Pitney Bowes D1600 manual

Document Inserting System DI500/DI600 Operator Guide US/Canada English V ersion SV40221 Rev A book.indb 3 9/14/2004 5:52:23 PM[...]

FCC Compliance This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC rules. These limits are designed to provide reasonable protection against interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio freque[...]

i SV40221 Rev . A T able o f C ontents Pitney Bowes Contact Information List v Chapter 1 Introduction Safety ................................................................................ 1-2 T o The Operator ................................................................ 1-3 Machine Configurations ...............................................[...]

T able of Contents ii SV40221 Rev . A Chapter 3 Operator Functions About this Chapter ............................................................. 3-2 Connecting Power ............................................................. 3-2 Running a Job ................................................................... 3-3 SwiftStart™ ...............[...]

T able of Contents iii SV40221 Rev . A Chapter 5 Optical Mark Recognition (OMR) OMR Availability ................................................................ 5-2 What is OMR? ................................................................... 5-2 OMR Marks Available ........................................................ 5-3 OMR Mark Options .[...]

T able of Contents iv SV40221 Rev . A Chapter 7 Reference Specifications .................................................................... 7-2 Sheet Feeders ........................................................... 7-2 Fold T ype and Overall Thickness Limits .................... 7-3 Insert Feeders ..............................................[...]

v SV40221 Rev . A Pitney Bowes C ontac t Information Lis t USA Contacts  Product Name - DI500 or DI600  For frequently asked questions, go to: www .pb.com and click on Customer Support .  T o place requests for service or training, go to: www .pb.com and click on My Account .  T o order PB supplies and accessories, go to: www .pb.com an[...]

vi SV40221 Rev . A SV40221 Rev A book.indb vi 9/14/2004 5:51:02 PM[...]

1-1 SV40221 Rev . A 1 • Introduction This chapter pre sents important safety information and describes the main controls and features of your machine. Important Safety Notes ...................................................... 1-2 T o The Operator ................................................................ 1-3 Machine Configurations ......[...]

1 • Introduction 1-2 SV40221 Rev . A Important Safety Notes Follow these basic safety precautions when operating this machine: • Use only Pitney Bowes approved supplies, in particular aerosol dusters. Improper storage and use of aerosol dusters or flammable aerosol dusters, can cause an explosive-like condition that could result in a personal i[...]

Introduction • 1 1-3 SV40221 Rev . A T o the Operator Y our new Folding/Inserting Machine has an easy to follow user interface which makes it simple to set up, whilst offering the following features: • Envelope seal/no seal/safe seal. • Fully automatic material separation on sheet feeders. • Fully automatic fold adjustments. • Fully autom[...]

1 • Introduction 1-4 SV40221 Rev . A Machine Configurations The following machine configurations are available, depending on your local market: • T wo Sheet Feeders Only • Four Sheet Feeders Only • T wo Sheet Feeders and One Insert Feeder • T wo Sheet Feeders and T wo Insert Feeders • Four Sheet Feeders and One Insert Feeder • Four Sh[...]

Introduction • 1 1-5 SV40221 Rev . A Sheet Feeders Feeder Configuration Insert Feeders Envelope Feeder Manual Feeder A B C D E H G F SV40221 Rev A book.indb 1-5 9/14/2004 5:51:02 PM[...]

1 • Introduction 1-6 SV40221 Rev . A Machine Identification Sheet Feeders Use these feeders to feed sheets that require folding. They automatically detect if more than one sheet feeds (double detect), giving security to your mailings. Depending on the job being run and availability of feeders, there also is an option to ‘link’ these feeders s[...]

Introduction • 1 1-7 SV40221 Rev . A Manual Feeder (also known as Convenience Feeder or Daily Mail Feeder) Use this feeder to manually feed stapled or unstapled sets of up to 5 sheets (see specifications, page 7-2). The machine waits for each set to be manually fed before folding and inserting the set automatically into the envelope. A Supervisor[...]

1 • Introduction 1-8 SV40221 Rev . A PacPilot™ Control Panel Control Panel Keys Reset Counters If only piece count is displayed, press this key to reset the piece count to zero. If both piece and batch counters are displayed, pressing this key allows either or both counters to be reset. Help (not available in some markets) Press this key to vie[...]

