Pitney Bowes DI500 Operator's Manual
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Pitney Bowes DI500 Operator's Manual

Pitney Bowes DI500 Operator's Manual

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Document Inserting System
DI500/DI600
16 Luzerne Avenue
Suite 145
West Pittston, Pa. 18643
(570)569-2071
(570)614-2222 fax
www.firstchoicepb.com
Operator Guide
US/Canada English Version
(Enhanced Edition)

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  • Page 1 Document Inserting System DI500/DI600 16 Luzerne Avenue Operator Guide Suite 145 West Pittston, Pa. 18643 US/Canada English Version (570)569-2071 (Enhanced Edition) (570)614-2222 fax www.firstchoicepb.com...
  • Page 2 Canada. SV40221 Rev. C 3/08 ©2004, 2006, 2007, 2008 Pitney Bowes Inc. All rights reserved. This guide may not be reproduced in whole or in part in any fashion or stored in a retrieval system of any type or transmitted by any means, electronically or mechanically, without the express, written permission of Pitney Bowes.

  • Page 3: Table Of Contents

    Table of Contents Chapter 1 Introduction Safety ................1-2 To The Operator ..............1-3 Machine Configurations .............1-4 Machine Identification ............1-6 Control Panel ..............1-8 Control Panel Keys ............ 1-8 Mail Piece Icon Tree ..........1-10 Common Terms ...............1-14 Chapter 2 Using the Menus The Home Screen .............2-2 The Menu Structure ............2-4 SV40221 Rev.
  • Page 4 Table of Contents Chapter 3 Operator Functions About this Chapter .............3-2 Connecting Power .............3-2 Running a Job ..............3-3 Selecting a Job ............3-3 Loading Material ............3-4 Other Settings ............3-5 Running a Trial Piece ..........3-5 Automatic Processing ..........3-7 Batch Count ...............
  • Page 5 Table of Contents Chapter 5 Optical Mark Recognition (OMR) OMR Availability ..............5-2 What is OMR? ..............5-2 OMR Marks Available ............5-3 OMR Mark Options ............5-6 OMR Specifications ............5-9 Creating, Deleting and Viewing OMR Codes ....5-13 Create New OMR Code ...........5-14 Delete OMR Code ............5-16 View OMR Code ..............5-17 Creating an OMR Job ............5-18 OMR Scanner Adjustments ..........5-22...
  • Page 6 Table of Contents Chapter 7 Reference Specifications ..............7-2 Sheet Feeders ............7-2 Fold Type and Overall Thickness Limits ....7-3 Insert Feeders ............7-4 Envelope Feeder ............7-4 Envelope Sealer ............7-6 Drop Stacker .............. 7-6 Material Requirements ..........7-6 Machine Specifications ..........
  • Page 7 Pitney Bowes Contact Information List USA Contacts ▪ Product Name - DI500 or DI600 ▪ For frequently asked questions, go to: www.pb.com and click on Customer Support. ▪ To place requests for service or training, go to: www.pb.com and click on My Account. ▪ To order PB supplies and accessories, go to: www.pb.com and click on Online Store. ▪ To view and pay invoices online, go to: www.pb.com and click on My Account.
  • Page 8 SV40221 Rev. C...
  • Page 9 1 • Introduction This chapter presents important safety information and describes the main controls and features of your machine. Important Safety Notes ............1-2 To The Operator ..............1-3 Machine Configurations ............1-4 Machine Identification ............1-6 Control Panel ..............1-8 Control Panel Keys ............1-8 Mail Piece Icon Tree ..........1-10 Common Terms ..............1-14 SV40221 Rev.

  • Page 10: Safety

    • To obtain Pitney Bowes supplies, please contact our Supply Line or on the web at PB.com (see the Pitney Bowes Contact Information List at beginning of this guide). Material Safety Data Sheets can also be acquired from the Supply Line or PB.com.

  • Page 11: Introduction • 1

    Introduction • 1 • Immediately report to Pitney Bowes Service any damaged or non-functioning components. The unit may be unsafe for use. • To prevent overheating, do not cover the vent openings. Allow ample spacing around the unit for ventilation.

  • Page 12: Machine Configurations

    1 • Introduction Machine Configurations The following machine configurations are available, depending on your local market: • Two Sheet Feeders Only • Four Sheet Feeders Only • Two Sheet Feeders and One Insert Feeder • Two Sheet Feeders and Two Insert Feeders •...
  • Page 13 Introduction • 1 Sheet Feeders Insert Feeders Manual Feeder Envelope Feeder Feeder Configuration SV40221 Rev. C...

  • Page 14: Machine Identification

    1 • Introduction Machine Identification Sheet Feeders Use these feeders to feed sheets that require folding. A double detect feature can be enabled which checks to see if more than one sheet feeds (a double detect), giving security to your mailings. Depending on the job being run and availability of feeders, there also is an option to ‘link’...
  • Page 15 Drop Stacker. Mailing Machine Interface (not llustrated) This is an option which automatically transports Mail Pieces to a Pitney Bowes Mailing Machine for postal ‘franking’. Sealer Bottle The sealer bottle is located inside an opening cover at the front right side of the machine.

