Pitney Bowes Relay 3000 User Manual
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Pitney Bowes Relay 3000 User Manual

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See also: Operator's Manual
Shipping & Mailing
Inserter
Relay
™
Document Inserting Systems with
Touch Screen and Barcode Scanning
User Guide
International English Edition
SV63138 Rev. A
August 1, 2015
3000/4000

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Table of Contents
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Summary of Contents for Pitney Bowes Relay 3000

  • Page 1 Shipping & Mailing Inserter Relay 3000/4000 ™ Document Inserting Systems with Touch Screen and Barcode Scanning User Guide International English Edition SV63138 Rev. A August 1, 2015...
  • Page 2 Your inserter system may not have some of the features described in this book. E-Z Seal is a registered trademark of Pitney Bowes Inc. ENERGY STAR is a registered trademark of the United States Environmental Protection Agency.

  • Page 3: Table Of Contents

    Table of Contents Safety ................... v Chapter 1 System Overview Relay Inserter Introduction ..........1-3 Inserter Component Identification ........1-4 Touch Screen Display Identification ........1-6 Control Panel Icons ............1-8 Turn the Touch Screen On/Off .........1-10 Use the Touch Screen Keyboard ........1-11 Change the Display Language ........
  • Page 4 Table of Contents Chapter 3 Run a Job Run a Job ................3-3 Verify the Inserter Has Power ..........3-4 Turn On the Touch Screen ..........3-4 Log In .................3-4 Select a Job ............... 3-5 Manual Feed Jobs .............3-6 Load Material ..............3-7 Adjust and Load the Sheet Feeders ......3-7 Adjust and Load the Envelope Feeder .......
  • Page 5 Table of Contents Parity ................4-8 Re-timing Mark ............4-8 Select Feed (SF1, SF2) ..........4-9 Auto Batch ..............4-9 Wrap Around Sequence (WAS1, WAS2, WAS3) ..4-9 OMR Mark Grouping ............4-10 C-Fold and Double-Fold Jobs ........4-10 Z-Fold and Single-Fold Jobs ........4-11 Adjust the OMR Scanner ..........4-12 OMR Troubleshooting ............4-14 Error Recovery for OMR Jobs ........
  • Page 6 Table of Contents Chapter 6 Clear Material Clear Material ..............6-3 Access Areas of the Inserter for Jam Removal ....6-3 Sheet Feeders Trays - Remove and Replace .... 6-3 Fold Plates - Remove and Replace ......6-4 Insert Tray - Remove and Replace ......6-4 Access the Carriage Assembly ........

  • Page 7: Safety

    Safety Safety Information Follow these precautions whenever you use your inserting system: • Read all instructions before you attempt to operate the system. • Use this equipment only for its intended purpose. • Place the system close to an easily accessible wall outlet. •...
  • Page 8 Safety • Operation of this equipment without periodic maintenance will inhibit optimum operating performance and could cause the equipment to malfunction. • Always follow specific occupational safety and health standards for your workplace. • To reduce the risk of fire or electrical shock, DO NOT attempt to remove covers or disassemble the control panel or its base.
  • Page 9 1 • System Overview Contents Relay Inserter Introduction .........1-3 Inserter Component Identification.......1-4 Touch Screen Display Identification......1-6 Control Panel Icons ............1-8 Turn the Touch Screen On/Off ........1-10 Use the Touch Screen Keyboard ........1-11 Change the Display Language ........1-11 Touch Screen Usernames and Passwords....1-12 Rename or Create an Operator Username ..
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  • Page 11: Relay Inserter Introduction

    The Relay 3000 and 4000 Inserters offer touch screen functionality and barcode scanning. The touch screen is standard on the Relay 4000 and an option for the Relay 3000. The touch screen is necessary for barcode scanning, which is an option for both systems.

  • Page 12: Inserter Component Identification

    1 ● System Overview Inserter Component Identification 2D Camera — Converts barcode characters into mailpiece processing information. Touch Screen Display — Use this interface to enter commands, setup jobs, and change settings. Symbols and icons on the display show the system status. Insert Feeder —...
  • Page 13 1 ● System Overview Envelope Inverter - Transports the envelope into the stacker face up. Drop Stacker or Output Device — located at the exit of the inserter, this device collects finished mailpieces. This device can be latched against the inserter when not in use. Alternatively, a range of power stackers are available which offer greater capacity than the standard drop stacker.

