Formax 6204 Series User manual

6204 Series
Low-Volume Inserter
MAINTENANCE MANUAL
6/2012

Table of Contents
1 Introduction ................................................................................................................................1
2 Health, safety and environment ...............................................................................................5
3 General description ...................................................................................................................8
4 User interface ...........................................................................................................................27
5 Transport, storage and installation ........................................................................................42
6 Mechanical description ...........................................................................................................51
7 Electrical description ............................................................................................................138
8 Preventive maintenance .......................................................................................................156
9 Fault Finding ..........................................................................................................................161
10 Upgrading and installing accessories ................................................................................196
11 Technical specifications .......................................................................................................199
12 Parts lists ...............................................................................................................................208
13 Appendix ................................................................................................................................289
063.1 Service Guide

Introduction1
1 Introduction ........................................................................................................1
About this manual .............................................................................2
Abbreviations ....................................................................................2
Terminology ......................................................................................3
1
1
063.1 Service Guide

About this manual
Audience
This manual is meant for service engineers.
Symbols
This manual uses the symbols listed below.
WARNING : indicates a human safety hazard.
ATTENTION : brings to your attention a risk for equipment or mail that could result
froman action you may perform.
NOTE : 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.
Abbreviations
ExplanationAbbrev.ExplanationAbbrev. Interface Spe-
cification for In-
serter Systems
ISISBusiness Reply EnvelopeBRE
Left HandLHCounter ClockwiseCCW Mixed Mail
Feeder / Ad-
vanced Feeder
MMF/AFClockwiseCW
MailingSystemMSDouble Feed ControlDFC Not ApplicableNADocument SystemDS On Line Ser-
vices
OLSFirst In First OutFIFO
Optical Mark
Recognition
OMRFranking MachineFM
Printed Circuit
Board
PCBGraphical User InterfaceGUI
Postal Product
Code
PPCHuman Machine InterfaceHMI
Right handRHInserterIN User InterfaceUIInsert’n FrankINF
2
1
063.1 Service Guide

Terminology
DescriptionTerm
Double Feed Control is the sensor that measures the thickness of a
sheet to check if the inserting system does not accidentally take more
sheets than intended. DFC sensors exist on Feeders (double sheet de-
tection). Currently DFC's on Neopost inserting systems perform relative
measurements, which means that they need a cycle to 'learn' the thick-
ness of a sheet.
Also the length of the document is measured so partly overlapping sheets
will be detected.
Double Feed Control (DFC)
Situation in which the top of the sheet is closest to the separation unit in
a document feeder.
Leading
The various documents of a set are fed from the feeders in such a way
that these documents are partly overlapping each other. This pane-like
overlapping ensures a higher throughput.
Pane Cycle
Documents are transported along the vertical track without touching each
other. Only after joining the set in the making they do touch each other.
Sequential Cycle
The partially completed set in the collator is moved from the collator area
in the direction of the fold unit (short shunt).
Shunting
Situation in which the bottom of the sheet is closest to the separation
unit in a document feeder.
Trailing
1
063.1 Service Guide
3

4
1
063.1 Service Guide

Health, safety and
environment
2
2 Health, safety and environment ........................................................................5
Safety ................................................................................................6
Symbols on the system ......................................................................6
End of Life .........................................................................................7
5
2
063.1 Service Guide

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.
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.)
Symbols on the system
Warning
This symbol identifies situations where improper use of the machine can result in personal injury or
permanent/catastrophic damage to the machine.
This symbol also indicates to consult the operator manual in relation to this action.
Warning
This symbol indicates a danger caused by high voltage.
6
2
063.1 Service Guide

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.
2
063.1 Service Guide
7

General description3
3 General description ...........................................................................................8
The system ........................................................................................9
Denominations ..................................................................................9
Paper flow .......................................................................................10
Process description .........................................................................11
Electronics .......................................................................................20
Optional features .............................................................................25
8
3
063.1 Service Guide

