6306 Series Inserters

11/2016 OPERATOR MANUAL

TABLE OF CONTENTS
1 Health, Safety and Environment ...................................................... 2
1.1 Precautions and Safety Issues ................................................... 2
1.2 End of Life .............................................................................. 4
2 Functional description ..................................................................... 5
2.1 Overview ................................................................................ 5
2.2 Operating Controls .................................................................. 7
2.3 Control Panel .......................................................................... 8
2.4 Software Description ................................................................ 8
3 Operating Instructions .................................................................. 12
3.1 Installation .. .......................................................................... 12
3.2 Preparation .. ......................................................................... 12
3.3 Starting Up ............................................................................ 13
3.4 Loading Documents ................................................................ 14
3.5 Loading Envelopes .................................................................. 16
3.6 Filling the Sealing Liquid Reservoir ............................................ 17

ENGLISH
3.7 Run a Job .............................................................................. 17
3.8 Using an Automatic Job.................... ........................................ 18
3.9 Daily Mail .............................................................................. 18
3.10 Stopping the system ............................................................... 19
4 Job Programming .......................................................................... 20
4.1 Create a Job .......................................................................... 20
4.2 Job Settings .......................................................................... 21
4.3 Edit a Job .............................................................................. 27
4.4 Copy a Job ............................................................................ 28
4.5 Delete a Job .......................................................................... 28
5 Options .......................................................................................... 29
5.1 Activate an Option .................................................................. 29
5.2 Reading .. .............................................................................. 29
5.3 Online Services ...................................................................... 36
5.4 Production Feeder ................................................................... 39
5.5 High Capacity Feeder .............................................................. 41
5.6 High Capacity Vertical Stacker .................................................. 42
5.7 Side exit ............................................................................... 42
5.8 Mail Piece Production Control (MPPC) (Option) ............................ 42
6 Operator Maintenance ................................................................... 43
7 Fault finding .................................................................................. 44
7.1 Error Messages ...................................................................... 44
7.2 Clearing Stoppages ................................................................. 45
7.3 Operator Troubleshooting ........................................................ 46
8 Specifications ................................................................................ 50
8.1 Technical Specifications ........................................................... 50
8.2 Configuration Dimensions ........................................................ 50
8.3 Other Specifications ................................................................ 50
8.4 Document Specifications ......................................................... 51
8.5 Envelope and Insert Specifications ............................................ 51
8.6 Specifications High Capacity Vertical Stacker .............................. 52
8.7 Specifications Production Feeder................................................ 53
9 Terminology .................................................................................. 54

Index.............................................................................................. 59

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1. HEALTH, SAFETY AND ENVIRONMENT

1.1 Precautions and Safety Issues

Thoroughly read this operator manual, before using this system.

Warnings
Disconnect the mains supply before performing any maintenance.
Before connecting check if the system is suitable for the local mains voltage. Refer to
the type plate.

Safety Precautions
Only competent personnel should operate this system.
If incompetent personnel do operate this system, 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 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 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

Precaution
The general process of automated document handling can sometimes create a build up of
static electricity. Therefore we recommend that the following measures are taken to
reduce the side effects of any electrostatic charge.
Make sure that you operate the system within the recommended temperature and
humidity conditions.
Make use of antistatic mats where appropriate.
If necessary, make use of an ionizer to reduce static charge build up in the room
where the system is located.
Please contact your supplier for further information.

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Conventions
Warning
This symbol:
Identifies situations where improper use of the system can result in
personal injury or permanent/catastrophic damage to the system.
Indicates that the operator manual should be consulted.
Note
A note gives additional relevant information.

Caution
Indicates the presence of a hazard that can cause personal injury or property damage, if
the hazard is not avoided.

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FCC Classification:
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

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4
2. FUNCTIONAL DESCRIPTION
The 6306 Series feeds, folds and inserts documents into envelopes, then seals and stacks
the envelopes. Automatic monitoring ensures the correct number of inserts per envelope.
The system 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 (document type, envelope type and fold type) is recorded in
so-called jobs. These jobs can be programmed by an authorized user.
The 6306 Series is equipped with a variety of special features as programmable jobs,
AutoSet, double feed control, hopper swap, multifeed, and daily mail.

2.1 Overview

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The system consists of the following areas:

2
5
3

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2.1.1 Document Feeders (1)
This 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 feeding system is equipped with double feed control. In
this way the system can detect faulty sets of documents. The 6306 Series is equipped with
cascade mode. 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 the system. Its 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.
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 Folding Area (3)

The folding unit folds the documents. The following fold types are possible (see
Terminology on page 54):
No fold
Single fold
Letter fold
Zig-zag fold
Double parallel fold

2.1.4 Envelope Feeder (4)

The envelopes are picked up and transported to the insert position inside the system.

2.1.5 Inserter (5)

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.

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2.2 Operating Controls

F
E
G
A B C D
H

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N

T S R Q P O M J L K J

A catch tray K sensors

B envelope glides L bellows
C control panel with touch screen M unlocking handle for rollers envelope
track
D upper unit N sealing liquid reservoir
E locking hand grip upper unit O side cover (opened)
F document feeder tray P ruler
G collator arm Q thumb wheel for side guide adjustment
H collating area R side guides envelope hopper
I power inlet, power switch, S handle for separation adjustment
RS232 connector / USB / modem
J handles for clearing stoppages T Envelope support bracket

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2.3 Control Panel
The system has a graphical touch screen.
There are two buttons next to the touch screen:

: the start key

When the start key is pressed the system starts
processing.

the stop key

When the stop key is pressed, the system completes the current set and stops.

Caution
The touch screen is covered with a thin pressure-sensitive layer. To avoid permanent
damage of the touch screen, do not use sharp objects to press on the touch screen.

2.4 Software Description

2.4.1 Home
When you start up the system, the home menu
appears. With the arrows you can scroll through the
jobs. If you want more information on a job, select
the job (see 2.4.2 Job Description on page 8).
If you just want to start without job definition, press
New job and select Automatic (see 3.8 Using an
Automatic Job (AutoSet) on page 18).

With the home button you get back to the

home menu.
The MENU button opens the main menu (see 2.4.3 Main Menu on page 10).

2.4.2 Job Description

If you want more information on a job, select the job
in the home menu.
The current job menu shows the following
information of the selected job:
Job number and Job name
Total: total number of envelopes that have been
processed using this job
To do: number of envelopes to do. Only
indicated if a stop at value is set.

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 Stop at: number of processed envelopes at which the system stops. You can set this
number with the Counters button. You can set it 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.The stop counter is switched off when it is set to
zero.
If you want to reset the daily job counter and the stop counter, press the Reset
counters button in the counters menu.

Note
The counter settings are job related.

A picture of the system with symbols for the selected features. The following symbols
can be used:

3X Shows the feeders selected to pick documents from (black is selected).

Every selected feeder shows how many sheets will be fed from that

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2X
feeder and the length of the sheets.

This sign indicates that the relevant feeders are linked. This means that
3X when one feeder is empty, the system automatically starts picking
documents from the other feeder.
OMR This sign indicates that for the selected feeder OMR or BCR is switched
on (optional).
BCR
This sign indicates that the relevant feeder is set for daily mail.

Gives information about the envelope size (ISO format or height in mm).
An envelope with a cross means that no envelopes are used.
Shows the type of fold, in this case letter fold.

The sign indicates that for the relevant feeder the double feed detection
is switched on.
Edit button: use this button to edit the job (see
Edit a Job on page 27).
Info button: if you press the Info button, the
screen shows how to position the envelope and
documents in the feeders.
From this menu you can press a button to view
the reading settings.

