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Formax 6404 Series, Operator'S Manual

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Table of Contents

1

Read this First ..............................................................................................1

Warning............................................................................................................1
About this manual............................................................................................1
Safety...............................................................................................................2
Country Specific Conditions.............................................................................3
End of Life........................................................................................................4

2

Meet your Document System ......................................................................5

Overview..........................................................................................................5
Operating Controls...........................................................................................8
Control  Panel...................................................................................................9
Installing the Document Feed Trays...............................................................10
High Capacity Vertical Stacker.......................................................................11
Power Up........................................................................................................11
Home Menu....................................................................................................12
Job  Info..........................................................................................................13
Side  Guides...................................................................................................15
Document  Orientation....................................................................................16
Filling the Document Feeder Tray...................................................................17
Loading Envelopes.........................................................................................17
Sealing  Envelopes.........................................................................................19
Filling the Sealing Liquid Reservoir................................................................20
Shut Down the System...................................................................................20

3

Options ........................................................................................................21

Production 

Feeder..................................................

..

.....................................21

Installing the 

Production 

Feeder....................................................................21

Adjusting the 

S

ide Guides.....

....................

.....................................................22

Adjusting the Document Separation.

....................

..........................................23

Feeding documents 

with Production 

Feeder

.

.................................................24

High Capacity Document Feeder (HCDF)......................................................24

|  Page 1 | TOC | jan-06-2012 13:58 |

Summary of Contents for 6404 Series

Page 1: ...Formax 6404 Series Folder and Inserter Instruction Manual...

Page 2: ...6404 Series Mid Volume Inserter OPERATOR MANUAL 2 2012 MyBinding com 5500 NE Moore Court Hillsboro OR 97124 Toll Free 1 800 944 4573 Local 503 640 5920...

Page 3: ...11 Power Up 11 Home Menu 12 Job Info 13 Side Guides 15 Document Orientation 16 Filling the Document Feeder Tray 17 Loading Envelopes 17 Sealing Envelopes 19 Filling the Sealing Liquid Reservoir 20 Shu...

Page 4: ...RE or Inser ts 31 Document Separation 32 Adjustment of the Document Stoppers 33 Processing Daily Mail 34 Test Run 35 Adjusting the Address Position 35 Adjusting the Envelope Insert Fingers 36 Verifyin...

Page 5: ...re licensed options 62 Activating an option 62 Test Menu 63 Running diagnostics 64 Job Settings Supervisor 65 Flap Closer Offset 66 Envelope Clearing 66 System Output 67 Changing Document Offset 68 Ch...

Page 6: ...ance Schedule 90 Clean and replace brushes 91 Replace or clean moistening cloth 91 Clean the sensors on the envelope or document path 92 Clean the exit sensors 92 Resetting Photocells 93 10 Fault Find...

Page 7: ...l Stacker Specifications 109 12 Terminology 110 Terminology 110 13 EC Declaration of Conformity 116 EC Declaration of Conformity DS 85 M8500 FPi 5600 FD6404 116 EC Declaration of Conformity HCVS 1 117...

Page 8: ...Page 6 TOC jan 06 2012 13 58 MyBinding com 5500 NE Moore Court Hillsboro OR 97124 Toll Free 1 800 944 4573 Local 503 640 5920...

Page 9: ...ot have an operator manual in your country s language s contact your authorized distributor Software The software used for the reading option is based in part on the work of the Independent JPEG Group...

Page 10: ...r mail SUPERVISOR Indicates that you have to use the supervisor menu to perform the procedure Safety Warnings Disconnect the power supply before performing any maintenance Before connecting the system...

Page 11: ...n 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 12 pole conne...

Page 12: ...arly 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 t...

Page 13: ...y means of a user friendly interface The settings of the system types of documents type of envelopes and the type of fold is recorded in so called jobs These jobs can be programmed by an authorized us...

Page 14: ...m switches to the other feeder Meanwhile the empty feeder can be refilled without stopping the system The upper automatic feeder is equipped with a daily mail function You can use this feeder to proce...

