Pitney Bowes Epic v3.1 Operator'S Manual Download Page 22

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Component Overview - Epic v3.1 (ZVE0)

The Epic v3.1 (ZVE0) Inserting system consists of these main modules and sections.

Item Description

Input modules

Sealer

Buffer

Turnover

Chassis

Print+ Messenger Printer

(optional)

Insert Feeders

Vertical Stacker (with flats stacker)

Engine

On Edge Stacker

Envelope Feeder

Product Overview

Pitney Bowes

Epic v3.1 (ZVE0) Operator Guide

May, 2018

Page 15 of 328

Summary of Contents for Epic v3.1

Page 1: ...Shipping Mailing Inserting Epic v3 1 ZVE0 Inserting System Auto Adjust Chassis Operator Guide US English Edition SV63233 RevG May 8 2018...

Page 2: ...tute an infringement of intellectual property rights of Pitney Bowes and Pitney Bowes assumes no responsibility for any such use of the information We have made every reasonable effort to ensure the a...

Page 3: ...DRAFT October 25 2016 Draft release Safety certification SV63233 RevA July 24 2017 Initial release SV63233 RevB September 15 2017 Direct Connect section reworked for localization content updated and...

Page 4: ...P Operator Guide SV63088 l Print Messenger Digital Inkjet System Operator Guide OG_APF_PRINT_020111 l Hunkeler UW6 Unwinding Module Operator Guide OG Hunk Unwinder l Auto Buckle Chute Y488 Y20R Y20S O...

Page 5: ...ail Date 37 Checking Status with Job Manager 38 Accessing Reports in DC 39 Starting and Stopping the Inserter Using DC 40 Assigning an MRDF File File Based Jobs 41 Disabling and Enabling the Inserter...

Page 6: ...Mechanical Adjustments 137 Changing Out the Booklet Feeder Separator Assemblies 138 Adjusting the Booklet Feeder Separator Gap 145 Adjusting the Booklet Feeder Side Guides 148 Adjusting the Booklet F...

Page 7: ...Troubleshooting Troubleshooting 248 Engine Troubleshooting 249 Chassis Troubleshooting 252 Buffer Troubleshooting 258 10 Maintenance Operator Maintenance 260 Replacing Suction Cups in the Engine 262...

Page 8: ...1 Safety In this section Safety Information 2 Power 3 Operation 4 Maintenance 5 Warning Labels and Cautions 6 Safety Features 10...

Page 9: ...perchlorate Ear Protection Noise Exposure Guidelines Ear protection is required if noise exposure exceeds OSHA standards There are many factors to be taken into consideration in each individual work...

Page 10: ...from the AC power supply for Lock Out Tag Out LOTO l Do not use an adapter plug on the line cord or wall outlet l Do not route the power cord over sharp edges or trap it between furniture l Ensure th...

Page 11: ...ng l Keep loose clothing jewelry long hair and neckties away from all moving parts Make sure that clothing and hair fit closely to your body and remove all jewelry l When lifting covers wait for all p...

Page 12: ...s approved printer ink and cleaners l To prevent overheating do not cover the vent openings l Do not store flammable fluids inside this machine l Do not place any container with liquid on this machine...

Page 13: ...ns Caution Pinch Point Rotating Shaft Pinch hazard rotating shaft Keep hands clear during operation Caution Pinch Point Rollers Pinch hazard moving belts and rollers in this area Do not operate with c...

Page 14: ...eep hands clear during operation Caution Hand Crush Crush hazard use caution when working in this area Caution Hot Surface Burn hazard hot surface inside Allow to cool before servicing Caution Motor C...

Page 15: ...abrasion Caution Hair Entanglement Caution rotating parts Keep hair jewelry and loose clothing away during operation to prevent potential injury Caution Cut Hazard Caution sharp blades Keep hands cle...

Page 16: ...esidual risk remains The feed station is open to allow for paper loading onto the feed hopper belts Although these belts travel very slowly always be aware of the moving belts and use proper caution i...

Page 17: ...immediate stop When the ESTOP is activated the main DC screen will indicate this as well as which location on the machine the ESTOP was engaged Only use ESTOPs for emergency situations with the potent...

Page 18: ...top option The covers should not be opened while the machine is running If an interlock cover is accidentally opened while the inserter is running the connection is broken via the latch magnet and the...

Page 19: ...o disable the rotary feeder locally In this case the feeder is disabled with no power The inserter system still has power but is not able to run when the feder interlock switch is engaged Insert Rotar...

Page 20: ...2 Product Overview In this section Epic v3 1 ZVE0 Inserting System 14 Component Overview Epic v3 1 ZVE0 15 Indicator Lights 17 About the Remote Control 18...

Page 21: ...inal Epic engine plus auto adjusting chassis side guides and new buffer ZVB4 design These side guides work the same as the other engine auto adjust features in that they automatically adjust to the me...

Page 22: ...s Item Description Item Description 1 Input modules 7 Sealer 2 Buffer 8 Turnover 3 Chassis 9 Print Messenger Printer optional 4 Insert Feeders 10 Vertical Stacker with flats stacker 5 Engine 11 On Edg...

Page 23: ...staged in this module and fed into the engine as needed l Engine This is where the envelope flap is opened and the collation is inserted into the envelope After insertion the envelope with collation i...

Page 24: ...direct an operator to the appropriate area of the machine Indicator lights also alert operators when there is an open cover or ESTOP activated and when the material in the insert feeder gets low LED...

Page 25: ...ould be used as much as possible to operate the system Remote Control Functions l Start and Stop Press the Start and Stop buttons to start and stop the machine l Cycle If the input is in Service mode...

Page 26: ...3 Power the System On and Off In this section Powering Up the System 20 Powering Down the System 22...

Page 27: ...em both the inserter and the Direct Connect computer Power Up the Inserter 1 Locate the red and yellow ON OFF power switch near left most chassis feeder on lower cabinet ON OFF Switch Power the System...

Page 28: ...e Begin Login window hold down the CTRL and ALT keys at the same time and press the Delete key The Login window opens 2 To log into Windows if the system is connected to a network enter the system pas...

Page 29: ...oth the inserter and the Direct Connect computer Power Down the Direct Connect Computer 1 Clear all the material in the paper path 2 Click Control Power Down on the DC main menu bar 3 When the Power D...

Page 30: ...s in the system to shut down safely 1 Locate the red and yellow ON OFF power switch on the lower cabinet near the left most chassis feeder 2 To turn the system OFF rotate the red section of the switch...

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Page 32: ...are Details 32 Logging In and Logging Out of DC 33 Loading a Mode 35 Setting the Mail Date 37 Checking Status with Job Manager 38 Accessing Reports in DC 39 Starting and Stopping the Inserter Using DC...

Page 33: ...nt is fed into the inserter DC reads and decodes the barcode and the information is used to control the inserting process for the mailpieces File Based Scanning Fle based scanning is when DC uses an I...

Page 34: ...ponents on your actual machine You can control operations of the system from this main screen Note This screen is configurable The items shown in this example are for reference only and may not match...

