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Pitney Bowes DI900 Operator'S Manual Download Page 99

SV61311 Rev. E  

5-7

Troubleshooting • 5 

Table 5-1   Startup Problems

Problem

Cause

Action

System won’t power up.

System power cord is not plugged into 

the wall outlet. 

Plug power cord into wall outlet.

No power at outlet.

Check outlet. Verify that wall outlet has power.

Faulty Power Supply, circuit board 

wiring, or Power Switch.

Call your system supplier.

Table 5-2   Control Panel Problems

Problem

Cause

Action

• 

No display; but system 

power is on. (LED in 

upper right corner of the 

Control Panel is orange or 

green.)

• 

Display locks up.

• 

Screen Option Keys don’t 

work.

• 

Machine Keys don’t work.

Faulty circuit boards or power supply, 

loose wiring, or poor connections.

Press the power button to restart system. If 

problems persist, call your system supplier.

Display timeout.

Press the 

OK 

key turn on the display.

Display is too light or dark 

(contrast and/or readability 

problem).

Poor contast/brightness adjustment.

Adjust contrast and/or brightness settings. 

See 

Adjustng Screen Brghtness and 

Contrast

 in this chapter.

The system will generate an error message when a problem occurs. The 

message identifies the error and possibly the cause of it. Advice on fixing the 

problem will also display. In addition to these messages, use the:

•  Tables that appear in this manual to identify problems and corrective 

action(s).

•  Help file, that is accessible through the Control Panel by pressing HELP, 

to view information on system functions and procedures.

If you cannot resolve your problem using these self-help aides, call your sys-

tem supplier.

Troubleshooting 

Tables

Summary of Contents for DI900

Page 1: ...Operator Guide US Canada English Version DI900 DI950 FastPac Document Inserting System ...

Page 2: ...rity to operate the equipment SV61311 Rev E 2006 Pitney Bowes Inc All rights reserved This book 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 We have made every reasonable effort to ensure the accuracy and usefulness of this manual...

Page 3: ...tem System Components 2 2 Feeder Tower 2 4 Feeder Trays 2 5 Sheet Trays 2 5 Insert Trays 2 6 Manual Feeder 2 7 Transport Deck 2 8 Mail Piece Path 2 8 Pre fold Accumulator 2 8 Folder 2 9 Post fold Accumulator 2 9 Insertion Area 2 9 Folder Bypass Path 2 9 Moistener Closer Sealer 2 9 About the Control Panel 2 10 Screen Option Keys 2 10 Fixed Function Keys 2 11 Machine Action Keys 2 13 Screen Navigati...

Page 4: ...ower 3 7 Loading Material into the Trays 3 8 Loading the DI950 High Capacity Envelope Feeder HCEF 3 13 Making Pre Run Adjustments 3 18 Adjusting the Envelope Openers 3 18 Running a Trial Piece 3 22 Reviewing the Job Settings 3 24 Starting the Job 3 25 SwiftStart Jobs 3 25 Using SwiftStart 3 26 Creating a Job 3 26 Job Options 3 30 Envelope Options 3 30 Fold Options 3 32 Sheet Options 3 33 Insert Op...

Page 5: ...shooting Tables 5 7 Routine Maintenance 5 16 Daily Tasks 5 16 Replacing the Moistener Wick 5 16 Replacing the Moistener Brushes 5 18 6 Reference Overview 6 2 System Specifications 6 2 Component Specifications 6 4 Feeder Tower and Base Material Specifications 6 7 General Information 6 7 Outer Envelopes 6 7 Inserts 6 10 Sheets 6 11 High Capacity Sheet Feeder HCSF Material Specifications 6 12 General...

Page 6: ...guration 8 6 Setting Up a BCR Scan Configuration 8 9 Editing a Scan Configuration 8 13 Editing an OMR Scan Configuration 8 13 Editing a BCR Scan Configuration 8 14 Copying a Scan Configuration 8 15 Deleting a Scan Configuration 8 15 Reviewing a Scan Configuration 8 16 Viewing the Job List 8 16 Assigning a Scan Configuration to an Existing Job 8 17 Adjusting the Scan Heads 8 19 Adjusting the Scan H...

Page 7: ...nts Appendix A Glossary Basic Terms A 2 Material References A 2 Machine Functions A 3 Icon Glossary A 4 Envelope Icons A 4 Fold Icons A 5 Sheet Icons A 5 Insert Icons A 6 Feeder Assignment Icons A 7 Other Icons A 7 Index Index I 1 ...

Page 8: ...vi SV61311 Rev E Table of Contents This page is intentionally blank ...

Page 9: ...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 8 00 PM ET To obtain Material Safety Data Sheets call the Supply Line or go to www pb com and click on Customer Support Canada Contacts Product Name DI900 or DI950 For frequently asked questions or to or...

Page 10: ...vi SV61311 Rev E Contact Information List This page is intentionally blank ...

Page 11: ...311 Rev E A Note to the Operator 1 2 Viewing this Guide as a PDF File 1 2 About Your System 1 3 Standard Systems 1 4 System Options 1 5 Safety Information 1 6 Warning Labels 1 7 Book Contents 1 8 1 Introduction ...

Page 12: ...y chapter are hyperlinks although they are not high lighted Move the Hand tool over a table of contents entry until it points then click to jump to the location of the entry in the Help guide Page numbers in the Index are hyperlinks although they are not high lighted Move the Hand tool over the page number until it points then click on the page number to jump to that page of the Help guide Highlig...

Page 13: ...0 system is equipped with a dedicated High Capacity Envelope Feeder HCEF that allows for greater speed and throughput The systems also accept material from optional upstream input devices such as High Capacity Sheet Feeders Attached Printer and other devices Basic system features are summarized in this chapter Refer to Chapter 6 for detailed equipment and material specifications The systems are co...

Page 14: ...1 4 SV61311 Rev E 1 Introduction DI900H DI900C DI950H DI950C Letter and Flats Drop Stacker standard on all systems Standard Systems ...

Page 15: ...eet Feeder HCSF OptiFlow Vertical Power Stacker Exit Transport Belt Stacker Tandem Belt Stacker DM Series Mailing System DM800i DM1000 System Options Furniture designed specifically for the system is also available DI900 DI950 Document Printing Options Beta Attached Printer Flats Sealer ...

Page 16: ...r trap it between piec es of furniture Make sure there is no strain on the power cord 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 enclos es hazardous parts If you should damage the unit contact Your system supplier Refer to the Contact Information List at the front of this guide for more information If the ...

Page 17: ...this guide for more information If your stacker has an AC adapter to power the stacker Use only the AC adapter designed specifically for the stacker Third party AC adapters may damage the stacker To protect against electrical shock plug the AC adapter power cord into a properly grounded wall outlet Do not route the AC adapter cable over sharp edges or trap it between furniture Safety Information c...

Page 18: ...s screen adjustment procedures lists errors and their corrective actions and describes routine mainte nance procedures Chapter 6 Reference lists system specifications Chapter 7 Add On Modules provides a brief description of each add on module Chapter 8 Scanning explains scanning options Appendix A Glossary contains definitions for commonly used terms and explanations of the icons you ll see on the...

Page 19: ...r Bypass Path 2 9 Moistener Closer Sealer 2 9 About the Control Panel 2 10 Screen Option Keys 2 10 Fixed Function Keys 2 11 Machine Action Keys 2 13 Screen Navigation Keys 2 13 Display Screen 2 14 Header Area 2 14 Status Area 2 15 Access Rights 2 20 Logging In 2 21 Logging Out 2 21 About System Covers 2 22 Opening the Covers 2 23 Closing the Covers 2 23 About the Paper Release Knobs Levers 2 24 Ab...

Page 20: ...ial of the system System Components 1 Feeder Tower Trays feed sheets or inserts to the Feeder Tower NOTE If enabled the lower left Tray is assigned with the letter A on the Mail Piece Icon Tree When a High Capacity Envelope Feeder is not part of the system configuration this Tray is the primary Tray for feeding envelopes designated for a given job 2 Feeder Tower is a two sided Tray holder material...

Page 21: ...to an outer envelope 8 Moistener Closer Sealer Brushes sweep across the envelope flap to wet the glued area of the flap The letter size envelope then moves through the Closer and Sealer areas of the unit to complete the mail piece 9 Sealing Solution Bottle is located inside an opening cover at the front right side of the machine It provides sealing solution to the envelope sealing system 10 Contro...

Page 22: ...ollers This makes it easy to ac cess media that may stop as it exits the Tower Depending on the Configura tion the Tower accepts two or four Feeder Trays Feeder Tower Figure 2 2 2 Two sided Feeder Tower Open for easy access to Feed Rollers Figure 2 2 1 Latch Opens Feeder Tower Push latch up to open Tower cover CAUTION Moving mechanism can result in personal injury Keep hands long hair ties jewelry...

