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Pitney Bowes D1500 User's Manual

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1. 08 6 13 Access to Top Cover Sheet Feed Area 08 6 13 Access to Envelope Exit Area cseeeeeeeeees 6 14 Access to Envelope Inserting Sealing Area 6 14 Envelope Stop Position cccccceceeeeeeeeeeeeeteees 6 15 SV40221 Rev A iii Table of Contents Chapter7 Reference Index Specifications ecccecececcceceeeeeeeeeeeeeeeeeceeeeeeeeeeeeeeeeeeees 7 2 Sheet Feeders 0 0 0 0 ccccceccececeeeeeeeeeeececeeeeeeeeeeeeseeeeenenes 7 2 Fold Type and Overall Thickness Limits 7 3 Insert Feeders ts a ee daca 7 4 Envelope Feedet 2 c ccccecccceeeeeeeeeeeeneccaneeeeeeees 7 4 Envelope Seallev 2 cccecccececeeeeeeeeeeeecsuneeeeeeees 7 6 Drop Stacker eicceec tees ves ntveeddiee deed toed eh eed 7 6 Material Requirement ccccccceeeeeeeeeeeeeteeeeeeees 7 6 Machine Specifications 0 cccccceeeeeeeeeeeeseeteeeeeeees 7 7 Changing the Envelope Sealer Unit Felts ee 7 8 SENCE eee et tats el eae dete dust a a ae 7 10 l i SV40221 Rev A 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 onl
2. 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 A feeder assignment letter A to G will be placed Qo alongside the Mailing Object Icon to indicate which feeder the object should be loaded into Two or more feeder assignment letters alongside a single Mailing Object Icon indicate that linked feeders Q have been selected The item should be loaded in Q all the feeders indicated When one feeder becomes empty feed will automatically switch to the next linked feeder and so on in a continuous cycle iid If Double Detect is in use the Double Detect Icon will Q appear immediately to the left of the relevant Mailing B Collated Set Object Icon A e On an Optical Mark Recognition OMR job a Q variable number of pages might be fed under control of the OMR marks and so a small letter n will appear in place of the number Also an asterisk will be displayed in the Mail Piece Icon Tree to remind you that the job is an OMR job If any Sheet Feeder s are programmed to feed Pre Collated Sets multiple sheets a modified ico
3. Fan 1 15 Features Machine 1 3 Fold Icons 1 12 Fold Type 1 14 Fold Type and Overall Thickness Limits 7 3 H Help Button 1 8 Help Desk iii Home Button 1 9 Home Screen 1 16 2 2 2 3 l 2 SV40221 Rev A Index 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 amp 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 Name 4 5 Running a Job 3 3 Selecting a Job 3 3 Startup Screen 3 3 Job Comments 4 5 Job Definition 1 16 4 6 Job Definitions 3 3 Job Name 4 5 L Language 3 19 Linked Feeders 1 11 1 16 Loading Instructions 1 10 SV40221 Rev A l 3 Index 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
4. Machine 6 3 Sheets 6 5 Tips 6 2 WwW Wedge 3 17 Wrap Around Sequence WAS for OMR 5 5 SV40221 Rev A Index Index l 10 SV40221 Rev A z PitneyBowes Engineering the flow of communication 1 Elmcroft Rd Stamford Connecticut 06926 0700 www pitneybowes com PB Form SV40221 Rev A 9 04 Printed in the USA or Canada te Printed on recyclable paper SV40221 Ax O221REV S 5500 Explorer Drive Mississauga Ontario L4W5C7 www pitneybowes ca
5. Safety 1 2 Safety SAF OMR 5 3 Safe Seal 1 16 3 19 Scanners 5 9 Aligning the Scanners 5 18 Setting Bottom OMR Scanner 5 20 Setting Top OMR Scanner 5 19 Screen Name 2 3 Screen Keys 1 9 Screen Key Selections 2 3 Sealer Bottle Description 1 7 Sealer Bottle Cover 3 18 Seal Icons 1 12 Selecting a Job 3 3 Select Feed SF n for OMR 5 4 Service Information iii 7 10 Sheet Description 1 14 SV40221 Rev A l 7 Index Sheet Feeders Explanation 1 6 Linking 3 17 Removal amp 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 Support Information iii Support Web Sites iii SwiftStart 3 6 Constraints and Requirements 3 6 Folds 3 7 Loading Envelope Feeder 3 7 Loading Insert Feeder s 3 7 Loading Material 3 6 Operation 3 8 Saving a SwiftStart Job 3 8 System Information 3 19 System Menu 4 8 Manual Feed Options 4 8 l 8 SV40221 Rev A 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
6. When on the Safe Seal icon amp appears on the Mail Piece Icon Tree alongside the Outer Envelope icon Safe Seal allows more time for moisture to soften the gum on the Outer Envelope allowing it to become more sticky This function therefore improves sealing of certain types of envelope but will slow the machine down System Information This screen displays information such as machine serial number your local service and supplies telephone number software versions and total item count SV40221 Rev A 3 19 3 Operator Functions 3 20 SV40221 Rev A 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 c cccecccececeeeeeeeeeeeeceneeeeeeeeeneess 4 2 Supervisor Access Code cc eeeeeeeeceeceeeeeeeeeeeeteeeeeeeeee 4 2 Create JODis iinei eo aie a a ee a a 4 3 Edit JOD anana eis hae ee ite ee 4 4 Create From niies ie eiiiai abrea tera arin nde 4 6 Delete JOD ornina iin ia a edie 4 7 OMR Men maii aein aiaee oiee nadae ade iaaea 4 8 System Men eiee reiia ee tle eee 4 8 Manual Feed Option cccccceeceeeseeeeesetceeeeeeeeeeees 4 8 SV40221 Rev A 4 1 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 a
7. them as described in the previous sections Some marks will disappear once selected as they can only be used once within the code Other marks can be used multiple times and so will remain available in the list Once a mark is selected a representation with its abbreviation will appear on the left hand side of the screen If you press Cancel whilst in this screen the last selected mark will be removed SV40221 Rev A 5 11 5e 5 12 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 Once the name of the code has been entered correctly select the Save screen key to save the code within the machine s memory TIPS The representation of the OMR mark on the left hand side of the screen will display as a dashed line if the Absent option is selected Up to 9 characters can be used to name an OMR code 10 codes can be stored in the machine s memory All codes to be saved must be named No two codes can have the same name SV40221 Rev A Optical Mark Recognition OMR 5 Delete OMR Code
8. 1 11 Seal Icons 1 12 Sheet Icons 1 12 Mail Piece Icon Tree Icons 1 11 Manual Advance Knob 6 8 Description 1 7 Manual Feed 3 9 Constraints and Requirements 3 9 Feeding Further Sets 3 11 Folds 3 10 Loading Envelope Feeder 3 9 Loading Material for Manual Feed Mode 3 9 Operation 3 10 Trial Piece 3 10 Manual Feeder Description 1 7 Manual Feed Option 4 8 Material Requirements 7 6 Measuring Scale 1 7 l 4 SV40221 Rev A 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 Optical Mark Recognition 1 4 1 11 All Sheets Page 1 Only Last Page Only 5 7 Always Present or Never Present 5 7 Beginning of Collation BOC 5 3 Benchmark BM 5 3 5 12 Clear Zone 5 8 5 9 Continuous Sequence or Page 1 Reset 5 6 Create New OMR Code 5 11 Creating Deleting and Viewing OMR Codes 5 10 Creating an OMR Job 5 15 Defining the Clear Zone 5 17 Defining the first mark position and code length 5 16 Delete OMR Code 5 13 Description 1 16 SV40221 Rev A l 5 Index End of Collatio
9. Feeding multiple feeders can be linked to allow continuous operation OMR functionality storing up to 10 codes on models where OMR is enabled Load on the fly operation Manual Feed facility for occasional one off jobs SV40221 Rev A 1 3 1 Introduction Machine Configurations The following machine configurations are available depending on your local market e Two Sheet Feeders Only e Four Sheet Feeders Only e Two Sheet Feeders and One Insert Feeder e Two Sheet Feeders and Two Insert Feeders e Four Sheet Feeders and One Insert Feeder e Four Sheet Feeders and Two Insert Feeders Each feeder location has its own letter designation which remains the same irrespective of machine configuration Therefore machine configurations with less than the full complement of feeders will use feeder designations which are not in alphabetical sequence this is normal The processing speed will also vary depending on machine configuration See Specifications in Chapter 7 for further details The illustration on the next page shows feeder locations and designations In addition an Optical Mark Recognition OMR option can be added to any model This allows control of machine functions and Mail Piece make up by scanning material passing through the machine for machine readable marks OMR Marks For further information refer to Chapter 5 of this guide This guide covers all models If a function is dependent on m
10. Screen select Menu select Supervisor Functions enter the Supervisor Access Code see page 4 2 select Create Job Action The machine will ask you a number of specific easy to answer questions about the make up of the finished Mail Piece in order to create the Job Definition Some of the questions asked will be based on the answers previously given and so the sequence will vary from job to job As you create the job the Mail Piece Icon Tree will be built on the left side of the display This shows how to load material into each feeder Once the job is created named and any comments entered you must select Save to store it in the machine s memory TIPS Placing a job description in the job comments will make it easy for an Operator to select the correct job Use the Batch Counter if you want to automatically process a pre defined number of Mail Pieces When the Batch Count is complete the machine will stop allowing the Operator to empty the stacker Pressing Start will commence processing of the next batch If you are using OMR within a job an OMR code must be pre programmed into the machine s memory For details of programming OMR codes refer to Chapter 5 OMR jobs cannot utilise linked feeders SV40221 Rev A 4 3 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 s