Page 15: ...ed to the inserter The inserter inserts the documents into a waiting envelope The inserter seals the envelope or not depending on the settings Automatic monitoring ensures the correct number of insert...

Page 16: ...side guide adjustment V side guides envelope feed tray W lever for envelope separation adjust ment X envelopes support A High Capacity Vertical Stacker B loc cover C unlocking lever for loc D power in...

Page 17: ...mode Press the On Off button to switch back to the user mode B Stop The system completes the current mail set and stops leaving the system empty and ready for a new set C Start The system starts to pr...

Page 18: ...f the document feed tray underneath the two black rollers 3 Move the document feed tray upwards lifting the black rollers until it is possible to hook the feeder into place 4 Move the document feed tr...

Page 19: ...on hooks over the two rods upper and lower and lower it 3 Connect the connector 4 Adjust the side guides with wheel A until a margin of 3 to 5 mm is left between the envelopes and the side guides 5 Fo...

Page 20: ...When you start up the system the home menu appears With the arrows you can scroll through the jobs If you want more information on a job select the job If you just want to start without job definition...

Page 21: ...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 count...

Page 22: ...OMR or BCR is switched on optional This sign indicates that the relevant feeder is set for daily mail Gives information about the envelope size ISO format or height in mm An envelope with a cross mea...

Page 23: ...s in the middle and push them apart as far as possible 5 Put a small stack of documents between the side guides 6 Grab the side guides in the middle and push them to wards the documents The space betw...

Page 24: ...Document Orientation In case the optional extended powerFold is installed the following feeding rules apply to documents with bottom address position 16 Page 16 jan 06 2012 13 58 2 English...

Page 25: ...rn the left side guide upwards again 4 Feed the documents depending on the type of documents and the type of fold see Document Orientation on page 16 Loading Envelopes Before you load the envelopes ma...

Page 26: ...ver A to set the separation 5 Insert one envelope up to the stoppers The position of the envelope is flap down and trailing bottom side of the envelope pointing to the system 6 Return lever A 7 Loosen...

Page 27: ...isable the envelope sealing or towards to enable the envelop sealing 3 Close the top cover Before you start a job with sealing w ait approximately 5 minutes for the brushes to moisten or use moistened...

Page 28: ...moistened brushes For instructions on the installation of brushes see Clean and replace brushes on page 91 If the liquid reservoir is almost empty the touchscreen shows a message to warn you that you...

Page 29: ...ers To install the production feeder as follows 1 Lift the paper feed rollers with the front edge of the production feeder 2 Move the production feeder forward until it hooks behind the frame axle 3 C...

Page 30: ...ments BREs and place them in the feeder tray BREs with flap down and leading top side pointing to system 2 Adjust the side guides by turning the thumb wheel A so the documents BREs just fit and can mo...

Page 31: ...e C as far as possible to the front 3 Push knob D forward until it clicks 4 Place a document BRE on the feeder tray and slide it in the system till the leading edge is not visible anymore Turn knob D...

Page 32: ...1 Squeeze the two blue handles A and B 2 Shift the feeding plate C to the rear position 3 Loosen the stack of documents and place them in the feeder BREs with flap down and leading top side pointing...

Page 33: ...CDF 1 Pull down lever A 2 Hook in the feeder tray 3 Release lever A Adjusting the HCDF Side Guides To adjust the side guides B 1 Loosen the knob D half a turn 2 Put a small stack of documents between...

Page 34: ...et automatically There are no manual adjustments needed Feeding documents HCDF To fill the document feeder tray 1 Pull down lever A The feeder rollers C move up to filling level 2 Place a stack of doc...

Page 35: ...d below the envelope support and carefully rotate the envelope support until it is fitted correctly 5 Fasten the finger knob 6 Connect the connector Side Exit The system can be equipped with a side ex...