  • Page 14: Touch Screen Display Identification

    1 ● System Overview Touch Screen Display Identification 14 13 Name of Jobs - Accesses the change job name screen. Setup - Tap to access setup mode to program jobs into system memory and change options in existing jobs. (Supervisor function; setup mode only) - Tap these icons to scroll through available options for job settings.
  • Page 15 1 ● System Overview Job - Tap repeatedly to scroll through programmed jobs that are stored in the inserter and select a job you want to run. The inserter can store up to 21 jobs (including one default job). Trial Piece - Tap to run a single test piece to check inserter setup. You must run a trial piece before you begin automatic operation using the Start button.

  • Page 16: Control Panel Icons

    1 ● System Overview Control Panel Icons Used on sheet feeders to signify that the feeder is on without double detection. Used on sheet feeders to signify that the feeder is on with double detection. Used on insert feeder to signify that the feeder is on without double detection.
  • Page 17 Indicates a no-fold insert operation Indicates a material stoppage. The position of this symbol in the display indicates where the stoppage has occurred. Call Pitney Bowes for service Indicates the paper size, address orientation and fold(s) set for sheet feeder Indicates a material stoppage in a downstream device, such as a power stacker.

  • Page 18: Turn The Touch Screen On/Off

    1 ● System Overview Turn the Touch Screen On/Off 1. Verify the inserter is powered up before you turn on the touch screen. 2. Press and hold the ON/OFF power button for a few seconds. The power button is located on the top eft frame of the touch screen. NOTE: If the touch screen is in sleep mode, press the ON/OFF button.

  • Page 19: Use The Touch Screen Keyboard

    1 ● System Overview Use the Touch Screen Keyboard NOTE: If the Windows task bar does not show along the bottom of the display, swipe your finger down toward the bottom of the screen. 1. To launch the keyboard, tap the icon on the task bar in the lower right corner of the display.

  • Page 20: Touch Screen Usernames And Passwords

    1 ● System Overview Touch Screen Usernames and Passwords Operators and Supervisors can rename operator usernames and change operator passwords. NOTE: The customer service representative who installs your system provides the Supervisor password. Supervisor passwords cannot be changed. Rename Default Operator Usernames Each operator requires a unique username.

  • Page 21: Change An Existing Operator Password

    1 ● System Overview Change an Existing Operator Password This procedure can be used to change an existing operator password. 1. Tap the icon twice. 2. When the Operator List displays select an Operator username and 3. To launch the keyboard, tap the icon on the bottom right corner of the screen and enter the Operator password in the field.

  • Page 22: Rename An Existing Default Job

    1 ● System Overview Rename an Existing or Default Job When a new job is created, a new name can be assigned to a default job. Operators and Supervisors can rename a job. 1. Tap the icon twice. 2. When the Operator List displays select an Operator and tap 3.

  • Page 23: Inserter Control Reports (On The Touch Screen)

    1 ● System Overview Inserter Control Reports (on the Touch Screen) The touch screen offers mailpiece reporting features on inserters running enhanced barcode scanning applications. The reports capture mailpiece data for a specified period of time or for specific jobs. Report Data When running an enhanced barcode scanning application, the reports contain unique information found within the barcode.

  • Page 24: Access Reports

    1 ● System Overview Access Reports Users are not required to log in to the touch screen to access inserter reports. There are two ways to access report data - you can select a specific date or set of dates or you can select a specific job or set of jobs. Select by Date To view inserter reports by a date or set of dates, follow these steps.

  • Page 25: Archive Reports

    1 ● System Overview Archive Reports You can archive reports by setting up the system to automatically save them to the pre-installed SD card in the touch screen. This is typically a Supervisor activity. 1. Tap the icon twice. 2. S elect an Operator name and tap 3.
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  • Page 27 2 • Program a Job Contents Navigate Using the Touch Screen ......2-3 Scanning and Non-Scanning Jobs ......2-4 Program a Job ............2-5 Log In ...............2-5 Enter Supervisor Access Code ......2-5 Select the Job Number (New or Existing Job) ........2-5 Program a Scanning Job .........2-6 Program a Non-Scanning Job ......2-14 Modify an Existing Job..........2-23 Delete a Job ............2-23...
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  • Page 29: Navigate Using The Touch Screen

    Program a Job ● 2 This section provides step-by-step instructions for setting up and saving a new scanning or non-scanning job and saving it using the touch screen display. Programming a job is typically a Supervisor activity. Navigate Using the Touch Screen To help visually guide you through the programing sequence, a icon appears on the display next to the area being set.

