Pitney Bowes DI425 FastPac Operator'S Manual Download Page 97

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Index

SV61789 Rev. A

Index-3

Face

Down, Definition

A-4

Up, Definition

A-4

Failure

Definition

A-4

Fanning

Definition

A-4

Features, Machine 1-3

Feed

Manual, Notes about 2-16

Feed Direction

for C- and Double Fold OMR

Jobs 3-8

for Z- and Single Fold Jobs 3-9

Feeder

Definition

A-4

Envelope, Location of 1-7

Envelope, Setting the 2-6

Linking a 2-15

Main Sheet, Setting the 2-15

Sheet, Setting the 2-4

Supplementary, Setting the 2-16

Felts, Sealer Unit

Changing the 4-5

Filling the Sealer 2-10

Flap

Depth, Definition

A-5

First, Definition

A-5

Last, Definition

A-5

Side Down, Definition

A-5

Side Up, Definition

A-5

Fold

A, Setting the 2-19

B, Setting the 2-20

Making Minor Adjustments to 2-23

Modes Available 4-19

Panel, Definition

A-5

Plates

Removal and Replacement 4-2

1 and 2, Location of 1-6

Poor Quality 4-9

Type, Setting the 2-13

Type and Thickness Limits 4-16

Fold-Only Mode 2-17

Folder

Definition

A-5

Forward

Flap Envelope, Definition

A-5

Order, Definition

A-5

Hand Wheel

Definition

A-6

Help, Getting iii

Insert

Definition

A-5

Double Document Detector Material

Range 4-17

Feeder, Definition

A-5

Feeder, Location of 1-6

Feeder, Setting the 2-8, 2-17

Feed Poor 4-10

Feed Tray Capacity 4-17

Paper Weights 4-17

Problems 4-7

Size 4-17

Tray

Removal and Replacement 4-2

Insertion

Mode 2-17

Problems 4-7

Integrity

Definition

A-5

Item

Definition

A-6

Job

Button 1-8

Changing an Existing 2-24

Creating a New 2-11

Definition

A-6

Deleting a 2-24

Number, Choosing the 2-12

Programming 2-11

Summary of Contents for DI425 FastPac

Page 1: ...FastPac Document Inserting System DI425 Operator Guide US Canada English Version ...

Page 2: ...t 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 We have made every reasonable effort to ensure the accuracy and use fulness of this manual however we cannot assume responsibility for errors or omissions or liability for the misuse or misapplication of our products Due to o...

Page 3: ...ay Symbols 1 9 Chapter 2 Operation About this Chapter 2 1 Connecting Power 2 1 Select a Job 2 2 Run a Trial Piece 2 3 Start Machine Operation 2 3 Setting the Sheet Feeders 2 4 Setting the Envelope Feeder 2 6 Setting the Insert Feeder 2 8 Filling the Sealer 2 10 Adjusting the Stacker 2 10 Programming Jobs 2 11 Creating a New Job 2 11 Confirming the Job Setup 2 22 Testing the Job 2 23 Changing an Ex...

Page 4: ...ilable 3 6 OMR Mark Grouping 3 8 Programming an OMR Job 3 10 Adjustment of OMR Scanner 3 16 OMR Troubleshooting 3 18 Chapter 4 Reference Changing the Display Language 4 1 Clearing Material 4 1 Changing the Sealer Unit Felts 4 5 General Troubleshooting 4 7 Error Messages 4 12 Material Specifications 4 15 Machine Specifications 4 19 Jobs Customer Job Programming Record 5 1 Appendix A Glossary of Ter...

Page 5: ...To view and pay invoices online go to www pb com and click on My Account To view inventory go to www pb com and click on My Account For direct questions call 1 800 522 0020 Customer Service Representatives are available Monday through Friday 8 00 AM to 8 00 PM ET Canada Contacts Product Name FastPac Document Inserting System Model DI425 For frequently asked questions or to order supplies go to www...

Page 6: ...Table of Contents iv SV61789 Rev A ...

Page 7: ...se an adapter plug on the line cord or wall outlet DO NOT remove the ground pin from the line cord Make sure the area in front of the wall outlet into which the ma chine is plugged is free from obstruction DO NOT route the power cord over sharp edges or trap it be tween pieces of furniture Make sure there is no strain on the power cord To reduce the risk of fire or electrical shock DO NOT attempt ...

Page 8: ...aintenance will inhibit optimum operating performance and could cause the equipment to malfunction Contact your system supplier for the required service schedule Always follow specific occupational safety and health standards for your workplace To reduce the risk of fire or electrical shock DO NOT attempt to remove covers or disassemble the control panel or its base The cabinet encloses hazardous ...

