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Formax 6204 Series, Maintenance Manual

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6204 Series

Low-Volume Inserter

MAINTENANCE MANUAL

6/2012

Summary of Contents for 6204 Series

Page 1: ...6204 Series Low Volume Inserter MAINTENANCE MANUAL 6 2012 ...

Page 2: ... User interface 27 5 Transport storage and installation 42 6 Mechanical description 51 7 Electrical description 138 8 Preventive maintenance 156 9 Fault Finding 161 10 Upgrading and installing accessories 196 11 Technical specifications 199 12 Parts lists 208 13 Appendix 289 063 1 Service Guide ...

Page 3: ......

Page 4: ...Introduction 1 1 Introduction 1 About this manual 2 Abbreviations 2 Terminology 3 1 1 063 1 Service Guide ...

Page 5: ...the supervisor menu to perform the procedure Abbreviations Explanation Abbrev Explanation Abbrev Interface Spe cification for In serter Systems ISIS Business Reply Envelope BRE Left Hand LH Counter Clockwise CCW Mixed Mail Feeder Ad vanced Feeder MMF AF Clockwise CW Mailing System MS Double Feed Control DFC Not Applicable NA Document System DS On Line Ser vices OLS First In First Out FIFO Optical ...

Page 6: ...n in which the top of the sheet is closest to the separation unit in a document feeder Leading The various documents of a set are fed from the feeders in such a way that these documents are partly overlapping each other This pane like overlapping ensures a higher throughput Pane Cycle Documents are transported along the vertical track without touching each other Only after joining the set in the m...

Page 7: ...4 1 063 1 Service Guide ...

Page 8: ...Health safety and environment 2 2 Health safety and environment 5 Safety 6 Symbols on the system 6 End of Life 7 5 2 063 1 Service Guide ...

Page 9: ...connection must be easily accessible preferably close to the system For safety reasons it is essential that the system is connected to a socket outlet that has a protective earth ground connection Overcurrent protection in the equipment also relies on the branch circuit protection max 20 A The following part s is are considered the equipment disconnect device s Power supply cord plug or appliance ...

Page 10: ...the environment in the European Community More particularly certain materials and components of waste electrical and electronic equipment need special treatment as improper handling or disposal on or into land water or air would represent a major threat to the environment and human health In order to facilitate collection and treatment separated from normal domestic waste electrical and electronic...

Page 11: ...General description 3 3 General description 8 The system 9 Denominations 9 Paper flow 10 Process description 11 Electronics 20 Optional features 25 8 3 063 1 Service Guide ...

Page 12: ...rs L Bellows M Handle for clearing stoppages N Sealing liquid reservoir O Side cover opened P Ruler Q Thumb wheel for side guide adjustment R Side guides envelope hopper S Knob for separation adjustment T Envelope support bracket A Envelope catch tray B Envelope slide C Display with operating buttons D Upper unit E Locking hand grip upper unit F Document feeders G Collator arm H Collator area I Po...

Page 13: ...der 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 Finally the envelope is sealed and transported to the envelope receiving tray 10 3 063 1 Service Guide ...

Page 14: ...mechanical items that are strictly necessary to explain the process are projected on the left hand side of the machine This implies that not all auxiliary mechanical items such as gears and belts are shown See Section Mechanical description on page 51 and Section Illustrated parts list on page 208 for more details on the mechanics Parts with an arrow are mechanically driven by the main motor M2 or...

Page 15: ...in drive 15 17 19 20 22 23 If the upper unit is in place items 14 16 24 and 26 are driven as well All items that are directly driven by M2 can be activated with the LH hand knob M2 Pulse disc mounted on roller 19 Monitored by slotted photocell SPH1 PD1 Safety switch that guards the part of the collator area that can be opened by the user MS1 Safety switch for the front cover MS2 Safety switch for ...

Page 16: ...er photocell PH2 Driven output rollers 70 Counter rollers for 70 71 Lower separation roller 72 Feed axle with upper separation roller 73 Paper puller axle with two rubber rollers 74 Document thickness measuring unit DFC2 Upper feeder 3 Feeder photocell PH3 Driven output rollers 77 Counter rollers for 77 78 Lower separation roller 79 Feed axle with upper separation roller 80 Paper puller axle with ...

Page 17: ...llers for 68 in upper unit 69 Driven vertical transport axle On this axle feeder 3 upper clutch CL3 is mounted at the LH side of the machine This clutch drives 77 80 and 81 75 Counter rollers for 75 in upper unit 76 Reading head photocell Only operational if OMR is installed PH4 Collator Description No Collator motor Drives 46 50 53 56 and 60 in forward or reverse direction M1 Pulse disc mounted o...

Page 18: ...RH Controls movement of 40 37 Brake disc for first fold table Spring loading ensures two static mechanical states 38 Cam disc of first fold table Monitored by slotted photocell SPH3 PD3 Control axle for second fold table Hinge for 32 and 33 Moves the lever that in its turn moves the flap actuator of 34 upwards 31 Control axle for second fold table Hinge for 32 and 33 Moves the lever that in its tu...