  • Page 16: Control Panel

    1 • Introduction Control Panel Control Panel Keys Screen Keys Navigation Keys Reset Counters If only piece count is displayed, press this key to reset the piece count to zero. If both piece and batch counters are displayed, pressing this key allows either or both counters to be reset. Help Press this key to view an electronic Quick Reference Guide giving you quick access to basic information regarding operation of your...
  • Page 17 Introduction • 1 Home Press this key to take you back to the Home Screen. The Home Screen is where you can run jobs and is the starting point for accessing the menus. Start Starts automatic operation. Trial Piece Press this key to run test piece(s) so that you can check the machine setup.

  • Page 18: Mail Piece Icon Tree

    1 • Introduction Mail Piece Icon Tree The Mail Piece Icon Tree is located on the left side of the display. It displays the Mailing Object Icons required, based on the Job Definition. The icons inform you which feeders to load, the type of object (sheet, insert, etc.) to be loaded into each designated feeder and the loading orientation of each object.
  • Page 19 Introduction • 1 Mail Piece Icon Tree Icons Each Mailing Object Icon has one darker edge either at the top or bottom that indicates the leading edge of the object when loaded into the assigned feeder. The leading edge of an object is the edge that feeds into the machine first.
  • Page 20 1 • Introduction Envelope Icons Sheet Icons No Window, No address, Flap side up, Face Down, Flap Last Bottom First Window, No address, Flap side up, Face Down, Flap Last Top First No address, Seal Icons Face Up, Seal On Bottom First No address, Safe Seal On...
  • Page 21 Introduction • 1 Mail Piece Icon Tree Example An example Mail Piece Icon Tree is shown below. This explains the information that is available and how it assists you in loading and running a job. Window Envelope loaded Flap Side Up fed Flap Last Envelope sealing turned on loaded into feeder E...

  • Page 22: Common Terms

    1 • Introduction Common Terms Throughout the machine screens and this guide, standard terms are used to describe the elements of the Mail Piece and functions of the equipment. It is therefore important that you fully understand the following basic terms to get the best from your machine: MATERIAL Sheet...
  • Page 23 Introduction • 1 MATERIAL (continued) Insert An item that doesn’t require folding before being placed into an envelope. There are four kinds of Inserts: Reply Envelope A return envelope placed into the Outer Envelope with the other Mal Pece contents. Booklet An item with a stapled and folded binding edge.
  • Page 24 1 • Introduction MACHINE FUNCTIONS Home Screen The initial screen displayed after turning power on. From this screen you can select pre-programmed Job Defntons, enter the menu functions or run the machine. Pressing the Home key on the Control Panel will return you to this screen at any time.

  • Page 25: Using The Menus

    2 • Using the Menus This chapter explains the Home Screen and the menu structure accessed via the Control Panel The Home Screen ..............2-2 The Menu Structure ............2-4 SV40221 Rev. C...

  • Page 26: The Home Screen

    2 • Using the Menus The Home Screen The Home Screen is the first screen shown on the display after the machine has finished powering up. The last Job Definition selected is displayed with the relevant Mail Piece Icon Tree on the left hand side. The ▲ and ▼ navigation keys can be used to scroll through the icon tree and highlight individual items.
  • Page 27 Using the Menus • 2 Name of Machine selected Job Status Screen Counter(s) Name Home Piece Count: READY Batch Count: INVOICE A Use ▼, ▲ to view loading Instructional Text instructions > Select Job Job comments text area > SwiftStart > Menu Screen Selections Mail Piece Icon Tree Machine Graphic The Home Screen SV40221 Rev.

  • Page 28: The Menu Structure

    2 • Using the Menus The Menu Structure The diagram on the facing page shows the menu structure available when you press the Menu Screen Key. You will see that the menu follows a logical structure with similar functions grouped together. The menu structure is split into two sections: ● The first section is available to all Operators and contains settings and adjustments that might be required when...
  • Page 29 Using the Menus • 2 Home Screen Select Job > (p.3-3) SwiftStart > (p.3-8) Menu > (p.3-21) Language > (p.3-21) Display Adjustments > (p.3-21) Safe Seal > (p.3-21) System Information > (p.3-21) Supervisor Supervisor Functions > (p.4-1) Functions require a Supervisor Access Code Create Job...
  • Page 30 2 • Using the Menus SV40221 Rev. C...
  • Page 31 3 • Operator Functions This chapter lists the functions that can be carried out by an Operator. Primarily, this includes selecting Job Definitions, running the various operator modes and loading material. About this Chapter ..............3-2 Connecting Power ..............3-2 Running a Job ..............3-3 Selecting a Job ............3-3 Loading Material ............3-4 Other Settings ..............3-5...

  • Page 32: About This Chapter

    3 • Operator Functions About this Chapter This chapter explains functions on the machine that can be carried out by an Operator. This includes: • Selecting and running a pre-programmed Job Definition • Using the SwiftStart™ mode • Using the Manual Feeder •...

  • Page 33: Running A Job

    Operator Functions • 3 Running a Job Selecting a Job This section assumes the job to be run has already been created by a Supervisor. If the job has not been created, refer to Create Job on page 4-3. When the machine is turned ON, a ‘Startup Screen’ showing an ‘hour glass’...

  • Page 34: Loading Material

    3 • Operator Functions Loading Material If feeders are NOT linked... Load material into all the feeders as indicated by the Mail Piece Icon Tree (refer to setting the feeders on pages 3-14 to 3-19). If feeders ARE linked... For Job Definitions which contain linked feeders, the loading of the feeders must be in the correct order to minimize the risk of the sheets becoming out of sequence.