Page 9: ...sertion Manually fed semi automatic insertion of single and multiple sheet collations Option of single fold letter C fold accordion Z fold or double fold Job recall facility Linked feeding three station machines only Optical Mark Recognition OMR scanning some models Machine Configurations The following machine configurations are available 1 Station One sheet feeder only 2 Station One sheet feeder ...

Page 10: ...d paper that is perpendicular to the direction of paper travel This line must be thick and dense enough to trigger the system s OMR scan ner The scanner together with the system software checks for one or more different OMR marks on a document as it feeds through the system Tracking of these marks enhances mail piece integrity by assuring that documents that belong together a set stay together thr...

Page 11: ... of up to five sheets The ma chine waits for you to feed each set by hand into sheet feeder 1 before folding and inserting the set automatically See the Specifications section of this guide for full details of the sets possible Sheet Feeder 2 For feeding material that requires folding Its functions are similar to those of sheet feeder 1 but the manual feed option is NOT available from this feeder ...

Page 12: ...ly suited to feeding pre folded or thicker inserts Fold Plates 1 and 2 These units create the desired fold in material fed from the sheet feeder s The fold plates are auto matically set from the control panel Display Control Panel This is where you enter commands and where the machine informs you of its status through sym bols and icons Each button is explained on page 1 8 3 4 5 6 Machine Identifi...

Page 13: ...ance Knob This is located inside an opening cover at the lower center of the machine Use it to turn the machine by hand to help clear material stoppages Envelope Feeder This feeder feeds envelopes into the inserting area where they are filled with the material requested from the other feeder s Sealer Bottle The sealer bottle is located inside an opening cover at the front right side of the machine...

Page 14: ...fter a stoppage has occurred Trial Piece Press to run a single test piece to check machine setup You must run a trial piece before you begin automatic operation using the Start button If you re using double detection the machine sets itself automatically as it runs the trial piece The trial piece envelope will be unsealed and counted as one item Start Press to start automatic operation Stop Press ...

Page 15: ... on without double detection Used on insert feeder to signify that the feeder is on with double detection Used on sheet feeder 1 to signify that the feeder is set for manual feed Used on envelope feeder to signify that the feeder is on Indicates the setting from 1 to 5 of the envelope stop Indicates that the sealer bottle needs refilling Indicates the envelope depth Indicates that the sealer unit ...

Page 16: ...le fold is selected Indicates a single fold is selected Indicates a no fold insert operation Indicates a material stoppage The position of this symbol in the display indicates where the stoppage has occurred Call Pitney Bowes for service Indicates the paper size address orientation and fold s set for sheet feeder Indicates a material stoppage in a downstream de vice such as a power stacker or mail...

Page 17: ...t programmed the job see to Programming Jobs on page 2 11 Connecting Power Read the safety information on page 1 1 before connecting the machine Connect the power cord to the socket on the back of the machine Plug the power cord into a suitable power outlet Make sure the pow er outlet is near the machine and is easily accessible Turn the power switch ON as shown at the right ...

Page 18: ...ce for you to check If you don t have material loaded do this now then return to this section You ll find instructions for loading the machine on pages 2 4 to 2 9 Note You may have selected a manual feed job where sheet feeder 1 is set for manual feed of collated sets If this is the case DO NOT load the sheet feeder Instead you ll feed collated sets one at a time by hand as required by the machine...

Page 19: ...en you use linked feeding load both sheet feeders before you run a trial piece 2 If you load material during a run which seems to have differ ent characteristics weight color shade etc or if you have any problems with double detection run another trial piece This causes the machine to recalibrate the double detect function for the new material which may vary slightly from the old Start Machine Ope...

Page 20: ... between the guides and the material 2 Take the stack of paper and aerate fan it to ensure that individual sheets are not stuck together 3 Jog the stack back into align ment The sheet feeders take the paper stack aligned in a manner similar to that used for a photocopier paper cas sette 4 The display indicates the correct orientation of the paper FACE UP HEAD FIRST ABC FACE DOWN FEET FIRST A B C ...

Page 21: ...deck Allow the deck to move down and the top of the paper stack to slide under the feed roller Note When you use both sheet feeders use the feeder listed below for the prime address bearing document C or Double fold Use sheet feeder 1 Z or Single fold Use sheet feeder 2 ...

Page 22: ...ss the envelope feeder loading switch to lower the feeder tray 2 Adjust the side guides to the width of the envelopes Use the side guide adjustment knob then back off 1 4 turn This sets the correct clear ance between the guides and envelopes 3 Take the stack of envelopes and fan it to ensure that in dividual envelopes are not stuck together ...