Page 23: ...type of material selected for a given job Feeder Trays Sheet Trays Sheet Trays feed flat unfolded material Use only the recommended materi als Refer to the specifications in Chapter 6 NOTE Sheet Trays have fill marks on their side walls Be sure to keep your stack of materials at or below these marks to avoid feed problems Figure 2 3 1 Sheet Trays ...

Page 24: ...lets slips and pre folded media into the system Insert Trays have a weighted sliding mechanism known as a Sled that keeps pressure on the material for proper feeding Insert Trays have two sets of maximum fill lines one set for slips and a second set for envelopes Insert Trays Figure 2 3 2 Insert Tray Sled mechanism ...

Page 25: ...he current job has to be defined as Manual for the feature to work The job with the manual fed piece can also include items from other feeders including sheets or inserts To use the Manual Feeder 1 Select a job that uses the Manual Feeder 2 Push the Manual Feed lever up 3 Press TRIAL PIECE to start the machine 4 Feed each set by pushing the edge into the rollers one at a time 5 Push the lever down...

Page 26: ...ished mail piece that is dropped into a stacking bin or onto an optional high capacity output stacker A brief description of the function of each module in the paper path is presented next Mail Piece Path Pre fold Accumulator The Pre fold Accumulator is the first stop in the paper path The Pre fold Accumulator is a stacking place for the material that needs to be collated and folded When the appro...

Page 27: ...nents are present the stack moves to the Insertion Area Insertion Area The contents of the mail piece meet the outer envelope at the Insertion Area The envelope arrives at the Insertion Area with its front face down and flap open Envelope Openers on the Insertion Area open the envelope wide enough to allow the contents to be slid inside Folder Bypass Path The outer envelope fed from the Feeder tha...

Page 28: ...eft in the Display and to apply selections that you ve made Machine Action Keys control hardware components and mechanical movements LED Status Indicator About the Control Panel The Screen Option Keys are the eight keys on the right side of the screen These keys correspond to options on the screen and therefore have no dedicated labels Use these keys to highlight an item in a displayed pick list a...

Page 29: ...er appears in the bottom portion of the Display screen It is a cumulative counter i e it increments for each completed mail piece If you run the same job but for a different customer and or use different materials you ll need to zero the counter and ready it for counting the com pleted mail pieces in the new run To reset the Piece Counter 1 Press RESET COUNTERS to display the Reset Counters screen...

Page 30: ... 3 You will be returned to the Home screen The Piece Counter at the bot tom of the screen will read 0 and the Batch Counter will return to its original setting Help Select Help for information about the screen that currently displays and for access to the entire Help file Cancel Select Cancel to return to the previous screen NOTE If you made changes to a job before pressing Cancel you are prompted...

Page 31: ...of materials currently in process in the paper paths NOTE Only press CLEAR DECK when prompted by the system to minimize lost material and manual mail piece generation Stop Press STOP to finish in process mail Machine Action Keys The four keys along the bottom of the Control Panel are called Machine Ac tion keys Use these keys to run the system Screen Navigation Keys The Screen Navigation Keys move...

Page 32: ... navigation directions Header Area Display Screen The Display screen is divided into two major areas Header area Status area Display screen Header Area Status Area Home Job ABC Low Sealant Select Another Job SwiftStart Menu Loading Instructions and Pre Run Adjustments Run Trial Piece Job Items A B D Pieces 1658 The top blue band dis plays the name of the screen and Job The bottom green band displa...

Page 33: ...t icon indicates that the seal feature is enabled Status Area Each icon has one darker edge either at the top or bottom that indicates the leading edge of the material The leading edge of an object is the edge that feeds into the machine first For example a sheet that must be loaded face up with the top of the sheet leading would be represent ed by a face up sheet icon containing a leading edge li...

Page 34: ...rol of the OMR or Barcode marks and so a small letter n will appear in place of the number 3 Number of sheets in set Lines between the icons indicate the way the mailpiece is assembled The outer envelope is at the top of the icon tree Making any change to the job settings can cause the Feeder Tray as signments to change in the Mail Piece Icon Tree NOTE Any time the job set up changes be sure to ch...

Page 35: ... lated together and the C Fold is applied to them An Insert see the Reply Envelope icon above always appears as a single set within the Mail Piece Icon Tree Example Mail Piece Icon Tree Window Envelope loaded flap down flap last Envelope sealing turned on loaded into Feeder G C Fold selected Top address loaded Face Up fed Top First loaded into Feeder C Double Detect is on Additional Sheet No addre...

Page 36: ...t an icon in the Mail Piece Icon Tree to display information about the item that the icon represents In most instances a picture appears in the Status Area of the screen and shows the required orientation for loading the item into the Tray Figure 2 6 Sample Material Orientation Picture Status Area continued ...

Page 37: ... a selected item in the screen Selection of the available options is done via the Screen Option Keys that were described earlier in this chapter See the example screens below Example Options Display Example Functions Display A D B C Jobs Job 123 Job Items A D B C Edit Current Job Review Current Job Save Current Job Create New Job Delete Saved Job Finished Select Job A D B C Edit Outer Envelope Job...

Page 38: ...perators have access to any of the function not listed as supervisor or manager functions System operators may be required to log in and out of the system if a security mode has been enabled Chapter 3 describes the steps involved with performing each of the non re stricted procedures Supervisors have access to all Operator functions and the following after logging in with the correct access code o...

Page 39: ...g in to perform operator functions 1 The Select User screen displays Select the appropriate user ID NOTE If necessary press Next to view additional user IDs 2 Enter your password NOTE Passwords are four digit numeric codes Numbers 1 2 3 4 and 5 display on the first screen Press Next to access numbers 6 7 8 9 and 0 3 Press Accept once you have entered your password The Home screen displays If Login...

Page 40: ... access to Paper Release Knobs Covers on the top of the Transport Deck open to provide access to the roll ers in the main paper path Post fold Accumulator Cover Insertion Area Cover Figure 2 7 2 Top Covers Pre fold Accumulator Cover Folder Cover Figure 2 7 1 Front Covers Sealer Replacement Cover closed Tower Base Cover closed Main Transport Deck Cover open ...

Page 41: ...ansport Deck Cover 2 Pull down on the Tower Base Cover handle The Tower Base Cover interlocks with the Main Transport Deck Cover This means that you cannot open the Tower Base Cover unless you open the Main Transport Deck Cover first Opening the Covers Closing the Covers To close the Lower Tower and or the Main Transport Cover push the cover up until it is seated in place on the system deck CAUTIO...

Page 42: ...ach Paper Release Lever opens an area of the system and allows you to clear any material that may have stalled The illustrations below indicate the various knob lever locations as well as the areas each knob moves material through and each lever opens 1 7 8 2 4 9 6 1 4 2 7 8 9 6 Paper Release Knob Lever Locations and Related Areas Controlled by Knob Z About Add On Modules The system accepts a numb...

Page 43: ...High Capacity Envelope Feeder HCEF 3 13 Making Pre Run Adjustments 3 18 Adjusting the Envelope Openers 3 18 Running a Trial Piece 3 22 Reviewing the Job Settings 3 24 Starting the Job 3 25 SwiftStart Jobs 3 25 Using SwiftStart 3 26 Creating a Job 3 26 Job Options 3 30 Envelope Options 3 30 Fold Options 3 32 Sheet Options 3 33 Insert Options 3 36 Editing a Job 3 39 Modifying Job Settings 3 40 Editi...

Page 44: ...blems are detected the system will display information directing you to a solution to the problem NOTE When power cycling the system be sure to power cycle any optional add on equipment as well Powering Up Connecting to Power WARNING Read the safety information in Chapter 1 before con necting the system to power To connect the system to power 1 Connect the power cord to the socket on the back of t...

Page 45: ...e means to select a different job edit settings for the displayed job use the SwiftStart feature and view loading instructions for the selected job Home Screen If you need to adjust the screen brightness or contrast refer to Chapter 5 for detailed procedures Home Screen Home Job ABC Low Sealant Select Another Job SwiftStart Menu Loading Instructions and Pre Run Adjustments Run Trial Piece Job Item...

Page 46: ... pile of material that is loaded into a Feeder Follow the loading instructions each time before you run a job The load ing orientation may change depending on the Feeder assignment and job settings For instance one Feeder may need to be loaded bottom first and another top first Feeder assignments are determined by the machine to best optimize the job This means they are assigned only after a job i...

Page 47: ...e in that category 3 Select the desired job from the list If the job does not appear on the first page use the UP DOWN arrow keys to scroll through the list As any job is highlighted in the list the Mail Piece Icon Tree for the job appears on the display so that it can be identified Selecting the Job If the job that you want to run is the one that currently displays in the Home screen proceed to t...