11. e Ifyou need confirmation of the job details use the A and Y keys to scroll through the list As each job is highlighted the Mail Piece Icon Tree and Job Comments if entered will change to reflect the highlighted job When you are certain which job you want press the corresponding Screen Key to select it TIP In either case if the job you require is not on the first screen use the lt and gt keys to move to the screen containing the required job The selected job s Mail Piece Icon Tree will now be displayed This shows the job make up and the loading orientation of material in the feeders The message Trial Piece Required will be shown at the top of the display TIP Once a job is selected you can use the A and Y keys to scroll through the icons on the Mail Piece Icon Tree As each icon is highlighted loading instructions related to the particular item will be displayed SV40221 Rev A 3 3 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 Now run a Trial Piece as de
12. only e Sheet Feeders do not operate in this mode e The Envelope Sealer is always on except for the Trial Piece e The Batch Count is always off e Sets should contain sheets of the same length e This mode will not work with OMR Loading Material for Manual Feed Mode Loading Insert Feeder s Insert Feeder s will only operate if they have been enabled by a Supervisor using the Manual Feed Option explained on page 4 8 of this guide For a single Insert load Insert Feeder F For two Inserts load Insert Feeders F and G Booklets must be loaded into Insert Feeder F only and should be loaded with the binding edge first Pre folded Inserts should be fed with the open edge last Loading Envelope Feeder Envelopes are loaded into Envelope Feeder E flap side up flap last SV40221 Rev A 3 9 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 5 1 5 x 8 1 2 sheets inserted into a 6 x 9 envelope will only require a Single fold Sheets over 12 305mm long inserted into a 10 envelope wil
13. or both Insert Feeders are loaded with material when SwiftStart is selected the machine will feed the Inserts and make them part of the SwiftStart job For a single Insert load Insert Feeder F For two Inserts load Insert Feeders F and G Booklets must be loaded into Insert Feeder F only and should be loaded with the binding edge first Pre folded Inserts should be fed with the open edge last Loading Envelope Feeder Envelopes are loaded into Envelope Feeder E flap side up flap last SV40221 Rev A 3 7 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 During this process if the material in any of the feeders is too heavy the Double Detect for the relevant feeder s will be turned off automatically This will be indicated by a message on the display The machine will ask if the Trial Piece is OK If the Trial Piece is OK select Yes and follow the instructions in the section Saving a SwiftStart Job below If the Trial Piece is NOT OK select No and follow the on screen instructions to correct the error You can adjust the address position fold panel length and or th
14. 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 The envelope stack will rise to the normal feeding position and processing will continue automatically SV40221 Rev A 3 15 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 If you need help understanding the Insert icons refer to page 1 12 of this guide 1 Adjust the side guides to the width of the Inserts being fed using the Side Guide Adjustment Knob then back off 1 4 of a turn This will set the correct clearance between the guides and Inserts 2 Refer to the labels located on each Insert Feeder Match your insert type Slip Reply Envelope Pre Folded or Booklet with the relevant icon and colour indicator on each label Where a range of settings is indicated on the label the thicker the insert the higher the number or letter that should be selected i e The blue Booklet range runs from 6 to 9 and from C to D A
15. thin Booklet might be set to 6 or 7 and C whereas a thick booklet might need settings 9 and D to run effectively 3 Set the blue separator gap lever to the number required 3 16 SV40221 Rev A 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 Note If Insert Feeders F and G are linked running the same inserts make sure the lever settings in steps 3 and 4 are set the same on both feeders SV40221 Rev A 3 17 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 Unscrew the cap and fill the bottle with sealing solution EZ Seal Refit the cap and place the bottle
16. window or the front face of a windowless envelope Additional Sheet or Additional Set Additional sheet s or set s can be added to the Prime Sheet or Prime Set They will be fed from other Sheet Feeder s and are placed into the envelope behind the Prime Fold Type The style of fold to be applied C Fold Y also know as standard fold Z Fold Cc also known as accordion fold Single Fold 7 one fold applied usually folded in half Double Fold folded in half and then in half again SV40221 Rev A 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 J stapled and folded binding edge Slip A single thickness piece of paper or card Pre Folded Insert A sheet that has Fz been folded prior to loading and requires no further folding by the machine Outer Envelope The envelope which contains all the items placed into it by the machine Mail Piece A single assembled article of mail usually an envelope with correct contents Fan The process of flicking through a stack of material to separate the items prior to loading Shingle The method of loading Inserts into a feeder in a partially ov
17. z Pitney Bowes 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 Operation of this equipment in a residential area is likely to cause interference in which case the user will be required to correct the interference at his own expense Use only a shielded interface cable to operate this equipment with a printer or other peripheral device CAUTION Changes or modifications to this equipment not expressly approved by the party responsible for compliance Pitney Bowes could void the user s authority to operate the equipment Canada EMC Compliance This Class A digital apparatus complies with Canadian ICES 003 Cet appareil num rique de la classe A est conforme a la norme NMB 003 du Canada V40221 Rev A 9 04 2004 Pitney Bowes Inc All rights reserved This guide may not be reproduced in whole or in part in any fashion or stored in a retrieval system of any type or transmitted by any means electronically or mechanically w
18. 1 is programmed if relevant feeder is set to feed pre to feed a Pre collated sets Collated Set Correct loading or have Supervisor 4 4 correct Job Definition as necessary Address in wrong position in envelope window First Sheet Set Load First address bearing Sheet incorrectly loaded or Set in the correct orientation as shown by the Mail Piece Icon Tree Address Position Run a Trial Piece Say No to Trial 3 4 incorrectly set Piece OK and adjust the address position Poor Folding A fold is almost Run a Trial Piece Say No to Trial 3 4 corresponding with Piece OK and slightly change the a perforation on fold positions the sheet causing a box fold or third fold SV40221 Rev A 6 5 6 Troubleshooting Problem Remedy Page INSERTS Poor Insert Feed Insert Feeder Set guides to Insert width and back 3 16 side guides set off 1 4 turn incorrectly Insert Feeder Make sure the two Insert Feeder 3 16 separator adjustments number and letter adjustments settings are set correctly for the incorrect type of Insert being run Inserts loaded Make sure stack has been fanned 3 17 incorrectly before loading Changing the orientation of the Insert stack may help Insert Feeder Let the Wedge slide down behind 3 17 Wedge used the Insert stack to support it incorrectly Booklets not Booklets must only be run from 1 15 feeding correctly Insert Feeder F 3 16 Chec
19. 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 Cancel Press this key to take you back to the previous screen If you have made changes or defined settings on the screen you are cancelling these will be lost Multiple presses of the Cancel key will step you back through the screens you have visited until you get back to the Home Screen 1 8 SV40221 Rev A 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 If the job includes an Outer Envelope it will be unsealed so that the contents can be easily checked Clear Deck Press this key to drive the material through and out of the system It can be used to clear the machine ready for automatic operation after a stoppage has
20. EET 5 16 SV40221 Rev A 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 Note that setting the Clear Zone closer to the beginning and end of the OMR marks decreases the possibility of any poor print or imperfections on the material being interpreted as OMR marks Conversely setting the Clear Zone too close to the beginning and end of the OMR marks could cause problems if the position registration of the printing on the material varies A good guide is to limit the Clear Zone but always allow at least 3 4 20mm before and after the OMR marks TOP OF SHEET Grey area indicates printed matter on material SV40221 Rev A 5 17 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 Aligning t
21. ON AND ARE SUBJECT TO TEST SV40221 Rev A 7 3 7 Reference Insert Feeders F and G Minimum Insert size Maximum Insert size Paper Weights Maximum compressed thickness of insert Double Detect material range Insert feed tray capacity Envelope Feeder Minimum envelope size Maximum envelope size Envelope depths for SwiftStart and Manual Feed Envelope weights 7 4 5 127mm Width 3 1 4 82mm Depth 9 230mm Width 6 152mm Depth 20 Ib 75g m2 Minimum single sheet slip 16 Ib 60g m Minimum folded material 48 Ib 180g m Maximum single sheet slip 08 2mm from feeder F 06 1 5mm from feeder G 16 Ib 60g m Minimum 32 Ib 120g m Maximum Up to a maximum of 300 Inserts in each feeder dependent on thickness and weight of inserts 3 7 8 98mm Depth 8 5 8 220mm Width DEPTH 6 1 2 164mm Depth WIDTH 9 1 2 242mm Width 4 1 4 to 6 3 8 109mm 111mm 114mm 121mm 162mm 16 Ib 65g m Minimum 26 Ib 100g m Maximum SV40221 Rev A Reference 7 Envelope tray capacity Up to a maximum of 300 26 Ib 90g m 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 Depth Clearance The Mail Piece Contents must allow a minimum