Page 23: ...envelope stack to the normal feeding position TIP To quickly load envelopes during a run without the need to stop and start the machine Press the envelope feeder loading switch to lower the feeder tray Load envelopes as described above Press the envelope feeder loading switch again The envelope stack rises to the normal feeding position and processing continues automatically ...

Page 24: ... the labels located on the insert feeder Match your insert type slip reply envelope pre folded or booklet with the relevant icon and color indicator on each label If the label indicates a range of settings follow this general rule The thicker the insert the higher the number or letter you should select For example The blue booklet range runs from 6 to 9 and C to D A setting for a thin booklet migh...

Page 25: ... right and place them onto the feed deck Loading orientation can vary depending on the actual in serts you re running However as a general guideline load in serts as follows Slip Face up bottom edge first Reply Envelope Face up top edge first Pre Folded Face up closed edge first Booklet Face up bound edge first 7 Let the wedge material prop slide down behind the stack to support the inserts ...

Page 26: ...ttle up to the level indi cated Place the sealer bottle in posi tion in the machine and close the cover Note If the sealer unit was completely empty allow time for the fresh solution or water to soak through the sealer before you resume operation This helps assure a good seal Adjusting the Stacker Adjust the drop stacker to suit the material you re running Lift the lever at the rear of the stacker...

Page 27: ...pur chased To program an OMR job go to page 3 10 of this guide To program a non OMR job continue by entering the Setup Mode Programming Jobs You can program your machine with jobs that remain in its memory You can recall these jobs at the touch of a button All models have a capacity of 20 operator programmable jobs plus one default job that s set by your Pitney Bowes Service Representa tive Enteri...

Page 28: ...s you are about to make If you want to find a currently unused job number press Change until you see a job where the display shows no symbols alongside the feeders or in the fold setup area This means the job number is unused and available Press Next to advance to the next setting OMR On models equipped with OMR ONLY you will now be asked to se lect the OMR mode For a non OMR job use Change to sel...

Page 29: ...jobs DO NOT manually change the automatically set fold length dimensions at the Fold A and Fold B settings on pages 2 19 and 2 20 When the fold type is selected the display indicates the correct ori entation of the paper for loading into the feeders When the fold type is set as required press Next to go the next setting FACE UP HEAD FIRST ABC FACE DOWN FEET FIRST A B C ...

Page 30: ...rned on with sheets feeding from the main feeder This feeder normally contains the address sheet Accumulation From Suppl Accumulation is turned on with sheets feeding from the sup plementary feeder that is one address sheet from the main feeder followed by multiple sheets from the supplementary feeder Press Next to advance to the next setting Accumulation 2 to 10 Select how many pages you want to ...

Page 31: ...n you want On Double Detect Feeder on with the dou ble detector operating The double detector stops the machine if two or more sheets feed simultaneously from the feeder Off Feeder turned off for this job On Feeder on without the double detector Manual Feed Allows you to manually feed collated sets This is available only on sheet feeder 1 Also see notes on following page Linked On Linked On Double...

Page 32: ...running manual feed mode sheet feeder 2 becomes inop erable When the first sheet feeder is set as required press Next to ad vance to the next setting Setting the Second Supplementary Sheet Feeder Select whether you want to use the second sheet feeder Press Change until you see the option you want On Double Detect Feeder on with the double detector operating The double detector stops the machine if...

Page 33: ...on without the double detector Off Feeder turned off for this job When the Insert Feeder is set as required press Next to ad vance to the next setting Mode The machine needs to know if the job requires inserting into an en velope or if it is a fold only job Press Change to switch between the options Insertion Mode Activates the envelope feeder for a normal inserting job Fold Only Mode Turns the en...

Page 34: ...e sure the sealer water bottle is full of E Z Seal or water see page 2 10 Off Turns the sealer unit off Envelopes will be ejected unsealed When the sealer is set as required press Next to advance to the next setting If you have selected either of the sheet feeders the next setting of fered will be paper length If you are using the insert feeder only folding is not possible and the display advances...

Page 35: ... type and paper length the machine will sugges the correct dimension for the first fold Most of the time this setting will prove satisfactory If you want to change the stan dard setting press Change until the length of fold required is displayed The symbol shows the fold panel you are adjust ing The machine will automatically limit your choices to what is physi cally possible within the machine sp...

Page 36: ...rect press Next to advance to the next setting If you re programming an inserting job the envelope depth setting will now appear If you re programming a fold only job the display advances straight to the Confirming the Job Setup section on page 2 22 Envelope Depth Select the depth of your enve lopes in millimeters Again you can use the scale on the front cover to measure the depth of your envelope...