The system
The system feeds, folds and inserts documents into envelopes and then seals and stacks the envelopes.
The system is equipped with a variety of special features as programmable jobs, Automatic jobs, flexFeed, double
feed control, hopper swap, multifeed, daily mail and powerFold.
Denominations
K- Sensors
L-Bellows
M- Handle for clearing stoppages
N-Sealing liquid reservoir
O- Side cover (opened)
P- Ruler
Q- Thumb wheel for side guide adjustment
R- Side guides envelope hopper
S- Knob for separation adjustment
T- Envelope support bracket
A- Envelope catch tray
B- Envelope slide
C- Display with operating buttons
D- Upper unit
E- Locking hand grip upper unit
F- Document feeders
G- Collator arm
H- Collator area
I- Power inlet, power switch, RS232 connector / USB /
modem
J- Knobs for clearing stoppages
3
063.1 Service Guide
9

Paper flow
The figure shows an overview of the system.
The documents are vertically transported from the document feeder(s) (1) to the collator (2). When the required
documents are collected, the document pile is transported horizontally to the document folder (3). After folding, the
documents are inserted into an envelope by the inserter (5). Finally, the envelope is sealed and transported to the
envelope receiving tray.
10
3
063.1 Service Guide

Process description
The processing of documents by the system can be divided into a number of distinct sequential partial processes.
These processes will be discussed in some more detail:
• Document feeding
• Document transport
• Collating the document set
• Document folding
• Envelope feeding
• Inserting process
• Envelope exit process
The following figure shows a schematic overview of the process. All mechanical items that are strictly necessary
to explain the process are projected on the left-hand side of the machine. This implies that not all auxiliary mechanical
items (such as gears and belts) are shown.
See Section “Mechanical description on page 51” and Section “Illustrated parts list on page 208” for more details on
the mechanics.
Parts with an arrow are mechanically driven (by the main motor M2 or by the collator DC
motor M1).
For reasons of cross-reference the nomenclature for sensors and actuators as used in the
electrical description is mentioned here as well.
3
063.1 Service Guide
11

General
DescriptionNo.
Main motor. Provides the primary mechanical drive for the feeder clutches CL1 – CL3, the
folder clutches CL4 – CL7 and the envelope track clutch CL8. Directly drives the vertical
track transport (75, 68, 61, 45) and the inserter main drive (15, 17, 19, 20, 22, 23). If the
upper unit is in place, items 14, 16, 24 and 26) are driven as well. All items that are directly
driven by M2 can be activated with the LH hand knob.
M2
Pulse disc (mounted on roller 19). Monitored by slotted photocell SPH1.PD1
Safety switch that guards the part of the collator area that can be opened by the user.
MS1
Safety switch for the front cover.MS2
Safety switch for the upper unit.MS3
12
3
063.1 Service Guide

Feeders
DescriptionNo.
Lower feeder (1)
Feeder photocell.PH1
Driven output rollers.63
Counter rollers for 63.64
Lower separation roller.65
Feed axle with upper separation roller.66
Paper puller axle with two rubber rollers.67
Document thickness measuring unit.DFC1
Middle feeder (2)
Feeder photocell.PH2
Driven output rollers.70
Counter rollers for 70.71
Lower separation roller.72
Feed axle with upper separation roller.73
Paper puller axle with two rubber rollers.74
Document thickness measuring unit.DFC2
Upper feeder (3)
Feeder photocell.PH3
Driven output rollers.77
Counter rollers for 77.78
Lower separation roller.79
Feed axle with upper separation roller.80
Paper puller axle with two rubber rollers.81
Document thickness measuring unit.DFC3
3
063.1 Service Guide
13

