Formax 6206 Series User Manual Download

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6206 Series

Low-Volume Desktop Inserters

OPERATOR MANUAL

3/2013

Summary of Contents for 6206 Series

Page 1: ...6206 Series Low Volume Desktop Inserters OPERATOR MANUAL 3 2013...

Page 2: ...trol Panel and Home Menu 9 Job Menu 10 Loading Documents 12 Loading BREs option 14 Loading Envelopes 16 Filling the Sealing Liquid Bottle 18 Shut Down the System 20 Processing Mail Sets 21 3 New Mail...

Page 3: ...39 Adjusting Reading Settings 46 Test Reading with BCR 41 Process Mail Sets with BCR 42 OMR Code 43 Adjusting Reading Settings 46 Test Reading with OMR 47 Process Mail Sets with OMR 47 Online Services...

Page 4: ...ing 62 9 Error Messages 62 Clearing Stoppages 63 Calibrate Sensors 68 Troubleshooting 69 Troubleshooting Tables 69 Specifications 75 10 Technical Specifications 75 Feeder and Stacker Capacities 76 Dim...

Page 5: ......

Page 6: ...e 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...

Page 7: ...electrical supply ensure that the system is suitable for the local mains voltage Refer to the serial plate on your system for voltage requirements Precaution The general process of automated document...

Page 8: ...n 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 coupler CAUTION DO...

Page 9: ...h and 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...

Page 10: ...olding 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...

Page 11: ...a double feed control DFC DFC detects if one or more documents are fed at the same time If two document feeders are available you can use Feeder Linking This means that two feeders can be linked as pa...

Page 12: ...d 8 The fold unit folds the documents The following fold types are possible see Terminology No fold V fold C fold Z fold Double V fold Inserter 7 After the documents are folded the documents are trans...

Page 13: ...nection B LAN for the Online Services connection C Mini USB port device for a connection to a PC for service purposes only D USB port host for an analogue modem or connection to an USB flash drive E R...

Page 14: ...r the system switches to power save mode Press the ON OFF button to switch back to user mode 3 Saved Jobs Screen Displays a list of available settings jobs 4 Home Screen Shows your document system wit...

Page 15: ...Job Menu The New Job Menu is displayed when The system is started The Home icon is pressed A green feeder indicates that the system detected documents or envelopes in the indicated feeder 10 2 English...

Page 16: ...ress Position Sets the address position If the address is not fully visib le through the envelope win dow use this button to adjust the position 4 Enclosure document feeder Sets the number of docu men...

Page 17: ...p and leading Address carrier in upper feeder Face up and leading Address carrier Face up and leading Address carrier in upper feeder Face up and leading no fold V fold C fold double V fold Address ca...

Page 18: ...velope fits between the documents and the side guides over the whole length of the feeder the play is correct 4 Place a stack of documents in the f eeder do not place more documents than indicated by...

Page 19: ...k support B 3 Put a small stack of documents or BREs between the side guides 4 Release back support B 5 Move the side guides toward the documents or BREs The play between the side guides and the docum...

Page 20: ...hat the envelope flap is facing you and in downward position see picture Refer to the specifications for the maximum amount of documents or BREs you can load into the feeder You can also use C5 BREs T...

Page 21: ...ng envelopes correctly will help prevent jams and mis feeds To load envelopes 1 Rotate thumb wheel A to move the side guides apart 2 Pull back support C 3 Put a small stack of envelopes between the si...

Page 22: ...s the play is correct 6 Extend supports B when you work with wide envelopes 7 Place a stack of envelopes in the hopper see figure Refer to the specifications for the maximum amount of envelopes you ca...

Page 23: ...system is out of sealing liquid the mailing process continues but the envelopes will not be sealed properly The sealing liquid level detection system will warn you when your sealing liquid bottle is a...

Page 24: ...net thread to open 4 Fill the bottle with sealing liquid up to the filling level indicator and close it Fill the sealing liquid bottle with the sealing product that is recommended by your dealer Any o...

Page 25: ...nsure that bottle is placed correctly 6 Close the system Shut Down the System 1 Press the On Off button to shut down the system When the system is busy it completes and inserts the current set stops a...

Page 26: ...of the appropriate feeder changes color to indicate that documents are present Only the feeders where documents are present are used to process mail sets Make sure that the liquid reservoir is filled...

Page 27: ...ail sets when one of the feeders is empty or the red Stop button is pressed Mail sets with BRE or inserts A mail set with BRE consists of documents from one or more document feeders and an insert BRE...

Page 28: ...n page 24 Before you start ensure you have read the introduction on processing mail sets on page 21 The daily mail feeder has a fixed width letter We recommend you to use only documents of this size 1...

Page 29: ...you have to select a fold type 2 By default the V fold is selected to change the fold type follow the instructions on the screen 3 Load documents in the document feeders BRE feeder or daily mail feed...

Page 30: ...ument for your document set This is called Multi Feed Multi feed is not available on the BRE feeder 1 Press the Document Feeder icon next to one of the feeders 2 Press the or button to set the number...

