Document Inserting System DI500/DI600 Operator Guide US/Canada English Version
FCC Compliance This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC rules. These limits are designed to provide reasonable protection against 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 the instruction manual, may cause interference to radio communications.
Table of Contents Pitney Bowes Contact Information List Chapter 1 v Introduction Safety ................................................................................1-2 To The Operator ................................................................1-3 Machine Configurations .....................................................1-4 Machine Identification ........................................................1-6 PacPilot™ Control Panel ...................................................
Table of Contents Chapter 3 Operator Functions About this Chapter .............................................................3-2 Connecting Power .............................................................3-2 Running a Job ...................................................................3-3 SwiftStart™........................................................................3-6 Manual Feed......................................................................3-9 Setting the Sheet Feeders ..............
Table of Contents Chapter 5 Optical Mark Recognition (OMR) OMR Availability ................................................................5-2 What is OMR? ...................................................................5-2 OMR Marks Available ........................................................5-3 OMR Mark Options ............................................................5-6 OMR Specifications ...........................................................
Table of Contents Chapter 7 Reference Specifications ....................................................................7-2 Sheet Feeders ........................................................... 7-2 Fold Type and Overall Thickness Limits .................... 7-3 Insert Feeders ............................................................ 7-4 Envelope Feeder ........................................................ 7-4 Envelope Sealer .........................................................
Pitney Bowes Contact Information List USA Contacts Product Name - DI500 or DI600 For frequently asked questions, go to: www.pb.com and click on Customer Support. To place requests for service or training, go to: www.pb.com and click on My Account. To order PB supplies and accessories, go to: www.pb.com and click on Online Store. To view and pay invoices online, go to: www.pb.com and click on My Account. To view inventory, go to: www.pb.com and click on My Account. For direct questions, call: 1.800.522.
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1 • Introduction This chapter presents important safety information and describes the main controls and features of your machine. Important Safety Notes ...................................................... 1-2 To The Operator ................................................................ 1-3 Machine Configurations ..................................................... 1-4 Machine Identification ........................................................ 1-6 PacPilot™ Control Panel .........................
1 • Introduction Important Safety Notes Follow these basic safety precautions when operating this machine: • • • • • • • • • • 1-2 Use only Pitney Bowes approved supplies, in particular aerosol dusters. Improper storage and use of aerosol dusters or flammable aerosol dusters, can cause an explosive-like condition that could result in a personal injury and/or property damage. Never use aerosol dusters labeled flammable and always read instructions and safety precautions on the duster container.
Introduction • 1 • • Immediately report to Pitney Bowes Service any damaged or nonfunctioning components. The unit may be unsafe for use. To prevent overheating, do not cover the vent openings. Allow ample spacing around the unit for ventilation. NOTE: Always follow the specific occupational safety and health standards for your workplace.
1 • Introduction Machine Configurations The following machine configurations are available, depending on your local market: • • • • • • Two Sheet Feeders Only Four Sheet Feeders Only Two Sheet Feeders and One Insert Feeder Two Sheet Feeders and Two Insert Feeders Four Sheet Feeders and One Insert Feeder Four Sheet Feeders and Two Insert Feeders Each feeder location has its own letter designation which remains the same irrespective of machine configuration.
Introduction • 1 Sheet Feeders Insert Feeders Manual Feeder H A G B C F D E Envelope Feeder Feeder Configuration SV40221 Rev.
1 • Introduction Machine Identification 2 3 4 1 9 5 8 7 1 6 Sheet Feeders Use these feeders to feed sheets that require folding. They automatically detect if more than one sheet feeds (double detect), giving security to your mailings. Depending on the job being run and availability of feeders, there also is an option to ‘link’ these feeders so that when the first feeder runs out of material, feed will automatically switch to the next linked feeder.
Introduction • 1 3 Manual Feeder (also known as Convenience Feeder or Daily Mail Feeder) Use this feeder to manually feed stapled or unstapled sets of up to 5 sheets (see specifications, page 7-2). The machine waits for each set to be manually fed before folding and inserting the set automatically into the envelope. A Supervisor can also configure the machine to place insert(s) within the set if Insert Feeder(s) are fitted.
1 • Introduction PacPilot™ Control Panel Control Panel Keys Screen Keys Navigation Keys Reset Counters If only piece count is displayed, press this key to reset the piece count to zero. If both piece and batch counters are displayed, pressing this key allows either or both counters to be reset. Help (not available in some markets) Press this key to view an electronic Quick Reference Guide giving you quick access to basic information regarding operation of your machine.
Introduction • 1 Home Press this key to take you back to the Home Screen. The Home Screen is where you can run jobs and is the start point for accessing the menus. Start Starts automatic operation. Trial Piece Press this key to run test piece(s) so that you can check the machine setup. Trial Piece(s) must be run before automatic operation can be commenced using the Start key. If double detection is in use, the machine calibrates itself automatically as it runs the Trial Piece(s).
1 • Introduction Mail Piece Icon Tree The Mail Piece Icon Tree is located on the left side of the display. It displays the Mailing Object Icons required, based on the Job Definition. The icons inform you which feeders to load, the type of object (sheet, insert, etc.) to be loaded into each designated feeder and the loading orientation of each object. It is therefore extremely important that you become familiar with the icons themselves and the make-up of the Mail Piece Icon Tree.
Introduction • 1 Mail Piece Icon Tree Icons Each Mailing Object Icon has one darker edge either at the top or bottom that indicates the leading edge of the object when loaded into the assigned feeder. The leading edge of an object is the edge that feeds into the machine first. For example, a sheet that must be loaded face up with the top of the sheet leading would be represented by a “face-up” sheet icon containing a “leading edge” line on top.
