION...

  • Page 2: Table Of Contents

    1-800-658-8788 www.abcoffice.com CONTENTS Section Page Section Page Precautions Feeding documents MaxiFeeder Special national conditions General Function Preparations Understanding the machine Adjustments Operating controls Fault finding Display Preparations 10.1 General 10.2 Clearing stoppages Operating the system 10.3 Operator troubleshooting Switching on 10.4 Error codes The main menu...

  • Page 3: Precautions

    1-800-658-8788 www.abcoffice.com PRECAUTIONS Italic text: Additional information Special national conditions Before using this system, thoroughly read the operating instructions. In the European Union Denmark: In Denmark, certain types of Class 1 an operator manual printed in the national appliances may be provided with a plug not language(s) is supplied with the system.
  • Page 4 1-800-658-8788 www.abcoffice.com FlexFeed™; see 1 Collating area; see 2 The FlexFeed™ is the feeding part of the After feeding, the documents are gathered in the system. There are two types of feeders collating area. available. The automatic and the special feeder. IntelliDeck™;...
  • Page 5 1-800-658-8788 www.abcoffice.com Inserter; see 5 After folding (or not folding) the documents are transported to the inserter unit where the documents are inserted into a envelope (not inserted when processing without envelopes). Automatic monitoring ensures the correct number of inserts per envelope. Present on deck;...

  • Page 6: Operating Controls

    1-800-658-8788 www.abcoffice.com Operating controls J : vertical transport K : vertical transport hand grip A : side exit L : document feed tray B : stacker M : collator arm C : side guides stacker N : collator area D : display O : locking handle PowerFold™...

  • Page 7: Display

    1-800-658-8788 www.abcoffice.com Press the start key to start the machine. After pressing the stop key the system does not stop immediately, but on the first opportunity while processing. Because of this there can be incomplete sets in some parts of the system. When the clear key is pressed during processing documents the system will stop feeding documents after completing the set.

  • Page 8: The Main Menu

    1-800-658-8788 www.abcoffice.com The main menu The main menu consists of 2 menus, "main • sealing "on" ( ) or "off" ( ). menu (1)" and "main menu (2)". Press key 6 in • document thickness detection "on" ( ) or the main menu (1), to go to the main menu (2).

  • Page 9: Adjustments For Document Feeding

    1-800-658-8788 www.abcoffice.com Only programmed jobs can be selected (maximum of 20 jobs). Main menu (2) The “main menu (2)” shows the following functions (see figure below): • Job information ( • display contrast lighter. • display contrast darker. • Job menu (only for authorized personnel). •...
  • Page 10 1-800-658-8788 www.abcoffice.com • grab the side guides in the middle and push Adjustment of the document stoppers them towards the documents. Initially the document stoppers are adjusted for • the space between the side guides and the position B (see figure below). In this position a documents should be such that the wide variety of documents can be handled (max.
  • Page 11 1-800-658-8788 www.abcoffice.com Feeding documents The feeding of documents is shown in the figure below. feeder swap one document two documents document + enclosure no fold single fold letter fold double parallel fold Address carrier in Address carrier in top linked Address carrier in Address carrier in top top feeder.

  • Page 12: Adjustments For Envelope Feeding

    1-800-658-8788 www.abcoffice.com Daily mail The daily mail function can be used for processing documents or sets which can not be processed automatically. The upper feeder of a feeder module can be equipped with a daily mail switch. Switch to daily mail in the following way: •...
  • Page 13 1-800-658-8788 www.abcoffice.com • set the insert position to the left. Then adjust each finger so that the tip enters • save the insert position setting with "OK" about 5 mm (0.2 inch) into the envelope. Re- which will get you to the “main menu (1)”. tighten the knurled knob.
  • Page 14 1-800-658-8788 www.abcoffice.com The document will be folded and inserted in the envelope. The address carrier must be put into the upper feeder. Testset run Press key 3 to start a testset run in the AutoSet screen (see figure above). The settings of the testset run will be saved.

  • Page 15: Job Programming

    1-800-658-8788 www.abcoffice.com • DFC settings other than for the address Press the escape key to get back to the carrying feeder. previous menu. • the OMR function. Create job menu When an AutoSet™ job is defined successfully these settings can be stored into a After pressing key 2 in the "job menu"...

  • Page 16: Copy Job Menu

    1-800-658-8788 www.abcoffice.com All job settings are described in the chapter "Job settings". Copy job menu After pressing key 4 in the "job menu" the "Copy job" menu is shown. The "copy job" menu shows the following functions (see figure below): •...

