Formax 6602 Series User Manual Download

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6602 Series

Inserters

OPERATOR MANUAL

FIRST EDITION

8/2007

Summary of Contents for 6602 Series

Page 1: ...6602 Series Inserters OPERATOR MANUAL FIRST EDITION 8 2007...

Page 2: ...3 Operating Instructions 22 3 1 Installation 22 3 2 Preparation 22 3 2 1 Document Feed Trays 22 3 3 Starting Up 23 3 4 Loading Documents 24 3 4 1 Document Orientation 24 3 4 2 Side Guides 25 3 4 3 Do...

Page 3: ...1 Function 61 4 4 2 Preparations 61 4 4 3 Adjust Side Guides 62 4 4 4 Document Separation 62 4 4 5 Feeding Documents 63 4 5 Thin Booklet Feeder 63 4 5 1 Installation 64 4 5 2 Operating Controls 65 4...

Page 4: ...ions 80 7 1 Technical Specifications Inserter System 80 7 2 Configuration Dimensions 80 7 3 Other Specifications 80 7 4 Document Specifications 80 7 5 Envelope and Insert Specifications 81 7 6 Specifi...

Page 5: ...mains voltage Refer to the type plate Safety Precautions Only competent personnel should operate this machine If incompetent personnel do operate this machine the manufacturer does not accept responsi...

Page 6: ...5 ENGLISH Conventions Note A note gives additional relevant information...

Page 7: ...6...

Page 8: ...operated by means of a user friendly interface The settings of the system document type envelope type and fold type is recorded in jobs These jobs can be programmed by an authorized user The system is...

Page 9: ...sets of documents which cannot be processed automatically e g stapled 2 1 2 Collating Area 2 After feeding the documents are gathered and aligned in the collating area 2 1 3 Divert 3 The Divert autom...

Page 10: ...e stacker automatically stacks inserted documents 2 1 8 Side exit 8 The documents inserted are transported to the side exit depending on the programmed job The side exit can be used for sorting and st...

Page 11: ...ading head cover I vertical transport J hand grip vertical transport cover K document feed tray L collator arm M operator manual storage space N Folder O locking handle Folder P handle for manual enve...

Page 12: ...the clear process will be continued ignoring the empty feeder B the start key When the start key is pressed the system starts processing C the stop key After pressing the stop key the system does not...

Page 13: ...180 Only available if the insert n Frank insert n Mail option level 2 or 3 is installed go to the main menu 2 The main menu 2 shows 6 different functions job information see 2 4 2 Job Info on page 13...

Page 14: ...n menu 1 2 press The info job 1 menu contains the following information Shows the feeders selected to pick documents from black is selected The numbers below this icon indicate the number of sheets th...

Page 15: ...icates which envelopes leave from the side exit the arrow up indicates which envelopes are stacked The example shows exit settings by batching 5 envelopes to the side exit 5 envelopes to the stacker S...

Page 16: ...tween 0 switched off and 9999 The system will continue until the job counter reaches the stop counter value The system stops and can be re started Note The counter settings are job related 2 4 4 Displ...

Page 17: ...1 again After entering the correct pin code the job menu appears This menu enables the creation deletion and or editing of jobs The job menu shows the following functions job information see 2 4 2 Jo...

Page 18: ...tton this shows the software versions that are present in the total system shows option information and system information The chip ID The system ID The installed options For installing new options se...

Page 19: ...n to improve the envelope sealing process Mode Menu When selecting from the supervisor menu the mode menu appears In this menu for each of the jobs 1 through 25 and AutoSet a choice can be made betwee...

Page 20: ...e not overlapping each other i e the document offset value The default value is 50 mm 2 0 inch The document offset can be varied between 20 mm 0 8 inch and 75 mm 3 0 inch BRE Offset When selecting fro...

Page 21: ...lding and inserting Flap Closer When selecting from the supervisor menu the flap closer menu appears Use this function to improve the envelope sealing process for a job The offset can be varied betwee...

Page 22: ...opened from the test menu Use this menu to align and test the OMR reading head see Reading Head Position on page 49 The menu consists of the following functions align the OMR reading head Put a docum...

Page 23: ...ent 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 two black ro...

Page 24: ...tem 1 Connect the machine to the mains power supply 2 Use the power switch to switch the machine on The power switch is located on the back of the machine The display shows main menu 1 the main displa...