Page 31: ...roceed as follows 1 Press the Fold Type icon to select a fold type After a testrun at the fold type icon an arrow is visible 2 When you press the the Fold Length screen is displayed The fold length sc...

Page 32: ...tion Run a Batch If you have to run a fixed number of mail sets you use batch 1 Load the documents BREs or inserts and envelopes into the feeders 2 Set any options like feeder linking and multi feed 3...

Page 33: ...er and vice versa Meanwhile the empty feeder can be refilled without stopping the system To link two feeders 1 Press the Feeder Linking icon The Feeder Linking screen is displayed 2 Select Yes and pre...

Page 34: ...the job and immediately start without defining any settings The following settings are saved in a job Address position Batch counter Envelope type Feeder linking on off Fold type and fold lengths If...

Page 35: ...est run or batch To save your settings to a job 1 Press the icon in the job settings menu 2 Follow the instructions on screen enter a job name and press the OK button You can only save a job if you do...

Page 36: ...r select and sort on frequency If one of the feeders shows a warning symbol it means the selected job wants to use this feeder but the system does not find any documents or envelopes in this feeder 2...

Page 37: ...ou want to edit a job 1 Select a job from the job list 2 Edit the job settings See Job Menu on page 10 3 Press the save button 4 Choose Overwrite to save the changes to the job The modified job is sav...

Page 38: ...Delete a Job If you want to delete a job 1 Select a job from the job list 2 Press the icon and press OK confirm The job is deleted 4 English 33...

Page 39: ...lowing is explained How to set the language How to set the date and time How to add an option Setting the Language Date and Time To set the language date and time 1 Press the icon in the home menu to...

Page 40: ...censed Options You can add the following options with a license key special code Reading barcode and OMR Online Services Insert n Frank insert n Mail For information about options that are available t...

Page 41: ...s Menu 2 Press Supervisor Licensed options The Licensed options menu appears The menu shows the options that are already available 3 Press the Add option button 4 Enter the license key of the option y...

Page 42: ...nts The system can read two code types BCR BarCode Recognition OMR Optical Mark Recognition Depending on the settings the code tells the system if The document set is complete Enclosures must be added...

Page 43: ...have equal intensity Print the code at the same position on every sheet Be aware of background noise The reading function can be disturbed by color changes on the form background design or a logo or...

Page 44: ...ead 1D vertical and horizonal barcodes Minimum line thickness of a bar 0 25 mm 0 01 The thickness ratio of thick bars versus thin bars 2 2 The white area in the picture shows the limits where the code...

Page 45: ...ate Sheet sequence every sheet has a number regardless of the document set it is par t of If a sheet is missing an error is generated Group sequence every document in a set has the same group number I...

Page 46: ...te a test to ensure that The system finds the reading code on the document The reading code is of sufficient quality To test reading 1 From the Settings Menu press Reading 2 Press the Test reading but...

Page 47: ...arcodes in the main document f eeder see for more information about the orientation BCR code on page 39 The first sheet of a set alw ays contains the address The code must appear in the same location...

Page 48: ...st mark from the top is set to 100 mm 3 9 This parameter is set in the Service Settings menu Reading Optical Mark Reading The code must have a consistent number of marks on every page The white area i...

Page 49: ...e In these situations the safety mark is not read and the system will give an error The safety mark also indicates the end of the reading code This mark must always be present on the document if it is...

Page 50: ...If the system reads the function an enclosure from the enclosure feeder is added to the set Sequence Check Ensures that no documents are missing from the set each sheet has a number that is part of th...

Page 51: ...of the OMR code on a document not relevant to BCR BCR configuration sheet Set BCR configuration code by reading a sheet with a configuration code not relevant for OMR Max Number of Sheets Define the m...

Page 52: ...system read marks but it did not match OMR as defined in the system Contact the service organization for more information on the OMR definition Process Mail Sets with OMR To process mail sets with OMR...

Page 53: ...and system problems Receiving messages on new options etc It is always the system that initiates the connection It is not possible to make a connection from outside to the system Connection Settings...

Page 54: ...ur situation and press OK You can find detailed information about the OLS settings in the installation guide that is delivered with this product In case you do not have this document go to the followi...

Page 55: ...ne connection 2 From the Settings Menu select Supervisor Communication Settings 3 Press Analogue Modem Settings 4 Make the settings applicable to your situation and press OK You can find detailed info...

Page 56: ...gs Menu and then press Forward 7 Select Change 8 Select Analogue Modem and press OK 9 Make your connection with the OLS server see connecting to the online server on page 51 Connecting To The Online S...

Page 57: ...ead the error message for more information If the connection fails execute the tests in Test OLS with LAN or Test OLS with modem Viewing Connection History The Connection history menu shows previous c...

Page 58: ...to 30 messages 1 From the Settings Menu select Online services 2 Select Messages A check mark indicates that the message is read a star indicates that the message is not read 3 To view the contents of...

Page 59: ...lect Online services 2 Select Messages A check mark indicates that the message is read a star indicates that the message is not read 3 To view the contents of a message select a message from the list...