22. R Availability c ccccccceeeeeeeeeeeeeceneeceeeeeeeeeeeeeeteees 5 2 What iS OMR ae a Taa aa aranna Taaa aai ea aeee iA 5 2 OMR Marks Available 0 ccccceeeseeeeeeeeceeeeeeeeeeeeeeteeeeees 5 3 OMR Mark Options isishini aannaaien a 5 6 OMR Specifications 00 cccccceeceeeeeeeeeececeeeeeeeeeeeeeteeeeeees 5 8 Creating Deleting and Viewing OMR Codes 5 10 Create New OMR Code 0 cceeeeeeeeeceeeceeeeeeeeeeeeeeneees 5 11 Delete OMR Cod Karhinen a aa aaa E 5 13 View OMR Code assyriernas aane a aaan 5 14 Creating AN OMR JObDinsioreissii dii rodini nainii a 5 15 OMR Scanner Adjustments 0 cccceeseeeeeeeeenteeeeeeenaaes 5 18 Chapter 6 Troubleshooting Troubleshooting TIpS sseeseesseseeeessesirssseerrnsseerrrssreerrssreeene 6 2 General Troubleshooting ccccccceeeteeeseeeneeeeeeeeneaeees 6 3 Machinen iiie oae aee ell aie an a aaa 6 3 Envelopes aeaee aa aa Ea Ea 6 4 SNGOUS erie ee a a aa eaa at 6 5 SEI E E TE E E A E EE 6 6 Double Detect nnrir eveia 6 7 Clearing Material Stalls cceeceeeeeeeeeeeeeeeeeeeeseeneeees 6 8 The Manual Advance Knob ccceeeeeeeeeteteees 6 8 Removal Replacement of Sheet Feeder Trays 6 9 Removal Replacement of Insert Tray s ee 6 9 Access to Internal Areas 1 to 5 eseese 6 10 ACCESS AO ACA Oyina nn e aE 6 12 Access to Areas 7 and 8 eeeeeeseeerrssrrres 6 12 Access to Removeable Paper Path
23. SV40221 Rev A 7 Reference This chapter lists the specifications of your machine and describes operations that may only need to be carried out occasionally Specifications arauera eereae are em aE a eet 7 2 Sheet FEGders orias Whe cet niaaa aA 7 2 Fold Type and Overall Thickness Limits 7 3 Insert FeederS eiii ea e ae tee Alaa 7 4 Envelope Feedet cccccceceeeeeeeeeeeenceneeeeeeeetees 7 4 Envelope Seallet 2 cccccccceceeeeeeeeeeeeeceeeeeeeeeeees 7 6 Drop Stacker iae tenes aetna 7 6 Material Requirement 0 ccccccceeeeeseseeceeeeeeeeeeees 7 6 Machine Specifications ccccceceeeeeeceeceeeeeeeeeees 7 7 Changing the Envelope Sealer Unit Felts 005 7 8 DONVICE te aces face er ace ttle E E E EAA 7 10 SV40221 Rev A 7 1 7 Reference Specifications Sheet Feeders A B C and D Minimum sheet size Maximum sheet size Paper weights Fold configurations Single fold C fold Z fold Double fold Double Document Detector Material range Sheet Feed tray capacity Manual Feed mode 7 2 5 127mm Width non OMR 8 203mm Width with OMR 6 7 8 175mm Length 9 229mm Width 16 406mm Length 16 Ib 60g m Minimum non OMR 20 Ib 75g m Minimum with OMR 32 Ib 120g m Maximum Sheet length limits before folding 6 7 8 12 175mm 305mm 9 1 2 13 5 8 242mm 347mm 9 1 2 13 5 8 242m
24. Sise aan besa esac aes 6 4 SNE CIS kisi eee ese ee aes aga Ped Sara tetas 6 5 a tee EE EE AA eal ean ett 6 6 Double Detect cccecececeeceeeeeeeeeeeseeeeenceaeeeeeeenees 6 7 Clearing Material Stalls 2 0 00 eceeeeeeeeeeeeeeeeeeeeeeeeneeees 6 8 The Manual Advance Knob c cccceeeeeeteteeeeeeee 6 8 Removal and Replacement of Sheet Feeder Trays 6 9 Removal and Replacement of Insert Tray s 6 9 Access to Internal Areas 1 to 5 ceseeeeeeeeteteees 6 10 Access to Alea 0 v 22 tet rise het ated 6 12 Access to Areas 7 and 8 0 ccceeeeeeeecttceeeeeeeeeeetees 6 12 Access to Removeable Paper Path 8 6 13 Access to Top Cover Sheet Feed Area 6 13 Access to Envelope Exit Area csceeeeeteeteees 6 14 Access to Envelope Inserting Sealing Area 6 14 Envelope Stop Position cccccceeeeeeeeeeeeeseneeeeeees 6 15 SV40221 Rev A 6 1 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 If problem
25. SwiftStart can be used as a way to quickly program a new Job Definition Load material and run SwiftStart A Supervisor can save the new job and then use the Edit Job function see page 4 4 to make minor changes if necessary Constraints and Requirements e Only use closed flap envelopes e Feeds only single sheets from each Sheet Feeder e This mode cannot be used to run fold only or inserts only e You cannot link Sheet Feeders in this mode e The Envelope Sealer is always on except for the Trial Piece e The Batch Count is always off e The Maximum Sheet Length is 11 e Can run 10 and 6 x 9 sized envelopes e This mode will not work with OMR Loading Material for SwiftStart Loading Sheet Feeders Depending on your envelope depth the machine will automatically select the fold type Single or C standard fold For example an 8 1 2 x 11 sheet inserted into a 10 envelope will receive a C fold whereas a 8 1 2 x 11 sheet inserted into a 6 x 9 envelope will only require a Single Fold 3 6 SV40221 Rev A 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 Loading Insert Feeder s If either
26. The process of controlling machine functions and Mail Piece make up by scanning material passing through the machine for machine readable marks OMR Marks SV40221 Rev A 2 Using the Menus This chapter explains the Home Screen and the menu structure accessed via the PacPilot Control Panel The Home SCreeni citviccieie et tind ivi es vided eeeae eb 2 2 The Menu Structure cece iute A Nn 2 4 SV40221 Rev A 2 1 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 A and Y 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 Alternatively press the relevant Screen Key to Select Another Job from those already programmed into the machine See page 3 3 Initiate the SwiftStart feature See page 3 6 Select the Menu Screen Key to access Operator Functions See page 3 19 Supervisor Functions See page 4 2 You can also use the Manual Feed feature See page 3 9 2 2 SV40221 Rev A Using the Menus 2 Machine Name of Status selected Job Screen Name Counter s Piece Count Batch Count Invoice Job Use VY A to v
27. 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 A Y lt P 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 e Select Yes to confirm deletion e Select No to return you to the OMR Menu without deleting any codes TIPS Make sure that the code you are deleting is the correct code Once deleted it cannot be retrieved This function is not available if there are no OMR codes to delete Any code that is being used within a saved Job Definition cannot be deleted You must first either delete the relevant Job Definition s or edit the affected Job Definition s to use a different OMR code SV40221 Rev A 5 13 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 A V lt P keys in the normal way The highlighted OMR code will then be displayed on the left side of the screen If you require more detailed information about the co
28. achine configuration the accompanying text will explain this 1 4 SV40221 Rev A Introduction 1 Sheet Feeders Insert Feeders Manual Feeder Envelope Feeder Feeder Configuration SV40221 Rev A 1 5 1 Introduction Machine Identification 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 This allows a higher volume of material to be processed before refilling is required 6 PacPilot Control Panel This is where you enter commands to run the machine or configure Job Settings The control panel display also shows you the machine status loading instructions and details of the job See Control Panel on the page 1 8 for more details 1 6 SV40221 Rev A Introduction 1 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 Fe
29. and running a pre programmed Job Definition e Using the SwiftStart mode e Using the Manual Feeder e Loading the feeders e 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 Connecting Power Read the safety information on page 1 2 before connecting the machine Connect the power cord to the socket on the back of the machine Plug the power cord into a suitable power outlet Make sure the power outlet is near the machine and is easily accessible Turn the machine power switch ON 3 2 SV40221 Rev A 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 If the job loaded is not the one required press the Select Job Screen Key A list of Job Definitions that have been created will appear alphabetically on the screen Then e Ifyou are certain which job you want press the Screen Key alongside the desired job to select it immediately
30. ark within the code It may be used more than once within the code This can be useful to enable existing codes from other equipment to be used as certain marks might not be applicable to this machine SV40221 Rev A 5 5 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 Increment or Decrement When choosing Increment the relevant code s binary value will increase If you choose to use Decrement the relevant code s binary value will decrease Include Zero or Omit Zero 0 as a Value If Include Zero is chosen the relevant code s binary value would allow zero which is represented by no marks being printed within that section of the code When choosing to use Omit Zero the relevant code s binary value will NOT include zero as a value Therefore a mark will ALWAYS be printed within that section of the code Continuous Sequence or Page 1 Reset When using Continuous Sequence the binary value within the relevant part of the code increments or decrements continuously on every sheet fed irrespective of set boundaries If Page 1 Reset is used
31. back into the machine Close the Sealer Bottle Cover TIPS If filling the Envelope Sealer for the first time or if the sealer has been allowed to completely empty you should allow time for the solution to soak through the sealer mechanism before processing material The use of water in the sealer is not recommended We recommend EZ Seal as it improves sealing performance and minimises growth of algae and scale build up It can be purchased directly from Pitney Bowes When refitting the Sealer Bottle cap the pointed part of the cap fits into the bottle neck and the cap screws into place 3 18 SV40221 Rev A Operator Functions 3 Menu Select the Menu Screen Key to access the following Operator Options within the menu structure e Language e 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 The default language is set to your preference by your local service engineer at installation Display Adjustments Select this option and follow the simple on screen instructions to change the contrast or brightness levels of the display to suit your needs Safe Seal This option allows you to switch Safe Seal on or off