Page 37: ... next set Batch Counter The batch counter allows you to automatically process pre defined batches of finished mailpieces When the batch is complete the ma chine stops automatically Press Start to begin processing the next batch If batch counter is not selected the display counter simply counts the number of items processed until you press Reset Counter Press Change to switch batch mode On or Off W...

Page 38: ...utton to back track to the setting and correct it When you re satisfied with the job setup press the Setup button The machine will save the job in its memory and reset to the new job When this is complete the display will show the new job with the message Trial Piece Required The machine retains job settings even with power disconnected un til you change or delete them as described on page 2 24 ...

Page 39: ...ld settings FOLD TYPE ADDRESS TOO LOW ADDRESS TOO HIGH C Letter Fold Decrease Fold A Increase Fold A and increase Fold B by the same amount Z Accordion Increase Fold A Decrease Fold A a Fold increase Fold B by the same amount Single Fold Increase Fold A Decrease Fold A Double Fold Decrease Fold A Increase Fold A We suggest you change the fold by 0 20 inches 5mm each time and run a new trial piece ...

Page 40: ... buttons to change the options and or di mensions you want 5 Press Setup to leave setup mode and save the changes Deleting a Job To erase an existing job from memory follow the steps below 1 Enter the setup mode as described on page 2 11 2 Use the Change buttons to display the job you want to de lete 3 Press the Delete button The display reads Press again to con firm Press Delete again The display...

Page 41: ...arks on a docu ment while it is fed through the system The tracking of these OMR marks by the system increases the chance that a set of sheets which belong together a set actually stays together throughout the inserting process Use the Prev and Next buttons to step forward or back ward through the settings available Once the item displays use the Change buttons to select the option you want A Brie...

Page 42: ...ary the number of pages per envelope in a run from one envelope to another through the use of OMR marks The machine will fold each OMR sheet separately and insert it into an envelope starting with the last sheet of the set and adding each folded sheet in turn until the address sheet has been inserted The machine will then eject the envelope after sealing if selected Enhanced OMR allows you to stop...

Page 43: ...t clear from print and any other marks that the scanner might read in error This area is called the clear zone There should be no print on the opposing face of the sheet immedi ately behind the clear zone Note Diagram is not to scale 1 65 inches 42mm maximum 0 118 inch 3mm minimum pitch 0 393 inches 10mm minimum 1pt to 2pt 0 014 inch 0 35mm to 0 027 inch 0 7mm thick 0 078 inch 2mm minimum 0 078 in...

Page 44: ...ingle Fold Bottom scanning bottom right corner Standard OMR Positions 54mm min 96mm max 20mm min Clear Zone 20mm x 115mm min 69mm max 27mm min 20mm min Clear Zone 20mm x 100mm min Feed Direction for Top Scanning C and Double Fold Feed Direction for Bottom Scanning Z and Single Fold 115mm min 100mm min Vertically center group within area indicated ...

Page 45: ...in Z Fold and Single Fold Bottom scanning right margin Offset OMR Positions 125mm min 20mm min 80mm max 20mm min Feed Direction for Top Scanning C and Double Fold Feed Direction for Bottom Scanning Z and Single Fold 95mm max 65mm min 40mm min Bench Mark 65mm min 115mm min Note Diagram is not to scale ...

Page 46: ... Collation EOC This mark indicates that the sheet is the last sheet fed within the col lation set the address sheet Your system operates on the absence of this mark that is the action will take place if the mark is not read by the scanner It is therefore indicated on the OMR code as Not EOC Beginning of Collation BOC This mark indicates that the sheet is the first sheet fed within the col lation s...

Page 47: ... For Z and single fold the primary feeder is sheet feeder 2 Use Select Feed 2 marks in the primary sheet feeder to select mate rial from the insert feeder For C and double fold the primary feeder is sheet feeder 1 For Z and single fold the primary feeder is sheet feeder 2 Auto Batch This mark identifies the last set of a batch when the batch function is in use It must appear on all sheets of the O...

Page 48: ...plus Group 2 and or Group 3 as needed for a particular job C Fold and Double Fold Jobs Place marks in the upper left corner of the sheet Print marks in top to bottom order Benchmark fixed Safety fixed Not EOC Not BOC Parity Retiming fixed Select Feed 1 Select Feed 2 Auto Batch Retiming fixed if this group is in use Wrap Around Sequence 3 WAS3 Wrap Around Sequence 2 WAS2 Wrap Around Sequence 1 WAS1...

Page 49: ... cessed in each set is the address sheet and the last sheet processed is the last of each set Retiming fixed if this group is in use Wrap Around Sequence 1 WAS1 Wrap Around Sequence 2 WAS2 Wrap Around Sequence 3 WAS3 Retiming fixed if this group is in use Auto Batch Select Feed 2 Select Feed 1 Retiming fixed Parity Not BOC Not EOC Safety fixed Benchmark fixed Group 3 Group 2 Group 1 Mandatory Feed...

