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Muller 6609 Operating Instructions Manual Download Page 2

Mod. 6609d-6612d: 

Automatic Forms Cutter

13.12.2006

-2-

List of Contents

 

EC Declaration of Conformity

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Safety Instructions

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1. Setting up the machine

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1.1 Selecting a location

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1.2 Unpacking the machine and checking the parts

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1.3 Parts list

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1.4 Installing the stacker tray

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1.5 Testing the forms cutter

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1.6 Subassemblies 

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2. Starting up 

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2.1 Switching the machine on

 

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2.2 Selecting the program

 

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2.3 Loading paper 

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2.3.1 Inserting the paper

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2.3.2 Adjusting the edge blades

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2.3.3 Automatic positioning of the forms

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2.3.4 Paper adjustment with reader from above

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2.3.5 Paper adjustment with reader from below

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2.4 Starting the forms cutter 

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2.4.1 Display

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2.4.2 Test cut

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3. Operating the machine 

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3.1 The operating terminal

 

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3.1.1 Introduction to the operation of the machine

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3.1.2 Panel keys

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Summary of Contents for 6609

Page 1: ...Braillo Cut Operating Instructions Automatic Forms Cutter Model 6609d 6612d Release 12 12 2006 ...

Page 2: ... Subassemblies 8 2 Starting up 9 2 1 Switching the machine on 9 2 2 Selecting the program 9 2 3 Loading paper 9 2 3 1 Inserting the paper 9 2 3 2 Adjusting the edge blades 9 2 3 3 Automatic positioning of the forms 10 2 3 4 Paper adjustment with reader from above 11 2 3 5 Paper adjustment with reader from below 11 2 4 Starting the forms cutter 12 2 4 1 Display 12 2 4 2 Test cut 12 3 Operating the ...

Page 3: ... 1 Parameter a Label 23 3 3 1 2 Parameter f Speed 24 3 3 1 3 Parameter g Pause 24 3 3 1 4 Parameter h Fine Position 25 3 3 1 5 Parameter k Reader 26 3 3 1 6 Parameter l Copy 27 3 3 2 Programming the OMR routines 29 3 3 2 1 Explanation of terms relating to optical mark recognition OMR 29 3 3 2 2 Entering the 5 digit number for the pattern of marks code 32 3 3 2 3 Entering the 5 digit number for the...

Page 4: ...Mod 6609d 6612d Automatic Forms Cutter 13 12 2006 4 ...

Page 5: ... service routines given in the operating instructions you should never attempt to repair the machine yourself If problems arise call the service technician at your customer service centre Keep long hair fingers and jewellery well away from rotating machine parts 1 Setting up the machine 1 1 Selecting a location The following factors are important in selecting a location for the machine Avoid direc...

Page 6: ...nd is not required for installation 1 4 Installing the stacker tray 1 Unpack all parts Unscrew the fasteners on the side pieces These parts are fixed to the side pieces with a nut The nut is only for protection during transport Make sure that the disc springs are fitted in the correct position 2 Screw the side pieces to the stacker tray and hang in position on the back of the machine 3 Fit the pap...

Page 7: ...eed as follows 1 Unscrew the housing from the right side wall of the forms cutter 2 Slowly turn by hand the large belt pulley to which the connecting rod is fastened No strong resistance should be felt 3 Raise the upper blade to its maximum position by turning the pulley From the back of the forms cutter insert a sheet of paper on the far left between the upper and lower blades and perform a cross...

Page 8: ...ts 1 Chassis 2 Driving shafts for Randschneider 3 Driving shafts for Tractor 4 Chassis and Platine 5 Safety cover 6 Cross cutter blade bar 7 Cross cutter ejector 8 Cross cutter driving unit 9 Tractor unit 10 Tractor left and right 11 Edge cutter unit 12 Edge cutter left and right 13 Terminal 14 Electronic 15 Stand 16 Fan 17 ...

Page 9: ... tractor screws Set the tractors at approximately the width of the paper but do not lock them Insert the paper Make sure that the leading edge is cleanly torn off as otherwise the paper will not be cut on the cross perforation Now close the tractor covers and position the paper in the centre of the machine Use the centre paper guide as an aid Fix the screws on one of the tractors and adjust the te...