Page 35: ...2 Banner Area 7 Alarm Icon 3 Buttons 8 Alarm Message Box 4 Icons may look different site to site 9 Speed Indicators 5 Start Bar Menu Start Stop Cycle buttons 10 Inserter Model Using Direct Connect Pit...

Page 36: ...art bar start and stop DC includes Menu and Cycle buttons l Menu button options to start or stop a job reset the count load a mode open a file or clear deck l Alarm icon indicates an error click to vi...

Page 37: ...e main menu bar on the main DC screen 1 Click Control on the DC main menu bar 2 Hover over Switch Languages and select the language you want Note The UI display language is typically set by Service du...

Page 38: ...the main DC screen 1 Click Control on the DC main menu bar 2 Select Power Down and click Yes when prompted This shuts down the DC computer Note If you are logged in as an Operator you cannot exit DC...

Page 39: ...about the DC software from the main menu bar on the main DC screen 1 Click About on the main menu bar in DC a dialog opens with software details version install date ID number 2 Click Close to exit U...

Page 40: ...hen the User Login dialog opens double click Operator or your login name 4 When prompted enter your password and click OK Logging Out 1 Click the Login button on the main DC screen 2 Select Logout fro...

Page 41: ...s with Job Manager l Access standard report l Start and stop the inserter l Assign an MRDF file l Enable and disable inserter components l Clear the deck l Monitor speed indicators l View and access a...

Page 42: ...ode layout forms length and the icons displayed on the main DC screen Note In order to see available modes you must be logged in to DC Typically operators load modes they do not create them Loading a...

Page 43: ...ou are setting up and click OK Note After you load the mode successfully the mode name appears in the banner area at the top of the main DC screen Using Direct Connect Pitney Bowes Epic v3 1 ZVE0 Oper...

Page 44: ...e you run it 1 Click the JobMgr button on the main DC screen 2 Select Set Mail Date from the drop down menu 3 When the dialog opens type in the mail date It must be today s date or a date in the futur...

Page 45: ...n the current job the operator etc 1 Click the JobMgr button on the main DC screen 2 Select Status from the drop down menu A Job Manager Status dialog opens and displays information about the machine...

Page 46: ...or Close to exit Accessing Saved Reports Feature To view the reports you may have previously saved 1 Click the Reports button the main DC screen 2 Select Reports View Saved Reports from the drop down...

Page 47: ...the Menu Start and Cycle buttons are replaced by the Stop button Stop Button When you click the Stop button the system stops at a predetermined state to ensure all the mailpieces in process are contr...

Page 48: ...ns etc If this is not a file based job you can skip this step 1 Click on the Menu button on the bottom of the main DC screen near the Start bar 2 Select Open File or Start Job from the drop down menu...

Page 49: ...ivity preserving data that may be helpful for diagnosing issues When you are ready to start running the job again you can enable the system 1 Click the Menu button on the bottom of the main DC screen...

Page 50: ...ntrol wait for about 1 second and then press the Stop button while still holding down the Cycle button l Click the Chassis object on the main DC screen and select Clear Deck from the menu What Happens...

Page 51: ...in the paper path not the material in the insert feeders You can initiate Clear Deck and Feeders manually or set it up to run automatically whenever you initiate a Clear Deck function Initiate Clear...

Page 52: ...ck 1 Click the Chassis object on the main DC screen and select Setup from the drop down menu 2 When the Chassis Setup dialog opens select the Clear feeders on clear deck checkbox Every time you initia...

Page 53: ...ages are fed in number of mailpieces per hour shown as 0 below as well as the total number of pages fed shown as 63 here The output speed indicator displays the output speed in numbers of mailpieces p...

Page 54: ...in screen over the start bar Alarm Message Box When an alarm displays in the alarm message box you can get more information about what and where the issue is and suggestions on how to solve it Refer t...

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Page 56: ...the Flat Stacker 84 About the On Edge Stacker OES 88 Setting Up the Entrance to the On Edge Stacker 90 Centering Mail on the On Edge Stacker Conveyor Belt 94 Adjusting the Belt Speed and Stack Pressu...

Page 57: ...sting the Booklet Feeder Side Guides 148 Adjusting the Booklet Feeder Pack Control Ramp 151 Adjusting the Booklet Feeder Double Detect Feature 155 Adjusting the Bulk Loader Hopper Deck 158 Adjusting t...

Page 58: ...Feeders insert feeder l Booklet Feeder l Buffer Note After loading a mode home the chassis by pressing the Start button once Job Changeovers Changeover adjustments may be required if the new job you a...

Page 59: ...is set based on envelope thickness If the gap is too tight envelopes will not feed If the gap is open too wide multiple envelopes will feed 1 Pull the separator access lever towards you until it stop...

Page 60: ...Rollers 3 Release the access lever 4 Turn the separator knob to adjust for thickness You should feel a very slight drag on the envelope as you try to remove it from the separator roller Adjust the sep...

Page 61: ...t gets the feeder gap close to the final setting During operation testing additional adjustments may be necessary if doubles or no envelopes are feeding Operator Adjustments Pitney Bowes Epic v3 1 ZVE...

Page 62: ...p down and facing to the right in the envelope hopper 2 Loosen the lock down lever and slide the envelope fence up or down until the alignment arrow lines up with the top edge of the envelopes Loosen...

Page 63: ...ver 2 Lift the upper engine to access the vacuum deck 3 Open the envelope and fold the flap inside so the throat of the envelope is showing 4 Align the top of the envelope flap crease line with the de...

Page 64: ...5 Close the upper engine Close Upper Engine Envelope Aligned view from above Operator Adjustments Pitney Bowes Epic v3 1 ZVE0 Operator Guide May 2018 Page 57 of 328...

Page 65: ...6 Use the operator setup tool to loosen the three suction cup lockdown screws Suction Cup Lockdown Screws Operator Adjustments Pitney Bowes Epic v3 1 ZVE0 Operator Guide May 2018 Page 58 of 328...

Page 66: ...cups Item Description 1 Envelope Flap 2 Envelope Throat 3 Suction Cups 4 1 8 inch 3 mm space Position Suction Cups 1 8 inch 3 mm from throat 8 Tighten the suction cup lockdown screws 9 Remove the env...

Page 67: ...position 1 Lift the engine cover 2 Lift the upper engine to access the vacuum deck 3 Open the flap of the envelope and fold the flap inside so the envelope throat is showing 4 Align the top of the en...

Page 68: ...engine Close Upper Engine 6 Use the operator setup tool to loosen both horizontal tongue lockdown screws Tongue Lockdown Screws Operator Adjustments Pitney Bowes Epic v3 1 ZVE0 Operator Guide May 201...

Page 69: ...on 1 Tongue Assembly 2 Envelope Throat 3 1 8 3 mm gap between tongue and throat Position Tongue Assembly 8 Tighten the lockdown screws 9 Remove the envelope 10 Lower the upper engine 11 Close the engi...

Page 70: ...ntify the thickest collation or largest number of panels to be run in this job 2 Open the engine top cover and open the upper engine 3 Locate the lockdown screw to adjust the tongue height and loosen...

