Formax 6404 Series User Manual

6404 SeriesMid-Volume InserterOPERATOR MANUAL2/2012

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

2. Rotate a slightly moistened cotton swab in the upper hole, to clean the upper exitsensor.3. Calibrate the photocells (see Resetting photocells on p

Fault Finding10Error MessagesWhen an error occurs the display shows a screen showing the following information:• An indication of the area in which th

Clearing StoppagesStoppages can occur in the following areas:1. Feeding area2. Collating area3. Folding area4. Lower envelope track5. Moistening a

For clearing of stoppages, six system sections can be opened:A - loc cover, to reach the sealing and exit areaB - inserter cover, to reach the moisten

Exit, Sealing and Inserting AreaWhen a stoppage occurs in this area, remove the material as follows:1. Open the side cover F.2. Lift the locking lever

Envelope HopperWhen 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 leve

3. Remove the envelope(s) from the lower envelope track.4. Close the side cover.5. Press the [Reset] button to reset the error and restart the job.Fol

Feed TowerWhen a stoppage occurs in the Feed Tower, remove the documents as follows:f1. Pull the vertical transport hand grip A upward to open the ver

3. Lower the collator arm.4. Press the [Reset] button to reset the error and restart the job.Operator TroubleshootingTo resolve problems:1. Write down

Loading Envelopeson page 17Adjust envelope sepa-ration.Envelope separationnot correctly set.Envelopes are doublefed.Loading Envelopeson page 17Check a

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

Adjusting the enve-lope insert fingerson page 36Check fingers posi-tion, adjust if needed.Fingers not correctlyadjusted.System stops whileinserting (s

Filling the documentfeeder tray on page17Refill feeder.Feeder empty.No document fed.Adjusting DocumentSeparation on page32Adjust the separation.Sepa

Specifications11Technical SpecificationsDS-85, M8500, FPi 5600, FD6404ModelInserter system for medium office use.Type4000 inserts per hour, depending

Hopper and feeder capacity325 envelopes (80 g/m²)Envelope hopper325 sheets (80 g/m²)Document feeder tray725 sheets (80 g/m²)High Capacity Document Fee

V-fold - 10 sheets (max. 80 g/m²)C-fold/Z-fold - 8 sheets (max. 80 g/m²)Double V-fold - 4 sheets (max. 80 g/m²)Folding capacityStandard BRE (Business

Remarks:• The specification of the paper handling equipment is often wider than that of theenvelopes and documents handled. The condition of material

See Document Specifications on page106 andEnvelope Specifications on page 107.Document / BRE insert specificationsHigh Capacity Vertical Stacker Speci

Terminology12TerminologyDescriptionTermThe 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

Meet your Document System2OverviewIntroductionThe system is a folding and inserting system for processing mail easily. The system:• Feeds documents• F

An OMR code for which the meaning of the OMR marks can be pro-grammed in a dedicated way for a specific customer. This is normallyused to support the

Optical Mark RecognitionOMRStandard 1-track OMR code definition. Specifies the amount of readingmarks used and the functionality linked to each of the

A V-fold implies the document/set is folded once. The fold-position isadjustable. This fold is illustrated in the picture below:Synonym: Single fold.V

The figure shows an overview of the system.Document Feeders (Tower) (1)This is the feeding part of the system.There are two types of feeders: the auto

Folding unit (4)The fold unit folds the documents. The following fold types are possible (see Terminologyon page 110):• No fold• V-fold• C-fold• Z-fol

Operating ControlsM - locking handle Folding unitN - handle for manual transport of the enve-lopeO - air plugs for cleaning the sensorsP - handle for

Control PanelThe control panel consists of the touch screen and the following buttons:A: On/Off ( ): Switches the system on or off. If the system is n

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

High Capacity Vertical StackerThe High Capacity Vertical Stacker can be used to stack filled envelopes. The verticalstacker can store up to 325 filled

2. Use the power switch to switch the system on. The power switch is located on theback of the system.3.Press the on/off button next to the display.

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

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 (b

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 OrientationIn case the optional extended powerFold is installed, the following feeding rules apply todocuments with bottom address position:1

Filling the Document Feeder TrayFill the document feeder tray as follows:1. Open the left-hand side guide A by turning it downwards.The feed rollers w

3. Move the side guides towards the envelopes.The space between the side guides andthe envelopes should be such that the envelopes have just enough pl

Sealing EnvelopesSwitch the envelope sealing on or off:1. Lift the handgrip to open the top cover.2.Shift the blue handle A towardsto disable the enve

Filling the Sealing Liquid Reservoir1. Open the front cover A.2. Fill the reservoir B to the "Max" lip with sealing liquid.3. Close the fron

Options3Production FeederThe production feeder is a feeder that can be loaded with a high number of documents. Thisfeeder is intended to be used for B

Adjusting the Production Feeder Side GuidesAdjust the side guides:1. Take a stack of documents/BREs and place them in the feeder tray.BREs with flap d

Installing the HCDF...25Adjusting the HCDF Side Guides...

Adjusting the Production Feeder Document SeparationWhen the production feeder is used at an automatic separation feeder, the separation is setautomati

Feeding documents (Production Feeder)To feed documents:When filling the production feeder, make sure that the document/BREs are positioned parallel in

Installing the HCDFTo install the feeder tray of the HCDF:1. Pull down lever A.2. Hook in the feeder tray.3. Release lever A.Adjusting the HCDF Side G

3. Rotate wheel E.The space between the side guides and the documents should be such that thedocuments have just enough play to move freely.4. Re-tigh

Conveyor StackerIn case you have a conveyor stacker, install it as follows on your system:1. Position the fork in a forward direction.2. Move the conv

insert'n Frank / insert'n MailIf this system is connected to a mailing/franking system, insert'n Frank / insert'n Mail allowsyou t

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

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

Reading settings (option)...52Double feed control settings...