  • Page 30: Scanning And Non-Scanning Jobs

    2 ● Program a Job Scanning and Non-Scanning Jobs If scanning functionality (OMR or barcode) is enabled on your system, operators can toggle scanning on and off depending on the job. If scanning functionality is not available on your inserter, your job setup will differ slightly.

  • Page 31: Program A Job ● 2

    Program a Job ● 2 Program a Job Log In Log in with Supervisor level access. 1. Tap the icon twice at the bottom of the touch screen desktop. 2. When the Operator List displays select Supervisor username or an Operator not in use (typically indicated as Operator 1 - Operator 10).

  • Page 32: Program A Scanning Job

    2 ● Program a Job Program a Scanning Job Enable Scanning (OMR or Barcode) 1. When prompted, tap the icons to select one of the OMR on settings. (Refer to the OMR Settings table included here.) 2. Tap to accept the selection and advance to the next setting. SV63138 Rev.
  • Page 33 Program a Job ● 2 Scanning Settings Table (OMR and Barcode) Some of the OMR settings have been configured to apply to both OMR and barcode scanning jobs. When you are running barcode scanning applications, use the OMR functions that apply to barcode scanning. OMR and Barcode Settings Table OMR Settings Description...
  • Page 34 2 ● Program a Job Set the Fold Type 1. Tap the icons to scroll through the fold types. 2. Tap to accept the fold type and advance to the next setting. Fold Types C - Letter Z - Accordion Double Single When the fold type is selected, the display indicates the correct orientation...
  • Page 35 Program a Job ● 2 Set Select/Supplementary Sheet or Insert Feeder Select feed allows for one piece to be selectively fed from either feeder per envelope. 1. Tap the icons to scroll through the options. (Refer to the Additional Feeder Options, Scanning Jobs table for details.) 2.
  • Page 36 2 ● Program a Job Set the Sealer This setting appears only if insertion mode is selected. To select whether or not you want to seal envelopes. 1. Tap the icons to toggle the option to On or Off. 2. Tap to accept the option and advance to the next setting.
  • Page 37 Program a Job ● 2 Set Fold A 1. Select the size of the first fold required. NOTE: Depending on the settings you made earlier for fold type and paper length, the inserter suggests the correct dimension for the first fold. Most of the time this setting will prove satisfactory.
  • Page 38 2 ● Program a Job Set the Envelope Stop NOTE: The stop has five positions numbered 1 to 5. Setting 3 is the standard setting for normal weight paper with standard folds. A thinner/lighter insert requires a lower setting and a thicker/heavier insert requires a higher setting. 1.
  • Page 39 Program a Job ● 2 Run a Trial Piece Run a trial piece to test the job settings. 1. Load material and tap the Trial Piece button. 2. If you need to make changes to the settings based on the trial piece: a.

