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6402 Series
Inserters
5
/2007
OPERATOR MANUAL
FIRST EDITION
TABLE OF CONTENTS
1 Health, Safety and Environment ...................................................... 3
Precautions and Safety Issues ................................................... 3
Functional Description ..................................................................... 6
Overview ................................................................................ 7
(1) ................................................................ 7
2.1.2 Collating Area (2) .......................................................... 8
®
(3) ............................................................. 8
(4) .............................................................. 8
2.1.5 Inserter (6) .................................................................. 8
Operating Controls .................................................................. 9
Display Buttons ...................................................................... 10
2.3
2.4
2.4.4 Display Settings ........................................................... 13
2.4.5 Job Menu ..................................................................... 14
2.4.6 Supervisor Menu .......................................................... 14
Operating Instructions .................................................................. 20
Software Description ............................................................... 10
2.4.1 Main Menu ................................................................... 10
2.4.2 Job Info ...................................................................... 12
2.4.3 Counters ..................................................................... 13
3.3
Installation ............................................................................ 20
Preparation ........................................................................... 20
3.2.1 Document Feed Trays ................................................... 20
3.2.2 Conveyor Stacker ......................................................... 21
Starting Up ............................................................................ 21
Loading Documents ................................................................ 22
3.4.1 Document Orientation ................................................... 22
3.4.2 Side Guides ................................................................. 23
3.4.3 Document Separation .................................................... 23
3.4.4 Filling the Document Feed Tray ...................................... 24
3.4.5 Adjustment of the Document Stoppers ............................ 24
Loading Envelopes .................................................................. 25
3.5.1 Adjusting Side Guides ................................................... 25
3.5.2 Envelope Separation ..................................................... 25
3.5.3 Feeding Envelopes ........................................................ 26
Sealing Envelopes .................................................................. 26 3.6
3.7 Job Selection or AutoSet ...................................................... 27
3.7.1 Using AutoSet .............................................................. 27
3.7.2 Select Another Job ........................................................ 29
Run the Daily Mail .................................................................. 30
Create a Job .......................................................................... 31
3.9.1 Job Settings ................................................................. 32
3.9.2 Envelope Settings ......................................................... 32
3.9.3 Document Settings ....................................................... 33
3.9.4 Fold Settings ................................................................ 34
3.9.5 Optical Mark Recognition Settings (Option) ...................... 36
3.9.6 Double Feed Control Settings ......................................... 37
3.9.7 Job Name .................................................................... 38
1
3.9.8 Mailing/Franking Settings (Option) .................................. 39
Edit a Job .............................................................................. 40
Copy a Job ............................................................................ 40
Delete a Job .......................................................................... 41
Options.......................................................................................... 42
Activate an Option .................................................................. 42
Optical Mark Recognition (OMR) ............................................... 42
4.2.1 General ....................................................................... 42
4.2.2 Alignment .................................................................... 43
4.2.3 Document Orientation ................................................... 44
4.2.4 OMR Codes .................................................................. 44
Online Services ...................................................................... 48
4.3.1 General ....................................................................... 48
4.3.2 Start-Up Online Services ............................................... 48
4.3.3 Connection .................................................................. 48
4.3.4 Messages ................................................................... 49
4.3.5 Configuration Menu ....................................................... 50
4.4 Production Feeder................................................................... 51
4.4.1 Function ...................................................................... 51
4.4.2 Preparations ................................................................ 51
4.4.3 Adjust Side Guides ....................................................... 52
4.4.4 Document Separation .................................................... 52
4.4.5 Feeding Documents ...................................................... 52
insert’n Frank™ (insert’n Mail) ................................................. 53
Maintenance .................................................................................. 54
Operator Maintenance ............................................................. 54
Fault Finding.................................................................................. 55
Error Messages ...................................................................... 55
Clearing Stoppages ................................................................ 56
6.2.1 Exit, Sealing and Inserting Area ..................................... 56
6.2.2 Envelope Hopper .......................................................... 57
6.2.3 Lower Envelope Track ................................................... 57
® ............................................................................................................................ 58
6.2.6 Collating Area .............................................................. 58
Operator Troubleshooting ........................................................ 58
Specifications ................................................................................ 62
Technical Specifications ........................................................... 62
Configuration Dimensions ........................................................ 62
Other Specifications ................................................................ 62
Document Specifications ......................................................... 62
Envelope and Insert Specifications ............................................ 63
Terminology .................................................................................. 65
2
1. HEALTH, SAFETY AND ENVIRONMENT
1.1
Precautions and Safety Issues
Thoroughly read this operator manual, before using this machine.
Warnings
• 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
3
Conventions
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.
Warning
This symbol indicates a danger caused by high voltage.
Note
A note gives additional relevant information.
4
.
5
2. FUNCTIONAL DESCRIPTION
The 6402 Series 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 (types of documents, type of envelopes and the type of fold) is recorded in so-called jobs. These jobs can be programmed by an authorized user.
The 6402 Series is equipped with a variety of special features as document thickness detection, programmable jobs, AutoSet, double feed control, hopper swap, multifeed, and daily mail.
6
2.1
Overview
The system consists of the following parts:
1. FlexFeed®
2. Collating area
3. Divert Deck
4. Folding area
5. Envelope feeder
6. Inserter
7. Envelope exit (including conveyor stacker)
1
7
6
3
4
2
5
2.1.1 FlexFeed
®
(1)
The flexFeed
®
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 flexFeed
®
is equipped with double feed control. In this way the system can detect faulty sets of documents. The flexFeed
®
is equipped with hopper swap. 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.
7
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 Deck (3)
The Divert Deck automatically throws out incorrect sets of documents. In this way the system does not need to stop. Correct sets will be transported to the Folding area.
2.1.4 Folding area (4)
The Folding area folds the documents. The following fold types are possible:
• No fold
• Single fold
• Letter fold
• Zig-zag fold
• Double parallel fold
2.1.5
Inserter (6)
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 conveyor stacker. Automatic monitoring ensures the correct number of inserts per envelope.
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2.2
Operating Controls
A B C D E
I
H
G
F
J
K
L
M
N
X W
A conveyor stacker
V U
B loc cover
C unlocking lever for loc
D power inlet, power switch
E inserter cover
F RS232 connector / USB / modem
G display (operator panel)
H OMR reading head cover
I hand grip vertical transport cover
J document feed tray
K collator arm
L operator manual storage space
M folding area
T
S R Q P O
N locking handle
O air plugs for cleaning the sensors
P handle for manual envelope transport
Q unlocking handle for rollers envelope track
R water reservoir
S bellows for cleaning sensors
T side cover (opened)
U thumb wheel for side guide adjustment
V side guides envelope feed tray
W lever for envelope separation adjustment
X envelopes support
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2.4.2
Job Info
To enter the “job info” menu, press
This menu displays all relevant information about the selected job.
.
If the optional OMR is used the "1 track OMR info" menu is also available using the button.
To return to the “main menu (1/2)”, press .
The “job info” menu contains the following information:
Gives information about the envelope size (ISO format or height in mm).
Shows the type of fold.
3
2
1
Shows the feeders selected to pick documents from (black is selected).
3
2
The sign below this icon shows if the document double feed detection for the relevant feeder is switched on - or off - .
The number under this icon indicates the number of sheets that must be picked from the relevant feeder.
This sign indicates that the relevant feeder is set for daily mail.
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).
12
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 restarted.
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 °.
13
2.4.5
Job Menu
After pressing the menu opens.
button a login
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
•
: create a job (see 3.9 ”Create a
•
: edit a job (see 3.10 ”Edit a Job” on page 40).
: copy a job (see 3.11 ”Copy a Job” on page 40).
: delete a job (see 3.12 ”Delete a Job” on page 41).
• : exit and return to the “main menu (1)”.
2.4.6
Supervisor Menu
After pressing the menu opens.
button a login
Enter the PIN-code 2546 to access the “supervisor menu”.
14
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 present in the total system.
: this shows the software versions that are
The chip ID
: shows option information and system information:
The system ID
The installed options
For installing new options, see 4.1 ”Activate an Option” on page 42.
•
: opens the “job settings” supervisor menu (see ”Job Settings
(Supervisor)” on page 16). From this menu system parameters can be set.
•
: opens the “test menu” (see ”Test” on page 18). Use this menu to
test the system.
•
messages.
15
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 16).
• : opens the “document offset” menu to set the document offset in a set of
documents for a job (see ”Document Offset” on page 17).
• : opens the “BRE offset” menu to set the BRE offset on or off (see
•
: opens the “flap closer” menu (see ”Flap Closer” on page 18). 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 the default setting.
button. Mode 2 is
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 powerFold
®
, 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.