Introduction • 1 1-9 SV40221 Rev . A Home Press this key to take you back to the Home Screen. The Home Screen is where you can run jobs and is the start point for accessing the menus. Start Starts automatic operation. T rial Piece Press this key to run test piece(s) so that you can check the machine setup. T rial Piece(s) must be run before autom[...]

1 • Introduction 1-10 SV40221 Rev . A Mail Piece Icon T ree The Mail Piece Icon T ree 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[...]

Introduction • 1 1-1 1 SV40221 Rev . A Mail Piece Icon T ree Icons Each Mailing Object Icon has one darker edge either at the top or bottom that indicates the leading edge of the object when loaded into the assigned feeder . The leading edge of an object is the edge that feeds into the machine first. For example, a sheet that must be loaded face [...]

1 • Introduction 1-12 SV40221 Rev . A No Window , Flap side up, Flap Last Window , Flap side up, Flap Last Envelope Icons No address, Face Down, Bottom First No address, Face Down, T op First No address, Face Up, Bottom First No address, Face Up, T op First T op address, Face Down, Bottom First T op address, Face Down, T op First T op address, Fa[...]

Introduction • 1 1-13 SV40221 Rev . A Mail Piece Icon T ree Example An example Mail Piece Icon T ree 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 C Fold selected Prime Sheet wit[...]

1 • Introduction 1-14 SV40221 Rev . A Common T erms 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: MA TERIAL Sheet A single piece of pap[...]

Introduction • 1 1-15 SV40221 Rev . A MA TERIAL (continued) Insert An item that doesn’t require folding before being placed into an envelope. There are four kinds of Inserts: Reply Envelope A return envelope placed into the Outer Envelope with the other Mail Piece contents. Booklet An item with a stapled and folded binding edge. Slip A single t[...]

1 • Introduction 1-16 SV40221 Rev . A MACHINE FUNCTIONS Home Screen The initial screen displayed after turning power on. From this screen you can select pre-programmed Job Definitions , enter the menu functions or run the machine. Pressing the Home key on the Control Panel will return you to this screen at any time. Job Definition The collection [...]

2-1 SV40221 Rev . A 2 • Using the Menus This chapter explains the Home Screen and the menu structure accessed via the PacPilot™ Control Panel The Home Screen ............................................................. 2-2 The Menu Structure ........................................................... 2-4 SV40221 Rev A book.indb 2-1 9/14/2004 5[...]

2 • Using the Menus 2-2 SV40221 Rev . A 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 T ree on the left hand side. The ▲ and ▼ navigation keys can be used to scroll through the icon tree and hi[...]

Using the Menus • 2 2-3 SV40221 Rev . A Menu Home Piece Count: READY Batch Count: Invoice Job Use ▼ , ▲ to view loading instructions Screen Name Counter(s) Mail Piece Icon T ree Machine Graphic Screen Key Selections Instructional Te x t Name of selected Job Machine Status The Home Screen Select Job SwiftStart > > > Job comments text [...]

2 • Using the Menus 2-4 SV40221 Rev . A The Menu Structure The diagram on the facing page shows the menu structure available when you press the Menu Screen Key . Y ou 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[...]

Using the Menus • 2 2-5 SV40221 Rev . A Home Screen Select Job (p.3-3) > SwiftStart (p.3-6) > Menu (p.3-19) > Language (p.3-19) > Display Adjustments (p.3-19) > Safe Seal (p.3-19) > System Information (p.3-19) > Supervisor Functions (p.4-1) > Create Job (p.4-3) > Edit Job (p.4-4) > Create From (p.4-6) > Delete Job[...]

2 • Using the Menus 2-6 SV40221 Rev . A SV40221 Rev A book.indb 2-6 9/14/2004 5:51:09 PM[...]

3-1 SV40221 Rev . A 3 • O perator 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 • Operator Functions 3-2 SV40221 Rev . A About this Chapter This chapter explains functions on the machine that can be carried out by an Operator . This includes: • Selecting and running a pre-programmed Job Definition • Using the SwiftStart™ mode • Using the Manual Feeder • Loading the feeders • Filling the sealer Functions that ca[...]

Operator Functions • 3 3-3 SV40221 Rev . A Running a Job Selecting a Job This section assumes the job to be run has already been created by a Supervisor . If the job has not been created, refer to Create Job on page 4-3. When the machine is turned ON, a ‘ Startup Screen’ showing details of your machine and contact details will be displayed fo[...]