  • Page 40: Program A Non-Scanning Job

    2 ● Program a Job Program a Non-Scanning Job Follow this sequence of steps to program a non-scanning job. NOTE: If scanning is not available on your system, begin with "Set Accumulation." Disable Scanning (OMR or Barcode) if Functionality Exists If scanning is enabled on your system, set it to OMR off.
  • Page 41 Program a Job ● 2 Set Accumulation If accumulation is enabled, it allows multiple sheets to be fed from the sheet feeder into the envelope. This setting is only available for non- scanning jobs. 1. Tap the icons to scroll through the accumulation options. 2.
  • Page 42 2 ● Program a Job Set First/Main Sheet Feeder The first feeder is automatically selected depending on the fold type. • Collating different sheets using both sheet feeders - load the prime (address-bearing) document into sheet feeder 1 for C and double folds.
  • Page 43 Program a Job ● 2 Manual Feed Option • The manual feed setting allows you to run stapled sets of up to five sheets - a maximum of 100 lbs.(400gsm) per set. The maximum compressed thickness of the set after folding must not exceed 0.08 inches (2mm).
  • Page 44 2 ● Program a Job Set the Insert Feeder Select whether you want to use the insert feeder and how it will be used. 1. Tap the icons to scroll through the options. (Refer to the Insert Feeder Options table for descriptions.) 2.
  • Page 45 Program a Job ● 2 Set the Sealer This setting appears only if insertion mode is selected. 1. Select whether or not you want to seal envelopes. 2. Tap the icons to toggle the option to On or Off. 3. Tap to accept the option and advance to the next setting.
  • Page 46 2 ● Program a Job Set Fold A 1. Select the size of the first fold required. NOTE: Depending on the settings you made earlier for fold type and paper length, the inserter suggests the correct dimension for the first fold. Most of the time this setting will prove satisfactory.
  • Page 47 Program a Job ● 2 Set the Envelope Stop NOTE: The stop has five positions numbered 1 to 5. Setting 3 is the standard setting for normal weight paper with standard folds. A thinner/lighter insert requires a lower setting and a thicker/heavier insert requires a higher setting. 1.
  • Page 48 2 ● Program a Job Run a Trial Piece Run a trial piece to test the job settings. 1. Load material and tap the Trial Piece button. 2. If you need to make changes to the settings based on the trial piece: a.

  • Page 49: Modify An Existing Job

    Program a Job ● 2 Modify an Existing Job To modify an existing job follow these steps. (This requires Supervisor level access.) 1. Tap the Setup button to enter setup mode. 2. The Enter Access Code field displays over the inserter model on the touch screen display.
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  • Page 51 3 • Run a Job Contents Run a Job ............3-3 Verify the Inserter Has Power ......3-4 Turn On the Touch Screen........3-4 Log In..............3-4 Select a Job ..........3-5 Manual Feed Jobs ..........3-6 Load Material ............3-7 Adjust and Load the Sheet Feeders ..... 3-7 Adjust and Load the Envelope Feeder ..
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  • Page 53 Run a Job The operating activities outlined here assume that a job has already been programmed into the Relay 3000 or 4000 inserter. (Programming a job is typically a Supervisor function.) Activities Operators perform with the touch screen to run a previously programmed job: •...

  • Page 54: Verify The Inserter Has Power

    3 ● Run a Job Verify the Inserter Has Power 1. Verify the power cord is connected to the socket on the back of the inserter. 2. Verify the power cord is plugged into a power outlet near the machine and is easily accessible.

  • Page 55: Select A Job

    3 ● Run a Job Select a Job When the inserter is turned ON and you are logged in, the touch screen displays the last job run with the message Trial Piece Required. Select the job you wish to run. 1.

  • Page 56: Manual Feed Jobs

    3 ● Run a Job Manual Feed Jobs If you select a manual feed job where sheet feeder 1 is set for manual feed of collated sets, DO NOT load the sheet feeder. Instead, you will feed collated sets one at a time, by hand, as required. Before you run a manual feed job, pull back the lever (shown here).

  • Page 57: Load Material

    3 ● Run a Job Load Material Adjust and Load the Sheet Feeders 1. Adjust the side guides to the width of the material, then back-off a quarter turn on the side guide control. This sets the correct clearance between the guides and the material.

  • Page 58: Adjust And Load The Envelope Feeder

    3 ● Run a Job Adjust and Load the Envelope Feeder The envelope feeder feeds the outer envelope for the inserting job. 1. Press the envelope feeder loading switch to lower the feeder tray. 2. Use the side guide adjustment knob to adjust the side guides to the width of the envelopes.
  • Page 59 3 ● Run a Job Load Envelopes without Stopping the Inserter 1. Press the envelope feeder loading switch to lower the feeder tray. 2. Load envelopes as described earlier in this section. 3. Press the envelope feeder loading switch again. The envelope stack rises to the normal feeding position and processing continues...

  • Page 60: Adjust And Load The Insert Feeder

    3 ● Run a Job Adjust and Load the Insert Feeder The insert feeder feeds items that do not require folding. Depending on configuration of your inserter, you may not have an insert feeder. 1. Use the side guide adjustment knob to adjust the side guides to the width of the inserts you are running.
  • Page 61 3 ● Run a Job 5. Take the stack of inserts and aerate and fan it to ensure that individual pieces are not stuck together. 6. Shingle the inserts (as shown here) and place them on the feed deck. Loading orientation can vary depending on the inserts.