16
• Anticipation call for the envelope is used. That means that a (folded) set is leaving the flexFeed
®
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 flexFeed
®
.
It is advised to use Mode 1 with a paper thickness of 65 g/m properly. In all other cases Mode 2 is advised.
2
or less, a document length of 12 inch (305 mm) or higher, and for situations where Mode 2 is not functioning
If you select Mode 2, select if the reply envelope has a window or not.
Document Offset
When selecting from the “supervisor menu”
, offset” menu appears.
, the “document
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” menu appears.
, , the “BRE offset”
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.
17
The conditions are:
• The feeder that supplies this upper document (BRE) is set to one document per set
(no multi feeding).
• The document directly beneath this document must be at least 60 mm (2.4 inch) longer than the BRE.
• The upper document must be longer than the set address fold.
• The folding mode is either single fold or letter fold (no Z-fold).
• The upper document must be shorter than the envelope height.
Note
It is possible to use the BRE offset for a BRE and an enclosure (card) in one set. The extra condition is that this enclosure is equal to or smaller than the set address fold and should be placed direct underneath the BRE in the set.
The whole BRE offset is based on friction between documents within a set. Therefore it is necessary to make use of these conditions to reduce the risk of bad transporting, folding and inserting.
Flap Closer
When selecting from the “supervisor menu”
, , the “flap closer” menu appears. Use this function to improve the envelope sealing process for a job. The offset can be varied between -20 and 20. If for example the offset is set to +10 the sealing process will be activated 10 pulses later than initially.
For each of the jobs 1 through 25 and AutoSet an offset can be set.
Test
The “test menu” menu can be opened from the
“supervisor menu”. Use this menu to check the system, reset all photocells and execute an OMR test. The menu consists of the following functions:
• : use this function to check if all motors, clutches and sensors are correctly connected. This test derives the status of the actuators and clutches by briefly activating the actuators and then measuring the current.
Note
Remove all paper and close all covers before testing.
18
• : use this function to calibrate all photocells.
Note
Remove all paper and close all covers before calibration.
•
: use this function to align and test the OMR reading head (see ”OMR
OMR Test
The “OMR test” menu can be opened from the “test menu”. Use this menu to align and test the OMR
reading head (see ”Reading Head Position” on page
43). The menu consists of the following functions:
• : align the OMR reading head.
Put a document with reading marks in the feeder and press this button.
• : shows the mark quality and the number of read marks from the last processed document. Also the gain of the OMR amplifier is shown.
19
3. OPERATING INSTRUCTIONS
3.1
Installation
Caution
You can severely damage the machine if it is connected to the incorrect power supply.
Before plugging in the machine, check if the local voltage is the same as the voltage mentioned on the type plate.
3.2
Preparation
3.2.1
Document Feed Trays
Place the document feed trays in position:
1. Hold the document feeder slightly inclined as shown in the figure.
2. Place the front end of the document feed tray underneath the two black rollers.
3. Move the document feed tray upwards (lifting the black rollers), until it is possible to ‘hook’ the feeder into place.
4. Move the document feed tray towards the machine and move the hooks over the mounting points (on both sides).
5. Let the document feed tray rest on the machine.
20
3.4
Loading Documents
3.4.1
Document Orientation
one document hopper swap
Type of documents two documents
Fold type document + enclosure no fold single fold letter fold double parallel fold
Address carrier in top feeder.
Face up and leading.
Address carrier in top linked pair feeders.
Face up and leading.
Address carrier in top feeder.
Face up and leading.
Address carrier in top feeder.
Face up and leading.
zig-zag fold
Address carrier in bottom feeder.
Face down and trailing.
Address carrier in bottom linked pair feeders.
Face down and trailing.
Address carrier in bottom feeder.
Face down and trailing.
Address carrier in top feeder.
Face down and trailing.
In case the optional extended powerFold
®
is installed, the following feeding rules apply to documents with bottom address position:
Type of documents one document hopper swap two documents document + enclosure
Fold type no fold single fold zig-zag fold
Address carrier in top feeder.
Face up and leading.
Address carrier in top linked pair feeders.
Face up and trailing.
Address carrier in top feeder.
Face up and trailing.
Address carrier in top feeder.
Face up and trailing.
22
3.4.2
Side Guides
To adjust the side guides it is best to remove the document feed tray from the feeder as follows:
1. Push handle A downwards.
2. Lift the document feed tray upwards to unhook it and then pull it out from the feeder.
A
3. Loosen the knob B half a turn.
4. Grab the side guides in the middle and push them apart as far as possible.
5. Put a small stack of documents between the side guides.
6. Grab the side guides in the middle and push them towards the documents.
The space between the side guides and the documents should be such that the documents have just enough play to move freely.
7. Re-tighten knob B.
8. Remove the stack of documents.
9. Replace the document feed tray (3.2.1 ”Document Feed Trays” on page 20).
B
3.4.3
Document Separation
The term ‘Document separation’ refers to the adjustment required for separating the upper document from the rest of the documents in the stack. This prevents picking up to much documents from the stack at the same time.
The document separation for the automatic feeders is set automatically. There are no manual adjustments needed.
23
The document separation for special feeders must be adjusted manually as follows:
1. Push the knob B forward until it clicks.
2. Open the left-hand side guide A by turning it downwards.
3. Place a document on the feed tray and slide it about 60 mm (2.4 inch) into the system (turn the knob B counter clockwise if the separation is set to narrow).
4. Push the document between the separation rollers, which are behind the rubber paper pullers.
A B
5. Turn the knob B clockwise to get more resistance or counter clockwise to lower the resistance.
The separation is adjusted correctly when a slight resistance is felt on the document.
6. Pull the knob B back again when ready.
7. Close the left-hand side guide.
3.4.4
Filling the Document Feed Tray
Fill the document feed tray as follows:
1. Open the left-hand side guide A by turning it downwards.
The feed rollers will automatically be lifted.
2. Place a stack of documents between the side guides.
3. Turn the left side guide upwards again.
4. Feed the documents (depending on the type of documents and the type of fold) as
shown in 3.4.1 ”Document Orientation” on page 22.
3.4.5
Adjustment of the Document Stoppers
The document stoppers mark the position at which the documents coming from the feeder turn towards the folding area. The position of the document stoppers is automatically determined by the system during the job programming.
24
Initially the document stoppers are adjusted for position B. In this position a wide variety of documents can be handled (max. 297 mm; 11.7 inch) and adjustment is not needed.
When a job is selected in which a different stopper position has been programmed, the operator has to put the document stoppers in the correct position as indicated by the display.
To adjust the stopper position:
1. Lift and hold the collator arm D.
2. Squeeze the stopper and pull the front side tab up.
To replace the stopper:
A B C D
1. Place the flat back tab into the slotted hole.
2. Push the stopper into position.
Stop position A can handle documents up to 148 mm (5.8 inch), stop position B can handle documents up to 297 mm (11.7 inch) and stop position C can handle documents up to 356 mm (14 inch).
3.5
Loading Envelopes
3.5.1
Adjusting Side Guides
Adjust side guides C by rotating thumb wheel D, so that the envelopes:
• Fit exactly between the side guides
• Can move freely
Note
If the distance between the side guides is too large, the envelopes will twist sidewards, when transported into the machine.
3.5.2
Envelope Separation
To set the envelope separation:
1. Pull down small lever A.
2. Insert one envelope up to the stoppers.
3. Return lever A.
Now the envelope separation is set.
C
B
A C D
25
3.5.3
Feeding Envelopes
1. Place the bottom envelope between the rollers
(flap down and trailing - bottom side of envelope pointing to the machine).
2. Loosen the stack of envelopes and place the stack on top of the bottom envelope.
3. Shift envelope support B in or out, so that the flap side of the envelope is lifted approximately
20 mm (0.8").
4. Turn envelope support B so the weight of the envelopes is distributed evenly on both sides.
3.6
Sealing Envelopes
Note
Refer to 5.1 ”Operator Maintenance” on page 54 as well.
B
Switch the envelope sealing on or off:
1. Lift the handgrip to open the top cover.
2. Shift the blue handle A towards the envelope sealing or towards the envelop sealing.
3. Close the top cover.
to disable
to enable
When the sealing of the envelopes is enabled, the sealing liquid reservoir must be filled:
1. Open the front cover A.
2. Fill the reservoir B to the “Max” level indication with sealing liquid.
3. Close the front cover A.
Before starting the job, wait approximately 5 minutes for the brushes to moisten.
A
B
A
26
Insert Position
Note
This adjustment must only be checked in case of problems or when changing the envelope type.