Page 48: ...t you will need to load material into it Refer to Adjusting the HCSF Guides in Chapter 7 for more informa tion Setting Up Feeders and Loading Materials The procedure for attaching either type of Tray to the Feeder Tower at the location indicated by the Mail Piece Icon Tree and loading instructions is essentially the same NOTE Use both hands when attaching or removing a Tray 1 Align the back end of...

Page 49: ... at the angle at which the Tray sits to ensure it is securely attached If it isn t repeat the procedure until the Tray seats properly and securely Figure 3 1 2 Check Tray Seating Figure 3 1 2 Tray Seated Properly in Tray Mount Bottom View Notch on Tray Groove on tray mount Removing Trays from the Feeder Tower The procedure for removing a Sheet or Insert Tray consists of the following 1 Grasp the o...

Page 50: ... information will display Graphic of the document media type Tray type into which the document media should be loaded Orientation of the document in the Tray It is important to loosen fan any items in the stack that may be stuck to gether BEFORE you place the material in the Tray To do this 1 Hold one end of the stack in one hand 2 Flip through the opposite end of the stack with your other hand 3 ...

Page 51: ...hand against the Side Guide Adjustor at the open end of the Tray 2 Use the palm of your hand to turn the Side Guide Adjustor Turn the Adjustor counterclockwise to move the Side Guides in to wards the material Turn the Adjustor clockwise to move the Side Guides out and away from the material 3 When the Side Guides contact the material in the Tray remove your hand from the Adjustor The Guides will a...

Page 52: ...ng a Sheet Tray NOTE To view a demo of the Sheet Tray loading and Side Guide adjustment processes go to the Home screen and select Loading Instructions and Pre Run Adjustments Use the UP DOWN arrow keys to select a Sheet being fed by the Feeder Tower from the Mail Piece Icon Tree then select Feeders Setup Demo To load media into a Sheet Tray 1 Using the Side Guide Adjustor open the sides of the Tr...

Page 53: ... the sides of the Tray beyond the width of the material 3 Stand a stack of material straight up and against the front end of the Tray and in the orientation specified on the Mail Piece Icon Tree and Home screen loading instructions 4 Using the Side Guide Adjustor bring the sides of the Tray lightly against the material then release the Adjustor The Guides will automatically spring back to a positi...

Page 54: ...Allow the Sled to move forward 8 Slide the Sled until it contacts the end piece in the stack of material and then release your hold on the material NOTE Items in the Mail Piece Icon Tree on the Display represent the mate rial in the selected job Use the Arrow keys to highlight any icon to view a picture of the orientation of material in the Tray and the designated location of that Tray on the Feed...

Page 55: ... Adjustments Use the UP DOWN arrow keys to select the envelope being fed by the HCEF then select Feeders Setup Demo Adjusting the HCEF Side Guides 1 Place an envelope between the Side Guides 2 Using the Adjustor knob bring the Side Guides in to lightly touch the en velope 3 Release the knob The Guides will spring back to the correct position to allow free sliding of the envelope between the Side G...

Page 56: ...Ensure the envelope is centered not angled on the Center Guide to obtain correct positioning If the position of the envelope is incorrect the Separator Gap adjustment will be incorrect as well 2 Push up and release the blue Wedge Locking Lever 3 Slide the Wedge toward the envelope until the top edge of the envelope fits into the center slot of the Wedge Loading the DI950 HCEF continued Figure 3 7 ...

Page 57: ...1 Rev E 3 15 Basic Operation 3 4 Push down on the Trail Prop Locking Lever to lock the Wedge into place and remove the envelope Loading the DI950 HCEF continued Figure 3 7 2 Corner of Envelope in Center Slot ...

Page 58: ...p Refer to Adjusting the HCEF Wedge in this chapter for more information 1 Prepare an envelope for the separator gap adjustment a Cut a strip of 20 lb 75 gsm paper to fit inside an envelope b Insert the strip of paper into the envelope NOTE Tap the envelope lightly against a hard surface to ensure the strip of paper rests all the way down at the bottom of the envelope c Close the envelope flap 2 P...

Page 59: ...st ing the Printer Interface Guides in Chapter 7 of this guide for more informa tion If you are using scanning you may need to adjust the scan head to ensure the bar code or OMR mark is read Refer to Adjusting the Scan Heads in Chapter 8 of this guide for more information 2 Place the envelope bottom edge first into the Separator so the top edge flap crease lines up with the edge of the tab on the ...

Page 60: ...g Instructions from the Home screen and then select Pre Run Adjustments and finally select Envelope Opener Settings NOTE The system will automatically select the Feeder when only one outer envelope is being used If multiple outer envelopes are to be used you need to select an envelope Feeder 3 Press TRIAL PIECE to feed one envelope to the Insertion Area 4 Open the Insertion Area Cover and observe ...

Page 61: ...ointers with the outer edges of the envelope Push down on the thumbscrews to ensure the Outer Envelope Open ers align with the envelope If using small envelopes less than 194mm wide move the Outer Envelope Openers out and away from the outer edges of the enve lope If using windowed envelopes ensure the Outer Envelope Openers do not touch the edges of the window 3 Tighten the thumbscrew on the top ...

Page 62: ...velope Openers continued Figure 3 9 4 Inner Envelope Opener Locations Inner Envelope Opener Thumbscrews a Position the Inner Envelope Openers so they do not touch the edge of the window In unusual circumstances i e vertical windows it may be necessary to place the Opener on the window to prevent the Opener from catching on the window s edge b Tighten the thumbscrews for the adjusted Openers 2 Pres...

Page 63: ...are positioned correctly that is aligned cor rectly to open the envelope select OK If more adjustments are needed repeat the steps stated in the previ ous sections until proper alignment is achieved NOTE Each time you press TRIAL PIECE a complete Trial Piece will be generated Adjusting the Envelope Openers continued Figure 3 9 5 Inner Envelope Openers Inserted into Envelope Insertion Edges of Inne...

Page 64: ...he material in the Tray and loca tion of the Tray on the Feeder Tower 2 Load the mail piece components into the Feeder Trays 3 Press TRIAL PIECE The system collates all contents of the mail piece according to the job parameters The resulting mail piece is fed to the Upper Divert Area waiting for your inspection It does not go through the Sealer The Trial Piece Complete screen will display 4 Examin...

Page 65: ... s in the mail piece run Trial Piece again to verify machine function and mail piece accuracy Any edits you make are NOT saved unless a Supervisor Manager specifically saves them d If you need to check verify the job settings access the Review Job screen select Home then select Menu Jobs and finally Re view Job 5 Depending on your findings choose one of the following options listed on the Trial Pi...

Page 66: ...Jobs then Review Current Job 3 Use the Arrow Keys to scroll through the settings for the job and each of the included items Select Edit Job to access screens for making changes Select Finish to return to the Menu screen Press HOME to return to the Home screen NOTE Make sure that the materials in the mail piece meets material specifi cations Refer to the Specifications listed in Chapter 6 Review Jo...

Page 67: ...l piece content of four sheets and three inserts DI900 or four sheets and four inserts DI950 Fold will be determined by sheet length and envelope depth NOTE The maximum content options are available only when two HCSFs are present Maximum sheet length is 11 5 8 297 mm Only envelope depths of 4 1 4 to 6 3 8 109 mm 111 mm 114 mm 121 mm and 162 mm can be used Cannot be used to run fold only or insert...

Page 68: ...esent this job When all items from loaded Trays Feeders have been fed the system produces a sample mail piece 4 Check the trial piece and then make any needed adjustments Repeat the trial piece run until the mail piece meets your specifications 5 Press START to run your job 6 If you wish to save this job you will need supervisor or manager access to enter a name in the save job screen Creating a n...

Page 69: ...Outer Envelopes Validate the available options and press Accept when done NOTE If this is a scanning job and you will be using dynamic enve lope selection you must select No Two Outer Envelopes 5 The Create Select Next Item screen displays Select the appropriate option Menu Options Associated Options Actions Reply Card Reply Envelope Pre Folded Insert Small Booklet Slip Generic Insert Large Bookle...

Page 70: ... Configuration The Content in Line with Marks screen displays If there is content in line with the scan marks select Yes If there is no content in line with the scan marks select No If you selected Yes the Mark Locations Settings screen appears Follow the steps below to enter the various mark related measurements Select an option then use the UP DOWN arrow keys to enter the appropriate measurement...

Page 71: ... Select this option if you will be using the Mail Machine Interface MMI This interface enables communication between the Inserting System and either a DM Series DM800i or DM1000 mailing system via a USB connection The system sends start and stop signals to the mailing system and the mailing system can send error messages back to the inserter to stop feeding Toggle Off means this feature will not f...