Page 71: ...lation under the tongue adjust the tongue up or down so there is a no drag to about a 1 to 2 mm gap Small Gap 1 to 2 mm between Tongue and Collation 6 Remove all material from under the tongue and ins...

Page 72: ...rd Horn standard 8 mm 3 Thick Horn 13 mm l Narrow horn used when the envelope is 8 or less and when the collation thickness is less than 3 mm Used for applications with tight end clearance l Standard...

Page 73: ...sing the short setup tool Short Setup Tool ZX84205 The short screw is captured and will not come out of the horn assembly When loosening the screw do not hold the horn or you can damage it Short Screw...

Page 74: ...loosen the single locking screw and remove the horn strap Item Description 1 Mounting Screw 2 Horn Strap 3 Horn Remove the Horn Strap Operator Adjustments Pitney Bowes Epic v3 1 ZVE0 Operator Guide M...

Page 75: ...holder and store the removed horn back in the holder Horn on Holder 4 Install the new horn by aligning the horn mounting with the horn mount Horn Mounting Screw Operator Adjustments Pitney Bowes Epic...

Page 76: ...in place NOTE Don t hold the horn while you tightening it it may cause damage Item Description 1 Horn Mounting Screw 2 Horn Mount Operator Adjustments Pitney Bowes Epic v3 1 ZVE0 Operator Guide May 2...

Page 77: ...on left or right and slide the slotted mounting bracket under the mounting screw and between the horn opening c Tighten the horn mounting screw in place and verify that the horn pivots freely without...

Page 78: ...lope properties for any reason this is where you would do that 1 Log into DC as Key Operator access level or higher 2 Click the Engine object on the main DC screen and select Setup from the drop down...

Page 79: ...largest point from crease required field l Flap delta difference in flap size at flapper exit sensors i e how much shorter is the flap at the sealer The sensor itself is about 2 9 inches 74 mm off the...

Page 80: ...envelope measurements to identify the flap delta Use this information as a reference to enter the proper envelope settings into DC for your job Using the Flap Delta Envelope Guide Template To identif...

Page 81: ...arrow on the top of the template 5 Square up the envelope with the guidelines on the bottom of the template Item Description 1 Center line of template aligned with center of envelope 2 Bottom of envel...

Page 82: ...lap crosses this scale l Left side of the scale is in inches and should be recorded as 1 2 3 4 5 6 7 etc l Right side of the scale is in millimeters In this Example Flap Delta is 7 inches 7 Enter the...

Page 83: ...t from the crease line to the edge of the center of the flap that is your flap height measurement for entry into DC Envelope Information Flap Height Measurement Operator Adjustments Pitney Bowes Epic...

Page 84: ...inches 74 mm off of the center line 2 Measure the height difference from the marked point to the top center of the flap that is your flap delta measurement for entry into DC Envelope Information Flap...

Page 85: ...p covers 2 Locate the adjustable roller locking screw for the two exit rollers Item Description 1 Tensioner 2 Locking Screw RAT Roller Tension and Locking Screw 3 Using a 3 16 setup tool loosen the lo...

Page 86: ...6 Perform on other roller if needed 7 Close covers Operator Adjustments Pitney Bowes Epic v3 1 ZVE0 Operator Guide May 2018 Page 79 of 328...

Page 87: ...ealer Fluid The default amount of fluid applied to the envelope is determined by the envelope parameters entered in the Engine Setup screen in DC The amount of fluid used to seal the envelopes may nee...

Page 88: ...e displayed in the field up to 30 seconds This feature is not active while the system is running Note Make small changes with the slider checking often to see if you are getting the desired results Ex...

Page 89: ...tion of travel of the envelope Vertical Stacker Screws on Wheels 2 Angle the roller more to the right to direct the envelope toward the back wall of the vertical stacker Sliding the roller to the left...

Page 90: ...and remove the guide from the module Adjust a Vertical Stacker Side Guide To adjust the position of a vertical stacker side guide 1 Loosen both thumb screws and slide the guide on the bars to the des...

Page 91: ...has the appropriate mounting features and electrical connections to make it work When you are not running flat envelopes the stacker can be removed from the work cell to increase access to the On Edg...

Page 92: ...Unscrew the connector at the base b Squeeze the top and bottom tab while gently pulling the connector free c Pull the blue connector off the base Item Description A Connector B Tab C Pull connector of...

Page 93: ...rical connection disconnected and the latches down grasp the handle on the other side of the module and roll the unit out from under the vertical stacker 4 Move the module to a secure location to prev...

Page 94: ...ectrical connections a Align the starting tab and tighten the ring on the connector b Align the connector so the starting tab is in the correct orientation and then press the connector together until...

Page 95: ...ES Components Item Description 1 Stacker Entrance Envelope Guides 2 Pack Pressure Adjustment Knob on backside not visible here 3 Control Panel 4 OES Fingers on backside not visible here 5 Bin Full Swi...

Page 96: ...escription 1 ESTOP 2 Pack Pressure LED 3 Reset Button not available 4 Actuator Switch 5 Conveyor Speed On Edge Stacker Control Panel Operator Adjustments Pitney Bowes Epic v3 1 ZVE0 Operator Guide May...

Page 97: ...m off the deck Item Description 1 1 2 inch 12 7 mm Offset from Deck 2 Paper Flow and Stacker Exit Envelopes Set to 1 2 inch 12 7 mm Off the Deck shown here in closeup 2 To adjust the height move the a...

Page 98: ...on the operator side guide and slide the entrance guides open Item Description 1 Non Operator Entrance Guide loosen screw 2 Operator Entrance Guide Loosen Screws loosening screw on non operator side...

Page 99: ...half of the envelope under the rollers and half under the entrance of the OES Item Description 1 Vertical Stacker Rollers 2 Entrance to OES Positioning the Envelope in the Vertical Stacker Operator A...

Page 100: ...ator Side Guide outer 2 Top Seam of Envelope 3 1 8 inch Gap 4 Operator Side Guide inner Positioning of the Inner and Outer Guides 7 Take the inner guide operator side and position it 1 4 inch 6 3 mm a...

Page 101: ...or Belt When possible it is best to stack the mail in the center of the belt on the On Edge Stacker OES or as close to the center as possible Mail Centered Operator Adjustments Pitney Bowes Epic v3 1...

Page 102: ...nce toward or away from the envelope as needed Item Description 1 Top Knob 2 Mail Stacking Fence Mail Centering Adjustment Note If you are getting inconsistent stacking it may be necessary to move the...

Page 103: ...the On Edge Stacker OES Properly stacked mail is perpendicular to the belt Improper vertical stacking can cause jams at the stacker exit Proper Vertical Stacking mailpieces are straight and even Impr...

Page 104: ...mines how far the mailpiece advances with each pulse of the belt The conveyor speed dial controls the speed of the stacker conveyor belt Adjust the conveyor speed by turning the speed dial clockwise t...

Page 105: ...ressure in the stack ensures adequate sealing of the envelopes You can control the pack pressure with the pack pressure adjustment knob located on the backside of the OES While the system is running i...