Page 19: ...ng sealing and exiting Insert table photocell PH9 Fingers solenoid Moves fingers forward into envelope to enable inserting the set So1 Lower insert roller 13 Upper insert roller in the upper unit 14 Lower first ejection roller On the axle at the LH side of the machine the LH hand knob is mounted On this axle at the RH side of the machine the main pulley is mounted 15 Upper first ejection roller in...

Page 20: ...cal track consists of one driven axle per feeder 75 68 61 plus one driven axle in the lower vertical track 45 All these axles carry two rollers except for 75 at the top feeder which carries four rollers This is necessary for straightening the paper prior to passing the optional reading head The driven rollers have their counterparts in rollers 76 69 62 and 44 If the OMR option is installed the pap...

Page 21: ...are activated Short shunt Document folding The paper of a completed set leaves the collator area This is detected by the folder entry photocell PH6 First fold The fold input rollers 42 and 43 transport the paper to the first fold table The flap 41 moves up Paper that enters the first fold table will be directed in upward direction At the appropriate time the flap 41 moves back and the fold plate 4...

Page 22: ... fold parameters Envelope feeding All the rollers for this process stage 1 4 6 8 10 and 11 are engaged to the main drive by the envelope track clutch CL8 During the document and insert stage these rollers are disengaged The envelope transport subsystem can be manually moved by the right hand knob at the left hand side of the machine The counter rollers 3 5 7 9 and 12 can be de coupled from there d...

Page 23: ... contact the lower reverse roller 24 by a spring A certain time after triggering the PH11 the sealing solenoid So3 is activated The envelope is between the upper and lower reverse rollers By the So3 action the upper reverse roller now is temporarily lowered Given the turning direction of the lower reverse roller the transport direction of the envelope is abruptly changed from an upstream to a down...

Page 24: ...l counter ID tag 7 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 3 063 1 Service Guide 21 ...

Page 25: ...rview 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 22 3 063 1 Service Guide ...

Page 26: ... factory flash To backup inserter information and export it to XML format To restore information into the inserter from a previous backup The Concorde application has been developed in such a way so that it requires minimal upgrades in the future For more information please see the online help contained in the Concorde application The ID tag Each time the inserter is started the presence of the ID...

Page 27: ... disconnected the latest counter can be used 2 Replacement of PCB or replacement of both the ID Tag and PCB 3 PCB replacement Tag OK 4 PCB and ID Tag replacement new ID Tag 5 if incorrect Tag is installed software controlled options and connectivity will not function correctly 24 3 063 1 Service Guide ...

Page 28: ...ntains information about the processing of the sheets The code on the last sheet of the set always contains the insert instructions The other sheets carry the accumulate instruction If a parity check is used this is checked on each sheet The code must appear in the same location on every page regardless of the actual code length Reading can be activated by a system specific license code You can fi...

Page 29: ...e 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 The receiving tray can be fitted to the left or to the right of the side exit to achieve vertical stacking 26 3 063 1 Service Guide ...

Page 30: ...User interface 4 4 User interface 27 Operator menus 28 Job and supervisor menus 28 Service menu 28 27 4 063 1 Service Guide ...

Page 31: ...perator 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 28 4 063 1 Service Guide ...

Page 32: ...olenoid So3 You can use this function to improve the sealing process The timing has influence on the position of the filled envelope with its flap fixed between rollers 21 and 22 prior before it is transported between the sealing rollers This position can be adjusted between 10 and 10 pulses with respect to the default envelope position You can also adjust the flap closer offset per job Service me...

Page 33: ... speed at which the document set enters the folding table The folder ratio is the ratio between pulses and mm The ratio can be adjusted between 0 940 and 0 950 The optimum value is 0 945 Job settings Flap closer The flap closer offset is set in the System Settings menu Flap closer offset In the Flap closer menu in the Job Settings menu you can adjust the timing of the activation of the sealing sol...

Page 34: ... directly beneath this document must be at least 60 mm 2 4 inch longer than the BRE The upper document must be longer than the set address fold The folding mode is either single fold or letter fold no Z fold The upper document must be shorter than the envelope height It is possible to use the BRE offset for a BRE and an enclosure card in one set The extra condition is that this enclosure is equal ...

Page 35: ...sting the photocells it is strongly recommended to remove all paper from the machines and to clean all the sensors both transmitter and receiver of the photocells After the photocell have been adjusted the percentages in the screens should be lower if the cleaning advice was followed If no paper is present the photocell output voltage should have a value between 0 8 V and 1 5 V A value below this ...

Page 36: ... you can switch the motor off or let it run continuously during actuator tests The following tests are possible Main motor M2 the motor runs as long as the Test button is pressed Fingers magnet So1 the fingers move forward as soon as the Test button is pressed Only after releasing the Test button the fingers will move back to their rest position Eject roller magnet So2 press the Test button and ke...