3 • Operator Functions 3-4 SV40221 Rev . A Running a Trial Piece A T rial Piece is required to enable you to check the Mail Piece contents and to allow the machine to calibrate itself for the material being run. Press the T rial Piece key . The machine runs a single Mail Piece which exits the machine unsealed so that you can check the contents. T[...]

Operator Functions • 3 3-5 SV40221 Rev . A Automatic Processing After confirming a T rial Piece is OK... Press the Start key to commence automatic operation. The machine will operate until:  material runs out  the Stop key is pressed  the batch count is reached (if batch count is being used) If you choose No... The adjustment(s) you have[...]

3 • Operator Functions 3-6 SV40221 Rev . A SwiftStart™ SwiftStart™ allows you to load material into the feeders and run a simple job with minimal setup information. The job can then either be run without saving it to the machine’s memory , or a Supervisor can name and save the Job Definition for future recall as and when required. TIP: Swif[...]

Operator Functions • 3 3-7 SV40221 Rev . A For a C fold Job: Load the Sheet Feeders from the top feeder downwards, in sequence (first sheet in top feeder). Load Sheets Face Up and T op First. For a Single fold job: Load the Sheet Feeders from the bottom feeder upwards, in sequence (first sheet in bottom feeder). Load Sheets Face Down and Bottom F[...]

3 • Operator Functions 3-8 SV40221 Rev . A SwiftStart™ Operation Load material as previously described and select SwiftStart . The machine will feed an envelope and depending on the depth of the envelope, will automatically select the fold type – Single or C fold. A T rial Piece is automatically produced, enabling you to check the job and to [...]

Operator Functions • 3 3-9 SV40221 Rev . A Manual Feed Manual Feed allows you to feed stapled or unstapled sets of up to 5 sheets of 20 lb. (80g/m 2 ) to a maximum total weight of 100 lb. (400g/m 2 ) . The sets are fed by hand, one set at a time, for processing by the machine. Using the Manual Feed automatically turns off all Sheet Feeders. Y ou [...]

3 • Operator Functions 3-10 SV40221 Rev . A Manual Feed Operation Make sure Envelopes and Inserts (if required) are loaded as previously described. Y ou must now decide which way round to feed the set into the Manual Feeder , as this depends on the type of fold the set requires. Depending on your Envelope depth and Sheet length, the machine will [...]

Operator Functions • 3 3-1 1 SV40221 Rev . A Manually Feeding Further Sets After confirming a T rial Piece is OK, the machine will remember it’s settings and process further manually fed sets automatically . While the motor runs, the machine will remain in Manual Feed mode. If no further sets are fed whilst the motor is running, after a brief d[...]

3 • Operator Functions 3-12 SV40221 Rev . A Setting the Sheet Feeders Sheet Feeders A to D feed sheets that require folding by the machine. The Mail Piece Icon T ree 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 1-1 1 of this guide. The Firs[...]

Operator Functions • 3 3-13 SV40221 Rev . A 3. Jog the stack back into alignment. 4. The Mail Piece Icon T ree will show the correct orientation of the sheets in the Stack. Make sure you load sheets in the orientation indicated. 5. The Sheet Feeders take the paper Stack in a similar way to a photocopier paper cassette. Place the Stack onto the de[...]

3 • Operator Functions 3-14 SV40221 Rev . A Setting the Envelope Feeder Envelope Feeder E feeds the Outer Envelope for the inserting job being run. The Mail Piece Icon T ree 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 1-1[...]

Operator Functions • 3 3-15 SV40221 Rev . A 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: T o quickly load envelopes during a run, without the need to stop and start the machine... • Press the[...]

3 • Operator Functions 3-16 SV40221 Rev . A Setting the Insert Feeder(s) Insert Feeders F and G feed items that do not require folding by the machine. Depending on configuration, your machine may have no Insert Feeders, one Insert Feeder or two Insert Feeders. Insert Feeder F is capable of feeding thicker Inserts than Insert Feeder G. Therefore, [...]

Operator Functions • 3 3-17 SV40221 Rev . A 4. Set the blue separator shield lever to the letter required. 5. T ake the stack of inserts and fan it to ensure individual Inserts are not stuck together . 6. ‘Shingle’ the inserts to be run so that they look like the photograph on the right and place them onto the feed deck. The Mail Piece Icon T[...]