Page 25: ...er in top feeder Face up and leading Address carrier in top feeder Face up and leading Address carrier in bottom feeder Face down and trailing Address carrier in bottom linked pair feeders Face down a...

Page 26: ...le and push them towards the documents The space between the side guides and the documents should be such that the documents have just enough play to move freely 7 Re tighten knob B 8 Remove the stack...

Page 27: ...resistance is felt on the document 6 Pull the knob B back again when ready 7 Close the left hand side guide 3 4 4 Filling the Document Feed Tray Fill the document feed tray as follows 1 Open the left...

Page 28: ...handle documents up to 297 mm 11 7 inch and stop position C can handle documents up to 356 mm 14 inch 3 5 Loading Envelopes 3 5 1 Adjusting Side Guides Adjust side guides B by rotating thumb wheel C...

Page 29: ...n with sealing liquid 3 Close the front cover B Before starting the job wait approximately 5 minutes for the brushes to moisten 3 7 Job Selection or AutoSet When you are ready with the preparations pa...

Page 30: ...lopes with open flap For the envelope exit only the stacker is possible Note Before starting AutoSet be sure that no documents or envelopes are left in the machine 1 Load envelopes 2 Load the document...

Page 31: ...ert Fingers To adjust the envelope insert fingers 1 Loosen the knurled knob C 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 k...

Page 32: ...ing running the display shows the inserting menu 2 Press the button to stop the job The machine will stop immediately 3 Press the button to clear the document path to prepare the machine for a new job...

Page 33: ...envelope will not be sealed and ejected to the present on deck location When finished testing start the job see Starting the Job on page 31 If you want to test if the job s weight values are correctl...

Page 34: ...with Daily Mail press the button to stop the job 9 Turn left side guide A down 10 Move the Daily Mail handle to the AUTO position to disable the Daily Mail and to enable the automatic document separat...

Page 35: ...explained in 3 9 1 Job Settings on page 35 Note A new selected job number starts with default settings 6 Press to save the job with the entered settings under the specified job number and name To nam...

Page 36: ...162 mm 6 38 inch Use the second button to enter the envelope weight Weight information is used for selecting exit settings see 3 9 8 Exit Select Settings on page 43 Envelope settings see 3 9 2 Envelo...

Page 37: ...erent feeders Press to set the number of sheets for the different feeders Press to select a feeder or the optional Thin Booklet Feeder The selected feeder will be highlighted Press the arrows to chang...

Page 38: ...ess to link two feeders This function enables to fill two adjacent feeders with the same documents When the first feeder is empty the system automatically swaps to the other feeder Press to select two...

Page 39: ...3 9 8 Exit Select Settings on page 43 3 9 4 Fold Settings This screen enables the adjustment of the folding dimensions and the address type If the system is equipped with a third fold table and turnin...

Page 40: ...ers the following settings Code type default is the setting none OMR is disabled Change the setting using the button The following codes are possible 1 track OMR 2 track OMR only OMR level 5 Fold type...

Page 41: ...osures and selective enclosures can be handled with reverse reading When reverse reading is used the reverse reading symbol is shown in the job info screen In case the feeder runs empty the last set i...

Page 42: ...menu covers the following setting Stop on misread press to set if the machine should stop or not on misreading an optical mark When stop on misread is set to yes the machine stops after detecting an O...

Page 43: ...en per feeder is used for a reference measurement When a document is exceeding that reference thickness an error will be displayed Note When Daily mail is selected the DFC will be switched off automat...

Page 44: ...e to let the system continue on the side exit if the stacker is full Side exit Select the button if you want to create batches Alternate batches of inserted envelopes are stacked or leave from the sid...

Page 45: ...batch counter is set to 50 The preferred exit will change if the batch is complete or an OMR mark changes Select the button if you want to select the exit depending on the weight of the filled envelop...

Page 46: ...envelopes and the envelope width can be entered Use the and buttons to enter these data Press the button to return to the previous screen To link a mailing franking job to the inserter job use the arr...

Page 47: ...see 2 4 5 Job Menu on page 16 3 Press The copy job menu appears 4 Press the arrows if you want to select an other job number to copy from or to copy to Note You can only copy job settings to new jobs...

Page 48: ...code The job menu opens see 2 4 5 Job Menu on page 16 3 Press The delete job menu appears 4 Press the arrows if you want to select an other job number 5 Press for job details 6 Press The job will be...