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2.4.3 Main Menu
When you press the MENU button the main menu
appears. This menu allows you to change system
settings and define jobs. The screen shows the
following functions:
Display settings: change touch screen and
volume settings (see Display Menu on
page 10)
Supervisor menu: change system settings and
define jobs (see Supervisor Menu on page 10),
only for authorized personnel)

2.4.4 Display Menu

When you press the Display settings button in the
main menu, the display settings menu appears.
Use the arrow buttons to adjust the touch screen
contrast and the volume of acoustic signals. The
figure between the arrow buttons shows the level of
contrast or volume.

2.4.5 Supervisor Menu

When you press the Supervisor menu button in the
main menu, a login menu opens. Enter the PIN-code
2546 to access the supervisor menu.
If you enter 3 times a wrong pin code the touch screen shows the main menu again.
When you enter the correct pin code the supervisor
menu appears. This menu enables you to check and
configure the system and maintain jobs.
The supervisor menu shows the following functions:
System info: shows system information, like:
- The software versions that are present in
the total system
- The flex certificate, used for reading
- The counter value since the last service visit
- The last error generated by the system
Options: shows option information and system information:
- The chip ID
- The system ID
- The installed options
For installing new options, see 5.1 Activate an Option on page 29.

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 Test: opens the test menu (see 2.4.6 Test Menu on page 11). Use this menu to
test the system.
Online services: opens the Online Services menu (option, see 5.3 Online Services
on page 36). This menu enables to connect the system to a server and receive
messages.
Job menu: opens the job menu. In this menu you can create, edit, copy or delete
jobs (see 2.4.7 Job Menu on page 11).
Read config sheet: reads Barcode Reading (BCR) settings from a BCR configuration
sheet.

2.4.6 Test Menu

Open the test menu from the supervisor menu.
Use this menu to check the system, reset all
photocells and execute a reading test. The test

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menu shows the following functions:
Diagnostics: use this function to verify that all
motors, clutches and sensors are correctly
connected. This test briefly activates the
actuators and then measures the current to
determine the status of the actuators and
clutches.

Note
Remove all paper and close all covers before testing.

Reset photocells: used for photocell calibration.

OMR test: use this menu to test the reading head and the quality of the codes on the
sheets. Follow the directions on screen.
BCR test: use this menu to test the reading head and the quality of the codes on the
sheets. Follow the directions on screen.

2.4.7 Job Menu

When you press the Job menu button in the
supervisor menu, the job menu opens. This menu
enables you to create, edit, copy or delete jobs.
The job menu shows the following functions:
Create job (see 4.1 Create a Job on page 20)
Edit job (see 4.3 Edit a Job on page 27)
Copy job (see 4.4 Copy a Job on page 28)
Delete job (see 4.5 Delete a Job on page 28)

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3. OPERATING INSTRUCTIONS

3.1 Installation
Warning
You can severely damage the system if it is connected to the incorrect power supply.
Before plugging in the system, check if the local voltage is the same as the voltage
mentioned on the type plate.

3.2 Preparation

3.2.1 Document Feeder Trays

Note
The system can be delivered with a tray to manually adjust the separation (special
feeder). This tray fits in all positions, but the adjustment is only possible when fitted on
the lowest position (position one).

To place the document feeder trays in position:

1. Hold the tray slightly inclined as shown in the
figure.
2. Place the front end of the tray underneath the
two black rollers.
3. Move the tray upwards (lifting the black rollers),
until it is possible to hook the tray into place.

4. Move the tray towards the system and move the

hooks over the mounting points (on both sides).
5. Let the tray rest on the system.

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3.2.2 Slide and Envelope Catch Tray
To attach the slide and envelope catch tray:
1. Attach the slide as shown in the figure.

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2. Position the envelope catch tray into the holes
underneath the envelope hopper as shown in the
figure.
The distance A should be approximately 1.5 x
the envelope height.

3.3 Starting Up A
To start up the system:
1. Connect the system to the mains power supply.
2. Use the power switch to switch the system on.
The power switch is located at the back of the
system.
The software will ask you to select the required
language.
3. Select the required language for the touch
screen.
The software will ask you if you want the select
language option to be displayed every time the
system is switched on.
4. Select either Yes or No.
5. Press the OK button.
The touch screen shows the home menu.

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3.4 Loading Documents

3.4.1 Document Orientation

See also the job information on the touch screen.

one document feeder swap two documents document + enclosure

no fold

single fold

letter fold

Address carrier in Address carrier in upper Address carrier in Address carrier in upper
upper feeder. linked pair feeders. upper feeder. feeder.
double
Face up and leading. Face up and leading. Face up and leading. Face up and leading.
parallel fold

zig-zag fold

Address carrier face Address carrier in lower Address carrier in lower Address carrier in upper
down and trailing. linked pair feeders. feeder. feeder.
Face down and trailing. Face down and trailing. Face down and trailing.

3.4.2 Adjusting Side Guides

To adjust the side guides of the document feeder trays:
1. Remove the tray from the feeder as follows:
a Push handle A downwards.
b Lift the tray upwards to unhook it and then
pull it out from the feeder.

14
2. Loosen the knob B half a turn.
3. Grab the side guides in the middle and push
them apart as far as possible.
4. Put a small stack of documents between the side
guides.
5. 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 B
have just enough play to move freely.
6. Re-tighten knob B.
7. Remove the stack of documents.
8. Replace the document feeder tray (3.2.1 Document Feeder Trays on page 12).

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3.4.3 Document Separation
Document separation means the adjustment that is required to separate 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.
Feeder 1 (the feeder in lowest position) can be a special feeder. You can manually adjust
the separation of special feeders as follows:
1. Remove feeder trays 2 and 3 (the upper trays).
2. Push the knob B forward until it clicks.
3. Turn the left-hand side guide A downwards.
4. Place a document on the feeder 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.
5. Push the document between the separation
rollers, which are behind the rubber paper
pullers.
6. Turn the knob B clockwise to increase resistance
or counter clockwise to lower the resistance. A B
The separation is adjusted correctly when a slight resistance is felt on the document.
7. Pull the knob B back again when ready.
8. Close the left-hand side guide.

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3.4.4 Filling the Document Feeder Tray
To fill the document feeder tray:
1. Turn the left-hand side guide A downwards.
The feed rollers are lifted automatically.
2. Place a stack of documents between the side guides.
Feed the documents (depending on the type of documents and the type of fold) as
shown in 3.4.1 Document Orientation on page 14.
3. Turn the left side guide upwards again.

3.5 Loading Envelopes

To load the envelopes:
1. Adjust the side guides C with 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 C
large, the envelopes will twist sidewards, when
transported into the system. B

Note
If you use the optional High Capacity Vertical
Stacker, also adjust the side guides of this A C D
stacker (see Adjusting the Side Guides on
page 42).

2. Set the envelope separation as follows:

a Pull down small lever
b Insert one envelope horizontally up to the stoppers.
c Return lever A.
3. Place the bottom envelope between the rollers
(flap down and trailing - bottom side of envelope
pointing to the system).
4. Loosen the stack of envelopes and place the
stack on top of the bottom envelope.

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5. Shift envelope support B in or out, so that the
top side of the envelope lies against the dotted
line on the support.
6. Turn envelope support B so the weight of the
envelopes is distributed evenly on both sides.

