Pitney Bowes Epic v3.1 Operator's Manual
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Pitney Bowes Epic v3.1 Operator's Manual

Pitney Bowes Epic v3.1 Operator's Manual

Inserting system, auto adjust chassis
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Shipping & Mailing
Inserting
Epic™ v3.1(ZVE0)
Inserting System
Auto Adjust Chassis
Operator Guide
US English Edition
SV63233 RevG
May 8, 2018

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Summary of Contents for Pitney Bowes Epic v3.1

  • Page 1 Shipping & Mailing Inserting Epic™ v3.1(ZVE0) Inserting System Auto Adjust Chassis Operator Guide US English Edition SV63233 RevG May 8, 2018...
  • Page 2 However, we cannot assume responsibility for errors or omissions or liability for the misuse or misapplication of our products. Except as provided in writing, duly signed by an officer of Pitney Bowes, no license either express or implied, under any Pitney Bowes or third party’s patent, copyright or other...
  • Page 3 This guide is designed to support proper setup, operation, jam removal, troubleshooting, and basic maintenance activities associated with the Epic v3.1 Inserting System. This guide covers Epic v3.1 system components from the Buffer through the On Edge Stacker. System input content can be found in related operator guides listed here in the "Related Documentation"...
  • Page 4 Print+ Messenger Digital Inkjet System Operator Guide (OG_APF_PRINT_020111) Hunkeler UW6 Unwinding Module Operator Guide (OG-Hunk-Unwinder) Auto Buckle Chute (Y488, Y20R, Y20S) Operator Guide (OG-APF-INPU-011513) Y254 Vacuum Sheet Feeder Operator Guide (SV63223) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page iv of 7...

  • Page 5: Table Of Contents

    2 - Product Overview Clear Deck Function About the Speed Indicators in DC Epic v3.1 (ZVE0) Inserting System About the DC Alarm Message Box Component Overview - Epic v3.1 (ZVE0) Indicator Lights About the Remote Control 5 - Operator Adjustments Operator Adjustments...
  • Page 6 Adjusting the Booklet Feeder Side Guides Removing Finished Mail from the On Edge Adjusting the Booklet Feeder Pack Control Stacker Ramp Removing Mail from the Flat Conveyor Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page vi of 7...
  • Page 7 Removing Material Jams in the Flat Conveyor 244 Epic Edge Markers (Y367, Y368, Y369 ) Environmental Operating Conditions Network and Power Requirements 9 - Troubleshooting Air Requirements Expected Lifetime Troubleshooting Engine Troubleshooting Chassis Troubleshooting Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page vii of 7...
  • Page 8 1 - Safety In this section Safety Information Power Operation Maintenance Warning Labels and Cautions Safety Features...

  • Page 9: Safety

    90dBA time weighted average over an 8-hour shift mandates hearing protection is used. (European Union standard is 85dBA) Note: Local jurisdictions may have more stringent requirements. Refer to local regulations for standards and requirements in your area. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 2 of 328...

  • Page 10: Power

    For input and output modules - power is distributed from the chassis. Use the AC connectors supplied with the modules to connect to system power. Do not connect external devices to the inserter. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 3 of 328...

  • Page 11: Operation

    It is essential that personnel employ safe working practices and observe all related regulations and legal requirements for safety when operating this product. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 4 of 328...

  • Page 12: Maintenance

    A setup tool is supplied for adjustments to accommodate different size paper on the inserter. Use only Pitney Bowes approved printer ink and cleaners. To prevent overheating, do not cover the vent openings. Do not store flammable fluids inside this machine.

  • Page 13: Warning Labels And Cautions

    Safety Warning Labels and Cautions Pitney Bowes declines all liability in the event of material damage or bodily injury resulting from negligence in the application of these precautions in respect to handling, operating, or servicing, even if not expressly stated in these instructions.
  • Page 14 Burn hazard; hot surface inside. Allow to cool before servicing. Caution: Motor Capacitor Discharge Allow six minutes for motor capacitors to discharge before servicing motor driver module. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 7 of 328...
  • Page 15 Caution: Cut Hazard Caution, sharp blades. Keep hands clear during operation. Caution: Sharp Point Caution, sharp points. Use care when working in this area; keep hands clear during operation. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 8 of 328...
  • Page 16 Caution: Pinch Point - Infeed Envelope Conveyor Gripper To prevent potential injury do not put your hands near the infeed envelope conveyor gripper area. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 9 of 328...

  • Page 17: Safety Features

    There is an ESTOP icon on the Direct Connect main screen that indicates there is an ESTOP or interlock open, prohibiting the machine from starting. ESTOP Icon - Main DC Screen (red) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 10 of 328...
  • Page 18 If the cover is partially closed, the icon on the main DC screen will not change color or indicate an open cover, but the machine will not start. If this occurs, verify the cover is fully closed. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 11 of 328...
  • Page 19 The inserter system still has power but is not able to run when the feder interlock switch is engaged. Insert Rotary Feeder Interlock Switch (gray) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 12 of 328...
  • Page 20 2 - Product Overview In this section Epic v3.1 (ZVE0) Inserting System Component Overview - Epic v3.1 (ZVE0) Indicator Lights About the Remote Control...

  • Page 21: Product Overview

    Direct Connect (DC) software. The Epic v3.1 (ZVE0) Inserter has all the auto adjustments features of the original Epic engine, plus auto adjusting chassis side guides and new buffer (ZVB4) design. These side guides work the same as the other engine auto adjust features, in that they automatically adjust to the measurements defined in the mode setting for each job.

  • Page 22: Component Overview - Epic V3.1 (Zve0)

    Product Overview Component Overview - Epic v3.1 (ZVE0) The Epic v3.1 (ZVE0) Inserting system consists of these main modules and sections. Item Description Item Description Input modules Sealer Buffer Turnover Chassis Print+ Messenger Printer (optional) Insert Feeders Vertical Stacker (with flats stacker)
  • Page 23 A stacker for flats can be installed under a vertical stacker, and is operator removable. On Edge Stacker - This is where the finished mailpieces are stacked vertically, until they are removed and placed in mail trays. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 16 of 328...

  • Page 24: Indicator Lights

    System Indicator Lights LED State Meaning Ready to run Slow blink Feeder material low Fast blink Interlock open System Indicator Lights Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 17 of 328...

  • Page 25: About The Remote Control

    Clear Deck - To clear the deck (an operating sequence that clears the inserter deck of all mailpieces), press the Stop and Cycle buttons at the same time. Refer to the Clear Deck Function topic for more information. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 18 of 328...

  • Page 26: Power The System On And Off

    3 - Power the System On and Off In this section Powering Up the System Powering Down the System...

  • Page 27: Powering Up The System

    There are specific instructions for powering up the system, both the inserter and the Direct Connect computer. Power Up the Inserter 1. Locate the red and yellow ON/OFF power switch (near left most chassis feeder on lower cabinet). ON/OFF Switch Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 20 of 328...
  • Page 28 Note: Depending on your site, the Windows log in may be automatic and you will not be prompted to perform this step. 3. Log in to DC. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 21 of 328...

  • Page 29: Powering Down The System

    2. Click Control > Power Down on the DC main menu bar. 3. When the Power Down window opens, click Yes. This powers down the DC computer. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 22 of 328...
  • Page 30 2. To turn the system OFF, rotate the red section of the switch counterclockwise from the 12:00 position, so the arrow is facing in the 9:00 position. Main Power Switch - ON position and OFF position Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 23 of 328...
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  • Page 32 4 - Using Direct Connect In this section Direct Connect Software Overview DC Main Screen Changing the UI Display Language Powering Down the DC Computer Viewing DC Software Details Logging In and Logging Out of DC Loading a Mode Setting the Mail Date Checking Status with Job Manager Accessing Reports in DC Starting and Stopping the Inserter Using DC...

  • Page 33: Using Direct Connect

    Using Direct Connect Direct Connect Software Overview Pitney Bowes inserters are controlled by Direct Connect™ (DC) software. This software provides centralized control that allows the DC PC to control operational areas on the inserter. The software can detect inserter issues while the machine is running. When material jams or inserter problems occur, the software pinpoints them swiftly to minimize machine downtime.

  • Page 34: Dc Main Screen

    This screen is configurable. The items shown in this example are for reference only and may not match the DC screen on the inserter(s) at your site. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 27 of 328...
  • Page 35 Menu Button Banner Area Alarm Icon Buttons Alarm Message Box Icons (may look different site to site) Speed Indicators Start Bar (Menu, Start/Stop, Cycle buttons) Inserter Model Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 28 of 328...
  • Page 36 Alarm icon - indicates an error (click to view more error information) Alarm message box - displays specific error Speed indicators - displays sheets fed and sheets processed Inserter model - graphic representation of the inserter modules Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 29 of 328...

  • Page 37: Changing The Ui Display Language

    1. Click Control on the DC main menu bar. 2. Hover over Switch Languages and select the language you want. Note: The UI display language is typically set by Service during the installation process. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 30 of 328...

  • Page 38: Powering Down The Dc Computer

    2. Select Power Down and click Yes when prompted. This shuts down the DC computer. Note: If you are logged in as an Operator, you cannot exit DC, you can only power down the DC computer. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 31 of 328...

