Formax 6204 Series User Manual Page 1

6204 SeriesLow-Volume Desktop InserterOPERATOR MANUAL7/2012

End of LifeThe objectives of the European Community's environment policy are, in particular, topreserve, protect and improve the quality of the e

Meet your DocumentSystem2OverviewIntroductionThe system is a folding and inserting system for processing mail easily. The system:• Feeds documents• Fo

The figure shows an overview of the system.Document Feeders (flexFeed) (1)The flexFeed is the feeding part of the system. There are two types of feede

• Double V-foldEnvelope feeder (4)Envelopes that are placed on a stack by the user, are fed one by one into the system bythe envelope feeder.Inserter

K - SensorsL - BellowsM - Handle for clearing stoppagesN - Sealing liquid reservoirO - Side cover (opened)P - RulerQ - Thumb wheel for side guide adju

Installing the Document Feed TraysPlace the document feed trays in position:1. Hold the document feeder slightly inclined as shown in the figure.2. Pl

Installing the Slide and Catch trayTo install the slide and the catch tray:1. Attach the slide as shown in the figure.2. Position the envelope catch t

Power UpTo start up the system:You can severely damage the machine if it is connected to theincorrect power supply. Before plugging in the machine, ch

Job InfoIf you want more information on a job, select the job in the ‘home’ menu.The ‘current job’ menu shows the following information of the selecte

• A picture of the system with symbols for the selected features. The followingsymbols can be used:Shows the feeders selected to pick documents from (

Table of Contents1 Read this First ...1Warning...

Side GuidesTo adjust the side guides it is best to remove the document feed tray from the feeder asfollows:1. Push handle A downwards.2. Lift the docu

Document OrientationFilling the Document Feeder TrayFill the document feeder tray as follows:1. Open the left-hand side guide A by turning it downward

Loading EnvelopesBefore you load the envelopes, make sure the envelope separation and side guides arecorrectly set. Proceed as follows:1. Rotate thumb

5. Place the bottom envelope between the rollers (flap down and trailing - bottom sideof the envelope pointing to the machine).6. Loosen the stack of

2. Shift the blue handle A towardsto disable the envelope sealing or towardsto enable the envelop sealing.3. Close the top cover.Before you start a jo

2. Fill the reservoir B to the "Max" lip C with sealing liquid.3. Close the front cover A.Before starting the job, wait approximately 5 minu

Options3Side ExitThe system can be equipped with a side exit and catch tray. The side exit can be fittedinstead of the standard envelope receiving tra

Processing Mail Sets4IntroductionWith the system you can process mail sets in the following ways:• Automatic job: The system automatically picks one s

Processing a Basic Mail SetA basic mail set consists of documents from one or more document feeders. This set isinserted into an envelope.Before you s

Processing a Mail Set with BRE or InsertsA mail set with BRE consists of documents from one or more document feeders and aninsert/BRE from the BRE fee

Processing a Mail Set with BRE or Inserts...24Document Separation...

Document SeparationThe term ‘Document separation’ refers to the adjustment required for separating the upperdocument from the rest of the documents in

6. Place the document or document set in the feeder (see Filling the Document FeederTray on page 16).The document or document set will be folded and i

4. Press No if asked if the address is readable.5. Follow the steps in the wizard.Adjusting the Envelope Insert FingersTo make a good insert of the do

Verifying the Insert PositionTo make a good insert of the document set into the envelope, the envelope should bepositioned correctly.The document set

Working with Jobs5What is a jobIf you have to process a lot of mail sets of the same type (for example bills), you can savethe settings to a 'job

2. Press [Manual] to create a new job.For [Automatic], see Processing a basic mail set.3. Enter the pin code 2546.4. Press the [Job wizard] button to

5. Press [OK] to confirm the selected free job number.A new selected job number starts with default settings.The job settings menu opens. The meaning

2. Select the job you want to use.3. Click the [1x] button.4. Follow the steps in the wizard.Adjusting the Envelope PositionBefore performing a test r

3.Press the to check the new alignment.4. Press the [OK] button to accept the new alignment.Using a jobIf you want to use an existing job:1. From the

Editing a jobTo edit an existing job:1. From the home menu, select a job you want to edit.2. Press the [Edit] button.3. Enter the pin code 2546.The jo

Running diagnostics...517 Reading ...