3.6 Filling the Sealing Liquid

Reservoir
When you want to seal envelopes, the sealing liquid
reservoir must be filled. B
1. Open the front cover A.
2. Fill the reservoir B up to lip C with sealing liquid.
3. Close the front cover A.

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Before you start the job, wait approximately 5 C
minutes for the brushes to moisten.
If the liquid reservoir is almost empty the
touchscreen shows a message to warn you that you
should refill the reservoir.

A
3.7 Run a Job
To run a job:
1. From the home menu select a job.
If you press the OK button, the job information
appears (see Job Description on page 8).
2. Load envelopes as specified in the job. Press the
Info button for details.
3. Load the documents face up and leading, as
specified in the job. Press the Info button for
details.
Place the address carrier in the upper feeder.
4. Press the 1x button to start a test run or press

the button to start the job.

If you press the 1x test button, the screen shows questions that help you to solve any
problems on mail set quality. If necessary this troubleshooting wizard helps you to:
- adjust envelope position (see 7.3.1 Insert Position on page 49)
- adjust finger position (see 7.3.2 Envelope Insert Fingers on page 49)
- adjust address position (see 7.3.3 Address Position on page 49)

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3.8 Using an Automatic Job (AutoSet)
If you do not want to define a job and just want to do some inserts, you can let the
system determine the job settings for you.
This automatic job determines automatically 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 document set) and the
length of the envelope, the fold type is determined.

Note
Automatic job cannot be used together with linked feeders, multifeed, daily mail and
reading functionality.
The function Automatic job is not possible in the no envelopes mode or with usage of
envelopes with open flap.
In an Automatic job only the Double Feed Control (DFC) of the upper feeder is selected.

Note
Before starting an Automatic job, be sure that no documents or envelopes are left in the
system.

To start an Automatic job:

1. From the home menu, press the New job
button.
2. Press the Automatic button.
3. Load envelopes.
4. Load the documents face up and leading.
Place the address carrier in the upper feeder.
5. Press the 1x button to start a test run (see

3.7 Run a Job on page 17) or press the

button to start the job.
6. If you press the Save button you can copy this job to a job number.

3.9 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 use the Daily Mail function:
1. Select a job where the daily mail function is selected. You can recognize the daily mail

by the icon in the job information menus.

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2. Turn down the left side guide A of the upper B
tray.
Now you can see the Daily Mail handle B

( ).
3. Move the handle to enable the Daily Mail
function.
4. Place the document or document set in the
feeder (see Filling the Document Feeder Tray
on page 16) and turn side guide A upwards.

5. Press the button to start the job.

A
The document or document set will be folded
and inserted into the envelope as described in the selected job.

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6. Place the next document or document set in the feeder. The system will keep running
to process the inserted document or document set.

7. When finished with Daily Mail, press the button to stop the job.
8. Set the Daily Mail handle B to the AUTO position to disable the Daily Mail and enable
the automatic document separation.

3.10 Stopping the system

To stop the system press the button. The system completes and inserts the current
set and stops. This results in a cleared system which is ready to process a new job.

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4. JOB PROGRAMMING

4.1 Create a Job

To c reate a n ew j ob:
1. From the home menu, press the New job button.
2. Press Manual to create a new job.
For Automatic, see Using an Automatic Job (AutoSet) on page 18.
3. Enter the pin code 2546.
4. Press Wizard to create a new job with the job
creation wizard or press Advanced (experienced
users only).
If you use the job creation wizard, follow the
steps on screen. The system stores the new job
under the lowest free job number.
You can manually select a free job number to
save the new job. The screen will show the
lowest free job number.
If you use the advanced way of job
programming, continue as follows:
5. Press OK to confirm the selected free job number.

Note
A new selected job number starts with default settings.

The job settings menu opens. The meaning of all buttons and settings is explained in
4.2 Job Settings on page 21.
6. Press Save to save the job with the entered settings under the specified job number
and name.
To n ame a j ob, see 4 .2.6 Job Name on page 26.
7. Press the 1x button to verify that the insert position and address position are correct
(see 7.3.1 Insert Position on page 49 and Address Position on page 49).

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4.2 Job Settings
From the job settings menu the following settings
are available:
Envelope settings (see 4.2.1 Envelope
Settings on page 21)
Document settings (see 4.2.2 Document
Settings on page 22)
Fold settings (see 4.2.3 Fold Settings on
page 24)
Reading settings (if installed) (see
4.2.4 Reading Settings (Option) on page
25)
Double feed control settings (see
4.2.5 Double Feed Control Settings on

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page 26)
Job name settings (see 4.2.6 Job Name on
page 26)

Mail Piece Production Control (MPPC)

settings (if installed)
See the appendix operator manual Mail
Piece Production Control

If you want to view the job details of the current job, press the button. If you want to
run a test set or test envelope, you can use the green buttons in this menu.

4.2.1 Envelope Settings

In the envelope settings menu you can define the
envelope properties and switch the sealing on and
off.
In the top of the screen, three selection buttons are
displayed, from which one can be selected. The
selected settings button will be highlighted.

Press to select an envelope with closed

flap. This means that the envelopes are fed with

closed flap. Use the upper button to enter

the applicable dimensions.
It is also possible to select ISO standard envelopes or dimensions in inches (depends
on the installation settings).
The envelope height can be set between 90 mm (3.5 inch) and 162 mm (6.38 inch).

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 Use the button to switch automatic envelope sealing on, off or use reading (in
case of a job with reading settings, see Sealing Control on page 34).

Press to select an envelope with open flap.

This means that envelopes are fed with open

flap. Use the upper button to enter the

applicable dimensions.
The envelope height can be set between 90 mm
(3.5 inch) and 162 mm (6.38 inch).
It is also possible to select ISO standard
envelopes or dimensions in inches (depends on
the installation settings).

Use the second button to enter the flap height.

The flap height can be set between 32 mm and the envelope height minus 32 mm
(1.26 inch).

Use the button to switch automatic envelope sealing on or off.

Press to define 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.

4.2.2 Document Settings

In the document settings menu you define 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 is 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 selected 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 menu.

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Note
The maximum number of sheets in a set 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.

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 is highlighted.

- Press to show a numeric keypad to enter the exact dimension of the

document.
Dimensions can be entered in mm, inches or as standard ISO paper dimensions
(depending on installation settings). The system will not allow entering

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dimensions out of 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).

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.

Note
When a feeder is selected for reading, the feeder below can not be linked to this reading
feeder. The reading feeder can be linked to a feeder above when it is not selected for
selective feeding.

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 3.9 Daily Mail on page 18). The upper feeder is
automatically selected.

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 - Press to enable the daily mail function. The icon appears behind the

upper feeder. If you press again the daily mail function will be disabled.

Note
The daily mail function is only available when reading is not activated. When daily mail is
set, the links to the daily mail feeder will be deselected automatically.

Note
When the daily mail function is selected DFC is not available.

4.2.3 Fold Settings

In the fold settings menu you can adjust the folding dimensions and folding type.
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 touch screen shows a simple diagram of the

document with the fold positions. To change the fold positions press next to a fold.
Enter the required position of the relevant fold.