1 • Introduction Envelope Icons Sheet Icons No Window, Flap side up, Flap Last No address, Face Down, Bottom First Window, Flap side up, Flap Last No address, Face Down, Top First No address, Face Up, Bottom First Seal Icons Seal On No address, Face Up, Top First Safe Seal On Fold Icons C Fold (letter fold) Top address, Face Down, Bottom First Z Fold (accordion fold) Top address, Face Down, Top First Single Fold Top address, Face Up, Bottom First Double Fold Top address, Face Up, Top First B
Introduction • 1 Mail Piece Icon Tree Example An example Mail Piece Icon Tree is shown below. This explains the information that is available and how it assists you in loading and running a job.
1 • Introduction Common Terms Throughout the machine screens and this guide, standard terms are used to describe the elements of the Mail Piece and functions of the equipment. It is therefore important that you fully understand the following basic terms to get the best from your machine: MATERIAL Sheet A single piece of paper that will require folding by the machine before it is placed into an envelope. Pre-Collated Set A set of sheets printed in a collated sequence i.e. sheet 1, sheet 2, sheet 3, etc.
Introduction • 1 MATERIAL (continued) Insert An item that doesn’t require folding before being placed into an envelope. There are four kinds of Inserts: Reply Envelope A return envelope placed into the Outer Envelope with the other Mail Piece contents. Booklet An item with a stapled and folded binding edge. Slip A single thickness piece of paper or card. Pre-Folded Insert A sheet that has been folded prior to loading and requires no further folding by the machine.
1 • Introduction MACHINE FUNCTIONS Home Screen The initial screen displayed after turning power on. From this screen you can select pre-programmed Job Definitions, enter the menu functions or run the machine. Pressing the Home key on the Control Panel will return you to this screen at any time. Job Definition The collection of settings that define how a Mail Piece is to be created by the machine. Up to 20 Job Definitions can be stored for instant recall.
2 • Using the Menus This chapter explains the Home Screen and the menu structure accessed via the PacPilot™ Control Panel The Home Screen ............................................................. 2-2 The Menu Structure ........................................................... 2-4 SV40221 Rev.
2 • Using the Menus The Home Screen The Home Screen is the first screen shown on the display after the machine has finished powering up. The last Job Definition selected is displayed with the relevant Mail Piece Icon Tree on the left hand side. The ▲ and ▼ navigation keys can be used to scroll through the icon tree and highlight individual items. As you do this, the loading instructions associated with the highlighted item will be shown. From this screen you can run the job displayed.
Using the Menus • 2 Name of selected Job Machine Status Screen Name Counter(s) Home READY Piece Count: Batch Count: Invoice Job Use ▼, ▲ to view loading instructions Instructional Text Select Job > SwiftStart > Menu > Job comments text area Screen Key Selections Mail Piece Icon Tree Machine Graphic The Home Screen SV40221 Rev.
2 • Using the Menus The Menu Structure The diagram on the facing page shows the menu structure available when you press the Menu Screen Key. You will see that the menu follows a logical structure with similar functions grouped together. The menu structure is split into two sections: The first section is available to all Operators and contains settings and adjustments that might be required when running jobs on the machine.
Using the Menus • 2 OPERATOR FUNCTIONS Home Screen Select Job (p.3-3) > SwiftStart (p.3-6) > Menu (p.3-19) > Language (p.3-19) > Display Adjustments (p.3-19) > Safe Seal (p.3-19) > System Information (p.3-19) > SUPERVISOR FUNCTIONS Supervisor Functions (p.4-1) > Create Job (p.4-3) > Menu items below this line require a Supervisor Access Code Edit Job (p.4-4) > Create From (p.4-6) > Delete Job (p.4-7) > OMR Menu (p.4-8) > Systems Menu (p.4-8) > Manual Feed Option (p.
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3 • Operator Functions This chapter lists the functions that can be carried out by an Operator. Primarily, this includes selecting Job Definitions, running the various operator modes and loading material. About this Chapter ............................................................. 3-2 Connecting Power ............................................................. 3-2 Running a Job ................................................................... 3-3 SwiftStart™.........................................
3 • Operator Functions About this Chapter This chapter explains functions on the machine that can be carried out by an Operator. This includes: • Selecting and running a pre-programmed Job Definition • Using the SwiftStart™ mode • Using the Manual Feeder • Loading the feeders • Filling the sealer Functions that can only be carried out after entry of a Supervisor Access Code are described in the next chapter, ‘Supervisor Functions’.
Operator Functions • 3 Running a Job Selecting a Job This section assumes the job to be run has already been created by a Supervisor. If the job has not been created, refer to Create Job on page 4-3. When the machine is turned ON, a ‘Startup Screen’ showing details of your machine and contact details will be displayed for a short time. After a few seconds, the Home Screen will appear. The last Job Definition selected will be loaded, with the message ‘Trial Piece Required’ displayed at the top of the screen.
3 • Operator Functions Load material into all the feeders as indicated by the Mail Piece Icon Tree (refer to setting the feeders on pages 3-12 to 3-17). If required, reset the item and/or batch counters by pressing the Reset Counters key. If necessary, fill the Sealer with sealing solution or water (see page 3-18). If you are running an Optical Mark Recognition (OMR) job, the OMR Scanner must be aligned to the OMR marks on the material being run. Refer to page 5-18 for instructions.