Page 72: ...p is a regular envelope Forward Flap means the window and flap are on the same side of the envelope Bottom Flap means the flap is at the bottom instead of the top of the envelope Seal refers to using the Moistener unit to close the envelope Off means the envelope will not be sealed closed or On means the envelope will be sealed closed Safe Seal means the envelope will be sealed closed However the ...

Page 73: ...y from the edge of the window if present at least 5 mm away from the edge of flap and cannot lie on top of a seam For best results be sure to avoid areas that overlap with the window flap or seams Action On Double allows you to select where the items should be fed to if a double is detected Feeder Type allows you to change the Feeder setting when material is problematic Normal is used for most ite...

Page 74: ...een for each fold type address combination Use the UP DOWN Arrow Keys to select desired length Press Accept when done Fold Options Envelope Options continued Menu Item Associated Options and Actions Additional Settings continued Envelope Select Feed allows you to indicate when the envelope should be used Toggle Main Alternate NOTE This option is enabled only when the Scan feature is activated two ...

Page 75: ...e 1 2 3 4 5 6 Custom Quantity Use UP DOWN arrows to select number Select Accept when done NOTE Quantity is always set to Variable n for scanning jobs Page Order identifies the feeding pattern of multiple sheets that are not identical Forward indicates page 1 is on top and pages 2 3 4 etc follow in that order Reverse indicates that the last page for example page 4 is first followed by pages 3 then ...

Page 76: ...e allows you to select where the items should be fed to if a double is detected Feeder Type allows you to change the Feeder setting when material is problematic or to indicate that the job requires a Custom Feeder NOTE This menu option is not available when the job requires an Attached Printer Normal is used for most items Manual Feed is used when items will be fed into the system by hand Refer to...

Page 77: ...ear Zone to the first mark Refer to OMR Specifications in Chapter 8 for more information on the Clear Zone and mark location settings Item Over Count Quantity is the number of sheets to be accumulated before the system takes an alternate action Item Over Count Action indicates what will happen to items that exceed the item over count quantity Choices include Divert Select this option if the Scan C...

Page 78: ...nclude in each mail piece NOTE This menu option is not available when Large Booklet is the selected insert 1 2 3 4 5 6 Custom Quantity Use UP DOWN arrow keys to select number Select Accept when done Variable used with scanning controlled jobs NOTE At this time only a single insert can be added to each mail piece When using a flat envelope the insert must be a Reply Envelope BRE Page Order identifi...

Page 79: ...t in millimeters Select Accept when you are done Action On Double allows you to select where the items should be fed to if a double is detected Feeder Type allows you to change the Feeder setting when material is problematic or to indicate that the job requires a Custom Feeder NOTE This menu option is not available when the job requires an Attached Printer Normal is used for most items Manual Feed...

Page 80: ...beginning of the Clear Zone Length of Clear Zone is the distance from the top of the Clear Zone to the first mark Refer to OMR Specifications in Chapter 8 for more information on the Clear Zone and mark location settings Item Over Count Quantity is the number of inserts that cannot be run normally NOTE At this time only a single insert can be added to each mail piece When using a flat envelope the...

Page 81: ...an item to a different position in the mail piece collation Modifying settings for the job NOTE The options available in the Edit Job screen vary and depend on the item selected and the number of available Trays on the Feeder Tower Edit Job Screen Edit Job Job 123 A B C D Press to highlight an item to edit Job Items Edit Job Settings Edit Highlighted Item Move Highlighted Item Delete Highlighted I...

Page 82: ...an Item You can edit items to your mail piece one at a time using the procedure de scribed below To edit an item in a mail piece 1 From the Home screen select Menu Jobs and then Edit Current Job The Edit Job screen will display 2 Use the UP DOWN Arrow Keys to select the item A highlight will appear around the selected item 3 Select Edit Highlighted Item 4 The next screen that displays depends on t...

Page 83: ...dd Insert or Add Large Booklet the Add Item Location screen displays Adding an Item a Use the UP DOWN Arrow Keys to indicate where in the Mail Piece Icon Tree the mail piece collation to place the new item An Insert Marker highlights the selected area b Press Accept Highlighted Location when you are done c Depending upon the item you selected the Add Sheet Add In sert or Add Booklet screen appears...

Page 84: ...decide that you don t want the changes that you ve made press CANCEL The Confirm Cancel prompt displays Press Don t Keep Changes to discard the new entries You will be returned to the Edit Job screen 7 To retain your changes for this job select Accept in the Edit Job screen To store the job changes permanently select Save Job in the Menu screen You must have supervisor or manager access rights to ...

Page 85: ...e Move Item Location screen shown below will display 4 Use the UP DOWN Arrow Keys to move the red insert marker to the area in the collation where you want to relocate the item 5 Select Accept Highlighted Location You will be returned to the Edit Job screen NOTE Recheck the Mail Piece Icon Tree Moving an item can cause the Feeder assignment to change If it does be sure to load the designated item ...

Page 86: ...will display 2 Use the UP DOWN arrows to select the item to be deleted A highlight will appear around the selected item 3 Select Delete Highlighted Item 4 Select Yes Delete Item You will be returned to the Edit Job screen NOTE Recheck the Mail Piece Icon Tree Deleting an item can cause the Feeder assignment to change If it does be sure to load the designated item into the correct Feeder ...

Page 87: ...1 Rev E 4 Advanced Operation Overview 4 2 Using the Alphanumeric Matrix 4 2 Saving a Job 4 3 Deleting a Job 4 4 Assigning User IDs and Passwords 4 5 Enabling and Disabling the High Capacity Sheet Feeder HCSF 4 5 ...

Page 88: ...s Overview The alphanumeric matrix allows you enter text for naming items and job for entering job comments and for logging in and out of the system Using the Alphanumeric Matrix 1 Use the UP DOWN and LEFT RIGHT Screen Navigation Arrow keys to select any of the following Desired character Add a blank space in the Job Name and or Job Comments Backspace to delete the character that appears immediate...

Page 89: ... Select Save Current Job from the Job Screen Refer to Editing a Job in Chapter 3 of this guide for more information NOTE If you are not logged in with supervisor or manager access rights you will be prompted to enter an access code 2 The Save Job screen displays Select Finished to save updates and edits made to the current job To save current job as a different job new or replace existing job 1 Se...

Page 90: ... with supervisor or manager access rights you will be prompted to enter an access code 4 Select the name of the job you want to delete 5 Select Delete job to confirm the delete command NOTE Selecting Delete causes permanent deletion of this job from the system s memory However if this is the current job the job name will appear on the Home screen as it is still in the system s working memory Addit...

Page 91: ...lays a Use the UP DOWN arrow keys to select the appropriate access level operator supervisor or manager NOTE Refer to Access Rights in Chapter 2 of this guide for more infor mation b Select Accept User Level when done 7 The Enter Password screen displays a Enter the password NOTE Passwords are four digit numeric codes Numbers 1 2 3 4 and 5 display on the first screen Press Next to access numbers 6...

Page 92: ...4 6 SV61311 Rev E 4 Advanced Operation This page is intentionally blank ...

Page 93: ... 4 Refilling the Sealing Solution 5 5 Handling Material Stoppages 5 5 Clearing a Stoppage 5 5 Resuming the Job 5 6 Handling Outsorted Material 5 6 Troubleshooting Tables 5 7 Routine Maintenance 5 16 Daily Tasks 5 16 Replacing the Moistener Wick 5 16 Replacing the Moistener Brushes 5 18 5 Troubleshooting and Maintenance ...

Page 94: ...ntrast screen Press the UP DOWN arrow key s to increase decrease screen brightness Press the LEFT RIGHT arrow key s to decrease increase screen contrast To return to the default settings select Restore Defaults 6 When you are done Press Finished to back through the configure system screens and return to the Home screen Your settings will be saved OR Press HOME to save your adjustments and return d...

Page 95: ... will be prompted to enter an access code 5 Press the LEFT RIGHT arrow key s to select the item you want to change i e Month Day Year Hour or Minute The items highlight as you press the LEFT RIGHT arrow key s 6 Press the UP DOWN arrow key s to select the desired number 7 When you are done Press Finished to back through the configure system screens to the Home screen Your settings will be saved OR ...

Page 96: ...3 The Change Language screen displays the list of available languages If necessary use the Next and Previous options to view additional lan guages on the list then select the appropriate language 4 Select Finished when done 5 Press HOME to return directly to the Home screen Change Language Screen Change Language English International English North American Français Canada Deustch Español Français ...

Page 97: ...will require a brief waiting period to allow the wick to get moist Handling Material Stoppages If a stoppage occurs the system immediately stops the run and displays an error message Follow the instructions on the Display screen to get your system running again The procedure s involved with removing material that has caused the stop page resuming the run and handling the outsorts are explained nex...