3 • Operator Functions 3-18 SV40221 Rev . A Filling the Envelope Sealer Make sure the Envelope Sealer is filled with sealing solution before running a job that has sealing turned on. When the sealer needs refilling, a warning message will automatically appear on the display and, if sealing, the sealing icon will flash. Add sealing solution (EZ-Se[...]

Operator Functions • 3 3-19 SV40221 Rev . A 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[...]

3 • Operator Functions 3-20 SV40221 Rev . A SV40221 Rev A book.indb 3-20 9/14/2004 5:51:15 PM[...]

4-1 SV40221 Rev . A 4 • S upervisor 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 Cr[...]

4 • Supervisor Functions 4-2 SV40221 Rev . A 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[...]

Supervisor Functions • 4 4-3 SV40221 Rev . A 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... select Menu select Supervisor Functions enter th[...]

4 • Supervisor Functions 4-4 SV40221 Rev . A 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[...]

Supervisor Functions • 4 4-5 SV40221 Rev . A TIPS: Highlight the Job Name to edit the following items: Job Name Job Comments Batch Counter Maximum Sheet Length OMR set up Highlight the Envelope icon to edit envelope and sealing settings. The Outer Envelope and First sheet cannot be added or deleted. Don’t forget to edit the job comments to corr[...]

4 • Supervisor Functions 4-6 SV40221 Rev . A 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 ch[...]

Supervisor Functions • 4 4-7 SV40221 Rev . A Delete Job What is it? Delete Job allows a Supervisor to remove a stored Job Definition permanently from the machine’s memory . Where is it? From the Home Screen... select Menu select Supervisor Functions enter the Supervisor Access Code (see page 4-2) select Delete Job Action… Once Delete Job has [...]

4 • Supervisor Functions 4-8 SV40221 Rev . A OMR Menu This function lets a Supervisor setup Optical Mark Recognition (OMR) codes for inclusion within Job Definitions. All OMR functions are explained fully within Chapter 5 - OMR. System Menu What is it? This menu lets a Supervisor adjust the following system setting:  Manual Feed Option Where i[...]

5-1 SV40221 Rev . A 5 • O ptical Mar k Recognition (OMR) This chapter gives background and setup information for using O ptical M ark R ecognition (OMR) on a machine equipped with the OMR option. OMR Availability ................................................................ 5-2 What is OMR? .....................................................[...]

5 • Optical Mark Recognition (OMR) 5-2 SV40221 Rev . A OMR A vailability Y our 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 dif ferent codes for you to select when creating Job Definitions that use OMR. What is OMR? An OMR mark[...]

Optical Mark Recognition (OMR) • 5 5-3 SV40221 Rev . A OMR Marks Available This section gives brief descriptions of the OMR Marks that can be allocated to an OMR Code and lists the options available for use with each mark. The section following, OMR Mark Options on page 5-6 then gives greater detail of each option. NOTE: Some marks within this se[...]

5 • Optical Mark Recognition (OMR) 5-4 SV40221 Rev . A EOC - End of Collation This is a mandatory mark which indicates that it is the last sheet fed within the OMR set . This can only be selected once within the code and is the only mark used when using the Single Mark option. Options available: • Present or Absent STP - Stop This mark is a pro[...]

Optical Mark Recognition (OMR) • 5 5-5 SV40221 Rev . A P AR - Parity This mark is a security feature , that when printed always makes the number of marks total an odd or even number . If any one of the marks within the code is missed during scanning, the machine will stop functioning, allowing the error to be rectified. No more than 1 Parity mark[...]

5 • Optical Mark Recognition (OMR) 5-6 SV40221 Rev . A OMR Mark Options This section gives brief descriptions of the OMR Mark Options that can be allocated to relevant OMR marks. The previous section, OMR Marks Available on page 5-3 lists which options can be selected with each mark. Present or Absent When Present the machine will act upon scanni[...]

Optical Mark Recognition (OMR) • 5 5-7 SV40221 Rev . A Least or Most Significant Mark nearest to Benchmark This option gives the choice of orientation of the binary digit count within the relevant part of the OMR code. When Least Significant Mark is chosen, the mark within the relevant part of the code nearest to the Benchmark would be represente[...]