Page 106: ...causing jams turn the knob counterclockwise to remove some of the pressure Item Description 1 Pack too loose leaning back 2 Pack too tight possible jamming Note Do not over adjust the knob in the cloc...

Page 107: ...odule the fingers guide it to get in line behind the mailpieces that are already on the conveyor Note It may be beneficial to remove the finger guides when stacking 6 x 9 and other types of envelopes...

Page 108: ...on Item Description 1 Finger Guides 2 Tip of the D Roller Aligned Finger Guides 3 Once aligned tighten the four thumbscrews to set the new adjustment in place Note Additional adjustments may be requir...

Page 109: ...he chassis deck is full stop the machine with the remote or using DC 3 View the collations mailpieces resting underneath each feeder a If collation mailpiece is more than 1 inch away from the pushers...

Page 110: ...needed until the proper position is achieved Note When you find a setting that works note the location of the strap indicator tabs to use for future jobs Operator Adjustments Pitney Bowes Epic v3 1 Z...

Page 111: ...locking nut on the appropriate straps Provide guideline for default strap location angle 4 Rotate to adjust the strap as needed 5 Use a 3 16 Allen to tighten the locking nut 6 Lower the feeders 7 Clos...

Page 112: ...et manually 1 Measure the length of the largest document to be run on the chassis This can be from the input or an insert feeder 2 Click the Chassis object on the main DC screen and select Setup from...

Page 113: ...3 In the Chassis Setup dialog type the new collation length in the Collation length field 4 Click OK Operator Adjustments Pitney Bowes Epic v3 1 ZVE0 Operator Guide May 2018 Page 106 of 328...

Page 114: ...he inserter is running NOTE This is a site specific setting access permission to perform this function varies from site to site 1 Click the Chassis object on the main DC screen and select Chassis Spee...

Page 115: ...ouse to click in the text field above the buttons and type a number to manually adjust the speed 3 When the desired speed is set click OK Note If the speed of the chassis is changed while the system i...

Page 116: ...ents operators will need to perform on the friction feeders to be prepared for successful job runs l Adjusting the Separator l Adjusting the Side Guides l Adjusting the Pack Control Ramp Operator Adju...

Page 117: ...t the start of the job Note The belts shown in these photos are blue but feeder belts can also be red tan or black depending on the system configuration and the material being processed 1 Loosen the f...

Page 118: ...ck Control Knob 4 Place a single piece of insert material on the feeder belts and slide it to the left under the separator The separator knob is on the other side of the separator it s not visible her...

Page 119: ...r to the right as if you were trying to remove it you should feel a slight drag l If there is no drag turn the separator knob counterclockwise until you feel a slight drag l If there is too much drag...

Page 120: ...he side guides to accommodate different insert material sizes To adjust the friction feeder side guides 1 Loosen the feeder side guide lockdown knobs Item Description 1 Lockdown Knobs 2 Side Guide Adj...

Page 121: ...des opened as wide as they can go place a 1 inch 25 4mm stack of insert material from the job in the selected feeder and hold it between the side guides just above the adjustment knob Position Materia...

Page 122: ...nsert material Allow a 1 16 inch 1 6mm gap between each side of the material and side guide Adjusting the Side Guides 1 16 inch 1 6mm gap 5 Tighten the side guide lockdown knobs 6 Remove the material...

Page 123: ...ol ramp in each friction feeder To adjust the pack control ramp 1 Loosen the pack control knob Item Description 1 Pack Control Guide 2 Pack Control Knob slides to the right Pack Control Knob 2 Slide t...

Page 124: ...o between 1 32 79 mm and 1 16 1 5 mm from the material Position Material 1 32 inch 7 mm to 1 16 inch 1 5 mm gap 5 Tighten the pack control knob Operator Adjustments Pitney Bowes Epic v3 1 ZVE0 Operato...

Page 125: ...e prepared for successful job runs l Using Rotary Feeder Suction Cups l Adjusting the Side Guide and Backstop l Adjusting the Deck Position l Adjusting the Feed Deck Angle l Adjusting the Separator Pi...

Page 126: ...he rotary feeder pull the insert material from the stack in the rotary feeder down into the drum of the feeder preparing it for insertion Rotary Feeder Suction Cups Operator Adjustments Pitney Bowes E...

Page 127: ...cluded here to determine the proper suction cup type and position for your job Material Type Cup Type Cup Position Single sheet 10 A4 single sheet short blue ring 0 Half fold non glossy single sheet s...

Page 128: ...e suction cup arm locking screw 3 Using the scale on the suction cup arm move the arm to get the suction cups in the proper position Item Description 1 Locking Screw 2 Suction Cup Arm 3 Scale Position...

Page 129: ...rd or backward against the material and lock the knob in place Do not move the backstop too close to the material as it can restrict the material from dropping to the deck naturally Item Description 1...

Page 130: ...es too close to the material as it can restrict the material from dropping to the deck naturally Item Description 1 Side Guide 2 Side Guide Locking Knobs 3 Control Knob Adjust the Side Guides 6 Lock t...

Page 131: ...ings The position of the rotary feeder deck depends on the type of material you are running Use this table as a reference when setting the deck position Material Type Deck Position 10 A4 single sheet...

Page 132: ...uter deck blue locking knobs 2 Slide the deck to the appropriate setting use table here as a reference Slide the Deck to the Setting 3 Tighten the outer deck locking knobs Operator Adjustments Pitney...

Page 133: ...er Deck Angle Settings Use this table as a reference to adjust the rotary feeder deck to the proper angle Material Type Deck Position 10 A4 Single Sheet 1 Half fold non glossy single sheet 1 Half fold...

Page 134: ...ounterclockwise to adjust the angle up or down Item Description 1 Angle Adjustment Knob 2 Angle Adjustment Marks Adjust the Rotary Feeder Deck Angle 2 Use the angle adjustment marks on the side frame...

Page 135: ...ted on the center gate The two inner pins are closest to the center of the gate and the two outer pins are closer to the suction cups l Inner pins used for most material l Outer pins used for unusual...

Page 136: ...he separator pins Material Type Pins Single Sheet 10 A4 half fold non glossy half fold glossy inner fuly in toward stack Folded perfume inner fuly in toward stack BRE inner fuly in toward stack Bookle...

Page 137: ...ted on the back of the center gate to adjust each separator pin 2 Use the table in this topic to determine the proper pin setting based on the type of material you are running Separator Pin Adjustment...

Page 138: ...re support Refer to the table included here to see if the material you are running requires the use of the wedge Material Type Wedge Single Sheet 10 A4 half fold non glossy half fold glossy optional F...

Page 139: ...il it rests on the feeder deck Slide Wedge 3 Load the material into the feeder as usual 4 When the job is finished slide the wedge off the feeder and return to the back wall Operator Adjustments Pitne...

Page 140: ...the rotary feeder l Jog Only This jog feature is for clearing jams It turns the feeder drum one cycle so you can easily remove jammed material l Feed with Jog This jog feature can help verify feeder...