Copying a jobTo copy existing job settings to a new job:1. Press the [Supervisor] menu button from the main menu.2. Enter the pin code 2546.3. Press t

5. Press the arrows if you want to select another job number to copy from or to copy to.You can only copy job settings to new jobs.6.Press the button

4. Press the [Delete job] button.The delete job menu appears.When you press [OK], the job is deleted without a warning.5. Select a job number and pres

Envelope settingsIn the ‘envelope settings’ menu you can define the envelope properties.In the top of the screen, three selection buttons are displaye

Document settingsIn the ‘document settings’ menu you define the document formats and the number ofdocuments that must be picked from the different fee

•Press the button to enter the document height. The height or the ISO format ofthe document will be displayed next to the relevant feeder.•Press the b

When a feeder is selected for reading, the feeder below can not belinked to this reading feeder.•Press the button to enter the setting of the daily ma

To change the fold positions press the button next to a fold. Enter the required positionof the relevant fold.Maximum positionMinimum positionFold typ

Reading settings (option)For a full function description of reading, see Reading Introduction on page 52. In the‘reading settings’ menu it is possible

Double feed control settingsIn the ‘DFC settings’ menu you can set Double Feed Control (DFC) for the different feederson or off.•Press the button to s

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Job nameIt is possible to store the job with a meaningful job name, to easily recognize the job. Thisname is displayed at job selection. Enter a job n

Advanced Settings6What are Advanced Setting?Advanced Settings are all settings that can be found under the Display Settings Menu andthe Supervisor Men

• System info (see Viewing System info and Software versions);• Options (see Activating an option on page 49);• Test (see Test menu on page 50);• Onli

Viewing System info and Software versionsFrom the Supervisor menu, you can view the System info and Software versions.Proceed as follows:1. From the S

What are licensed options?The Option menu shows the following information:• Chip ID• System ID• Installed options.These software options are enabled u

2. Use the keypad to enter the license key code that you received from the supplier toactivate the relevant option on this machine.If needed, use the

Running diagnosticsTo run a diagnostics of the system:1. In the Test menu, press the [Diagnostics] button. The Hardware test screen appears.2. Remove

Reading7IntroductionThe folding and inserting system can be equipped with reading. This allows the system toread special codes that have been printed

General requirements for printing codesIf you print documents for reading:• Make sure the ribbon or toner quality is sufficient.• Print the code in bl

5. Divide the paper guides B along the width of the document.6. When the reading head is adjusted it is possible that paper guides have to be removeda

Read this First1WarningEnsure you have read and fully understood the safety requirementsin this section.About this manualLanguagesAccording to the EC

OMR Code DescriptionPosition of the code on the document:Minimum line thickness of a mark: 0.2 mm (0.008 inch)Default the first mark from the top is s

OMR basic licenseFor the OMR basic license the following functions are available:• Start mark: indicates the start of the code.• Insert/Accumulate: de

OMR advanced licenseFor the OMR advanced license the following functions are available:• The basic functions (Start, Insert, Parity, Safety)• Divert -

An Example of OMR CodeIn the figure the legend for the following example is shown. In this example feeder station3 is the reading feeder. The feeder s

3. In the Results screen, evaluate the test results.Use the button to see the OMR info.4. Press the [Back] button to return to the OMR test menu.7Engl

Operator Maintenance8Maintenance ScheduleDisconnect the mains power supply before performing anymaintenance.The user must not attempt to service the a

Clean and replace brushesWhen dirty or saturated, clean the brushes of the envelope sealing or replace them asfollows:1. Moisten the new brushes in wa