  • Page 39: Viewing Dc Software Details

    DC screen. 1. Click About! on the main menu bar in DC, a dialog opens with software details (version, install date, ID number). 2. Click Close to exit. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 32 of 328...

  • Page 40: Logging In And Logging Out Of Dc

    When a user is logged in, the Login button shows an unlocked padlock icon and the operator's name is displayed in the banner area of the screen. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 33 of 328...
  • Page 41 Monitor speed indicators View and access alarm screens View Help dialogs Note: Key Operators have the same access operators do, and they can get to some additional setup screens. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 34 of 328...

  • Page 42: Loading A Mode

    Before you run a job, load the mode. 1. Log in to DC. 2. Click the Mode button on the main DC screen. 3. Select Load Mode from the drop-down menu. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 35 of 328...
  • Page 43 4. Highlight the mode for the job you are setting up and click OK. Note: After you load the mode successfully, the mode name appears in the banner area at the top of the main DC screen. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 36 of 328...

  • Page 44: Setting The Mail Date

    2. Select Set Mail Date from the drop-down menu. 3. When the dialog opens, type in the mail date. (It must be today's date or a date in the future.) 4. Click OK. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 37 of 328...

  • Page 45: Checking Status With Job Manager

    2. Select Status from the drop-down menu. A Job Manager Status dialog opens and displays information about the machine, the current job, the operator, etc. 3. Click Close to exit. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 38 of 328...

  • Page 46: Accessing Reports In Dc

    3. When the folder opens, browse through the reports you saved and double-click the desired report to view details. Note: The Direct Reports option is not available at an Operator log in access level. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 39 of 328...

  • Page 47: Starting And Stopping The Inserter Using Dc

    Also, when you click Stop, the Menu, Start, and Cycle buttons display again. Note: You can also start or stop the inserter using the remote control. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 40 of 328...

  • Page 48: Assigning An Mrdf File (File Based Jobs)

    3. In the Select Mailrun field, type in the name of the MRDF file or scan it from the work order. 4. When the file name populates the field, click OK to open it. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 41 of 328...

  • Page 49: Disabling (And Enabling) The Inserter

    3. When you are ready to run the inserter, click the Menu button and select Enable System. The inserter is enable to start when you are ready. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 42 of 328...

  • Page 50: Clear Deck Function

    If the machine is not running when Clear Deck is initiated, the next time the machine is started, all mail that was being processed is completed and then the system will stop. Once initiated, the Clear Deck message flashes at the bottom of the screen. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 43 of 328...
  • Page 51 Initiate Clear Deck and Feeders Manually 1. Click the Chassis object on the main DC screen and select Clear Deck & Feeders from the drop- down menu. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 44 of 328...
  • Page 52 2. When the Chassis Setup dialog opens, select the Clear feeders on clear deck checkbox. (Every time you initiate the Clear Deck function, the material in the armed area of the insert feeders is also cleared.) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 45 of 328...

  • Page 53: About The Speed Indicators In Dc

    The output speed indicator displays the output speed in numbers of mailpieces per hour (shown as 677 here), as well as the total number of mailpieces that reached the output stacker (shown as 12 here). Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 46 of 328...

  • Page 54: About The Dc Alarm Message Box

    When an alarm displays in the alarm message box, you can get more information about what and where the issue is, and suggestions on how to solve it.. Refer to the Alarm Recovery topic for more detailed information on how to manage DC alarms. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 47 of 328...
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  • Page 56: Operator Adjustments

    5 - Operator Adjustments In this section Operator Adjustments Adjusting the Envelope Feeder Separator Gap Adjusting the Envelope Fence Adjusting the Suction Cups in the Engine Adjusting the Engine Tongue Position Adjusting the Engine Tongue Height About Engine Horns Changing Engine Horns Envelope Settings Setting Up the RAT (Right Angle Transfer) Adjusting Amount of Sealer Fluid Applied...
  • Page 57 Setting Backup Feeders (Backup Feed Mode) Transport Envelope Setup (Xport Setup) Setting Separator Options for Friction Feeders Recalibrating the Double Detect Feature Adjusting Buffer Upper O-ring Belt Height Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 50 of 328...

  • Page 58: Operator Adjustments

    Some of the adjustments for a job changeover the system makes automatically, and some you need to make manually. Refer to the "Job Changeover Guidelines" topic for detailed information. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 51 of 328...

  • Page 59: Adjusting The Envelope Feeder Separator Gap

    If the gap is too tight, envelopes will not feed. If the gap is open too wide, multiple envelopes will feed. 1. Pull the separator access lever towards you until it stops and hold it in place. Pull Back Separator Access Lever Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 52 of 328...
  • Page 60 If there is too much drag on the envelope, open the knob to reduce drag. b. If there is not enough drag on the envelope, close the knob to increase drag. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 53 of 328...
  • Page 61 Note: This adjustment gets the feeder gap close to the final setting. During operation testing additional adjustments may be necessary if doubles or no envelopes are feeding. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 54 of 328...

  • Page 62: Adjusting The Envelope Fence

    2. Loosen the lock down lever and slide the envelope fence up or down until the alignment arrow lines up with the top edge of the envelopes. Loosen Lever and Use Alignment Arrows 3. When the fence is properly positioned, lock it in place. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 55 of 328...

  • Page 63: Adjusting The Suction Cups In The Engine

    4. Align the top of the envelope (flap crease line) with the deck lines shown here. (This is where the envelope is staged. All adjustments should be made from this position.) Align Envelope Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 56 of 328...
  • Page 64 Operator Adjustments 5. Close the upper engine. Close Upper Engine Envelope Aligned - view from above Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 57 of 328...
  • Page 65 Operator Adjustments 6. Use the operator setup tool to loosen the three suction cup lockdown screws. Suction Cup Lockdown Screws Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 58 of 328...
  • Page 66 Position Suction Cups - 1/8-inch (3 mm) from throat 8. Tighten the suction cup lockdown screws. 9. Remove the envelope. 10. Lower the upper engine. 11. Close the cover. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 59 of 328...

  • Page 67: Adjusting The Engine Tongue Position

    4. Align the top of the envelope (flap crease line) with the deck lines shown here. (This is where the envelope is staged. All adjustments should be made from this position.) Envelope Flap Against Insert Ledge Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 60 of 328...
  • Page 68 Operator Adjustments 5. Close the upper engine. Close Upper Engine 6. Use the operator setup tool to loosen both horizontal tongue lockdown screws. Tongue Lockdown Screws Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 61 of 328...
  • Page 69 1/8" (3 mm) gap between tongue and throat Position Tongue Assembly 8. Tighten the lockdown screws. 9. Remove the envelope. 10. Lower the upper engine. 11. Close the engine cover. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 62 of 328...

  • Page 70: Adjusting The Engine Tongue Height

    2. Open the engine top cover and open the upper engine. 3. Locate the lockdown screw to adjust the tongue height and loosen it. Tongue Height Lockdown Screw Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 63 of 328...
  • Page 71 Small Gap (1 to 2 mm) between Tongue and Collation 6. Remove all material from under the tongue and insert area. 7. Lower the upper engine. 8. Close the engine cover. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 64 of 328...

  • Page 72: About Engine Horns

    Thick horn - this horn is used for applications running thicker collations, up to 13 mm. Use the horn that is saved to the mode, otherwise timing and adjustments may not be properly completed. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 65 of 328...

  • Page 73: Changing Engine Horns

    The short screw is captured and will not come out of the horn assembly. When loosening the screw, do not hold the horn or you can damage it. Short Screw - Horn Mounting Screw Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 66 of 328...
  • Page 74 Operator Adjustments 2. Using the setup tool, loosen the single locking screw and remove the horn strap. Item Description Mounting Screw Horn Strap Horn Remove the Horn Strap Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 67 of 328...
  • Page 75 3. Remove the horn you are going to use from the holder, and store the removed horn back in the holder. Horn on Holder 4. Install the new horn by aligning the horn mounting with the horn mount. Horn Mounting Screw Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 68 of 328...
  • Page 76 Operator Adjustments 5. Tighten the horn in place. (NOTE: Don't hold the horn while you tightening it; it may cause damage.) Item Description Horn Mounting Screw Horn Mount Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 69 of 328...
  • Page 77 Tighten the horn mounting screw in place and verify that the horn pivots freely without binds. Item Description Mounting Screw Horn Strap Horn Install Horn Strap 7. Load the mode for the new application. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 70 of 328...

  • Page 78: Envelope Settings

    1. Log into DC as Key Operator access level or higher. 2. Click the Engine object on the main DC screen and select Setup from the drop-down menu. Engine Object Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 71 of 328...
  • Page 79 Weight - weight of the envelope (optional) Thickness - (referring to material thickness) the thickness of a single insert or document page that will be fed from this feeder. (optional) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 72 of 328...
  • Page 80 Using the Flap Delta Envelope Guide Template To identify the envelope flap delta using the flap delta envelope guide template (SV63174): 1. Lay the envelope flap template on a flat surface. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 73 of 328...
  • Page 81 5. Square up the envelope with the guidelines on the bottom of the template. Item Description Center line of template (aligned with center of envelope) Bottom of envelope (parallel with template guides) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 74 of 328...
  • Page 82 Right side of the scale is in millimeters. In this Example - Flap Delta is .7 inches 7. Enter the value of the Flap Delta (measured in step #6) in the Engine Setup screen. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 75 of 328...
  • Page 83 1. Measure the flap height from the crease line to the edge of the center of the flap - that is your flap height measurement for entry into DC. Envelope Information - Flap Height Measurement Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 76 of 328...
  • Page 84 2. Measure the height difference from the marked point to the top center of the flap - that is your flap delta measurement for entry into DC. Envelope Information - Flap Delta Measurement Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 77 of 328...

