Formax 6602 Series User manual

6602 Series
Inserters
OPERATOR MANUAL
FIRST EDITION
8/2007

1
ENGLISH
TABLE OF CONTENTS
1 Health, Safety and Environment ...................................................... 4
1.1 Precautions and Safety Issues ................................................... 4
2 Functional Description..................................................................... 7
2.1 Overview ................................................................................ 7
2.1.1 Feeder (1) .................................................................... 8
2.1.2 Collating Area (2) .......................................................... 8
2.1.3 Divert (3) ..................................................................... 8
2.1.4 Folder (4) ..................................................................... 8
2.1.5 Inserter (5) .................................................................. 8
2.1.6 Present on Deck (6) ....................................................... 8
2.1.7 Stacker (7) ................................................................... 9
2.1.8 Side exit (8) ................................................................. 9
2.2 Operating Controls ................................................................. 10
2.3 Display Buttons ...................................................................... 11
2.4 Software Description ............................................................... 11
2.4.1 Main Menu ................................................................... 11
2.4.2 Job Info ...................................................................... 13
2.4.3 Counters ..................................................................... 15
2.4.4 Display Settings ........................................................... 15
2.4.5 Job Menu ..................................................................... 16
2.4.6 Supervisor Menu .......................................................... 16
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 Document Separation .................................................... 25
3.4.4 Filling the Document Feed Tray ...................................... 26
3.4.5 Adjustment of the Document Stoppers ............................ 26
3.5 Loading Envelopes .................................................................. 27
3.5.1 Adjusting Side Guides ................................................... 27
3.5.2 Stacker Side Guides ...................................................... 27
3.5.3 Envelope Separation ..................................................... 27
3.5.4 Feeding Envelopes ........................................................ 28
3.6 Sealing Envelopes .................................................................. 28
3.7 Job Selection or AutoSet .......................................................... 28
3.7.1 Using AutoSet .............................................................. 28
3.7.2 Select Another Job ........................................................ 31
3.8 Run the Daily Mail .................................................................. 32
3.9 Create a Job .......................................................................... 33
3.9.1 Job Settings ................................................................. 35
3.9.2 Envelope Settings ......................................................... 35
3.9.3 Document Settings ....................................................... 36
3.9.4 Fold Settings ................................................................ 38

2
3.9.5 Optical Mark Recognition Settings (Option) ...................... 39
3.9.6 Double Feed Control Settings ......................................... 42
3.9.7 Job Name .................................................................... 43
3.9.8 Exit Select Settings ....................................................... 43
3.9.9 Mailing/Franking Settings (Option) .................................. 44
3.10 Edit a Job .............................................................................. 45
3.11 Copy a Job ............................................................................ 46
3.12 Delete a Job .......................................................................... 46
4 Options.......................................................................................... 48
4.1 Activate an Option .................................................................. 48
4.2 Optical Mark Recognition (OMR) ............................................... 48
4.2.1 General ....................................................................... 48
4.2.2 Adjustments ................................................................ 49
4.2.3 Document Orientation ................................................... 50
4.2.4 OMR Codes .................................................................. 50
4.2.5 2-track OMR ................................................................ 56
4.3 Online Services ...................................................................... 58
4.3.1 General ....................................................................... 58
4.3.2 Start-Up Online Services ............................................... 58
4.3.3 Connection .................................................................. 58
4.3.4 Messages ................................................................... 59
4.3.5 Configuration Menu ....................................................... 60
4.4 Production Feeder ................................................................. 61
4.4.1 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
4.5.3 Side Guide Adjustment .................................................. 65
4.5.4 Document Separation Adjustment .................................. 65
4.5.5 Hopper Capacity ........................................................... 66
4.5.6 Clearing Stoppages ....................................................... 67
4.5.7 Support for Curved Reply Envelopes (option) ................... 67
4.6 Mailing Machine connection ...................................................... 68
4.7 Display Mounted on Inserter Deck ............................................ 68
4.8 Envelope Support ................................................................... 69
4.9 Power Stacker Support ............................................................ 69
4.10 High Capacity Envelope Hopper (EF-4) ...................................... 69
4.11 High Capacity Conveyor Belt (CS-2) .......................................... 70
4.11.1 Installation .................................................................. 71
4.11.2 Operation .................................................................... 71
4.12 Catch tray ............................................................................. 71
4.13 Side Exit on the LH Side .......................................................... 71
5 Maintenance .................................................................................. 72
5.1 Operator Maintenance ............................................................. 72
6 Fault Finding.................................................................................. 73
6.1 Error Messages ...................................................................... 73
6.2 Clearing Stoppages ................................................................ 74