  • Page 35: Other Settings

    Operator Functions • 3 All of the Linked Feeders must be loaded in the same sequence in which they become empty, this ensures that the sheets stay in the correct order. If the feeders are not loaded in the correct order, the machine will display the following options: Exclude This option allows you to exclude a feeder from a run until...
  • Page 36 3 • Operator Functions If the Trial Piece is NOT OK, select No and follow the on-screen instructions to correct the error. You can adjust the address position, fold panel length and/or the envelope stop position. The envelope stop position will rarely need adjusting - for more information, see page 6-15.

  • Page 37: Automatic Processing

    Operator Functions • 3 Automatic Processing After confirming a Trial Piece is OK... Press the Start key to begin automatic operation. The machine will operate until: ● material runs out ● the Stop key is pressed ● the batch count is reached (if batch count is being used) ● the first Select Feed sheet is fed (if the Select Feed feature in OMR is being used). ● the OMR ‘Stop’ feature is activated (see page 5-4 for more details). Batch Count If the Batch Count function was set when the job was created, the machine will stop automatically after processing the required number of Mail Pieces.

  • Page 38: Swiftstart

    3 • Operator Functions SwiftStart™ SwiftStart™ allows you to load material into the feeders and run a simple job with minimal setup information. The job can then either be run without saving it to the machine’s memory, or a Supervisor can name and save the Job Definition for future recall as and when required.
  • Page 39 Operator Functions • 3 For a C fold Job: Load the Sheet Feeders from the top feeder downwards, in sequence (prime sheet in top feeder). Load Sheets Face Up and Top First. For a Sngle fold job: Load the Sheet Feeders from the bottom feeder upwards, in sequence (prime sheet in bottom feeder).

  • Page 40: Saving A Swiftstart™ Job

    3 • Operator Functions SwiftStart™ Operation Load material as previously described and select SwiftStart. The machine will feed an envelope and depending on the depth of the envelope, will automatically select the fold type – Single or C fold. If the envelope depth cannot be accurately determined, the machine will stop and request you to enter the measurement manually.

  • Page 41: Manual Feed

    Operator Functions • 3 Manual Feed Manual Feed allows you to feed stapled or unstapled sets of up to 5 sheets of 20 lb. (80g/m2) to a maximum total weight of 100 lb. (400g/m2). The sets are fed by hand, one set at a time, for processing by the machine.
  • Page 42 3 • Operator Functions Manual Feed Operation Make sure Envelopes and Inserts (if required) are loaded as previously described. You must now decide how to feed the set into the Manual Feeder, as this depends on the type of fold the set requires. Depending on your Envelope depth and Sheet length, the machine will automatically select the fold type –...
  • Page 43 Operator Functions • 3 Manually Feeding Further Sets After confirming a Trial Piece is OK, the machine will remember its settings and process further manually fed sets automatically. While the motor runs, the machine will remain in Manual Feed mode. If no further sets are fed whilst the motor is running, after a brief delay, the motor stops and the machine reverts to the previous Job Definition selected.

  • Page 44: Setting The Sheet Feeders

    3 • Operator Functions Setting the Sheet Feeders Sheet Feeders A to D feed sheets that require folding by the machine. The Mail Piece Icon Tree for the job being run will show which feeders need to be loaded and the sheet orientation. If you need help understanding the sheet icons, refer to page 1-12 of this guide.
  • Page 45 Operator Functions • 3 3. Jog the stack back into alignment. 4. The Mail Piece Icon Tree will show the correct orientation of the sheets in the Stack. Make sure you load sheets in the orientation indicated. 5. The Sheet Feeders take the paper Stack in a similar way to a photocopier paper cassette.

  • Page 46: Setting The Envelope Feeder

    3 • Operator Functions Setting the Envelope Feeder Envelope Feeder E feeds the Outer Envelope for the inserting job being run. The Mail Piece Icon Tree for the Job Definition being run will show if the feeder needs to be loaded and the envelope orientation. If you need help understanding the envelope icons, refer to page 1-12 of this guide.
  • Page 47 Operator Functions • 3 4. Place the stack of envelopes into the feeder with the flap side up and flap last. 5. Press the Envelope Feeder loading switch again to raise the envelope stack to the normal feeding position. TIP: To quickly load envelopes during a run, without the need to stop and start the machine...

  • Page 48: Setting The Insert Feeder(S)

    3 • Operator Functions Setting the Insert Feeder(s) Insert Feeders F and G feed items that do not require folding by the machine. Depending on configuration, your machine may have no Insert Feeders, one Insert Feeder or two Insert Feeders. Insert Feeder F is capable of feeding thicker Inserts than Insert Feeder G.
  • Page 49 Operator Functions • 3 4. Set the blue separator shield lever to the letter required. 5. Take the stack of inserts and fan it to ensure individual Inserts are not stuck together. 6. ‘Shingle’ the inserts to be run so that they look like the photograph on the right and place them onto the feed deck.

  • Page 50: Filling The Envelope Sealer

    3 • Operator Functions Filling the Envelope Sealer Make sure the Envelope Sealer is filled with Sealing Solution before running a job that has sealing turned on. When the sealer needs refilling, a warning message will automatically appear on the display and, if sealing, the sealing icon will flash.