Page 50: ...advance to the next setting Choosing the New Job Number The machine asks for the job number you wish the new set tings to be stored under Use the Change buttons to display the job number you want Notes If you use an existing job number the system will over write the old settings will the new settings you are about to make If you want to find a currently unused job number press Change until you see...

Page 51: ...t feed Basic scanning Select Feed Autobatch scanning for this job with standard OMR mark positioning OMR Select feed Sequence Basic scanning Select Feed Autobatch Wrap Around Sequence scanning for this job with standard OMR mark posi tioning OMR Offset on OMR is turned on Basic Scanning for this job with offset OMR mark positioning OMR Offset Sequence Basic scanning Wrap Around Sequence scanning f...

Page 52: ...Select feed autobatch offers the following scanning functions Select feed 1 Select feed 2 Autobatch Retime Sequence offers Three wrap around page sequence marks Retime The maximum pages per set that can be fed from either sheet feeder 1 or 2 when using the OMR function must fall within the limits de tailed on page 4 16 of this guide Press Next to advance to the next setting ...

Page 53: ...n you select either a C fold or a double fold the machine auto matically selects top sheet feeder 1 as the scanning feeder If you select either a Z fold or a single fold the machine automatically se lects bottom sheet feeder 2 as the scanning feeder The display shows the correct orientation of the paper for loading into the feeders FACE UP HEAD FIRST ABC FACE DOWN FEET FIRST A B C When you ve set ...

Page 54: ...u want On Double Detect The feeder is on with the double detector operating The double detector stops the machine if two or more sheets feed simultaneously from the feeder On The feeder is on without the double detector When you ve set the sheet feeder as required press Next to advance to the next setting ...

Page 55: ...her feeder per envelope On Double Detect Feeder on with the double detector operating without select feed The double detector stops the machine if more than one sheet simultaneously feeds from the feeder On SF Double Detect Select feeder on with the double detector operating The double detector stops the machine if more than one sheet simultaneously feeds from the feeder On SF Select feeder on wit...

Page 56: ...d on the material To locate the scanning head for the TOP Sheet Feeder 1 open the Top Cover The scanning head can be found at the rear of the ma chine To locate the Scanning head for the BOTTOM Sheet Feeder 2 re move both sheet feeder 2 and the fold plate situated below sheet feeder 2 You ll find the scanning head mounted to the front of the machine Bottom Sheet Feeder Scanner Top Sheet Feeder Sca...

Page 57: ...subtract this measure ment from the half fold measurement Example For an A4 size form the half fold measurement is 105mm If the distance from the edge of the form to the middle of the scan dash marks is 10mm the scan ning head setting will be 95mm 105mm 10mm Loosen the knurled locking knob and set the relevant scanning head to the correct setting Retighten the locking knob If you ve adjusted the b...

Page 58: ...the Clear Deck key The envelope at the insertion area will eject into the stack er You must MANUALLY remove the remaining pages of the set from the appropriate feeder and fold insert into the envelope Then continue to run once you ve determined the cause of the stoppage Error Recovery for Empty Feeders If any feeder runs out of material the machine will stop and the fol lowing messages will scroll...

Page 59: ... have an EVEN number of marks OMR Sequence Error The sequence number is not sequential with the previous page fed Sheets are in the wrong order or missing OMR SF marks Inconsistent The Selective feed and Autobatch marks at positions 7 to 9 are different from those on the previous sheet of this set OMR SF not in Use A selective feed mark is present at positions 7 to 8 but the job setup does not inc...

Page 60: ...3 OMR 3 20 SV61789 Rev A ...

Page 61: ...aterial Note All the following illustrations show the three station machine other models are similar The machine is designed to assure maximum performance In the event of a material stoppage the display flashes a symbol indicating where the stoppage has occurred First press Clear Deck to attempt to feed the material through the machine If not successful the sec tions below tell you how to remove t...

Page 62: ...achine The tray will auto matically drop into its correct position Removal and Replacement of the Fold Plates To remove Pull the two catches on the underside of the plate outward to release them Pull the plate straight out of the machine To replace Pull the two catches on the un derside of the plate outward to release them Slide the plate into its location guides and release the catches to lock th...

Page 63: ...e arrow right Lift the envelope area feed rollers to gain access To relatch feed rollers Release the envelope area feed rollers and let them rest in posi tion Push the rollers firmly down until they latch into position Note You can get better access to this area by removing fold plate 1 and sheet feeder 2 Access to the Envelope Exit Area Pull down the access door as shown at the right to gain acce...