  • Page 17: Document Settings Menu

    1-800-658-8788 www.abcoffice.com Envelope with closed flap The envelope height can be set between 90 mm (3.54 inch) and 162 mm (6.38 inch). The flap When the "envelope with closed flap" screen is height can be set between 32 mm and the selected the following choices are available (see envelope height minus 32 mm (1.26 inch).
  • Page 18 1-800-658-8788 www.abcoffice.com • select a lower feeder number. The document size can be set between 90 mm • increase the number of documents of the (3.54 inch) and 356 mm (14 inch) in steps of 1 selected feeder. mm (0.04 inch). •...

  • Page 19: Fold Settings Menu

    1-800-658-8788 www.abcoffice.com The reading feeder can be linked to a feeder When the "fold settings" menu is selected and above when it is not selected for selective key 3 is pressed in the "job settings" menu the feeding. following choices are available: 1.
  • Page 20 1-800-658-8788 www.abcoffice.com Letter fold When letter fold is selected the following choices are available (see figure below): • go to the double parallel folding menu. • increase the position of the first fold to the right. • decrease the position of the first fold to the left.

  • Page 21: Omr Settings Menu

    1-800-658-8788 www.abcoffice.com OMR settings menu Refer to chapter "Optical Mark Reading". DFC (Double Sheet Control) menu The “DFC settings” menu shows the following functions (see figure below): • select the required feeder and/or document set on the inserter. The standard position of the measurement area •...
  • Page 22 1-800-658-8788 www.abcoffice.com Exit settings overview On the machine Exit 1 is the Stacker and Exit 2 is the Side exit. Sorting Symbol Exit Swap Inserted envelopes are stacked until the stacker is full. Inserted envelopes leave from the side exit when the stacker is full.

  • Page 23: Test Set

    1-800-658-8788 www.abcoffice.com Test set After pressing key 4 in the "Job settings" menu the display shows the screen as shown in the figure below. With this function it is possible to test the programmed job before saving it. The following choices are available: •...

  • Page 24: Job Edit Menu Structure

    1-800-658-8788 www.abcoffice.com Job edit menu structure The Job edit menu structure is shown in the figures below. Job menu Job Settings Envelopes Documents Folds Envelope with closed flap Number of sheets No fold Envelope with open flap Document lenght Single fold No envelopes Hopper swap Letter fold...
  • Page 25 1-800-658-8788 www.abcoffice.com Reading Double Sheet Detection Exit Select Select code type and feeder DFC on/off Swap 1st mark from top Measurement area Batching Stop on misread...

  • Page 26: Optical Mark Reading (Optional)

    1-800-658-8788 www.abcoffice.com OPTICAL MARK READING • adjust the reading head A according to the (OPTIONAL) middle of the marks. • divide the paper guides B along the width of The folding and inserting machine can be the document. equipped with Optical Mark Reading. With this When the reading head is adjusted it is possible option the system reads optical marks that have that some paper guides B have to be removed...

  • Page 27: The Omr Position

    1-800-658-8788 www.abcoffice.com • select if reverse reading is used (refer to The maximum amount of sheets in a set is 25. section "Reverse reading"). When the documents have to be folded the • select the required reading code. maximum amount of sheets in a set is 8; this is •...

  • Page 28: Linking Of Reading Feeders

    1-800-658-8788 www.abcoffice.com Linking of reading feeders When two feeders are linked and used as reading feeders, you need to use sequence check for a good level of security. When this is done make sure that the feeders are (re)filled in the correct order (feeder 1 first) to prevent sequence errors.

  • Page 29: Feeding Documents

    1-800-658-8788 www.abcoffice.com Feeding documents The feeding of documents is shown in the figure below. Fold type Type of documents Loading positions no fold first page single fold letter fold stop start reading address reading double Address carrier, parallel fold face up and leading. last page (duplex printed) zig-zag fold...
  • Page 30 1-800-658-8788 www.abcoffice.com Line 1 6,3 mm 8,5 mm Line 2 Line 3 Start mark Line 4 8,5 mm Insert/accumulate Line 5 Line 6 4,2 mm 4,2 mm In some cases, on request of the customer, the Code width, character space and pitch reading of the basic commands can be set The minimum width of the code area is 7 reversed by the service organisation.
  • Page 31 1-800-658-8788 www.abcoffice.com Divert & stop When the “divert & stop” mark is printed also special sets will be sorted and diverted, however in this case the system will stop. Divert & stop is Start mark only executed together with accumulate. Insert/accumulate Divert &...
  • Page 32 1-800-658-8788 www.abcoffice.com • pages are numbered 1-2-3-4-5-6-7-8-1-2-3- sheet 4: no mark printed sequence check 4 a mark printed sequence check 2 etc. This requires three additional sequence a mark printed sequence check 1 marks. sheet 5: a mark printed sequence check 4 no mark printed sequence check 2 no mark printed sequence check 1 sheet 6: a mark printed sequence check 4...
  • Page 33 1-800-658-8788 www.abcoffice.com Programming the code The information on the last sheet of a set is used for further processing the set. The following print instruction can be set. Accumulate Is it the last Print the start mark, leave the second mark blank sheet of a (print nothing if 1 mark code is set).