Vertical track
DescriptionNo.
Counter roller of 45 (in the upper unit).44
Driven vertical transport axle. On this axle the folding reverse clutch CL5 is mounted (at
the RH side of the machine). This clutch drives 42, 43, 35, 36, 27 and 28 in the reverse
direction during the second stage of a long shunt.
45
Driven vertical transport axle. On this axle feeder 1 (lower) clutch CL1 is mounted (at the
LH side of the machine). This clutch drives 63, 66 and 67.
61
Counter rollers for 61 (in upper unit).62
Driven vertical transport axle. On this axle feeder 2 (middle) clutch CL2 is mounted (at the
LH side of the machine). This clutch drives 70, 73 and 74.
68
Counter rollers for 68 (in upper unit).69
Driven vertical transport axle. On this axle feeder 3 (upper) clutch CL3 is mounted (at the
LH side of the machine). This clutch drives 77, 80 and 81.
75
Counter rollers for 75 (in upper unit).76
Reading head photocell. Only operational if OMR is installed.PH4
Collator
DescriptionNo.
Collator motor. Drives 46, 50, 53, 56 and 60 in forward or reverse direction.M1
Pulse disc mounted on the axle of the collator motor M1. Monitored by slotted photocell
SPH2.
PD4
Collating area photocell.PH5
Collator rollers driven (either forward or reverse) by the collator motor M1. In collator arm.46, 50, 53, 56, 60
Document stop position for 6-inch documents.51
Document stop position for 12-inch and A4-sized documents.57
Document stop position for 14-inch documents.59
Free running collator rollers.47, 48, 49, 52, 54, 55,
58
14
3
063.1 Service Guide

Fold unit
DescriptionNo.
Folder input photocell.PH6
Lower fold input roller. On this axle on the RH side the folding forward clutch CL4 is mounted.
This clutch drives 42, 43, 35, 36, 27 and 28. Operational during the fold process and during
the first stage of a long shunt.
42
Upper fold input roller.43
Lower fold roller for first fold table.35
Upper fold roller for first fold table. In upper unit.36
Lower fold roller for second fold table.27
Upper fold roller for second fold table. In upper unit.28
Control axle for first fold table. Hinge for 40. Moves the lever that in its turn moves the flap
actuator of 41 upwards.
39
Fold plate for first fold table.40
Flap for first fold table.41
Curve gears for first fold table (1 x LH, 1 x RH). Controls movement of 40.37
Brake disc for first fold table. Spring loading ensures two static mechanical states.38
Cam disc of first fold table. Monitored by slotted photocell SPH3.PD3
Control axle for second fold table. Hinge for 32 and 33. Moves the lever that in its turn
moves the flap actuator of 34 upwards.
31
Control axle for second fold table. Hinge for 32 and 33. Moves the lever that in its turn
moves the flap actuator of 34 upwards.
29
Brake disc for second fold table. Spring loading ensures two static mechanical states.30
Cam disc of second fold table. Monitored by slotted photocell SPH4.PD2
Fold plate for second fold table.32
Moving paper guide for second fold table.33
Flap for second fold table.34
Fold forward clutch. Used during a fold cycle and in the first stage of a long shunt.CL4
Fold reverse clutch.CL5
First fold table clutch. Drives 37.CL6
Second fold table clutch. Drives 29.CL7
3
063.1 Service Guide
15

Envelope feeding
DescriptionNo.
Envelope track clutch. Mounted on clutch shaft, at the RH side of the machine. On this shaft
two gears take care for the mechanical interface between the permanently M2 driven sub-
system and the envelope track subsystem. CL8 drives 1, 4, 6, 8, 10 and 11.
CL8
Feed roller. Activated by the envelope track clutch CL8.1
Separation roller.2
Driven envelope transport rollers. Activated by the envelope track clutch CL8.4, 6, 8
Counter rollers for 4, 6 and 8. These rollers can be moved (by the release handle) in order
to solve a paper jam in the envelope track.
3, 5, 7
Envelope track photocell.PH7
Driven envelope transport roller (flap opening stage). Activated by the envelope track clutch
CL8.
10
Driven envelope transport roller (flap opening stage). Activated by the envelope track clutch
CL8. On the axle at the LH side of the machine the RH hand knob is mounted.
11
Counter rollers for 10, 11. These rollers can be moved (by the release handle) in order to
solve a paper jam in the envelope flap track.
9, 12
Friction brake.9a
Envelope flap track photocell.PH8
Inserting, ejecting, sealing and exiting
Insert table photocell.PH9
Fingers solenoid. Moves fingers forward into envelope to enable inserting the set.So1
Lower insert roller.13
Upper insert roller (in the upper unit).14
Lower first ejection roller. On the axle at the LH side of the machine the LH hand knob is
mounted. On this axle at the RH side of the machine the main pulley is mounted.
15
Upper first ejection roller (in the upper unit). Lowered by the action of the insert table
solenoid So2.
16
Insert table solenoid.So2
Lower second ejection roller. In this area the moistening brushes are located.17
Upper second ejection roller (in the upper unit).18
Driven sealing track roller. On the axle at the RH side of the machine the pulse disc PD1
(monitored by slotted photocell SPH1) is mounted.
19
Driven sealing track roller.20
Counter roller for 22 (in the upper unit).21
Lower sealing roller. A gear on the axle (on the RH side of the machine) provides via an
intermediate gear the mechanical interface to all the driven parts in the upper unit (14, 16,
24, 26).
22
Upper sealing roller.23
Photocell.PH11
Sealing solenoid. Moves 25 down during a short time.So3
Lower reverse roller (in the upper unit).24
Upper reverse roller (in the lower unit). Lowered by the action of the sealing solenoid So3.25
16
3
063.1 Service Guide