Page 64: ...tration can be unlatched to allow access to stalled material Access to the Sheet Feed Area To gain access Open the top cover Squeeze the two blue handles together and pivot the guide assembly to the right to gain ac cess To relatch Squeeze the two blue handles together and pivot the guide assembly back to its closed position Release the two blue handles making sure the assembly is securely latched...

Page 65: ...e rear right hand side of the machine Remove the bottle 2 Open the envelope inverter access door and lift the inser tion area plastic cover 3 Squeeze the two blue tabs A together and lift the blue tab B to gain access to the sealer unit felts 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 B B...

Page 66: ...kit remove all four felts from the sealer tank Discard these old felts 7 Install the four new felts into the sealer tank They will only fit one way Make sure to push them fully down into the tank 8 Push down on the blue tab to return the upper felt as sembly to its operating posi tion Make sure that the blue latches A spring out and fully latch into position 9 Put the water bottle back into positi...

Page 67: ...y for cover information Feed trays fold plates not located correctly Remove and relocate all feeders and fold plates Make sure they are in their correct positions and fully seated 4 2 Insertion Problems Outer envelope contents do not enter the envelope correctly Check envelope troubleshooting table Check that the fold selected is cor rect for the material size you re using If you re running heavy ...

Page 68: ...lopes loaded incorrectly Load envelopes flap side up with the flap feeding last 2 7 Envelopes Fail to Open Envelopes loaded incorrectly Load envelopes flap side up with the flap feeding last 2 7 Poor envelope quality Check that envelopes are not stuck due to excessive dampness Try a new box of envelopes 4 17 Envelope Sealing Problems No sealing solu tion Refill sealer unit 2 10 Seal mode not selec...

Page 69: ...Manual feed mode is selected Check job setup and manual feed lever position 2 2 Sheets loaded in correctly Make sure to fan stack before load ing 2 4 Address in Wrong Position in Envelope Window Address bearing sheets incorrectly loaded Load sheets so that the address appears through the envelope win dow 2 4 Folds incorrectly set Check job setup 2 22 2 23 Poor Folding A fold is almost correspondin...

Page 70: ...justments incorrect Make sure the two insert feeder adjustments number and letter set tings are set correctly for the type of insert you re running 2 8 Inserts loaded in correctly Make sure to fan the stack before loading Changing the orientation of the insert stack may help 2 9 Insert feeder wedge used incor rectly Let the wedge slide down behind the insert stack to support it 2 9 Inserts out of ...

Page 71: ...d ON Check double detect status Double detect icon will appear alongside all items where double detect is operational Correct loading or correct job setup as necessary Chapter 2 Double detect is not correctly cali brated Run a trial piece whenever a new batch of material is loaded to re calibrate double detect The new batch might be of slightly different thickness 2 3 ...

Page 72: ...pe has failed to open Check enve lopes are loaded correctly Reload envelopes and restart machine CLEAR FOLD PLATE Material was detected inside the fold plate in dicated on the display Remove fold plate and check for any material Install fold plate CLEAR INSERTION AREA Material was detected in the inserting area Open tinted plastic cover on left hand side of machine and remove any material Close co...

Page 73: ...tes and restart MANUAL FEED TIMEOUT Material feed has not been detected within a predetermined time In manual feed mode you must feed material within a set time Restart the machine by pressing Start PAPER SHORT The inserter detected that the material used is too short in length Check that actual material length matches the length displayed If cor rect request another trial piece PAPER SHORT CHECK ...

Page 74: ...her from the feed tray indicated Remove the stream feed from the stacker Reload ma chine and restart SYSTEM ERROR POWER DOWN A fault has been detected in the main soft ware Switch machine off and on and retry If problem persists call for service TRAY EMPTY The tray indicated has no material Reload tray and press Start ...

Page 75: ...d 8 in 201mm 14 in 356mm Double fold 12 in 305mm 16 in 406mm Double Document Detector Material range 60g m2 16 lb Min 120g m2 32 lb Max Feed Tray Capacity Up to a maximum of 325 sheets of 20 lb bond 80g m2 Manual Feed Mode In manual feed mode the machine will pro cess stapled sets of up to five sheets of 20 lb bond 80g m2 to a maximum total weight of 100 lbs 400g m2 per set Note For manual feed ap...

Page 76: ...weights of paper Important DO NOT program jobs that exceed these maximums or impose them by OMR code printing and or OMR selective feed Note You can use the sheet limits above with one additional sheet from the supplementary feeder plus one insert only if total mail piece contents do not exceed 0 078 in 2mm total compressed thickness For single fold only using 16 lb to 20 lb 60 80g m2 paper only y...