32. clearance of 1 8 3mm for unfolded inserts and 1 4 6mm for folded material below the flap crease after being fully inserted into the envelope Envelope flap and throat requirements Min 1 25 5mm Max 2 1 2 63mm 3 4 149mm Min 1 4 6mm Max 1 5 8 41mm Min 1 16 1 6mm Max 1 4 6mm throat depth at 3 4 19mm in from edge of envelope Closed flap tip should not come closer than 1 3 4 44mm to bottom of envelope ALL SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTIFICATION AND ARE SUBJECT TO TEST SV40221 Rev A 7 5 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 Recommended storage conditions 65 F 18 C to 77 F 25 C 40 to 60 relative humidity ALL SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTIFICATION AND ARE SUBJECT TO TEST 7 6 SV40221 Rev A Reference 7 Machine Specifications Physical Dimensions Length 54 1370mm Depth 22 1 2 570mm Height 30 760mm Minimum Weight 194 Ibs 88kg Maximum Weight 225 Ibs 102kg Weight will depend on machine configuration Weights stated do not include mate
33. ctive Feed Job Definition by not allocating any of the Select Feed SF marks to a feeder when creating the Job Definition Setting the OMR Scanning Area Material is scanned as it feeds through the machine This means that the OMR Scanner reads a vertical strip or margin down the page defined by the OMR Specifications on pages 5 8 and 5 9 The machine must now be told if the entire OMR margin the strip down the page that is scanned for OMR marks is clear of any other printing or punched holes etc If the area IS clear the machine can normally detect the OMR marks with no further setup If the entire margin is NOT clear or the machine cannot set itself automatically it will ask questions to ascertain where it needs to look for OMR marks and where it should ignore other printed matter Depending on the type of OMR code being used the machine will ask you to define either the first mark position and code length OR the Clear Zone as described on the following pages SV40221 Rev A 5 15 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 SH
34. d this option defines whether the number of marks should be oad or even If any mark is missed during scanning the machine will stop indicating a problem Always Present or Never Present This option is used in conjunction with the Safety mark only When Always Present is selected the Safety mark must be printed on all pages within the first set If Never Present is selected the Safety mark will not be printed and this mark position must be kept blank SV40221 Rev A 5 7 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 The center line of the marks must fall within a range from 2 3 8 59mm to 4 3 4 108mm from the center line of the sheet The OMR marks should not be closer than 3 4 20mm from the Lead Edge or 1 3 16 30mm from the Trail Edge of the sheet An area around the marks should be kept clear from print etc that may be read by the scanner in error this area is called the Clear Zone The Clear Zone must be at least 1 8 3mm each side of the marks 3 4 20mm before the first mark and 3 4 20mm after the last mark There shou
35. de either select the relevant screen key for that code or press the OK key once the relevant code has been highlighted Scroll up and down the selected OMR code by using the A and V navigation keys to review detailed information about the selected code From this screen you can select the corresponding screen key to Delete this Code View another Code e Return to OMR Menu TIPS The representation of the OMR mark on the left hand side of the screen will display as a dashed line if the Absent option is selected This function is not available if there are no OMR codes to view 5 14 SV40221 Rev A 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 If either of these options are greyed out it means an OMR code of the required type has not yet been created and saved into the machine s memory When creating a Job Definition using Select Feed marks additional questions will be asked to assign feeders to required Select Feed mark s TIP Note that a Selective Feed code can be used in a non Sele
36. e envelope stop position The envelope stop position will rarely need adjusting for more information see page 6 15 Saving a SwiftStart Job After confirming a Trial Piece is OK you will be given the option to save the current SwiftStart setup as a Job Definition for recall in future This function requires Supervisor level access see page 4 2 If you do NOT save the SwiftStart setup it will only be retained while you are running the current job If another Job Definition is selected or if power is turned off the SwiftStart settings will be lost Automatic Processing Whether you have chosen to save the SwiftStart job or not you can now commence automatic processing in the normal way Press the Start key to commence automatic operation The machine will operate until either material runs out or the Stop key is pressed 3 8 SV40221 Rev A Operator Functions 3 Manual Feed Manual Feed allows you to feed stapled or unstapled sets of up to 5 sheets of 20 Ib 80g m to a maximum total weight of 100 Ib 400g m 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 Constraints and Requirements e Only use closed flap envelopes e This mode cannot be used to run fold only or inserts
37. e 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 The Manual Advance Knob Having located the material you may need to use the Manual Advance Knob to manually feed material out of the grip of rollers etc The Manual Advance Knob is located behind the lower door at the center front of the machine 6 8 SV40221 Rev A Troubleshooting 6 Removal amp 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 Ifthe 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 Removal amp Replacement of the Insert Tray s F and G To remove Pull the Insert Tray straight outwards from the machine To replace Slide the tray into its location guides and push until it clicks into place SV40221 Rev A 6 9 6 Troubleshooting Access to Internal Areas 1 to 5 If material stalls within the internal areas of the machine the display will ind
38. ear e Create New OMR Code e Delete OMR Code e View OMR Code Note that some options will be unavailable if you have no current OMR code s stored in the machine s memory 5 10 SV40221 Rev A 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 You will then be asked to set the End of Collation mark options i e will the mark be Present or Absent Once a mark is selected a representation with its abbreviation will appear on the left hand side of the screen When complete you will be asked to name the OMR Code see tips on following page If Multi Mark is selected You will be able to select from the available OMR Marks in the list on the screen This is done by scrolling up or down the list by using the A and Y navigation keys The marks must be selected in the correct order starting with the mark located towards the top head of the page first Once the required mark is highlighted press the OK key to select it Certain marks may have a number of options associated with
39. ect System Information 7 10 SV40221 Rev A 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 Cc 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 Button 1 9 Navigation Keys 1 9 Reset Counters Button 1 8 Screen Keys 1 9 Start Button 1 9 Stop Button 1 9 Trial Piece Button 1 9 Convenience Feeder See Manual Feeder Counter s 2 3 Create From jobs 4 6 Create Job 4 3 Create New OMR Code 5 11 SV40221 Rev A l 1 Index D Daily Mail Feeder See Manual Feeder Delete Job 4 7 Display Adjustments 3 19 Double Detect 1 11 Drop Stacker 1 7 7 6 E Edit Job 4 4 End of Collation EOC 5 4 End of Collation EOC for OMR 5 12 Envelope Feeder Changing the Envelope Sealer Unit Felts 7 8 Description 1 7 Envelope Stop Position 6 15 Loading switch 3 14 Material Specifications 7 5 Setting the Envelope Feeder 3 14 Side Guide Adjustment Knob 3 14 Envelope Icons 1 12 Envelope Sealer 3 18 7 6 Filling 3 18 Sealer Bottle Cover 3 18 Envelope Stop Position 6 15 Envelope Feeder loading switch 3 15 F
40. eder s are fitted Insert Feeder s not on all model configurations Use these feeders to add additional inserts to your envelope Inserts fed from these feeders cannot be folded by the machine so they must already be folded or be a size that does not require folding Drop Stacker not illustrated A fold down stacker is located at the exit from the machine to collect the finished Mail Pieces This unit can be latched against the machine when not in use Power stacker not illustrated This is an optional extra which automatically collects and neatly stacks finished Mail Pieces It locates at the exit of the machine in place of the Drop Stacker Sealer Bottle The sealer bottle is located inside an opening cover at the front right side of the machine It provides sealing solution to the Envelope Sealer Manual Advance Knob The Manual Advance Knob is located inside an opening cover at the lower center of the machine It can be used to manually turn the machine mechanisms to assist in clearing a material stoppage Measuring Scale The scale is located on the left side of the machine near the sheet feeders as an aid in measuring material and envelopes Envelope Feeder This feeder feeds envelopes into the inserting area where they are filled with the material requested from the other feeder s SV40221 Rev A 1 7 1 Introduction PacPilot Control Panel Control Panel Keys Screen Keys Navigation Keys Reset