Page 36: ...settings on page 57 Refer to the appendix for an extensive description of the mailing franking option Mail Piece Production Control The document system can be equipped with Mail Piece Production Cont...

Page 37: ...will be folded if necessary and inserted into an envelope Only the feeders that feed successfully will be selected Only the Double Feed Control DFC of the upper f eeder will be selected this is done...

Page 38: ...tic to start an Automatic job 3 Load the documents and envelopes into the feeders 4 Press the 1x test run button to create one mail set and follow the instructions on screen After a successful test ru...

Page 39: ...the BREs with the flap down flap leading 1 From the home menu press the New job button 2 Choose Automatic to start an Automatic job 3 Load the documents BREs or inserts and envelopes into the feeders...

Page 40: ...ly possible when they are fitted on position 1 and 2 Adjust the separation of special feeders as follows Adjusting the separation using a special feeder is especially important when you want to proces...

Page 41: ...not needed When a job is selected in which a different stopper position has been programmed the operator has to put the document stoppers in the correct position as indicated b y the display To adjus...

Page 42: ...ected You can recognize the daily mail by the icon in the job information menus 2 Turn down the left side guide A of the upper tray Now you can see the Daily Mail handle B 3 Move the handle to the rig...

Page 43: ...fold settings for one set Check if the address is correctly positioned behind the envelope window Adjusting the Address Position If the address on your mail is not correctly positioned behind the en...

Page 44: ...he wizard To adjust the envelope insert fingers 1 Loosen the knurled knob D on top of each finger 2 Adjust each finger so that the tip enters about 5 mm 0 2 inch into the envelope 3 Re tighten the knu...

Page 45: ...underneath the green roller C To verify the insert position This adjustment must only be checked in case of prob lems or when changing the envelope type 1 Choose a job and press the 1x button 2 Lift t...

Page 46: ...be fed from each feeder and document height for each feeder Feeder linking on off If BREs or insert cards should be included Address position Fold settings Double feed control settings Reading settin...

Page 47: ...age 30 3 Enter the pin code 2546 4 Press OK to confirm the selected free job number A new selected job number starts with default settings The job settings menu opens The meaning of all buttons and se...

Page 48: ...are correct see Verifying the Insert Position on page 37 and Adjusting the address position on page 35 Performing a test run Before starting a job it is possible to perform a single test run with the...

Page 49: ...ting the Envelope Position Before performing a test run it is possible to adjust the envelope position To adjust the envelope position 1 Press the button to start adjusting the envelope position 2 Use...

Page 50: ...n to do a test run 3 If you want to change the counter for this job Press the Counters button to make changes to the amount of mail sets that the job produces 4 Press the Start button to start the job...

Page 51: ...e specified job n umber and name 5 Press the 1x button to verify that the insert position and address position are correct see Verifying the Insert Position on page 37 and Adjusting the address positi...

Page 52: ...can only copy job settings to new jobs 6 Press the button for details of the job to copy from 7 Press OK to copy the job settings If all jobs are programmed the touch screen shows No more free jobs It...

Page 53: ...sor menu button from the main menu 2 Enter the pin code 2546 3 Press the Job menu button The job menu opens 4 Press the Delete job button The delete job menu appears When you press OK the job is delet...

Page 54: ...d control settings on page 55 Job name settings see Job name settings on page 56 Mailing Franking settings if installed see Mailing and Franking settings on page 57 Mail Piece Production Control MPPC...

Page 55: ...ss the button to select an en velope with open flap This means that envelopes are fed with open flap Use the upper button to enter the applicable dimensions The envelope height can be set between 90 m...

Page 56: ...for your document set from each feeder This is called Multi Feed Press the arrows to change the number of sheets that must be picked from the highlighted feeder When the number of documents is 0 the...

Page 57: ...an be set between 90 mm 3 54 inch and 356 mm 14 inch The default document size setting of a new job is 297 mm 11 7 inch Press the button to link two feeders This function enables to fill two adjacent...