  • Page 51: Menu

    Operator Functions • 3 Menu Select the Menu Screen Key to access the following Operator Options within the menu structure: • Language • Display Adjustments • Safe Seal • System Information Language When this option is selected, a choice of languages will be displayed. Choose the required language from the list and all display text will change to the selected language.
  • Page 52 3 • Operator Functions 3-22 SV40221 Rev. C...
  • Page 53 4 • Supervisor Functions This chapter lists the functions that can be carried out by a Supervisor. Primarily this includes creating, editing and deleting jobs. About this Chapter ..............4-2 Supervisor Access Code ............4-2 Create Job ................4-3 Edit Job................4-4 Create From ...............4-6 Delete Job ................4-7 OMR Menu .................4-8 System Menu..............4-8...

  • Page 54: About This Chapter

    4 • Supervisor Functions About this Chapter This chapter describes the functions available within the Supervisor Functions menu. All of the functions are set by following a sequence of screens and answering simple questions presented on the display. Therefore, this chapter does not take you through every function step by step. It gives you background information on the function and offers helpful tips to get the best out of your machine.

  • Page 55: Create Job

    Supervisor Functions • 4 Create Job What is it? This function allows a Supervisor to create new Job Definitions to be stored within the machine’s memory for easy access by an Operator. The machine can store a maximum of 20 Job Definitions. Where is it? From the Home Screen...

  • Page 56: Edit Job

    4 • Supervisor Functions Edit Job What is it? Edit Job allows a Supervisor to add and delete items within an existing Job Definition. It also lets a Supervisor alter the job setup such as batch count, job comments and job name. The Edit Job function is used to change a Job Definition, and so always over-writes the original Job Definition in the machine’s memory (even if the Job Name has been edited).
  • Page 57 Supervisor Functions • 4 TIPS: Highlight the Job Name to edit the following items: Job Name Job Comments Batch Counter Maximum Sheet Length OMR feature set up Highlight the Envelope icon to edit envelope and sealing settings. The Outer Envelope and Prime Sheet cannot be added or deleted.

  • Page 58: Create From

    4 • Supervisor Functions Create From What is it? A Supervisor can use the Create From function to create a NEW Job Definition which is SIMILAR to an existing job and leave the existing Job Definition untouched. This can save time programming a new Job Definition when it is almost identical to an existing job but for a small change such as an extra Insert or Sheet, etc.

  • Page 59: Delete Job

    Supervisor Functions • 4 Delete Job What is it? Delete Job allows a Supervisor to remove a stored Job Definition permanently from the machine’s memory. Where is it? From the Home Screen... select Menu select Supervisor Functions enter the Supervisor Access Code (see page 4-2) select Delete Job Action…...

  • Page 60: Omr Menu

    4 • Supervisor Functions OMR Menu This function lets a Supervisor setup Optical Mark Recognition (OMR) codes for inclusion within Job Definitions. All OMR functions are explained fully within Chapter 5 - OMR. System Menu What is it? This menu lets a Supervisor adjust the following system setting: ● Manual Feed Setup Where is it? From the Home Screen...
  • Page 61 5 • Optical Mark Recognition (OMR) This chapter gives background and setup information for using Optical Mark Recognition (OMR) on a machine equipped with the OMR option. OMR Availability ..............5-2 What is OMR? ..............5-2 OMR Marks Available ............5-3 OMR Mark Options .............5-6 OMR Specifications ............5-9 Creating, Deleting and Viewing OMR Codes ....5-13 Create New OMR Code............5-14...

  • Page 62: Omr Availability

    5 • Optical Mark Recognition (OMR) OMR Availability Your machine can be equipped with Optical Mark Recognition (OMR) functionality either on installation or as an added option after purchase. The machine can store up to 10 different codes for you to select when creating Job Definitions that use OMR.

  • Page 63: Omr Marks Available

    Optical Mark Recognition (OMR) • 5 OMR Marks Available This section gives brief descriptions of the OMR Marks that can be allocated to an OMR Code and lists the options available for use with each mark. The section following, OMR Mark Optons on page 5-6 then gives greater detail of each option.
  • Page 64 5 • Optical Mark Recognition (OMR) EOC - End of Collation This is a mandatory mark within the Muti-Mark option, when used on the Prime Sheet Set. This mark indicates that it is the last sheet fed wthn the OMR set. This is the only mark used when using the Single Mark option and can only be selected once within the code.
  • Page 65 Optical Mark Recognition (OMR) • 5 PAR - Parity This mark is a securty feature, that when printed always makes the number of marks total an odd or even number. If any one of the marks within the code is missed during scanning, the machine will stop functioning, allowing the error to be rectified.

  • Page 66: Omr Mark Options

    5 • Optical Mark Recognition (OMR) TM - Timing This mark is needed by some other machines to read OMR marks correctly. This machine does NOT need Tmng marks, but the mark(s) may be left within an existing code and will add integrity to your Mail Piece.

  • Page 67: Continuous Sequence Or Page 1 Reset

    Optical Mark Recognition (OMR) • 5 Partial Random This option is available for Match Code only, and when selected the code’s binary value changes in a random order, but the binary value cannot be the same as the previous Mail Piece. Automatic This option is available for Match Code only.

  • Page 68: All Sheets, Page 1 Only, Last Page Only

    5 • Optical Mark Recognition (OMR) All Sheets, Page 1 Only, Last Page Only If All Sheets is selected, the relevant code is expected on all sheets wthn the Prme Set. When using Page 1 Only or Last Page Only, the relevant code will only be expected on the frst page of the set or the last page of the set, depending on the option chosen.