Fold type Minimum position Maximum position

Single fold 75 mm (2.95) Longest document length
minus 25 mm (0.98)
Letter fold First fold 75 mm (2.95) Longest document length
minus 50 mm (1.97)
Second fold Position first fold Longest document length
plus 26 mm (1.02) minus 25 mm (0.98)
Zig-zag fold First fold 75 mm (2.95) Longest document length
minus 100 mm (3.94)
Second fold Position first fold Longest document length
plus 25 mm (0.98) minus 75 mm (2.95)
Double parallel First fold 75 mm (2.95) Longest document length
fold minus 51 mm (2.0)
Second fold Position first fold Longest document length
plus 25 mm (0.98) minus 25 mm (0.98)

24
Note
The touch screen will indicate when entered positions are out of range.

4.2.4 Reading Settings (Option)

For a full function description of reading, see
5.2 Reading on page 29. In the reading settings
menu it is possible to enable or disable the Optical
Mark Recognition (OMR) or Barcode Reading (BCR)
function and to adjust the basic settings.
The first reading settings menu covers the following
settings:
Code type: default is the setting none: reading
is disabled.

ENGLISH
Change the setting with the button. The
following codes are possible:
- 1-track OMR for reading Formax codes
- BCR for reading barcodes
- Flex 1-9 for reading non-Formax codes (only if flex dongle is installed)

Read from feeder: press the button to select a feeder to activate reading on.

By pressing the button the next reading

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). If you selected BCR, a second
keypad is available to enter the length of the
code.
Max. sheets: use the arrow buttons to select the maximum amount of sheets in the
set of documents.

25
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 148 mm for a C5/6 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 system stops and error INS-RE-14 will be displayed. After removing
the set and pressing the Reset button, the system will start and repeat the process until
an insert or divert mark is encountered, error INS-RE-15 (final set part) will be displayed.

4.2.5 Double Feed Control Settings

In the DFC settings menu you can set Double Feed
Control (DFC) for the different feeders on or off.
To set the DFC for the different feeders:

1. Press the button to select a feeder.

2. Press the button to switch the DFC on or

off. When switched on, the icon is displayed.
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.

4.2.6 Job Name

It is possible to store the job with a meaningful job
name, to easily recognize the job. This name is
displayed at job selection. Enter a job name with the
alpha-numeric keypad.

Use the button to clear a character left of

the cursor position (backspace).

Use the button to clear all entered

characters and start again.

26
27
ENGLISH
4.4 Copy a Job
To 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 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 an other
job number to copy from or to copy to.

Note
You can only copy job settings to new jobs.

6. Press for details of the job to copy from.

7. Press OK to copy the job settings.
If all jobs are programmed the touch screen shows No more free jobs.
It is possible to copy an Automatic job into a job. Before an Automatic job can be copied,
it has to be defined successfully (see 3.8 Using an Automatic Job (AutoSet) on page
18).

4.5 Delete a Job

To 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 button.
The job menu opens.
4. Press the Delete job button.
The delete job menu appears.
5. Select a job number and press OK. The job will
be deleted without a warning.

28
5. OPTIONS

5.1 Activate an Option

To activate a new option:
1. From the supervisor menu choose Options.
Software options are enabled with license codes. These license codes, together with
the identification number of the system enable the relevant options. The enabled and
available software options are displayed in this menu. Contact your dealer for
information about these license codes.
2. Press Add to activate other software options.
3. Enter the license key code that you received
from the supplier to activate the relevant option
on this system.

ENGLISH
Use the arrow keys to navigate through the
entered characters.
4. Press OK to confirm the license key and to
return to the options menu.
5. Switch the system off and on.

5.2 Reading

5.2.1 Introduction
The folding and inserting system can be equipped with reading. 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. Two types of codes are available:
OMR: Optical Mark Recognition
BCR: Barcode Reading
The sheets with the printed code are placed in the reading 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 must appear in the same location on every
page regardless of the actual code length.
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 with OMR, this is checked on
each sheet. If the page n of m code is used with BCR, the set will be inserted when n
equals m.
Both reading options can be enabled with a special license code (refer to Activate an
Option on page 29).

29
5.2.2 Adjust Reading Head Position
The horizontal position of the reading head must be adjusted to the same position of the
printed marks on the documents.
To adjust the reading head, proceed as follows:
1. Fold a document with reading code on the first
mark.

2. Open the upper unit.

A B
3. Hold the document in the middle against the
ruler.
4. Shift the reading head A so it is positioned
exactly above the middle of the reading marks.
5. Divide the paper guides B along the width of the
document.

Note
When the reading head is adjusted it is possible
that paper guides have to be removed and
placed on the other side of the reading head.

30
5.2.3 Document Orientation
Switch on the reading function and set the position of the reading marks as described in
Reading Settings (Option) on page 25.
Document orientation:
Fold type Type of documents Loading positions

12
no fold 3
first page

single fold

letter fold stop

start reading
reading
address
Double

ENGLISH
parallel fold Address carrier, face up and leading.
32
last page 1
(duplex printed)

zig-zag fold

address

stop
start reading
reading
Address carrier, face down and trailing.

5.2.4 Reading 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 reading function.
The ribbon or toner quality must be checked before printing.

31
OMR Code Specification
The following specifications apply to OMR codes:

Leading
>15 mm

>8.5 mm
Reading direction

2.54 - 6.36 mm
>8.5 mm
>30 mm

>4.2 mm >4.2 mm
>7 mm Trailing >7 mm >6.3 mm

Minimal distance from top of sheet to first mark 15 mm (0.59 inch)

Minimal distance from bottom of sheet to last mark 30 mm (1.18 inch)
Minimal distance from side edges of sheet to marks 7 mm (0.28 inch)
Minimal free space above and below the marks 8.5 mm (0.33 inch)
Minimal free space on both sides of the marks 4.2 mm (0.17 inch)
Minimum space between OMR marks 2.54 mm (0.10 inch)
Maximum space between OMR marks 6.35 mm (0.25 inch)
Minimum width of the marks 6.3 mm (0.24 inch)
Minimum line thickness of a mark 0.2 mm (0.008 inch)

Default the first mark from the top is set to 100 mm (3.9 inch). This parameter is set
in the Reading settings menu of the Job settings menu.
The code must appear in the same location and have a consistent number of marks on
every page.

32
BCR Code Specification
Minimal distance from top of sheet to first bar 15 mm (0.59 inch)
Minimal distance from bottom of sheet to last bar 30 mm (1.18 inch)
Minimal distance from side edges of sheet to barcode 7 mm (0.28 inch)
Minimal free space above and below the barcodes 8.5 mm (0.33 inch)
Minimal free space on both sides of the barcodes 4.2 mm (0.17 inch)
Minimum height of a bar 9 mm (0.35 inch)
Minimum line thickness of a bar 0.25 mm (0.01 inch)
The length of the code is a job setting. The code must appear in the same location on
every page.

Minimum Code/Basic Commands

In case of OMR the minimum code is one mark in
one line (insert). However for reliability it is advised

ENGLISH
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.

In case of BCR the minimum codes are also for

accumulate and insert.

33
Additional Codes
When it is required to control more functions in the
inserter system, additional codes are available.
Start mark
The following additional functions are possible via
Insert/accumulate
software options:
Divert mark
Divert Stop mark
Selective feed 1
Stop
Selective feed 2
Selective feed from station 1 Selective feed 3

Selective feed from station 2 Sealing control

Sequence check 4
Selective feed from station 3 Sequence check 2

Sealing control Sequence check 1

Parity (even parity)
Sequence check 4, 2 and 1 (respectively with 1, Safety mark
2 or 3 marks, only OMR)
Parity check mark (even, only OMR)
Safety mark (only OMR)
General remarks:
In case of OMR 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 processed by reading.
The mark definition is a service setting (OMR).
Other functions are possible via special codes
(Flex codes)

Divert
The system stops, manually remove the set from the
collator. Reset and start again.