Page 58: ...to enable the daily mail function The icon appears behind the upper feeder If you press the button again the daily mail function will be disabled The daily mail function is only available when reading...

Page 59: ...old Z fold For Bottom address only three fold types are possible Except when no fold is required the touch screen sho ws a simple diagram of the document with the fold positions To change the fold pos...

Page 60: ...ription of reading see Reading Introduction on page 70 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 t...

Page 61: ...fine the location and the width of the OMR code The position from top should be between 15 mm 0 6 inch and the document length min us 20 mm 0 8 inch If you press Next you can load an OMR sheet to veri...

Page 62: ...the system starts processing again The diverted set should be checked by the operator When stop on sheet overflow is set to no the system does not stop when a set exceeds the maximum number of sheets...

Page 63: ...t taken per feeder is used for a reference measurement When a document is exceeding that reference thickness an error will be displayed Press the button to set Continue on double on or off If Continue...

Page 64: ...ognize the job This name is displayed at job selection Enter a job name with the alpha numeric keypad Use the button to clear a character left of the cursor position backspace Use the CE button to cle...

Page 65: ...utton you can choose a franking job from the franking machine Inserter the mailing franking system will print frank the envelopes according to the size data communicated by the inserter When you press...

Page 66: ...Mail Piece Production Control settings option For Mail Piece Production Control settings see the appendix operator manual Mail Piece Production Control 58 Page 58 jan 06 2012 13 58 5 English...

Page 67: ...u The Display Settings menu contains the following settings Set screen brightness see Changing the Display Settings on page 60 Set interface volume see Changing the Display Settings on page 60 Change...

Page 68: ...edit any of the Anvanced Settings 1 From the home menu press the Menu button 2 Choose if you want to see the Display Settings or the Supervisor Menu Press the according button to enter that menu Pleas...

Page 69: ...ere the following information is shown Flex certificate this option is used for OMR Counter since last visit the counter value since the last service visit Last error The last error generated by the s...

Page 70: ...t these license codes The system supports the following licensed options Advanced reading see Reading Introduction on page 70 OMR 1 track see OMR Code Description on page 77 BCR 1D see BCR Code Descri...

Page 71: ...s The menu consists of the following functions Diagnostics Use this function to check if all motors clutches and sensors are correctly connected This test derives the status of the actuators and clutc...

Page 72: ...e all covers before starting the diagnose 3 In the Hardware test menu press the Start diagnose button When the test is finished the Status report is shown showing a list of all problems found during d...

Page 73: ...s by changing the flap closer offset for one or more defined jobs see Changing the Flap Closer Offset on page 66 Envelope clearing Use this option to define when envelopes are cleared from the system...

Page 74: ...the sealing process will be activated 10 pulses later than initially 3 Press the Save button to save the changes to the selected job Envelope Clearing To define when envelopes are cleared 1 Use the n...

Page 75: ...set is going into the collator already This results in temporary overlapping sets with two different transport directions In mode 1 the set has left the collator completely before the next set enters...

Page 76: ...r This overlapping scheme ensures that the documents are properly aligned in the collator area In the document offset menu you can set the extend to which the documents are not overlapping each other...

Page 77: ...insertion into the envelope the documents of the set will be realigned The conditions are The feeder that supplies this upper document BRE is set to one document per set no multi feeding The document...

Page 78: ...ode the other feeders can be used as selective feeders to add enclosures In case of a Z fold the address has to be pr inted on the last page of the set seeDocument orientation on page 72 for the code...

Page 79: ...ng Reverse reading means that the insert mark OMR 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 In case of BCR use the Customer ID...

Page 80: ...n Switch on the reading function and set the position of the reading marks as described in BCR Code Description on page 73 and OMR Code Description on page 77 Document orientation 72 Page 72 jan 06 20...

Page 81: ...hickness of a bar 0 25 mm 0 01 inch The thickness ratio of thick bars versus thin bars 2 2 The white area in the picture shows the limits where the code can be printed BCR license types There are two...