3
ENGLISH
TABLE OF CONTENTS
6.2.1 Exit, Sealing and Inserting Area ...................................... 74
6.2.2 Lower Envelope Track ................................................... 74
6.2.3 Folder ......................................................................... 75
6.2.4 Feeder ........................................................................ 76
6.2.5 Collating Area .............................................................. 76
6.3 Operator Troubleshooting ........................................................ 76
7 Specifications ................................................................................ 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 Specifications Production Feeder ............................................... 82
7.7 Specifications Thin Booklet Feeder ............................................ 83
7.8 Specifications High Capacity Envelope Hopper ............................ 84
7.9 Specifications High Capacity Conveyor Belt ................................ 84
8 Terminology .................................................................................. 85
Index.............................................................................................. 95

4
1. HEALTH, SAFETY AND ENVIRONMENT
1.1 Precautions and Safety Issues
Thoroughly read this operator manual, before using this machine.
According to the European Guideline for machine safety (EC98-37), this operator manual
must be available in the national language(s) of the country where the machine is
delivered. Therefore, if you do not have an operator manual in your country’s language(s),
contact your authorized distributor.
Warnings
• Disconnect the mains power supply before performing any maintenance.
• If the feed/fold unit and inserter unit have to be physically separated, the operator
should pay attention to the heavy weight of the unit during separation.
• Before connecting check whether the system is suitable for the local 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
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 machine 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 machine.
• For safety reasons, it is essential that the machine is connected to a socket outlet that
has a protective earth connection.
• Over-current 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
- 12-pole connector, located on the right-hand side

5
ENGLISH
Conventions
Note
A note gives additional relevant information.
Warning
This symbol:
• Identifies situations where improper use of the machine can result in
personal injury or permanent/catastrophic damage to the machine.
• Indicates that the operator manual should be consulted.

6
2005.

7
ENGLISH
2. FUNCTIONAL DESCRIPTION
The system feeds, folds and inserts documents into envelopes and then seals and stacks
the envelopes. Automatic monitoring ensures the correct number of inserts per envelope.
The machine is a sophisticated folding and inserting system which can process large
quantities of mail rapidly and easily. The system can be 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 equipped with a variety of special features as document thickness
detection, programmable jobs, AutoSet,Feeder, double feed control, hopper swap,
multifeed, daily mail, Divert and Folder.
2.1 Overview
The system consists of the following parts:
1
2
3
4
6
5
7
8
1. Feeder
2. Collating area
3. Divert
4. Folder
5. Inserter
6. Present on deck
7. Stacker
8. Side exit

8
2.1.1 Feeder (1)
The Feeder is the feeding part of the system. There are two types of feeders available: the
automatic and the special feeder. The automatic feeder does not require any adjustments
for the separation. The Feeder is equipped with double feed control. In this way the
system can detect faulty sets of documents. The Feeder is equipped with cascade mode.
This means that two feeders can be linked as pairs. When the first feeder is empty, the
system switches to the other feeder. Meanwhile the other empty feeder can be refilled
without stopping. It’s also possible to feed multiple documents from one feeder. In this
way more documents can be fed from one station, for example an original and a copy of a
document.
The upper automatic feeder is equipped with a “daily mail” function for processing
documents or 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 automatically throws out incorrect sets of documents. In this way the system
does not need to stop. Correct sets will be transported to the Folder unit.
2.1.4 Folder (4)
The Folder unit folds the documents. The following fold types are possible:
•Nofold
•Singlefold
• Letter fold
• Zig-zag fold
• Double parallel fold
2.1.5 Inserter (5)
After folding the documents are transported to the inserter unit where the documents are
inserted into a waiting envelope. The inserter then seals the envelope (or not) and stacks
them on the stacker. Automatic monitoring ensures the correct number of inserts per
envelope.
2.1.6 Present on Deck (6)
The documents inserted (or not) can leave the inserter from the upper unit (present on
deck). This can occur when
• Clearing the machine
• Making a test set
• Depending on the OMR (Optical Mark Recognition) code

9
ENGLISH
2.1.7 Stacker (7)
The documents inserted (or not) are transported to the stacker depending on the
programmed job. The 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 stacking of documents into the catch tray as
well as transporting to the optional conveyor belt or franking/mailing machine.