1. Lift the locking lever of the loc and pull the loc into the vertical position.
The flap folding line must be positioned under the green indicator C. If not, adjust the insert position as follows:
2. Press on the left or right side of to adjust the insert position to the left or the right.
Each button stroke stops the next envelope
0.5 mm (0.02 inch) to the right (earlier) or to the left (later).
3. Press to load a new envelope into the insert position.
4. Recheck the insert position, and adjust as required.
If necessary adjust the envelope insert fingers, see ”Adjust the Envelope Insert
Adjust the Envelope Insert Fingers
To adjust the envelope insert fingers:
1. Loosen the knurled knob D on top of each finger.
2. Adjust each finger so that the tip enters about 5 mm (0.2 inch) into the envelope.
3. Re-tighten the knurled knob.
The fingers can be moved sideways to the desired position.
Caution
When adjusting the fingers sideways, be sure that finger A is not positioned over sensor
B. When an incorrect finger position is adjusted the display shows an error screen.
4. Place the outer fingers about 5 to 10 mm (0.2 to 0.4 inch) from the edges of the envelope.
Check the position of the insert fingers when changing to a different type of envelope.
Address Position
When the envelope position and the position of the fingers is correct:
1. Press to load a folded sheet into the envelope.
The envelope will be sealed (when enabled, refer to 3.6 ”Sealing Envelopes” on page
26) and ejected to the conveyor stacker.
2. Check the position of the address in relation to the address window in the envelope.
28
3. If necessary, press the Up or Down button to adjust the address position.
Each key stroke brings the address 1 mm (0.04 inch) with a maximum of 12 mm
(0.48 inch) lower or higher.
If the required address position is beyond the maximum range of 24 mm (0.96 inch), the AutoSet function can not be used. Use a programmed job instead.
4. Press to make another test run.
5. Recheck the position of the address, and adjust as required.
6. Press to leave this screen to return to the “main menu (1)” or press the button to immediately start the job.
Starting the Job
To start a job:
1. Press the button to start the job.
During running the display shows the “inserting” menu.
2. Press the button to stop the job. The machine will stop immediately.
3. Press the job.
button to clear the document path to prepare the machine for a new
When an AutoSet job is defined successfully these settings can be stored into a job. Use
the copy function in the job menu (see 3.11 ”Copy a Job” on page 40) to store the
settings.
3.7.2
Select Another Job
To select another job:
1. Press predefined job.
to select another
2. Press the arrows to select another job number.
The screen shows the job options of the relevant
job (see 2.4.2 ”Job Info” on page 12).
3. Press to confirm the selected job.
29
Perform a Test Run
To perform a test run:
1. Press menu.
to display the “test run”
A message can appear: “Set manual feeding” or
“Set automatic feeding”. In that case: a Check if the daily mail handle is in the
correct position (see 3.8 ”Run the Daily
b Correct if necessary.
c Press the button. d Press
The “test run” menu displays.
2. Press to load a new envelope into the insert position. This gives the
possibility to check and correct the insert position of the envelope (see ”Insert
3. When the envelope position and the position of the fingers is correct, press
to load a folded sheet in the envelope.
The envelope will be sealed (when enabled, refer to 3.6 ”Sealing Envelopes” on page
26) and ejected to the conveyor stacker.
When finished testing start the job (see ”Starting the Job” on page 29).
3.8
Run the Daily Mail
To process documents or sets of documents, which can not be processed automatically
(e.g. stapled documents), the top feeder is equipped with a daily mail switch.
To switch to the daily mail function:
1. Select a job where the daily mail function has been set to on: a From the “main menu (1)”, press .
b Search for a job with the daily mail function using the arrows. The daily mail function can be recognized by the icon in the “job info” screen.
c Press to select the job and return to the “main menu (1)”
30
2. Turn left side guide A of the upper tray down.
The Daily Mail handle B will become visible.
B
3. Move the handle to
Mail function.
to enable the Daily
4. Turn left side guide A upwards.
5. Place the document or document set in the feeder.
If necessary adjust the side guides (see
3.4.2 ”Side Guides” on page 23).
6. Press the button to start the job.
A
The document or document set will be folded and inserted in the envelope as described in the selected job.
7. Place the following document or document set in the feeder. The machine will keep running to process the inserted document or document set.
8. When finished with Daily Mail, press the
9. Turn left side guide A down.
button to stop the job.
10. Move the Daily Mail handle to the ‘AUTO’ position to disable the Daily Mail and to enable the automatic document separation.
3.9
Create a Job
To create a new job:
1. Press
2. Enter the pin code.
from “main menu (2)” (see 2.4.1 ”Main Menu” on page 10).
The “job menu” opens (see 2.4.5 ”Job Menu” on page 14).
3. Press .
The “create job” menu appears. The new job must be stored under a job number. The screen will show the lowest free job number.
Press the arrows to select a higher or lower free job number (if available).
4. Press to confirm the selected free job number.
The “job settings” screen opens. The meaning of all buttons and settings will be
explained in 3.9.1 ”Job Settings” on page 32.
31
5. Press and name.
to save the job with the entered settings under the specified job number
To name a job, see 3.9.7 ”Job Name” on page 38.
6. Press
to perform a test run with the new job settings (see ”Perform a
Note
A new selected job number starts with default settings.
3.9.1
Job Settings
From the “job settings” menu the following settings are available:
Envelope settings (see 3.9.2 ”Envelope
Document settings (see 3.9.3 ”Document
Fold settings (see 3.9.4 ”Fold Settings” on page 34)
Optical Mark Recognition (OMR) settings (if
installed) (see 3.9.5 ”Optical Mark
Recognition Settings (Option)” on page 36)
Double feed control settings (see
3.9.6 ”Double Feed Control Settings” on page 37)
Job name settings (see 3.9.7 ”Job Name” on page 38)
Mailing/Franking settings (if installed) (see
3.9.8 ”Mailing/Franking Settings (Option)” on page 39)
3.9.2
Envelope Settings
In this screen the properties of the used envelopes must be entered.
In the top of the screen, two selection buttons are displayed, from which one can be selected. The selected settings button will be highlighted yellow.
• Press to select an envelope size. Use the
button to enter the applicable dimensions.
It is also possible to select ISO standard envelopes or dimensions in inches (depends on the installation settings).
32
The envelope height can be set between 90 mm (3.5 inch) and 162 mm (6.38 inch).
• Press to set a job without inserting the documents in envelopes (no envelope mode). This can be useful for jobs, where documents only have to be sorted and/or folded.
3.9.3
Document Settings
This screen enables the setting of the document formats and the number of documents that must be picked from the different feeders.
• Press to set the number of sheets for the different feeders.
-
-
Press to select a feeder. The selected feeder will be highlighted.
Press the arrows to change the number of sheets that must be picked from the highlighted feeder.
When the number of documents is 0, the relevant feeder will be deselected.
Note
When a feeder is set to daily mail the number of documents is always 1 and can not be set in this screen.
Note
The maximum number of sheets per feeder is 25. When folding is used the maximum set thickness is 8 sheets in letter fold and 10 sheets (80 gr./m2) in single fold. When using powerFold
®
and bottom address (see 3.9.4 ”Fold Settings” on page 34) the number of
sheets is limited further.
• Press to enter the document height. The height or the ISO format of the document will be displayed next to the relevant feeder.
Press to select a feeder. The selected feeder will be highlighted.
Press document.
to display a numeric keypad to enter the exact dimension of the
Dimensions can be entered in mm, inches or as standard ISO paper dimensions
(depending on installation settings). The machine will not allow entering dimensions outer technical ranges. The document size can be set between 90 mm
(3.54 inch) and 356 mm (14 inch). The default document size setting of a new job is 297 mm (11.7 inch).
33
• Press to link two feeders. This function enables to fill two adjacent feeders with the same documents. When the first feeder is empty, the system automatically swaps to the other feeder.
Press to select two adjacent feeders. The selected feeders will be highlighted.
Press to link two highlighted feeders.
The will be displayed between the selected feeders.
Note
When linking two feeders, the program will automatically apply the number and format of the documents of the lowest feeder to the other feeder.
• Press to enter the setting of the Daily Mail function.
This function enables to process documents or sets of documents, which can not be
processed automatically (see 3.8 ”Run the Daily Mail” on page 30). The feeder that is
fit for the Daily Mail function will automatically be selected.
Press to enable the Daily Mail function. The icon daily mail feeder. If you press
appears behind the
again the Daily Mail function will be disabled.
3.9.4
Fold Settings
This screen enables the adjustment of the folding dimensions and the address type.
If the system is equipped with a third fold table and turning unit (‘extended powerFold
®
’) the “fold settings” menu consists of two parts:
• In the first part you can set the Address type.