  • Page 85: Setting Up The Rat (Right Angle Transfer)

    4. With the locking screw loose, adjust the tension of the roller. (The left side is lighter, press to the right is more pressure.) 5. Tighten the locking screw. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 78 of 328...
  • Page 86 Operator Adjustments 6. Perform on other roller if needed. 7. Close covers. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 79 of 328...

  • Page 87: Adjusting Amount Of Sealer Fluid Applied

    1. Click the Sealer object on the main DC screen and select Sealer Control from the drop-down. Sealer Object Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 80 of 328...
  • Page 88 Make small changes with the slider checking often to see if you are getting the desired results. Excessive fluid will drain into the overflow tube into the overflow catch bin. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 81 of 328...

  • Page 89: Setting Up The Vertical Stacker

    Rollers are used to correct small amounts of skew or misalignment only; adjustments should be slight. Always check upstream of where the skew / misalignment occurred to see if another area is the issue. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 82 of 328...
  • Page 90 1. Loosen both thumb screws and slide the guide on the bars to the desired position. 2. Tighten the thumb screws. Note: When running flats, remove the guides from all vertical stackers before the flats conveyor stacker. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 83 of 328...

  • Page 91: Moving The Flat Stacker

    When you are not running flat envelopes, the stacker can be removed from the work cell to increase access to the On Edge Stacker. Note: The stacker can be removed and installed while the system is powered on. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 84 of 328...
  • Page 92 Squeeze the top and bottom tab while gently pulling the connector free. c. Pull the blue connector off the base. Item Description Connector Pull connector off Remove Electrical Connections Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 85 of 328...
  • Page 93 3. With the electrical connection disconnected and the latches down, grasp the handle on the other side of the module, and roll the unit out from under the vertical stacker. 4. Move the module to a secure location to prevent damage. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 86 of 328...
  • Page 94 Align the pin into the blue plug and press them together. Item Description Connector Align and press together Electrical Connections Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 87 of 328...

  • Page 95: About The On Edge Stacker (Oes)

    Pack Pressure Adjustment Knob (on backside, not visible here) Control Panel OES Fingers (on backside, not visible here) Bin Full Switch with 3/4 Full Sensor On Edge Stacker (OES) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 88 of 328...
  • Page 96 Operator Adjustments Control Panel Item Description ESTOP Pack Pressure LED Reset Button (not available) Actuator Switch Conveyor Speed On Edge Stacker Control Panel Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 89 of 328...

  • Page 97: Setting Up The Entrance To The On Edge Stacker

    2. To adjust the height, move the actuator switch up or down. 3. After setting the proper height, adjust the entrance guides to keep the same height consistent. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 90 of 328...
  • Page 98 Item Description Non-Operator Entrance Guide (loosen screw) Operator Entrance Guide Loosen Screws - loosening screw on non-operator side guide shown here Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 91 of 328...
  • Page 99 5. Place the setup envelope under the rollers of the vertical stacker - position half of the envelope under the rollers and half under the entrance of the OES. Item Description Vertical Stacker Rollers Entrance to OES Positioning the Envelope in the Vertical Stacker Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 92 of 328...
  • Page 100 7. Take the inner guide (operator side) and position it 1/4-inch (6.3 mm) away from the bottom seam of the envelope and use the operator setup tool to tighten the cap head screws. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 93 of 328...

  • Page 101: Centering Mail On The On Edge Stacker Conveyor Belt

    When possible it is best to stack the mail in the center of the belt on the On Edge Stacker (OES) or as close to the center as possible. Mail Centered Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 94 of 328...
  • Page 102 Note: If you are getting inconsistent stacking, it may be necessary to move the stacking fence left or right 1/8-inch to 1/4-inch to get a better stack. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 95 of 328...

  • Page 103: Adjusting The Belt Speed And Stack Pressure On The On Edge Stacker

    Stacker (OES). Properly stacked mail is perpendicular to the belt. Improper vertical stacking can cause jams at the stacker exit. Proper Vertical Stacking - mailpieces are straight and even Improper Vertical Stacking - mailpieces are uneven and not tightly packed Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 96 of 328...
  • Page 104 The conveyor speed dial controls the speed of the stacker conveyor belt. Adjust the conveyor speed by turning the speed dial clockwise to make the belt move faster or counterclockwise to make the belt move slower. Speed Dial Adjustment Knob Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 97 of 328...
  • Page 105 OES. While the system is running it is possible to make small movements (about 20 increments turn on the scale) to adjust it. Pack Pressure Adjustment Knob Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 98 of 328...
  • Page 106 Pack too loose (leaning back) Pack too tight (possible jamming) Note: Do not over adjust the knob in the clockwise direction or you will bend the pack pressure arm. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 99 of 328...

  • Page 107: Adjusting On Edge Stacker Fingers

    It may be beneficial to remove the finger guides when stacking 6 x 9 and other types of envelopes. If the fingers have been moved and need to be repositioned: 1. Loosen the four adjustment thumbscrews. Finger Guides - Adjustment Thumbscrews Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 100 of 328...
  • Page 108 Tip of the D Roller Aligned Finger Guides 3. Once aligned, tighten the four thumbscrews to set the new adjustment in place. Note: Additional adjustments may be required when running. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 101 of 328...

  • Page 109: Adjusting Chassis Material Center Deck Control Strap

    Operator setup tool and rotate the indicator level to the left to loosen strap pressure. Item Description Lockdown Screw Indicator Lever Adjust Chassis Material Deck Center Control Strap Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 102 of 328...
  • Page 110 4. Run more material and adjust the straps as needed until the proper position is achieved. Note: When you find a setting that works, note the location of the strap indicator tabs to use for future jobs. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 103 of 328...

  • Page 111: Adjusting Chassis Side Guide Control Straps

    5. Use a 3/16” Allen to tighten the locking nut. 6. Lower the feeders. 7. Close all the covers. Side Guide Strap -Loosen Locking Nut - Rotate Strap to Adjust Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 104 of 328...

  • Page 112: Setting The Chassis Collation Length

    1. Measure the length of the largest document to be run on the chassis. (This can be from the input or an insert feeder.) 2. Click the Chassis object on the main DC screen and select Setup from the drop-down. Chassis Object Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 105 of 328...
  • Page 113 Operator Adjustments 3. In the Chassis Setup dialog type the new collation length in the Collation length field. 4. Click OK. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 106 of 328...

  • Page 114: Setting The Chassis Speed

    (NOTE: This is a site specific setting, access permission to perform this function varies from site to site.) 1. Click the Chassis object on the main DC screen and select Chassis Speed from the drop-down. Chassis Object Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 107 of 328...
  • Page 115 3. When the desired speed is set, click OK. Note: If the speed of the chassis is changed while the system is running, the speed will gradually change after the new speed values are entered. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 108 of 328...

  • Page 116: Friction Feeder Mechanical Adjustments

    There are several mechanical adjustments operators will need to perform on the friction feeders to be prepared for successful job runs. Adjusting the Separator Adjusting the Side Guides Adjusting the Pack Control Ramp Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 109 of 328...

  • Page 117: Adjusting The Friction Feeder Separator

    2. Turn the side guide adjustment knob clockwise until it stops (side guides all the way open). Item Description Locking Knobs Side Guide Adjustment Knob Separator Knob Feeder Side Guide Control Knobs Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 110 of 328...
  • Page 118 4. Place a single piece of insert material on the feeder belts and slide it to the left under the separator. (The separator knob is on the other side of the separator, it's not visible here.) Position Material on the Feeder Belts - Separator Under Roller Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 111 of 328...
  • Page 119 If there is too much drag, turn the separator knob clockwise until you feel a slight drag. 7. When you have the correct drag, remove the insert material. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 112 of 328...

  • Page 120: Adjusting The Friction Feeder Side Guides

    To adjust the friction feeder side guides: 1. Loosen the feeder side guide lockdown knobs. Item Description Lockdown Knobs Side Guide Adjustment Knob Side Guide Lockdown Knobs Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 113 of 328...
  • Page 121 3. With the side guides opened as wide as they can go, place a 1-inch (25.4mm) stack of insert material from the job in the selected feeder and hold it between the side guides just above the adjustment knob. Position Material in Side Guides Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 114 of 328...
  • Page 122 (Allow a 1/16-inch (1.6mm) gap between each side of the material and side guide.) Adjusting the Side Guides (1/16-inch / 1.6mm gap) 5. Tighten the side guide lockdown knobs. 6. Remove the material. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 115 of 328...