Operator Functions • 3 If you choose No... The adjustment(s) you have just changed will only be retained while you are running the current job. If another Job Definition is selected or if power is turned off, next time the original Job Definition is selected, the modified adjustment(s) will have returned to the value saved within the Job Definition. TIPS: If you reload material during a run which seems to have different characteristics (weight, colour shade, etc.
3 • Operator Functions SwiftStart™ SwiftStart™ allows you to load material into the feeders and run a simple job with minimal setup information. The job can then either be run without saving it to the machine’s memory, or a Supervisor can name and save the Job Definition for future recall as and when required. TIP: SwiftStart™ can be used as a way to quickly program a new Job Definition. Load material and run SwiftStart™.
Operator Functions • 3 For a C fold Job: Load the Sheet Feeders from the top feeder downwards, in sequence (first sheet in top feeder). Load Sheets Face Up and Top First. For a Single fold job: Load the Sheet Feeders from the bottom feeder upwards, in sequence (first sheet in bottom feeder). Load Sheets Face Down and Bottom First.
3 • Operator Functions SwiftStart™ Operation Load material as previously described and select SwiftStart. The machine will feed an envelope and depending on the depth of the envelope, will automatically select the fold type – Single or C fold. A Trial Piece is automatically produced, enabling you to check the job and to allow the machine to calibrate itself for the material being run.
Operator Functions • 3 Manual Feed Manual Feed allows you to feed stapled or unstapled sets of up to 5 sheets of 20 lb. (80g/m2) to a maximum total weight of 100 lb. (400g/m2). The sets are fed by hand, one set at a time, for processing by the machine. Using the Manual Feed automatically turns off all Sheet Feeders. You can, however, use the Insert Feeder(s) if they have been enabled by a Supervisor using the Manual Feed Option explained on page 4-8.
3 • Operator Functions Manual Feed Operation Make sure Envelopes and Inserts (if required) are loaded as previously described. You must now decide which way round to feed the set into the Manual Feeder, as this depends on the type of fold the set requires. Depending on your Envelope depth and Sheet length, the machine will automatically select the fold type – Single, C or double fold. For example: 8-1/2” x 11” sheets inserted into a #10 envelope will receive a C fold.
Operator Functions • 3 Manually Feeding Further Sets After confirming a Trial Piece is OK, the machine will remember it’s settings and process further manually fed sets automatically. While the motor runs, the machine will remain in Manual Feed mode. If no further sets are fed whilst the motor is running, after a brief delay, the motor stops and the machine reverts to the previous Job Definition selected. If you wish to leave Manual Feed mode while the motor is running, press Cancel twice.
3 • Operator Functions Setting the Sheet Feeders Sheet Feeders A to D feed sheets that require folding by the machine. The Mail Piece Icon Tree for the job being run will show which feeders need to be loaded and the sheet orientation. If you need help understanding the sheet icons, refer to page 1-11 of this guide. The First Sheet or Set (normally containing the address) will be fed from the top feeder for C or Double Fold jobs and from the bottom feeder for single or Z fold jobs.
Operator Functions • 3 3. Jog the stack back into alignment. 4. The Mail Piece Icon Tree will show the correct orientation of the sheets in the Stack. Make sure you load sheets in the orientation indicated. 5. The Sheet Feeders take the paper Stack in a similar way to a photocopier paper cassette. Place the Stack onto the deck of the feeder. Depress the Stack and slide it fully under the feed roller. SV40221 Rev.
3 • Operator Functions Setting the Envelope Feeder Envelope Feeder E feeds the Outer Envelope for the inserting job being run. The Mail Piece Icon Tree for the Job Definition being run will show if the feeder needs to be loaded and the envelope orientation. If you need help understanding the envelope icons, refer to page 1-12 of this guide. 1. Press the Envelope Feeder loading switch to lower the feeder tray ready for loading. 2.
Operator Functions • 3 4. Place the stack of envelopes into the feeder with the flap side up and flap last. 5. Press the Envelope Feeder loading switch again to raise the envelope stack to the normal feeding position. TIP: To quickly load envelopes during a run, without the need to stop and start the machine... • • • Press the Envelope Feeder loading switch to lower the feeder tray. Load envelopes as described above. Press the Envelope Feeder loading switch again.
3 • Operator Functions Setting the Insert Feeder(s) Insert Feeders F and G feed items that do not require folding by the machine. Depending on configuration, your machine may have no Insert Feeders, one Insert Feeder or two Insert Feeders. Insert Feeder F is capable of feeding thicker Inserts than Insert Feeder G. Therefore, booklets must only be fed from Feeder F. The Mail Piece Icon Tree for the job being run will show if the feeder needs to be loaded and the Insert orientation.
Operator Functions • 3 4. Set the blue separator shield lever to the letter required. 5. Take the stack of inserts and fan it to ensure individual Inserts are not stuck together. 6. ‘Shingle’ the inserts to be run so that they look like the photograph on the right and place them onto the feed deck. The Mail Piece Icon Tree will show the correct orientation of the Inserts. 7. Let the Wedge slide down behind the stack so that the Inserts are supported.
3 • Operator Functions Filling the Envelope Sealer Make sure the Envelope Sealer is filled with sealing solution before running a job that has sealing turned on. When the sealer needs refilling, a warning message will automatically appear on the display and, if sealing, the sealing icon will flash. Add sealing solution (EZ-Seal™ is recommended) in the following way: Hinge open the Sealer Bottle Cover located at the front right hand side of the machine. Remove the bottle.