Page 141: ...eeder do not physically pull the material from the transport belts Use the Jog button to move the material to the deck for easy removal 1 Click the desired Rotary Feeder object on the main DC screen F...

Page 142: ...is initiated in DC press the mechanical Jog button on the feeder and the jammed material feeds out Jog Button on the Rotary Feeder Operator Adjustments Pitney Bowes Epic v3 1 ZVE0 Operator Guide May...

Page 143: ...from the drop down menu If Feed with Jog is not in the drop down list select Jog Only click the Feeder object again and Feed with Jog is now listed 3 Once the Feed with Jog mode is initiated in DC pre...

Page 144: ...l Adjusting Pack Control Ramp l Adjusting the Double Detect Feature Booklet Feeder with Bulk Hopper Booklet feeders that are mounted in the most upstream position can have an additional bulk loading h...

Page 145: ...separator can be adjusted to accommodate various insert thickness There are two separator options for the booklet feeder a stone or a stripper bar You can switch between the two separator options dep...

Page 146: ...r Bar 1 Turn the separator knob so at least 5 16 8 mm of thread is showing above the knob This makes it easier to remove the separator assembly Separator Knob Operator Adjustments Pitney Bowes Epic v3...

Page 147: ...assembly and use a setup tool to loosen and remove the screw and wedge block Locking Screw Location Closeup View of Screw and Wedge Block Item Description 1 Locking Screw 2 Wedge Operator Adjustments...

Page 148: ...d pivot the separator assembly out Removing the Separator Assembly Note Take care not to lose or damage a spring or photocell wires while removing the assembly Operator Adjustments Pitney Bowes Epic v...

Page 149: ...and wedge block are installed on the operator side of the assembly remove them at this time 3 Angle and slide the separator assembly in place Help guide the assembly into position taking care not to l...

Page 150: ...bly needs to be fully installed to your left The wedge block must be sitting in the groove when the screw is tightened otherwise the separator assembly might come loose Wedge Block Seated Correctly le...

Page 151: ...the separator gap for the insert material in the job Refer to the Adjusting the Separator Gap topic for more information Operator Adjustments Pitney Bowes Epic v3 1 ZVE0 Operator Guide May 2018 Page 1...

Page 152: ...thicknesses of material The adjustment outlined here gets the gap very close to the final setting but additional fine tuning may be required 1 Loosen the feeder side guide thumbscrews and slide the gu...

Page 153: ...eparator roller or stripper bar Stripper Bar 4 If the material does not slide under the roller or bar turn the separator knob clockwise until it does Operator Adjustments Pitney Bowes Epic v3 1 ZVE0 O...

Page 154: ...he separator knob counterclockwise until you feel a slight drag l If there is too much drag turn the separator knob clockwise until you feel a slight drag 6 When you have the correct amount of drag re...

Page 155: ...d height adjustment screws for each side guide Item Description 1 Height Adjustment Screws 2 Position Mounting Screws Position Mounting and Height Adjustment Screws 4 Raise the side guide to its upper...

Page 156: ...de is over the belt or roller adjust the height of the side guide so there is a 2 mm gap l If the bottom of the guide is not over a belt or roller lower the side guide to its lowest position Height Ad...

Page 157: ...centered and straight no taper l Side guides should only be 1 16 to 1 8 1 6 mm to 3 1 mm larger than the insert Item Description 1 Adjust guides to insert width 2 Gap 1 16 to 1 8 gap use insert Operat...

Page 158: ...rator This allows inserts to be placed continuously into the separator of the feeder Note Prior to doing this it s easier if the separator gap has already been set If not the separator gap may need to...

Page 159: ...To adjust the pack control ramp 1 Loosen the pack control thumb screw and slide the ramp to the left Operator Adjustments Pitney Bowes Epic v3 1 ZVE0 Operator Guide May 2018 Page 152 of 328...

Page 160: ...m the job over the center of the lower feed roller and hold in place Material Centered Over the Blue Roller even with front of separator not shown here Operator Adjustments Pitney Bowes Epic v3 1 ZVE0...

Page 161: ...ed over the center of the feed roller The pack control ramp just touches the trail edge of the booklet Pack Control Ramp Adjusted to Trail Edge of Booklet 4 Tighten the pack control thumb screw Operat...

Page 162: ...g Double Detect Note l When you check the double detect it s important to set the double detect for the insert material for the job l Also use the same location on the insert that the double detect ro...

Page 163: ...ecure the mounting screws in this position temporarily 3 Turn the double detect knob to adjust the space between the bracket and the mount about 1 2 13 mm to 5 8 16mm Operator Adjustments Pitney Bowes...

Page 164: ...of the feeder should illuminate NOTE If the light does not illuminate turn the double detect adjustment knob counterclockwise until it comes on 8 Remove the two inserts and the light should turn off...

Page 165: ...ck 1 Open both buffer side covers 2 While holding the hopper deck in place loosen both lockdown knobs under the deck This lets you slide the deck Bulk Loader Hopper Deck Lockdown Knobs one of two visi...

Page 166: ...the five blue locking knobs for both side guides and slide the guides to the center towards the flat belts Locking Knobs Operator Adjustments Pitney Bowes Epic v3 1 ZVE0 Operator Guide May 2018 Page 1...

Page 167: ...rom the trail edge of the booklet Red Hopper Belts 1 8 3 mm Away from Ramp 5 Tighten the lockdown knobs under the bulk loader hopper deck 6 Adjust the bulk loader hopper side guides Refer to the Adjus...

Page 168: ...ch point will occur 1 Be sure the bulk loader hopper deck is properly adjusted Refer to the Adjusting the Bulk Loader Hopper Deck for details 2 With the bulk loader hopper deck and booklet feeder side...

Page 169: ...guides Note The booklet must move freely between both side guides on the bulk loader hopper If the space is too tight they will into feed into the booklet feeder Operator Adjustments Pitney Bowes Epic...

Page 170: ...activities for each access level are grouped here Be sure you are logged into DC at the correct level to access these features Adjustment Friction Feeder Rotary Feeder Access Level Enable and Disable...

Page 171: ...mail run To enable or disable feeders during a job 1 Visually check the status of the feeder on the main DC screen Item Description 1 Enabled feeder object is gray 2 Disabled feeder object is white Fe...

Page 172: ...ght Friction Rotary Booklet Feeders Width and length are mandatory fields and must be done for every feeder if it is not included in the mode 1 Measure the width and length of the insert for each feed...

Page 173: ...al width and length in the Width and Length fields 5 Enter the weight in the Weight field if you have that information 6 Click OK Operator Adjustments Pitney Bowes Epic v3 1 ZVE0 Operator Guide May 20...

Page 174: ...der only 1 Log in as Key Operator access level or higher 2 Click the desired Feeder object from the main DC main and select Setup from the drop down Feeder Objects Operator Adjustments Pitney Bowes Ep...

Page 175: ...oklet Folded style inserts checkbox if you are running that type of material If not verifythis box is not selected 4 Click OK Operator Adjustments Pitney Bowes Epic v3 1 ZVE0 Operator Guide May 2018 P...