Drive rollers for future use.26
Exit photocell.PH10
Document feeding
The system has feeders with automatic separation.
For the documents to be fed the following rules apply:
• Documents with the fold types single fold, letter fold, and double parallel fold must be fed with the orientation
face up and leading. The address carrying document is to be fed by the highest active feeder.
• Documents with the fold type zigzag fold must be fed with the orientation face down and trailing. The
address-carrying document is to be fed by the lowest active feeder.
The feeding process
• A document is separated by 79 - 81 (feeder 3), 72 - 74 (feeder 2) or 65 - 67 (feeder 1).
• The document is exited to the vertical track by 77 and 78 (feeder 3), 70 and 71 (feeder 2) or 63 and 64 (feeder
1).
• The paper transport is monitored by the feeder photocell PH3 (feeder 3), PH2 (feeder 2) or PH1 (feeder 1).
• The thickness is measured by the thickness measuring unit (DFC unit) DFC3 (feeder 3), DFC2 (feeder 2) or
DFC1 (feeder 1).
• The feeders are mechanically driven from the main motor M2 by a clutch (feeder clutches CL1 - CL3).
Document transport
Depending on the number of documents to be delivered by each feeder there are two ways in which documents
can be transported along the vertical track: pane cycle and sequential cycle.
• Pane Cycle: The various documents of a set are fed from the feeders in such a way that these documents
are partly overlapping each other. This pane-like overlapping ensures a higher throughput.
• Sequential Cycle: Documents are transported along the vertical track without touching each other. Only after
joining the set in the making they do touch each other.
The transporting area
• The vertical track consists of one driven axle per feeder (75, 68, 61), plus one driven axle in the lower vertical
track (45).
• All these axles carry two rollers, except for 75 (at the top feeder), which carries four rollers. This is necessary
for straightening the paper prior to passing the optional reading head.
• The driven rollers have their counterparts in rollers 76, 69, 62 and 44.
• If the OMR option is installed, the paper transport prior to entering the reading head located directly below
PH4) is monitored by the reading head photocell (PH4). This monitoring is necessary for establishing the
reading window.
Collating the document set
The following rules apply to the way in which a set is collated (i.e. composed):
• The highest active feeder is processed first, the lowest active feeder last. This is independent of the fold type.
• If a feeder adds two or more documents to a set (multi-feeding), these documents are first of all processed
in the order in which they are separated from the feeder hopper.
Based on the actual number of documents from each cycle, the system composes a set based on the minimum
amount of cycles and, if possible, a pane cycle in stead of a sequential cycle (see Section 3.4.2 “Document transport”).
In the case of multi-feeding of ’n’ documents from the same feeder there are always at least ’n-1’ sequential cycles
involved. In the case of OMR processing the document(s) from feeder 3 is/are always processed via sequential
cycles.
Shunting
Shunting is necessary between two successive cycles of the collating process, before a new document joins a
partially completed set. During shunting, the partially completed set in the collator is moved from the collator area
in the direction of the fold unit (short shunt). This is necessary to prevent the paper entering from the vertical track
from interfering with the partially completed set.
3
063.1 Service Guide
17