  • Page 69: Omr Specifications

    Optical Mark Recognition (OMR) • 5 OMR Specifications OMR Marks and Clear Zone Specifications The mark must be a solid black line between 1pt and 2pts thick 1/64” (0.35mm to 0.7mm) and at least 3/8” (10mm) wide. Each mark position must be evenly spaced and at least 1/10” (2.54mm) apart.
  • Page 70 5 • Optical Mark Recognition (OMR) Sheet OMR Code positions EXCEPT for the special Prime Sheet/Set application shown on page 5-11. LEADING EDGE 3/4” (20mm) 2-3/8” 2-3/8” (59mm) (59mm) 4-3/4” 4-3/4” (107mm) max (107mm) max 1/8” (3mm) min 1/8” (3mm) min The white areas indicate possible locations where OMR marks can be printed.
  • Page 71 Optical Mark Recognition (OMR) • 5 Prime Sheet/Set OMR Code positions when using Single or Z Fold with Selective Feed Only 7” (176mm) min to 9” (229mm) max The white areas indicate possible locations where OMR marks can be printed. This depends on the physical positions of the scanners fitted to the machine and the face of the sheet on which the OMR marks are printed.
  • Page 72 5 • Optical Mark Recognition (OMR) Insert OMR Code positions The white area indicates possible locations where OMR marks can be printed. OMR marks must face upwards and be towards the front (operator) side of the machine when the Insert is loaded into Insert Feeder F or G.

  • Page 73: Creating, Deleting And Viewing Omr Codes

    Optical Mark Recognition (OMR) • 5 Creating, Deleting and Viewing OMR Codes The OMR Menu contains functions which allow a Supervisor to create, delete and view OMR Codes. Where is it? From the Home Screen… Select Menu Select Supervisor Functions Enter the Supervisor Access Code (see page 4-2) Select OMR Menu Action…...

  • Page 74: Create New Omr Code

    5 • Optical Mark Recognition (OMR) Create New OMR Code This function lets a Supervisor create a new OMR code to be stored in the machine’s memory so that it can be used when creating a Job Definition that uses OMR. Action…...
  • Page 75 Optical Mark Recognition (OMR) • 5 used once within the code. Other marks can be used multiple times and so will remain available in the list. Once a mark is selected, a representation with its abbreviation will appear on the left hand side of the screen. If you press Cancel whilst in this screen, the last selected mark will be removed.

  • Page 76: Delete Omr Code

    5 • Optical Mark Recognition (OMR) Delete OMR Code This function lets a Supervisor delete a current OMR code which is stored in the machine’s memory. Action… Select Delete OMR Code from the OMR Menu screen. A list of all the current OMR Codes will be displayed. Select the OMR code you wish to delete from the list using the ▲▼◄►...

  • Page 77: View Omr Code

    Optical Mark Recognition (OMR) • 5 View OMR Code This function lets a Supervisor view any current OMR codes, which are stored in the machine’s memory. Action… Select View OMR Code from the OMR Menu screen. A list of all the current OMR Codes will be displayed. Select the OMR code you wish to view from the list using the ▲▼◄►...

  • Page 78: Creating An Omr Job

    5 • Optical Mark Recognition (OMR) Creating an OMR Job Before you Start Before creating a Job Definition using OMR, make sure that the required OMR code has been set up as described in Create New OMR Code on page 5-14. Setting the Type of OMR During the Create Job process, the machine will ask whether OMR is being used within the job being programmed.

  • Page 79: Setting The Omr Scanning Area

    Optical Mark Recognition (OMR) • 5 Setting the OMR Scanning Area Material is scanned as it feeds through the machine. This means that the OMR Scanner reads a vertical strip or margin down the page, defined by the OMR Specifications on pages 5-9 to 5-12. The machine must now be told if the entire OMR margin (the strip down the page that is scanned for OMR marks) is clear of any other printing or punched holes, etc.
  • Page 80 5 • Optical Mark Recognition (OMR) Defining the first mark position and code length Take a sheet/Insert that has at least the FIRST and LAST OMR mark printed on it. When requested by the machine, measure and enter the distance (A) from the top edge of the sheet or the lead edge of the Insert to the FIRST OMR mark, in millimeters.
  • Page 81 Optical Mark Recognition (OMR) • 5 Defining the Clear Zone When requested by the machine, measure and enter the distance (A) from the top edge of the sheet or the lead edge of the Insert to the point after the printed matter where you wish the machine to START scanning.