Page 176: ...is gray l Priority Select the feeder provides an insert when a feed select code is present and the weight of the insert does not cause the total weight of the mailpiece to exceed its current weight b...

Page 177: ...the drop down Feeder Objects 3 In the Feed Mode field select the desired feed mode from the drop down list Note Backup feed mode requires additional setup If you select this mode refer to the Backup...

Page 178: ...paper travels of the primary feeder In this example the following feeders are assigned l Feeder 3 is the primary feeder and set in backup mode l Feeder 2 downstream is set to back up Feeder 3 l When F...

Page 179: ...feeder 1 Log in as Key Operator access level or higher 2 Click the desired Feeder object on the main DC screen and select Setup from the drop down Feeder Objects Operator Adjustments Pitney Bowes Epi...

Page 180: ...a In the Feed mode field select Backup from the drop down list b In the Backup for field select the feeder to use as a backup from the drop down list 4 Click OK Operator Adjustments Pitney Bowes Epic...

Page 181: ...events the pushers from hitting or opening the envelope flap To adjust the transport envelope setup 1 Log in as Key Operator access level or higher 2 Click the desired Feeder object on the main DC scr...

Page 182: ...the beginning of a job or if you see continued issue with feeding inserts during a job 1 Visually inspect the insert material you are loading into the friction feeders If you find twisted or compromi...

Page 183: ...this option they are separated without stopping before the lead edge reaches the nips l Twisted Return Envelopes this setting can help if you are having trouble feeding badly twisted envelopes when s...

Page 184: ...If the first piece is a double then all single pieces will be reported as too thin and recalibration is necessary If the double detect feature needs to be calibrated 1 Log in as Operator 2 Click the...

Page 185: ...gap between the upper and lower O ring belts at the entrance of the buffer OR l The upper O rings are even with the bottom of the upper P2L idler rollers O ring Even with Bottom of Upper P2L Idler Rol...

Page 186: ...belts In most cases once they are set these belts do not need to be adjusted 1 Locate the adjustment screw 2 Using the 3 16 operator setup tool turn the screw as needed to raise or lower to achieve co...

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Page 188: ...6 Job Changeover Guidelines In this section Job Changeover Guidelines 182 Auto Adjustments Engine and Chassis 185 Manually Adjusting Engine and Chassis Auto Settings 187...

Page 189: ...eover Some of these adjustments the system performs automatically and some an operator performs manually Refer to the Operator Adjustments chapter in this guide for detailed procedures auto adjust x m...

Page 190: ...ntrol Straps x x Buffer Chassis Side Guides Center Deck Nip Rollers Friction Feeder Side Guides x Pack Control Ramp x Separator x Feeder Setup GUI Screen x Rotary Feeder Suction Cups x Deck x Deck Ang...

Page 191: ...e or thickness Control Document changes length width thickness O ring Belt Height x Vertical Stacker Side Guide Adjustment x Flat Stacker x On Edge Stacker OES Entrance Setup x DC Load Mode x x x Job...

Page 192: ...e Engine Setup screen Horns Settings The horns adjust to be centered on the envelope The width of the horns uses the widest measurement of either the envelope or material on the chassis The horn width...

Page 193: ...s are adjusted to the width of the largest document from either the input or the insert feeder for the collation The side guides can be manually adjusted for guide width and center offset in the Chass...

Page 194: ...adjustments using the Engine Setup and Chassis Setup screens which can both be accessed by clicking on their associated objects on the main DC screen Item Description 1 Engine Object 2 Chassis Object...

Page 195: ...ket select Close to move the slider towards 9 to widen the pocket select Open to move the slider towards 9 l Pocket Center Offset to move the pocket to the left select Left to move the slider towards...

Page 196: ...the settings in the mode the changed field turns yellow to indicate a change has been made Changes made here are temporary unless saved to mode l Clicking Zero returns the adjustable axis to its defa...

Page 197: ...Chassis Settings 1 Click the Chassis object on the main DC main screen and select Side Guide Setup from the drop down list Job Changeover Guidelines Pitney Bowes Epic v3 1 ZVE0 Operator Guide May 2018...

Page 198: ...t 1 0 To move the guides farther away from each other move the slider to the right 1 0 All Guides Center Offset To move the center of the guides away from operator side to the left click Left to move...

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Page 200: ...Reloading the Envelope Feeder 196 Loading the Insert Feeders 199 Loading the Booklet Feeder 200 Reloading Insert Feeders with the system is running 201 Removing Finished Mail from the On Edge Stacker...

Page 201: ...ddle and slide it down toward the right side of the feeder facing it 2 Place envelopes in the feeder flap side down with the flap facing out to the right Envelopes Positioned in the Feeder 3 Verify th...

Page 202: ...eder paddle into position at the end of the stack Do not drop the paddle Lower the Envelope Feeder Paddle Caution Do not drop the paddle Running the System Pitney Bowes Epic v3 1 ZVE0 Operator Guide M...

Page 203: ...creen At this point when the operator adds more envelopes to the feeder the system will continue to run and the warning message turns off Follow these steps to reload envelopes while the inserter is r...

Page 204: ...cing to the right Item Description 1 Paddle 2 Envelopes to right of paddle Add Envelopes 2 Lift up the feeder paddle and slide it over to the end of the envelope stack Slide Feeder Paddle Over Running...

Page 205: ...3 Lower the feeder paddle into position at the end of the stack Do not drop the paddle Lower the Paddle Running the System Pitney Bowes Epic v3 1 ZVE0 Operator Guide May 2018 Page 198 of 328...

Page 206: ...of material and place it on top of the single piece 3 Continue this until the stack is just about even with the top of the pack control ramp and then stack to desired height Stack the Feeder do not sh...

Page 207: ...belts Booklet Flat on Feeder Belts 2 Shingle a few more booklets and place them on top of the first booklet 3 Continue to stack the booklets until the feeder is about halfway full Running the System P...

Page 208: ...without shingling the material if the feeder is still filled above the pack control ramp 2 If the feeder is low or empty refer to the Loading Insert Feeders topic Low Material Level Running the Syste...

Page 209: ...the stacker conveyer belt and it also pivots up vertically When finished mailpieces reach the stacker belt the paddle will slowly move down the conveyor belt allowing more mail to be stacked on the be...

Page 210: ...t the paddle Item Description 1 Paddle 2 Raise and slide the paddle in this direction Move Paddle 2 Lift the paddle with your right hand 3 Slide the paddle to the left for a distance equal to the amou...

Page 211: ...hree quarters full with a message on the bottom of the main DC screen in the alarm message box When the paddle reaches the switch located on the stacker the machine will come to a controlled stop and...

Page 212: ...tical stacker onto the conveyor As more mail is processed the conveyor transfers the finished material out from the under the vertical stacker To manually remove the mailpieces from the conveyor 1 Pre...

Page 213: ...brush detects no water flow and the system stops 1 Fill a container that has a funnel or spout with fluid 2 Open the sealer reservoir cover 3 Carefully pour water into the reservoir do not overfill t...