Operator Functions • 3 Menu Select the Menu Screen Key to access the following Operator Options within the menu structure: • • • • Language Display Adjustments Safe Seal System Information Language When this option is selected, a choice of languages will be displayed. Choose the required language from the list and all display text will change to the selected language. This is a temporary setting. Switching the machine Off and then back On will revert to the default language.
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4 • Supervisor Functions This chapter lists the functions that can be carried out by a Supervisor. Primarily this includes creating, editing and deleting jobs. About this Chapter ............................................................. 4-2 Supervisor Access Code ................................................... 4-2 Create Job ......................................................................... 4-3 Edit Job .............................................................................
4 • Supervisor Functions About this Chapter This chapter describes the functions available within the Supervisor Functions menu. All of the functions are set by following a sequence of screens and answering simple questions presented on the display. Therefore, this chapter does not take you through every function step by step. It gives you background information on the function and offers helpful tips to get the best out of your machine.
Supervisor Functions • 4 Create Job What is it? This function allows a Supervisor to create new Job Definitions to be stored within the machine’s memory for easy access by an Operator. The machine can store a maximum of 20 Job Definitions. Where is it? From the Home Screen...
4 • Supervisor Functions Edit Job What is it? Edit Job allows a Supervisor to add and delete items within an existing Job Definition. It also lets a Supervisor alter the job setup such as batch count, job comments and job name. The Edit Job function is used to change a Job Definition, and so always over-writes the original Job Definition in the machine’s memory (even if the Job Name has been edited).
Supervisor Functions • 4 TIPS: Highlight the Job Name to edit the following items: Job Name Job Comments Batch Counter Maximum Sheet Length OMR set up Highlight the Envelope icon to edit envelope and sealing settings. The Outer Envelope and First sheet cannot be added or deleted. Don’t forget to edit the job comments to correspond to your revised job setup! When editing a job, it is recommended that you start at the top of the Mail Piece Icon Tree and work downwards. OMR jobs cannot utilise linked feeders.
4 • Supervisor Functions Create From What is it? A Supervisor can use the Create From function to create a NEW Job Definition which is SIMILAR to an existing job and leave the existing Job Definition untouched. This can save time programming a new Job Definition when it is almost identical to an existing job but for a small change such as an extra Insert or Sheet, etc. The machine will copy the existing Job Definition and ask for the new job to be named.
Supervisor Functions • 4 Delete Job What is it? Delete Job allows a Supervisor to remove a stored Job Definition permanently from the machine’s memory. Where is it? From the Home Screen... select Menu select Supervisor Functions enter the Supervisor Access Code (see page 4-2) select Delete Job Action… Once Delete Job has been selected, choose the Job Definition you wish to delete from the alphabetical job list using the ▲▼◄► keys in the normal way.
4 • Supervisor Functions OMR Menu This function lets a Supervisor setup Optical Mark Recognition (OMR) codes for inclusion within Job Definitions. All OMR functions are explained fully within Chapter 5 - OMR. System Menu What is it? This menu lets a Supervisor adjust the following system setting: Manual Feed Option Where is it? From the Home Screen...
5 • Optical Mark Recognition (OMR) This chapter gives background and setup information for using Optical Mark Recognition (OMR) on a machine equipped with the OMR option. OMR Availability ................................................................ 5-2 What is OMR? ................................................................... 5-2 OMR Marks Available ........................................................ 5-3 OMR Mark Options ............................................................
5 • Optical Mark Recognition (OMR) OMR Availability Your machine can be equipped with Optical Mark Recognition (OMR) functionality either on installation or as an added option after purchase. The machine can store up to 10 different codes for you to select when creating Job Definitions that use OMR. What is OMR? An OMR mark is normally a dark solid line on a sheet of light coloured paper that is perpendicular to the direction of travel of the paper.
Optical Mark Recognition (OMR) • 5 OMR Marks Available This section gives brief descriptions of the OMR Marks that can be allocated to an OMR Code and lists the options available for use with each mark. The section following, OMR Mark Options on page 5-6 then gives greater detail of each option. NOTE: Some marks within this section are available as added features which expand OMR capability. Contact your machine supplier for details. OMR features available will vary depending on the country you are in.
5 • Optical Mark Recognition (OMR) EOC - End of Collation This is a mandatory mark which indicates that it is the last sheet fed within the OMR set. This can only be selected once within the code and is the only mark used when using the Single Mark option. Options available: • Present or Absent STP - Stop This mark is a processing feature which tells the machine to stop once the completed Mail Piece has exited the machine.
Optical Mark Recognition (OMR) • 5 PAR - Parity This mark is a security feature, that when printed always makes the number of marks total an odd or even number. If any one of the marks within the code is missed during scanning, the machine will stop functioning, allowing the error to be rectified. No more than 1 Parity mark can be used within the code. Options available: • Odd or Even WAS - Wrap Around Sequence This is a numbering system which uses a sequential binary coding.
5 • Optical Mark Recognition (OMR) OMR Mark Options This section gives brief descriptions of the OMR Mark Options that can be allocated to relevant OMR marks. The previous section, OMR Marks Available on page 5-3 lists which options can be selected with each mark. Present or Absent When Present the machine will act upon scanning the relevant mark. When Absent the machine will act upon NOT scanning the relevant mark.
Optical Mark Recognition (OMR) • 5 Least or Most Significant Mark nearest to Benchmark This option gives the choice of orientation of the binary digit count within the relevant part of the OMR code. When Least Significant Mark is chosen, the mark within the relevant part of the code nearest to the Benchmark would be represented by the lowest binary digit within that part of the code.