Stop
The system stops, manually remove the set from the collator. Reset and start again.

Selective Feed
The system will selectively feed an enclosure when commanded so.

Sealing Control
When the sealing control mark is printed, sets will not be sealed. When no sealing
control mark is printed, sets will be sealed.

34
Sequence Check (only OMR)
Sheets in a stack can accidentally get out of 1
sequence or can be missing. This can be A 2
detected by the system when the sequence A 3
function is used. Each sheet has a number B 4
that forms part of the reading code. B 5
B 6
These are the available possibilities: #1 C 7
1 mark: pages are numbered 1-2-1-2-1- #2 C
etc. #3
#4
2 marks: pages are numbered 1-2-3-4-1- #1
2-3-4-1-2-etc. (see figure) #2
#3
3 marks: pages are numbered 1-2-3-4-5-
6-7-8-1-2-3-etc.

ENGLISH
The table shows examples of sequence check.
Marks on the sheets: sheet count
1 2 3 4 5 6 7 8
Sequence check 4 (3 marks used)
- - - - - - - -
Sequence check 2 (2 marks used)
- - - - - - - -
Sequence check 1
(1 mark used)
- - - - - - - -
- = Mark printed, - = No mark printed
Note
If you use sequence control and the system stopped, you can reset the sequence counter

as follows: press the (stop) button and press the Yes button to confirm.

Parity Mark (only OMR)

By adding a parity mark the reading code can be checked. When the OMR advanced
package is used the sum of the marks has to be even.

Safety Mark (only OMR)

The safety mark is used as an extra security. With Normal paper flow Skewed paper flow
skewed paper the reading head can miss part of the
reading code. In these situations the safety mark is Start mark Start mark
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 Safety mark Safety mark
if it has been activated as an OMR code. reading direction reading direction

35
Page n of m (only BCR)
BCR uses the code page n of m to complete a set. If n is less than m, the sheets are
accumulated. If n = m, this is the last sheet of the set and the set will be inserted.

Example of OMR Code

In the figure the legend for the following example is
mark printed reading feeder 3
shown. In this example feeder station 3 is the no mark printed selective feeder 2
accumalate selective feeder 1
reading feeder. The feeder stations 1 and 2 are insert
selected for selective feeding. or
no selective feed
In this example, a set of 8 sheets with two selective wanted, mark not
printed
feeds (station 2 and 1) and three sequence check selective feed
marks is shown. wanted, mark
printed
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 and 4 are reserved for selective
feeding from station 2 and 1. Print a mark on
position 3 when a selective feed from station 2
Sheet 1 Sheet 2 Sheet 3 Sheet 4 Sheet 5 Sheet 6 Sheet 7 Sheet 8
is required. Print a mark on position 4 when a
selective feed from station 1 is required. The
marks are printed on the last sheet of the set.
Position 5, 6 and 7 are used for the sequence check marks. The meaning of the
sequence check marks is explained in section Sequence Check (only OMR) on page
35.

5.3 Online Services

The folding and inserting system can be equipped with Online Services. This option
enables the system to connect to a central server. During the connection data is
downloaded to and uploaded from the system. The system always initiates the
connection, it is not possible to make a connection from outside to the system. Ask your
supplier if this option is available.

5.3.1 Start-Up Online Services

To s tart-up O nline Services:
1. From the supervisor menu choose Online
services.
The Online Services menu shows the following
functions:
Connection: opens the connection menu to
create a connection to a central server and to
view the connection history (see Connection
on page 37).

36
 Messages: opens the messages menu to view received messages (see Messages
on page 37).
Configuration: opens the configuration menus to change Online Services settings
(see Configur ation Menu on page 38).

Connection
The system makes a connection on fixed times. It is
possible that you manually connect the system to
the server. To connect to the server:
1. Press Connection in the Online Services
menu.
The touch screen shows the connection menu.
2. Press Connect to manually connect the system
to the OLS server.

ENGLISH
You can view the status of the connection on the
screen. The text on the button changes to Disconnect.
Press Disconnect to terminate connection with the server.
The connection menu shows the following functions:
History: opens the history menu to view the connection history (see History on
page 37).
New messages: this button appears when the system received new messages and
opens the messages menu (see Messages on page 37).

History
The history menu shows previous connections of
the system to the server.
1. Press the arrows to select a previous
connection.

2. Press to view details on selected previous

connection.

Messages
After pressing Messages in the Online Services
menu the touch screen will show messages received
from the server. A message has content like a new
job or new software.
1. Press the arrows to select a message.

2. Press for more information over a selected

message.
In case a new job or new software can be installed
the Continue button appears.

37
To install a new job or new software:
1. Press Continue.

The new job available menu or new software menu appears. Press for more
information on the new job or new software.
2. Press Install to install the new job or new software or press Reject to reject it.
After pressing Install a confirmation menu opens:
In case of a new job press the arrows to select a free job number (see 4.1 Create a
Job on page 20).
Press OK to confirm the selected job number or press Cancel to return to the new
job available menu.
In case of new software press OK to confirm the installation or Cancel to return to
the new software menu.
After confirming the installation of the new job or new software the message menu
appears.

Configuration Menu
After pressing Configuration in the Online
Services menu the configuration menu opens. Use
this menu to modify the OLS settings.
The menu consists of two submenus containing the
following functions:
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 OK 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 OK to confirm the new number.
Country: use the arrows to select a country from where you are dialing.
Date and time: enter the current date and time.

a Press .
b Enter the correct date and time using the numeric keypad.
c Press OK to confirm the new date and time.

38
 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.

Volume of modem: set the modem volume.

a Press 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.
Press OK to confirm modified settings.

5.4 Production Feeder

ENGLISH
5.4.1 Function
The Production Feeder is a feeder that 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 156 mm (6.1") length can be processed with it.

5.4.2 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.
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 the system is switched on. This makes it easy
to switch over from the standard document feeder 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 5.4.4 Document Separation on page 40).

To make use of a Production Feeder it is not necessary to (re-)program the jobs.

39
5.4.3 Adjust Side Guides
Adjust the side guides:
1. Take a stack of documents/BREs and place them
in the feeder tray.
BREs with flap down and leading (top side
pointing to system).
2. Adjust the side guides by turning the thumb
wheel G so the documents/BREs just fit and can
move without resistance.
Too much play causes skewing.

G H I J
5.4.4 Document Separation
When the Production Feeder is used at an automatic
separation feeder, the separation is set E
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.

Note
The lowest feeder is feeder 1.
C D F
2. Squeeze the two blue handles C and D and shift
the feeding plate F as far as possible to the front.
3. Push knob E forward until it clicks.
4. Place a document/BRE on the feeder tray and slide it in the system till the leading
edge is not visible anymore. Turn knob E counterclockwise if the separation is set to
narrow.
5. Push the document/BRE between the rollers.
6. Turn knob E 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 E back when ready.
8. Remount feeders 2 and 3.

5.4.5 Feeding Documents

To feed documents:
1. Squeeze the two blue handles C and D.
2. Shift the feeding plate F to the rear position.

40
3. Loosen the stack of documents and place them in the feeder.
BREs with flap down and leading (top side pointing to system).
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.

5.5 High Capacity Feeder

This option can only be installed from factory. The High Capacity Feeder has a capacity for
up to 725 sheets. The normal document feeder tray has a capacity of 325 sheets.