  • Page 123: Adjusting The Feeder Pack Control Ramp

    2. Slide the pack control guide to the right. 3. Place a 1-inch (25 mm) stack of material between the side guides at the same height as the top of the pack control ramp. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 116 of 328...
  • Page 124 4. Slide the pack control guide to between 1/32 "(.79 mm) and 1/16" (1.5 mm) from the material. Position Material - 1/32-inch (.7 mm) to 1/16-inch (1.5 mm) gap 5. Tighten the pack control knob. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 117 of 328...

  • Page 125: Rotary Feeder Mechanical Adjustments

    Using Rotary Feeder Suction Cups Adjusting the Side Guide and Backstop Adjusting the Deck Position Adjusting the Feed Deck Angle Adjusting the Separator Pins Using the Wedge Using the Jog Function Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 118 of 328...

  • Page 126: Using Rotary Feeder Suction Cups

    The suction cups in the rotary feeder pull the insert material from the stack in the rotary feeder down into the drum of the feeder, preparing it for insertion. Rotary Feeder Suction Cups Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 119 of 328...
  • Page 127 Half-fold, glossy (single sheet) short, blue ring Folded, perfume tall, red ring tall, red ring Booklet (thick .125" max) tall, red ring Booklet (thin) short, blue ring Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 120 of 328...
  • Page 128 3. Using the scale on the suction cup arm, move the arm to get the suction cups in the proper position. Item Description Locking Screw Suction Cup Arm Scale Position Suction Cup Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 121 of 328...

  • Page 129: Adjusting The Rotary Feeder Side Guide And Backstop

    Item Description Center Gate Backstop Backstop Locking Knob 4. Loosen the side guide locking knobs. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 122 of 328...
  • Page 130 Item Description Side Guide Side Guide Locking Knobs Control Knob Adjust the Side Guides 6. Lock the side guides in place. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 123 of 328...

  • Page 131: Adjusting The Rotary Feeder Deck Position

    Material Type Deck Position #10, A4 (single sheet) Half-fold, non-glossy (single sheet) Half-fold, glossy 3, 4 Folded, perfume Booklet (thick .125" max) Booklet (thin) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 124 of 328...
  • Page 132 2. Slide the deck to the appropriate setting (use table here as a reference). Slide the Deck to the Setting 3. Tighten the outer deck locking knobs. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 125 of 328...

  • Page 133: Setting The Rotary Feeder Feed Deck Angle

    Use this table as a reference to adjust the rotary feeder deck to the proper angle. Material Type Deck Position #10, A4 (Single Sheet) Half-fold, non-glossy (single sheet) Half-fold, glossy Folded, perfume Booklet (thick .125" max) Booklet (thin) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 126 of 328...
  • Page 134 Item Description Angle Adjustment Knob Angle Adjustment Marks Adjust the Rotary Feeder Deck Angle 2. Use the angle adjustment marks on the side frame for reference. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 127 of 328...

  • Page 135: Adjusting The Rotary Feeder Separator Pins

    Inner pins - used for most material Outer pins - used for unusual inserts (booklets) to allows the staple to miss the pins Rotary Feeder Separator Pins (outer pins shown here) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 128 of 328...
  • Page 136 (toward stack) inner fuly in (toward stack) Booklet (thick .125" max) all pins fully out (away from stack) Booklet (thin) inner fully in (toward stack) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 129 of 328...
  • Page 137 2. Use the table in this topic to determine the proper pin setting based on the type of material you are running. Separator Pin Adjustment Screws Note: The pins are all the way exposed for most applications. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 130 of 328...

  • Page 138: Using The Wedge Accessory On The Rotary Feeder

    Booklet (thick .125" max) Booklet (thin) Installing the Wedge on the Rotary Feeder 1. Lift the wedge off the back wall of the feeder. Wedge Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 131 of 328...
  • Page 139 3. Load the material into the feeder as usual. 4. When the job is finished, slide the wedge off the feeder and return to the back wall. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 132 of 328...

  • Page 140: Using The Jog Function On The Rotary Feeder

    Feed with Jog - This jog feature can help verify feeder setup. It clears all the material in the feeder drum and then acquires and feeds another insert to confirm correct setup. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 133 of 328...
  • Page 141 2. Select Jog Only from the drop-down list. (If Jog Only is not in the drop-down list, select Feed with Jog; click the Feeder object again and Jog Only is now listed. ) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 134 of 328...
  • Page 142 3. Once Jog Only mode is initiated in DC, press the mechanical Jog button on the feeder and the jammed material feeds out. Jog Button on the Rotary Feeder Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 135 of 328...
  • Page 143 3. Once the Feed with Jog mode is initiated in DC, press and hold the Jog button on the feeder. The material in the feeder drum is cleared and another insert is acquired and fed to confirm correct setup. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 136 of 328...

  • Page 144: Booklet Feeder Mechanical Adjustments

    These procedures are for this optional bulk hopper. Adjusting the Pack Control Ramp Adjusting the Bulk Loader Hopper Side Guides Adjusting the Bulk Loader Hopper Deck Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 137 of 328...

  • Page 145: Changing Out The Booklet Feeder Separator Assemblies

    You can switch between the two separator options depending on the type of insert material you are running. If the stone separator is not working, try using the stripper bar. Both styles are removed or replaced the same way. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 138 of 328...
  • Page 146 1. Turn the separator knob so at least 5/16" (8 mm) of thread is showing above the knob. This makes it easier to remove the separator assembly. Separator Knob Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 139 of 328...
  • Page 147 2. Locate the 3/16" locking screw on the operator side of the separator assembly and use a setup tool to loosen and remove the screw and wedge block. Locking Screw Location Closeup View of Screw and Wedge Block Item Description Locking Screw Wedge Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 140 of 328...
  • Page 148 3. With the screw and wedge block removed, slide and pivot the separator assembly out. Removing the Separator Assembly Note: Take care not to lose or damage a spring or photocell wires while removing the assembly.   Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 141 of 328...
  • Page 149 4. With the separator assembly in place, install the 3/16" screw and wedge block on the operator side. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 142 of 328...
  • Page 150 The wedge block must be sitting in the groove when the screw is tightened, otherwise the separator assembly might come loose. Wedge Block Seated Correctly (left) and Wedge Block Seated Incorrectly (right) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 143 of 328...
  • Page 151 Operator Adjustments 6. Adjust the separator gap for the insert material in the job. (Refer to the Adjusting the Separator topic for more information.) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 144 of 328...

  • Page 152: Adjusting The Booklet Feeder Separator Gap

    1. Loosen the feeder side guide thumbscrews and slide the guides to their widest position. 2. Loosen the pack control knob and slide the pack control ramp to the left. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 145 of 328...
  • Page 153 3. Place the insert material under the separator roller or stripper bar. Stripper Bar 4. If the material does not slide under the roller or bar, turn the separator knob clockwise until it does. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 146 of 328...
  • Page 154 6. When you have the correct amount of drag , remove the sample insert material. 7. Adjust the position of the pack control ramp. (Refer to the topic on Adjusting the Booklet Feeder Pack Control Ramp for details.) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 147 of 328...

  • Page 155: Adjusting The Booklet Feeder Side Guides

    5. Using the scale provided, slide the side guide so the inner edge of the side guide aligns with the width of the measured insert. 6. Using the scale provided, slide the other side guide to align with the width of the measured insert. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 148 of 328...
  • Page 156 If the bottom of the guide is not over a belt or roller, lower the side guide to its lowest position. Height Adjustment 9. Tighten both height adjustment screws for each side guide. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 149 of 328...
  • Page 157 Side guides should only be 1/16" to 1/8" (1.6 mm to 3.1 mm) larger than the insert. Item Description Adjust guides to insert width Gap 1/16 to 1/8" gap (use insert) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 150 of 328...

  • Page 158: Adjusting The Booklet Feeder Pack Control Ramp

    Prior to doing this, it's easier if the separator gap has already been set. If not, the separator gap may need to be adjusted (opened) to get the material to fit between the separator roller and lower feed roller. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 151 of 328...
  • Page 159 Operator Adjustments To adjust the pack control ramp: 1. Loosen the pack control thumb screw and slide the ramp to the left. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 152 of 328...
  • Page 160 2. Place the lead edge of the material from the job over the center of the lower feed roller, and hold in place. Material Centered Over the Blue Roller (even with front of separator, not shown here) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 153 of 328...
  • Page 161 (The pack control ramp just touches the trail edge of the booklet.) Pack Control Ramp Adjusted to Trail Edge of Booklet 4. Tighten the pack control thumb screw. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 154 of 328...

  • Page 162: Adjusting The Booklet Feeder Double Detect Feature

    1. Loosen both mounting screws using the setup tool, and slide the double detect bracket to its highest position. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 155 of 328...
  • Page 163 2. Secure the mounting screws in this position temporarily. 3. Turn the double detect knob to adjust the space between the bracket and the mount, about 1/2"(13 mm) to 5/8" (16mm). Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 156 of 328...
  • Page 164 If the light does not go off, try repeating steps 7 and 8. 10. To check the adjustment, remove the single insert and put two inserts back under the roller, the light should turn on. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 157 of 328...

