Formax 6206 Series User manual

6206 Series
Low-Volume Desktop Inserters
OPERATOR MANUAL
3/2013

Table of Contents
Read this First ...............................................................................................11
Warning............................................................................................................1
About this manual............................................................................................1
Safety...............................................................................................................2
Country Specific Conditions.............................................................................3
End of Life........................................................................................................4
Meet your Document System ......................................................................52
Power Up..........................................................................................................5
Overview..........................................................................................................5
Control 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 ..................................................................................213
New Mail Sets................................................................................................21
Basic Mail Sets ..............................................................................................22
Mail sets with BRE or inser ts.........................................................................22
Daily Mail.......................................................................................................23
Fold Only........................................................................................................24
Multi Feed......................................................................................................25
Change Fold Type..........................................................................................26
Address Position............................................................................................27
Run a Batch...................................................................................................27
Linking Feeders..............................................................................................28
| Page 1 | TOC | okt-05-2012 11:39 |

Working with Jobs ......................................................................................294
What Is A Job.................................................................................................29
Save Settings to a Job ...................................................................................30
Selecting a Job ..............................................................................................31
Edit a Job.......................................................................................................32
Delete a Job...................................................................................................33
Advanced Settings .....................................................................................345
Introduction....................................................................................................34
Setting the Language, Date and Time............................................................34
Licensed Options...........................................................................................35
Add an Option................................................................................................36
Reading .......................................................................................................376
Introduction Reading......................................................................................37
BCR Code......................................................................................................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 ...........................................................................................487
Online Services Introduction (OLS)...............................................................48
Connection Settings.......................................................................................48
LAN Configuration for OLS............................................................................49
Analogue Modem Configuration for OLS.......................................................50
Connecting To The Online Server..................................................................51
Viewing Connection History...........................................................................52
Viewing Messages.........................................................................................53
Downloading and installing jobs and software with OLS................................54
| Page 2 | TOC | okt-05-2012 11:39 |

Operator Maintenance ................................................................................558
Maintenance Schedule..................................................................................55
Clean or Replace the Brush...........................................................................56
Replace separation rollers of the document f eeder.......................................59
Fault Finding ...............................................................................................629
Error Messages..............................................................................................62
Clearing Stoppages.......................................................................................63
Calibrate Sensors...........................................................................................68
Troubleshooting..............................................................................................69
Troubleshooting Tables...................................................................................69
Specifications .............................................................................................7510
Technical Specifications.................................................................................75
Feeder and Stacker Capacities......................................................................76
Dimensions....................................................................................................76
Document and Inser t Specifications..............................................................77
Envelope Specifications.................................................................................78
EC Declaration of Conformity ....................................................................8111
EC Declaration of Conformity.........................................................................81
| Page 3 | TOC | okt-05-2012 11:39 |

| Page 4 | TOC | okt-05-2012 11:39 |

Read this First1
Warning
Ensure you have read and fully understood the safety requirements
in this section.
About this manual
Languages
According to the EC (European Commission) declaration following the Low Voltage Directive
(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), contact your authorized distributor.
Software
The software used for the reading option is based in part on the work of the Independent
JPEG Group.
Audience
This manual is meant for operators of the document system.
1
| Page 1 | okt-05-2012 11:39 |
1
English

Symbols
This manual uses the symbols listed below.
WARNING : Indicates a human safety hazard.
ATTENTION : A risk to the equipment or mail could result from an
action you may perform.
NOTE : A remark that explains different cases or specificities.
TIP : Advice to help save you time when processing your 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 to the 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 handling can sometimes create a build up of
static electricity. Therefore we recommend that the following measures are taken to reduce
the side effects of any electrostatic charge.
• Make sure that you operate the system within the recommended temperature and
humidity conditions.
• Make use of antistatic mats where appropriate.
• If necessary, make use of an ionizer to reduce static charge build up in the room
where the system is located.
Please contact your supplier for further information.
2
| Page 2 | okt-05-2012 11:39 |
1
English