Page 98: ...se The job will resume counting from the last complete mail piece that it produced During the recovery from jams and other machine stoppages the system will automatically clear material from the transport deck that cannot be completed by the inserter The system counts all mail pieces that it has successfully completed trial pieces included but partially assembled pieces are not counted and are tra...

Page 99: ...utton to restart system If problems persist call your system supplier Display timeout Press the OK key turn on the display Display is too light or dark contrast and or readability problem Poor contast brightness adjustment Adjust contrast and or brightness settings See Adjusting Screen Brightness and Contrast in this chapter The system will generate an error message when a problem occurs The messa...

Page 100: ...prevent material from feeding Check that material is loaded in the correct feeder and in the proper orientation Paper fragments or debris in tray rollers or tower transport Inspect feed rollers and transport path Remove paper fragments before running a clear deck Double or multiple feeds stream feeding Material not within specifications Check that all material meets published specifications Refer ...

Page 101: ...trial piece again Refer to Sheet Options or Insert Options and Running a Trial Piece in Chapter 3 for more information If the problem persists turn double detect off Tray is feeding a mix of different thickness sheets paper e g some 20 lb and 24 lb sheets mixed If the material is consistently a certain weight i e printer was initially loaded with 20 lb paper then accidentally loaded with 24 lb the...

Page 102: ...s Check Side Guide adjustment on Trays Skewed material is a common cause of problems in the Tower area Refer to Adjusting Tray Side Guides in Chapter 3 of this guide for instructions Paper fragments or other obstruction in transport Inspect Clean Flexible plastic material guides in Tower area are broken or displaced Open Tower cover and inspect If replacement is necessary call your system supplier...

Page 103: ...ause material to become skewed in machine Refer to Adjusting Tray Side Guides in Chapter 3 of this guide for instructions Contents of insertion pack are catching on side seam inside of envelope Contents of insertion pack are thick and difficult to insert into smaller envelopes Adjust the Aligner custom settings NOTE If the contents of the insertion pack are thick and you are having trouble inserti...

Page 104: ... exact dimensions of the insertion pack 1 From the Home screen select Menu then Jobs 2 Select Edit Current Job Edit Job Settings then Advanced 3 Select Aligner then On with Custom Settings The Customer Aligner Settings screen displays 4 Select Envelope Width Use the UP DOWN arrow keys to increase or decrease the measurement as necessary Select Accept when done 5 Select Widest Enclosure Width Use t...

Page 105: ...s nested stuck or glued together Remove unsatisfactory envelopes System incorrectly detects double feeds Double detect is seeing flap or seam of insert envelope Set the custom double detect window where there is no flap seam or window on the envelope OR Turn double detect off Refer to Insert Options in Chapter 3 of this guide for more information First piece following trial piece is a false double...

Page 106: ... window Item loaded incorrectly Lead edge is not in the lead position Reload item Refer to Loading Trays in Chapter 3 of this guide Ensure lead edge is in correct position as indicated in the loading instructions on the display screen On Trial Piece Complete screen press Adjust Address and follow the instruction that appear Job is set up incorrectly Ensure the item with the address is personalized...

Page 107: ...ptions on the Control Panel Material loaded in incorrect order Load material in correct order Adverse paper motion This refers to any misalignment of paper that can cause a misread It includes paper skew paper slippage and paper offset to one side of the transport Make sure material is properly loaded In particular check the feeder side guides Check the transport is free of obstructions Poor OMR o...

Page 108: ... towels on the Sealer deck to the left of the reservoir The towels will capture any water that may drip from the old wick car tridge This section outlines the maintenance tasks you can perform on the system Be sure to schedule routine service with your system supplier at the appro priate intervals Remove any excess paper dust that has accumulated on or around the system modules Use a damp cloth to...

Page 109: ...u Replacing the Moistener Wick continued b Place the index finger of the other hand on other latch closest to you c Slide the latches away from each other until both latches are free of the wick cartridge below them 4 Pull the old wick cartridge straight up and out of the reservoir and place it on the paper towels Figure 5 2 Releasing the Rear Latch Figure 5 3 Removing the Old Wick Cartridge ...

Page 110: ...ss down on the ends of the cartridge to make the two bump features of the cartridge sit below the top edges of the reservoir 8 Slide the plastic latches toward each other and over the new wick car tridge until they snap into place 9 Close the Insertion Area cover Replacing the Moistener Brushes Replace the moistener brushes when they show wear To do this 1 Open the Insertion Area cover Figure 5 4 ...

Page 111: ...istortion of the bristles will prevent envelopes from sealing correctly a Hold the blue brush holder in place with one hand b Insert the metal edge of the new brush into the channel opening in front of the brush holder c Slightly push the brush into the channel of the brush holder to start it d Slide the new brush completely into the holder by its bristles until it stops NOTE The brush is complete...

Page 112: ...5 20 SV61311 Rev E 5 Troubleshooting This page is intentionally blank ...

Page 113: ...ations 6 4 Feeder Tower and Base Material Specifications 6 7 General Information 6 7 Outer Envelopes 6 7 Inserts 6 10 Sheets 6 11 High Capacity Sheet Feeder HCSF Material Specifications 6 12 General Information 6 12 Sheets 6 12 Materials Not Certified for Use 6 13 6 Reference ...

Page 114: ...nclude HP4700 weight Electrical All systems require a grounded outlet preferably unswitched Use of ungrounded outlets outlets with incorrect polarity or ground adapters can constitute a safety hazard and are unacceptable Professional Compact Line Voltage 88 264 VAC 88 264 VAC Current Draw 900 V Amps maximum 450 V Amps maximum Frequency 476 63 Hz 47 63 Hz Environmental Limits Temperature F C Humidi...

Page 115: ...1 787 mm Dimensions for DI900C and DI950C Systems Dimensions for DI900H and DI950H System 60 5 1537 mm 10 254 mm 29 737 mm 118 LOA 2997 mm 14 5 368 mm 28 6 726 mm 14 356 mm Drop Stacker 33 5 851 mm 31 787 mm NOTE System depth is 22 8 in 579 mm Drawings are not to scale All dimensions approximate The DI900 does not include the High Capacity Envelope Feeder ...

Page 116: ...tacker 250 pieces letter mail assumes single sheet insert Production Power Stacker At least one USPS mail tray two feet of finished mail Moistener Closer Sealer 8 000 letters before refilling Component Specifications Folder Fold Types Top address documents C fold Z fold single and double fold Maximum number of sheets per collation 8 20 lb 80 gsm Bottom address documents see Notes below C fold Z fo...

Page 117: ...ctions Supported Variable page documents selective feeding feeder to feeder matching force divert mark for special handling Barcode Formats Supported Code 39 3 of 9 Interleaved 2 of 5 Notes The horizontal position of the scanner is operator adjustable Documents from any feeder can be scanned Documents should be printed on a laser printer for scanning Photo copied documents and documents printed on...

Page 118: ...heets with two 500 sheet trays Printing Options Simplex single sided and Duplex double sided Notes Printed sheets can be C or single folded and inserted or inserted into flat envelopes without folding no fold Sheets cannot utilize top address Z fold with the Attached Printer The Attached Printer supports all scanning functions except BOC control Scanning marks are not required on documents when ru...

Page 119: ...made of glassine or poly styrene material Patches shall be glued within 0 06 inch 1 6 mm from the top edge of the patch material to the window cutout Envelope materials shall include new or recycled white wove manila and lithographic material Non woven or synthetic envelopes e g Tyvek or envelopes with external fasteners are not permitted Envelopes with remoistenable flap adhesives made of starch ...

Page 120: ...ed at the center line C 25 inch 6 mm Minimum throat depth within a 4 inch 100 mm area centered at the center line D 08 inch 2 mm Minimum distance from top of window to the envelope throat measured at a distance of 5 3 inches 135 mm centered at the center line A C 5 3 in 135 mm Centered at Center Line Center Line B D 4 in 100 mm Centered at Center Line Envelope Throat Definitions NOTE Diagram is no...

Page 121: ... mm HCEF 8 9 225 mm Feeder Tower 10 5 266 mm HCEF 10 4 264 mm Depth Feeder Tower 3 5 89 mm HCEF 3 9 98 mm 6 5 165 mm Throat Depth 0 25 6 35 mm 1 49 37 846 mm executive 1 61 40 894 mm Paper Weight 18 lb 70 gsm 24 lb 90 gsm Flap Depth 1 2 30 mm 2 5 63 mm within 1 4 35 mm of Center 1 85 47 mm outside 1 4 35 mm of Center See Envelope Throat Definitions in this chapter for more information Feeder Tower...

Page 122: ... Material Substrates Acceptable paper types include new or recycled bond text laser and offset Offset coatings include matte dull or gloss NOTE Use of glossy material may degrade system performance Grain Material may be short or long grain Printing Printing may be simplex one side or duplex both sides with no restriction on color Coating Varnish applied to sheets to modify finish is allowed Feeder...