You can switch between Top and Bottom using the button. If you choose Address type
Bottom you only have three possible fold settings left.
After pressing the button the second fold setting screen opens.
34
• In the second fold setting screen you can select the fold type.
The following choices are available:
No fold (no settings required)
Single fold
Letter fold
Double parallel fold
Zig-zag fold
Except when no fold is required, the display shows a simple diagram of the document with the fold positions. To change the fold positions press required position of the relevant fold.
The next table shows possible fold positions:
Fold type
Single fold
Letter fold
Zig-zag fold
Double parallel fold
First fold
Second fold
First fold
Second fold
First fold
Second fold
next to a fold. Enter the
Minimum position
75 mm (2.95")
25 mm (0.98") (extended powerFold
®
)
75 mm (2.95")
25 mm (0.98") (extended powerFold
®
)
Position first fold plus
25 mm (0.98")
75 mm (2.95")
25 mm (0.98") (extended powerFold
®
)
Position first fold plus
25 mm (0.98")
75 mm (2.95")
25 mm (0.98") (extended powerFold
®
)
Position first fold plus
25 mm (0.98")
Maximum position
Longest document length minus 25 mm (0.98")
Longest document length minus 50 mm (1.97")
Longest document length minus 25 mm (0.98")
Longest document length minus 100 mm (3.94")
Longest document length minus 75 mm (2.95")
Longest document length minus 50 mm (1.97")
Longest document length minus 25 mm (0.98")
Note
The display will indicate when entered positions are out of range.
35
3.9.5
Optical Mark Recognition Settings (Option)
For a full function description of Optical Mark
Recognition (OMR), see 4.2 ”Optical Mark
Recognition (OMR)” on page 42. Flex-OMR is also
optional. Flex-OMR can read non-Formax codes.
In the “OMR settings” menu it is possible to enable or disable the OMR function and to adjust the basic settings for OMR.
The first “OMR settings” menu covers the following settings:
• Code type: default is the setting “none”: OMR is disabled.
Change the setting using the button. The following codes are possible:
- 1-track OMR for reading Formax codes
- Flex 1-9 for reading non-Formax codes
• Read from feeder: press the button to select a feeder to activate OMR on.
• Reverse reading: reverse reading means that the insert mark is on the first page of the set. The system will detect the end of a set by detecting the first page of the next set. Because of the feeding and collating principal reverse reading has the following limitations:
The last mark of the code should be printed maximally 85 mm (3.3 inch) from the top.
Enclosures and selective enclosures cannot be handled.
In case the feeder runs empty the last set is still on the collator because the beginning of the next set could not be detected. In this case the feeder empty message contains an inserted.
function. By pressing the button the set on the collator will be
Note
Reverse reading is not available in OMR level 0, 1, 2 and 3.
By pressing the button the next “OMR settings” menu appears. This menu covers the following settings:
• 1st mark from top: press to set the position of the first optical mark, measured from top of the sheet. The value can be varied between 15 mm (0.6 inch) and 277 mm
(10.9 inch).
36
• Max. sheets: select the maximum amount of sheets in the set of documents using the arrow buttons.
Note
The maximum number of sheets in a set is 25. When the number of sheets exceeds 8 or
10, depending on the fold, the document can not be folded anymore. In this case, the maximum length of sheets is 156 mm (6.1 inch) for a C5 envelope. Also make sure that the fold is set to No fold.
Ignoring this will certainly lead to stoppages.
When the maximum number of sheets exceeds the programmed maximum number of sheets in a set, the machine stops and error VS:110 will be displayed. After removing the set and pressing the button, the machine will start and repeat the process until an insert or divert mark is encountered, error VS:135 (final set part) will be displayed.
By pressing the button the next “OMR settings” menu appears. This menu covers the following setting:
• Stop on misread: press to set if the machine should stop or not on misreading an optical mark.
When “stop on misread” is set to “yes”, the machine stops after detecting an OMR misreading. The incorrect set is diverted. After resetting the machine, the final part of the set is also diverted and the system starts processing again. The diverted set(s) should be checked by the operator.
When “stop on misread” is set to “no” the machine does not stop after detecting an OMR misreading. The incorrect set is diverted. The final part of the set is also diverted and then the machine starts processing again. After detecting 5 OMR misreadings in a row, the system stops and an error code is generated.
3.9.6
Double Feed Control Settings
This screen enables to set the Double Feed Control
(DFC) settings for the different feeders on or off and to set the thickness measurement.
To set the DFC for the different feeders:
1. Press the button to select a feeder.
2. Press the or off - .
button to switch the DFC on -
37
If the DFC is on you can set Continue on double on or off using the button. If
Continue on double is on (“yes”), the machine will not stop if two sheets are feeded instead of one. The document-set containing the double sheets will be diverted.
When a job is started, the first document taken per feeder is used for a reference measurement. When a document is exceeding that reference thickness an error will be displayed.
Note
When Daily mail is selected, the DFC will be switched off automatically.
To set the thickness measurement:
1. Press the button to select the inserter area.
2. Press the button to switch the thickness measurement on - or off - .
If the thickness measurement is on you can set the measurement area:
3. Press the button.
4. Set the measurement area using the arrow buttons.
The standard position of the measurement area is sufficient for a great variety of documents. Only when using special types of documents, for example small cards, the position of the measurement area might be adjusted.
When the set thickness is not corresponding the reference value an error will be displayed.
3.9.7
Job Name
It is possible to store the job with a meaningful job name, to easily recognize the job. This name will be displayed in the Main screen during job selection.
1. Enter a job name using the alpha-numeric keypad.
2. Press to clear a character left of the cursor position (backspace).
3. Press to clear all entered characters and start again.
38
3.9.8
Mailing/Franking Settings (Option
1
)
If this machine is connected to a mailing/franking machine, this option allows you to select the franking mode.
Press the button to select:
• Pass through
The mailing (franking) machine will let the envelopes pass through without printing/ franking. Press the the “job menu”.
• Franking machine
button to return to
The mailing (franking) machine will print/frank the envelopes according to the local mailing (franking) machines settings.
If you press the button a screen appears in which it is possible to link a mailing (franking) job to the inserter job. Use the arrow buttons to select a job. If no link is required, select
“Current job”. Press the to the “job menu”.
• Inserter data
button to return
The mailing (franking) machine will print/frank the envelopes according to the weight and size data communicated by the inserter.
If you press the button a screen appears via which the weight of single documents and envelopes and the envelope width can be entered. Use the
and buttons to enter these data. Press the button to return to the previous screen.
To link a mailing (franking) job to the inserter job, use the arrow buttons to select a
button to return to job. If no link is required, select “Current job”. Press the the “job menu”.
Refer to the appendix for an extensive description of this option.
39
3.10
Edit a Job
To edit an existing job:
1. Press
2. Enter the pin code.
from “main menu (2)” (see 2.4.1 ”Main Menu” on page 10).
The “job menu” opens (see 2.4.5 ”Job Menu” on page 14).
3. Press .
The “edit job” menu appears.
4. Press the arrows if you want to select an other job number.
5. Press number.
to confirm the selected job
The “job settings” screen opens. Refer to 3.9.1 ”Job Settings” on page 32 for the
meaning of all buttons and settings.
6. Press and name.
to save the job with the entered settings under the specified job number
To name a job, see 3.9.7 ”Job Name” on page 38.
7. Press
to perform a test run with the new job settings (see ”Perform a
3.11
Copy a Job
To copy existing job settings or AutoSet jobs to a new job:
1. Press
2. Enter the pin code.
from “main menu (2)” (see 2.4.1 ”Main Menu” on page 10).
The “job menu” opens (see 2.4.5 ”Job Menu” on page 14).
3. Press .
The “copy job” menu appears.
4. Press the arrows if you want to select an other job number to copy from or to copy to.
40
Note
You can only copy job settings to new jobs.
5. Press for details of the job to copy from.
6. Press to copy the job settings.
If all jobs are programmed the display shows “No more free jobs”.
It is possible to copy a AutoSet job into a job. Before a AutoSet job can be copied
AutoSet has to be defined successfully (see 3.7.1 ”Using AutoSet” on page 27).
3.12
Delete a Job
To delete an existing job:
1. Press
2. Enter the pin code.
from “main menu (2)” (see 2.4.1 ”Main Menu” on page 10).
The “job menu” opens (see 2.4.5 ”Job Menu” on page 14).
3. Press .
The “delete job” menu appears.