Page 214: ...cess water is present The water from this tank may evaporate faster than it accumulates and never require emptying Overflow Reservoir Note Do not reuse water emptied from the overflow reservoir to fil...

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Page 216: ...ial Jams in the Friction Feeder 221 Removing Material Jams in the Rotary Feeder 224 Removing Material Jams in the Booklet Feeder 227 Removing Material Jams in the Engine 231 Removing Material Jams in...

Page 217: ...mation on how to view resolve and clear them Material Jams Material jams can be caused by things liked blocked photocells paper dust worn belts poor material condition etc When a material jam occurs i...

Page 218: ...ds out of ink interlock open scanner errors can cause alarms Also material jams can show up as alarms An alarm causes the machine to stop running In this section learn how to l View alarm details l Re...

Page 219: ...double click it or click View The Alarm History window opens This window has information about where the error occurred Device error details Information and a suggested course of action Suggestion Ite...

Page 220: ...ck Clear on the Alarm message box at the bottom of the screen to clear the alarm 4 Click Start on the main DC main screen to start running again 5 If the error still occurs repeat the error recovery p...

Page 221: ...select History from the drop down menu The Alarm History dialog opens Alarm Icon Alarm History Alarms with a stop sign next to them indicate events that stopped the inserter 2 To view details about a...

Page 222: ...This image shows an inserter without a booklet feeder If a booklet feeder was installed here only the front side covers would pivot up to help you gain access to the buffer and dump station Item Desc...

Page 223: ...escription 1 Folder Cover Buffer Entrance 2 Left Buffer Cover 3 Right Buffer Cover 4 Bulk Load Hopper Booklet Feeder Option Error Recovery Pitney Bowes Epic v3 1 ZVE0 Operator Guide May 2018 Page 216...

Page 224: ...cated 3 Lift up on the nip levers blue handle above the nip to remove material located under the nip Nip Levers 4 Once the material is removed lower nip arm 5 Close the cover Note When you remove a ja...

Page 225: ...Pull the dump station latch toward you approximately 1 25 mm 4 Lift up on the dump station 5 To close the dump station push down on the dump station cross brace to lower the unit 6 Press the dump stat...

Page 226: ...g up and away on the side guide The feeder pivots up and away allowing access to the bottom of feeder and chassis deck area Raise the Feeder Material Access Caution Do not press on the LED lens cover...

Page 227: ...4 Lower the feeder down being cautious not to allow feeder to drop onto deck 5 Close any opened front feeder covers Error Recovery Pitney Bowes Epic v3 1 ZVE0 Operator Guide May 2018 Page 220 of 328...

Page 228: ...ont feeder cover where the indicator light is flashing 2 Raise the feeder by pushing up and away on the side guide The feeder pivots allowing access to the bottom of feeder and chassis deck area DO NO...

Page 229: ...ate the separator bridge to the left while continuing to pull on the two locking knobs away from you and lift the friction feeder separator bridge Rotate Knob Lift Separator Bridge 3 Release the locki...

Page 230: ...while holding the knob out Transport Knob 4 Remove the jam 5 Close the transport make sure it locks in the closed position Be sure the knob is pushed all the way in towards the non operator side of t...

Page 231: ...ial Jams in the Rotary Feeder There are two areas in the rotary feeders where material jams may occur l Feeder deck l Feeder drums Error Recovery Pitney Bowes Epic v3 1 ZVE0 Operator Guide May 2018 Pa...

Page 232: ...Lift Feeder Feeder Pivots Giving Access to Jammed Material Caution Do not press on the LED cover when lifitng the feeder 3 Remove the jammed material 4 Lower the feeder down being cautious not to allo...

Page 233: ...s the Cycle button on the feeder so the drum rotates and feeds damaged insert to the deck Cycle Button 2 Open the feeder deck door 3 Clear the piece from the deck Error Recovery Pitney Bowes Epic v3 1...

Page 234: ...ay encounter material jams in the mid or exit areas of the booklet feeder Mid Area 1 Open the Booklet Feeders top and chassis access doors Booklet Feeder Access Doors Error Recovery Pitney Bowes Epic...

Page 235: ...t put one finger behind the roller and lift it Center Blue Roller Booklet Feeder 3 With the roller up slide the booklet out towards you and release the blue roller 4 Close the covers Error Recovery Pi...

Page 236: ...er 2 Locate the exit roller pivot latch and press it down to raise the blue rollers this removes pressure off the booklet Exit Roller Pivot Latch 3 With the rollers up slide out the booklet out toward...

Page 237: ...4 Release the exit roller pivot latch 5 Close the cover Error Recovery Pitney Bowes Epic v3 1 ZVE0 Operator Guide May 2018 Page 230 of 328...

Page 238: ...ms in the Engine The several areas in the engine where material jams may occur l Upper engine l Engine exit l Arming area l Lower engine Error Recovery Pitney Bowes Epic v3 1 ZVE0 Operator Guide May 2...

Page 239: ...per engine handle and lift up for access to the insertion area Lift Upper Engine Handle Upper Engine Raised 3 Remove the jam 4 Close the engine handle 5 Close the cover Error Recovery Pitney Bowes Epi...

Page 240: ...jam by pulling the edge of the envelope and sliding it out toward the engine exit This releases the rollers Pull the Envelope Toward the Engine Exit 3 Close the cover Error Recovery Pitney Bowes Epic...

Page 241: ...the upper engine Lift Upper Engine 2 Lift the arming area Lift Arming Area 3 Remove the jam 4 Lower the upper engine it will press down and close the arming area Error Recovery Pitney Bowes Epic v3 1...

Page 242: ...s Engine Deck Buttons 2 Remove the jam 3 Press and hold both buttons until the lower engine is completely closed If you release the buttons before the engine is fully closed the engine will drop back...

Page 243: ...be up to two envelopes in the lower engine that need to be removed whenever the lower pocket is opened Arrows in this image indicate location Pocket Envelope and Flapper Envelope Error Recovery Pitney...

Page 244: ...pe feeder where material jams may occur l Envelope transport l Envelope separator Envelope Transport 1 Pull down on the envelope feeder transport handle and to push it open Envelope Feeder Handle Erro...

Page 245: ...3 Grasp and press the feeder transport handle upwards to close Caution Pinch Point The feeder handle snaps shut keep hands away from the inside when closing Error Recovery Pitney Bowes Epic v3 1 ZVE0...

Page 246: ...n the separator roller The separator is spring loaded so hold the lever with one hand and reach in with the other hand Separator Lever 2 Remove the jam 3 Release the lever to engage the separator Erro...

Page 247: ...r to open the sealer cover 1 Pull up on the interlocked handles to lift the cover Item Description 1 Sealer Cover Handle 2 Vertical Stacker 1 Cover Handle Cover Handles 2 Remove the jam 3 Realign any...

Page 248: ...Removing Material Jams in the Turnover 1 Lift the turnover cover Cover Opened 2 Remove the jam 3 Close the cover Error Recovery Pitney Bowes Epic v3 1 ZVE0 Operator Guide May 2018 Page 241 of 328...