41. er the Supervisor Access Code see page 4 2 select System Menu Manual Feed Option This function lets a Supervisor choose whether or not the Insert Feeder s are active when a Manual Feed operation is carried out The default setting is for both Insert Feeders to be ignored with a Manual Feed Changing this setting will feed Insert s from either or both Insert Feeders if they are loaded For more details of Manual Feed see page 3 9 of this guide 4 8 SV40221 Rev A 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 ayia ean iin ieee A etic 5 2 What is OMR 442 ie fie niacin Pad aie Aran a es 5 2 OMR Marks Available 2 cceeeeeeeeeeeeceeeeeeeeeeeeteeeeeneeee 5 3 OMR Mark Options 0 0 cccececeeeeeeeeeeeeecaeeeeeeeeeeeeteeeseees 5 6 OMR Specifications ssie terrina iieiea aeiiae 5 8 Creating Deleting and Viewing OMR Codes 5 10 Create New OMR Code eececeeceeeeeeeeeeeteeeenneees 5 11 Delete OMR Code 0 cccccececeeeceeceeceeeeeeeeeeeteeeennteeaeeees 5 13 VIEW OMR Code 222037 ferent aaa emis ania AAE aes 5 14 Creating AN OMR Jobsi sibiirns iaieiiea aiaa RR 5 15 OMR Scanner Adjustments ccceecceeeeeseeeeeeeeseeeaees 5 18 SV40221 Rev A 5 1 5 Optical Mark Recognition OMR OMR Availability Your mach
42. erlapped manner like tiles on a roof SV40221 Rev A 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 Mail Piece Icon Tree Situated down the left side of the display A graphical representation of the items that make up the currently selected Job Definition Trial Piece Test piece run by the machine before automatic operation can be started A Trial Piece allows the machine to calibrate itself and the Mail Piece make up to be checked Safe Seal A modified sealing mode that allows better amp sealing of poor envelopes Safe Seal will allow more time for the envelope flap gum to soften but will slow machine operation Linked Feeders Allows more than one feeder to be configured to run the same Stack When the first feeder runs out of material feed will automatically switch to the next linked feeder and so on in a continuous cycle This allows empty feeder s to be loaded while another linked feeder is feeding material Optical Mark Recognition OMR
43. ess Cancel twice The Manual Feed settings will be lost once a pre programmed Job Definition is selected or SwiftStart is operated SV40221 Rev A 3 11 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 This will be indicated by the Mail Piece Icon Tree Sheet Feeders can feed single Sheets or Pre Collated Sets depending on job setup The Mail Piece Icon Tree will tell you the quantity of sheets that the machine is programmed to run from each feeder if Pre Collated sets are programmed If you need help understanding the terms Sheet or Pre Collated Set refer to page 1 14 of this guide 1 Adjust the side guides to the width of the material being fed using the Side Guide Adjustment Knob then back off 1 4 of a turn This will set the correct clearance between the guides and sheets 2 Take the relevant Stack of sheets and fan it to ensure individual sheets are not stuck together 3 12 SV40221 Rev A Operator Functions 3 3 Jog the stack back into alignment 4 The Mail P
44. f Collation This mark indicates that it is the first sheet fed within a set This mark may only be selected once within the code Options available e Present or Absent SV40221 Rev A 5 3 5 Optical Mark Recognition OMR EOC End of Collation This is a mandatory mark which indicates that it is the Jast 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 e 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 Options available e Present or Absent All Sheets Page 1 Only or Last Page Only e Marked Piece to be left Unsealed Yes or No SF n Select Feed These marks instruct the machine to select material from specified feeders This feature is only available to select sheets when C fold is used and the material is under 12 305mm in length Selectively fed inserts are available for all types of folds and sheet lengths within the specifications of the machine Up to 8 Select Feed Marks can be within to the code 5 of these marks can be allocated to specified feeders when creating a Job Definition The other 3 marks will be automatically ignored Allowing 8 Select Feed Marks to be used gives greater flexibility in reusing existing codes from production type machines which may have greater Select Feed capability Op
45. 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 Adjustment Scale Bottom Scanner Adjusting Knob Indicator 5 20 SV40221 Rev A 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 When setting the Top Scanner use the appropriate adjustment scale depending on the location of the Bottom Scanner The front scale for a Front Bottom Scanner and the rear scale for a Rear Bottom Scanner Top Scanner position Mt 60 70 M Ao Bottom Scanner position Top Scanner Bottom Scanner SV40221 Rev A 5 21 5 Optical Mark Recognition OMR 5 22 SV40221 Rev A 6 Troubleshooting Troubleshooting Tips 0 00 0 ceeeeceeeeeeeeeeeeeneeeeeeeeeteeeeeeeaaes 6 2 General Troubleshooting ccceeeceeeeeceeeeeeeeneeeeeeeeeneeeees 6 3 MaGhING sa AE A cee eee hee ee ats 6 3 Envelope
46. he material and the machine 5 2 SV40221 Rev A 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 BM Benchmark This is a mandatory mark within the Multi Mark option it must be either the first or last mark of the code and will appear on every page within the first set This mark may only be selected once within the code SAF Safety This mark improves the integrity of your Mail Piece It can be placed anywhere within the code but benefits from being at the opposite end of the code to the Benchmark When the Safety mark is placed in this position with the option Always Present and No other marks other than the OMR code in the margin is chosen when creating the job the machine will automatically work out the length of the code This makes creating jobs using this code easier Otherwise the machine will ask for a code length when creating a job This mark may appear more than once within the code Options available Always Present or Never Present BOC Beginning o
47. he Scanners It is essential that the OMR Scanner being used is correctly aligned over the OMR marks printed on the sheet s Failure to align the scanner will result in scanning errors It is therefore essential that the scanner alignment is checked before commencing any OMR job Measure the OMR mark position Take a sheet printed with the OMR marks to be used and fold it in half in the direction of feed to locate the sheet s center line Now measure from the center line to the center of the OMR marks in millimetres Take a note of this measurement X OMR marks position used depends on scanner location Folded center line 5 18 SV40221 Rev A 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 ey Top Scanner Adjusting Knob Adjustment Scale Rear Adjustment Scale Indicator Front Adjustment Scale uE EA NOTE Illustration shows adjustment for a front scanner If using a rear scanner refer to the scale towards the rear of the machine SV40221 Rev A 5 19 5 Optical Mark Recognition OMR Setting the Bottom Scanner Position This scanner position is used
48. icate 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 The illustrations on the next page show each area in more detail 6 10 SV40221 Rev A Troubleshooting 6 Area 1 Area 2 Pull upwards to unlatch Rotate clockwise to unlatch Relatch by pressing assembly Relatch by rotating lever fully firmly down at the center counterclockwise Area 3 Area 4 Rotate counterclockwise to unlatch Rotate counterclockwise to unlatch Push assembly back into position Push assembly back into position and relatch by rotating lever fully and relatch by rotating lever fully clockwise clockwise Area 5 Rotate clockwise to unlatch Push assembly back into position and relatch by rotating lever fully counterclockwise SV40221 Rev A 6 11 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 Therefore before access can be gained to a material stall in these areas the Inser
49. iece 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 A 3 13 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 Adjust the side guides to the width of the envelopes being fed using the Side Guide Adjustment Knob then back off 1 4 of a turn This will set the correct clearance between the guides and envelopes 3 Take the stack of envelopes and fan it to ensure individual envelopes are not stuck together 3 14 SV40221 Rev A 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
50. iew loading Instructional instructions Text Job comments text area l Screen Key Selections Mail Piece Icon Tree Machine Graphic The Home Screen SV40221 Rev A 2 3 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 The second section is only available to a Supervisor upon entry of a Supervisor Access Code This section allows supervisors to create edit and delete jobs as well as set more advanced features The following two chapters in this guide Operator Functions and Supervisor Functions give details of the functions available to each level of user Use this diagram as a quick reference to find the function s that you require then refer to the relevant page in this guide Each screen can be identified by its title located in the top left corner 2 4 SV40221 Rev A Using the Menus 2 Home Screen 2 Select Job p 3 3 gt 2 SwiftStart 0 3 6 gt 9 Menu p 3 19 gt 5 re ad O a Language p 3 19 gt Display Adjustments p 3 19 gt Safe Seal p 3 19 gt System Information p 3 19 gt
51. ine 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 0020 Customer Service Representatives are available Monday through Friday 8 00 AM 8 00 PM ET Canada Contacts Product Name DI500 or DI600 For frequently asked questions or to order supplies go to www pitneybowes ca For direct questions call 1 800 672 6937 Customer Service Representatives are available Monday through Friday 8 30 AM 4 00 PM ET SV40221 Rev A v vi SV40221 Rev A 1 Introduction This chapter presents important safety information and describes the main controls and features of your machine Important Safety Notes ee eeeeeeeeeeeeeeneeeeeeentaeeeeeeeaas 1 2 To The Operator iania ii edanen aiai 1 3 Machine Configurations cccccececeeeeeeeeenneeeeeeenteeeeeeeaas 1 4 Machine Identification c ccceccceceeeeeeeeeeeeetneteeeeeeees 1 6 PacPilot Control Panel cccccceceeeeeeeeeeeeceeeeeeeeees 1 8 Control Panel Keys cccccceceeceeeeeeeeeeeeseeneeeeeeeeaees 1 8 Mail Piece ICON Tree ccccccceeeeeeteseeestceeeaeeeeeees 1 10 Common Terms sche heen e aeai aa aea 1 14 SV40221 Rev A 1 1 1 Introduction Important Safety Notes Follow these basic safety precautions when operating this machine e Use only Pitney Bowes approved supplies in particular aerosol dusters Im