  • Page 165: Adjusting The Bulk Loader Hopper Deck

    2. While holding the hopper deck in place, loosen both lockdown knobs under the deck. This lets you slide the deck. Bulk Loader Hopper Deck Lockdown Knobs (one of two visible here) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 158 of 328...
  • Page 166 Operator Adjustments 3. Loosen the five blue locking knobs for both side guides and slide the guides to the center (towards the flat belts). Locking Knobs Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 159 of 328...
  • Page 167 5. Tighten the lockdown knobs under the bulk loader hopper deck. 6. Adjust the bulk loader hopper side guides. (Refer to the Adjusting Bulk Loader Hopper Side Guides topic for details.) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 160 of 328...

  • Page 168: Adjusting The Bulk Loader Hopper Side Guides

    Bulk Loader Hopper Side Guides (inside booklet feeder side guides) 3. Continue to align the side guides, keeping them parallel to the two red drive belts. (There is a scale to help with this adjustment.) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 161 of 328...
  • Page 169 The booklet must move freely between both side guides on the bulk loader hopper. If the space is too tight, they will into feed into the booklet feeder. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 162 of 328...

  • Page 170: Insert Feeder Software Adjustments

    • • Key Operator Backup Feed Mode • • Key Operator Xport Setup • • Key Operator Separator Control • Operator Recalibrate Double Detect • • Operator Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 163 of 328...

  • Page 171: Enabling And Disabling Feeders

    Feeder Objects - Check Feeder Status 2. Click a Feeder object and select Disable or Enable from the drop-down menu. 3. Repeat this for all feeders that require the change. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 164 of 328...

  • Page 172: Document Information

    2. Log in as Key Operator access level or higher. 3. Click the desired Feeder object on the main DC screen and select Setup from the drop-down. Feeder Objects Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 165 of 328...
  • Page 173 4. Enter the material width and length in the Width and Length fields. 5. Enter the weight in the Weight field if you have that information. 6. Click OK. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 166 of 328...
  • Page 174 1. Log in as Key Operator access level or higher. 2. Click the desired Feeder object from the main DC main and select Setup from the drop-down. Feeder Objects Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 167 of 328...
  • Page 175 Operator Adjustments 3. Select the Booklet/Folded style inserts checkbox if you are running that type of material. If not, verifythis box is not selected. 4. Click OK. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 168 of 328...

  • Page 176: Setting Feeder Feed Modes

    Feeder object has purple stripes. Item Description Item Description Backup Priority Select Priority Fill Data Select Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 169 of 328...
  • Page 177 3. In the Feed Mode field select the desired feed mode from the drop-down list. Note: Backup feed mode requires additional setup. If you select this mode, refer to the Backup Feeder (Feed Mode) topic for more instructions. 4. Click OK. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 170 of 328...

  • Page 178: Setting Backup Feeders (Backup Feed Mode)

    When Feeder #3 runs low on material, Feeder #2 takes over until Feeder #3 is reloaded and in a ready state Item Description Feeder #3 Backup Feeder #2 Backup Feeder (green stripes) Backup Feeder Locations Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 171 of 328...
  • Page 179 1. Log in as Key Operator access level or higher. 2. Click the desired Feeder object on the main DC screen and select Setup from the drop-down. Feeder Objects Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 172 of 328...
  • Page 180 In the Feed mode field select Backup from the drop-down list. b. In the Backup for field, select the feeder to use as a backup from the drop-down list. 4. Click OK. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 173 of 328...

  • Page 181: Transport Envelope Setup (Xport Setup)

    2. Click the desired Feeder object on the main DC screen and select Setup from the drop-down. 3. Click the Xport Setup tab. 4. Select the Flap first, short-flap return envelope checkbox. 5. Click OK. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 174 of 328...

  • Page 182: Setting Separator Options For Friction Feeders

    2. Log in as Key Operator access level or higher. 3. Click the desired Feeder object on the main DC screen and select Setup from the drop-down. Feeder Objects Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 175 of 328...
  • Page 183 Acceleration: this feature controls how fast the separator belts spin at startup. The lower the number, the slower the belts turn The higher the number, the faster the belts turn 6. After you make your selections, click OK. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 176 of 328...

  • Page 184: Recalibrating The Double Detect Feature

    If the double detect feature needs to be calibrated: 1. Log in as Operator. 2. Click the desired Feeder object on the main DC screen. Feeder Objects 3. Select Recalibrate from the drop-down menu. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 177 of 328...

  • Page 185: Adjusting Buffer Upper O-Ring Belt Height

    A 2 mm gap between the upper and lower O-ring belts at the entrance of the buffer The upper O-rings are even with the bottom of the upper P2L idler rollers O-ring Even with Bottom of Upper P2L Idler Roller Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 178 of 328...
  • Page 186 1. Locate the adjustment screw. 2. Using the 3/16" operator setup tool, turn the screw as needed to raise or lower to achieve correct height adjustment. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 179 of 328...
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  • Page 188: Job Changeover Guidelines

    6 - Job Changeover Guidelines In this section Job Changeover Guidelines Auto Adjustments - Engine and Chassis Manually Adjusting Engine and Chassis Auto Settings 187...

  • Page 189: Job Changeover Guidelines

    Separator Gap Fence Rollers Engine Setup GUI Screen Engine Pocket Width Horn Position Horns Style / Thickness Suction Cup Location Tongue Position Tongue Height Observation Guides Backwall Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 182 of 328...
  • Page 190 Pack Control Ramp Separator Feeder Setup GUI Screen Rotary Feeder Suction Cups Deck Deck Angle / Side Guides Separator Pins Feeder Setup GUI Screen Buffer Deck Height Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 183 of 328...
  • Page 191 O-ring Belt Height Vertical Stacker Side Guide Adjustment Flat Stacker On Edge Stacker (OES) Entrance Setup Load Mode Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 184 of 328...

  • Page 192: Auto Adjustments - Engine And Chassis

    DC. These default adjustments settings will be sufficient for most standard material, but occasionally minor adjustments are needed. Note: Areas of the Epic v3.1 system that auto adjust are identified in the Job Changeover Guidelines section. Auto Adjust Engine Settings Engine Settings The entrance nip rollers and the pocket stops adjust to the length of the envelope in the mode.
  • Page 193 The side guides can be manually adjusted for guide width and center offset in the Chassis Side Guide Setup screen. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 186 of 328...

  • Page 194: Manually Adjusting Engine And Chassis Auto Settings

    Engine Setup and Chassis Setup screens, which can both be accessed by clicking on their associated objects on the main DC screen. Item Description Engine Object Chassis Object Engine and Chassis Object - Main DC Screen Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 187 of 328...
  • Page 195 Backwall - to move the envelope flap closer to the sealer brush select Move In to move the slider towards -1.0; to move it farther away select Move Out to move the slider towards +1.0 Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 188 of 328...
  • Page 196 Changes made here are temporary unless saved to mode. Clicking Zero returns the adjustable axis to its default location, based on mode parameters. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 189 of 328...
  • Page 197 Job Changeover Guidelines Manually Adjust Chassis Settings 1. Click the Chassis object on the main DC main screen and select Side Guide Setup from the drop-down list. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 190 of 328...
  • Page 198 .9". Click Open to move the slider towards 1.0". Note: Clicking Zero returns the adjustable axis to its default location based off the material parameters in the mode. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 191 of 328...
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  • Page 200 7 - Running the System In this section Loading the Envelope Feeder Reloading the Envelope Feeder Loading the Insert Feeders Loading the Booklet Feeder Reloading Insert Feeders (with the system is running) 201 Removing Finished Mail from the On Edge Stacker Removing Mail from the Flat Conveyor Adding Sealer Fluid...

  • Page 201: Running The System

    Envelopes Positioned in the Feeder 3. Verify the tops of the envelopes are squared up and no envelopes are sticking out from the stack or stuck together. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 194 of 328...
  • Page 202 4. Lower the envelope feeder paddle into position at the end of the stack. Do not drop the paddle. Lower the Envelope Feeder Paddle Caution: Do not drop the paddle. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 195 of 328...

  • Page 203: Reloading The Envelope Feeder

    The envelopes rest on rotating bars while the machine is running. Do not allow your fingers to come into contact with these bars while the machine is running. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 196 of 328...
  • Page 204 Envelopes to right of paddle Add Envelopes 2. Lift up the feeder paddle and slide it over to the end of the envelope stack. Slide Feeder Paddle Over Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 197 of 328...
  • Page 205 Running the System 3. Lower the feeder paddle into position at the end of the stack. Do not drop the paddle. Lower the Paddle Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 198 of 328...

  • Page 206: Loading The Insert Feeders

    3. Continue this until the stack is just about even with the top of the pack control ramp and then stack to desired height. Stack the Feeder - do not shingle beyond the point noted in this image Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 199 of 328...

  • Page 207: Loading The Booklet Feeder

    2. Shingle a few more booklets and place them on top of the first booklet. 3. Continue to stack the booklets until the feeder is about halfway full. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 200 of 328...

  • Page 208: Reloading Insert Feeders (With The System Is Running)

    1. Fill the feeder without shingling the material if the feeder is still filled above the pack control ramp. 2. If the feeder is low or empty, refer to the Loading Insert Feeders topic. Low Material Level Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 201 of 328...