5 • Optical Mark Recognition (OMR) 5-8 SV40221 Rev . A OMR Specifications The mark must be a solid black line between 1pt and 2pts thick 1/64” (0.35mm to 0.7mm) and at least 3/8” (10mm) wide. Each mark position must be evenly spaced and at least 1/10” (2.54mm) apart. The maximum amount of mark positions allowed within the code is 24; this i[...]

Optical Mark Recognition (OMR) • 5 5-9 SV40221 Rev . A 3/4” (20mm) min 2-3/8” (59mm) min 1-3/16” (30mm) min 1/8” (3mm) min 1/8” (3mm) min Place marks in this area for: C/Double Fold Rear T op Scanner Single/Z Fold Rear Bottom Scanner Place marks in this area for: C/Double Fold Front T op Scanner Single/Z Fold Front Bottom Scanner The wh[...]

5 • Optical Mark Recognition (OMR) 5-10 SV40221 Rev . A Creating, Deleting and Viewing OMR Codes The OMR Menu contains functions which allow a Supervisor to create, delete and view OMR Codes. Where is it? From the Home Screen… Select Menu Select Supervisor Functions Enter the Supervisor Access Code (see page 4-2) Select OMR Menu Action… Once [...]

Optical Mark Recognition (OMR) • 5 5-1 1 SV40221 Rev . A Create New OMR Code This function lets a Supervisor create a new OMR code to be stored in the machine’s memory so that it can be used when creating a Job Definition that uses OMR. Action… Select Create New OMR Code from the OMR Menu screen and the machine will ask if you are creating a [...]

5 • Optical Mark Recognition (OMR) 5-12 SV40221 Rev . A The Benchmark is a mandatory mark and must be either the first or last mark within the code. The End of Collation Mark is the only other mandatory mark and so must also be selected, but it can be placed anywhere within the code. If either of the mandatory marks are not selected, the Finish s[...]

Optical Mark Recognition (OMR) • 5 5-13 SV40221 Rev . A 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 [...]

5 • Optical Mark Recognition (OMR) 5-14 SV40221 Rev . A 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 [...]

Optical Mark Recognition (OMR) • 5 5-15 SV40221 Rev . A 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 5-1 1. Setting the T ype of OMR During the Create Job process, the machine will ask whether OMR is being used with[...]

5 • Optical Mark Recognition (OMR) 5-16 SV40221 Rev . A Defining the first mark position and code length T ake a sheet that has at least the FIRST and LAST OMR mark printed on it . When requested by the machine, measure and enter the distance (A) from the top edge of the sheet to the FIRST OMR mark, in millimetres. Again, when requested by the ma[...]

Optical Mark Recognition (OMR) • 5 5-17 SV40221 Rev . A Defining the Clear Zone When requested by the machine, measure and enter the distance (A) from the top edge of the sheet to the point after the printed matter where you wish the machine to ST ART scanning. Again, when requested by the machine, measure and enter the distance (B) from the star[...]

5 • Optical Mark Recognition (OMR) 5-18 SV40221 Rev . A OMR Scanner Adjustments The machine can be fitted with one T op Scanner and one Bottom Scanner . If the sheet(s) bearing OMR marks are loaded face up, the T op Scanner will be used. If they are loaded face down, the Bottom Scanner will be used. The loading orientation required for the partic[...]

Optical Mark Recognition (OMR) • 5 5-19 SV40221 Rev . A Setting the T op Scanner Position This scanner position is used for C and Double Folds. Open the T op Cover and locate the blue T op Scanner adjusting knob and adjustment scale for the side the scanner is fitted. Rotate the adjusting knob until the indicator is aligned with the measurement ([...]

5 • Optical Mark Recognition (OMR) 5-20 SV40221 Rev . A Setting the Bottom Scanner Position This scanner position is used for Z and Single Folds. Open the upper central front door and locate the blue Bottom Scanner adjusting knob and adjustment scale. Rotate the adjusting knob until the indicator is aligned with the measurement (X) you just made.[...]

Optical Mark Recognition (OMR) • 5 5-21 SV40221 Rev . A Once the Bottom Scanner is aligned, the T op Scanner (or paper guide if a corresponding T op Scanner is not fitted) must be positioned so that the sheet being scanned is kept at a controlled distance from the scanner . This is achieved by adjusting the T op Scanner as described on page 5-19,[...]

5 • Optical Mark Recognition (OMR) 5-22 SV40221 Rev . A SV40221 Rev A book.indb 5-22 9/14/2004 5:51:22 PM[...]