Adjustment of the Document StoppersThe document stoppers mark the position at which the documents coming from the feederturn towards the folding area.

Processing Daily MailThe daily mail function is only available when reading is notactivated. When daily mail is set, the links to the daily mail feede

8. When finished with Daily Mail, press the [stop] button to stop the job.9. Set the Daily Mail handle B to the ‘AUTO’ position to disable the Daily M

Adjusting the Envelope Insert FingersTo make a good insert of the document set into the envelope, the insert fingers A shouldbe about 5 mm (0.2 inch)

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 on page 30.3. Enter the pin code 2546.4. Press [OK] to confirm

5. Press [Save] to save the job with the entered settings under the specified job numberand name.To name a job, see Job name settings on page 56.6. Pr

4.Press the button if you want to adjust the envelope position before runningthe test run (see Adjusting the Envelope Position on page 41).5. Press

Using a jobIf you want to use an existing job:1. From the home menu, select the job you want to use.2. If you want to perform a test run:Press the [1x

Connecting to the server...83Viewing the history...

3. Enter the pin code 2546.The job settings menu opens. See Job settings on page 46 for the meaning of allbuttons and settings.4. Press [Save] to save

3. Press the [Job] menu button.The job menu opens.4. Press the [Copy job] button.The copy job menu appears.5. Press the arrows if you want to select a

Deleting a jobTo delete an existing job:1. Press the [Supervisor menu] button from the main menu.2. Enter the pin code 2546.3. Press the [Job menu] bu

5. Select a job number and press [OK].Job settingsFrom the job settings menu the following settings are available:• Envelope settings (see Envelope se

In the top of the screen, three selection buttons are displayed, from which one can beselected. The selected settings button will be highlighted.•Pres

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

When a feeder is selected for reading, the feeder below can not belinked to this reading feeder. The reading feeder can be linked toa feeder above whe

Select the fold type. The following choices are available for top address:• No fold (no settings required)•V-fold• C-fold• Double V-fold• Z-foldFor Bo

The touch screen will indicate when entered positions are out ofrange.Reading settings (option)For a full function description of reading, see Reading

Configuration Dimensions...106Document and Inser t Specifications...

•Code type: default is the setting ‘none’: reading is disabled.Change the setting with the button. The following codes are possible:- 1-track OMR- B

• Stop on misread: define if the system should stop or not when a code is misread. Incase of “yes”, the system stops after a misread. The incorrect se

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

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

Mailing/Franking settings (option)If this machine is connected to a mailing/franking machine, this option allows you to selectthe franking mode.Use th

Mail Piece Production Control settings (option)For Mail Piece Production Control settings, see the appendix operator manual Mail PieceProduction Contr

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

• System info (see Viewing System info and Software versions);• Options (see Activating an option on page 62);• Test (see Test menu on page 63);• Onli

2. Use the arrows next to the volume symbol to increase or decrease the interfacevolume.3.Press the button to toggle the orientation of the display

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

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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

Job Settings (Supervisor)Job settings normally will be changed by a service engineer only.Therefore first consult the supplier’s Helpdesk before chang

Flap Closer OffsetTo change the flap closer offset for a selected job:1. Use the arrows next to "Select job" to select for which job (Job 1-

System OutputTo change the output mode for a selected job:1. Use the arrows next to "Select job" to select for which job (Job 1-25 or Auto)

Changing Document OffsetTo change the document offset for a selected job:1. Use the arrows next to "Select job" to select for which job (Job

2.Use the button next to BRE with window to set the BRE offset to On of Off.If a document is longer than the set address fold but shorter than the e

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

Document OrientationSwitch on the reading function and set the position of the reading marks as described inBCR Code Description on page 73 and OMR Co

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

BCR Code DescriptionPosition of the code on the document.Minimum line thickness of a bar: 0.25 mm (0.01 inch)The thickness ratio of thick bars versus

BCR basic licenseFor the BCR basic license the following functions are available:• Page N of M: as long as N is below M, the document set is not compl

3. Press the [Run sheet] button.The BCR settings screen appears.4. In the BCR settings screen, confirm that all settings are read correctly.Note that

Running a BCR testTo run a BCR test:Before running a BCR test, select a job that uses BCR reading.1. In the Test menu, press the [BCR test] button. Th

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, a set of 8sheets with one selective feed and three

2. Press the [Test] button to start the OMR test. After the test is finished, the Resultscreen appears.3. In the Results screen, evaluate the test res

Online Services8Online ServicesThe folding and inserting system can be equipped with Online Services.This option enablesthe system to connect to a cen

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

Connecting to the serverThe system makes a connection on fixed times. It is possible that you manually connectthe system to the server.To connect to t

2.Press the button to view details on selected previous connection.Viewing messagesAfter pressing Messages in the ‘Online Services’ menu the touch s

Installing a new job or new softwareAfter pressing Messages in the ‘Online Services’ menu the touch screen will show messagesreceived from the server.

4. In case of a new job:Press the arrows to select a free job number (see Creating a new job on page 38).andPress [OK] to confirm the selected job num

Changing the telephone numberTo change the number:1.Press the button next to the telephone number.2. Enter the correct number using the numeric keyp

Selecting the countryTo select a country from where you are dialing:1. Use the up and down arrows to select the country from where you are dialing.2.

Setting the dial tone detectionTo toggle the dial tone detection:1.Press the button next to dialtone detection to toggle the dial tone detection on/

Operator Maintenance9Maintenance 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 sensors on the envelope or document pathWhen the display warns about dusty sensors in the envelope or document path, clean themas follows:1.