Safety Precautions
• Only competent, trained personnel should operate this system. If non-trained
personnel do operate this system, the manufacturer will not accept responsibility
for any resulting accidents or injuries.
• Only skilled persons, who are aware of the risks involved, may open the protective
covers.
For safety reasons, the system will not function when the covers are open.
• Keep long hair, fingers, jewelry, etc. away from rotating and moving parts.
• The power 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 coupler.
CAUTION: DOUBLE POLE / NEUTRAL FUSING
(this means that after operating of the fuse, parts of the equipment
that remain energized, might represent a hazard during servicing.)
Country Specific Conditions
Denmark
In Denmark, certain types of Class 1 appliances may be provided with a plug that does not
provide an adequate earth (ground) connection when inserted into a Danish socket outlet.
Make sure the system has a good functioning connection that has protective earthing (the
plug and socket outlet must match).
Japan
•Establish an earth (ground) connection before connecting the mains plug to the power
supply.
• First disconnect the power supply before removing the earth (ground) connection.
1
English
3
| Page 3 | okt-05-2012 11:39 |

End of Life
The objectives of the European Community's environment policy are, in particular, to
preserve, protect and improve the quality of the environment, protect human health and
utilize natural resources prudently and rationally. That policy is based on the precautionary
principle and principles that preventive action should be taken, that environmental damage
should as a priority be rectified at source.
Separating waste during collection is the precondition to ensure reuse and recycling of waste.
The proper disposal of electrical or electronic equipment is necessary to achieve the chosen
level of protection of human health 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 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 electronical equipment is marked with the following logo:
By law, not only are you not allowed to dispose of the waste equipment via other waste
channels, but we encourage you to actively contribute to the success of such collection
and to the common good and better quality of life of present and future generations. For
more information on the correct disposal of this product, please contact your local service
organization.
4
| Page 4 | okt-05-2012 11:39 |
1
English

Meet your Document System2
Power Up
Make sure the system is connected to the power supply.
1. Press the On/Off button next to the display.
The touch screen shows the Home Menu.
Overview
Introduction
The 6206 Series is a folding 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 ensures the correct number of documents per envelope. The system
is equipped with a variety of special features: double feed control, feeder linking, multi feed,
daily mail, reading (option) and a vertical stacker.
5
| Page 5 | okt-05-2012 11:39 |
2
English

The figure shows an overview of the 6206 Series.
Envelope Hopper (1)
The envelopes are picked up and transported to the insert position (7) inside the system.
Document Feeders (3)
Depending on the configuration, one or two document feeders are available. The upper
feeder is the main document feeder, the lower feeder is the enclosure feeder. The system
can feed one or more documents (multi feed) from one feeder. The feeders have 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 pairs. When the first feeder is empty, the system switches to the
other feeder, and vice versa. Meanwhile the empty feeder can be refilled without stopping
the system.
Daily Mail (2)
At the envelope hopper an extra document feeder is available for 'daily mail' (2). You can
use this feeder to process sets of documents that you cannot process automatically (for
example: stapled documents and sets with varying thickness).
6
| Page 6 | okt-05-2012 11:39 |
2
English

BRE or Insert Feeder (4) (Optional)
The system is (optionally) equipped with a special feeder for Business Reply Envelopes
(BRE) and other small inserts.
Collating Area (5)
All documents of a document set are assembled in the collating area.
Fold (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 transported to the inserter. The inserter
inserts the documents into a waiting envelope. The inserter seals the envelope or not,
depending on the settings.
Stacker (6)
When the envelope leaves the system it is stacked in the stacker.
2
English
7
| Page 7 | okt-05-2012 11:39 |

Connections
The document system has the following connections:
A: Power connection
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: RS232 port: for the connection with a franking/mailing machine
8
| Page 8 | okt-05-2012 11:39 |
2
English