4. Press the arrows if you want to select an other job number.
5. Press for job details.
6. Press . The job will be deleted without a warning.
41
4. OPTIONS
4.1
Activate an Option
To activate a new option:
1. From the “supervisor menu” choose .
Software options are enabled using license codes. These license codes, together with the identification number of the machine enable the relevant options. The enabled and available software options are displayed in this screen. Contact your dealer for information about these license codes.
2. Press to activate other software options.
3. Enter the license key code that you received from the supplier to activate the relevant option on this machine.
Use the arrow keys to navigate through the entered characters.
4. Press to confirm the license key and to return to the “options” menu.
5. Switch the system off and on.
4.2
Optical Mark Recognition (OMR)
4.2.1
General
The folding and inserting system can be equipped with Optical Mark Recognition (OMR) or
Flex-OMR. This allows the system to read special codes that have been printed on the documents. These codes contain information about the processing of the sheets. With
Flex-OMR, the system can also ‘read’ non-Formax codes.
The sheets with the printed code are placed in a feeder. Depending on the programmed code, the other feeders can be used as selective feeders to add enclosures.
In case of a zig-zag fold, the address has to be printed on the last page of the set. With the other fold types, the first sheet of a set always contains the address. A full length code is printed on every sheet of a set.
The code on the last sheet of the set contains the insert instruction. The other sheets carry the accumulate instruction. If a parity check is used, this is checked on each sheet.
If the set contains only one sheet, it is the ‘last’ sheet. The code must appear in the same location on every page regardless of the actual code length.
42
4.2.2
Alignment
Reading Head Position
The horizontal position of the reading head must be aligned to the same position of the printed marks on the documents. To align the reading head, proceed as follows:
1. Open the “OMR test” menu from the “Test
menu” (refer to 2.4.6 ”Supervisor Menu” on page 14).
2. Press procedure.
to start the alignment
3. Put a document with reading marks in the feeder (either feeder 1 or 2, depending on the selected job).
4. Press .
The document will be transported to the reading head position.
5. Open the special OMR reading head cover in the feeder.
6. Shift the reading head until the red pointer is positioned exactly above the middle of the reading marks.
7. Open the vertical transport cover and remove the document.
8. Press to determine the alignment.
9. Press to finish the alignment procedure.
Note
When the reading head is aligned it is possible that paper guides have to be removed and placed on the other side of the reading head.
43
4.2.3
Document Orientation
Switch on the OMR-function and set the position of the reading marks as described in
“Optical Mark Recognition Settings (Option)” on page 36.
Document orientation:
Fold type
Type of documents
direction no fold letter fold single fold double parallel fold address
OMR start reading
OMR first page stop reading
Address carrier, face up and leading.
(duplex printed)
123 direction address
32
1 zig-zag fold
OMR stop reading
OMR start reading last page
Address carrier, face down and trailing.
4.2.4
OMR Codes
Printing Quality
• Marks should be printed in black.
• Marks on the same sheet must have equal intensity.
• Marks must be printed on the same position on every sheet.
• For matrix printers near letter quality (NLQ) printed characters are preferred to obtain maximum blackness (double strike).
• Be aware of background ‘noise’. Color changes on the form, background design, a logo or copy on the opposite side of the sheet that will bleed through can be read by the reading head causing disturbances of the OMR function.
• The ribbon or toner quality must be checked before printing.
44
Minimum Code / Basic Commands
The minimum code is one mark in one line (insert).
However for reliability it is advised to use at least 2 marks.
The first line is the start mark.
A mark printed on the second line means insert. No mark on the second line means accumulate.
Start mark
Insert/accumulate
Note
In some cases, on request of the customer, the reading of the basic commands can be reversed by the service organization. This means that no mark is interpreted as an insert command and that for the accumulate command a mark has to be printed.
Length
Above the first mark and below the last mark a space of 8.5 mm (0.33") must be kept without printing. This means that the minimum code area consists of 6 lines:
• 2 lines to print the (basic) commands
• 4 lines free space
Line distance may be 2.54 mm (0.1") to 6.35 mm
(0.4").
8,5 mm
8,5 mm
6,3 mm
Line 1
Line 2
Line 3
Line 4
Line 5
Line 6
Code Width, Character Spacing and Pitch
The minimum width of the code area is 7 character spaces. From left to right:
4,2 mm 4,2 mm
• 2 characters space not printed (4.2 mm; 0.17")
• Track mark (3 characters or 6.3 mm; 0.24")
• 2 character spaces not printed
Pitch 10 or 12 is accepted.
The track mark can be printed using the underline sign (_), which must have a thickness of at least 0.2 mm (0.08").
45
Additional Marks
When it is required to control more functions in the inserter system, the use of more marks is needed.
The following additional functions are possible via software options:
• Divert mark (divert & continue)
• Stop mark (divert & stop)
• 1 mark: selective feed from station x (max. 6 depending on configuration)
• 1, 2 or 3 marks: respectively sequence check 4,
2 and 1
• 1 mark: parity check mark (even)
• 1 mark: safety mark
General remarks:
Start mark
Insert/accumulate
Divert mark
Stop mark
Selective feed 1
Selective feed 2
Selective feed 3
Selective feed 4
Selective feed 5
Selective feed 6
Sequence check 4
Sequence check 2
Sequence check 1
Parity (even parity)
Safety mark
• The marks must always be used in the above sequence.
• If a function is suppressed the following function will move upwards one line.
• The chosen code must always be used on all material which must be processed by the
Optical Mark Recognition.
• The length of the code and the mark definition is a service setting.
• Other marks/functions are possible via special codes (Flex codes).
Divert Mark (Divert & Continue)
The set will be diverted and the system continues.
Stop Mark (Divert & Stop)
The set will be diverted and the system stops indicating error VS:113 (stop mark read).
Selective Feed Mark
The machine will selectively feed an enclosure when commanded so.
Sequence Check
Sheets in a stack can accidentally get out of sequence or can be missing. This can be detected by the sequence check.
Each sheet has a binary code that is a part of the reading code.
Parity Mark
By adding a parity mark the reading code can be checked. When the OMR-2 code is used the sum of the marks has to be even.
46
Safety Mark
The safety mark is used as an extra security. With skewed paper the reading head can miss part of the reading code. In these situations the safety mark is not read, and the system will give an error.
The safety mark also indicates the end of the reading code.
This mark must always be present on the document if it has been activated as an OMR code.
Examples of OMR Code
In the figure the legend for the following example is shown. In this example feeder station 1 is the reading feeder. The feeder stations 2 through 6 are selected for selective feeding.
or
Normal paper flow
Start mark
Safety mark reading direction mark printed no mark printed accumalate insert no selective feed wanted, mark not printed selective feed wanted, mark printed
Skewed paper flow
Start mark
Safety mark reading direction selective feeder 6 selective feeder 5 selective feeder 4 selective feeder 3 selective feeder 2 reading feeder 1
Example Code
In this example a set of 8 sheets with three selective feeds (station 2, 3 and 4) and three sequence check marks is shown.
• The first position is used for the start mark which must be printed on every sheet.
• The second mark position is used for the insert/ accumulate command. The mark is printed on the last sheet of the set (inserting is required).
• Position 3, 4 and 5 are reserved for selective feeding from station 2, 3 and 4. Print a mark on position 3 when a selective feed from station 2 is required. Print a mark on position 4 when a selective feed from station 3 is required. Print a mark on position 5 when a selective feed from station 4 is required.
• Position 6, 7 and 8 are used for the sequence check marks.
Sheet 1 Sheet 2 Sheet 3 Sheet 4 Sheet 5 Sheet 6 Sheet 7 Sheet 8
47
4.3
Online Services
4.3.1
General
The folding and inserting system can be equipped with Online Services. This option enables the machine to connect to a central server. During the connection data is downloaded to and uploaded from the machine. The machine always initiates the connection, it is not possible to make a connection from outside to the machine. Ask your supplier if this option is available.
4.3.2
Start-Up Online Services
To start-up Online Services:
1. Select from the “main menu (2)”.
2. Enter the PIN-code 2546 to access the supervisor menu.
3. Press .
The “Online Services” menu shows the following functions:
• : opens the “connection” menu to create a connection to a central server and to view the connection history (see
4.3.3 ”Connection” on page 48).
•
•
: opens the “messages” menu to view received messages (see
: opens the “configuration” menus to change Online Services settings
(see 4.3.5 ”Configuration Menu” on page 50).
4.3.3
Connection
The machine makes a connection on fixed times. It is possible that you manually connect the machine to the server. To connect to the server:
1. Press menu.
in the “Online Services”
The display shows the “connection” menu.
2. Press to manually connect the machine to the OLS server.
You can view the status of the connection on the screen. The text on the button changes to
Press to terminate connection with the server.
.