Page 60: ...ation Keep the system in proper condition remove dust paper remains etc When dirty clean the sealing area and rubber rollers with a slightly wetted cloth soaked in warm water When dirty or saturated c...

Page 61: ...ling the envelopes If the brush is dirty or if you have to replace the brush proceed as follows 1 Open the system 2 Remove the sealing liquid bottle bef ore removing the brush After removing the seali...

Page 62: ...he brush cover opens 5 Open the system 6 Remove the brush a Lift the combiroller A b Lift the pressplate B and keep it in the upright position with your hands c Press the clips on the side of the brus...

Page 63: ...h or moisten the new brush with running tap water 8 Replace the brush in the system 9 In the replace brush menu press Close the brush cover closes 10 Place the sealing liquid bottle and close the syst...

Page 64: ...e document feeder Make sure you have spare parts kit 2828602K available To remove the separation rollers from the feeders 1 Pull the document feeder out of the system 2 Pull the flap with rollers out...

Page 65: ...pecial tool available in the spare parts kit to pick up the axle 4 Attach the new separation axle to the tool 5 Install the separation axle in the document feeder The cupper part must fit into the squ...

Page 66: ...6 Place the new flap with the seperation rollers in the feeder 7 Install the document feeder in the system Push it into the system until you hear a click 8 English 61...

Page 67: ...i button to view detailed information about the error and the possible actions to avoid the error re occurring In case of reading errors when reading is enabled the document stops in the collating ar...

Page 68: ...ws steps how to solve it If a document or envelope is at an other location check the following locations Document feeders pull out the feeder trays BRE feeder lift the feeder out of the system Inside...

Page 69: ...3 Squeeze C and open the collator area 4 Rotate E to rotate the collator 5 Open the envelope path pull lever A and lift part F 64 9 English...

Page 70: ...6 Rotate wheel G to move the fold knife 7 Push levers H and lift the folding pocket I out of the system 9 English 65...

Page 71: ...8 Lift B to lift the combi roller Rotate J to remove any envelopes 66 9 English...

Page 72: ...0 On the front side push the grips at the bottom of the bottom cover as indicated in the figure and remove the bottom cover from the system 11 Remove any envelopes from the transport belt 12 When read...

Page 73: ...move all paper and envelopes from the system 2 From the Settings Menu select Supervisor select Maintenance select Photocells 3 Select Calibrate to start the calibration of the photocells After a short...

Page 74: ...tem operation 4 When the error still occurs contact your service organization Troubleshooting Tables Startup Problems Reference Remedy Possible cause Symptom Connect the system to the power supply Sys...

Page 75: ...ed Filling the sealing li quid bottle on page 18 Check water level refill if needed Water level low Flap not sufficiently moistened Replace brush on page 56 Check brush replace if necessary by the ext...

Page 76: ...adjust if needed Side guides of the envelope hopper are set too wide Envelope stops skewed Loading envelopes on page 16 Refill hopper Hopper almost empty Envelopes are fed ir regularly Loading envelo...

Page 77: ...ide guides set too wide Skewed documents fed Loading documents Adjust the side guides Side guides set too narrow Poor or irregularly fed documents Replace separation rollers of document feeder on page...

Page 78: ...ca tions Check envelope spe cifications Envelope throat incor rect Insert failure Eliminate faulty envel opes Envelope glued in side Eliminate faulty envel opes Window not glued properly Loading Docum...

Page 79: ...ptom Calibrate sensors on page 68 Reset the system If the error persists calibrate the sensors Sensors are dirty Error message Dusty sensor The system shows an error message orOn line Services is call...

Page 80: ...200 W 100 VAC 60 Hz Maximum 5 A 200 W Power consumption running mode 0 5 W Power consumption standby mode 100 240 VAC 10 6 Voltage tolerance 230 VAC 10 10 EMC Certificate conform EMC Directive Approva...

Page 81: ...0 g m Daily mail feeder 250 BRE s of 80 g m2 250 insert cards of 160 g m or 1 mm 0 04 thickness BRE feeder 250 envelopes of 100 g m Envelope hopper 250 envelopes depending on the set size and fold typ...

Page 82: ...size daily mail Do not place staples in the center of the document 75 mm 3 to either side of the centre line Daily mail V fold 8 sheets max 80 g m C fold and Z fold 5 sheets max 80 g m Double V fold 2...

Page 83: ...84 mm 32 mm 90 mm 160 mm 220 mm Min size 2 mm A 14 mm B 6 mm 54 mm 162 mm 165 mm 242 mm Max size 15 lb bond 5 1 3 3 1 3 1 3 6 3 8 7 Min size 0 08 A 0 55 B 0 02 2 1 2 1 6 5 9 5 Max size The maximum fl...

Page 84: ...J I H G 45 85 0 26 mm 68 mm Throat length 45 85 10 36 mm 43 mm Throat length 45 85 0 1 0 2 7 Throat length 45 85 0 4 1 4 1 7 Throat length 10 English 79...

Page 85: ...easeline Window size Maximum set thickness is 2 mm 0 08 Maximum insert specifications are based on single sheets When multiples are handled more room inside the envelope is needed depending on the app...

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