Page 10: ...n the machine it is important to chec k that the leading edge of the paper has been clean ly torn off at the cross perforation This is necessary because due to the automatic positioning of the paper on the cutting edge the forms will otherwise not be cut exactly on the cross perforation The machine automatically recognizes the leading edge of the paper and transports it immediately to the cutting ...

Page 11: ...e line before or below under parameter k 2 3 5 Paper adjustment with reader from below See also 3 3 1 5 parameter k With reading from below the OMR mark cannot be dete cted when positioning the paper So you have to make a p unch in the paper as below The adjustment line should be marked by means of punch pliers before inserting the paper The hole must be punched in the center of the reading mark P...

Page 12: ...nuous operation the fine position cutting edge the feed rate and the pause between two forms can be altered The preset counter the actual counter and the group counter are also shown F1 Fine position 1 192 reverse F2 Fine position 1 192 forward F3 Alter feed rate Level 1 to 7 maximum speed F4 Alter pause Level 7 to 0 7 longest pause All these changes will be automatically saved in the current prog...

Page 13: ...n of the machine Explanation of terms Parameter Before forms can be cut a number of different values have to be set such as sheet length type of cut or speed These values are calledparameters The parameters are entered via the terminal program A program consists of several parameters The programs are saved in the terminal Up to 100 programs can be saved The programs saved are numbered continuously...

Page 14: ...VER and the machine will stop at the end of the current cycle READY This message appears after the paper has been positioned at the blade edge before starting the machine When the Start button is then pressed continuous operation begins CALL SERVICE If a 3 digit number e g 031 is shown this is a sign of malfunction Make a note of the 3 digit number and inform the service technician For service mes...

Page 15: ...all keys which display several responsi ve values have a repeat function i e by holding t he button down it repeats its function Panels with a grey background in the operating instructions indicate a flashing display See above for notes on the flashing speed 3 1 5 Information to the INFO button After pressing the INFO button a number appears on the display This number represents sections as the ta...

Page 16: ...am can be selected by pressing buttons F1 F4 The program selected then appears in the left upper display Press the Prog button to obtain PARAMETER SELECT Use buttons F1 and F2 to browse through the parameters 3 2 1 1 Parameter b Length In the Length parameter you can set the FORM LENGTH The form length is measured in 1 6 1 inch 25 4mm or 1 8 line space Measure the form first on the plexiglass cove...

Page 17: ...an not be used together with the OMR system Select parameter c and enter the length step for Special Length 1 6 1 8 or 1 24 The length step in parameter b is not applicable Parameter i Special Length Here you can enter up to 4 different lengths The order is not important at this point The sequence of lengths is set in parameter j F4 Press Input Enter length F1 Select number 0 9 e g 10x1 6 R 1 6 is...

Page 18: ...erformed completely o r whether the form is to be chopped Chopping witdh 3 6 means that a feed length of 2 will be cut with 4 cycles 1 cycle 3 6 When using counter function ONLINE 00 01 see section 3 3 3 note the following The function entered under line 01 is carried out until the section before the last section is reached The function entered under line 00 is carried out when the last section is...

Page 19: ...g Any leftovers longer than this will automatically be chopped Edge cut can be set by entering cut width step NO CUT F4 Press Input F1 and F2 Multiplier for cut width step 0 9 F3 Cut width step NO CUT 1 6 1 8 or 1 24 R z B 0 x NO CUT No cross cut 0 x 1 6 Single cut 2 x 1 8 Double cut at the upper and the lower edge of the form 1 8 will be cut away Possible cuts No cross cut only the margins will b...

Page 20: ...meter e Counter Function In addition the SUB counter group counter and the ACT counter actual can be set at 00000 F4 Press Input F1 Select number 0 9 R F2 Current write position _ R F3 Set SUB counter at 00000 first time F3 is pressed The SUB counter is used for all operations with counter functions except NONE F3 Set ACT counter at 00000 second time F3 is pressed The ACT counter can be used as a ...