  • Page 209: Removing Finished Mail From The On Edge Stacker

    As the belt becomes full of finished mail, the mail is ready to be placed into a mail tray. Stacker Paddle Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 202 of 328...
  • Page 210 2. Lift the paddle with your right hand. 3. Slide the paddle to the left for a distance equal to the amount of mail that will fit into a mail tray. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 203 of 328...
  • Page 211 The machine will not start while the paddle is pressing on the switch. This feature works only when the paddle is in the down position and the inserter is running. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 204 of 328...

  • Page 212: Removing Mail From The Flat Conveyor

    1. Press the button located on the end of the conveyor to turn the belt on and move the flat mailpieces out from under the vertical stacker and down the belt. 2. Neatly stack the mail and remove it from the belt. Flat Conveyor - Button Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 205 of 328...

  • Page 213: Adding Sealer Fluid

    3. Carefully pour water into the reservoir; do not overfill the container. 4. Close the sealer reservoir cover. Item Description Sealer Reservoir (cover open) Overflow Reservoir (partially pulled out) Sealer and Overflow Reservoirs Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 206 of 328...
  • Page 214 Do not reuse water emptied from the overflow reservoir to fill the sealer reservoir; use only clean water. If you mix in used water, you may cause damage to the system. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 207 of 328...
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  • Page 216 8 - Error Recovery In this section Error Recovery Alarms in Direct Connect Removing Material Jams in the Buffer Removing Material Jams Under the Nip Rollers Removing Material Jams in the Dump Station Exit Removing Material Jams on Chassis Deck Removing Material Jams in the Friction Feeder Removing Material Jams in the Rotary Feeder Removing Material Jams in the Booklet Feeder...

  • Page 217: Error Recovery

    Take care when removing jams in any area of the system. Belts and straps can be moved or fall off during this process. Be sure to check all parts are in the right spot after clearing the jams to prevent further jamming issues. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 210 of 328...

  • Page 218: Alarms In Direct Connect

    Also, material jams, can show up as alarms. An alarm causes the machine to stop running. In this section, learn how to: View alarm details Resolve and clear alarms View alarm history   Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 211 of 328...
  • Page 219 This window has information about where the error occurred (Device), error details (Information), and a suggested course of action (Suggestion). Item Description Device (where the error occurred) Information (details about the error) Suggestion (suggested course of action) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 212 of 328...
  • Page 220 4. Click Start on the main DC main screen to start running again. 5. If the error still occurs, repeat the error recovery process. 6. If after repeating the process the error remains, contact Service. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 213 of 328...
  • Page 221 2. To view details about a specific alarm, double-click it or highlight it, and click View. 3. Click Close and Close again, to exit out of alarm history and back to the maIn DC screen. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 214 of 328...

  • Page 222: Removing Material Jams In The Buffer

    Item Description Folder Cover / Buffer Entrance Left Buffer Cover (closed) Right Buffer Cover (closed) Non-Booklet Feeder Option Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 215 of 328...
  • Page 223 Error Recovery Item Description Folder Cover / Buffer Entrance Left Buffer Cover Right Buffer Cover Bulk Load Hopper Booklet Feeder Option Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 216 of 328...

  • Page 224: Removing Material Jams Under The Nip Rollers

    4. Once the material is removed lower nip arm. 5. Close the cover. Note: When you remove a jam be sure the orange O-ring belting is still intact on both the left and right pulleys. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 217 of 328...

  • Page 225: Removing Material Jams In The Dump Station Exit

    5. To close the dump station push down on the dump station cross brace to lower the unit. 6. Press the dump station down to the lock position making sure the latch completely latches. Dump Station Closed - Black Knob Dump Station Open Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 218 of 328...

  • Page 226: Removing Material Jams On Chassis Deck

    Raise the Feeder; Material Access Caution: Do not press on the LED lens cover when lifting the feeder. 3. Remove the jammed material. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 219 of 328...
  • Page 227 Error Recovery 4. Lower the feeder down being cautious not to allow feeder to drop onto deck. 5. Close any opened front feeder covers. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 220 of 328...

  • Page 228: Removing Material Jams In The Friction Feeder

    DO NOT press on LED lens cover when lifitng feeder. Feeder Lifted; Material Access Area 3. Remove the jammed material. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 221 of 328...
  • Page 229 Rotate Knob - Lift Separator Bridge 3. Release the locking knobs. 4. Remove the jam. 5. Close the separator bridge; make sure both locking knobs latch closed. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 222 of 328...
  • Page 230 5. Close the transport; make sure it locks in the closed position. ( Be sure the knob is pushed all the way in towards the non-operator side of the machine.) 6. Close the feeder cover. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 223 of 328...

  • Page 231: Removing Material Jams In The Rotary Feeder

    Error Recovery Removing Material Jams in the Rotary Feeder There are two areas in the rotary feeders where material jams may occur: Feeder deck Feeder drums Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 224 of 328...
  • Page 232 3. Remove the jammed material. 4. Lower the feeder down being cautious not to allow feeder to drop onto deck. 5. Close any opened front feeder covers. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 225 of 328...
  • Page 233 1. With all doors shut, press the Cycle button on the feeder so the drum rotates and feeds damaged insert to the deck. Cycle Button 2. Open the feeder deck door. 3. Clear the piece from the deck. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 226 of 328...

  • Page 234: Removing Material Jams In The Booklet Feeder

    You may encounter material jams in the mid or exit areas of the booklet feeder. Mid Area 1. Open the Booklet Feeders top and chassis access doors. Booklet Feeder Access Doors Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 227 of 328...
  • Page 235 Center Blue Roller - Booklet Feeder 3. With the roller up, slide the booklet out towards you and release the blue roller. 4. Close the covers. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 228 of 328...
  • Page 236 2. Locate the exit roller pivot latch and press it down to raise the blue rollers; this removes pressure off the booklet. Exit Roller Pivot Latch 3. With the rollers up, slide out the booklet out towards you. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 229 of 328...
  • Page 237 Error Recovery 4. Release the exit roller pivot latch. 5. Close the cover. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 230 of 328...

  • Page 238: Removing Material Jams In The Engine

    Error Recovery Removing Material Jams in the Engine The several areas in the engine where material jams may occur: Upper engine Engine exit Arming area Lower engine Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 231 of 328...
  • Page 239 2. Grasp the upper engine handle and lift up for access to the insertion area. Lift Upper Engine Handle Upper Engine Raised 3. Remove the jam. 4. Close the engine handle. 5. Close the cover. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 232 of 328...
  • Page 240 2. Remove the jam by pulling the edge of the envelope and sliding it out, toward the engine exit. This releases the rollers. Pull the Envelope Toward the Engine Exit 3. Close the cover. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 233 of 328...
  • Page 241 Lift Upper Engine 2. Lift the arming area. Lift Arming Area 3. Remove the jam. 4. Lower the upper engine; it will press down and close the arming area. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 234 of 328...
  • Page 242 3. Press and hold both buttons until the lower engine is completely closed. (If you release the buttons before the engine is fully closed, the engine will drop back down.) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 235 of 328...
  • Page 243 Depending on the material size you are running, there can be up to two envelopes in the lower engine that need to be removed whenever the lower pocket is opened. (Arrows in this image indicate location.) Pocket Envelope and Flapper Envelope Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 236 of 328...

  • Page 244: Removing Material Jams In The Envelope Feeder

    There are two areas in the envelope feeder where material jams may occur: Envelope transport Envelope separator Envelope Transport 1. Pull down on the envelope feeder transport handle and to push it open. Envelope Feeder Handle Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 237 of 328...
  • Page 245 3. Grasp and press the feeder transport handle upwards to close. Caution! Pinch Point The feeder handle snaps shut, keep hands away from the inside when closing. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 238 of 328...
  • Page 246 Separator Lever 2. Remove the jam. 3. Release the lever to engage the separator. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 239 of 328...

  • Page 247: Removing Material Jams In The Sealer Or Vertical Stacker #1

    Item Description Sealer Cover Handle Vertical Stacker #1 Cover Handle Cover Handles 2. Remove the jam. 3. Realign any straps or belts if needed. 4. Close the cover. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 240 of 328...

  • Page 248: Removing Material Jams In The Turnover

    Error Recovery Removing Material Jams in the Turnover 1. Lift the turnover cover. Cover Opened 2. Remove the jam. 3. Close the cover. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 241 of 328...

  • Page 249: Removing Material Jams In The Vertical Stackers

    1. Lift the vertical stacker covers. 2. Hold the cover up while accessing the area. Vertical Stacker Cover 3. Remove the jam. 4. Lower the cover. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 242 of 328...

  • Page 250: Removing Material Jams In The On Edge Stacker

    1. Pull open the latch on the On Edge Stacker door. On Edge Stacker Latch 2. Remove the jam. 3. Close the door. Note: Be careful not to accidentally pull the belts off the pulleys. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 243 of 328...

  • Page 251: Removing Material Jams In The Flat Conveyor

    1. Press and hold the button at the end of the flat conveyor to start the belt and move the material out from under the vertical stacker. Flat Conveyor Button Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 244 of 328...
  • Page 252 2. If there is any material jammed under the vertical stacker on the flat conveyor deck lift the foam roller by the handle to gain access to the jammed mailpieces. Foam Roller Down Lifting the Foam Roller Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 245 of 328...
  • Page 253 Error Recovery Foam Roller Raised for Jam Removal Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 246 of 328...

