Formax 6602 Series User manual

6602 Series
Inserters
OPERATOR MANUAL
FIRST EDITION
8/2007

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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

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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

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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

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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

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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.

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2005.

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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

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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

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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.