10
2.2 Operating Controls
U TVW PQRS
K
L
N
O
H
I
G
C
BA
F
E
D
M
J
Acatchtray
B side exit / stacker unit
C side guides stacker
D power inlet, power switch
E RS232 connector / USB / modem
F unlocking lever for upper unit
G display (operator panel)
H OMR reading head cover
I vertical transport
J hand grip vertical transport cover
K document feed tray
Lcollatorarm
M operator manual storage space
NFolder
O locking handle Folder
P handle for manual envelope transport
Q handle for manual envelope transport
R unlocking handle for rollers envelope
track
S water reservoir
T side cover (opened)
U thumb wheel for side guide adjustment
V side guides envelope feed tray
W knob for envelope separation
adjustment

11
ENGLISH
2.3 Display Buttons
The machine has a graphical touch screen.
There are three buttons mounted at the display:
• A: the clear key
When the clear key is pressed during processing
documents, the system will stop feeding
documents after completing the set. The set will
be inserted resulting in a cleared system which
is ready to process a new job. The envelopes
have to be removed manually if necessary.
When the system is stopped already and the
clear key is pressed, it will process one set of
documents and the system will be cleared.
When a feeder runs empty after the clear key is pressed, an button will be
displayed together with the feeder empty message. By pressing the button
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:thestopkey
After pressing the stop key the system does not stop immediately, but on the first
opportunity while processing. Because of this there can be incomplete sets in some
parts of the system.
Caution
The display is covered with a thin pressure-sensitive layer. To avoid permanent damage of
the display, do not use sharp objects to press on the display.
2.4 Software Description
2.4.1 Main Menu
After starting up, the “main menu (1)” screen will
appear.
The screen shows the selected job number and the
total number of envelopes that have been processed
using this job.
The main menu consists of 2 menus, “main menu
(1)” and “main menu (2)”.
The “main menu (1)” shows 7 different functions:
• : job information (see 2.4.2 ”Job
Info” on page 13): shows job details.
A
B
C

12
The job information function is available in all the menus where the button
is shown.
• : go to the “job selection” menu to select another job (see
3.7.2 ”Select Another Job” on page 31).
• : go to the “test run” menu to perform a test run (see ”Perform a Test
Run” on page 32).
• : go to the “counters” menu to reset the counter or to set a stop value
(see 2.4.3 ”Counters” on page 15).
• : go to the “AutoSet” menu to start an AutoSet job (see
3.7.1 ”Using AutoSet” on page 28).
• : rotate display 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): shows job details.
• : change display and volume
settings (see 2.4.4 ”Display Settings” on page
15).
• : go to the “job menu” to create,
edit, copy or delete a job (see 2.4.5 ”Job Menu”
on page 16, only for authorized personnel).
• : go to the “supervisor menu” to change system settings (see
2.4.6 ”Supervisor Menu” on page 16, only for authorized personnel).
• : return to the “main menu (1)”.
• : rotate display 180°. Only available if the insert’n Frank™ / insert’n
Mail option, level 2 or 3, is installed.

13
ENGLISH
2.4.2 Job Info
To enter the “info-job” menu, press .
The “info-job” menu consists of 3 submenus.
If the optional insert‘n Frank™ is used an extra job
info screen is available: the “insert‘n Frank™ info”
menu, displaying weight information and the
franking job (see 3.9.9 ”Mailing/Franking Settings
(Option)” on page 44).
If the optional OMR is used an extra job info screen
is available: the “OMR settings” menu displaying the
available OMR marks and settings (see 4.2.4 ”OMR
Codes” on page 50).
The “info-job” menus display all relevant information about the selected job.
To return to the “main 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 that must be
picked from the relevant feeders.
Below this icon, the format of the document in the relevant feeder is
indicated (ISO standard or height in mm).
This sign indicates that the relevant feeders are linked. This means that
when one feeder is empty, the system automatically starts picking
documents from the other feeder.
The sign indicates that for the relevant feeder the Optical Mark Recognition
(OMR) 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).
1
2
3
2
3

14
The “info-job (2)” menu contains the following extra
job information:
The “info-loading instructions (3)” menu shows the
way you should load documents (see
3.4.1 ”Document Orientation” on page 24) and
envelopes (see 3.5.4 ”Feeding Envelopes” on page
28).
The example shows the following situation:
• Envelopes: flap down and trailing
• Address carrier in lower feeder (feeder 1), face
up and leading
• Document in other feeder (feeder 2), face up
and leading
Gives information about the exit
settings. The arrow to the left indicates
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. See
3.9.8 ”Exit Select Settings” on page 43.
The sign below this icon shows if the
document double feed detection for the
relevant feeder and (optional) Thin Booklet
Feeder is switched on - or off -
. This icon is also shown at the
inserter. In this case it indicates if the
document thickness detection is
switched on - or off - .
Shows the weight settings.
If this sign is shown sealing is on.
Shows the type of fold. The numbers next to this icon indicate the fold
positions.
Shows the document stopper position.
5
5
b

15
ENGLISH
2.4.3 Counters
To enter the “counters” menu, press
from the “main menu (1)”.
The “counters” menu shows the following functions:
• : press this button to reset the
daily job counter and stop counter to zero.
• : press this button to enter a
stop value.
The stop counter is switched off when it is set to
zero. The display will show “Stop at off”.
The stop counter can be set between 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 Display Settings
To enter the “display settings” menu, press
from the “main menu (2)”.
The “display settings” menu shows the following
functions:
• : enables to change the contrast of the
display. The graphic shows the contrast setting.
• : enables to adjust the volume of the
acoustic signals. The graphic shows the volume setting.
• Rotate display: press the button to rotate the display 180 °.