  • Page 34: Extended Powerfold

    1-800-658-8788 www.abcoffice.com Reverse reading (optional) Optional reverse reading is available. Reverse reading means that the insert mark is on the first page of the set. The system will detect the end of a set by detecting the first page of the next set.

  • Page 35: Bottom Addressing

    1-800-658-8788 www.abcoffice.com When the address fold is longer than the rest Single fold bottom fold, the maximum number of pages per set can When "Single fold bottom" is selected the be 5 pages (80 gr/m2) (depending on test). The following choices are available (see figure maximum set height in the second fold table below): when the turning function is used is 5.1 inch...
  • Page 36 1-800-658-8788 www.abcoffice.com "Zig-Zag fold bottom" can not be used when the document used is shorter than 4.9 inch (125 mm). Default the first addressing fold is set to the envelope height minus .24 inch (6 mm). The second addressing fold is set to the longest document used, minus the envelope height minus .24 inch (6 mm).

  • Page 37: Feeding Documents

    1-800-658-8788 www.abcoffice.com Feeding documents The feeding of documents is shown in the figure below. one document hopper swap two documents document + enclosure no fold single fold zig-zag fold Address carrier in Address carrier in Address carrier in top Address carrier in top linked top feeder.

  • Page 38: Adjustments

    1-800-658-8788 www.abcoffice.com Adjustments • adjust the side guides by turning the thumbwheel A (see figure below) to provide When the MaxiFeeder is used at an automatic enough space to move freely. Too much play separation feeder, the separation is set causes skewing.

  • Page 39: Clearing Stoppages

    1-800-658-8788 www.abcoffice.com • technical errors. Lower envelope track If an error occurs the display shows a screen When a stoppage occurs in the lower envelope with an error description and a suggested track, remove the envelopes as follows (see solution. figure below): When a paperflow error occurs the following •...
  • Page 40 1-800-658-8788 www.abcoffice.com • remove the documents. • close the vertical transport cover. Reset the error after solving the problem with key 6. Collating area When a stoppage occurs in the collating area, remove the documents from the collating area as follows (refer to "Operating controls"): •...

  • Page 41: Operator Troubleshooting

    1-800-658-8788 www.abcoffice.com 10.3 Operator troubleshooting Symptom Possible cause Remedy Section The machine cannot be Machine not connected Connect the machine to started after switching to mains. the mains. Fuse is blown. Replace fuse below power switch. A cover is opened. Close the covers Machine stops with Envelopes stacked...
  • Page 42 1-800-658-8788 www.abcoffice.com Symptom Possible cause Remedy Section Flap sticks. Store envelopes Specifications. according to specifications. Flap curled. Envelopes stored or Specifications. manufactured improperly. Separation set too Check separation Adjustments for narrow. settings, adjust if envelope feeding. needed. Fingers are placed on Fingers adjusted too Check fingers position, Adjustments for...
  • Page 43 1-800-658-8788 www.abcoffice.com Symptom Possible cause Remedy Section Envelope not always Inserted document too Check fold settings, Fold settings menu. transported from the big. adjust if needed. insert position. Document not inserted Check adjustment of Envelope insert position. deep enough. envelope stop position and fingers.

  • Page 44: Error Codes

    1-800-658-8788 www.abcoffice.com 10.4 Error codes error description suggested solution information Error code To many sheets in set. Remove the documents and Set size exceeded. 3 : 110 complete the set manually. Reading error. Remove the documents and Incomplete set. 3 : 111 complete the diverted set manually.
  • Page 45 1-800-658-8788 www.abcoffice.com error description suggested solution information Error code Reading stop. Remove the documents, Unmatched set 3 : 123 check the matched number and replace the set in the feeder or complete the set manually. Reading error. Remove the documents. Sequence error.
  • Page 46 1-800-658-8788 www.abcoffice.com error description suggested solution information Error code Incomplete set. Reload the remainder of the Empty feeder. 4 - 9 : 15 set into the reading feeder. Press "reset" to remove the error message and press "start" to resume operation. Service assistance is needed for the error codes with the message “technical failure”.

  • Page 47: 11. Maintenance

    1-800-658-8788 www.abcoffice.com 11. MAINTENANCE 11.4 Cleaning the moistening felt Clean the moistening felt and water tray when 11.1 Servicing dirty or saturated with glue. To remove the water Disconnect the mains supply before tray the side cover must be opened (refer to performing any maintenance.

  • Page 48: 13. Specifications

    1-800-658-8788 www.abcoffice.com A special support is available to allow curved envelopes to be processed correctly. It can be used for envelopes with a height up to 114 mm (4.49 inch). Power Stacker Support Depending on the inserted type and amount of document(s) set(s), the filled envelopes may stack fan-shaped when the stacker is used as exit device.

Table of Contents