Clean the exit sensorsTo clean the exit sensors:1. Rotate a slightly moistened cotton swab in the lower hole, to clean the lower exitsensor.2. Rotate

Fault Finding9Error MessagesWhen an error occurs the display shows a screen showing the following information:• An indication of the area in which the

Clearing StoppagesStoppages can occur in the following areas:1.Feed area2. Collating area3.Fold area4. Lower envelope track64| Page 64 | apr-16-2012 1

SymbolsThis manual uses the symbols listed below.WARNING : Indicates a human safety hazard.ATTENTION : A risk to the equipment or mail could result fr

For clearing of stoppages, three system sections can be opened:A - Top cover to reach the Fold and Feed area.B - Collator plate to reach the collator

6. Close the side cover.7. Press the [Reset] button to reset the error and restart the job.FlexFeedWhen a stoppage occurs in the flexFeed, remove the

2. Remove the documents from the collator area.3. Move the collator plate B up in position.4. Press the [Reset] button to reset the error and restart

Trouble Shooting TableReferenceRemedyPossible causeSymptom-Connect the systemto the mains.System notconnected to mains.The system cannotbe started aft

Verifying the InsertPosition on page 28Check specificationsand changeenvelopes if needed.Envelope not withinspecifications.Flap is wrinkled andsometim

Filling the SealingLiquid Reservoir onpage 19Check water level,refill if needed.Water level low.Flap not sufficientlymoistened.MaintenanceSchedule on

Verifying the InsertPosition on page 28Check insert position.Insert position notcorrect.Document set notcorrectly inserted.Adjusting theenvelope inser

Specifications10Technical Specifications62046eriesModelInserter system for medium office use.Type2000 inserts per hour, depending onapplication.Theor

Hopper and feeder capacity325 envelopes (80 g/m²)Envelope hopper325 sheets (80 g/m²)Document feeder trayConfiguration Dimensions2.5 stations2 stations

Minimum width: 130 mm (5.1")Maximum width: 236 mm (9.3"), whenfolded max. 230 mm (9.1")Minimum length: 90 mm (3.5"), the minimumdo

Safety Precautions• Only competent, trained personnel should operate this system. If non-trainedpersonnel do operate this system, the manufacturer wil

Envelope and Document Set SpecificationsGFEDCBA60 g/m284 mm3.3”130 mm5.1"10 mm0.4”32 mm1.25”90 mm3.5”160 mm6.3”Minimumsize2.5 mm***0.1” ***B-6B-0

Terminology11TerminologyDescriptionTermThe address carrier is the document that carries the address of theperson for who the mail-set is meant. The ad

Fold type in which a document-set is folded twice in which the foldedflaps are on top of each other. This fold is illustrated in the picture below.The

The double V-fold is a type of fold where the document is first foldedhalfway and the resulting folded set is again folded halfway. This foldis illust

• An insert is the action of inserting a document-set into anenvelope.• For native English speaking customers an insert is also a short,not to be fold

Condition in which the system could not reliably read or interpret theOMR reading marks or barcode from a sheet.Reading errorMarks added to documents

A Z-fold means that a document is folded twice in such a way that eachfolded flap is on a different size of the folded document, resulting in aZ-shape

EC Declaration ofConformity12EC Declaration of Conformity DS-63, M3300, FD6204(According to Annex III B of the Low Voltage Directive)Manufacturer: Neo

Note: this equipment has been tested and found to comply with the limits for class A digitaldevice, pursuant to Part 15 of the FCC Rules. These limits

Index1384| Page 84 | apr-16-2012 13:09 |13English

Country Specific ConditionsDenmarkIn Denmark, certain types of Class 1 appliances may be provided with a plug that does notprovide an adequate earth (

BBrushes 18, 19, 60, 61, 68CCan 2, 6, 12, 13, 21, 22, 25, 29, 38, 39, 43, 46, 47, 52, 55, 64, 76, 82Catch Tray 8, 11Control Panel 9Counter 13, 29, 76C