Page 49: ...k or 2 track or Flex OMR This allows the system to read special codes that have been printed on the documents These codes contain information about the processing of the sheets With Flex OMR the syste...

Page 50: ...s in the feeder either feeder 1 or 2 depending on the selected job 4 Press The document will be transported to the reading head position 5 Open the special OMR reading head cover in the feeder 6 Shift...

Page 51: ...o obtain maximum blackness double strike Be aware of background noise Color changes on the form background design a logo or copy on the opposite side of the sheet that will bleed through can be read b...

Page 52: ...ft hand and right hand side 7 mm 0 28 inch must be kept clear The code must appear in the same location and have a consistent number of marks on every page For each additional mark one additional line...

Page 53: ...code must always be used on all material which must be processed by the Optical Mark Recognition The length of the code and the mark definition is a service setting Other marks functions are possible...

Page 54: ...ck stop mark is printed special sets will be sorted and leave from the upper unit However in this case the system will stop Note The envelopes will not be sealed Sealing Control When the sealing contr...

Page 55: ...a mark printed sequence check 1 sheet 3 a mark printed sequence check 2 no mark printed sequence check 1 sheet 4 a mark printed sequence check 2 a mark printed sequence check 1 etc sheet 1 no mark pri...

Page 56: ...In this example feeder station 1 is the reading feeder The feeder stations 2 through 6 are selected for selective feeding sheet 6 a mark printed sequence check 4 no mark printed sequence check 2 a ma...

Page 57: ...the last sheet of the set Position 6 7 and 8 are used for the sequence check marks The meaning of the sequence check marks is explained in section Sequence Check on page 53 4 2 5 2 track OMR 2 track...

Page 58: ...n 3 Selective feed 4 Feed from station 4 Do not feed from station 4 Selective feed 5 Feed from station 5 Do not feed from station 5 Selective feed 6 Feed from station 6 Do not feed from station 6 Thin...

Page 59: ...code must always be used on all material which must be processed by the Optical Mark Recognition The length of the code and the mark definition is a service setting Other marks functions are possible...

Page 60: ...he Online Services menu the display will show messages received from the server A message has content like new software or a new job 1 Press or to select a message 2 Press for more information over a...

Page 61: ...t value is on This setting is relevant to some PABX telephone switch systems Press to switch the dial tone detection on or off Telephone number of server contact your supplier for the telephone number...

Page 62: ...Feeder should be installed at the position of feeder no 1 and or 4 It can be placed into position in the same way as the other document feeders are fitted Proceed as follows 1 Lift the paper feed roll...

Page 63: ...adjusted separation To adjust proceed as follows 1 Remove feeders 2 and 3 Note The lowest feeder is feeder 1 2 Squeeze the two blue handles A and B and shift the feeding plate C as far as possible to...

Page 64: ...e sure that the document BREs are positioned parallel in relation to the feed plate to ensure correct feeding Note When longer documents are used plate C can be extended by pulling out the adjustable...

Page 65: ...the left and right hand side panel of the Thin Booklet Feeder 4 Lift the Thin Booklet Feeder above the fixing plates and lower it until it locks into place Both sides are now locked 5 Place both hands...

Page 66: ...freely Too much play causes skewing 4 5 4 Document Separation Adjustment Note Check before the adjustment that the release handle D for the separation unit is in the closed down position The document...

Page 67: ...or feeding turn the separation adjustment wheel counter clockwise 4 5 5 Hopper Capacity To avoid irregular feeding there are three levels for the maximum heights of the hopper capacity The symbols for...

Page 68: ...se the feed unit a Place your hand on the push down area F b Push the feed unit down until it locks into place 5 Place release handle D of the separation unit in the closed position 6 Press at the ins...

Page 69: ...support 4 6 Insert n Frank insert n Mail If this machine is connected to a mailing franking machine insert n Frank allows you to Switch automatic mailing franking on or off Remotely select a mailing...

Page 70: ...get stack fan shaped at the stacker To prevent this an optional power stacker support can be used in order to stack the envelopes correctly 4 10 High Capacity Envelope Hopper EF 4 For feeding large am...

Page 71: ...el At that moment a sensor will detect the envelopes and the high capacity envelope hopper will stop transporting When the sensor does not detect envelopes anymore the hopper will start again and the...

