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Formax 6304 Series Operator's Manual

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6304 Series
Inserter
/2010
OPERATOR MANUAL
Rev. 1

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Summary of Contents for Formax 6304 Series

  • Page 1 6304 Series Inserter OPERATOR MANUAL Rev. 1 /2010...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Health, Safety and Environment ............2 Precautions and Safety Issues ........... 2 Functional description ..............5 Overview ................5 Operating Controls ..............7 Control Panel ................8 Software Description ..............8 Operating Instructions ..............12 Installation ................12 Preparation ..

  • Page 4: Health, Safety And Environment

    HEALTH, SAFETY AND ENVIRONMENT Precautions and Safety Issues Thoroughly read this operator manual, before using this system. According to the EC declaration (European Commission) following the Low Voltage Directive (2006/95/EC), this operator manual must be available in the national language(s) of the country where the system is delivered. Therefore, if you do not have an operator manual in your country’s language(s), contact your authorized distributor.
  • Page 5 Conventions Note A note gives additional relevant information. Caution Indicates the presence of a hazard that can cause personal injury or property damage, if the hazard is not avoided.
  • Page 6 Please use the subjoined return or...

  • Page 7: Functional Description

    FUNCTIONAL DESCRIPTION The system feeds, folds and inserts documents into envelopes and then seals and stacks the envelopes. Automatic monitoring ensures the correct number of inserts per envelope. The system is a sophisticated folding and inserting system which can process large quantities of mail rapidly and easily.
  • Page 8 2.1.1 Feeder (1) The feeder is the feeding part of the system. There are two types of feeders available: the automatic and the special feeder. The automatic feeder does not require any adjustments for the separation. The feeder is equipped with double feed control. In this way the system can detect faulty sets of documents.

  • Page 9: Operating Controls

    Operating Controls catch tray sensors envelope slide bellows control panel with touch screen unlocking handle for rollers envelope track upper unit sealing liquid reservoir locking hand grip upper unit side cover (opened) document feeder tray ruler collator arm thumb wheel for side guide adjustment collating area side guides envelope hopper power inlet, power switch,...

  • Page 10: Control Panel

    Control Panel The system has a graphical touch screen. There are two buttons next to the touch screen: • : the start key When the start key is pressed the system starts processing : the stop key When the stop key is pressed, the system completes the current set and stops. Caution The touch screen is covered with a thin pressure-sensitive layer.
  • Page 11 • Stop at: number of processed envelopes at which the system stops. You can set this number with the Counters button. You can set it between 0 (switched off) and 9999. The system will continue until the job counter reaches the stop counter value. The system stops and can be restarted.The stop counter is switched off when it is set to zero.

  • Page 12: Main Menu

    2.4.3 Main Menu When you press the MENU button the main menu appears. This menu allows you to change system settings and define jobs. The screen shows the following functions: • Display settings: change touch screen and volume settings (see “Display Menu” below) •...

  • Page 13: Test Menu

    • Test: opens the ‘test menu’ (see 2.4.6 ”Test Menu,” below). Use this menu to test the system. • Online services: opens the ‘Online Services’ menu (option, see 5.3 ”Online Services” on page 36). This menu enables to connect the system to a server and receive messages.

  • Page 14: Operating Instructions

    OPERATING INSTRUCTIONS Installation Warning You can severely damage the system if it is connected to the incorrect power supply. Before plugging in the system, check if the local voltage is the same as the voltage mentioned on the type plate. Preparation 3.2.1 Document Feeder Trays...

  • Page 15: Starting Up

    3.2.2 Slide and Envelope Catch Tray To attach the slide and envelope 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.

  • Page 16: Loading Documents

    Loading Documents 3.4.1 Document Orientation See also the job information on the touch screen. feeder swap document + enclosure one document two documents no fold single fold letter fold Address carrier in Address carrier in upper Address carrier in Address carrier in upper upper feeder.
  • Page 17 Loosen the knob B half a turn. Grab the side guides in the middle and push them apart as far as possible. Put a small stack of d o c u m e n t s between the side guides. Grab the side guides in the middle and push them towards the documents.

  • Page 18: Loading Envelopes

    3.4.4 Filling the Document Feeder Tray To fill the document feeder tray: Turn the left-hand side guide A downwards. The feed rollers are lifted automatically. Place a stack of documents between the side guides. Feed the documents (depending on the type of documents and the type of fold) as shown in 3.4.1 ”Document Orientation”...