Page 82: ...egardless of the document set it is part of If a sheet is missing an error is generated Group sequence every document in a set has the same group number If one document set is missing an error is gene...

Page 83: ...rts Use the arrows at the bottom of the screen to navigate between the two parts of this screen 5 Press the Back button to leave the BCR settings menu 6 Press the Save button to save the BCR settings...

Page 84: ...utton to start the BCR test After the test is finished the Result screen appears 3 In the Results screen evaluate the test results Use the button to see the BCR info or use the button to cycle through...

Page 85: ...ark from the top is set to 100 mm 3 9 inch This parameter is set in the job settings The code must have a consistent number of marks on every page The white area in the picture shows the limits where...

Page 86: ...he 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 part of the code definition The minimum code is one ma...

Page 87: ...closure when commanded so Sequence Check Sheets in a stack can accidentally get out of sequence or can be missing This can be detected by the sequence check Each sheet has a binary code that is a part...

Page 88: ...Therefore the mark is printed on the last sheet of the set Position 3 is reserved for selective feed from the enclosure feeder Print a mark on position 3 when a selective feed from the enclosure feed...

Page 89: ...R test After the test is finished the Result screen appears 3 In the Results screen evaluate the test results Use the button to see the OMR info 4 Press the Back button to return to the OMR test menu...

Page 90: ...option is available Start up Online Services To start up Online Services 1 From the supervisor menu choose Online services The Online Services menu shows the following functions Connection opens the...

Page 91: ...xt on the button changes to Disconnect 3 Press Disconnect to terminate connection with the server The connection menu shows the following functions History opens the history menu to view the connectio...

Page 92: ...screen will sho w messages received from the server A message has content like a new job or new software To view the messages 1 Press the arrows to select a message In case a new job or new software c...

Page 93: ...installed the Continue button appears To install a new job or new software 1 Press Continue The new job available menu or new software menu appears 2 Press the button for more information on the new...

Page 94: ...onfiguration menu opens Use this menu to modify the OLS settings The menu consists of two submenus containing the following functions Telephone number of server contact your supplier for the telephone...

Page 95: ...he new number 4 Press OK to confirm the modified settings and leave the Configuration Menu Changing the prefix To change the prefix 1 Press the button next to the prefix 2 Enter the correct prefix usi...

Page 96: ...m the modified settings and leave the Configuration Menu Entering date and time To enter the current date and time 1 Press the button next to the date time 2 Enter the correct date time using the nume...

Page 97: ...ed settings and leave the Configuration Menu Setting the modem volume To set the modem volume 1 Press the button next to the volume symbol to increase decrease the modem volume Do not set the volume t...

Page 98: ...is recommend ed to soak one set in water and use the other set Weekly When dirty or saturated clean the brushes of the envelope sealing or replace them see Clean and replace brushes on page 91 When d...

Page 99: ...ushes Make sure that the studs on the brushes are fitted in the corresponding holes in the brush holder Replace or clean moistening cloth When dirty or saturated clean the moistening cloth or replace...

Page 100: ...eeze a few times to blow the dust from the document path sensor 3 Place the bellows in the lower air plug and firmly squeeze a few times to blow the dust from the envelope path sensor 4 Calibrate the...

Page 101: ...e Reset photocells button The Calibrate photocells menu appears 2 Remove all documents and envelopes and close all covers before starting the calibration 3 In the Calibrate photocells menu press the C...

Page 102: ...e error the error screen will disappear Special Errors Reading errors when reading is enabled The document set is diverted The operator must remove the document set and has to complete the set manuall...

Page 103: ...area 2 Collating area 3 Folding area 4 Lower envelope track 5 Moistening and inserting area 6 Sealing and exit area 7 Envelope hopper 10 English 95 Page 95 jan 06 2012 13 58 MyBinding com 5500 NE Moo...

Page 104: ...ng area C collator arm to reach the collating area D vertical transport cover to reach the vertical transport and feeding area E Folding aread cover to reach the folding area F side cover to reach the...