Page 21: ...turns to 00000 CUT Edge cut only a cross cut is carried out on reaching the preset number SUB counter returns to 00000 ONLINE 00 01 The preset counter can be programmed to output any online functions No OMR system is required i e no reading head If this function is selected the reading head will be automatically dead A maximum of 2 functions 3 wit h new software can be performed one function sever...

Page 22: ...tton F4 push enter F1 Select Folder 1 4 R The sequence 1 4 is equal to the set up of the Folders in paperflow direction Max you can connect up to four Folders in line F2 Digit selection 0 9 R F3 actuall writte position _ R F4 End The fold length input is in mm i e 100 mm Fold length min 50 mm max 231 mm ...

Page 23: ...ugh all parameters a m in all programs 00 99 A limited number of service functions are available SERVICE 000 Return to program 008 Input OMR routines 078 079 Adjust brightness of display 080 089 Select language 104 107 For OMR precess 3 3 1 Selecting and altering parameters 3 3 1 1 Parameter a Label The Label parameter can be used to input program labels or names e g test program The labels can be...

Page 24: ... will automatically be saved in the current programm F1 and F2 Select level 1 7 F4 Exit 3 3 1 3 Parameter g Pause In the Pause parameter seven different pause intervals after cutting can be preset The shortest interval is level 1 0 03 sec longest interval is level 7 0 21 sec F4 Press Input The pause interval can also be changed during continous operation The change will automaticallybe saved in th...

Page 25: ...adjusted to a maximum of 31 192 forward or reverse F4 Press Input The fine position can also be changed during continous operation The change will automatically be saved i n the current program F1 1 192 reverse F2 1 192 forward F4 Exit The paper is moved forwards in relation to the blade The paper is moved backwards in relation to the blade F1 and F2 can be used to adust the cutting position durin...

Page 26: ...am 2 6 OMR programs which can be written by the user 7 Routine for cut at adjustment line 8 Reserved for special jobs 9 OMR routine for direct channel The marks read by the forms cutter will be evaluated in some other system e g the enveloping machine or the black box All information detected is transmitted to the evaluating system without being processed If the OMR system is to be used the adjust...

Page 27: ...rams from other program slots into the current program slot and save them F4 Press Input F1 Always goes to program slot 00 F2 Advances 10 program slots R F3 Advances 1 program slot R F4 Exit Example A program that has been entered or altered in program slot 00 is to be stored in slot 30 F4 Select program slot 30 Press PROG and select parameter l Copy with F1 ...

Page 28: ...tween 01 and 83 ca n be altered its parameters must first be copied into slot 00 The altered program is then recopied into its original slot It is not possible to copy programs i nto slots 84 99 Every time the machine is switched on fixed progra ms from the EPROM memory overwrite program slots 84 99 F1 Select program slot Press PROG F1 Select parameter l Copy F4 Input F2 At from enter 30 F4 Exit W...

Page 29: ... the user and which will be frequently used Form length Form length always refers to the uncut form This real length must be entered in parameter b to avoid producing form length errors Print lines Line feed in the computer printer can be in steps o f 1 8 or 1 6 The normal step is 1 6 The print lines are counted from the top of the form downwards in the direction of feed Thus the top line is line ...

Page 30: ... the position of the reading head The position of the adjustment line should be given in parameter k Read area The read area is the area on the paper within which the reader is active The adjustment line contains the first mark to be processed by the reading program Sixteen lines are evaluated including the adjustment line adjustment line plus 15 Through the allocation of codes the machine knows i...

Page 31: ...t beside the arrow The reading code is shown onthe display from the right to the left For example 00000000010 01001 together 16 reading lines means that in lin e 1 AL 4 and 7 a reading mark was detected No reading marks are printed in the remaining lines Read errors can have a variety of causes a The reading head and the mark are not on the same track b The reading head has not been correctly adju...

Page 32: ...2 3 collector enveloping and stop Each form see page 37 must contain the relevant code which gives the commands The code always consists of the adjustment line AL and one or more other marks The reading head detects the marks and passes on the functions information In example 1 the form will now be sent to deflector unit 1 if the mark is printed in the third line The equipment will stop if the mar...