  • Page 82: Omr Scanner Adjustments

    5 • Optical Mark Recognition (OMR) OMR Scanner Adjustments The machine can be fitted with one Top Scanner and one Bottom Scanner. If the sheet(s) bearing OMR marks are loaded face up, the Top Scanner will be used. If they are loaded face down, the Bottom Scanner will be used.
  • Page 83 Optical Mark Recognition (OMR) • 5 Setting the Top Scanner Position Open the Top Cover and locate the blue Top Scanner adjusting knob and adjustment scale. Rotate the adjusting knob until the indicator is aligned with the measurement (X) you just made. The Top Scanner will now be aligned.
  • Page 84 5 • Optical Mark Recognition (OMR) Setting the Bottom Scanner Position Open the upper central front door and locate the blue Bottom Scanner adjusting knob and adjustment scale. Rotate the adjusting knob until the indicator is aligned with the measurement (X) you just made. The Bottom Scanner will now be aligned.
  • Page 85 Optical Mark Recognition (OMR) • 5 Once the Bottom Scanner is aligned, the Top Scanner (or paper guide if a corresponding Top Scanner is not fitted) must be positioned so that the sheet being scanned is kept at a controlled distance from the scanner.
  • Page 86 5 • Optical Mark Recognition (OMR) Setting the Insert Scanner Position This scanner is used to scan Inserts. Remove the relevant Insert Feeder. Loosen the locking screw and align the Indicator with the measurement (X) you made on page 5-22. Retighten the locking screw.
  • Page 87 Optical Mark Recognition (OMR) • 5 Setting the Selective Feed Scanner Position This scanner is used to scan the Prime Sheet/Set controlling selectively fed Sheets when using Z and Single Fold ONLY. Remove Sheet Feeder D. Ascertain which scanner (top or bottom) needs to be set for the application being run.
  • Page 88 5 • Optical Mark Recognition (OMR) 5-28 SV40221 Rev. C...
  • Page 89 6 • Troubleshooting Refer to this chapter if you have problems with your machine. Troubleshooting Tips ............6-2 General Troubleshooting ............6-3 Machine ...............6-3 Envelopes ..............6-4 Sheets ................6-5 Inserts ................6-6 Double Detect ..............6-7 Clearing Material Stalls............6-8 The Manual Advance Knob ..........6-8 Removal and Replacement of Sheet Feeder Trays ..6-9 Removal and Replacement of Insert Tray(s) ....6-9 Access to Internal Areas 1 to 5 ........6-10 Access to Area 6 ............6-12...

  • Page 90: Troubleshooting Tips

    6 • Troubleshooting Troubleshooting Tips In most cases, the machine will generate an Error Message when a problem occurs, and the display will offer advice on how to rectify the problem immediately. An on-line guide is also available in many countries. Press the Help key and use the Screen Keys to select the information you require.

  • Page 91: General Troubleshooting

    Troubleshooting • 6 General Troubleshooting Problem Remedy Page MACHINE Blank Screen No power. Check power cord is firmly connected and wall socket is switched ON. Machine not Turn power switch (located on switched ON. lower front) ON. Display adjustment Turn machine off and on. Adjust 3-21 set too low for display adjustment to an acceptable...

  • Page 92: Envelopes

    6 • Troubleshooting Problem Remedy Page ENVELOPES Poor Envelope Feed Envelope side Set guides to envelope width and 3-16 guides set back off 1/4 turn. incorrectly. Poor envelope Check envelopes are not curled. quality. Try a new box of envelopes. Make sure stack has been fanned 3-16 before loading.

  • Page 93: Sheets

    Troubleshooting • 6 Problem Remedy Page SHEETS Poor Sheet Feed Sheet Feeder Set guides to Sheet width and back 3-14 side guides set off 1/4 turn. incorrectly. Sheets loaded Make sure stack has been fanned 3-14 incorrectly. before loading. Multiple sheets feed when one is expected Sheet Feeder Check Mail Piece Icon Tree to see 1-11...

  • Page 94: Inserts

    6 • Troubleshooting Problem Remedy Page INSERTS Poor Insert Feed Insert Feeder Set guides to Insert width and back 3-18 side guides set off 1/4 turn. incorrectly. Insert Feeder Make sure the two Insert Feeder 3-18 separator adjustments (number and letter adjustments settings) are set correctly for the incorrect.

  • Page 95: Double Detect

    Troubleshooting • 6 Problem Remedy Page DOUBLE DETECT The machine keeps turning Double Detect OFF Double Detect Double Detection might not be cannot calibrate possible with certain very thick itself properly. or heavily printed material. Either change material or choose to run with Double Detect OFF.

  • Page 96: Clearing Material Stalls

    6 • Troubleshooting Clearing Material Stalls Your machine has been designed to assure maximum performance. In the event of a material stall, the display will indicate where the stall has occurred and will suggest remedial action. Follow the advice given by the error screen regarding clearing the material.

  • Page 97: Removal/Replacement Of Sheet Feeder Trays

    Troubleshooting • 6 Removal & Replacement of the Sheet Feeder Trays A to D To remove… Lift the rear of the tray slightly and pull it straight outwards from the machine. Note: If the tray is loaded, gently hold the material in place to prevent it sliding forward as the tray is removed.

  • Page 98: Access To Internal Areas 1 To 5

    6 • Troubleshooting Access to Internal Areas 1 to 5 If material stalls within the internal areas of the machine, the display will indicate an area or areas (labelled 1 to 5) where the stalled material is located. Open both central front doors and the access points, as shown below, will be exposed.
  • Page 99 Troubleshooting • 6 Area 1 Area 2 Pull upwards to unlatch. Rotate clockwise to unlatch. Relatch by pressing assembly Relatch by rotating lever fully firmly down at the center. counterclockwise. Area 3 Area 4 Rotate counterclockwise to unlatch. Rotate counterclockwise to unlatch. Push assembly back into position Push assembly back into position and relatch by rotating lever fully...

  • Page 100: Access To Area 6

    6 • Troubleshooting Access to Area 6 Area 6 is located under Sheet Feeder D, where envelopes are fed into the system. Therefore, before access can be gained to a material stall in this area, Sheet Feeder Tray D should be removed as described on page 6-9.