6-1 SV40221 Rev . A 6 • T roubleshootin g Refer to this chapter if you have problems with your machine. T roubleshooting T ips ......................................................... 6-2 General T roubleshooting ................................................... 6-3 Machine ......................................................................[...]

6 • T roubleshooting 6-2 SV40221 Rev . A T roubleshooting 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[...]

T roubleshooting • 6 6-3 SV40221 Rev . A Problem Remedy Page MACHINE Blank Screen No power . Check power cord is firmly connected and wall socket is switched ON. 3-2 Machine not switched ON. T urn power switch (located on lower front) ON. 3-2 Display adjustment set incorrectly . Reset the Display Adjustment to an acceptable setting. 3-19 Performa[...]

6 • T roubleshooting 6-4 SV40221 Rev . A Problem Remedy Page ENVELOPES Poor Envelope Feed Envelope side guides set incorrectly . Set guides to envelope width and back off 1/4 turn. 3-14 Poor envelope quality . Check envelopes are not curled. T ry a new box of envelopes. Make sure stack has been fanned before loading. 3-14 Envelopes loaded incorre[...]

T roubleshooting • 6 6-5 SV40221 Rev . A Problem Remedy Page SHEETS Poor Sheet Feed Sheet Feeder side guides set incorrectly . Set guides to Sheet width and back off 1/4 turn. 3-12 Sheets loaded incorrectly . Make sure stack has been fanned before loading. 3-12 Multiple sheets feed when one is expected Sheet Feeder is programmed to feed a Pre- Co[...]

6 • T roubleshooting 6-6 SV40221 Rev . A Problem Remedy Page INSERTS Poor Insert Feed Insert Feeder side guides set incorrectly . Set guides to Insert width and back off 1/4 turn. 3-16 Insert Feeder separator adjustments incorrect. Make sure the two Insert Feeder adjustments (number and letter settings) are set correctly for the type of Insert be[...]

T roubleshooting • 6 6-7 SV40221 Rev . A Problem Remedy Page DOUBLE DETECT The machine keeps turning Double Detect OFF Double Detect cannot calibrate itself properly . Double Detection might not be possible with certain very thick or heavily printed material. Either change material or choose to run with Double Detect OFF . Machine stops for ‘do[...]

6 • T roubleshooting 6-8 SV40221 Rev . A Clearing Material Stalls Y our machine has been designed to assure maximum performance. In the event of a material stall, the display will indicate where the stall has occurred and will suggest remedial action. First press Clear Deck to attempt to feed the material through the machine. If not successful, t[...]

T roubleshooting • 6 6-9 SV40221 Rev . A Removal & Replacement of the Sheet Feeder Trays A to D T o 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. T o replace… Place the tray into[...]

6 • T roubleshooting 6-10 SV40221 Rev . A 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. 4 5 3 2 The illustrations [...]

T roubleshooting • 6 6-1 1 SV40221 Rev . A Area 2 Rotate clockwise to unlatch. Relatch by rotating lever fully counterclockwise. Area 1 Pull upwards to unlatch. Relatch by pressing assembly firmly down at the center . Area 4 Rotate counterclockwise to unlatch. Push assembly back into position and relatch by rotating lever fully clockwise. Area 3 [...]

6 • T roubleshooting 6-12 SV40221 Rev . A Access to Areas 7 and 8 Areas 7 and 8 are located at the inner ends of the Insert Feeders F and G. Therefore, before access can be gained to a material stall in these areas, the Insert T rays must be removed as described on page 6-9. Once the trays are removed, access to stalled material can be gained by [...]

T roubleshooting • 6 6-13 SV40221 Rev . A Access to the Removeable Paper Path (under Insert Feeder F) This removeable plate is located immediately below Insert Feeder F . Therefore, before access can be gained to a material stall in this area, Insert T ray F must be removed as described on page 6-9. Access can be gained by lifting the blue handle[...]

6 • T roubleshooting 6-14 SV40221 Rev . A Access to the Envelope Exit Area Pull down the envelope exit area door , as shown, to gain access to stalled material. When closing the door , make sure it is firmly latched into position. Access to the Envelope Inserting/Sealing Area Access can be gained to the insertion and sealing areas by lifting the [...]