Page 33: ...ector 00009 2 AL Enveloping 00017 3 AL Deflector unit 1 00005 4 AL Deflector unit 2 00003 5 AL Deflector unit 3 00033 6 AL Stop 00065 When entering the above code numbers make sure that the positions are entered in the OMR routine in ascendi ng order A maximum of 33 positions can be entered In our example six positions have been filled by en tering all the combinations that occur In order for the ...

Page 34: ...ried out as follows input for the function is described below In posiiton 32 it is possible to output one or mor e functions for forms which have caused areading error The function select is recommended if there is a def lector unit available The Code column in line 32 is here always 00000 In the Function column one or more functio ns can now be entered as in numbers 00 31 Se e also the function t...

Page 35: ...Mod 6609d 6612d Automatic Forms Cutter 13 12 2006 35 OMR data list ...

Page 36: ...is set at position 5 6 7 04096 Free 08192 Free 16384 Block Deflection see a 32768 Stop a Block Deflect Block Deflection can be performed by any Müller 6630 deflector unit The hinged cover of the first def lector unit after the cutting machine is opened by function 16384 andstays open until function 00001 End of group is recognised In the same way cross transport 6691 and block Deflection function ...

Page 37: ... 1 Standard OMR routine fixed program 2 6 OMR programs which can be written by the user F4 Exit F1 and F2 Select a position 00 32 R F3 Fill up the remaining positions Code 00000 is not permitted in the OMR routine Th is is so that if for example the machine does not recog nise a mark it will stop and show a reading error F4 Input F1 Select number 0 9 R F2 Current write position R F3 Select CODE or...

Page 38: ...r unit 2 Deflector unit 1 Collector Enveloping Deflector unit 3 Stop Free Free Free Free Free Free Free Free Free List 5 Deflector unit 3 Adjustment line Deflector unit 2 Deflector unit 1 Collector Enveloping Deflector unit 3 Stop Free Free Free Free Free Free Free Free Free List 2 Deflector unit 1 Adjustment line Deflector unit 2 Deflector unit 1 Collector Enveloping Deflector unit 3 Stop Free Fr...

Page 39: ...line Deflector unit 2 Deflector unit 1 Collector Enveloping Free Free Free Free Free Free Free Free Free Free Free List 5 Deflector unit 3 Adjustment line Deflector unit 2 Deflector unit 1 Collector Enveloping Free Free Free Free Free Free Free Free Free Free Free List 2 Deflector unit 1 Adjustment line Deflector unit 2 Deflector unit 1 Collector Eveloping Free Free Free Free Free Free Free Free F...

Page 40: ...Mod 6609d 6612d Automatic Forms Cutter 13 12 2006 40 OMR data list ...

Page 41: ...ut in the CODE column is of no significance 2 ONLINE functions The machine carries out the function entered under line 01 until the number before the preset numberon the counter is reached On reaching the preset number the mach ine carries out the function entered under line 00 At the same time the actual counter returns to 00000 Example Example In OMR program 2 three forms are to be collected and...

Page 42: ...oped one form will be deflected Routine 2 Code Function 00 00000 00004 deflect Sheet 00005 01 00000 00002 collect Sheets 00001 to 00003 02 00000 00001 enveloping Sheet 00004 3 4 The technician level level 3 In order to access the technician level the machine must first be switched off Then switch the machine on while holding down buttons F1 F4 When OK appears in the display press INFO once Then re...

Page 43: ... computer to correct deviations in the electronic system After automatic adjustment service 10 the DA values must not be greater than 200 for further information see pt 4 4 An error message 31 32 33 34 will appear in the display for values above 250 The machine can only be started after the error has been corrected Examples of possible errors are distance between scanner head and encoder disk fibr...

Page 44: ...e is started the adjustment line AL of the test fo rm must be positioned in the groove on the reading head Caution The machine must be switched off unplug all online machines Then start the test routine 001 first OMR mark AL 002 second mark 004 third mark and 008 fourth mark Altogether 015 In a correct reading operation the result shown in the display must be stable 018 Opto 8 End of paper 000 001...