  • Page 62: Run A Trial Piece

    3 ● Run a Job Run a Trial Piece Run a trial piece to test the job settings. 1. Load material and tap the Trial Piece button to verify setup is correct. 2. You can still make changes to the job settings at this point if the trial piece needs fine tuning.

  • Page 63: Start And Stop The Inserter

    3 ● Run a Job Start and Stop the Inserter 1. Tap the Start button on the touch screen to begin automatic operation. 2. The inserter runs until it runs out of material or you tap the Stop button on the touch screen.

  • Page 64: Fill The Sealer

    3 ● Run a Job Fill the Sealer When the sealer unit needs refilling, the Add Sealing Solution icon flashes in the display. ® When this happens, add E-Z Seal Sealing Solution or water: 1. Open the sealer bottle cover hinge located at the rear, right side of the inserter and remove the bottle.
  • Page 65 4 • OMR Scanning Contents Optical Mark Recognition (OMR)......4-3 Accuracy ............4-3 OMR and Feeders on the Inserter ......4-3 OMR Scanning Types ..........4-4 Basic OMR ............4-4 Enhanced OMR ..........4-4 OMR Mark Positions..........4-4 OMR Specifications ..........4-5 Standard OMR Positions ........4-6 Offset OMR Positions........4-7 Available OMR Marks ...........4-8 Benchmark ............4-8 Safety ..............4-8...
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  • Page 67: Optical Mark Recognition (Omr)

    OMR Scanning • 4 Optical Mark Recognition (OMR) An OMR mark is normally a dark solid line on a sheet of light colored paper that is perpendicular to the direction of paper travel. This line must be thick and dense to trigger the OMR scanner. The OMR scanner works with the OMR system software to check for one or more different OMR Typical...

  • Page 68: Omr Scanning Types

    4 • OMR Scanning OMR Scanning Types Basic OMR • Enables the collation of multi-page documents. • Enables you to vary the number of pages per envelope. • The inserter folds each OMR sheet separately and inserts it into an envelope, starting with the last sheet of the set and adding each folded sheet in turn until the address sheet has been inserted.

  • Page 69: Omr Specifications

    OMR Scanning • 4 OMR Specifications The OMR mark must be a solid black line between 1pt and 2pts thick (0.014 inch (0.35mm) to 0.027 inch (0.7mm]) and at least 0.393 inch (10mm) wide. Each mark position must be evenly spaced, at least 0.118 inch (3mm) apart.

  • Page 70: Standard Omr Positions

    4 • OMR Scanning Standard OMR Positions 54mm 96mm Feed Direction for Top 115mm Scanning (C- and Double Fold) 20mm Clear Zone 20mm x 115mm min Clear Zone 20mm x 100mm min 20mm Vertically center group within area indicated Feed Direction for 100mm Bottom Scanning (Z- and Single Fold)

  • Page 71: Offset Omr Positions

    OMR Scanning • 4 Offset OMR Positions 20mm 95mm Feed 40mm Direction for Top Scanning (C- and 125mm Double Fold) 65mm 65mm Bench Mark 115mm 80mm Feed Direction for Bottom Scanning 20mm (Z- and Single Fold) Position OMR marks as follows: •...

  • Page 72: Available Omr Marks

    4 • OMR Scanning Available OMR Marks This section gives brief descriptions of the OMR marks that can or must be allocated to an OMR Code. NOTE: Some marks within this section are available as added features that expand OMR capability. OMR features will vary depending on the options you purchased.

  • Page 73: Select Feed (Sf1, Sf2)

    OMR Scanning • 4 Select Feed (SF1, SF2) These marks are used to control the feed of material from the feeder holding the supplementary sheets/inserts on a set-by-set basis. Therefore you cannot use select feed on a single-station inserter. Use Select Feed 1 marks are in the primary sheet feeder to select material from the supplementary sheet feeder.

  • Page 74: Omr Mark Grouping

    4 • OMR Scanning OMR Mark Grouping Each OMR code begins with two fixed marks: benchmark and safety mark. These marks are located at the end nearest to the sensor. These are followed by one, two, or three groups of marks where each group comprises three data marks followed by a fixed mark.