52. ine 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 This line must be sufficiently thick dense and placed in the correct area to trigger the OMR scanner on the system Typical OMR marks There are many different OMR options available to you from a Single Mark option to Multi Mark options which have a maximum of 24 marks The OMR scanner working with the OMR system software checks for one or more different marks on the sheets while they are being fed through the system The tracking of these OMR marks by the system will aid the integrity of your mailing through error checking so generally the more marks you use the better the integrity of your Mail Piece As mentioned on page 7 3 of this guide there are limits on how many sheets the machine can fold at one time These limits are dependent on the paper weight of your sheets and fold type selected and should not be exceeded It is therefore strongly recommended that when programming your system to print your OMR sheets these limits are taken into account If these limits are exceeded it could result in a material stoppage or damage to t
53. ithout the express written permission of Pitney Bowes We have made every reasonable effort to ensure the accuracy and usefulness of this manual however we cannot assume responsibility for errors or omissions or liability for the misuse or misapplication of our products Due to our continuing program of product improvement equipment and material specifications as well as performance features are subject to change without notice Your inserter system may not have some of the features described in this book E Z Seal and PacPilot are trademarks or registered trademarks of Pitney Bowes Inc ENERGY STAR is a registered trademark of the United States Environmental Protection Agency Printed in the USA or Canada Table of Contents Pitney Bowes Contact Information List v Chapter 1 Introduction a Ei ET E E ta ei an en A ada 1 2 To The Operator c cececcecceceeeeeeeeeeeeeeceaeaeeeeeeeeeeeeteees 1 3 Machine Configurations cccceeeeeeeeeeeeseteeeeeeenneeeeeeeeaas 1 4 Machine Identification cccccccccecsceesesesesessseeeeeeeeseseeees 1 6 PacPilot Control Panel ccccccccccscccsssssecsssstessssseeseseeees 1 8 Control Panel Keys ccccceeeeeeeeeeeeceeeeeeeeteeeeeeenaaes 1 8 Mail Piece ICON Tree cccccesesessesessceeseeeceeeseeeeeees 1 10 COMMON TEMS si ts2 secretes ee Gl eter 1 14 Chapter 2 Using the Menus The Home Serea anche cones esate noe eet hoa 2 2 The Menu Struct
54. k the Mail Piece Icon Tree 1 12 loading instructions 1 13 Inserts out of Check specifications in this guide 7 4 specification Inserts won t feed when using Manual Feeder By default Insert A Supervisor can change this 4 8 Feeder s are disabled in Manual Feed mode default setting to allow Insert Feeders to operate in Manual Feed mode using the Manual Feed Option 6 6 SV40221 Rev A Troubleshooting 6 Problem Remedy Page DOUBLE DETECT The machine keeps turning Double Detect OFF Double Detect Double Detection might not be cannot calibrate possible with certain very thick itself properly 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 Check Double Detect status 1 11 not turned ON Double Detect icon will appear alongside all items where Double Detect is operational I Correct loading or have Supervisor 4 4 correct Job Definition as necessary Double Detect Run a Trial Piece whenever a 3 4 is not correctly new batch of material is loaded to calibrated recalibrate Double Detect The new batch might be of slightly different thickness SV40221 Rev A 6 7 6 Troubleshooting Clearing Material Stalls Your machine has been designed to assure maximum performance In th
55. l need a Double fold Use the following list as a guide for feeding the Manual Feed set C Fold Feed the set Face Up Top First Single Fold Feed the set Face Down Bottom First Double Fold Feed the set Face Up Top First Set the Manual Feeder side guides to control the sets to be fed The guides are self centering Take one set and feed it gently into the Manual Feeder until the machine automatically starts and draws the set from you A Trial Piece is produced enabling you to check the job setup The machine will ask if the Trial Piece is OK If the Trial Piece is OK select Yes and refer to Manually Feeding Further Sets on the next page If the Trial Piece is NOT OK select No and follow the on screen instructions to correct the error You can adjust the address position fold panel length and or the envelope stop position The envelope stop position will rarely need adjusting for more information see page 6 15 3 10 SV40221 Rev A 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 pr
56. ld be no print on the reverse of the sheet immediately behind the Clear Zone Clear Zone r 3 min 1 10 pitch 3 4 20mm min 10 linesinehy i E 1pt to 2pt 1 64 0 35mm to 0 7mm thick 3 4 20mm min 2 3 4 70mm max 1 8 3mm gt L lt 1 8 3mm min 3 8 min a 0mm Diagrams NOT to scale min 5 8 SV40221 Rev A Optical Mark Recognition OMR 5 LEADING EDGE 3 4 20mm min 2 3 8 2 3 8 gt 1 59mm 59mm e a ___ _ gt min min 4 3 4 108mm 4 3 4 108mm _ t max max 1 8 3mm min 1 8 3mm min gt Place marks in Place marks in this area for this area for C Double Fold C Double Fold Rear Top Scanner Front Top Scanner Single Z Fold Single Z Fold Rear Bottom Front Bottom Scanner 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 the scanners fitted to the machine SV40221 Rev A 5 9 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 Where is it From the Home Screen Select Menu Select Supervisor Functions Enter the Supervisor Access Code see page 4 2 Select OMR Menu Action Once the OMR Menu has been selected the three following options will app
57. lope 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 SV40221 Rev A 4 5 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 It will then allow you to edit the new job to meet the slightly changed requirements Where is it From the Home Screen select Menu select Supervisor Functions enter the Supervisor Access Code see page 4 2 select Create From Action Once Create From has been selected choose the Job Definition you wish to use as the basis of the new job from the alphabetical job list using the A V lt P keys in the normal way Once the Job Definition that you are creating from has been selected the machine will prompt you to enter a new Job Name as no two Job Definitions can have the same name After the J
58. m 347mm 12 1 2 16 319mm 406mm 16 Ib 60g m Minimum 32 Ib 120g m Maximum Up to a maximum of 325 sheets of 20 Ib 80g m Stapled or unstapled sets up to 5 sheets of 20 Ib 80g m toa maximum total weight of 100 Ib 400g m per set can be processed in the Manual Feed mode Glossy coated sheets are not recommended SV40221 Rev A 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 narbi Paper Weights in Ibs sheets 16 18 20 22 24 26 28 30 32 C Z S D C Z 8 D ZSD 862 czsDp C Z S D C Z S 3 ea C Z S D C Z S 84 erat C Z S D s 8 S For applications within this 9 s shaded area contact your S machine supplier for advice Fold Types C C Fold Z Z Fold S Single Fold D Double Fold Sheets above 12 305mm in length can only be folded C Z and D up to 5 sheets All the above sheet limits can be used with Inserts from feeders F and G only if the total Mail Piece contents are up to a maximum of 1 8 3mm total compressed thickness ALL SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTIFICATI
59. n 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 Area 5 15 Setting the Type of OMR 5 15 Setting Top Scanner 5 19 Single Mark 5 11 Stop STP 5 4 View OMR Code 5 14 What is OMR 5 2 Wrap Around Sequence WAS 5 5 OMR Menu 4 8 OMR Scanner Adjustments 5 18 Operator Functions 2 5 Other Icons 1 12 Outer Envelope 1 15 P Parity PAR for OMR 5 5 Pitney Bowes Contact Information List iii Power stacker 1 7 Power Switch 3 2 Pre Collated Set 1 14 Pre Collated Sets 1 11 Prime Sheet or Prime Set 1 14 l 6 SV40221 Rev A Index R Removal amp 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 Ato D 6 9 Reset Counters 1 8 Reset Counters Button 3 4 Running a Job 3 3 Running a Trial Piece 3 4 S
60. n indicating multiple sheets will appear together with a number showing the number of sheets in the Pre w pil bli 5 Lines between the Mailing Object Icons indicate the flow of material through the machine Refer to the table on the following page as a reference to all the icons that might appear on the Mail Piece Icon Tree SV40221 Rev A 1 11 1 Introduction Envelope Icons No Window Flap side up Flap Last Window Flap side up Flap Last Seal Icons letter fold Z Fold accordion fold Reply envelope Flap side down Flap First Booklet Face Down Bound Edge First Slip Face Up Bottom First Pre Folded Insert Sheet Icons No address Face Down Bottom First No address Face Down Top First No address Face Up Bottom First No address Face Up Top First Top address Face Down Bottom First Top address Face Down Top First Top address Face Up Bottom First Top address Face Up Top First Bottom address Face Down Bottom First Bottom address Face Down Top First Bottom address Face Up Bottom First Bottom address Face Up Top First Closed Side First Other Icons Double Detect On Q to Feeder Designators W200 8g y40221 Rev A 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