5 • Optical Mark Recognition (OMR) OMR Specifications The mark must be a solid black line between 1pt and 2pts thick 1/64” (0.35mm to 0.7mm) and at least 3/8” (10mm) wide. Each mark position must be evenly spaced and at least 1/10” (2.54mm) apart. The maximum amount of mark positions allowed within the code is 24; this includes ignored marks. The total length of the OMR code should not exceed 2-3/4” (70mm).
Optical Mark Recognition (OMR) • 5 LEADING EDGE 3/4” (20mm) min 2-3/8” (59mm) min 4-3/4” (108mm) max 1/8” (3mm) min 2-3/8” (59mm) min 4-3/4” (108mm) max 1/8” (3mm) min Place marks in this area for: Place marks in this area for: C/Double Fold Rear Top Scanner C/Double Fold Front Top Scanner Single/Z Fold Rear Bottom Scanner Single/Z Fold Front Bottom Scanner 1-3/16” (30mm) min The white areas in the diagram show the possible areas where OMR marks can be placed and depend on the physical location of
5 • Optical Mark Recognition (OMR) Creating, Deleting and Viewing OMR Codes The OMR Menu contains functions which allow a Supervisor to create, delete and view OMR Codes.
Optical Mark Recognition (OMR) • 5 Create New OMR Code This function lets a Supervisor create a new OMR code to be stored in the machine’s memory so that it can be used when creating a Job Definition that uses OMR. Action… Select Create New OMR Code from the OMR Menu screen and the machine will ask if you are creating a Single Mark or Multi-Mark Code: If Single Mark is selected... The machine automatically assigns the End of Collation mark as this is the only ‘single mark’ the machine uses.
5 • Optical Mark Recognition (OMR) The Benchmark is a mandatory mark and must be either the first or last mark within the code. The End of Collation Mark is the only other mandatory mark and so must also be selected, but it can be placed anywhere within the code. If either of the mandatory marks are not selected, the Finish screen key will not be activated. After all the required marks have been entered, select the Finish screen key. You will now be asked to name the OMR code.
Optical Mark Recognition (OMR) • 5 Delete OMR Code This function lets a Supervisor delete a current OMR code which is stored in the machine’s memory. Action… Select Delete OMR Code from the OMR Menu screen. A list of all the current OMR Codes will be displayed. Select the OMR code you wish to delete from the list using the ▲▼◄► keys in the normal way. Once selected, a message will be displayed asking you to confirm that you want to delete the selected code. Either... • • Select Yes to confirm deletion.
5 • Optical Mark Recognition (OMR) View OMR Code This function lets a Supervisor view any current OMR codes, which are stored in the machine’s memory. Action… Select View OMR Code from the OMR Menu screen. A list of all the current OMR Codes will be displayed. Select the OMR code you wish to view from the list using the ▲▼◄► keys in the normal way. The highlighted OMR code will then be displayed on the left side of the screen.
Optical Mark Recognition (OMR) • 5 Creating an OMR Job Before you Start Before creating a Job Definition using OMR, make sure that the required OMR code has been set up as described in Create New OMR Code on page 5-11. Setting the Type of OMR During the Create Job process, the machine will ask whether OMR is being used within the job being programmed. If you reply yes, you must select the type of OMR code you wish to use: Selective Feed or Non Selective Feed.
5 • Optical Mark Recognition (OMR) Defining the first mark position and code length Take a sheet that has at least the FIRST and LAST OMR mark printed on it. When requested by the machine, measure and enter the distance (A) from the top edge of the sheet to the FIRST OMR mark, in millimetres. Again, when requested by the machine, measure and enter the distance (B) from the FIRST OMR mark to the LAST OMR mark, in millimetres. TOP OF SHEET A B 5-16 SV40221 Rev.
Optical Mark Recognition (OMR) • 5 Defining the Clear Zone When requested by the machine, measure and enter the distance (A) from the top edge of the sheet to the point after the printed matter where you wish the machine to START scanning. Again, when requested by the machine, measure and enter the distance (B) from the start point just set, to the point you wish the machine to STOP scanning. This is called the Clear Zone.
5 • Optical Mark Recognition (OMR) OMR Scanner Adjustments The machine can be fitted with one Top Scanner and one Bottom Scanner. If the sheet(s) bearing OMR marks are loaded face up, the Top Scanner will be used. If they are loaded face down, the Bottom Scanner will be used. The loading orientation required for the particular job will be shown on the Mail Piece Icon Tree and depends on fold type, etc.
Optical Mark Recognition (OMR) • 5 Setting the Top Scanner Position This scanner position is used for C and Double Folds. Open the Top Cover and locate the blue Top Scanner adjusting knob and adjustment scale for the side the scanner is fitted. Rotate the adjusting knob until the indicator is aligned with the measurement (X) you just made. The Top Scanner will now be aligned.
5 • Optical Mark Recognition (OMR) Setting the Bottom Scanner Position This scanner position is used for Z and Single Folds. Open the upper central front door and locate the blue Bottom Scanner adjusting knob and adjustment scale. Rotate the adjusting knob until the indicator is aligned with the measurement (X) you just made. The Bottom Scanner will now be aligned. Bottom Scanner Adjusting Knob Adjustment Scale Indicator 5-20 SV40221 Rev.