48
The “connection” menu shows the following functions:
• : opens the “history” menu to view the connection history (see
• : this button appears when the machine received new messages and
opens the “messages” menu (see 4.3.4 ”Messages” on page 49).
History
The “history” menu shows previous connections of the machine to the server.
1. Press or connection.
to select a previous
2. Press to view details on selected previous connection.
4.3.4
Messages
After pressing in the “Online Services” menu the display will show messages received from the server. A message has content like new software or a new job.
1. Press or to select a message.
2. Press selected message.
for more information over a
In case new software or a new job can be installed the button appears.
To install new software or a new job:
1. Press .
The “new software” menu or the “new job” menu appears. Press more information on the software or the job.
2. Press to install the new software or the new job or press to reject the new software or new job.
After pressing a confirmation menu opens:
• In case of new software, press to “installation” menu.
to confirm installation or press
for
to return
49
• In case of a new job press
or
to select a free job number (see 3.9 ”Create
Press menu.
to confirm the selected job number or press to return to message
After conforming the installation of the new software or new job the “message” menu appears.
4.3.5
Configuration Menu
After pressing in the “Online Services” menu the “configuration” menu opens. Use this menu to modify the OLS settings.
The menu consists of two screens containing the following functions:
• Dial tone detection on / off
This setting is required if no dial tone is heard during establishing a connection. The default value is on. This setting is relevant to some
PABX telephone switch systems.
Press to switch the dial tone detection on or off.
• Telephone number of server: contact your supplier for the telephone number of the
OLS server.
To change the number: a Press . b Enter the correct number using the numeric keypad. c Press to confirm the new number.
• Prefix: use this function in case you need to dial a certain number or string to access an outside line. a Press .
b Enter the correct prefix using the numeric keypad. c Press to confirm the new number.
• Country: enter the country from where you are dialing.
Select the correct country from a list by pressing
• Date and time: enter the current date and time.
or .
a Press . b Enter the correct date and time using the numeric keypad. c Press to confirm the new number.
50
• Volume of modem: set the modem volume. a Press or to change the volume of the speaker.
Do not set the volume to zero as the sound of the modem is helpful during remote assistance.
b Press to confirm modified settings.
4.4 Production Feeder
4.4.1
Function
The Production Feeder can be loaded with a high number of documents. This feeder is intended to be used for Business Reply Envelopes (BRE), but also ‘standard’ documents up to 356 mm (14") length can be processed with it.
4.4.2
Preparations
The Production Feeder should be installed at the position of feeder no. 1.
It can be placed into position in the same way as the other document feeders are fitted.
Proceed as follows:
1. Lift the paper feed rollers with the front edge of the Production Feeder.
2. Move the Production Feeder forward until it hooks behind the frame axle.
3. Connect the connector A to the socket B.
A B
The Production Feeder is auto-detected by the system when it is switched on. This makes it easy to switch over from the standard document feed tray to the Production Feeder and vice versa.
Note
To allow easier hooking on of the Production Feeder it is advised to put the feeding plate in the
rear position (see 4.4.4 ”Document Separation” on page 52).
To make use of a Production Feeder it is not necessary to (re-)program the jobs.
51
4.4.3
Adjust Side Guides
Adjust the side guides:
1. Take a stack of documents/BREs and place them in the feed tray.
BREs with flap down and leading (top side pointing to machine).
2. Adjust the side guides by turning the thumb wheel A so the documents/BREs just fit and can move without resistance.
Too much play causes skewing.
A
4.4.4
Document Separation
When the Production Feeder is used at an automatic separation feeder, the separation is set automatically.
The Production Feeder can also be used on a feeder position with a manually adjusted separation.
To adjust, proceed as follows:
1. Remove feeders 2 and 3.
D
Note
The lowest feeder is feeder 1.
2. Squeeze the two blue handles A and B and shift the feeding plate C as far as possible to the front.
3. Push knob D forward until it clicks.
4. Place a document/BRE on the feed tray and slide it in the machine till the leading edge is not visible anymore. Turn knob D counterclockwise if the separation is set to narrow.
5. Push the document/BRE between the rollers.
6. Turn knob D clockwise to get more resistance and counterclockwise if the separation is set to narrow.
The separation is adjusted correctly when a slight resistance is felt on the document/BRE.
7. Pull knob D back when ready.
8. Remount feeders 2 and 3.
4.4.5
Feeding Documents
To feed documents:
1. Squeeze the two blue handles A and B.
A B C
52
2. Shift the feeding plate C to the rear position.
3. Loosen the stack of documents and place them in the feeder. BREs with flap down and leading (top side pointing to machine).
The feeding plate assembly will be shifted up automatically (when the system starts processing) until documents/BREs are underneath the rubber paper pullers.
Note
When filling the Production Feeder, make sure that the document/BREs are positioned parallel in relation to the feed plate to ensure correct feeding.
Note
When longer documents are used, plate C can be extended by pulling out the adjustable
feed plate extension.
53
5. MAINTENANCE
Disconnect the mains power supply before performing any maintenance.
The user must not attempt to service the appliance beyond that described in this operator manual. All other servicing must be carried out by qualified service personnel only.
Please contact your authorized distributor.
5.1
Operator Maintenance
Maintenance frequency
Daily
Weekly
Maintenance
• Check the system functions.
• Keep the system in proper condition by removing dust, paper remains, etc.
• When dirty, clean the sealing table and rubber rollers with a slightly wetted cloth, soaked in warm water.
• When dirty or saturated, clean the brushes of the envelope sealing.
The machine is delivered with an extra set of brushes. To always have one clean set available, it is recommended to soak one set in water and use the other set.
Remove the brushes one by one by pulling them down from the brush holder.
Replace the brushes and make sure that the studs on the brushes are fitted in the corresponding holes in the brush holder.
• Check moistening cloth and replace if necessary.
When dirty or saturated, clean the moistening cloth and the reservoir.
• Clean feed and insert rollers as instructed by the Service
Engineer.
When necessary • When the display warns about dusty sensors, the sensors on the envelope or document path must be cleaned using the bellows that is located behind the side cover.
Place the bellows in the upper air plug and firmly squeeze a few times to blow the dust from the document path sensor.
Repeat this procedure for the lower air plug to clean the envelope path sensor.
Calibrate the photocells (see ”Test” on page 18).
54
6. FAULT FINDING
6.1
Error Messages
When an error occurs the display shows a screen showing the following information:
• An indication of the area in which the error occurred
• An error description
• A suggested solution behind the pointing hand
Press to view more information about the occurred error and about the possible actions to avoid the error from re-occurring.
After solving the problem, press error (the error screen will disappear).
to reset the
Special Errors
• Reading errors (when Optical Mark Recognition is enabled)
The document set is diverted. The operator must remove the document set and has to complete the set manually!
• Technical errors
The display shows a message. The error cannot be solved by operating personnel and assistance of the service support is needed.
Warning Screen
When a cover is opened, the display shows a warning screen with the message "Cover
Open" and a suggested solution “Close cover”.
55
6.2
Clearing Stoppages
Stoppages can occur in the following areas:
1. FlexFeed
®
area
2. Collating area
3. PowerFold
®
area
4. Lower envelope track
5. Sealing and inserting area
6. Exit area
7. Envelope hopper
1
5
2
3
6
7
4
For clearing of stoppages, six system sections can be opened:
A loc cover, to reach the exit area
B inserter cover, to reach the sealing and inserter area
C collator arm, to reach the collating area
D feeder cover, to reach the feeding area
E powerFold
®
cover, to reach the folding area
F side cover, to reach the lower envelope track
A B
6.2.1
Exit, Sealing and Inserting Area
When a stoppage occurs in this area, remove the material as follows:
F
1. Open the side cover F.
2. Lift the locking lever of the loc and pull the loc up into the vertical position.
3. Lift the inserter cover.
4. Remove all material.
5. Lower the loc and the inserter cover.
6. Close the side cover.
E D C
7. Press to reset the error and restart the job.
56
6.2.2
Envelope Hopper
When an envelope gets stuck in this area, remove the envelope as follows:
1. Pull down small lever B.
Pins C will come down.
2. Push lever A to the right and hold it.
Pins C will go up.
3. Remove the stuck envelope.
4. Release lever A.
5. Return lever B.
6. Press job.
to reset the error and restart the
6.2.3
Lower Envelope Track
When a stoppage occurs in the lower envelope track, remove the envelopes as follows:
1. Open the side cover A.
2. Squeeze handles B to unlock the rollers.
3. Remove the envelopes.
4. Release handles B.
5. Close the side cover.
A
B
C
6. Press job.
to reset the error and restart the
If needed, envelopes and documents can be transported manually by means of handle C. To transport envelopes manually to the insert table or to the lower envelope track, joggle the handle. To transport a document manually push handle C inwards and then joggle.