  • Page 101: Access To Removable Paper Path

    Troubleshooting • 6 Access to the Removable Paper Path (under Insert Feeder F) This removable plate is located immediately below Insert Feeder F. Therefore, before access can be gained to a material stall in this area, Insert Tray F must be removed as described on page 6-9. Access can be gained by lifting the blue handle and then pulling the plate outwards.

  • Page 102: Access To Envelope Inserting/Sealing Area

    6 • Troubleshooting Access to the Envelope Inserting/Sealing Area Access can be gained to the insertion and sealing areas by lifting the plastic cover and lowering the envelope exit area door. Points arrowed in the illustration can be unlatched to allow access to stalled material.

  • Page 103: Envelope Stop Position

    Troubleshooting • 6 Envelope Stop Position This function lets you adjust the position where the Outer Envelope is held, waiting for material to be placed into it. It is accessed by running a Trial Piece and replying ‘No’ when asked if the Trial Piece is OK.
  • Page 104 6 • Troubleshooting 6-16 SV40221 Rev. C...
  • Page 105 7 • Reference This chapter lists the specifications of your machine and describes operations that may only need to be carried out occasionally. Specifications ..............7-2 Sheet Feeders .............7-2 Fold Type and Overall Thickness Limits ......7-3 Insert Feeders ..............7-4 Envelope Feeder ............7-5 Envelope Sealer ............7-6 Drop Stacker ..............7-6 Material Requirements ..........7-6...

  • Page 106: Specifications

    7 • Reference Specifications Sheet Feeders A, B C and D Minimum sheet size: 5" (127mm) Width (non OMR) 8" (203mm) Width (with OMR) 6-7/8" (175mm) Length Maximum sheet size: 9" (229mm) Width 16" (406mm) Length Paper weights: 16 lb. (60g/m ) Minimum (non OMR) 20 lb. (75g/m ) Minimum (with OMR) 32 lb. (120g/m ) Maximum Fold configurations : Sheet length limits before folding Single fold: 6-7/8"- 12" (175mm - 305mm) C fold: 9-1/2"- 13-5/8" (242mm - 347mm) Z fold:...

  • Page 107: Fold Type And Overall Thickness Limits

    Reference • 7 Fold Type and Overall Thickness Limits The table below shows the maximum number of sheets up to 12" (305mm) in length that can be accumulated or collated for each fold type, based on different weights of paper. It is important that jobs exceeding these maximums are NOT programmed into the machine or imposed by OMR code printing and/or OMR selective feed.

  • Page 108: Insert Feeders

    7 • Reference Insert Feeders F and G Minimum Insert size: 5" (127mm) Width (non-OMR) 5-3/8" (136mm) Depth (with OMR) 3-1/4" (82mm) Depth Maximum Insert size: 9" (230mm) Width 6" (152mm) Depth Paper Weights: 20 lb. (75g/m ) Minimum (single sheet/slip) 16 lb. (60g/m ) Minimum (folded material) 20 lb. (75g/m ) Minimum (folded material with OMR code) 48 lb. (180g/m ) Maximum (single sheet/slip) Maximum compressed...

  • Page 109: Envelope Feeder

    Reference • 7 Envelope Feeder Minimum envelope size: 3-7/8" (98mm) Depth 8-5/8" (220mm) Width WIDTH Maximum envelope size: 6-1/2" (164mm) Depth 9-2/3" (246mm) Width Envelope depths for SwiftStart™ and Manual Feed: 4-1/4" to 6-3/8" (109mm, 111mm, 114mm, 121mm, 162mm) Envelope weights: 16 lb. (65g/m ) Minimum 26 lb. (100g/m ) Maximum Envelope tray capacity: Up to a maximum of 300, 26 lb. (90g/m ) envelopes End Clearance: End clearance between the Insert and envelope is a minimum of 1/4" (6mm) at each side (i.e., a minimum of 1/2" [12mm] overall).

  • Page 110: Envelope Sealer

    7 • Reference Envelope Feeder (continued) Envelope flap and throat requirements: Min 1" (25.5mm) 3/4" (19mm) Max 2-1/2" (63mm) Min 1/4" (6mm) Max 1-5/8" (41mm) Min 1/16" (1.6mm) Max 1/4" (6mm) throat depth at 3/4" (19mm) Closed flap tip should not in from edge of come closer than envelope 1-3/4"...

  • Page 111: Machine Specifications

    Reference • 7 Machine Specifications Physical Dimensions Length 54" (1370mm) Depth 22-1/2" (570mm) Height 30" (760mm) Minimum Weight 194 lbs. (88kg) Weight will depend on machine configuration. Weights stated do not include material. Noise Level Running 72dBA - 74dBA Electrical AC Input 100VAC - 240VAC, 50/60Hz, 10A AC Output 100VAC - 240VAC, 50/60Hz, 4A Maximum Speed:...

  • Page 112: Changing The Envelope Sealer Unit Felts

    7 • Reference Changing the Envelope Sealer Unit Felts The sealer unit felts are supplied as part of a kit and can be changed by the operator in the following way: 1. Hinge open the Sealer Bottle cover located at the front right hand side of the machine.
  • Page 113 Reference • 7 4. Push the latch (A) back. Grasp the upper sealer felt (B), slide it towards the front of the machine and remove it from its mounting bar. Discard this old felt. 5. Fit the new upper felt. Locate the tabs on the back of the felt assembly into the corresponding...