T roubleshooting • 6 6-15 SV40221 Rev . A 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 T rial Piece and replying ‘No’ when asked if the T rial Piece is OK. This adjustment will only be needed in unusual situations wher[...]

6 • T roubleshooting 6-16 SV40221 Rev . A SV40221 Rev A book.indb 6-16 9/14/2004 5:51:28 PM[...]

7-1 SV40221 Rev . A 7 • Re f erence 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 T ype and[...]

7 • Reference 7-2 SV40221 Rev . A 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 2 ) Minimum (non OMR) 20 lb. (75g/m 2 ) Minimum (with OMR) 32 lb.[...]

Reference • 7 7-3 SV40221 Rev . A Number of sheets Paper Weights in lbs. 16, 18, 20 22, 24, 26 28, 30, 32 1 C,Z,S,D C,Z,S,D C,Z,S,D 2 C,Z,S,D C,Z,S,D C,Z,S 3 C,Z,S,D C,Z,S,D C,Z,S 4 C,Z,S,D C,Z,S,D 5 C,Z,S,D D 6 S,D D 7 S 8 S 9 S 10 S Fold T ypes: C = C Fold, Z = Z Fold, S = Single Fold, D = Double Fold Fold T ype and Overall Thickness Limits The[...]

7 • Reference 7-4 SV40221 Rev . A Insert Feeders F and G Minimum Insert size: 5" (127mm) Width 3-1/4" (82mm) Depth Maximum Insert size: 9" (230mm) Width 6" (152mm) Depth Paper Weights: 20 lb. (75g/m 2 ) Minimum (single sheet/slip) 16 lb. (60g/m 2 ) Minimum (folded material) 48 lb. (180g/m 2 ) Maximum (single sheet/slip) Maximu[...]

Reference • 7 7-5 SV40221 Rev . A ALL SPECIFICA TIONS ARE SUBJECT T O CHANGE WITHOUT NOTIFICA TION AND ARE SUBJECT TO TEST Envelope tray capacity: Up to a maximum of 300, 26 lb. (90g/m 2 ) 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] overal[...]

7 • Reference 7-6 SV40221 Rev . A Envelope Sealer The machine can seal up to a maximum of 3,000 envelopes between refills. Drop Stacker The Drop Stacker can accommodate up to 150 Mail Pieces. (This is dependent on the size and contents of the envelope). Material Requirements For best performance, use only materials approved by your machine suppli[...]

Reference • 7 7-7 SV40221 Rev . A Machine Specifications Physical Dimensions Length 54" (1370mm) Depth 22-1/2" (570mm) Height 30" (760mm) Minimum Weight 194 lbs. (88kg) Maximum Weight 225 lbs. (102kg) Weight will depend on machine configuration. W eights stated do not include material. Noise Level Running 72dBA - 74dBA Electrical A[...]

7 • Reference 7-8 SV40221 Rev . A Changing the Envelope Sealer Unit Felts The sealer unit felts are supplied as part of a kit and can be changed by the operator in the following way: 1. Hinge open the Sealer Bottle cover located at the front right hand side of the machine. Remove the Sealer Bottle. 2. Remove the Insert T rays (see page 5-9). Lift[...]

Reference • 7 7-9 SV40221 Rev . A 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 holes in the mounting bar and slide the felt toward[...]

7 • Reference 7-10 SV40221 Rev . A 8. Push down on the blue tab to return the upper felt assembly to its operating position. Make sure that the blue latches (A) spring out and fully latch into position. 9. Refit the Sealer Bottle and close the covers. The felts will take a few minutes to become fully wet and ready for use. A Service Service for y[...]

I-1 SV40221 Rev . A Inde x A Additional Sheet or Additional Set 1-14 Automatic Processing 3-4, 3-5, 3-8 B Batch Count 3-5 Beginning of Collation (BOC) for OMR 5-3 Benchmark (BM) for OMR 5-3, 5-12 Blue separator gap lever 3-16 Blue separator shield lever 3-17 C Cancel Button 1-8 Changing the Envelope Sealer Unit Felts 7-8 Clear Deck Button 1-9 Clear[...]

Index I-2 SV40221 Rev . A D Daily Mail Feeder . See Manual Feeder Delete Job 4-7 Display Adjustments 3-19 Double Detect 1-1 1 Drop Stacker 1-7, 7-6 E Edit Job 4-4 End of Collation (EOC) 5-4 End of Collation (EOC) for OMR 5-12 Envelope Feeder Changing the Envelope Sealer Unit Felts 7-8 Description 1-7 Envelope Stop Position 6-15 Loading switch 3-14 [...]