Page 37: ...ence and shows some unexpected value After a first sheet is passed through the feeder the DFC will be calibrated at about 3 96 voltage For the next sheet the DFC is functioning correctly During normal operation the system automatically recalibrates Manual DFC testing and calibration can be easily done by removing the cover with an opened loc and manually turning the feeder separation gear In the s...

Page 38: ...zero Reading OMR OMR code definition The OMR code definition menu allows you to define the OMR reading codes The Table summarizes the possibilities of the OMR code When some functions are not used marks will shift up The minimum amount of marks are Start mark accumulate or insert That is 2 marks in total However it is highly recommended to add a third mark the safety mark in the minimum configurat...

Page 39: ...top mark Yes Stop Mark advanced No stop mark No advanced Selective feed on station 1 Yes Selective feed 1 advanced No selective feed on sta tion 1 No advanced Selective feed on station 2 Yes Selective feed 2 advanced No selective feed on sta tion 2 No advanced No sequence check No Sequence check advanced Sequence check 1 1 mark Maximum 2 sheets in se quence count advanced Sequence check 2 2 marks ...

Page 40: ...p mark No advanced No sequence check No Sequence check Advanced Sequence check 1 1 mark Maximum 2 sheets in se quence count Advanced Sequence check 2 2 marks Sequence check 1 Maximum 4 sheets in se quence count Advanced Sequence check 4 3 marks Sequence check 2 Sequence check 1 Maximum 8 sheets in se quence count advanced Sequence check 8 4 marks Sequence check 4 Sequence check 2 Sequence check 1 ...

Page 41: ...rection Advanced Normal reading direction No Advanced Parity check based on an even parity mark Yes Parity check Advanced No parity check No Advanced Mark is no sealing space is sealing Yes Unseal Advanced No sealing control No 38 4 063 1 Service Guide ...

Page 42: ...itional OMRrelated information This information is based on the last read document and the job settings OMR code type etc The displayed information is what is interpreted from the read OMR code Select Show OMR to display a graphical representation of the marks that had been read oscilloscope function The information shown is derived from the most recently read document The information screen shows...

Page 43: ... the communication board and to reset the status of the communication board to undeclared Once the communication board has been reset it can be used in another system As soon as the communication board is installed in another system i e during a board replacement it will be automatically reset Test CB Select Test CB to check the following the serial port The system checks if the RS 232 serial port...

Page 44: ...tag or main board has been replaced To do this choose Remove blockage from the Service menu Main board replacement After a main board replacement No will be answered The identity backup counter and enabled features will be restored from the ID tag ID tag replacement After an ID tag replacement factory prepared Yes will be answered As a second question you will be asked to enter the new total count...

Page 45: ...sport storage and installation 5 5 Transport storage and installation 42 Transport 43 Storage 43 Unpacking Instructions 43 Installation 46 Test the System and Define Custom Jobs 49 42 5 063 1 Service Guide ...

Page 46: ...ed under the following conditions 10 to 40 C 50 to 104 F Storage temperature 30 to 80 Humidity Unpacking Instructions Removing packaging material Remove the material as follows 1 Remove the cardboard A 2 Remove the labelled pin B 3 Cut the binding strap C and remove it 4 Open accumulation table D by pushing the bottom half downwards and remove the foam block 5 Close the accumulation table 6 Open t...

Page 47: ...1 2 44 5 063 1 Service Guide ...

Page 48: ...3 4 5 063 1 Service Guide 45 ...

Page 49: ...onnected to a socket outlet that has a protective earth connection If all items are delivered and the machine is placed in the correct position continue with these instructions Installation Installing the Document Feed Trays Place the document feed trays in position 1 Hold the document feeder slightly inclined as shown in the figure 2 Place the front end of the document feed tray underneath the tw...

Page 50: ...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 1 Remove the envelope catch tray and the slide 2 Hook in the side exit 3 Mount the new catch tray 5 063 1 Service Guide 47 ...

Page 51: ...damage the machine if it is connected to the incorrect power supply Before plugging in the machine check if the local voltage is the same as the voltage mentioned on the type plate 1 Connect the system to the mains power supply 2 Use the power switch to switch the system on The power switch is located on the right hand side of the system 3 Select the language for the display 4 Press No if the soft...

Page 52: ... button to follow the status of the connection The declaration call is finished if the System status shows Declared Test the System and Define Custom Jobs Testing the System Test the system as follows 1 Load the document feeder trays 2 Load the envelope hopper 3 From the Home menu press New job Automatic 4 Press the 1x button If necessary adjust address position insert position and insert fingers ...

Page 53: ...et service menu System settings Folder offset 8 Make sure that the flap closer quality is sufficient If not correct adjust the flap closer offset service menu System settings Flap closer offset Define jobs Define any jobs according to the customer s wishes applications 50 5 063 1 Service Guide ...

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