  • Page 75: Z-Fold And Single-Fold Jobs

    OMR Scanning • 4 Z-Fold and Single-Fold Jobs Place marks in the lower right corner of the sheet. Print marks in bottom- to-top order: Re-timing (fixed if this group is in use) Wrap Around Sequence 1 (WAS1) Group 3 Wrap Around Sequence 2 (WAS2) Wrap Around Sequence 3 (WAS3) Re-timing (fixed if this group is in use) Auto Batch...

  • Page 76: Adjust The Omr Scanner

    4 • OMR Scanning Adjust the OMR Scanner In order for OMR scanning to work correctly, it is important to ensure that the scanning heads are positioned in line with the Scan Dash (OMR) marks printed on the material. 1. To locate the scanning head for the top sheet feeder 1, open the top cover.
  • Page 77 OMR Scanning • 4 Folding Example: For an A4 size sheet, the half fold measurement is 105mm. If the distance from the edge of the form to the middle of the scan dash marks is 10mm, the scanning head setting will be 95mm (105mm –...

  • Page 78: Omr Troubleshooting

    4 • OMR Scanning OMR Troubleshooting Error Recovery for OMR Jobs If the inserter stops during an OMR job, and indicates one of the error messages listed below, follow these steps. 1. Tap the Clear Deck button on the control panel. Any envelope at the insertion area will eject into the stacker.

  • Page 79: Omr Error Messages

    OMR Scanning • 4 OMR Error Messages Message Action Bad OMR marks Two marks that are closer together than half the Spacing expected distance are read. Check scan marks on material. No OMR marks • No marks on paper. • Scan sensor is not centered over scan marks. •...
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  • Page 81 5 • Barcode Scanning Contents Barcode Scanning ............5-3 How Barcode Scanning Works ......5-3 1D and 2D Barcode Scanning ......5-3 Jobs with Barcode Scanning ......5-4 Barcode Options ............5-4 Basic Barcode Reading (1D barcodes only) ..5-4 Enhanced Barcode Reading (2D barcodes only) ........5-4 Barcode Placement Specifications ......5-5 Barcode Placement Areas ........5-5 Barcode Zones - Clear and Blank ......5-7...
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  • Page 83: How Barcode Scanning Works

    Barcode Scanning • 5 Barcode Scanning Enhanced barcode applications support mailpiece integrity by ensuring proper mailpiece assembly. Barcodes that contain specific instructions about your job can be printed on the front of your primary sheet set. Information like record #, page number, and page total can be contained in the code.

  • Page 84: Jobs With Barcode Scanning

    5 • Barcode Scanning Jobs with Barcode Scanning • Sheet feeder 1 (the top feeder) holds the sheets with the barcodes printed on them. • Multiple sheets can be inserted into an envelope with barcode scanning. The number of sheets inserted into an envelope is determined by the information in the barcode.

  • Page 85: Barcode Placement Specifications

    Barcode Scanning • 5 Barcode Placement Specifications Barcode Placement Areas The barcode can be positioned anywhere within the barcode placement area shown in this diagram. The areas identified here are at the bottom (trail edge) of the sheet. The diagram below is for an 8.5 x 11-inch sheet. SV63138 Rev.
  • Page 86 5 • Barcode Scanning The diagram below is for an A4 sheet. SV63138 Rev. A...

  • Page 87: Barcode Zones - Clear And Blank

    Barcode Scanning • 5 Barcode Zones - Clear and Blank There are specific guidelines regarding printing text and additional barcodes in the areas around the primary barcode. Clear Zone (A) The clear zone is the closest area to the barcode. This area (represented by letter A in the diagram below) includes the size of the barcode plus 5mm on each side (10mm) and 5mm on the top and bottom (10mm).

  • Page 88: 2D Barcode Camera Setup

    5 • Barcode Scanning 2D Barcode Camera Setup Setting up the 2D barcode camera is an operator activity. Turn On the 2D Barcode Camera You can alternate between OMR (if your system has this option) and barcode scanning, depending on the features available on your system. 1.

  • Page 89: Adjust The Position Of The 2D Barcode Camera

    Barcode Scanning • 5 Adjust the Position of the 2D Barcode Camera 1. Verify the inserter is powered up and the 2D barcode camera is on. 2. Place the sheet with your barcode on it into the sheet feeder. 3. Loosen the two locking knobs on the scanner adjustment arms. 4.