Optical Mark Recognition (OMR) • 5 Once the Bottom Scanner is aligned, the Top Scanner (or paper guide if a corresponding Top Scanner is not fitted) must be positioned so that the sheet being scanned is kept at a controlled distance from the scanner. This is achieved by adjusting the Top Scanner as described on page 5-19, but to a setting 10mm (3/8”) different to the Bottom Scanner setting. For example, if the Bottom Scanner is set to 70mm, set the Top Scanner to 80mm.
5 • Optical Mark Recognition (OMR) 5-22 SV40221 Rev.
6 • Troubleshooting Refer to this chapter if you have problems with your machine. Troubleshooting Tips ......................................................... 6-2 General Troubleshooting ................................................... 6-3 Machine ...................................................................... 6-3 Envelopes ................................................................... 6-4 Sheets ......................................................................... 6-5 Inserts ........
6 • Troubleshooting Troubleshooting Tips In most cases, the machine will generate an Error Message when a problem occurs, and the display will offer advice on how to rectify the problem immediately. An on-line guide is also available in many countries. Press the Help key and use the Screen Keys to select the information you require. This Operating Guide contains additional troubleshooting information which, with the troubleshooting sources above, should resolve most problems.
Troubleshooting • 6 General Troubleshooting Problem Remedy Page MACHINE Blank Screen No power. Check power cord is firmly connected and wall socket is switched ON. 3-2 Machine not switched ON. Turn power switch (located on lower front) ON. 3-2 Display adjustment Reset the Display Adjustment to an set incorrectly. acceptable setting. 3-19 Performance Machine runs slowly. Is Safe Seal selected? ( icon in Icon Tree).
6 • Troubleshooting Problem Remedy Page ENVELOPES Poor Envelope Feed Envelope side guides set incorrectly. Set guides to envelope width and back off 1/4 turn. Poor envelope quality. Check envelopes are not curled. Try a new box of envelopes. Make sure stack has been fanned before loading. Envelopes loaded incorrectly. Load envelopes flap side up with the flap feeding last. 3-14 3-14 3-15 Envelopes Fail to Open Envelopes loaded incorrectly. Load envelopes flap side up with the flap feeding last.
Troubleshooting • 6 Problem Remedy Page SHEETS Poor Sheet Feed Sheet Feeder side guides set incorrectly. Set guides to Sheet width and back off 1/4 turn. 3-12 Sheets loaded incorrectly. Make sure stack has been fanned before loading. 3-12 Multiple sheets feed when one is expected Sheet Feeder is programmed to feed a PreCollated Set. Check Mail Piece Icon Tree to see if relevant feeder is set to feed precollated sets.
6 • Troubleshooting Problem Remedy Page INSERTS Poor Insert Feed Insert Feeder side guides set incorrectly. Set guides to Insert width and back off 1/4 turn. 3-16 Insert Feeder separator adjustments incorrect. Make sure the two Insert Feeder adjustments (number and letter settings) are set correctly for the type of Insert being run. 3-16 Inserts loaded incorrectly. Make sure stack has been fanned before loading. Changing the orientation of the Insert stack may help.
Troubleshooting • 6 Problem Remedy Page DOUBLE DETECT The machine keeps turning Double Detect OFF Double Detect cannot calibrate itself properly. Double Detection might not be possible with certain very thick or heavily printed material. Either change material or choose to run with Double Detect OFF. Machine stops for ‘doubles’ that aren’t there or feeds ‘doubles’ without stopping Double Detect is not turned ON. Check Double Detect status.
6 • Troubleshooting Clearing Material Stalls Your machine has been designed to assure maximum performance. In the event of a material stall, the display will indicate where the stall has occurred and will suggest remedial action. First press Clear Deck to attempt to feed the material through the machine. If not successful, the sections below tell you how to gain access to the material.
Troubleshooting • 6 Removal & Replacement of the Sheet Feeder Trays A to D To remove… Lift the rear of the tray slightly and pull it straight outwards from the machine. Note: If the tray is loaded, gently hold the material in place to prevent it sliding forward as the tray is removed. To replace… Place the tray into its location guides in the side frames. Lift the rear of the tray slightly and push it into the machine. The tray will automatically drop into its correct location.
6 • Troubleshooting Access to Internal Areas 1 to 5 If material stalls within the internal areas of the machine, the display will indicate an area or areas (labelled 1 to 5) where the stalled material is located. Open both central front doors and the access points, as shown below, will be exposed. 3 4 5 2 1 The illustrations on the next page show each area in more detail... 6-10 SV40221 Rev.
Troubleshooting • 6 Area 1 Area 2 Pull upwards to unlatch. Relatch by pressing assembly firmly down at the center. Rotate clockwise to unlatch. Relatch by rotating lever fully counterclockwise. Area 3 Area 4 Rotate counterclockwise to unlatch. Push assembly back into position and relatch by rotating lever fully clockwise. Rotate counterclockwise to unlatch. Push assembly back into position and relatch by rotating lever fully clockwise. Area 5 Rotate clockwise to unlatch.
6 • Troubleshooting Access to Area 6 Area 6 is located under Sheet Feeder D, where envelopes are fed into the system. Therefore, before access can be gained to a material stall in this area, Sheet Feeder Tray D should be removed as described on page 6-9. Once the tray is removed, access to stalled material can be gained by unlatching the lever shown in the illustration above. Access to Areas 7 and 8 Areas 7 and 8 are located at the inner ends of the Insert Feeders F and G.
Troubleshooting • 6 Access to the Removeable Paper Path (under Insert Feeder F) This removeable plate is located immediately below Insert Feeder F. Therefore, before access can be gained to a material stall in this area, Insert Tray F must be removed as described on page 6-9. Access can be gained by lifting the blue handle and then pulling the plate outwards. When refitting the plate, make sure it is fully latched into position.
