Formax 6204 Series Manual de usuario
6204 Series
Low-Volume Inserter
MAINTENANCE MANUAL
6/2012
Table of Contents
1 Introduction ................................................................................................................................1
2 Health, safety and environment ...............................................................................................5
3 General description ...................................................................................................................8
4 User interface ...........................................................................................................................27
5 Transport, storage and installation ........................................................................................42
6 Mechanical description ...........................................................................................................51
7 Electrical description ............................................................................................................138
8 Preventive maintenance .......................................................................................................156
9 Fault Finding ..........................................................................................................................161
10 Upgrading and installing accessories ................................................................................196
11 Technical specifications .......................................................................................................199
12 Parts lists ...............................................................................................................................208
13 Appendix ................................................................................................................................289
063.1 Service Guide
Introduction1
1 Introduction ........................................................................................................1
About this manual .............................................................................2
Abbreviations ....................................................................................2
Terminology ......................................................................................3
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063.1 Service Guide
About this manual
Audience
This manual is meant for service engineers.
Symbols
This manual uses the symbols listed below.
WARNING : indicates a human safety hazard.
ATTENTION : brings to your attention a risk for equipment or mail that could result
froman action you may perform.
NOTE : remark that explains different cases or specificities.
TIP : advice to help save you time when processing your mail.
SUPERVISOR : indicates that you have to use the supervisor menu to perform the
procedure.
Abbreviations
ExplanationAbbrev.ExplanationAbbrev. Interface Spe-
cification for In-
serter Systems
ISISBusiness Reply EnvelopeBRE
Left HandLHCounter ClockwiseCCW Mixed Mail
Feeder / Ad-
vanced Feeder
MMF/AFClockwiseCW
MailingSystemMSDouble Feed ControlDFC Not ApplicableNADocument SystemDS On Line Ser-
vices
OLSFirst In First OutFIFO
Optical Mark
Recognition
OMRFranking MachineFM
Printed Circuit
Board
PCBGraphical User InterfaceGUI
Postal Product
Code
PPCHuman Machine InterfaceHMI
Right handRHInserterIN User InterfaceUIInsert’n FrankINF
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063.1 Service Guide
Terminology
DescriptionTerm
Double Feed Control is the sensor that measures the thickness of a
sheet to check if the inserting system does not accidentally take more
sheets than intended. DFC sensors exist on Feeders (double sheet de-
tection). Currently DFC's on Neopost inserting systems perform relative
measurements, which means that they need a cycle to 'learn' the thick-
ness of a sheet.
Also the length of the document is measured so partly overlapping sheets
will be detected.
Double Feed Control (DFC)
Situation in which the top of the sheet is closest to the separation unit in
a document feeder.
Leading
The various documents of a set are fed from the feeders in such a way
that these documents are partly overlapping each other. This pane-like
overlapping ensures a higher throughput.
Pane Cycle
Documents are transported along the vertical track without touching each
other. Only after joining the set in the making they do touch each other.
Sequential Cycle
The partially completed set in the collator is moved from the collator area
in the direction of the fold unit (short shunt).
Shunting
Situation in which the bottom of the sheet is closest to the separation
unit in a document feeder.
Trailing
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063.1 Service Guide
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4
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063.1 Service Guide
Health, safety and
environment
2
2 Health, safety and environment ........................................................................5
Safety ................................................................................................6
Symbols on the system ......................................................................6
End of Life .........................................................................................7
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063.1 Service Guide
Safety
Warnings
• Disconnect the power supply before performing any maintenance.
• Before connecting the system to the electrical supply, Ensure that the system is suitable for the local mains
voltage. Refer to the serial plate on your system for voltage requirements.
Safety Precautions
• Only competent, trained personnel should operate this system. If non-trained
personnel do operate this system, the manufacturer will not accept responsibility
for any resulting accidents or injuries.
• Only skilled persons, who are aware of the risks involved, may open the protective covers.
For safety reasons, the system will not function when the covers are open.
• Keep long hair, fingers, jewelry, etc. away from rotating and moving parts.
• The power connection must be easily accessible, preferably close to the system.
For safety reasons, it is essential that the system is connected to a socket outlet that has a protective earth
(ground) connection.
• Overcurrent protection in the equipment also relies on the branch circuit protection (max. 20 A).
• The following part(s) is (are) considered the equipment disconnect device(s):
- Power supply cord plug or appliance coupler.
CAUTION: DOUBLE POLE / NEUTRAL FUSING
(this means that after operating of the fuse, parts of the equipment that remain energized,
might represent a hazard during servicing.)
Symbols on the system
Warning
This symbol identifies situations where improper use of the machine can result in personal injury or
permanent/catastrophic damage to the machine.
This symbol also indicates to consult the operator manual in relation to this action.
Warning
This symbol indicates a danger caused by high voltage.
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063.1 Service Guide
End of Life
The objectives of the European Community's environment policy are, in particular, to preserve, protect and improve
the quality of the environment, protect human health and utilize natural resources prudently and rationally. That
policy is based on the precautionary principle and principles that preventive action should be taken, that environmental
damage should as a priority be rectified at source.
Separating waste during collection is the precondition to ensure reuse and recycling of waste. The proper disposal
of electrical or electronic equipment is necessary to achieve the chosen level of protection of human health and the
environment in the European Community.
More particularly, certain materials and components of waste electrical and electronic equipment need special
treatment as improper handling or disposal on or into land, water or air would represent a major threat to the
environment and human health.
In order to facilitate collection and treatment separated from normal domestic waste, electrical and electronical
equipment is marked with the following logo:
By law, not only are you not allowed to dispose of the waste equipment via other waste channels, but we encourage
you to actively contribute to the success of such collection and to the common good and better quality of life of
present and future generations. For more information on the correct disposal of this product, please contact your
local service organization.
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063.1 Service Guide
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