61. nswering 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 Access Code Before you can access any of the functions in this menu you must enter a Supervisor Access Code This prevents unauthorised access to functions mainly related to administration of jobs and OMR Your installing engineer will tell you the Supervisor Access Code If you wish you can write it in the box on this page as a reminder However please be aware that this is then available to anyone using this Operator Guide and so you may wish to make a note of it and keep it in a more secure location The Supervisor Access Code cannot be changed from the one given to you by the installing engineer Supervisor Access Code Entering the Code When asked to enter the Supervisor Access Code use the A V lt gt keys to highlight the first digit of the code on the Numeric Matrix displayed and confirm this digit by pressing OK Repeat for the second digit When complete select Finished 4 2 SV40221 Rev A 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
62. ob Name has been entered the machine will ask you to enter the Job Comments The following screens will then be as in Edit Job described on page 4 4 TIPS The machine s memory holds a maximum of 20 Job Definitions All the tips for Edit Job page 4 5 also apply 4 6 SV40221 Rev A 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 A V lt gt keys in the normal way Once the required Job Definition is selected a message will be displayed which requires confirmation before the job is deleted TIP Make sure the Job Definition you are deleting is the correct job Once deleted it cannot be retrieved SV40221 Rev A 4 7 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 select Menu select Supervisor Functions ent
63. occurred etc Stop Stops automatic operation at the end of the next cycle Navigation Keys A V lt gt OK These keys are used to move a highlighted area around the display Once the desired area is highlighted press the OK key to select it The A and Y navigation keys can also be used to change values of machine settings Screen Keys These are the six round keys located directly to the right of the display These keys correspond to the changeable options on the display alongside them and therefore are not labelled SV40221 Rev A 1 9 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 Loading Instructions The A and Y navigation keys can be used to scroll through the Mail Piece Icon Tree When an item is highlighted the machine will give you the loading instructions associated with that item When you have viewed the loading instructions press Home or Cancel to return to the Home Screen or press Start or Trial Piece to immediately begin processing 1 10 SV40221 Rev A Introduction 1
64. osition 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 0 Standard setting for normal weight material 1 2 Places the material further into the mailing envelope which may be useful for light or thin material 1 2 Reduces how far the material goes into the envelope which may be useful for thicker or heavier material After carrying out this adjustment you will be offered two options 1 You can save the adjustment as part of the current Job Definition so that it is automatically recalled in future This requires a Supervisor Access Code to be entered because the Job Definition is being edited 2 You can run the current job with the adjustment applied temporarily Once a new Job Definition is selected or if power is turned off this temporary adjustment will be lost When the Envelope Stop is set to any position other than its standard 0 position a warning icon showing the modified setting will be displayed beneath the Machine O Graphic Envelope Stop Icon SV40221 Rev A 6 15 6 Troubleshooting 6 16
65. proper 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 To obtain Pitney Bowes supplies please contact our Supply Line or on the web at PB com see the Pitney Bowes Contact Information List at beginning of this guide Material Safety Data Sheets can also be acquired from the Supply Line or PB com Read all instructions before operating the equipment Only use the equipment for its intended purpose Operation of this equipment without periodic maintenance will inhibit optimum operating performance and could cause the equipment to malfunction Contact your Pitney Bowes Customer Service Representative for required service schedule Use the power cord supplied with the machine Plug it and all other supplied power cords into a properly grounded wall outlet that is located near the machine and easily accessible meaning it is free from obstruction and there is enough room around the unit for servicing The power cord wall plug is the primary means of disconnecting the machine from the AC supply Do not use an adapter plug on the line cord or wall outlet Do not remove the ground pin from the line cord Avoid using wall outlets controlled by wall switches or shared with other equipment Do not route the AC powe
66. r cord over sharp edges or allow it to be trapped between furniture and or furniture and the wall Avoid touching moving parts or materials while the machine is in use Keep hands loose clothing jewelry and long hair away from all moving parts Do not remove covers Covers enclose hazardous parts that should only be accessed by properly trained service personnel SV40221 Rev A Introduction 1 e Immediately report to Pitney Bowes Service any damaged or nonfunctioning components The unit may be unsafe for use e 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 To the Operator Your new Folding Inserting Machine has an easy to follow user interface which makes it simple to set up whilst offering the following features e Envelope seal no seal safe seal Fully automatic material separation on sheet feeders Fully automatic fold adjustments Fully automatic envelope separation Fully automatic Double Detect when selected Fold only option fold without insertion Fully automatic insertion of single and multiple sheet inserts on models fitted with insert feeders only Option of single fold C fold Z fold and double fold 20 Job recall facility User programmable SwiftStart allows you to quickly execute and save simple jobs without programming Linked
67. rial Noise Level Running 72dBA 74dBA Electrical AC Input 100VAC 240VAC 50 60Hz 10A AC Output 100VAC 240VAC 50 60Hz 4A Maximum Speed 3600 or 4000 cycles per hour depending on model fold type and material quality Figures stated are based on 2 sheets of 24 Ib 80g m Z folded and 1 insert placed into a 26 Ib 90g m 10 envelope Compliance Itis certified that the Folding Inserting machine complies with the requirements of the Low Voltage Directive 73 23 EEC and the EMC Directive 89 336 EEC The product was tested in a typical configuration WARNING 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 OMR Specifications are listed on pages 5 8 and 5 9 SV40221 Rev A 7 7 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 7 8 Hinge open the Sealer Bottle cover located at the front right hand side of the machine Remove the Sealer Bottle Remove the Insert Trays see page 5 9 Lift the insertion area plastic cover and open the envelope exit area access door Squeeze together the two blue tabs A and lift the blue tab B to gain access to the sealer unit felts SV40221 Rev A Reference 7 4 Push the latch A back Grasp the upper sealer felt B
68. running a job Window Envelope loaded Flap Side Up fed Flap Last Envelope sealing turned on loaded into feeder E C Fold selected Prime Sheet with Top Address loaded Face Up fed Top First loaded into feeders A and B feeders A and B Linked Double Detect turned on Additional Sheet loaded Face Up fed Top First loaded into feeders C and D feeders C and D Linked Reply Envelope loaded Flap Side Down fed Flap First loaded into feeder G Booklet loaded Face Down fed Bound Edge First loaded into feeder F SV40221 Rev A 1 13 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 Stack A pile of paper as received from the printer that will be loaded into a feeder or feeders on the machine A stack might consist of numerous individual Sheets or numerous Pre Collated Sets depending on how it was printed Prime Sheet or Prime Set This sheet or set normally contains the address It will be positioned closest to the envelope
69. s related to material handling persist make sure your material conforms to the machine specifications given in Chapter 7 of this guide If you still cannot resolve the problem call your machine supplier for help Contact details can be found e onthe back cover of this guide e Inthe System Information option in the menus At the Home Screen select Menu Then select System Information 6 2 SV40221 Rev A Troubleshooting 6 General Troubleshooting Problem Remedy Page MACHINE Blank Screen No power Check power cord is firmly 3 2 connected and wall socket is switched ON Machine not Turn power switch located on 3 2 switched ON lower front ON Display adjustment Reset the Display Adjustment to an 3 19 set incorrectly acceptable setting Performance Machine runs Is Safe Seal selected amp icon 3 19 slowly in Icon Tree Safe Seal provides improved sealing of difficult envelopes but slows machine operation Insertion Problems Outer Envelope Check envelope troubleshooting 6 4 contents do not table enter the envelope Check envelope depth setting for 4 4 correctly the job is correct within the Edit Job function If running heavy or light material 6 15 the Envelope Stop Adjustment might need changing SV40221 Rev A 6 3 6 Troubleshooting Problem Remedy Page ENVELOPES Poor Envelope Feed En
70. scribed in the following section Running a Trial Piece A Trial Piece is required to enable you to check the Mail Piece contents and to allow the machine to calibrate itself for the material being run Press the Trial Piece key The machine runs a single Mail Piece which exits the machine unsealed so that you can check the contents The machine then asks if the Trial Piece is OK If the Trial Piece is OK select Yes and follow the instructions in the section Automatic Processing on the following page If the Trial Piece is NOT OK select No and follow the on screen instructions to correct the error You can adjust the address position fold panel length and or the envelope stop position The envelope stop position will rarely need adjusting for more information see page 6 15 Once the adjustment is made and any further Trial Piece is OK you will be asked if you wish to save the changed settings as part of the Job Definition If you choose Yes The machine will save the changed setting s as part of the current job Next time the original Job Definition is selected the modified adjustment s will be remembered A Supervisor Access Code see page 4 2 will be requested as you are editing an existing Job Definition 3 4 SV40221 Rev A 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 selec