  • Page 254: Troubleshooting

    9 - Troubleshooting In this section Troubleshooting Engine Troubleshooting Chassis Troubleshooting Buffer Troubleshooting...

  • Page 255: Troubleshooting

    Here are some simple troubleshooting activities operators can perform to try and resolve system issues and stoppages. This includes things like material jamming, double feeds, material skew, etc. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 248 of 328...

  • Page 256: Engine Troubleshooting

    Dust or debris in paper path Remove and clean Lower Pocket Issue Cause Resolution Not flapping Envelopes loaded incorrectly Reload envelopes Flap glued closed Check material Excessive paper curl Check material Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 249 of 328...
  • Page 257 Envelope side seam Horns set too wide for envelope Decrease horn width damage Engine Exit Issue Cause Resolution Missing or late / skew Strap location or tension Adjust strap Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 250 of 328...
  • Page 258 Inspect for high seals and refer to Sealer Belt adjustment / envelope positioning Adjust the OES entrance setup Stacking too tight on belt Increase speed of conveyor belt Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 251 of 328...

  • Page 259: Chassis Troubleshooting

    Check material dimensions; check if there any side guide offsets In DC, click Chassis > Setup and make sure Enable Automatic Setup is not checked. Manually adjust the side guides as needed. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 252 of 328...
  • Page 260 Fan material; reload in a different orientation Stack height Check material dimensions; check if there any side guide offsets Separator gap Loosen separator, to a light drag Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 253 of 328...
  • Page 261 Material rips out of gripper Reduce stack height or move deck away Move each away from lead edge to next lower integer setting Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 254 of 328...
  • Page 262 Reset and/or loosen side guides preventing material from falling onto the pins Material too stiff Move deck away from the lead edge to the next greater setting Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 255 of 328...
  • Page 263 Material orientation Closed end first, curl up Lead edge is poorly justified Tamp lead edges even prior to loading Backstop, side guides set too tight Loosen guides Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 256 of 328...
  • Page 264 Material Fan material; reload in a different orientation Stack height Check material dimensions; reduce stack height Separator gap Loosen separator - set to little or no drag Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 257 of 328...

  • Page 265: Buffer Troubleshooting

    Check the height off the deck of the belts; be sure that all O-ring belts are properly aligned and on the pulleys Fold plates Check fold quality Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 258 of 328...
  • Page 266 10 - Maintenance In this section Operator Maintenance Replacing Suction Cups in the Engine Buffer Maintenance Rotary Feeder Maintenance Friction Feeder Maintenance Vertical Stacker Maintenance On Edge Stacker Maintenance...

  • Page 267: Maintenance

    Since a single list cannot address all applications and conditions, it is important to communicate with your Pitney Bowes Customer Service Representative to develop a maintenance program for your system. Safety Precautions Before performing maintenance on any equipment, follow these safety precautions: Remove all material and envelopes from the system before performing any maintenance activity.
  • Page 268 Any required maintenance activities for the input modules not included here, can be found in either the associated operator guide or on the system via the on-system support tool. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 261 of 328...

  • Page 269: Replacing Suction Cups In The Engine

    1. Lift the top engine cover. 2. Lift the upper engine handle to access the upper insertion area. Lift Upper Engine Handle 3. Locate the three suction cups. Suction Cups Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 262 of 328...
  • Page 270 5. Replace the suction cup by aligning the hole in the suction cup with the suction cup adapter and then gently push the suction up onto the adapter. (You may have to hold the adapter while pushing the suction cup on.) Replace the Suction Cup Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 263 of 328...
  • Page 271 2. Remove the envelopes away from the feed head. 3. Reach in and grasp the suction cup and pull it to your right until it pops off. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 264 of 328...
  • Page 272 4. Press the new suction cup in place until it is fully seated (just below the surface of the deck). 5. In the dialog, click Feeder Cup In. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 265 of 328...

  • Page 273: Buffer Maintenance

    3. Use low pressure shop air to blow dust and debris out of the paper path and remove any toner buildup on the deck. 4. Close the buffer covers. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 266 of 328...

  • Page 274: Rotary Feeder Maintenance

    4. If you need to replace the suction cup, pull it off the cup holder. 5. Remove the old suction cup from the ring. 6. Place the new suction cup on the ring. 7. Return the cup into the cup holder. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 267 of 328...

  • Page 275: Friction Feeder Maintenance

    10. Use the shop air with the blower attachment to blow dust and debris from the feeder deck. 11. Lower the feeder. 12. Close the clam shell. 13. Close the feeder cover. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 268 of 328...

  • Page 276: Vertical Stacker Maintenance

    2. Inspect the deck and rollers for glue buildup and toner; wipe down with damp, clean cloth and soapy water. 3. Use shop air with the blower attachment to blow dust and debris out of the paper path. 4. Close the cover. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 269 of 328...

  • Page 277: On Edge Stacker Maintenance

    3. Wipe down the rollers with a clean, damp cloth (soapy water). 4. Wipe down the back plate with a clean, damp cloth (soapy water). 5. Close the doors. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 270 of 328...

  • Page 278: 11 - Specifications

    11 - Specifications In this section Epic V3 Description and Features Epic Material Specifications Epic v3.1 Engine (ZVE0) Envelope Specifications MPS/Epic Friction Feeder (Y554) Epic Rotary Feeder (Y558) Epic Universal Friction Feeder (ZVF1) Epic P2L Buffer with TNT (ZVB2) Epic Turnover (Y370)

  • Page 279: Epic V3 Description And Features

    Collation gathering mechanism Smart jam clearance under insert feeders for quick jam removal and increased productivity Simplified center drive mechanics Automatic side guides Smart nip to nip control   Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 272 of 328...
  • Page 280 ZV20 B-4-4-4-4-4-E 21-station ZV21 B-3-3-3-4-4-4-E B = Buffer E = Engine Options The Epic v3.1 inserter can be configured with these options: Part # Flats / Folded Rotary Feeder Y558 Friction Feeder Y554 Pitney Bowes Epic v3.1 (ZVE0) Operator Guide...

  • Page 281: Epic Material Specifications

    Material should be stored within a temperature range of 65 - 85° (+/- 2% humidity Material should be stored within a range of 40% - 60% relative humidity Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 274 of 328...
  • Page 282 Pitney Bowes equipment is designed to handle a certain range of material. Envelopes that fall outside these specified ranges might run poorly or not at all.

  • Page 283: Epic V3.1 Engine (Zve0)

    Specifications Epic v3.1 Engine (ZVE0) The ZVE0 Epic v3.1 Engine / Sealer / Takeaway modules consists of the three areas described here. The engine supports letter and flat envelopes. Description The Engine / Sealer / Takeaway modules include: Envelope Hopper...
  • Page 284 The "Epic Throughput" table (included here) approximates the maximum system throughput based on a mathematical model of the Epic modules. Lower throughput can be caused by failure to follow the guidelines outlined in product specifications and/or poor material quality. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 277 of 328...
  • Page 285 6.25" (158 mm) 8.5" (216 mm) Width 5.5" (140 mm) 11" (279.4 mm) 12.0" (305 mm) Thickness 18 lb (70 gsm) 28 lb (110 gsm) 28 lb (110 gsm) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 278 of 328...
  • Page 286 Case #2: Flats mode, two subsets of five pages each. Chassis speed of 7.2K, jogger activates 2x per collation. Subset stops activate 1x per collation. All deck nips go up and down 1x per cycle. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 279 of 328...
  • Page 287 Print+ Messenger - Color Y360 Engine Scan Y55E Print+ Messenger - Mono Y361 Engine Dual Edge Markers Y367 Stacker Dual Edge Markers Y368 Add'l Dual Edge Markers Y369 Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 280 of 328...