Page 45: ...ge 040 the first 8 OMR marks 041 the next 8 OMR marks etc The same applies to service nos 044 047 048 051 etc Example Service no 040 and display 017 017 is composed of 001 016 Thus OMR marks have b een detected in line 1 1 and line 5 16 binary addition of the marks The adjustment line AL contains the first mark 044 to 047 Display OMR code 1 sheet before 000 255 display range 048 to 051 Display OMR...

Page 46: ...6 5 Language Spanish 006 087 5 Language Norwegian 007 088 5 Language Japanese 008 089 5 Language Swedish 009 090 5 Language Czech 010 096 097 ONLINE function ONLINE function see service routine 9 table N A maximum of two online functions can be performed with the counter maximum of three online functions can be performed with the counter 098 099 Fine offset 1 Fine offset 1 After changing or replac...

Page 47: ...oned to the blade or read head Display shows READY the sensor will be inoperative Notice The cutter will NOT stop at the end of paper end of web Use this feature for paper backside with solid black printing or holes in the paper web 114 115 Doublecut Increase see service routine 9 P Doublecut Offset adjustable 1 24 1 24 130 131 Standard 6 7 not crossed head 6 7 swapped over see service routine 9 t...

Page 48: ...is blocked winding or final stage is defective 026 Overcurrent at edge blade turbine motor Cause Motor is blocked winding or final stage is defective 031 2 Opto 1 Cross cutter DA value outside permissible range Cause Dirt on encoder disk or fibre optic Distance at scanner head not correct Fibre optic not plugged in Power supply interrupted After correcting the problem start service routine 10 032 ...

Page 49: ...erformed by a service technician every 2 million cutting cycles If necessary replace or turn around the edge and c ross cutter blades see Service Instructions Clean the sliding surfaces of the cross blade inspect for wear and grease lightly if necessary replace the rear cutter guide bar Apply one drop of oil to the upper pivot pins of the connecting rod on the cross cutter drive Wipe away any exce...

Page 50: ... has been altered End of paper cannot be detected Inform the service technician Forms are not cut straight Inform the service technician Forms are not cut Check the cut width factor NO CUT means edge cut only Programs cannot be copied You are not in the programming level see Section 3 3 Service routines cannot be called Check whether you are in the technician level For further information see Sect...

Page 51: ...o stop Stacker tray Rim chopper Automatic lowering stacker Automatic stop at end of paper OMR reader programmable Self diagnostic center Center Slitter Electronic fine adjustment Additional Vertical Slitter High speed interface Group separation other forms processing systems can Tension control be connected to high speed interface 6610 Remote control 6611 6612 and 6613 with online interface Multif...

Page 52: ...ime the error message 31 34 appears is widened caused by deviating DA values In addition the DA values are now directly shown on the display after running service routine 10 during turn of the Poti Please note that the displayed values for every channel one value can always be different By manufacturing tolerances of the semiconductors and of the fibre cable always individual differences result wi...

Page 53: ...Mod 6609d 6612d Automatic Forms Cutter 13 12 2006 53 4 4 1 Connections and electrical settings ...

Page 54: ...otor Ø belt pulley Motor for Cross Cutter left 20599 Ø 16 15250 Ø 21 Motor for Cross Cutter right 20599 Ø 16 15250 Ø 21 Motor for ejecter 20599 Ø 18 15250 Ø 24 Motor for Tractor 20599 Ø 18 15250 Ø 24 Motor for fan 26199 Ø 30 26199 Ø 30 Motor for fan and edge cutters 10179 Ø 9 10179 Ø 14 T Terminal H Hallsensor S Interface N Power supply ...

Page 55: ...terface 16 Label 20 Length 16 List of contents 2 Loading paper 9 Location 5 Maintenance 48 Notes 48 Number of cuts 50 OMR code 32 OMR data list 39 OMR mark 32 OMR routines 29 Online 40 Operating terminal 13 Operation 13 Operator level 16 Optical mark recognition 29 Optical scanner 10 Panel keys 14 Paper 14 Paper adjustment 10 Paper guide 9 Parameters 13 Pause 24 Print lines 29 Prog button 14 Progr...

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