Index I-3 SV40221 Rev . A I Ignore (IGN) for OMR 5-5 Insert 1-15 Insert Feeder(s) Blue separator gap lever 3-16 Blue separator shield lever 3-17 Description 1-7 Setting the Insert Feeder(s) 3-16 Side Guide Adjustment Knob 3-16 Speci fi cations 7-4 Wedge 3-17 Insert Icons 1-12 Insert T ray(s) Removal & Replacement 6-9 Instructional T ext 2-3 J [...]

Index I-4 SV40221 Rev . A M Machine, Parts Of 1-6 Machine Status 2-3 Machine Con fi gurations 1-4 Machine Graphic 2-3 Machine Identi fi cation 1-6 Machine Speci fi cations 7-7 Mail Piece 1-15 Mail Piece Icon T ree 1-10, 2-3, 3-3 De fi nition 1-16 Double Detect 1-1 1 Envelope Icons 1-12 Example 1-13 Fold Icons 1-12 Insert Icons 1-12 Linked Feede[...]

Index I-5 SV40221 Rev . A Menu, Operator Functions 3-19 Display Adjustments 3-19 Language 3-19 Safe Seal 3-19 System Information 3-19 Menu, Supervisor Functions 4-2 Create From (jobs) 4-6 Create Job 4-3 Creating, Deleting and Viewing OMR Codes 5-10 Creating an OMR Job 5-15 Delete Job 4-7 Delete OMR Code 5-13 Edit Job 4-4 Job Comments 4-5 Job Name 4[...]

Index I-6 SV40221 Rev . A End of Collation (EOC) 5-4, 5-12 Ignore (IGN) 5-5 Include Zero or Omit Zero (0) as a V alue 5-6 Increment or Decrement 5-6 Least or Most Signi fi cant Mark nearest to Benchmark 5-7 Marked Piece to be left Unsealed (Y es or No) 5-7 Multi-Mark 5-1 1 Odd or Even 5-7 OMR Availability 5-2 OMR Mark Options 5-6 OMR Scanners 5-9 [...]

Index I-7 SV40221 Rev . A R Removal & Replacement Access to Areas 7 and 8 6-12 Access to Area 6 6-12 Access to Internal Areas 1 to 5 6-10 Access to the Envelope Exit Area 6-14 Access to the Envelope Inserting/Sealing Area 6-14 Access to the Removable Paper Path (under Insert Feeder F) 6-13 Access to the T op Cover (Sheet Feed Area) 6-13 Insert [...]

Index I-8 SV40221 Rev . A Sheet Feeders Explanation 1-6 Linking 3-17 Removal & Replacement of T rays 6-9 Setting the Sheet Feeders 3-12 Speci fi cations 7-2 Sheet Icons 1-12 Shingle 1-15 Side Guide Adjustment Knob 3-14 Single Mark 5-2 Speci fi cations 7-2 Fold T ype and Overall Thickness Limits 7-3 Insert Feeders 7-4 Machine 7-7 Material Requ[...]

Index I-9 SV40221 Rev . A T T iming (TM) for OMR 5-5 T rial Piece 1-16, 3-10 Running a T rial Piece 3-4 T rial Piece Button 1-9 T roubleshooting 6-2 Clearing Material Stalls 6-8 Double Detect 6-7 Envelopes 6-4 Inserts 6-6 Machine 6-3 Sheets 6-5 T ips 6-2 W Wedge 3-17 Wrap Around Sequence (W AS) for OMR 5-5 SV40221 Rev A book.indb I-9 9/14/2004 5:51[...]

Index I-10 SV40221 Rev . A SV40221 Rev A book.indb I-10 9/14/2004 5:51:32 PM[...]

SV40221 Rev A book.indb 1 9/14/2004 5:52:23 PM[...]

*SV40221REVA* 1 Elmcroft Rd. Stamford, Connecticut 06926-0700 www .pitneybowes.com 5500 Explorer Drive Mississauga, Ontario L4W5C7 www .pitneybowes.ca PB Form SV40221 Rev A (9/04) Printed in the USA or Canada Printed on recyclable paper SV40221 Rev A book.indb 2 9/14/2004 5:52:23 PM[...]