Page 77: ...ld be fed from the Insert Feeder Double Document Detector Material Range 16 lbs 60g m2 minimum 32 lbs 120g m2 maximum Feed Tray Capacity Up to a maximum of 300 Inserts Sealer The machine can seal up to a maximum of 1200 envelopes between refills Stacker The envelope stacker can accommodate up to 150 filled envelopes depending on size and contents of the envelope Material Requirements For best perf...

Page 78: ...in the enve lope Depth Clearance The insert must allow a minimum clear ance of 0 118 in 3mm for unfolded documents and 0 236 in 6mm for folded documents below the flap crease after it is fully inserted into the envelope Envelope Flap and Throat Requirements See illustration below 19mm Min 1 6mm Max 6mm throat depth at 19mm in from edge of envelope Min 6mm Max 41mm Closed flap tip should not come c...

Page 79: ...ltage Directive 73 23 EEC and the EMC Directive 89 336 EEC The product was tested in a typical configuration The DI425 is UL approved US and CUL approved Canada Service Service for your new folding inserting machine is available through out the United States and Canada Should you have questions about your machine or require service or assistance with your particular application please refer to the...

Page 80: ...4 Reference 4 20 SV61789 Rev A ...

Page 81: ...JOBS SV61789 Rev A 5 1 Jobs Use the table below to keep a note of the jobs you ve programmed into the system Job Description Default 1 2 3 4 5 6 7 8 9 ...

Page 82: ...JOBS SV61789 Rev A 5 2 Job Description 10 11 12 13 14 15 16 17 18 19 20 ...

Page 83: ...a sheet is the first sheet fed in a collation This is used for error checking purposes only and provides additional verification that a collation is not split or combined with another collation into one package Benchmark An OMR code indicating that more OMR codes are to follow Also known as an OMR trigger The benchmark must appear on every page of the document It verifies that the scanner is worki...

Page 84: ...ed solely for the placement of OMR marks To ensure reliable scanning no other printed material background color changes or perforation lines can be present in the clear zone Collation Two or more pieces of material assembled at a given point in the machine in a specific order Compare to Accumulation and Set Contrast The difference in brightness between the light and dark areas of a display Control...

Page 85: ...ys in effect until changed by an operator or service per sonnel Synonymous with normal setting fac tory setting and standard setting The normal state of a machine or software option Double Detect The process of sensing the feed of two or more sheets when only one should feed Double Fold A fold style in which a sheet is folded in half and in half again Downstream Further along in the direction of f...

Page 86: ...system that requires remedial action on the part of the user or the system Any abnormal condition that causes the system to stop while running or prevents it from starting normally Any stoppage of paper while running that is not recoverable by the machine A paper jam A fault ESD Electrostatic Discharge Can damage delicate electronic components if proper grounding proce dures are not followed Face ...

Page 87: ...s a tri fold C and Z folds has three The panels are called top middle and bot tom Forward Flap Enve lope An envelope with the flap on the window side Of ten used with advertising printed on the non flap side Forward Order Multi page pieces in normal print order 1 n where page one is in front of subsequent pages GSM Grams per square meter See Paper Weight Insert Any piece of material placed into an...

Page 88: ...ically starts feeding This enables a higher volume of material to be processed before reloading is required Linked feeders are also referred to as cascading feed ers Linking feeders can improve throughput Mail Piece An assembled article of mail usually a letter flat or card with the correct contents Mail Piece Content The set of items inside a mail piece Content can consist of sheets envelopes car...

Page 89: ... is inserted into an envelope OMR Marks Control codes in the form of printed dash lines on sheets and inserts that tell an inserting system how to process and assemble a mail piece Also see Scan Window Open Edge First Describes the orientation of an insert in a feeder where the open edge feeds first Open Edge last For pre folded inserts describes the orientation of an insert in an insert feeder wh...

Page 90: ... is the weight of a single one square meter sheet measured in grams See GSM Parity A security feature of OMR marks that when printed always makes the number of marks total an odd or even number Piece Term applied to either a completed mail piece or a single sheet of material Power Stacker A motor driven belt stacker usually horizontal on to which finished mail pieces are deposited in an orderly sh...

Page 91: ...e Select Feed Marks Marks on the prime or control document or first sheet in the control document that indicate which downstream feeders should feed A downstream selectable feeder will feed if the mark is present on all pages of the control document Selective feed A function that instructs the inserter system to select material from specified feeders This is controlled by select feed OMR marks Set...