Page 72: ...able to the socket outlet 4 11 2 Operation The conveyor belt switch has three positions Mode D the belt moves in intervals Mode E the belt is switched off Mode F the belt moves continuously 4 12 Catch...

Page 73: ...saturated clean the brushes of the envelope sealing The machine is delivered with an extra set of brushes To always have one clean set available it is recommended to soak one set in water and use the...

Page 74: ...m re occurring After solving the problem press to reset the error the error screen will disappear Special Errors Reading errors when Optical Mark Recognition is enabled The document set is diverted Th...

Page 75: ...oppage occurs in the exit sealing and inserting area remove the material as follows 1 Open cover A 2 Remove all material 3 Close the cover 4 Press to reset the error and restart the job 6 2 2 Lower En...

Page 76: ...B 6 2 3 Folder When a stoppage occurs in the Folder remove the documents from the Folder as follows 1 Push the lower end of the locking handle A to open the Folder cover B 2 Remove the documents from...

Page 77: ...g Area When a stoppage occurs in the collating area remove the documents from the collating area as follows 1 Lift and hold the collator arm A 2 Remove the documents 3 Lower the collator arm 4 Press t...

Page 78: ...tions Envelope Settings on page 35 Wrong envelope type used not according specifications or job settings Change envelopes according to specifications Envelope Settings on page 35 Envelopes are double...

Page 79: ...rs adjusted too deep into the envelope Check fingers position adjust if needed Insert Position on page 30 Envelope stops too early Check envelope stop position adjust if needed Insert Position on page...

Page 80: ...72 Envelope not always ejected from sealer Inserted document too big Check fold settings adjust if needed Fold Settings on page 38 Document not inserted deep enough Check adjustment of envelope stop...

Page 81: ...conform EMC Directive FCC Certificate conform 47CFR part 15 CB Certificate conform IEC 60950 1 UL Listed I T E Information Technology Equipment conform UL IEC 60950 1 file E153801 Conform NEN EN IEC...

Page 82: ...356 mm 14 0 Folding capacity Single fold 10 sheets max 80 g m Letter fold Z fold 8 sheets max 80 g m Double parallel fold 4 sheets max 80 g m Envelope sizes Standard BRE Business Reply Envelopes Envel...

Page 83: ...al Specifications Inserter System on page 80 Power consumption low voltage supplied by the inserter system Approvals EMC Certificate conform EMC Directive FCC Certificate conform 47CFR part 15 UL List...

Page 84: ...ipment conform UL IEC 60950 1 file E153801 Conform NEN EN IEC 60950 1 and derivatives Height Width length 407 mm 16 0 inch 440 mm 17 3 inch 500 mm 19 7 inch Weight 30 5 kg 67 2 lbs Noise level 68 dB A...

Page 85: ...ifications on page 81 Feeder capacity max 1000 envelopes Model CS 2 Type High Capacity Conveyor Belt HCCB Power consumption 24V 1A max Approvals EMC Certificate conform EMC Directive FCC Certificate c...

Page 86: ...ses C fold See Letter fold Clear The function of an inserting system in which all mail sets in progress are finished and the document path is left empty Daily Mail Capability of an inserting system to...

Page 87: ...sheet is facing downwards when placed in a document feeder Face down leading Situation in which the front of a sheet is facing downwards and the top of the sheet is closest to the separation unit in...

Page 88: ...faulty documents before folding them while the system is still running Job A job is an actually produced collection of mail sets based on a certain Job Definition at a certain point in time for a spe...

Page 89: ...it is possible to analyze a problem on an inserting system from a remote location Service engineer Technical engineer whose task it is to resolve problems with systems in the field Besides dealing wi...

Page 90: ...dium office use 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 differe...

Page 91: ...15 settings 15 Divert 8 87 document 85 feed tray 10 height 36 offset 19 orientation 24 separation 25 settings 36 specifications 80 stopper 26 document orientation extended Folder 24 normal 24 OMR 50...

Page 92: ...counter 87 create 33 delete 46 edit 45 info 13 job menu 16 name 43 new 33 select another 31 settings 35 settings supervisor 18 start 31 L letter fold 87 loading envelopes 27 M Mail Piece Production C...

Page 93: ...7 start button 11 31 starting the job 31 stop button 11 31 stop counter 88 stoppage 74 collating area 76 exit 74 Feeder 76 inserting area 74 78 lower envelope track 74 Folder 75 sealing area 74 Thin B...

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