Page 123: ...Use of glossy material may degrade system performance Grain Material may be short or long grain Printing Printing may be simplex or duplex with no restriction on color Coating Varnish applied to sheets to modify finish is allowed Laser Printed Material Freshly laser printed material which meets the curl requirements is accept able Feeder Tower Sheet Specifications Parameter Minimum Value Maximum V...

Page 124: ...in Material may be short or long grain Printing Printing may be simplex or duplex with no restriction on color Coating Varnish may be applied to sheets to modify finish Laser Printed Material Freshly laser printed material which meets the curl requirements is accept able For reliable operation all materials must conform to published specifica tions Feed problems and high stall rates are often due ...

Page 125: ...gth Maximum material thickness for feeders 0 18 mm 0 007 when scanning otherwise 0 25 mm 0 009 Contaminants Materials with visible material loss loose powder ink surface glaze etc when hung free over a clean surface and struck sharply with a standard wood ruler should not be used Special Materials Do not use materials that are sensitive to heat such as thermal papers Do not use materials that are ...

Page 126: ...6 14 SV61311 Rev E 6 Reference This page is intentionally blank ...

Page 127: ...er 7 8 Attached Printer 7 9 Loading the Attached Printer 7 10 Adjusting the Printer Interface Guides 7 11 Printing a Cover Sheet to the Top of the Attached Printer 7 13 SureTrac Process Verification System 7 13 Exit Options 7 15 DM Series Mailing System Interface DM800i or DM1000 only 7 15 OptiFlow Vertical Power Stacker 7 18 OptiFlow Belt Stacker 7 18 Exit Transport 7 18 7 Add On Modules ...

Page 128: ...re determined order and travel down the vertical paper path and into the horizontal transport Depending on the job setup individual sheets are either transported directly into the main unit or they accumulate in the horizontal transport into a pre determined packet before being transported into the main unit When Feeder Linking is en abled you can reload and empty the inactive Feeder Tray that is ...

Page 129: ...indicator letter Loading the HCSF 2 Load approximately 1 inch of material into the Tray in the orientation specified in the loading instructions on the Home screen Green lights on the front panel of the HCSF indicate that the material is loaded and that the HCSF is operable 3 Turn the Feeder Tray s Side Guide Adjustor clockwise until the side guides touch the material and then back off slightly TI...

Page 130: ...Ready to Feed 4 Load the remaining paper up to the fill line 5 Repeat steps 2 5 for each remaining HCSF Tray 6 Press the button on the front of the HCSF for each of the Trays The loaded Tray s will move into position for feeding Figure 7 3 HCSF Loaded with Material Max fill line ...

Page 131: ... to Enabling and Disabling the High Capacity Sheet Feeder HCSF in Chapter 4 for more information 1 From the Home screen select Loading Instructions then Pre Run Adjustments and finally HCSF Guide Settings 2 Select the Feeder that you will be setting up 3 Press TRIAL PIECE 4 Open the front and top covers of the enabled HCSF accumulation area Adjusting the HCSF Guides Figure 7 6 HCSF Front and Top C...

Page 132: ...et the Width Guides a Turn the right hand knob on the side of the sheet transport to move the Width Guides b Move the Width Guides until they just make contact with the sides of the sheet then back off slightly approximately 1 3 of a turn The sheet should lay flat and not buckle 7 Close the front and top covers of the HCSF accumulation area 8 Press CLEAR DECK to remove any material in the paper pa...

Page 133: ...ealer closes the flap seals the envelope and sends it on to the next module downstream While the Flats Sealer is designed specifically to seal flat envelopes it has an exit path for sealed letter envelopes exiting the Moistener Sealer Clos er module Flats Sealer Downstream Attachments Letter Exit Path Drop Stacker Letter Mail OptiFlow Vertical Power Stacker Belt Stacker Exit Transport Mail Machine...

Page 134: ...sing through the letter exit path Replacing the Envelope Edge Marker Roller Follow the steps below to remove and replace the Envelope Edge Marker Roller NOTE Avoid touching the ink roller as it is covered in ink 1 Open the Flats Sealer cover 2 Grasp the tab at the top of the old ink roller and lift to remove 3 Grasp the tab at the top of the new ink roller and slide it onto the spin dle 4 Release ...

Page 135: ...gsm paper with the optional extra trays The Attached Printer operates with other system options including stackers postage printing and one High Capacity Sheet Feeder If present the At tached Printer must be the most upstream device in the configuration IMPORTANT When creating a job you must indicate that the Attached Printer is the printing source of the job Refer to Chapter 3 Sheet Options for m...

Page 136: ... Flap Face down bottom first Bottom Flap Face down top first NOTES Do not fan sheets when loading the Attached Printer Fanning sheets can cause static electricity which can cause sheets to stick together If your are loading letterhead or check stock find the paper direction for the desired fold type on the label in printer or on the Loading Instructions screen To view a demo of the Attached Printe...

Page 137: ...reen select Loading Instructions then Pre Run Adjustments and finally Printer Interface Guide Settings 2 Press TRIAL PIECE 3 Open the front and top covers of the Printer Interface accumulation area Adjusting the Printer Interface Guides 7 12 Printer Interface Covers Printer Interface Top Cover Printer Interface Front Cover Figure 7 13 Printer Interface Accumulation Area Front and Top Covers Open ...

Page 138: ...ced 5 Set the Width Guides a Turn the right hand knob on the side of the sheet transport to move the Width Guides b Move the Width Guides until they just make contact with the sides of the sheet then back off slightly approximately 1 3 of a turn counter clockwise The sheet should lay flat and not buckle 7 Close the front and top covers of the Printer Interface accumulation area 8 Press CLEAR DECK ...

Page 139: ...uments that the in serter turns into finished mail pieces You typically use the SureTrac Process Verification System to run jobs in either a closed loop mode or an open loop mode In the closed loop mode the client creates the PDF on the client PC and a Mail Run Data File MRDF on the server PC The server monitors and records information about every mail piece as it is processed on the inserter As t...

Page 140: ...oop job For a closed loop job use the Run Closed Loop Jobs module at the SureTrac Process Verification Server PC to select the MRDF file the MRDF is associated with a job and up to three inserter machines After electing the MRDF the server PC sends a message to the inserter tell ing it to make this the active job Instructions appear in the display on the inserter that tell you how to load the PDF ...

Page 141: ...can process the mail and will then resume When the mailing system is in maintenance mode the inserter will pause until the maintenance is complete If you want to operate the mailing system in standalone mode press the Stop key on the IntelliLink Control Center The inserter will finish creat ing any mail pieces in process Press Start at the mailing system to finish processing any pieces of mail on ...

Page 142: ...t The mode must be set if appropriate NOTE Refer to the Operator Guide for you mailing system for more informa tion about processing mail 5 Adjust the side guide to the width of an envelope that will be used See figures below for DM800i requirements NOTE The MMI does not support flats Figure 7 15 DM800i Side Guide DM800i Side Guide shown without MMI ...

Page 143: ...tem will then accept and process The mailing system sends the inserting system a message for each exiting piece of mail Clearing a Jam If a jam occurs on the mailing system while processing mail with the MMI the Remove Mailpiece screen appears on the IntelliLink Control Center Follow the steps below to clear the jam and resume processing mail 1 Lift the mailing system cover s and remove the piece ...

Page 144: ...ker is a compact powered bottom feed stacker that connects to the output of several Pitney Bowes Document In serting Systems including the DI900 and DI950 inserters It neatly stacks the mail pieces fed from the inserter and keeps them in the same order as they were originally loaded Sensors in the stacker monitor the mail pieces fed into it if a mail piece should stall or the stacker fills up the ...

Page 145: ...Reviewing a Scan Configuration 8 16 Viewing the Job List 8 16 Assigning a Scan Configuration to an Existing Job 8 17 Adjusting the Scan Heads 8 19 Adjusting the Scan Heads for Ladder Orientation Marks 8 19 Adjusting the Scan Heads for Picket Orientation Marks 8 22 OMR Specifications 8 24 Barcode Specifications 8 26 Setting the OMR Scanning Area 8 29 Defining the First Mark Position and Code Length...

Page 146: ...k criteria Normally a dark solid line s that is printed on a sheet of white or light colored paper prior to being delivered to the system user for folding and inserting functions to make the Mail Pieces The line runs is printed perpendicular to the direction of travel of the paper The line is sufficiently thick and dense enough to trigger the OMR scan ner on the system as it passes the scanner OMR...

Page 147: ... of 9 barcodes only Interleaved 2 of 5 Barcode The Interleaved 2 of 5 also called the I2of5 or ITF is a numeric barcode Start and stop characters are not required Interleaving allows the charac ters to overlap creating a higher density barcode than the Code 3 of 9 The symbology uses bars to represent the first character and the interleaved white spaces to represent the second character Each charac...