A
C
B
57
6.2.4
PowerFold
®
When a stoppage occurs in the powerFold
®
, remove the documents from the powerFold
®
as follows:
1. Push the lower end of the locking handle A to open the powerFold
®
cover B.
2. Remove the documents from the powerFold
®
.
3. Close the powerFold
®
cover.
4. Press job.
to reset the error and restart the
A B
6.2.5
FlexFeed
®
When a stoppage occurs in the flexFeed
® follows:
, remove the documents from the flexFeed
®
as
1. Pull the vertical transport hand grip upward to open the vertical transport cover.
2. Remove the documents.
3. Close the vertical transport cover.
4. Press to reset the error and restart the job.
6.2.6
Collating Area
When a stoppage occurs in the collating area, remove the documents from the collating area as follows:
1. Lift and hold the collator arm A.
2. Remove the documents.
3. Lower the collator arm.
4. Press job.
to reset the error and restart the
6.3
Operator Troubleshooting
To resolve problems:
1. Write down the error.
2. Try to solve the problem by consulting the troubleshooting table.
3. Switch the inserter off and on again, to verify system operation.
4. When the error still occurs contact your service organization.
A
58
Note
When contacting the service organization, you will also be asked for the last error message and the software version of the installed software. To determine the software
version, refer to 2.4.6 ”Supervisor Menu” on page 14.
Symptom
The system cannot be started after switching on.
System stops with envelope at insert position (flap not open).
Envelopes are double fed.
Envelope stop skewed.
Envelopes are fed irregularly.
Possible cause
System not connected to mains.
Fuse is blown.
Remedy
Connect the system to the mains.
A cover is opened.
Envelopes stacked reversed in the feed tray.
Replace fuse below power switch.
Close the covers.
Check envelope feed adjustments. Place envelopes correctly in feed tray.
Envelope flap sticks. Store envelopes according to specifications.
Wrong envelope type used (not according specifications or job settings).
Envelope separation not correctly set.
Envelopes not placed properly in the feed tray.
Side guides of the envelope feed tray are set too wide.
Change envelopes according to specifications.
Adjust envelope separation.
Check and replace if needed.
Check side guides and adjust if needed.
Feed tray almost empty.
Separation set too narrow.
Side guides set too narrow.
Envelope support not positioned correctly.
Refill feed tray.
Adjust envelope separation.
Check side guides and adjust if needed.
Reposition the envelope support.
Reference
-
-
-
“Loading Envelopes” on page 25
“Envelope Settings” on page 32
“Envelope Settings” on page 32
“Envelope Separation” on page 25
“Loading Envelopes” on page 25
“Loading Envelopes” on page 25
“Loading Envelopes” on page 25
“Envelope Separation” on page 25
“Loading Envelopes” on page 25
“Loading Envelopes” on page 25
59
Symptom
Flap is wrinkled and sometimes not opened.
Fingers are placed on top of the envelope.
System stops while inserting
(stoppage at the inserting point).
Possible cause
Envelope not within specifications.
Flap sticks.
Flap curled.
Separation set too narrow.
Fingers adjusted too deep into the envelope.
Envelope stops too early.
Fingers not correctly adjusted.
Inserted document too long for used envelope.
Envelope throat incorrect.
Envelope glued inside.
Window not glued properly.
Remedy
Check specifications and change envelopes if needed.
Store envelopes according to specifications.
Envelopes stored or manufactured improperly.
Adjust envelope separation.
Reference
“Envelope Separation” on page 25
Check fingers position, adjust if needed.
Check envelope stop position, adjust if needed.
Check fingers position, adjust if needed.
Check fold settings.
Check envelope specifications.
Eliminate faulty envelopes.
Eliminate faulty envelopes.
“Envelope Settings” on page 32
-
-
60
Symptom
Flap not sufficiently moistened.
Envelope not always ejected from sealer.
No document fed. Feeder empty.
Skewed documents fed.
Double documents fed.
Document stoppage at collating area.
Possible cause
Water level low.
Brushes dry.
Brushes dirty.
Remedy
Check water level, refill if needed.
Check brushes, replace if needed by the extra soaked set.
Check brushes, clean if needed.
Moistening felt dry.
Check the moistening felt, refill water tray if needed.
Moistening felt dirty. Check the moistening felt, clean if needed.
Moistening brushes inactive.
Brushes worn out.
Activate the moistening brushes.
Replace brushes.
Moistening felt worn out.
Inserted document too big.
Document not inserted deep enough.
Sealing area dirty.
Replace moistening felt.
Check fold settings, adjust if needed.
Check adjustment of envelope stop position and fingers.
Clean sealing area.
Reference
“Sealing Envelopes” on page 26
“Sealing Envelopes” on page 26
“Operator Maintenance” on page 54
“Sealing Envelopes” on page 26
“Operator Maintenance” on page 54
“Sealing Envelopes” on page 26
“Operator Maintenance” on page 54
“Operator Maintenance” on page 54
Separation set too wide / too tight.
Side guides set too narrow.
Side guides set too wide.
Separation set too wide.
Stopper position set incorrect.
Refill feeder.
Adjust the separation.
Adjust the side guides.
Adjust side guides.
Adjust the separation.
Adjust stopper position.
“Operator Maintenance” on page 54
“Document Separation” on page 23
“Document Separation” on page 23
61
7. SPECIFICATIONS
7.1
Technical Specifications
Model 6402 Series
Type
Theoretical max. speed
inserter system for medium office use.
4000 inserts per hour, depending on application.
Power consumption
100V AC/50Hz/3.0 Amps.
115V AC/50/60Hz/3.0 Amps.
230V AC/50Hz/1.5 Amps.
Fuse
100/115 Vac: T 5.0 A, 125 V
Time lag, 5.0 Amps. rated current, 125 V.
230 Vac: T 2.5 A H, 250 V
Time lag, 2.5 Amps. rated current, high breaking capacity, 250 V
Approvals
EMC Certificate conform EMC-Directive.
FCC Certificate conform 47CFR, part 15.
CB Certificate conform IEC 60950-1.
UL Listed I.T.E. (Information Technology Equipment), conform UL-IEC 60950-1, file: E153801.
Conform NEN-EN-IEC 60950-1 and derivatives.
7.2
Height
Width
Length
Weight
Configuration Dimensions
2 stations 4 stations 6 stations
570 mm (22.4 inch)
420 mm (16.5 inch)
1340 mm (52.8 inch)
(with receiving tray 1590 mm/
62.6 inch, with side exit 1440 mm/56.7 inch, with stacker 1840 mm/72.4 inch)
745 mm (29.3 inch) 920 mm (36.2 inch)
88.5 kg (195 lbs) 96.2 kg (212 lbs) 110 kg (242 lbs)
7.3
Other Specifications
Noise level
Operating temperature
Humidity
<66 dBA (according to ISO 11202)
10°C - 40°C (50°F-104°F)
30%-80%
7.4
Document Specifications
Paper quality
minimum 60 g/m² (15 lb bond) maximum 250 g/m² (62.5 lb bond), when folded max. 170 g/ m² (42.5 lb bond)
Booklets up to approximately 2 mm (0.08 inch) thickness, depending on stiffness
62
Paper size
Folding capacity
Envelope sizes
Envelope quality
7.5
Minimum width: 130 mm (5.1")
Maximum width: 242 mm (9.5"), when folded 230 mm (9.1")
Minimum length: 90 mm (3.5")
Maximum length: 356 mm (14")
Single fold - 10 sheets (max. 80 g/m²)
Letter fold / Z-fold - 8 sheets (max. 80 g/m²)
Double parallel fold - 4 sheets (max. 80 g/m²)
Standard BRE (Business Reply Envelopes) minimum 80 g/m² (20 lb bond) maximum 120 g/m² (30 lb bond)
Envelope and Insert Specifications
Minimum size mm
A
160
inches 6.3
Maximum size* mm
248
inches 9.7
B
90
3.5
162
6.38
C
32
1.25
B-32
D
10
0.4
75
B-1.25 2.9
E
-
-
F
84
3.3
A-12** B-6
A-0.47** B-0.2
G
60 g/m
2
60 g/m
2
2.5*
0.1
* Booklets up to approximately 2 mm (0.08 inch) thickness, depending on stiffness
** When insert is more than 1 mm (0.04 inch): A-15 mm / A-0.6 inch
Remarks:
• The specification of the paper handling equipment is often wider than that of the envelopes and documents handled. The condition of material handled will limit the specified environmental conditions.