  • Page 19: Filling The Sealing Liquid Reservoir

    Shift envelope support B in or out, so that the top side of the envelope lies against the dotted line on the support. Turn envelope support B so the weight of the envelopes is distributed evenly on both sides. Filling the Sealing Liquid Reservoir When you want to seal envelopes, the sealing liquid reservoir must be filled.

  • Page 20: Using An Automatic Job

    Using AutoSet If you do not want to define a job and just want to do some inserts, you can let the system determine the job settings for you. This ‘automatic’ job determines automatically its job settings by measuring the sizes of documents and envelope.

  • Page 21: Stopping The System

    Turn down the left side guide A of the upper tray. Now you can see the Daily Mail handle B Move the handle to enable the Daily Mail function. Place the document or document set in the feeder (see “Filling the Document Feeder Tray” on page 16) and turn side guide A upwards.

  • Page 22: Job Programming

    JOB PROGRAMMING Create a Job To c reate a n ew j ob: From the ‘home’ menu, press the New job button. Press Manual to create a new job. For Automatic, see “Using AutoSet” on page 18. Enter the pin code 2546. Press Wizard to create a new job with the job...

  • Page 23: Job Settings

    Job Settings From the “job settings” menu the following settings are available: Envelope settings (see 4.2.1 ”Envelope Settings," below) Document settings (see 4.2.2 ”Document Settings” on page 22) Fold settings (see 4.2.3 ”Fold Settings” on page 24) Reading settings (if installed) (see 4.2.4 ”Reading Settings (Option)”...

  • Page 24: Document Settings

    Use the button to switch automatic envelope sealing on, off or use reading (in case of a job with reading settings, see ”Sealing Control” on page 34). • Press to select an envelope with open flap. This means that envelopes are fed with open flap.
  • Page 25 Note The maximum number of sheets in a set is 25. When folding is used the maximum set thickness is 8 sheets in letter fold and 10 sheets (80 gr./m2) in single fold. • Press to enter the document height. The height or the ISO format of the document will be displayed next to the relevant feeder.
  • Page 26 Press to enable the daily mail function. The icon appears behind the upper feeder. If you press again the daily mail function will be disabled. Note 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.
  • Page 27 Note The touch screen will indicate when entered positions are out of range. 4.2.4 Reading Settings (Option) For a full function description of reading, see 5.2 ”Reading” on page 29. 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 28: Job Name

    Note The maximum number of sheets in a set is 25. When the number of sheets exceeds 8 or 10, depending on the fold, the document can not be folded anymore. In this case, the maximum length of sheets is 148 mm for a C5/6 envelope. Also make sure that the fold is set to No fold.

  • Page 29: Edit A Job

    4.2.7 Mailing/Franking Settings (Option If this system is connected to a mailing/franking system, this option allows you to select the franking mode. The ‘franking settings’ menu has the following options: • Franking: use the button to switch between - Yes (franking on) Pass through (franking off) •...

  • Page 30: Copy A Job

    Press Save to save the job with the entered settings under the specified job number and name. To n ame a j ob, see 4 .2.6 ”Job Name” on page 26. Press the button to verify that the insert position and address position are correct (see 7.3.1 ”Insert Position”...

  • Page 31: Options

    OPTIONS Activate an Option To activate a new option: From the ‘supervisor menu’ choose Options. Software options are enabled with license codes. These license codes, together with the identification number of the system enable the relevant options. The enabled and available software options are displayed in this menu.
  • Page 32 5.2.2 Adjust Reading Head Position The horizontal position of the reading head must be adjusted to the same position of the printed marks on the documents. To adjust the reading head, proceed as follows: Fold a document with reading code on the first mark.

  • Page 33: Printing Quality

    5.2.3 Document Orientation Switch on the reading function and set the position of the reading marks as described in “Reading Settings (Option)” on page 25. Document orientation: Fold type Type of documents Loading positions no fold first page single fold stop letter fold start...
  • Page 34 OMR Code Specification The following specifications apply to OMR codes: Leading >4.2 mm >4.2 mm Trailing >7 mm >7 mm >6.3 mm Minimal distance from top of sheet to first mark 15 mm (0.59 inch) Minimal distance from bottom of sheet to last mark 30 mm (1.18 inch) Minimal distance from side edges of sheet to marks 7 mm (0.28 inch)
  • Page 35 BCR Code Specification Minimal distance from top of sheet to first bar 15 mm (0.59 inch) Minimal distance from bottom of sheet to last bar 30 mm (1.18 inch) Minimal distance from side edges of sheet to barcode 7 mm (0.28 inch) Minimal free space above and below the barcodes 8.5 mm (0.33 inch) Minimal free space on both sides of the barcodes...