Page 148: ...Use Alternate Envelope Refer to Creating a Job in Chapter 3 or Assigning a Scan Configuration to an Existing Job in this chapter for more information Jobs using dynamic envelope selection must be set up with two outer en velopes The first set in the job must contain the information necessary to make the envelope selection either the Envelope Select scan mark or Item Overcount Action setting Second...

Page 149: ...er to Creating a Job in Chapter 3 or Assigning a Scan Configuration to an Existing Job in this chapter for more information Jobs using the divert sheet functionality will send diverted sets to the lower divert area The remaining parts of the mail piece will be processed inserted into an outer envelope and sent to the upper divert area NOTE If the mail piece contains only a single set which has bee...

Page 150: ...nager is required for use of these functions Refer to Access Rights in Chapter 2 in this guide for more information about logging in using the two security modes Setting Up a New Scan Configuration To setup an OMR Scan Configuration 1 From the Home screen select Menu then Tools 2 Select Configure System then Scan Configuration Setup NOTE If you are not logged in with supervisor or manager access r...

Page 151: ...ed when you are done 8 The Create OMR screen displays Use the UP DOWN arrows to high light an item in the OMR Marks list This list contains items added in step 7 9 Select Set Options for Highlighted Item NOTE The options that appear vary depending upon the selected function Menu Option Associated Options Actions Increase Count for Highlighted Item MC WAS only Allows you to increase the number of m...

Page 152: ...with the Attached Printer then MC must be controlling This tells the inserter that SureTrac will provide the control instructions to the inserter based on the MC read on each document and defines this as a closed loop Scan Code definition Wrap At Multi bit only Displays Wrap At numeric entry screen where you enter the maximum code value in decimal format If the count direction is Up the next code ...

Page 153: ...e unique across all scan types That is a BCR Scan Configuration name cannot be the same as an OMR Scan Configuration name Setting Up a BCR Scan Configuration Setting Up an OMR Scan Configuration continued Menu Option Associated Options Actions LSB Allows you to specify the least significant bit Toggles Last default farthest from top of page or First When First is selected for the Least Significant...

Page 154: ...mn Bit 0 is the right most bit least significant in each character For Code 3 of 9 barcodes bits are 5 4 3 2 1 and 0 For Interleaved 2 of 5 barcodes bits are 2 1 0 Items with Character set to zero will no be included in the final code For multi bit fields the entry in the S column depends on the code type For Bin S is the number of bits For CCD S is the number of charac ters 7 Select Set Options U...

Page 155: ... functions XCD for minimum code size this selection allows multibit fields to span partial characters These coding type options are intended to be consecutive numbers that either count up or count down They allow the system to count up to a maximum or down to either one or zero and wraps at to a defined maximum value BIN is a straight binary string It is loaded into the barcode construct at the st...

Page 156: ... closest to the right hand end of the string When First is selected which is very uncommon the bits are reversed 8 Select Finished once you have set all of the necessary options for the function 9 Repeat steps 6 to 8 for each additional function on the BCR Scan Con figuration Worksheet 10 Select Scan Mark to toggle the appropriate mark orientation ladder or picket as indicated on the BCR Scan Conf...

Page 157: ...ve until all necessary items have been added to the Selected list c Press Accept when you are done Once you have added the mark be sure to set the appropriate options Refer to the Set Options table in the Setting Up a OMR Scan Configuration section of this chapter for more information NOTES Items that can be added appear in the Available list Items that have been added appear in the Selected list ...

Page 158: ...e Allows you to increase the selected character bit or size for a function a Use the UP DOWN and LEFT RIGHT arrow keys to highlight the character C bit B or size S within the grid b Press Increase to edit the information for the highlighted item Decrease Allows you to decrease the selected character bit or size for a function a Use the UP DOWN and LEFT RIGHT arrow keys to highlight the character C...

Page 159: ...iguration cannot be deleted if it is a library Scan Configuration associ ated with a library job or if it is used by a saved job NOTE To see which jobs use a given Scan Configuration view the job list Refer to Viewing the Job List in this chapter for more information If necessary you can remove the association with a saved job via the Edit Job function for the job s listed in the dialog and then d...

Page 160: ...ppear in the Functions list Use the UP DOWN arrow keys to select the Function you want to review 7 Select Finished once you have reviewed the list Viewing the Job List Allows you to view the jobs associated with the selected Scan Configuration NOTE This option is not available if there are no jobs associated with the se lected Scan Configuration 1 From the Home screen select Menu then Tools 2 Sele...

Page 161: ... insert in the Mail Piece Icon Tree 4 Select Edit Highlighted Item 5 Select Additional Settings 6 Select Scan Item and toggle Yes 7 Select Scan Settings 8 The Select Scan Type screen displays Select the appropriate scan type OMR Code 3 of 9 or Interleaved 2 of 5 9 Select the appropriate scan configuration name from the list that ap pears If necessary select Next or Previous to move forward or back...

Page 162: ...ning each of the above measurements refer to OMR Specifications in this chapter Item Over Count Quantity Allows you to select the number of items that cannot be run normally a Use the UP DOWN arrow keys to enter the item over count quantity b Select Accept when you are done NOTE At this time only a single scanned insert can be added to each mail piece The scanned insert must be a Reply Envelope BR...

Page 163: ... read the marks correctly Additionally material must be jogged back into place and loaded as an even stack to ensure the Scan Head and marks align properly Refer to Loading Material into the Trays in Chapter 3 of this guide for more infor mation To adjust the scan heads 1 Fold one of the sheets to be scanned in half vertically side with mark facing up 2 Draw two arrows one at the top of the mark a...

Page 164: ...et Feeder J K L M open the HCSF Tower cover TIPS Remove the left Feeder Trays from the Feeder Tower to allow the HCSF Tower cover to open freely If you have two HCSFs on your system the first HCSF Tower will pre vent the second tower farthest from opening fully For best results be sure you have proper lighting when adjusting the Scan Head in the second tower 7 Determine the direction the Scan Head...

Page 165: ...Heads are to be used repeat step 1 to 8 for each 10 To verify the adjustment is correct a From the home screen select Loading Instructions and Pre Run Adjustments then Scanner Setup b Use the UP DOWN arrow keys to select a feeder to run c Press TRIAL PIECE to feed a piece from the highlighted feeder d Select Finish when done Adjusting the Scan Heads for Ladder Orientation Marks continued Figure 8 ...

Page 166: ...er Use the ruler to measure the distance from the center of the sheet lined up at 0 on the ruler to the center of the marks 5 Refer to the loading instructions to determine The Scan Head location to be used for this sheet Left or Right If the sheet will be loaded Top or Bottom first 6 Open the HCSF Tower cover TIPS Remove the left Feeder Trays from the Feeder Tower to allow the HCSF Tower cover to...

Page 167: ...on Move the thumbwheel until the pointer lines up with the measure ment distance from the center of the page to the center of the mark de fined in Step 7 9 If additional Scan Heads are to be used repeat step 1 to 8 for each 10 To verify the adjustment is correct a From the home screen select Loading Instructions and Pre Run Adjustments then Scanner Setup b Use the UP DOWN arrow keys to select a fe...

Page 168: ...w the relative differ ence between acceptable and unacceptable OMR mark thicknesses Each mark position must be evenly spaced and at least 0 125 3 175 mm and no more than 0 167 4 2 mm apart The maximum number of mark positions allowed within the code is 19 this includes ignored marks The total length of the OMR code should not exceed 3 5 89 mm On the HCSF the center line of the marks must fall with...

Page 169: ...ne dotted line 20 mm min to last mark OMR Mark Specs at a Glance Description Metric English Closest Fraction Minimum line width for OMR or barcode marks 10mm 0 40 7 16 Minimum spacing between OMR marks 2 5mm 0 10 1 10 Maximum spacing between OMR marks 4 5mm 0 18 3 16 Minimum space between mark clear zone and paper edge 11mm 0 42 7 16 Minimum clear zone on sides of marks 3mm 0 12 1 8 Minimum clear ...

Page 170: ... the HCSF the center line of the barcode must fall within a range of 1 25 32 mm to 4 125 105 mm from the center line of the sheet On the Feeder Tower the center line of the barcode must fall within a range of 0 787 20 mm to 4 92 125 mm from the center line of the sheet The barcode should not be closer than 79 20 mm from the Lead Edge nor closer than 79 20 mm from the Trail Edge of the sheet NOTE C...

Page 171: ...am Ladder Orientation Diagram is not to scale Feeder Tower 125 mm max HCSF 105 mm max Feeder Tower 20 mm min HCSF 32 mm min 1234567 1234567 16 point font min 17 mm min to clear zone dotted line 20 mm min to barcode 17 mm min to clear zone dotted line 20 mm min to barcode 1234567 1234567 1234567 1234567 1234567 1234567 1234567 Barcode Specifications continued ...