5.5.1 Installation of Feeder Tray

ENGLISH
To install the feeder tray of the High Capacity
Feeder:
1. Pull down lever A.
2. Hook in the feeder tray.
3. Release lever A.

5.5.2 Adjusting the Side Guides

To adjust the side guides B:
1. Loosen the knob D half a turn.
2. Put a small stack of documents between the side
guides.
A B C D E
3. Rotate wheel E.
The space between the side guides and the documents should be such that the
documents have just enough play to move freely.
4. Re-tighten knob D.

5.5.3 Document Separation

The document separation is set automatically. There are no manual adjustments needed.

5.5.4 Filling the High Capacity Feeder

To fill the document feeder tray:
1. Pull down lever A.
The feeder rollers C move up to filling level.
2. Place a stack of documents between the side guides (max. 725 sheets, 80 g/m).
Feed the documents (depending on the type of documents and the type of fold) as
shown in 3.4.1 Document Orientation on page 14.
3. Release lever A.

41
5.6 High Capacity Vertical Stacker
The High Capacity Vertical Stacker can be used to
stack filled envelopes. The vertical stacker can store
up to 500 filled envelopes. The vertical stacker can
be equipped with Mail Piece Production Control
(MPPC). A B

5.6.1 Adjusting the Side Guides

Adjust the side guides with wheel A so, that a
margin of 3 to 5 mm is left between the envelopes
and the side guides.
For small envelopes it can be necessary to remove
the extensions B from the envelope support.

5.7 Side exit

The system can be equipped with a side exit and

catch tray. The side exit can be fitted instead of the
standard envelope receiving tray. The side exit
allows a conveyor or a franking system to be fitted in
line with the system.
The side exit can also be used with a catch tray to
achieve vertical stacking. The catch tray is delivered
with the side exit.

5.8 Mail Piece Production Control

(MPPC) (Option1)
The folding and inserting system can be equipped with Mail Piece Production Control. This
option enables the system to verify the inserted documents or sets of documents with a
database, which is generated when you print the documents. The system gives a warning
when a mail piece is missing at the exit of the inserter.
Refer to the appendix Mail Piece Production Control for an extensive description of this
option.

1. Ask your supplier if this option is available for your system.

42
6. OPERATOR MAINTENANCE

Warning
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.

Maintenance Maintenance
frequency
Daily Check the system functions.
Keep the system in proper condition by removing dust, paper
remains, etc.

ENGLISH
When dirty, clean the sealing table and rubber rollers with a slightly
wetted cloth, soaked in warm water.
Weekly When dirty or saturated, clean the brushes of the envelope sealing.
The system 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 When the touch screen warns about dusty sensors, the sensors on
necessary the envelope or document path must be cleaned. Use the bellows
that is located behind the side cover.
Place the bellows in the hole and firmly squeeze a few times to blow
the dust from the sensor. Repeat this procedure for the hole to clean
the flap sensor.
If the exit sensors have to be cleaned, use a slightly wetted cotton
swab:
- Lower exit sensor: insert the wetted cotton swab into the hole
and spin once.
- Upper exit sensor: insert the wetted cotton swab into the hole
for the upper sensor and spin once.

Note
When finished cleaning the sensors always calibrate the sensors
(see 2.4.6 Test Menu on page 11).

43
7. FAULT FINDING

7.1 Error Messages

When an error occurs the touch screen shows a
menu 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 Reset to reset the
error (the error menu will disappear).

Special Errors
Reading errors (when reading is enabled)
The document stops in the collating area. The operator must remove the document
set and has to complete the set manually!
Technical errors
The touch screen 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 touch screen shows a warning screen with the message
Cover open and a suggested solution Close cover.

44
7.2 Clearing Stoppages
Stoppages can occur in the following areas:

A Folding and feeding area

A
B Collating area
C Envelope track and inserter area.

7.2.1 Folding or Feeding areas

When a stoppage occurs in the folding area or the
feeders , remove the documents as follows:
1. Open the upper unit A by pulling up the handle.

2. Remove the documents from the folding area or

C B

ENGLISH
the feeders .
3. Close the upper unit A.
4. Press Reset to reset the error and restart the job.

7.2.2 Collating Area

When a stoppage occurs in the collating area, remove the documents from the collating
area as follows:
1. Move the collator plate B down.
2. Remove the documents.
3. Move the collator plate B up in position.
4. Press Reset to reset the error and restart the job.

7.2.3 Lower Envelope Track

When a stoppage occurs in the lower envelope track,
remove the envelopes as follows:
1. Open the side cover C.
2. Pull down the blue handle D and remove the
envelope(s) from the lower envelope track. E
3. Close the side cover. F
4. Press Reset to reset the error and restart the
job.
D
If necessary, the envelopes and documents can be
transported manually:
C
Turn the blue knob E clockwise to transport an
empty envelope to the insert position.
Turn the blue knob F clockwise to transport the filled envelopes to the exit.

45
7.3 Operator Troubleshooting
To s olve p roblems:
1. Write down the error.
2. Consult the troubleshooting table to solve the problem.
3. Switch the inserter off and on again, to verify system operation.
4. When the error still occurs contact your service organization.

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 2.4.5 Supervisor Menu on page 10.

Symptom Possible cause Remedy Reference

The system System not Connect the system -
cannot be started connected to mains. to the mains.
after switching Fuse is blown. Replace fuse below -
on. power switch.
A cover is opened. Close the covers. -
System stops with Envelopes stacked Check envelope feed Loading Envelopes on
envelope at insert reversed in the adjustments. Place page 16
position (flap not hopper. envelopes correctly
open). in hopper.
Envelope flap sticks. Store envelopes Envelope Settings on
according to page 21
specifications.
Wrong envelope type Change envelopes Envelope Settings on
used (not according according to page 21
to specifications or specifications.
job settings).
Envelopes are Envelope separation Adjust envelope Loading Envelopes on
double fed. not correctly set. separation. page 16
Envelopes not placed Check and replace if Loading Envelopes on
properly in the needed. page 16
hopper.
Envelope stops Side guides of the Check side guides Loading Envelopes on
skewed. envelope hopper are and adjust if needed. page 16
set too wide.
Envelopes are fed Hopper almost Refill hopper. Loading Envelopes on
irregularly. empty. page 16
Separation set too Adjust envelope Loading Envelopes on
narrow. separation. page 16
Side guides set too Check side guides Loading Envelopes on
narrow. and adjust if needed. page 16
Envelope support not Reposition the Loading Envelopes on
positioned correctly. envelope support. page 16

46
Symptom Possible cause Remedy Reference
Flap is wrinkled Envelope not within Check specifications Envelope and Insert
and sometimes specifications. and change Specifications on
not opened. envelopes if needed. page 51
Flap sticks. Store envelopes Envelope and Insert
according to Specifications on
specifications. page 51
Flap curled. Envelopes stored or Envelope and Insert
manufactured Specifications on
improperly. page 51
Separation set too Adjust envelope Loading Envelopes on
narrow. separation. page 16
Fingers are placed Fingers adjusted too Check fingers Envelope Insert
on top of the deep into the position, adjust if Fingers on page 49

ENGLISH
envelope. envelope. needed.
Envelope stops too Check envelope stop Insert Position on
early. position, adjust if page 49
needed.
System stops Fingers not correctly Check fingers Envelope Insert
while inserting adjusted. position, adjust if Fingers on page 49
(stoppage at the needed.
inserting point). Inserted document Check fold settings. Fold Settings on
too long for used page 24
envelope.
Envelope throat Check envelope Envelope and Insert
incorrect. specifications. Specifications on
page 51
Envelope glued Eliminate faulty -
inside. envelopes.
Window not glued Eliminate faulty -
properly. envelopes.