6 • Troubleshooting Access to the Envelope Exit Area Pull down the envelope exit area door, as shown, to gain access to stalled material. When closing the door, make sure it is firmly latched into position. Access to the Envelope Inserting/Sealing Area Access can be gained to the insertion and sealing areas by lifting the plastic cover and lowering the envelope exit area door. Points arrowed in the illustration can be unlatched to allow access to stalled material. 6-14 SV40221 Rev.
Troubleshooting • 6 Envelope Stop Position This function lets you adjust the position where the Outer Envelope is held, waiting for material to be placed into it. It is accessed by running a Trial Piece and replying ‘No’ when asked if the Trial Piece is OK. This adjustment will only be needed in unusual situations where material is not being placed fully into the envelope, or is being driven too far, causing damage to the envelope or material. The Envelope Stop has five positions...
6 • Troubleshooting 6-16 SV40221 Rev.
7 • Reference This chapter lists the specifications of your machine and describes operations that may only need to be carried out occasionally. Specifications .................................................................... 7-2 Sheet Feeders ............................................................ 7-2 Fold Type and Overall Thickness Limits ..................... 7-3 Insert Feeders ............................................................. 7-4 Envelope Feeder ......................................
7 • Reference Specifications Sheet Feeders A, B C and D Minimum sheet size: 5" (127mm) Width (non OMR) 8" (203mm) Width (with OMR) 6-7/8" (175mm) Length Maximum sheet size: 9" (229mm) Width 16" (406mm) Length Paper weights: 16 lb. (60g/m2) Minimum (non OMR) 20 lb. (75g/m2) Minimum (with OMR) 32 lb.
Reference • 7 Fold Type and Overall Thickness Limits The table below shows the maximum number of sheets up to 12" (305mm) in length that can be accumulated or collated for each fold type, based on different weights of paper. It is important that jobs exceeding these maximums are NOT programmed into the machine or imposed by OMR code printing and/or OMR selective feed. Paper Weights in lbs.
7 • Reference Insert Feeders F and G Minimum Insert size: 5" (127mm) Width 3-1/4" (82mm) Depth Maximum Insert size: 9" (230mm) Width 6" (152mm) Depth Paper Weights: 20 lb. (75g/m2) Minimum (single sheet/slip) 16 lb. (60g/m2) Minimum (folded material) 48 lb. (180g/m2) Maximum (single sheet/slip) Maximum compressed thickness of insert: .08" (2mm) from feeder F .06" (1.5mm) from feeder G Double Detect material range: 16 lb. (60g/m2) Minimum 32 lb.
Reference • 7 Envelope tray capacity: Up to a maximum of 300, 26 lb. (90g/m2 ) envelopes End Clearance: End clearance between the Insert and envelope is a minimum of 1/4" (6mm) at each side (i.e., a minimum of 1/2" [12mm] overall). This measurement should be taken with all Mail Piece contents placed into the envelope.
7 • Reference Envelope Sealer The machine can seal up to a maximum of 3,000 envelopes between refills. Drop Stacker The Drop Stacker can accommodate up to 150 Mail Pieces. (This is dependent on the size and contents of the envelope). Material Requirements For best performance, use only materials approved by your machine supplier. Materials should be good quality and properly stored.
Reference • 7 Machine Specifications Physical Dimensions Length Depth Height Minimum Weight Maximum Weight 54" (1370mm) 22-1/2" (570mm) 30" (760mm) 194 lbs. (88kg) 225 lbs. (102kg) Weight will depend on machine configuration. Weights stated do not include material. Noise Level Running 72dBA - 74dBA Electrical AC Input AC Output 100VAC - 240VAC, 50/60Hz, 10A 100VAC - 240VAC, 50/60Hz, 4A Maximum Speed: 3600 or 4000 cycles per hour, depending on model, fold type and material quality.
7 • Reference Changing the Envelope Sealer Unit Felts The sealer unit felts are supplied as part of a kit and can be changed by the operator in the following way: 1. Hinge open the Sealer Bottle cover located at the front right hand side of the machine. Remove the Sealer Bottle. 2. Remove the Insert Trays (see page 5-9). Lift the insertion area plastic cover and open the envelope exit area access door. 3.
Reference • 7 4. Push the latch (A) back. Grasp the upper sealer felt (B), slide it towards the front of the machine and remove it from its mounting bar. Discard this old felt. A B 5. Fit the new upper felt. Locate the tabs on the back of the felt assembly into the corresponding holes in the mounting bar and slide the felt towards the rear of the machine. Make sure it has fully latched into position. 6. Using the plastic tweezers provided in the kit, remove all four felts from the Sealer Tank.
7 • Reference 8. Push down on the blue tab to return the upper felt assembly to its operating position. Make sure that the blue latches (A) spring out and fully latch into position. A 9. Refit the Sealer Bottle and close the covers. The felts will take a few minutes to become fully wet and ready for use. Service Service for your new Folding/Inserting machine is available throughout the world.
Index A Additional Sheet or Additional Set 1-14 Automatic Processing 3-4, 3-5, 3-8 B Batch Count 3-5 Beginning of Collation (BOC) for OMR 5-3 Benchmark (BM) for OMR 5-3, 5-12 Blue separator gap lever 3-16 Blue separator shield lever 3-17 C Cancel Button 1-8 Changing the Envelope Sealer Unit Felts 7-8 Clear Deck Button 1-9 Clear Zone (for OMR) 5-8 Common Terms 1-14 Configurations, Machine 1-4 Connecting Power 3-2 Control Panel 1-8 Cancel Button 1-8 Clear Deck Button 1-9 Description 1-6 Help Button 1-8 Home
Index D Daily Mail Feeder.