16
2.4.5 Job Menu
After pressing the button a login
menu opens.
To prevent jobs being edited or deleted without
informing the ‘job owner’, this menu is protected by
a PIN-code. The PIN-code is
2546 .
When a wrong pin code is entered, the cursor is set
to the first number to try again.
After 3 times entering a wrong pin code the display
shows the “main menu (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 ”Job
Info” on page 13).
• : create a job (see 3.9 ”Create a
Job” on page 33.)
• : edit a job (see 3.10 ”Edit a Job” on page 45).
• : copy a job (see 3.11 ”Copy a Job” on page 46).
• : delete a job (see 3.12 ”Delete a Job” on page 46).
• : exit and return to the “main menu (1)”.
2.4.6 Supervisor Menu
After pressing the button a login
menu opens.
Enter the PIN-code 2546 to access the “supervisor
menu”.

17
ENGLISH
After entering the correct pin code the “supervisor
menu” appears.
This menu enables checking and configuring the
system.
The “supervisor menu” shows the following
functions:
• : shows system information,
like:
- The flex certificate, used for OMR
- The counter since last visit: the counter value since the last service visit
- The last error generated by the system
The screen shows a button : this shows the software versions that are
present in the total system.
• : shows option information and system information:
-ThechipID
-ThesystemID
- The installed options
For installing new options, see 4.1 ”Activate an Option” on page 48.
• : opens the “job settings” supervisor menu (see ”Job Settings
(Supervisor)” on page 18). From this menu system parameters can be set.
• : opens the “test menu” (see ”Test” on page 20). Use this menu to
test the system.
• : opens the “Online Services” menu (option, see 4.3 ”Online Services”
on page 58). This screen enables to connect the system to a server and receive
messages.

18
Job Settings (Supervisor)
Caution
Job settings normally will be changed by a service engineer only. Therefore first consult
the supplier’s Helpdesk before changing any settings. Changes to the job settings can
result in malfunctioning of jobs.
The “job settings” menu (supervisor) can be opened
from the “supervisor menu”. From this menu system
parameters can be set. The “job settings” menu
shows the following functions:
• : opens the “mode menu” to set
the output mode for a job (see ”Mode Menu” on
page 18).
• : opens the “document offset”
menu to set the document offset in a set of
documents for a job (see ”Document Offset” on page 19).
• : opens the “BRE offset” menu to set the BRE offset on or off (see
”BRE Offset” on page 19).
• : opens the “flap closer” menu (see ”Flap Closer” on page 20). Use
this function 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 between output
Mode 1 and Mode 2 using the button. Mode 2 is
the default setting.
Mode 1 focuses on the versatility of paper
parameters (paper thickness; document length), i.e.
correct operation under even extreme paper conditions.
Mode 2 focuses on high speed and is achieved as follows:
• During multi feed (more than one page from one feeder) the movement on the
collator is minimal. In mode 1 the divert unit will be used for completing the collating
process (less paper on paper transport).
• During the transportation of a set from the collator into the Folder, the next 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 the collator.

19
ENGLISH
• Anticipation call for the envelope is used. That means that a (folded) set is leaving the
Feeder already before the envelope is ready on the insert position. In mode 1 the
envelope is on the insert position already before the set leaves the Feeder.
It is advised to use Mode 1 with a paper thickness of 65 g/m
2
or less, a document length
of 12 inch (305 mm) or higher, and for situations where Mode 2 is not functioning
properly. In all other cases Mode 2 is advised.
If you select Mode 2, select if the reply envelope has a window or not.
Document Offset
When selecting from the “supervisor menu”
, , the “document
offset” menu appears.
The vertical transport of documents fed by the
various feeders is arranged in such a way that the
documents are partially overlapping each other. 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, 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 from the “supervisor menu”
, , the “BRE offset”
menu appears.
If a document is longer than the set address fold but
shorter than the envelope height, this document
sometimes will be unnecessarily folded. Under
certain conditions this document can be prevented
from being folded. This can be implemented with the
menu “BRE offset” (BRE means Business Reply
Envelope).
For each of the jobs 1 through 25 and AutoSet an offset can be switched on or off
using the button.
In the case of offset “on” the last document that was added to the set will be shifted from
the rest of the set (offsetting). This document will be held back during a certain distance.
This means that the trailing edge of this upper document leaves the collator at last. This
document will not be folded. During the 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).