  • Page 288: Envelope Specifications

    Executive envelopes (to achieve maximum productivity, truncated flap is recommended) Diagonal cut envelopes Side seam envelopes McIntyre side seam envelopes (if examined and approved by Pitney Bowes) Envelope Guidelines All seams should be securely bonded to the bottom flap without exhibiting any curl or ripple between the flaps.
  • Page 289 A .75" (19.1 mm) end clearance is recommended to achieve maximum throughput for all categories. Experience has shown that end clearance requirements increase with the height of the collation and / or with the number of pages comprising the input document. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 282 of 328...
  • Page 290 Specifications Diagonal Seam Envelopes - Letter Mode Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 283 of 328...
  • Page 291 Specifications Diagonal Seam Envelopes - Flats Mode Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 284 of 328...
  • Page 292 Paper stock may range from 20 lb. (75 gsm) minimum to 28 lb. (105 gsm) maximum, but 24 lb. (90 gsm) is suggested. Envelopes whose characteristics fall outside of these construction guidelines must be evaluated by Pitney Bowes. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 285 of 328...
  • Page 293 Specifications Executive Envelopes - Letter Mode Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 286 of 328...
  • Page 294 Specifications Executive Envelopes - Flat Mode Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 287 of 328...
  • Page 295 Paper stock may range from 20 lb (75 gsm) minimum to 28 lb (105 gsm) maximum, but 24 lb (90 gsm) is suggested. Envelopes whose characteristics fall outside of these construction guidelines must be evaluated by Pitney Bowes. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 288 of 328...
  • Page 296 Specifications For speeds higher than 18.5K or #10 or DL envelopes, a truncated flaps is required, (see specifications indicated here). Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 289 of 328...
  • Page 297 Specifications Side Seam Envelopes - Letter Mode Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 290 of 328...
  • Page 298 Specifications Side Seam Envelopes - Flats Mode Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 291 of 328...
  • Page 299 Distance between the glue line and the envelope edge should be .125" (3.17 mm) or less. McIntryre Side Seam Envelopes These envelopes must be provided to PB Engineering to ensure the design is acceptable. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 292 of 328...
  • Page 300 For front / back double window envelopes, the window patches cannot be in opposite positions or the photocells will see through the envelopes, (see the example here). Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 293 of 328...
  • Page 301 Is measured by laying the sealed envelope on a flat surface and measuring from the surface to the highest point of the envelope Thickness will not exceed 0.32" (8 mm) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 294 of 328...
  • Page 302 2.50 6.40 9.00 1.25 2.50 9 x 12 9.00 12.0 1.75 2.25 9.00 12.8 1.75 3.25 9.80 13.8 1.75 5.25 10 x 13 10.0 13.0 1.75 4.25 Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 295 of 328...

  • Page 303: Mps/Epic Friction Feeder (Y554)

    Double detection and Fail to Feed detection Easy operator setup for material changeover Backup feeding option standard Cycling Speed Enclosure Length Cycling Speed Max (Depth) Epic <4" (102mm) >4" (102mm) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 296 of 328...
  • Page 304 Curl at Fold Folds must not result in the free ends being greater than .25" (6 mm) from a fold (see diagram). Free Ends at 1/4" (6 mm) Maximum Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 297 of 328...
  • Page 305 Cards should be centered on the carrier sheet in both side-to-side and lengthwise orientations. Carrier sheet must not exceed two times the length of the card. Requires application review. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 298 of 328...
  • Page 306 Enclosures should be free of paper shards, excessive dust, and powder. Options The Friction Feeder can be configured with these scanning options: Option Barcode Scanner Y551 Area Scan Camera Y55B Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 299 of 328...

  • Page 307: Epic Rotary Feeder (Y558)

    Easy operator setup for material changeover Backup feeding option standard Cycling Speed Enclosure Length Cycling Speed Max (Depth) Epic <4" (102 mm) >4" (102 mm) <6.25" (159 mm) >6.25" (159 mm) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 300 of 328...
  • Page 308 Cannot feed "Z" folds. Closed end first (see diagram) Folds should be sharply creased, flat, and free of edge curl(see diagram). Curl at Fold Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 301 of 328...
  • Page 309 Die cut labels without a backing sheet (such as remoistenable adhesive “stickers”) are not allowed. Glue Any enclosure with glued features must not allow stray glue to attach enclosures together. Exposed “remoistenable” adhesive is not allowed. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 302 of 328...
  • Page 310 Enclosures should be free of paper shards, excessive dust, and powder. Air Supply Requirements Each Rotary Feeder requires: Air Pressure: 70PSI (4.9 bar) Flow: 1.8 SCFM (51 l/min) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 303 of 328...
  • Page 311 Specifications Options The Rotary Feeder can be configured with these scanning options: Option Moving Beam Scanner Y556 Area Scan Camera Y55A Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 304 of 328...

  • Page 312: Epic Universal Friction Feeder (Zvf1)

    4" (102 mm) - 6.25" (159 mm) up to 18K 6.25" (159 mm) up to 14K * Actual cycling speed will be insert and application dependent; see section 6 in the Performance Guide Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 305 of 328...
  • Page 313 Short folds that result in either the leading or trailing edge being one and one half times as thick or thicker than the opposite edge are not allowed (see diagram). Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 306 of 328...
  • Page 314 Stacking Enclosures should be packaged in a way that will hold stacks even on the edges – uneven stacking can result in unacceptable edge curl. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 307 of 328...
  • Page 315 Cardboard chips at the top and bottom of each banded stack greatly reduce the chance of enclosure damage and allow for tighter bands to be used. Enclosures should be free of paper shards, excessive dust, and powder. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 308 of 328...

  • Page 316: Epic P2L Buffer With Tnt (Zvb2)

    Nip to nip hand-off between the buffer dump station and the chassis increases feed reliability Improved jam clearance in the dump station and buffer gates P2L module that rotates the collation +/- 90° Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 309 of 328...
  • Page 317 16 sheets 20 lb (80 gsm) half-fold 10 sheets 20 lb (80 gsm) tri-fold * The TNT does not support twisting of flat materials; any rotation is limited to 14,000. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 310 of 328...
  • Page 318 Length: 77" (195 cm) Width: 34" (86 cm) Height: 50.4" (128 cm) Heat Dissipation: 1260 watts/4300 BTU/Hr Weight: 520 lbs (234 kg) Air Consumption: 0.3 SCFM when in P2L mode Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 311 of 328...

  • Page 319: Epic Turnover (Y370)

    It also handles the entire range of Epic folded material and handles flats envelope up to 70 panels. Standard Features Parts include: Cabinet Servo-powered turnover belt Turn bar guide Exit nip roller DC-controlled linear speed Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 312 of 328...
  • Page 320 Thickness (10x13 - custom C4) single sheet 70 sheets Physical Characteristics Length: 55” (140 cm) Width: 26” (66 cm) Height: 46” (117 cm) Heat Dissipation: 117 KW (400 BTU/Hr) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 313 of 328...

  • Page 321: Epic V-Bin (Y31E, Y31F, Y31G, Y31H )

    The V-Bin modules provide the mounting base and electrical connections for top or bottom scanning or the Shingle Conveyor. These options are mutually exclusive and therefore only one option per V-Bin is permitted. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 314 of 328...
  • Page 322 The Epic V-Bins can handle the entire range of folded and flat materials of an Epic. Physical Characteristics Single Dual Length 17" (43 cm) 34" (86 cm) Width 32" (81 cm) 32" (81 cm) Height 39" (99 cm) 39" (99 cm) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 315 of 328...
  • Page 323 Output Area Scan Bottom Y55FB Output Line Scan Top Y55LT Output Line Scan Bottom Y55LB Manual Hand Feed OSSO Y55FT (image on left) and Manual Hand Feed (image on right) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 316 of 328...

  • Page 324: Epic On-Edge Stacker (Y396)

    The On-Edge Stacker can also be equipped with an optional Offset Kit to provide a visible break in the material flow, automating the production workflow even more. This Offset Kit can be activated to identify tray, zip or count breaks. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 317 of 328...
  • Page 325 Sliding drawer with dual sided access for storage and loading of mail trays Automatic operator visual notification for “Stacker Full” and “3/4 Full” Jam and stoppage detection UL, CE approved   Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 318 of 328...
  • Page 326 (2) Envelopes with external side seams require the External Side Seam kit Options The On Edge Stacker can be configured with these optional kits: Part # Offset Kit Y49B Side Seam Kit Y490011 Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 319 of 328...

  • Page 327: Epic Shingling Stacker (Y32S)

    78.0" (2 m) conveyor belt stacker Sponge roller to improve envelope sealing Integrated with DC Holds approximately 750-1000 9x12 (C4) envelopes with 10 page flats and no inserts Continuous unloading NRTL approved Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 320 of 328...

  • Page 328: Epic Edge Markers (Y367, Y368, Y369 )

    Includes two edge markers on the same side Y368B - Front Edge Markers Last Position Located just prior to the On-Edge Stacker Includes two edge markers on the same side Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 321 of 328...
  • Page 329 This adds back/rear edge markers to one of the other sets, for a total of four edge markers, (refer to the image here to see the four markers). Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 322 of 328...

  • Page 330: Environmental Operating Conditions

    Performance may degrade at environmental extremes. Paper has different humidity control requirements for normal operating conditions, storage, and shipping. 100% relative humidity up to 85° F. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 323 of 328...

  • Page 331: Network And Power Requirements

    Typical cutsheet MPS configuration (powered on and processing work) - 3 phase approximate 31A total (6.448KVA) Typical continuous MPS configuration (powered on and processing work) - 3 phase approximate 36A total (7.448KVA) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 324 of 328...
  • Page 332 Specifications Idle Power Requirements Powered on and at idle – approximately 8 amps (1.614KVA) BTUs Heat Dissipation: 2000 watts (7825 BTU/hr) Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 325 of 328...

  • Page 333: Air Requirements

    PB equipment. Air requirements: 6.3 SCFM @ 70 PSI .375" quick disconnect fitting included on the system Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 326 of 328...

  • Page 334: Expected Lifetime

    This audit could identify parts replacement for non-standard parts. In this case, there would be a proposal made to the customer to provide this 100M service above the standard support. Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 327 of 328...
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  • Page 336 3001 Summer Street Stamford, Connecticut 06926 www.pitneybowes.com SV63233 RevG ©2018 Pitney Bowes Inc. All Rights Reserved...

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