Index I Ignore (IGN) for OMR 5-5 Insert 1-15 Insert Feeder(s) Blue separator gap lever 3-16 Blue separator shield lever 3-17 Description 1-7 Setting the Insert Feeder(s) 3-16 Side Guide Adjustment Knob 3-16 Specifications 7-4 Wedge 3-17 Insert Icons 1-12 Insert Tray(s) Removal & Replacement 6-9 Instructional Text 2-3 J Jobs Automatic Processing 3-4, 3-5 Create Job 4-3 Creating an OMR Job 5-15 Delete Job 4-7 Edit Job 4-4 Envelope Stop Position 6-15 Job Comments 4-5 Job Definition 4-6 Job Definitions 3-3 Job
Index M Machine, Parts Of 1-6 Machine Status 2-3 Machine Configurations 1-4 Machine Graphic 2-3 Machine Identification 1-6 Machine Specifications 7-7 Mail Piece 1-15 Mail Piece Icon Tree 1-10, 2-3, 3-3 Definition 1-16 Double Detect 1-11 Envelope Icons 1-12 Example 1-13 Fold Icons 1-12 Insert Icons 1-12 Linked Feeders 1-11 Loading Instructions 1-10 Mail Piece Icon Tree Icons 1-11 Optical Mark Recognition (OMR) 1-11 Other Icons 1-12 Pre-Collated Sets 1-11 Seal Icons 1-12 Sheet Icons 1-12 Mail Piece Icon Tree
Index Menu, Operator Functions 3-19 Display Adjustments 3-19 Language 3-19 Safe Seal 3-19 System Information 3-19 Menu, Supervisor Functions 4-2 Create From (jobs) 4-6 Create Job 4-3 Creating, Deleting and Viewing OMR Codes 5-10 Creating an OMR Job 5-15 Delete Job 4-7 Delete OMR Code 5-13 Edit Job 4-4 Job Comments 4-5 Job Name 4-5 OMR Menu 4-8 Supervisor Access Code 4-2, 6-15 System Menu 4-8 View OMR Code 5-14 Menu Structure 2-4 Multi-Mark 5-2 N Name of selected Job 2-3 Navigation Keys 1-9, 2-2 O OMR (Opt
Index End of Collation (EOC) 5-4, 5-12 Ignore (IGN) 5-5 Include Zero or Omit Zero (0) as a Value 5-6 Increment or Decrement 5-6 Least or Most Significant Mark nearest to Benchmark 5-7 Marked Piece to be left Unsealed (Yes or No) 5-7 Multi-Mark 5-11 Odd or Even 5-7 OMR Availability 5-2 OMR Mark Options 5-6 OMR Scanners 5-9 OMR Scanner Adjustments 5-18 OMR Specifications 5-8 Parity (PAR) 5-5 Present or Absent 5-6 Safety (SAF) 5-3 Select Feed (SF(n)) 5-4 Setting Bottom Scanner 5-20 Setting the OMR Scanning Are
Index R Removal & Replacement Access to Areas 7 and 8 6-12 Access to Area 6 6-12 Access to Internal Areas 1 to 5 6-10 Access to the Envelope Exit Area 6-14 Access to the Envelope Inserting/Sealing Area 6-14 Access to the Removable Paper Path (under Insert Feeder F) 6-13 Access to the Top Cover (Sheet Feed Area) 6-13 Insert Tray(s) F and G 6-9 Sheet Feeder Trays A to D 6-9 Reset Counters 1-8 Reset Counters Button 3-4 Running a Job 3-3 Running a Trial Piece 3-4 S Safety 1-2 Safety (SAF) OMR 5-3 Safe Seal 1-1
Index Sheet Feeders Explanation 1-6 Linking 3-17 Removal & Replacement of Trays 6-9 Setting the Sheet Feeders 3-12 Specifications 7-2 Sheet Icons 1-12 Shingle 1-15 Side Guide Adjustment Knob 3-14 Single Mark 5-2 Specifications 7-2 Fold Type and Overall Thickness Limits 7-3 Insert Feeders 7-4 Machine 7-7 Material Requirements 7-6 Sheet Feeders A, B C and D 7-2 Stack 1-14 Startup Screen 3-3 Start Button 1-9 Stop (STP) for OMR 5-4 Stop Button 1-9 Supervisor Access Code 4-2, 6-15 Supervisor Functions 2-5 Suppor
Index T Timing (TM) for OMR 5-5 Trial Piece 1-16, 3-10 Running a Trial Piece 3-4 Trial Piece Button 1-9 Troubleshooting 6-2 Clearing Material Stalls 6-8 Double Detect 6-7 Envelopes 6-4 Inserts 6-6 Machine 6-3 Sheets 6-5 Tips 6-2 W Wedge 3-17 Wrap Around Sequence (WAS) for OMR 5-5 SV40221 Rev.
Index I-10 SV40221 Rev.
1 Elmcroft Rd. Stamford, Connecticut 06926-0700 www.pitneybowes.com PB Form SV40221 Rev A (9/04) Printed in the USA or Canada Printed on recyclable paper *SV40221REVA* 5500 Explorer Drive Mississauga, Ontario L4W5C7 www.pitneybowes.