Control Panel and Home Menu
When you start the system the Home menu appears.
1. Depending on which screen is open, one of these two menu icons will be displayed:
•- The Settings icon opens the Settings Menu.
•- The Home icon opens the Home Menu.
2. ON/OFF Button: Turns the system ON or OFF. If the system is not used for one hour,
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 with available feeders and settings.
5. STOP Button: Press the STOP button to complete the current mail set.
6. START Button: When you press the START button, the system starts to feed documents
and envelopes from feeders where material is detected. In other menus, the START button
will start to process mail sets.
2
English
9
| Page 9 | okt-05-2012 11:39 |

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
| Page 10 | okt-05-2012 11:39 |
2
English

The following is a list of icons and their descriptions.
9. Save
Saves the current job. You
can save a job after one set
is created.
1. Home / Settings menu
10. Recycle bin
Deletes the current job.
2. Daily mail
Turns daily mail on/off.
11. Feeder Linking
Turns linking on/off. Linking
means that when one feeder
is empty, the system automat-
ically starts feeding docu-
ments from the other feeder.
A symbol at the feeders
shows if the feeders are
linked or not.
3. Main Document feeder
Sets the number of docu-
ments to be fed from the
main document feeder.
12. Address Position
Sets the address position. If
the address is not fully visible
through the envelope win-
dow, use this button to adjust
the position.
4. Enclosure document
feeder
Sets the number of docu-
ments to be fed from the en-
closure feeder.
13. Fold type
Sets the fold type. Which fold
types are available depends
on the documents and envel-
opes in the system.
5. Batch counter
Sets the number of sets that
must be processed for each
batch.
14. BRE
Turns BRE feeder on/off.
6. Sealing
Turns sealing on/off. When
sealing is off, the flap of the
nevlope is closed but not
moistened.
15. Envelope hopper
Turns envelopes on/off. For
fold only mode, set the envel-
opes to No.
7. Reading
Turns reading on/off (BCR or
OMR).
Information8. 1x
Starts a test run.
2
English
11
| Page 11 | okt-05-2012 11:39 |

Loading Documents
The table below shows how to load documents depending on the fold type, and the optional
Enclosure and BRE feeders. See the job information on the touch screen.
document +
BRE/insert
document + en-
closure
feeder linking
one document
Address carrier
in upper feeder.
Face up 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 carrier
in upper feeder.
Face down and
trailing.
Address carrier
in lower feeder.
Face down and
trailing.
Address carrier.
Face down and
trailing.
Address carrier.
Face down and
trailing.
Z-fold
To load documents:
1. Rotate thumb wheel A to move the side guides apart on the feeder.
12
| Page 12 | okt-05-2012 11:39 |
2
English

2. Put a small stack of documents between the side guides.
3. Move the side guides toward the documents. The play between the side guides and
the documents should be about 0.5 mm (0.02'').
Use an envelope to measure the play. If an envelope 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 feeder, do not place more documents than indicated
by the "max" symbol on the feeder. See the previous figure for the correct orientation.
Make sure the paper touches the stop.
Refer to the specifications for the maximum amount of
documents you can load into the feeder.
2
English
13
| Page 13 | okt-05-2012 11:39 |

Loading BREs (option)
You can use the optional BRE feeder for small insert cards or BREs.
To load BREs:
1. Rotate thumb wheel A to move the side guides apart.
2. Pull back 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 documents should be about 0.5 mm (0.02'').
Use an envelope to measure the play. If an envelope fits between
the documents and the side guides, the play is correct.
14
| Page 14 | okt-05-2012 11:39 |
2
English

6. Place a stack of documents or BREs in the feeder. See the figure for the correct
orientation. In case you use BRE’s, ensure that 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. These will be folded and inserted. If
you want to use C5 BREs, position them in the feeder as shown in
the figure.
2
English
15
| Page 15 | okt-05-2012 11:39 |