  • Page 36: Additional Codes

    Additional Codes When it is required to control more functions in the inserter system, additional codes are available. The following additional functions are possible via Start mark Insert/accumulate software options: Divert mark • Divert Stop mark • Stop Selective feed 1 Selective feed 2 •...
  • Page 37 Sequence Check (only OMR) Sheets in a stack can accidentally get out of sequence or can be missing. This can be detected by the system when the sequence function is used. Each sheet has a number that forms part of the reading code. These are the available possibilities: •...

  • Page 38: Online Services

    Page n of m (only BCR) BCR uses the code ‘page n of m’ to complete a set. If n is less than m, the sheets are accumulated. If n = m, this is the last sheet of the set and the set will be inserted. Example of OMR Code In the figure the legend for the following example is mark printed...
  • Page 39 • Messages: opens the ‘messages’ menu to view received messages (see ”Messages” on page 37). • Configuration: opens the ‘configuration’ menus to change Online Services settings (see ”Configur ation Menu” on page 38). Connection The system makes a connection on fixed times. It is possible that you manually connect the system to the server.

  • Page 40: Configuration Menu

    To install a new job or new software: Press Continue. The ‘new job available’ menu or ‘new software’ menu appears. Press for more information on the new job or new software. Press Install to install the new job or new software or press Reject to reject it.

  • Page 41: Production Feeder (Mf-2)

    • Dial tone detection on / off This setting is required if no dial tone is heard during establishing a connection. The default value is on. This setting is relevant to some PABX telephone switch systems. Press to switch the dial tone detection on or off. •...
  • Page 42 5.4.3 Adjust Side Guides Adjust the side guides: Take a stack of documents/B REs 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 G so the documents/BREs just fit and can move without resistance.

  • Page 43: High Capacity Feeder

    Loosen the stack of documents and place them in the feeder. BREs with flap down and leading (top side pointing to system). The feeding plate assembly will be shifted up automatically (when the system starts processing) until documents/BREs are underneath the rubber paper pullers. Note When filling the Production Feeder, be sure that the document/BREs are positioned parallel in relation to the feed plate to ensure correct feeding.

  • Page 44: High Capacity Vertical Stacker (Hcvs-1)

    High Capacity Vertical Stacker (HCVS-1) The High Capacity Vertical Stacker can be used to stack filled envelopes. The vertical stacker can store up to 500 filled envelopes. The vertical stacker can be equipped with Mail Piece Production Control (MPPC). 5.6.1 Adjusting the Side Guides Adjust the side guides with wheel A so, that a margin of 3 to 5 mm is left between the envelopes...

  • Page 45: Operator Maintenance

    OPERATOR MAINTENANCE Warning • 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 46: Fault Finding

    FAULT FINDING Error Messages When an error occurs the touch screen shows a menu 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 to view more information about the error and about the possible actions to...

  • Page 47: Clearing Stoppages

    Clearing Jams Jams can occur in the following areas: Folder and feeder Collating area Envelope track and inserter area. 7.2.1 Folder or feeder When a jam occurs in the folder or the feeder, remove the documents as follows: Open the upper unit A by pulling up the handle. Remove the documents from the folder or the feeder.

  • Page 48: Operator Troubleshooting

    Operator Troubleshooting To s olve p roblems: Write down the error. Consult the troubleshooting table to solve the problem. Switch the inserter off and on again, to verify system operation. When the error still occurs contact your service organization. Note When contacting the service organization, you will also be asked for the last error message and the software version of the installed software.
  • Page 49 Symptom Possible cause Remedy Reference Flap is wrinkled Envelope not within Check specifications “Envelope and Insert and sometimes specifications. and change Specifications” on not opened. envelopes if needed. page 51 Flap sticks. Store envelopes “Envelope and Insert according to Specifications” on specifications.
  • Page 50 Symptom Possible cause Remedy Reference Flap not Water level low. Check water level, “Filling the Sealing sufficiently refill if needed. Liquid Reservoir” on moistened. page 17 Brushes dry. Check brushes, “Operator Maintenance” replace if needed by on page 43 the extra soaked set. Brushes dirty.
  • Page 51 7.3.1 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: Choose a job and press the button.