Page 92: ...ommon method than bot tom feed Top First A feed orientation in which the address or top line of printed material feeds first Top Scanning Scanning from a reader located above the paper path reading marks printed on the top sheet Trailing Edge The last edge of a piece of material to enter or leave a paper handling system Contrast with Leading Edge Tray A removable part of a feeder that holds materi...

Page 93: ... page of a print run which is sequential throughout the run The marks can be set to check for either as cending or descending sequence If one of these is chosen then the collation sets must occur in the correct sequence or the machine will stop mail processing and declare an error This feature pro vides an additional level of document processing integrity Z Fold A fold type where a sheet is folded...

Page 94: ...Appendix A Glossary SV61789 Rev A A 12 ...

Page 95: ...und Edge First Definition A 1 Brightness Definition A 1 Business Reply Envelope Definition A 1 C C Fold Definition A 2 Cancel Definition A 2 Card Definition A 2 Carriage Assembly Accessing the 4 3 Change Button 1 8 Changing an Existing Job 2 24 Checksum Definition A 2 Clear Deck Button 1 8 Definition A 2 Clearing Material 4 1 Clear Zone Definition A 2 Collation Definition A 2 Confirming Job Setup ...

Page 96: ...n A 3 Drop Stacker Definition A 3 Location of 1 7 Duplex Printing Definition A 3 E E Z Seal 2 10 Electrical Specifications 4 19 EMI EMC Definition A 3 End of Collation EOC 3 6 Definition A 4 Mark Definition A 4 End Clearance Envelope Definition A 3 Enhanced OMR 3 2 Envelope and Insert Sealing Area Accessing 4 4 Depth Definition A 4 Depth Setting the 2 20 Depth Clearance 4 18 End Clearance 4 18 Exi...

Page 97: ...the 2 20 Making Minor Adjustments to 2 23 Modes Available 4 19 Panel Definition A 5 Plates Removal and Replacement 4 2 1 and 2 Location of 1 6 Poor Quality 4 9 Type Setting the 2 13 Type and Thickness Limits 4 16 Fold Only Mode 2 17 Folder Definition A 5 Forward Flap Envelope Definition A 5 Order Definition A 5 H Hand Wheel Definition A 6 Help Getting iii I Insert Definition A 5 Double Document De...

Page 98: ... 1 Definition A 7 Safety Data Sheets 1 2 Maximum Number of Sheets Definition A 7 Measuring Scale Location of 1 7 Messages Error List of 4 12 Mode Fold Only 2 17 Insertion 2 17 Selecting the 2 17 Multiple Sheets Feed One Expected 4 9 N Navigate Definition A 7 Nesting Definition A 7 Noise Level 4 19 O OMR Availability 3 1 Basic 3 2 Enhanced 3 2 Error Messages 3 18 Functional Description 3 1 Function...

Page 99: ...ime Sheet Definition A 8 Processing Speed 1 4 Programming Jobs Changing an Existing Job 2 24 Choosing the New Job Number 2 12 Confirming the Job Setup 2 22 Creating a New Job 2 11 Deleting a Job 2 24 Entering the Setup Mode 2 11 Fold Type Selection 2 13 for OMR 3 10 for OMR Job Choosing the New Job Number 3 10 Selecting Fold Type 3 13 Selecting the OMR Functions 3 11 Setting Select Supplementary F...

Page 100: ...nition A 9 Sheet Feeders Accessing the 4 4 Address in Wrong Position 4 9 Double Document Detector Mate rial Range 4 15 Feed Tray Capacity 4 15 Fold Configurations 4 15 Manual Feed Mode 4 15 Multiple Sheets Feed 4 9 Paper Weights 4 15 Poor Folding 4 9 Poor Sheet Feed 4 9 Sheet Size 4 15 Tray Removal 4 2 Shingle Definition A 9 Single sheet Definition A 9 Slip Definition A 10 Specifications Machine 4...

Page 101: ... Definition A 11 Trial Piece Definition A 10 Running 2 3 Troubleshooting Address in Wrong Position in Enve lope Window 4 9 Blank Screen 4 7 Double Detect Problems 4 11 Envelopes 4 8 Envelope Sealing Problems 4 8 Envelopes Fail to Open 4 8 Insertion Problems 4 7 Inserts 4 10 Machine Won t Operate 4 7 Troubleshooting Continued Multiple Sheets Feed when One is Expected 4 9 OMR 3 18 Poor Envelope Feed...

Page 102: ...Index SV61789 Rev A Index 8 ...

Page 103: ......

Page 104: ... Stamford Connecticut 06926 0700 www pitneybowes com 5500 Explorer Drive Mississauga Ontario L4W5C7 www pitneybowes ca PB Form SV61789 Rev B 5 06 Printed in the USA or Canada Printed on recyclable paper SV61789REVA ...

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