47
Symptom Possible cause Remedy Reference
Flap not Water level low. Check water level, Filling the Sealing
sufficiently refill if needed. Liquid Reservoir on
moistened. page 17
Brushes dry. Check brushes, Operator Maintenance
replace if needed by on page 43
the extra soaked set.
Brushes dirty. Check brushes, clean Operator Maintenance
if needed. on page 43
Moistening felt dry. Check the moistening Filling the Sealing
felt, refill water tray Liquid Reservoir on
if needed. page 17
Moistening felt dirty. Check the moistening Operator Maintenance
felt, clean if needed. on page 43
Brushes worn out. Replace brushes. Operator Maintenance
on page 43
Moistening felt worn Replace moistening Operator Maintenance
out. felt. on page 43
Envelope not Inserted document Check fold settings, Fold Settings on
always ejected too big. adjust if needed. page 24
from sealer. Document not Check adjustment of Insert Position on
inserted deep envelope stop page 49
enough. position and fingers.
Sealing area dirty. Clean sealing area. Operator Maintenance
on page 43
No document fed. Feeder empty. Refill feeder. Filling the Document
Feeder Tray on page 16
Separation set too Adjust the Document Separation
wide / too tight. separation. on page 15
Side guides set too Adjust the side Adjusting Side Guides
narrow. guides. on page 14
Skewed Side guides set too Adjust side guides. Adjusting Side Guides
documents fed. wide. on page 14
Double Separation set too Adjust the Document Separation
documents fed. wide. separation. on page 15
Document set not Insert position not Check insert position. Insert Position on
correctly inserted. correct. page 49
Insert fingers not Check insert finger Envelope Insert
correctly positioned. position. Fingers on page 49
Address not Address position not Check address Address Position on
readable from correctly defined. position. page 49
window

48
7.3.1 Insert Position
To make a good insert of the document set into the
envelope, the envelope should be positioned
correctly.
The document set is inserted correctly if the flap
folding line of the envelope is positioned underneath
the green roller B.
A
B
C
D
To verify the insert position:

ENGLISH
1. Choose a job and press the 1x button.
2. Press No until the question about envelope
position appears.
3. Press No again and follow the instructions on
screen.

7.3.2 Envelope Insert Fingers

To make a good insert of the document set into the
envelope, the insert fingers A should be about 5 mm
(0.2 inch) inside the envelope.
The outer fingers D should be about 5 to 10 mm
(0.2 to 0.4 inch) from the edges of the envelope.
To verify that the position of the fingers is correct:
1. Choose a job and press the 1x button.
2. Follow the steps in the troubleshooting wizard.

7.3.3 Address Position

The address on the document set should be
positioned in a way that you can read it from the
envelope window. If it is not readable, adjust the
address position as follows:
1. Choose a job and press the 1x button.
2. Press No if asked if the mail set is correct.
3. Press Yes if asked if the documents are inserted
correctly.
4. Press No if asked if the address is readable.
5. Follow the steps in the troubleshooting wizard.

49
8. SPECIFICATIONS

8.1 Technical Specifications

Model 6306 Series
Type: Fold and insert system for medium office use
Theoretical max. 3600 inserts per hour, depending on application
speed
Power consumption: 100 VAC / 50 Hz / 3.0 Amps (voltage tolerance: +6%/-10%)
115 VAC / 60 Hz / 3.0 Amps (voltage tolerance: +6%/-10%)
230 VAC / 50 Hz / 1.5 Amps (voltage tolerance: +10%/-10%)
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, 250V
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

8.2 Configuration Dimensions

Height 720 mm (28.3 inch)
800 mm (31.5 inch) including High Capacity Vertical Stacker
Width 455 mm (17.9 inch) including side exit catch tray
Length 770 mm (30.3 inch) on covers
1120 mm (44.1 inch) including hopper and feeder trays
1200 mm (47.2 inch) including side exit
1270 - 1360 mm (50.0 - 53.5 inch) including catch tray
1360 mm (53.5 inch) including High Capacity Vertical Stacker
Weight 73 kg (160.9 lbs)

8.3 Other Specifications

Noise level <66 dBA (according to ISO 11202)
Operating 10C - 40C (50F-104F)
temperature
Humidity 30%-80%

50
8.4 Document Specifications
Paper quality minimum 60 g/m (15 lb bond)
maximum 250 g/m (62.5 lb bond), when folded
max. 170 g/m (42.5 lb bond)
Booklets up to approximately 1 mm (0.04 inch) thickness,
depending on stiffness

Paper size Minimum width: 130 mm (5.1")

Maximum width: 236 mm (9.3"), when folded 230 mm (9.1")
Minimum length: 90 mm (3.5")
Maximum length: 356 mm (14.0")

Folding capacity Single fold - 10 sheets (max. 80 g/m)

Letter fold / Z-fold - 8 sheets (max. 80 g/m)

ENGLISH
Double parallel fold - 4 sheets (max. 80 g/m)

Envelope sizes Standard BRE (Business Reply Envelopes)

Envelope quality minimum 80 g/m (20 lb bond)

maximum 120 g/m (30 lb bond)

8.5 Envelope and Insert Specifications

A B C D E F G
Minimum size mm 160 90 32 10 130 84 60 g/m2
inches 6.3 3.5 1.25 0.4 5.1 3.3 60 g/m2
Maximum size mm 248 162 B-32 35 A-12** B-6 2.5*
inches 9.7 6.38 B-1.25 1.4 A-0.47** B-0.2 0.1

* Booklets up to approximately 1 mm (0.04 inch) thickness, depending on stiffness

** When insert is more than 1 mm (0.04 inch): A-15 mm / A-0.6 inch

51
Remarks:
Maximum insert specifications are based on single sheets. When multiples are
handled, more room inside the envelope is needed depending on the application.
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.
We recommend that materials to be handled are stored at a temperature of 20C
(68F) 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 system
at least 24 hours before use.
Self-copying paper may cause rubber parts to wear quicker. The rubber used in this
system has the best resistance to Wiggins Teape material.

8.6 Specifications: High Capacity Vertical Stacker

Type high capacity vertical stacker

Suitable for all kinds of mail sets that consist of at least one 80
grams envelope and one folded document (80 gram).
Power consumption low voltage supplied by the inserter system
Approvals EMC Certificate conform EMC-Directive.
FCC Certificate conform 47CFR, part 15.
UL Listed I.T.E. (Information Technology Equipment),
conform UL-IEC 60950-1, file: E153801.
Conform NEN-EN-IEC 60950-1 and derivatives.
Height 550 mm(21.7 inch)
Width 440 mm (17.3 inch)
length 360 mm (14.2 inch)
Weight 12 kg (26.5 lbs)
Noise level see 8.3 Other Specifications on page 50
Operating 10C - 40C (50F-104F)
temperature
Humidity 30%-80%
Stacker capacity 325 envelopes, depending on application

52
8.7 Specifications: Production Feeder

Type high capacity feeder for BREs, small inserts

Theoretical max. see 8.1 Technical Specifications on page 50
speed
Power consumption low voltage supplied by the inserter system
Approvals EMC Certificate conform EMC-Directive.
FCC Certificate conform 47CFR, part 15.
UL Listed I.T.E. (Information Technology Equipment),
conform UL-IEC 60950-1, file: E153801.
Conform NEN-EN-IEC 60950-1 and derivatives.
Height 210 mm (8.3 inch)
Width 285 mm (11.2 inch)
length 425 mm (16.7 inch)

ENGLISH
Weight 5.05 kg (11.1 lbs)
Noise level see 8.3 Other Specifications on page 50
Operating 10C - 40C (50F-104F)
temperature
Humidity 30%-80%
Feeder tray capacity 1200 sheets 80 gr., max. length 156 mm (6.1 inch)
320x Business Reply Envelopes
Document / BRE see 8.4 Document Specifications on page 51 and
insert specifications 8.5 Envelope and Insert Specifications on page 51

53
9. TERMINOLOGY

Term Description
Address carrier 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.
Address position 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.