Page 172: ...icket Fence Orientation Diagram is not to scale Feeder Tower 125 mm max HCSF 105 mm max Feeder Tower 20 mm min HCSF 32 mm min 12 characters 3 of 9 or 18 characters I 2 of 5 max 1234567 1234567 1234567 1234567 1234567 17 mm min to clear zone dotted line 20 mm min to barcode 17 mm min to clear zone dotted line 20 mm min to barcode Barcode Specifications continued ...

Page 173: ... it will ask questions to ascertain where it needs to look for marks and where it should ignore other printed matter Depending on the type of code being used the machine will ask you to define either the first mark position and code length OR the Clear Zone as described on the following pages 1 Take a sheet that has at least the FIRST and LAST mark printed on it 2 When requested by the machine mea...

Page 174: ...called the Clear Zone NOTES Setting the Clear Zone closer to the beginning and end of the OMR marks de creases the possibility of any poor print or imperfections on the material being interpreted as marks Conversely setting the Clear Zone too close to the beginning and end of the marks could cause problems if the position registration of the printing on the material varies A good guide is to limit...

Page 175: ...low the steps below to navigate to the screen 1 From the Home screen select Menu then Tools 2 Select About My Machine One of the following marks must be present and must be marked as Is con trolling in the system EOC BOC PC or MC EOC is most frequently marked as Is controlling Additional restrictions apply to BOC and MC when marked as Is Con trolling Paper weight range for OMR is 18 lb 75 gsm to 3...

Page 176: ...is case the scan configuration should indicate Content in Line with Marks be set to Yes to enable the functionality Additionally the HCSF furthest upstream must be used Currently if the BOC mark is controlling the Content in Line with Marks option must be set to Yes and the mark locations settings must be entered into the system EOC End of Collation This normal controlling mark indicates that it i...

Page 177: ...odd number of marks Parity should be set to odd No more than one Parity mark can be used within the code SAF Safety OMR Only This mark improves the integrity of your Mail Piece It should be at the end of the code that is opposite to the Benchmark When the Safety mark is added the machine will automatically work out the length of the code This makes creating jobs using this code easier Otherwise th...

Page 178: ...e page number within a collation The system checks the order of pages and for missing or extra pages within the collation NOTE The Page Count and Page Number marks can be used together to ensure internal collation integrity WAS Wrap Around Sequence This is a numbering system which uses a sequential binary coding If a page becomes missing or the set becomes out of sequential order the system will s...

Page 179: ...e the Seal mark will not be sealed If Seal is set to absent and the Seal mark is on an item the Mail Piece will not be sealed An item that doesn t have the Seal mark will be sealed TIP This mark is useful when materials need to be hand stuffed into an envelope SF n Select Feed These marks instruct the machine to select material from specific feeders Up to nine Select Feed marks can be within the c...

Page 180: ...8 36 SV61311 Rev E 8 Scanning This page is intentionally blank ...

Page 181: ...ev E Basic Terms A 2 Material References A 2 Machine Functions A 3 Icon Glossary A 4 Envelope Icons A 4 Fold Icons A 5 Sheet Icons A 5 Insert Icons A 6 Feeder Assignment Icons A 7 Other Icons A 7 Appendix A Glossary ...

Page 182: ...uire folding before being placed into an en velope There are five kinds of inserts Reply Envelope An 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 thickness piece of paper or card Double detect is turned ON by default for this item Reply Card A single thickness piece of paper Double detect is turned O...

Page 183: ...een The initial screen displayed after turning power on From this screen you can run the machine select a pre programmed Job and enter the menu functions Mail Piece Icon Tree A graphic that runs down the left side of the display and contains icons small pictures that represent the items that make up the currently selected mail piece It also indicates the location of the feeder where each item need...

Page 184: ...dard Flap Flat Envelope N A Window Forward Flap Flat Envelope N A Window Bottom Flap Flat Envelope N A High Capacity Envelope Feeder The tables in this section provide descriptions of the various icons you will see on the display screen Dark lines within an icon represent features you can plainly see Where applicable the darkest edge of an icon is the edge that feeds first into the system Light gr...

Page 185: ...Orientation face down top first Orientation face down bottom first Sheet Not Personalized Sheet Top Address Sheet Middle Address Sheet Bottom Address Multiple Sheets Not Personalized Multiple Sheets Top Address Multiple Sheets Middle Address Multiple Sheets Bottom Address Fold Icons No Fold C Fold Z Fold Single Fold Double Fold ...

Page 186: ...down top first Orientation face down bottom first Slip or Generic Insert Reply Envelope N A N A N A Reply Card Multiple Slips or Generic Inserts Multiple Reply Envelopes N A N A N A Multiple Reply Cards Orientation closed edge first Pre Folded Insert Multiple Pre Folded Inserts Orientation bound edge first Letter Booklet Multiple Letter Booklets ...

Page 187: ...ower Bottom left feeder B Feeder Tower Bottom right feeder C Feeder Tower Top left feeder D Feeder Tower Top right feeder G High Capacity Envelope Feeder HCEF N A J High Capacity Sheet Feeder 1 HCSF Bottom feeder K High Capacity Sheet Feeder 1 HCSF Top feeder L High Capacity Sheet Feeder 2 HCSF Bottom feeder M High Capacity Sheet Feeder 2 HCSF Top feeder X Custom Feeder N A Z Attached Printer N A ...

Page 188: ...A 8 SV61311 Rev E A Glossary This page is intentionally left blank ...

Page 189: ...Index 1 SV61311 Rev E Index ...

Page 190: ...insert options 3 36 3 38 saving 4 3 sheet options 3 33 3 35 A Access Rights 2 20 2 21 manager 2 20 operator 2 20 restricted mode 2 20 secure mode 2 20 supervisor 2 20 Add On Modules 2 24 7 2 Adding items 3 41 jobs 3 26 3 27 3 28 3 29 Adjusting envelope openers 3 18 3 19 3 20 3 21 HCEF separator gap 3 16 HCEF side guides 3 13 HCEF wedge 3 14 scan head 8 19 screen brightness and contrast 5 2 Aligner...

Page 191: ...ations 6 5 Folder 2 3 description 2 9 location 2 8 specifications 6 4 Folder Bypass Path 2 9 Fold Options 3 32 fold length 3 32 fold type 3 32 setting auto fold length 3 32 Function Keys 2 13 Furniture 1 5 H Handling Outsorts 5 6 High Capacity Envelope Feeder HCEF 1 3 2 3 A 7 adjusting the separator gap 3 16 adjusting the side guides 3 13 adjusting the tail prop 3 14 specifications 6 5 troubleshoo...

Page 192: ... 2 13 Mail Machine Interface 1 5 3 29 Mail Piece A 2 Mail Piece Icon Tree 2 15 2 17 A 3 A 7 Mail Piece Path 2 8 Mail Piece Problems troubleshooting 5 14 Maintenance 5 16 Manager Access Rights 2 20 Manual Feed A 2 Manual Feeder 2 3 2 7 Material Safety Data Sheets v Material Specifications Feeder Tower 6 7 envelopes 6 7 6 8 inserts 6 10 sheets 6 11 HCSF 6 12 sheets 6 12 Moistener Closer Sealer capac...

Page 193: ... a Item 3 43 Removing Trays from the Feeder Tower 3 7 Renaming a Job 4 3 Replenish Sealer Fluid 5 5 Reply Card A 2 Reply Envelope A 2 Resetting batch counter 2 12 piece counter 2 11 Resuming the Job 5 6 Running a Job 3 4 Running a Trial Piece 3 22 3 23 S Safe Seal 3 30 Safe Seal Icon A 7 Safety Information 1 6 Saving a Job 4 3 Scan Configuration editing 8 13 Scan Configuration Worksheet 8 6 8 10 S...

Page 194: ...T Tandem Belt Stacker 1 5 7 18 Technical Support v Throughput 1 3 Transport Deck 1 3 2 8 mail piece path 2 8 pre fold accumulator 2 8 Trays attaching to feeder tower 3 6 removing from feeder tower 3 7 Trial Piece 3 22 A 3 double detect 2 13 key 2 13 Troubleshooting folder inverter problems 5 10 high capacity envelope feeder problems 5 13 inserter station problems 5 11 mail piece problems 5 14 mois...

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Page 196: ... 5C7 www pitneybowes ca 1 Elmcroft Road Stamford Connecticut 06926 0700 www pb com For Service or Supplies Printed on recyclable paper PB Form SV61311 Rev E 10 06 2006 Pitney Bowes Inc All Rights Reserved Printed in the USA or Canada SV61311reve ...

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