  • Page 52: Specifications

    SPECIFICATIONS Technical Specifications Type: Fold and insert system for medium office use Theoretical max. 3600 inserts per hour, depending on application speed Power consumption: 100 VAC / 50 Hz / 5.0 Amps (voltage tolerance: +6%/-10%) 115 VAC / 60 Hz / 5.0 Amps (voltage tolerance: +6%/-10%) 230 VAC / 50 Hz / 2.5 Amps (voltage tolerance: +10%/-10%) Fuse 100/115 VAC: T 5.0 A, 125 V.

  • Page 53: Document Specifications

    Document Specifications Paper quality minimum 60 g/m² (15 lb bond) maximum 250 g/m² (62.5 lb bond), when folded max. 170 g/m² (42.5 lb bond) Booklets up to approximately 1 mm (0.04 inch) thickness, depending on stiffness Paper size Minimum width: 130 mm (5.1") Maximum width: 236 mm (9.3"), when folded 230 mm (9.1") Minimum length: 90 mm (3.5") Maximum length: 356 mm (14.0")

  • Page 54: Specifications High Capacity Vertical Stacker

    Remarks: • Maximum insert specifications are based on single sheets. When multiples are handled, more room inside the envelope is needed depending on the application. • The specification of the paper handling equipment is often wider than that of the envelopes and documents handled.

  • Page 55: Specifications Production Feeder

    Specifications Production Feeder Model MF-2 Type high capacity feeder Theoretical max. see 8.1 ”Technical Specifications” on page 50 speed Power consumption low voltage supplied by the inserter system Approvals EMC Certificate conform EMC-Directive. FCC Certificate conform 47CFR, part 15. UL Listed I.T.E. (Information Technology Equipment), conform UL-IEC 60950-1, file: E153801.

  • Page 56: 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 carrier can consist of one or more sheets, from which at least the first sheet must contain the address.
  • Page 57 DFC sensors exist on feeders (double sheet detection). Currently DFCs on Formax inserting systems perform relative measurements, which means that they need a cycle to 'learn' the thickness of a sheet.
  • Page 58 Term Description Flexcode OMR An OMR code for which the meaning of the OMR marks can be programmed in a dedicated way for a specific customer. This is normally used to support the OMR codes from other suppliers. High Capacity Feeder that has a capacity for 725 sheets.
  • Page 59 Term Description Optical Mark Optical Mark Recognition is intended for reading and interpreting Recognition printed codes. These codes are one or more black marks which are (OMR) read from a document. These marks give information to the inserting system about how to build-up and handle a set. Reading error Condition in which the system could not reliably read or interpret the OMR reading marks or barcode from a sheet.
  • Page 60 Term Description Tray Contains a stack of paper for a printer or inserter. This paper is supplied to the system for further processing. Vertical transport The vertical transport section between feeders and collator. Z-fold A Z-fold means that a document is folded twice in such a way that each folded flap is on a different si e of the folded document, resulting in a Z-shape.
  • Page 61 EC DECLARATION OF CONFORMITY FOR ELECTRICAL PRODUCTS (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-75, M5500, Carat DELTA MAX, FPi 4500, •...

  • Page 62: Index

    Index height 23 orientation 31 separation 15 settings 22 address carrier 54 specifications 51 address position 49, 54 document orientation automatic job 18, 54 normal 31 reading 31 document set 54 Barcode Reading document stoppage see BCR see stoppage BCR 54 double feed control 6, 55 adjustments 29 double feed control settings 26...
  • Page 63 load 16 settings 21 remove 14 start 17 side guides 14 job list 8 special 6, 15 feeder linking 55 feeder tray 55 letter fold 56 install 12 loading envelopes 16 fill sealing liquid reservoir 17 finger position 49 flex certificate 10 Mail Piece Production Control 21 flex code 34 main menu 10...
  • Page 64 test run 57 touch screen 8 paper quality 51 contrast 10 paper size 51 settings 10 photocell calibration 11 tray 58 power consumption 50 troubleshooting 46 power switch 7 USB 7 reading head position 29 reading settings 25 reservoir vertical stacker 42, 56 fill 17 volume acoustic signals 10 RS232 connector 7...

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