  • Page 90: 2D Barcode Scanning Final Checklist

    5 • Barcode Scanning 2D Barcode Scanning Final Checklist • Confirm that you have the correct job selected. • Make sure that the barcode camera switch is in the ON position. • Verify the barcode camera is positioned correctly above the barcode; adjust if necessary.

  • Page 91: Barcode Error Messages

    Barcode Scanning • 5 Barcode Error Messages The inserter software uses the same error messages for both OMR and barcode scanning. Use this table as a reference for understanding and troubleshooting error messages. Message Issue Solution No OMR marks • Barcode was •...

  • Page 92: 2D Barcode Specifications

    5 • Barcode Scanning 2D Barcode Specifications Paper Specifications • 8.5 x 11 inches • • Minimum paper weight 70 gsm (47 lb) • Maximum paper weight 120 gsm (81 lb) • White paper only 2D Barcode Specifications • Print quality - Minimum requirement ANSI Grade B - Recommended ANSI Grade A - Black print on white paper...
  • Page 93 6 • Clear Material Contents Clear Material ............6-3 Access Areas of the Inserter for Jam Removal ..6-3 Sheet Feeders Trays - Remove and Replace .6-3 Fold Plates - Remove and Replace ....6-4 Insert Tray - Remove and Replace ....6-4 Access the Carriage Assembly .......6-4 Access to Envelope Feeder Area ....6-5 Access the Envelope Exit Area .......6-5 Access the Envelope Inserting/Sealing Area ..6-6...
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  • Page 95: Access Areas Of The Inserter For Jam Removal

    Clear Material • 6 Clear Material The inserter is designed to assure maximum performance. In the event of a material stoppage, the display flashes a symbol indicating where the stoppage has occurred. To clear a jam follow these steps. 1. Tap the Clear Deck button to feed the material through the inserter. 2.

  • Page 96: Fold Plates - Remove And Replace

    6 • Clear Material Fold Plates - Remove and Replace To remove the fold plates: 1. Pull the two catches on the underside of the plate outward to release them. 2. Pull the plate straight out of the inserter. To replace the fold plates: 1.

  • Page 97: Access To Envelope Feeder Area

    Clear Material • 6 Access to Envelope Feeder Area Unlatch the envelope area feed rollers to access a jam in the envelope feeder area. 1. Pull the release lever in the direction of the arrow. 2. Lift the envelope area feed rollers for access to the jam.

  • Page 98: Access The Envelope Inserting/Sealing Area

    6 • Clear Material Access the Envelope Inserting/Sealing Area To access the insertion and sealing areas: 1. Lift the tinted plastic cover and lower the envelope inverter access door. 2. The points identified in the image can be unlatched to allow access to stalled material.

  • Page 99: Chapter 7 Troubleshooting And Error Messages

    7 • Troubleshooting and Error Messages Contents General Troubleshooting ........7-3 Changing the Sealer Unit Felts Error Messages .............7-9 SV63138 Rev. A...
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  • Page 101: General Troubleshooting

    Troubleshooting and Error Messages • 7 General Troubleshooting Issue Possible Solutions INSERTER Blank Screen No power. Check that the power cord is firmly connected and the wall socket is switched ON. Inserter not Turn the power switch (located on left side) ON. switched ON.
  • Page 102 7 • Troubleshooting and Error Messages Issue Possible Solutions ENVELOPES Poor Envelope Feed Envelope side guides Set the guides to the envelope width and then set incorrectly. back off 1/4 turn. Poor envelope quality. Check that the envelopes are not curled. Try a new box of envelopes.
  • Page 103 Troubleshooting and Error Messages • 7 Issue Possible Solutions SHEETS Poor Sheet Feed Feeder not selected Check job setup. to feed. Sheet feeder Set guides to sheet width and back off 1/4 turn. side guides set incorrectly. Sheets loaded Make sure to fan stack before loading. incorrectly.
  • Page 104 7 • Troubleshooting and Error Messages Issue Possible Solutions INSERTS Poor Insert Feed Feeder not selected Check job setup. to feed. Insert feeder side Set guides to insert width and back off 1/4 turn. guides set incorrectly. Insert feeder Verify the two insert feeder adjustments (number separator and letter settings) are set correctly for the type adjustments...