63
• We recommend that materials to be handled are stored at a temperature of 20°C
(68°F) with a relative humidity factor of 50%. If difference in temperature occurs between store room and mailing area, the material has to be stored near the machine at least 24 hours before use.
• Self-copying paper may cause rubber parts to wear quicker. The rubber used in this machine has the best resistance to Wiggins Teape material.
64
8. TERMINOLOGY
Term
Address carrier
Address position
Description
The address carrier is the document that carries the address of the person for who the mail-set is meant. The address carrier can consist of one or more sheets, from which at least the first sheet must contain the address. The address must remain visible while enclosures are added and the document-set is folded. The fold type and selected envelope must ensure that the address is visible behind the window in the envelope. For personalized mailings there is always an address carrier present as long as envelope printing is not supported. Normally there is one address carrier.
Position of the address on the address carrier, measured from the upper left corner. The address position consists of a horizontal x coordinate, a vertical y coordinate, a horizontal width w and a vertical height h.
Business Reply
Envelope (BRE)
C-fold
Clear
Envelope included in outgoing mail-sets for addressee response purposes.
Conveyor stacker Stacks up filled envelopes from the system.
Daily Mail Capability of an inserting system to manually insert mail-sets one by one into the system, which are then inserted into an envelope.
Optionally, depending on settings, additional enclosures can be added and the mail-set can be folded. This function is intended for small amounts of mail that each can have a different build-up.
Document
The function of an inserting system in which all mail-sets in progress are finished and the document path is left empty.
Document-set
A document is one of the components of a mail-set. A document can consist of one or more sheets. Documents can be divided into address carriers and enclosures. For personalized mailings there is always one address carrier and an optional number of enclosures.
The document-set is the physical collection of address carrier and enclosure(s) that is under production in the Inserting System. The document-set is completed during production and is to be inserted in the envelope. The number of enclosures can range from 0 to the limit opposed by the number of available Feeders. Once the document set has been inserted into an envelope it is called mail set.
65
Term
Double Feed
Control (DFC)
Double parallel fold
Description
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 detection). Currently DFCs on Formax inserting systems perform relative measurements, which means that they need a cycle to 'learn' the thickness of a sheet.
Also the length of the document is measured so partly overlapping sheets will be detected.
The double parallel fold is a type of fold where the document is first folded halfway and the resulting folded set is again folded halfway.
This fold is illustrated in the picture below. The position of both folds is adjustable.
Envelope The envelope is the packaging of a mail set. Window envelopes are envelopes that have a transparent section through which the address on the address carrier can be read. Besides the normal top-closing window envelopes there are also bottom-closing envelopes.
Option, makes bottom address applications and short folds possible.
Extended powerFold
®
Face down
Face down leading
Face down trailing
Situation in which the front of a sheet is facing downwards when placed in a document feeder.
Situation in which the front of a sheet is facing downwards and the top of the sheet is closest to the separation unit in a document feeder.
Situation in which the front of a sheet is facing downwards and the bottom of the sheet is closest to the separation unit in a document feeder.
Face up Situation in which the front of a sheet is facing upwards when placed in a document feeder.
Face up leading Situation in which the front of a sheet is facing upwards and the top of the sheet is closest to the separation unit in a document feeder.
Face up trailing Situation in which the front of a sheet is facing upwards and the bottom of the sheet is closest to the separation unit in a document feeder.
Feeder A Feeder is a Module for the input of documents to the inserting system. The Feeder separates documents sheet by sheet from the stack of documents in the feed tray.
66
Term
Feeder linking
Feed tray
Flexcode OMR
FlexFeed
Insert
®
Description
The ability to load two feeders with the same document type where the Inserting System automatically switches to a second feeder when the first feeder is empty and vice versa. In the mean time the first feeder can be refilled, so the inserting system can keep running without having to stop for refilling the feeders.
Part of the feeder that contains the stack of documents.
An OMR code for which the meaning of the OMR marks can be programmed in a dedicated way for a specific customer. This is normally used to support the OMR codes from other suppliers.
The flexFeed
®
is the feeding part of the system.
• An insert is the action of inserting a document-set into an envelope.
Inserter
• For native English speaking customers an insert is also a short, not to be folded document, usually an enclosure.
An Inserter is the Module where the document-set is inserted into the envelope, the envelope is closed and if necessary sealed.
Inserting system The system of all the Modules that cooperate to perform the inserting function (accumulate document-set, fold and insert) and have a single point of control.
IntelliDeck
®
Job
Job counter
Letter fold
To avoid stoppages the IntelliDeck
®
diverts duplicate on faulty documents before folding them while the system is still running.
A job is an actually produced collection of mail-sets based on a certain
Job Definition at a certain point in time for a specific purpose. It consists of:
• The Job definition used for the production
• Information about the batch size
The counter that registers the number of mail-sets that is produced as part of a specific job.
Fold type in which a document-set is folded twice in which the folded flaps are on top of each other. This fold is illustrated in the picture below. The position of both folds is adjustable.
Linking
Synonym: C-fold.
See Feeder Linking.
67
Term Description
AutoSet
The feature of an Inserting System to automatically determine its Job settings by measuring the sizes of documents and envelope. From all
Feeders that are loaded one sheet will be taken. Based on the maximum document length (which is also the length of the documentset) and the length of the envelope the fold type is determined.
AutoSet job A job that is created with the AutoSet functionality.
Prod. Feeder Feeder with high capacity feed tray (e.g. 2000 sheets A4 80gr).
Multifeed
OMR
OMR code definition
The feature of an Inserting System in which more than one sheet is taken from a Feeder.
Optical Mark Recognition
Standard 1-track OMR code definition. Specifies the amount of reading marks used and the functionality linked to each of them (how each should be interpreted).
The person operating an Inserting System.
Operator
Optical Mark
Recognition
(OMR)
Optical Mark Recognition is intended for reading and interpreting printed codes. These codes are one or more black marks which are read from a document. These marks give information to the Inserting system about how to build-up and handle a set.
PowerFold
®
Reading error
The powerFold
®
can fold up tot 10 pages.
Condition in which the system could not reliably read or interpret the
OMR reading marks from a sheet.
Reading marks
Remote diagnostics
Marks added to documents containing finishing instructions that can be identified by an OMR head and interpreted according to the used
OMR code definition.
The feature that makes it is possible to analyze a problem on an
Inserting System from a remote location.
Service engineer Technical engineer whose task it is to resolve problems with systems in the field. Besides dealing with problems, service engineers are also responsible for preventive maintenance.
Single fold A single fold implies the document/set is folded once. The fold-position is adjustable. This fold is illustrated in the picture below:
Stacker
Stop counter
Supervisor
Used as storage for filled envelopes.
Counter which sets the amount of envelopes to be filled. After filling this amount of envelopes the system will stop (even during a clear).
Person who is responsible for the technical state of the machine.
Normally a supervisor has access to programming functions, which are restricted for standard users.
68
Term
Test run
Description
A test run is intended to validate the settings of the Inserting System:
• Inspect and adjust the stop position of the envelope.
• Check the fold settings for one set.
Thickness detection
Tray
• Check whether the address is correctly positioned behind the envelope window.
Checks the thickness of the document set. If the thickness is less or more than the set value an error message is displayed.
Contains a stack of paper for a printer or inserter. This paper is supplied to the machine for further processing.
Vertical transport The vertical transport section between feeders and collator.
Z-fold A Z-fold means that a document is folded twice in such a way that each folded flap is on a different size of the folded document, resulting in a Z-shape. This fold is illustrated in the picture below. The position of both folds is adjustable.
Synonyms: zigzag fold
69
This is a class A product. In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures.
Note: this equipment has been tested and found to comply with the limits for class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with this instruction manual, may cause harmful interference to radio communications.
Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.
70
Index
A
B
button 10
C
cover
D
DFC
contrast 13 rotate 11, 13 settings 13
72
document orientation extended powerFold
®
document stoppage
double feed control settings 37
E
envelope feeder
errors
reading errors 55 technical errors 55
extended powerFold
®
F
feed
flexFeed fold
double parallel 35 letter 35 none 35 single 35 zig-zag 35
franking
I
intelliDeck
J
L
AutoSet 27, 68
M
main menu 10
document separation 52 feed documents 52
N
O
offset
reverse reading 36 settings 36
Online Services 15, 48 online services 48
Optical Mark Recognition
option
73
P
powerFold
R
S
set automatic feeding 30 set manual feeding 30
software description 10
start button 10, 29 starting the job 29 stop button 10, 29
flexFeed
powerFold
stoppage at inserting point 60
T
touch screen 10
74
V
W
Z
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