71. sesion Bevetocs Hades Risers a e ea aL 2 4 SV40221 Rev A i Table of Contents Chapter 3 Operator Functions About this Chapter ccccececeeeeeeeeeeeeeneeeeeeeeeeeeeeeeees 3 2 Connecting POWE oaeee ara EEA AEE EE ARE 3 2 Runanga Joa a a TO a 3 3 SWIMS TAM aaaeaii aa E AEEA 3 6 Mantal Fed ariran a aaa AEA EEA aia one 3 9 Setting the Sheet Feeders eee cceeeeeeeeseeeeeeeeeeneeeees 3 12 Setting the Envelope Feeder 3 14 Setting the Insert Feeder Ss c ccceeeeseeceeeeeeeeeeseeeneeees 3 16 Filling the Envelope Sealer ccccceceeesieeeeeeeeeieeeeeeee 3 18 Menus fi savior adn eats oautina din Gases 3 19 LAN QUAG e EE EEE PA E aia ce E E tetas 3 19 Display Adjustment eceeeeeeseeeeeeeeeeeeetteeeeeeeenaees 3 19 Safe Seal vccice elas eigen vtieceev dances ev ine evened 3 19 System Information erriari 3 19 Chapter 4 Supervisor Functions About this Chapter cccccceeeeeeeeeeeeececeeeeeeeeeeeeeeeeees 4 2 Supervisor Access Code c ececceeeeeeeeeeeeeeteeeseaeees 4 2 Create Job is riea eee eel 4 3 Edit JOD MOE E ii ei a ee EA 4 4 Create From hinen alsa nena adil 4 6 Delete Jobenn tact eevee eh Anne eediad ee adii EN 4 7 OMR Ment 2 i ceie aceon ean 4 8 system Men serens eee ieee nee 4 8 Manual Feed Option ccccccececeeeeeeeceeceeeeeeeeeeees 4 8 ii SV40221 Rev A Table of Contents Chapter 5 Optical Mark Recognition OMR OM
72. slide it towards the front of the machine and remove it from its mounting bar Discard this old felt 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 old felts 7 Fit the four new felts into the Sealer Tank They will only fit one way round Make sure they are pushed fully down into the tank SV40221 Rev A 7 9 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 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 Should you have questions about your machine or require service or assistance with your particular application please call your machine supplier Your machine supplier will also offer a service maintenance contract to keep your machine in top condition at nominal cost Contact details can be found e On the Pitney Bowes Contact Information List on page v e Inthe System Information option in the menus At the Home Screen select Menu Then sel
73. t Trays must be removed as described on page 6 9 Once the trays are removed access to stalled material can be gained by unlatching the access covers shown 6 12 Area 8 SV40221 Rev A 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 Access to the Top Cover Sheet Feed Area Access can be gained to this area by unlatching the blue handle on the Top Cover and raising the cover When closing the cover make sure it is fully latched into position SV40221 Rev A 6 13 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 A Troubleshooting 6 Envelope Stop P
74. ted 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 or if you have any problems with double detect run another Trial Piece This allows the machine to recalibrate the double detect function for the new material in case the batches vary slightly When loading a C folded insert into feeder F or G load it with the open edge last and the double sheet thickness face up Automatic Processing After confirming a Trial Piece is OK Press the Start key to commence automatic operation The machine will operate until material runs out the Stop key is pressed the batch count is reached if batch count is being used Batch Count If the Batch Count function was set when the job was created the machine will stop automatically after processing the required number of Mail Pieces Remove the batch of Mail Pieces and press Start to recommence processing SV40221 Rev A 3 5 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
75. the first page of each set has a binary value of 1 therefore the count always stays within the boundaries of the set 5 6 SV40221 Rev A 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 owest binary digit within that part of the code When Most Significant Mark is chosen the mark within the relevant part of the code nearest to the Benchmark would be represented by the highest binary digit within that part of the code All Sheets Page 1 Only Last Page Only If All Sheets is selected the relevant code is expected on all sheets within that set When using Page 1 Only or Last Page Only the relevant code will only be expected on the first or last page fed depending on the option chosen Marked Piece to be left Unsealed Yes or No If Yes is selected the machine will stop when it sees the Stop mark with the relevant unsealed envelope in the stacker If No is selected the machine will also stop with the envelope in the stacker when it sees the Stop mark but envelope sealing will be processed as programmed in the relevant Job Definition Odd or Even This is an option used in conjunction with the Parity mark When the Parity mark is printe
76. tions available e Present or Absent All Sheets Page 1 Only or Last Page Only 5 4 SV40221 Rev A 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 f a page becomes missing or the set becomes out of sequential order the system will stop processing and declare an error message Up to 6 Wrap Around Sequence marks can be within the code Options available e Increment Ascending or Decrement Descending e Include or Omit Zero 0 as a value within the sequence e Continuous Sequence or Page 1 Reset e Least or Most Significant Mark nearest to Bench Mark code orientation e Number of Wrap Around Sequence Marks TM Timing This mark is needed by some other machines to read OMR marks correctly This machine does NOT need Timing marks but the mark s may be left within an existing code and will add integrity to your Mail Piece Timing mark s may appear more than once within the code and if used must always be present within the code IGN Ignore This feature is used to ignore a m
77. uch 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 If you wish to create a NEW Job Definition which is similar to an existing job and leave the existing Job Definition untouched use the Create From function described on page 4 6 Where is it From the Home Screen select Menu select Supervisor Functions enter the Supervisor Access Code see page 4 2 select Edit Job Action Once Edit Job has been selected choose the Job Definition you wish to edit from the alphabetical job list using the A V lt P keys in the normal way Edit Job allows a Supervisor to modify all Job Definition parameters except for adding or removing the Outer Envelope and the First Sheet or Set Highlight the item you wish to edit by scrolling through the Mail Piece Icon Tree using the A Y keys To add an Additional Sheet Set or a second Insert highlight the icon in the Mail Piece Icon Tree immediately adjacent to the point you wish to add the new item then select Add Item After or Add Item Before as applicable To add an Insert to a job currently without Inserts select Add Insert 4 4 SV40221 Rev A 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 Enve
78. velope side Set guides to envelope width and 3 14 guides set back off 1 4 turn incorrectly Poor envelope Check envelopes are not curled quality Try a new box of envelopes Make sure stack has been fanned 3 14 before loading Envelopes loaded Load envelopes flap side up with 3 15 incorrectly the flap feeding last Envelopes Fail to Open Envelopes loaded Load envelopes flap side up with 3 15 incorrectly the flap feeding last Poor envelope Check envelopes are not stuck due quality to excessive dampness Try a new box of envelopes Envelope Sealing Problems No sealing Refill Sealer Unit 3 18 solution Seal mode not If selected Mail Piece Icon Tree will 1 13 selected show Seal icon alongside the Envelope icon Envelope flaps Try using Safe Seal Safe Seal 3 19 spring open provides improved sealing of difficult envelopes but slows machine operation Poor Sealing It s possible that the sealing felts 7 8 need replacing Contact your machine supplier for more details 6 4 SV40221 Rev A Troubleshooting 6 Problem Remedy Page SHEETS Poor Sheet Feed Sheet Feeder Set guides to Sheet width and back 3 12 side guides set off 1 4 turn incorrectly Sheets loaded Make sure stack has been fanned 3 12 incorrectly before loading Multiple sheets feed when one is expected Sheet Feeder Check Mail Piece Icon Tree to see 1 1
79. zerren E ee Se niche E _ n below this line require a Supervisor A Create Job p 4 3 gt Pno 2 Edit Job p 4 4 gt z Create From p 4 6 gt a Delete Job p 4 7 gt a OMR Menu p 4 8 gt Z Systems Menu p 4 8 gt A 5 N Manual Feed Option p 4 8 gt The Menu Structure SV40221 Rev A 2 5 2 Using the Menus 2 6 SV40221 Rev A 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 Chapters ioe aa a aa 3 2 Connecting POWER coooa aa aa ia iA 3 2 Running a JOD ori header OEA A EAT 3 3 EEE E a PEE A E A E A aire alan E ee 3 6 Manal Fogd akorat AAAA AEA ERA 3 9 Setting the Sheet Feeders eeeseeeeeeeeteeeeeeeenaees 3 12 Setting the Envelope Feeder cceecceecseeeeeeeeeenees 3 14 Setting the Insert Feeder S eee eceeeeeseeeeeeeestteeeeeeenaees 3 16 Filling the Envelope Sealler cccccceeesceeeeeeeeeeieeeeeees 3 18 MOU st inetie iS Gehan tien Hee Gee 3 19 EANGQUAGE EEEE O E E A E N tenia 3 19 Display Adjustment eccceeeeeeeeeeeeenteeeeeeenaees 3 19 Dale Seal sews E E PE E AE E E ET 3 19 System Infomation abisinin iaaa 3 19 SV40221 Rev A 3 1 3 Operator Functions About this Chapter This chapter explains functions on the machine that can be carried out by an Operator This includes e Selecting

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