  • Page 105: Changing The Sealer Unit Felts

    Troubleshooting and Error Messages • 7 Changing the Sealer Unit Felts If you are experiencing poor sealing, the sealer unit felts may need to be changed. The sealer unit felts are supplied as part of a kit. Operators can change them as necessary. 1.
  • Page 106 7 • Troubleshooting and Error Messages 5. Remove it from its mounting bar and discard the old felt. 6. Install the new upper felt. Locate the tabs on the back of the felt assembly in the corresponding holes of the mounting bar and slide the felt toward the rear of the machine.

  • Page 107: Error Messages

    Troubleshooting and Error Messages • 7 Error Messages Message Action CALL SERVICE Power the inserter off and on. If the message is still displayed, call service. CHECK /CLEAR Feeder indicated has failed to feed material. FEEDER Remove material from the feed tray, reload and restart the inserter.
  • Page 108 7 • Troubleshooting and Error Messages Message Action CLEAR SEALER Material is detected in the sealer brush area. • Open the tinted plastic cover on left side of the inserter and remove any material. • Close cover and restart. CLOSE COVER Cover indicated is not fully closed.
  • Page 109 Troubleshooting and Error Messages • 7 Message Action PAPER SHORT The inserter detected that the material used is too short in length. • Check the actual material length matches the length displayed. • If correct, request another trial piece. PAPER SHORT The inserter detected that the material used is too CHECK STACKER short in length.
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  • Page 111 8 • Material Specifications Contents Material Specifications...........8-3 Sheet Feeders ..........8-3 Number of sheets ..........8-4 Paper Weights in Pounds........8-4 Insert Feeder ...........8-5 Sealer ..............8-5 Stacker ............8-5 Material Requirements ........8-5 Envelope Feeder ..........8-6 Inserter Specifications ...........8-7 SV63138 Rev. A...
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  • Page 113: Material Specifications • 8

    Material Specifications • 8 Material Specifications IMPORTANT: All specifications are subject to change without notification and are subject to test. Sheet Feeders Minimum Sheet Size: 5 inches (127mm) width 5 inches (127mm) length Maximum Sheet Size: 9 inches (229mm) width 16 inches (406mm) length Paper Weights: 16 lb.

  • Page 114: Number Of Sheets

    8 • Material Specifications Fold Type and Overall Thickness Limits Check this table for the maximum number of sheets that can be accumulated/collated for each fold type. IMPORTANT! Do not program jobs that exceed these maximums or impose them by OMR code printing and/or OMR selective feed. Paper Weights in Pounds Number of sheets...

  • Page 115: Insert Feeder

    The envelope stacker accommodates up to 150 filled envelopes (depending on size and contents of the envelope). Material Requirements • For best performance, use only materials approved by Pitney Bowes • Materials should be good quality and properly stored. •...

  • Page 116: Envelope Feeder

    8 • Material Specifications Envelope Feeder Minimum Envelope Size: 3.5 inches (88mm) depth 8.5 inches (220mm) width Maximum Envelope Size: 6.5 inches (164mm) depth WIDTH 9.5 inches (242mm) width Envelope Weights: 17 lbs. (65gsm) minimum 26 lbs. (100gsm) maximum Envelope Tray Capacity: Up to a maximum of 300 24 lb. (90gsm) envelopes.

  • Page 117: Inserter Specifications

    Material Specifications • 8 Inserter Specifications Physical Dimensions: Length: 38.6 inches (980mm) Depth: 20.25 inches (514mm) Height: 20.75 inches (525mm) Weight: 143 lbs. (65kg) Noise Level (system running): 73dBA Electrical: USA and Canada 120V, 60Hz, 6.0A Europe 220/240V 50Hz Japan 100V, 50/60 Hz Speed: Up to a maximum of 3,500 cycles per hour (depending on inserter...
  • Page 118 If you have questions about your inserter or require service or assistance with your application, refer to the Contact List at the front of this guide. Pitney Bowes also offers a service maintenance agreement to keep your inserter in top condition. For further information, contact your local Pitney Bowes office or authorized dealer.
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  • Page 120 3001 Summer Street Stamford, CT 06926-0700 www.pitneybowes.com SV63138 Rev. A © 2015 Pitney Bowes Inc. All Rights Reserved...

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