Automatic 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 document
set) and the length of the envelope the fold type is determined.
Automatic job A job that is created with the Automatic job functionality.
Barcode Reading Barcode Reading is intended for reading and interpreting printed
(BCR) barcodes. The codes give information to the inserting system about
how to build-up and handle a set.
Business Reply Envelope included in outgoing mail sets for addressee response
Envelope (BRE) purposes.
C-fold See Letter fold.
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 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.
Document set 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 into
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.

54
Term Description
Double Feed Double Feed Control is the sensor that measures the thickness of a
Control (DFC) 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.
Double parallel The double parallel fold is a type of fold where the document is first
fold 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.

ENGLISH
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.
Face down Situation in which the front of a sheet is facing downwards when
placed in a document feeder.
Face down Situation in which the front of a sheet is facing downwards and the top
leading of the sheet is closest to the separation unit in a document feeder.
Face down Situation in which the front of a sheet is facing downwards and the
trailing 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 feeder tray.
Feeder linking 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.
Feeder tray Part of the feeder that contains the stack of documents.

55
Term Description
Flexcode OMR 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.

High Capacity Feeder that has a capacity for 725 sheets.

Feeder
High Capacity Optional stacker that is mounted on the exit of the system, to stack
Vertical Stacker filled envelopes.
Insert An insert is the action of inserting a document set into an
envelope.
For native English speaking customers an insert is also a short,
not to be folded document, usually an enclosure.
Inserter 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.

Job 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
Job counter The counter that registers the number of mail sets that is produced as
part of a specific job.
Letter fold 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.

Synonym: C-fold.
Linking See feeder linking.
ProductionFeederFeeder with high capacity feeder tray
Multifeed The feature of an inserting system in which more than one sheet is
taken from a feeder.
OMR Optical Mark Recognition
OMR code Standard 1-track OMR code definition. Specifies the amount of reading
definition marks used and the functionality linked to each of them (how each
should be interpreted).

56
Term Description
Operator The person operating an inserting system.
Optical Mark Optical Mark Recognition is intended for reading and interpreting
Recognition printed codes. These codes are one or more black marks which are
(OMR) read from a document. These marks give information to the inserting
system about how to build-up and handle a set.
Reading error Condition in which the system could not reliably read or interpret the
OMR reading marks or barcode from a sheet.
Reading marks Marks added to documents containing finishing instructions that can
be identified by an reading head and interpreted according to the used
OMR code definition.
Remote The feature that makes it is possible to analyze a problem on an
diagnostics inserting system from a remote location.
Service engineer Technical engineer whose task it is to resolve problems with systems

ENGLISH
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 Used as storage for filled envelopes.

Stop counter Counter which sets the amount of envelopes to be filled. After filling
this amount of envelopes the system will stop.
Supervisor Person who is responsible for the technical state of the system.
Normally a supervisor has access to programming functions, which are
restricted for standard users.
Test run 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.
Check whether the address is correctly positioned behind the
envelope window.

57
Term Description
Tray Contains a stack of paper for a printer or inserter. This paper is
supplied to the system 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

58
Index height 23
orientation 31
A separation 15
address carrier 54 settings 22
address position 49, 54 specifications 51
automatic job 18, 54 document orientation
normal 31
B reading 31
Barcode Reading document set 54
see BCR document stoppage
BCR 54 see stoppage
adjustments 30 double feed control 6, 55
codes 31 double feed control settings 26
document orientation 31 double feeding 46, 48
settings 25 double parallel fold 55
test 11 E
bellows 7
brush replacement 43 envelope 55
business reply envelope 54 feed 16
button 8 insert position 49
load 16
C no envelope mode 22
calibrate photocell 11 quality 51
catch tray 7, 42 sealing 22
cleaning 43 separation 16
collating area 6 settings 21
collator arm 7 size 21, 22, 51
configuration 38 slide 7
configuration dimensions 50 specifications 51
connection 37 support 7, 17
connection history 37 envelope feeder
contrast 10 side guides 16
control panel 7, 8 error messages 44
counter 8 errors
cover 7 reading errors 44
technical errors 44
D
F
daily mail 54
daily mail handle 19 face down 55
daily mail settings 23 face down leading 55
date online services 38 face down trailing 55
DFC face up 55
settings 26 face up leading 55
diagnostics 11 face up trailing 55
dial tone detection 39 feed
display document 16
see touch screen envelope 16
display settings 10 feeder 55
document 54 automatic 6, 15
feeder tray 7 install 12
link 23

59
 settings 21
load 16 start 17
remove 14 job list 8
side guides 14
special 6, 15 L
feeder linking 55 letter fold 56
feeder tray 55 loading envelopes 16
install 12
fill sealing liquid reservoir 17 M
finger position 49 Mail Piece Production Control 21
flex certificate 10 main menu 10
flex code 34 maintenance 43
manual document feeding 23
fold Production Feeder39, 56
C 54 document separation 40
double parallel 24 feed documents 40

ENGLISH
letter 24 installation 39
none 24 side guides 40
single 24 menu button 8
zig-zag 24 menu, main 10
fold settings 24 message 37
franking modem 7
settings 27 modem volume 39
franking system 42 MPPC 21
fuse 46 multifeed 56

H N
High Capacity Feeder 41, 56 noise level 50
High Capacity Vertical Stacker 42, 56 number of sheets 22
home menu 8
O
I OMR 56
insert 56 1-track 25, 29
insert position 49 adjustments 30
insert specifications 51 align heads 30
inserter 56 codes 31
installation 12 description 29
document orientation 31
J settings 25
job 56 test 11
copy 28 online services 11, 36, 42
counter 56 operating controls 7
create 20 operating instructions 12
delete 28 Optical Mark Recognition
description 8 see OMR
edit 27 option
information 8 activate 29
job menu 11 information 10
name 26 license code 29
new 20 overview 5
select 17
 test menu 11
test run 57
P
touch screen 8
paper quality 51 contrast 10
paper size 51 settings 10
photocell calibration 11 tray 58
power consumption 50 troubleshooting 46
power switch 7
U
R
USB 7
reading head position 30
reading settings 25 V
reservoir vertical stacker 42, 56
fill 17 volume acoustic signals 10
RS232 connector 7 volume modem 39
run a job 17
Z
S
Z-fold 58
safety 2
seal envelope 22
sealing liquid reservoir 7
select a job 17
sensor dusty 43
side cover 7
single fold 57
slide 7
software description 8
software version 10
speed 50
stacker 42, 57
start button 8
starting the job 17
stop button 8
stop counter 9, 57
stop the system 19
stoppage
collating area 45
feeding area 45
inserting area 45, 47
lower envelope track 45
folding area 45
supervisor menu 10
system ID 10
system info 10

T
technical specifications
high capacity vertical stacker 52
inserter 50
Production Feeder 53
telephone number 38