Page 105: ...er of the loc and pull the loc up into the vertical position 3 Remove all material 4 Close the side cover 5 Lower the loc and the inserter cover 6 Press the Reset button to reset the error and restart...

Page 106: ...ing Envelopes on page 17 6 Return lever B 7 Press the Reset button to reset the error and restart the job Lower Envelope Track When a stoppage occurs in the lower envelope track remove the envelopes a...

Page 107: ...nts as follows 1 Push the lower end of the locking handle A to open the powerFold cover B 2 Remove the documents from the Folding area If necessary use the delivered pin to turn the rollers The pin is...

Page 108: ...he vertical transport cover B 4 Press the Reset button to reset the error and restart the job Collating Area When a stoppage occurs in the collating area remove the documents from the collating area a...

Page 109: ...e Remedy Possible cause Symptom Connect the system to the mains System not connect ed to mains The system cannot be started after switching on Replace fuse below power switch Fuse is blown Close the c...

Page 110: ...port not positioned correctly Verifying the Insert Position on page 37 Check specifications and change en velopes if needed Envelope not within specifications Flap is wrinkled and sometimes not opened...

Page 111: ...if needed by the extra soaked set Brushes dry Maintenance Sched ule on page 90 Check brushes clean if needed Brushes dirty Filling the Sealing Liquid Reservoir on page 20 Check the moistening felt re...

Page 112: ...on page 32 Adjust the separation Separation set too wide Double documents fed Verifying the Insert Position on page 37 Check insert position Insert position not correct Document set not correctly ins...

Page 113: ...rent 125 V 230 Vac T 2 5 A H 250 V Time lag 2 5 Amps rated current high breaking capacity 250 V EMC Certificate conform EMC Directive Approvals FCC Certificate conform 47CFR part 15 CB Certificate con...

Page 114: ...88 5 kg 195 lbs Weight Length with receiving tray 1590 mm 62 6 inch with side exit 1440 mm 56 7 inch with stacker 1840 mm 72 4 inch Document and Insert Specifications Minimum 60 g m 15 lb bond Maximum...

Page 115: ...cifications G F E D C B A 60 g m2 84 mm 3 3 10 mm 0 4 32 mm 1 25 90 mm 3 5 160 mm 6 3 Mini mum size 2 5 mm 0 1 B 6 B 0 2 A 12 A 0 47 75 mm 2 9 B 32 B 1 25 162 mm 6 38 248 mm 9 7 Maxi mum size Booklets...

Page 116: ...Model FD 6404 00 Model High capacity feeder Type 4000 inserts per hour depending on application see Technical Specifications on page 105 Theoretical max speed Low voltage supplied by the inserter sys...

Page 117: ...ate conform EMC Directive FCC Certificate conform 47CFR part 15 UL Listed I T E Information Technology Equipment conform UL IEC 60950 1 file E153801 Conform NEN EN IEC 60950 1 and derivatives Approval...

Page 118: ...orizontal width w and a vertical height h Address position The feature of an Inserting System to automatically determine its Job settings by measuring the sizes of documents and envelope From all Feed...

Page 119: ...always one address carrier and an optional number of enclosures Document The document set is the physical collection of address carrier and en closure s that is under production in the Inserting Syst...

Page 120: ...rds and the bot tom of the sheet is closest to the separation unit in a document feeder Face down trailing Situation in which the front of a sheet is f acing upwards when placed in a document feeder F...

Page 121: ...ll the Modules that cooperate to perform the inserting function accumulate document set fold and insert and have a single point of control Inserting system Interface for the Neopost franking machine i...

Page 122: ...at makes it is possible to analyze a problem on an Inserting System from a remote location Remote diagnostics Technical engineer whose task it is to resolve problems with systems in the field Besides...

Page 123: ...nd collator Vertical transport A Z fold means that a document is folded twice in such a way that each folded flap is on a different size of the folded document resulting in a Z shape This fold is illu...

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