  • Page 114: Service

    7 • Reference 8. Push down on the blue tab to return the upper felt assembly to its operating position. Make sure that the blue latches (A) spring out and fully latch into position. 9. Refit the Sealer Bottle and close the covers.
  • Page 115 Operator/Supervisor Training Checklist During initial Operator Training, the following aspects of the machine should be described:  Sheet Feeders  Envelope Feeder  Insert Feeder(s)  Manual Feeder  OMR Scanners (if applicable)  Sealer  Drop Stacker  Measuring Scale  Manual Advance Knob ...
  • Page 116  Supervisor Functions (Available only with Supervisor Access Code) • Create Job • Edit Job • Create From • Delete Job • OMR Menu (If available on machine) • System Menu/Manual Feed Setup  Stoppage Recovery  Maintenance – Sealer wicks and felt replacement The following operators have been trained on this equipment: Name Level...
  • Page 117 Index Additional Sheet or Additional Set 1-14 Automatic Processing 3-7, 3-10 Batch Count 3-7 Beginning of Collation (BOC) for OMR 5-3 Benchmark (BM) for OMR 5-3, 5-15 Blue separator gap lever 3-18 Blue separator shield lever 3-18 Cancel Button 1-8 Changing the Envelope Sealer Unit Felts 7-8 Clear Deck Button 1-9 Clear Zone (for OMR) 5-9...
  • Page 118 Index Daily Mail Feeder.See Manual Feeder Delete Job 4-7 Display Adjustments 3-21 Double Detect 1-11 Drop Stacker 1-7, 7-6 Edit Job 4-4 End of Collation (EOC) 5-4 End of Collation (EOC) for OMR 5-14 Envelope Feeder Changing the Envelope Sealer Unit Felts 7-8 Description 1-7 Envelope Stop Position 6-15 Loading switch 3-16...
  • Page 119 Index Ignore (IGN) for OMR 5-6 Insert 1-15 Insert Feeder(s) Blue separator gap lever 3-18 Blue separator shield lever 3-19 Description 1-7 Setting the Insert Feeder(s) 3-18 Side Guide Adjustment Knob 3-18 Specifications 7-4 Wedge 3-19 Insert Icons 1-12 Insert Tray(s) Removal &...
  • Page 120 Index Language 3-21 Linked Feeders 1-11, 1-16 Loading Instructions 1-10 Machine, Parts Of 1-6 Machine Status 2-3 Machine Configurations 1-4 Machine Graphic 2-3 Machine Identification 1-6 Machine Specifications 7-7 Mail Piece 1-15 Mail Piece Icon Tree 1-10, 2-3, 3-3 Definition 1-16 Double Detect 1-11 Envelope Icons 1-12 Example 1-13 Fold Icons 1-12 Insert Icons 1-12...
  • Page 121 Index Manual Feeder Description 1-7 Manual Feed Option 4-8 Material Requirements 7-6 Measuring Scale 1-7 Menu, Operator Functions 3-21 Display Adjustments 3-21 Language 3-21 Safe Seal 3-21 System Information 3-21 Menu, Supervisor Functions 4-2 Create From (jobs) 4-6 Create Job 4-3 Creating, Deleting and Viewing OMR Codes 5-13 Creating an OMR Job 5-18 Delete Job 4-7...
  • Page 122 View OMR Code 5-17 What is OMR? 5-2 Wrap Around Sequence (WAS) 5-5 OMR Menu 4-8 OMR Scanner Adjustments 5-22 Operator Functions 2-5 Other Icons 1-12 Outer Envelope 1-15 Parity (PAR) for OMR 5-5 Pitney Bowes Contact Information List iii SV40221 Rev. C...
  • Page 123 Index Power stacker 1-7 Power Switch 3-2 Pre-Collated Set 1-14 Pre-Collated Sets 1-11 Prime Sheet or Prime Set 1-14 Removal & Replacement Access to Areas 7 and 8 6-12 Access to Area 6 6-12 Access to Internal Areas 1 to 5 6-10 Access to the Envelope Exit Area 6-14 Access to the Envelope Inserting/Sealing Area 6-14 Access to the Removable Paper Path (under Insert Feeder F) 6-13...
  • Page 124 Index Selecting a Job 3-3 Select Feed (SF(n)) for OMR 5-4 Service Information iii, 7-10 Sheet Description 1-14 Sheet Feeders Explanation 1-6 Linking 3-4, 3-19 Removal & Replacement of Trays 6-9 Setting the Sheet Feeders 3-14 Specifications 7-2 Sheet Icons 1-12 Shingle 1-15 Side Guide Adjustment Knob 3-16 Single Mark 5-14...
  • Page 125 Index Timing (TM) for OMR 5-6 Trial Piece 1-16, 3-12 Running a Trial Piece 3-5 Trial Piece Button 1-9 Troubleshooting 6-2 Clearing Material Stalls 6-8 Double Detect 6-7 Envelopes 6-4 Inserts 6-6 Machine 6-3 Sheets 6-5 Tips 6-2 Wedge 3-19 Wrap Around Sequence (WAS) for OMR 5-5 SV40221 Rev.
  • Page 126 Index I-10 SV40221 Rev. C...
  • Page 128 1 Elmcroft Rd. 5500 Explorer Drive Stamford, Connecticut 06926-0700 Mississauga, Ontario L4W5C7 www.pitneybowes.com www.pitneybowes.ca PB Form SV40221 Rev C (3/08) Printed in the USA or Canada Printed on recyclable paper *SV40221REVC*...

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