Page 249: ...ile the covers are open Use caution when removing jams in this area 1 Lift the vertical stacker covers 2 Hold the cover up while accessing the area Vertical Stacker Cover 3 Remove the jam 4 Lower the...

Page 250: ...l open the latch on the On Edge Stacker door On Edge Stacker Latch 2 Remove the jam 3 Close the door Note Be careful not to accidentally pull the belts off the pulleys Error Recovery Pitney Bowes Epic...

Page 251: ...r 1 Press and hold the button at the end of the flat conveyor to start the belt and move the material out from under the vertical stacker Flat Conveyor Button Error Recovery Pitney Bowes Epic v3 1 ZVE...

Page 252: ...vertical stacker on the flat conveyor deck lift the foam roller by the handle to gain access to the jammed mailpieces Foam Roller Down Lifting the Foam Roller Error Recovery Pitney Bowes Epic v3 1 ZV...

Page 253: ...Foam Roller Raised for Jam Removal Error Recovery Pitney Bowes Epic v3 1 ZVE0 Operator Guide May 2018 Page 246 of 328...

Page 254: ...9 Troubleshooting In this section Troubleshooting 248 Engine Troubleshooting 249 Chassis Troubleshooting 252 Buffer Troubleshooting 258...

Page 255: ...hooting activities operators can perform to try and resolve system issues and stoppages This includes things like material jamming double feeds material skew etc Troubleshooting Pitney Bowes Epic v3 1...

Page 256: ...l Jams Improper envelope length set in DC Enter proper envelope length Fence rollers not adjusted to envelope height Adjust the fence rollers Separator too tight Adjust the separator Dust or debris in...

Page 257: ...just tongue Observation guide alignment Check observation side guide setup Bad or improper fold Folder Setup Chassis side guides Observation side guides Envelope side seam damage Horns set too wide fo...

Page 258: ...guide alignment Check observation side guide setup Flap not Sealed Incorrect backwall setting Engine setup Not enough fluid applied to flap Adjust sealer fluid On Edge Stacker OES Issue Cause Resoluti...

Page 259: ...rect width for the collation Side Guides Not adjusting to proper size Check material dimensions check if there any side guide offsets In DC click Chassis Setup and make sure Enable Automatic Setup is...

Page 260: ...rd skewing side Side guide Set side guide close 1 mm space on each side Belt contamination Clean belts and feed rollers with denatured alcohol L 6079 Excessive delays or Out of material errors Ramp Lo...

Page 261: ...ge of the material is at the font wall Fail to feed Material orientation Curl up if applicable Material is not at the pins backstop side guides may be too tight or deck angle Loosen guides or reduce d...

Page 262: ...entation Folded closed and first curl up BRE flap up and leading Perfume flap up Lead edge is poorly justfied Tamp lead edges even prior to loading Material is pinched at separation pins Increase deck...

Page 263: ...up Booklet too flimsy Turn inner pins fully in Fail to feed Material orientation Closed end first curl up Lead edge is poorly justified Tamp lead edges even prior to loading Backstop side guides set...

Page 264: ...t Side guide Set side guide close 1 mm space on each side make sure side guides are straight and not toed in at the bottom Belt contamination Clean belts and feed rollers with denatured alcohol L 6079...

Page 265: ...e deck height is properly adjusted to the folder O ring belts Check the height off the deck of the belts be sure that all O ring belts are properly aligned and on the pulleys Fold plates Check fold qu...

Page 266: ...section Operator Maintenance 260 Replacing Suction Cups in the Engine 262 Buffer Maintenance 266 Rotary Feeder Maintenance 267 Friction Feeder Maintenance 268 Vertical Stacker Maintenance 269 On Edge...

Page 267: ...es from the system before performing any maintenance activity l Use an industrial vacuum cleaner equipped with a non metallic tip to remove paper dust and debris from the system Overall System Mainten...

Page 268: ...on Feeder l Rotary Feeder l Engine l Vertical Stacker l On Edge Stacker Note Any required maintenance activities for the input modules not included here can be found in either the associated operator...

Page 269: ...suction cups are worn or cracked you will need to replace them Replacing Insert Suction Cups Upper Platform 1 Lift the top engine cover 2 Lift the upper engine handle to access the upper insertion ar...

Page 270: ...eplace the suction cup by aligning the hole in the suction cup with the suction cup adapter and then gently push the suction up onto the adapter You may have to hold the adapter while pushing the suct...

Page 271: ...ect and select Feeder Cup Out from the drop down menu Feeder Objects 2 Remove the envelopes away from the feed head 3 Reach in and grasp the suction cup and pull it to your right until it pops off Mai...

Page 272: ...s the new suction cup in place until it is fully seated just below the surface of the deck 5 In the dialog click Feeder Cup In Maintenance Pitney Bowes Epic v3 1 ZVE0 Operator Guide May 2018 Page 265...

Page 273: ...l Clean cloths l Shop air Cleaning Covers and Clearing the Paper Path 1 Wipe down the top buffer covers with PB approved cleaner polycarbonate cover cleaner 902 F 2 Open the top buffer covers 3 Use l...

Page 274: ...aced 1 Remove material from the hopper 2 Remove inspect and replace suction cups if damaged 3 Use low pressure shop air to blow dust and debris out of the paper path and remove any toner buildup on th...

Page 275: ...shell 5 Pull out on the two spring latches and pivot the one attached to the bridge assembly up to open the bridge remove any material if present 6 Use the shop air with the blower attachment to blow...

Page 276: ...hs l Shop air Cleaning Stacker Cover and Clearing Paper Path 1 Lift the vertical stacker cover 2 Inspect the deck and rollers for glue buildup and toner wipe down with damp clean cloth and soapy water...

Page 277: ...air Clearing Paper Path and Cleaning Components 1 Open both On Edge Stacker doors 2 Use the shop air with the blower attachment to blow dust and debris out of the paper path 3 Wipe down the rollers wi...

Page 278: ...554 296 Epic Rotary Feeder Y558 300 Epic Universal Friction Feeder ZVF1 305 Epic P2L Buffer with TNT ZVB2 309 Epic Turnover Y370 312 Epic V Bin Y31E Y31F Y31G Y31H 314 Epic On Edge Stacker Y396 317 Ep...

Page 279: ...ate to maintain an optimum material handling for all size and thickness During chassis stops acceleration and de acceleration the paper is stopped while under a nip reducing the dependence on straps t...

Page 280: ...ZV10 B 3 3 4 E 12 station ZV12 B 4 4 4 E 14 station ZV14 B 3 3 4 4 E 16 station ZV16 B 4 4 4 4 E 18 station ZV18 B 3 3 4 4 4 E 20 station ZV20 B 4 4 4 4 4 E 21 station ZV21 B 3 3 3 4 4 4 E B Buffer E...

Page 281: ...0gm sq m 28 lb bond 100 gm sq m Perforation Strength 6 lbs linear inches n a Document Dimensions when supplied from the input General Paper Requirements These material guidelines are recommended to ac...

Page 282: ...packaging improper handling and storage as well as temperature and humidity extremes These problems can originate at the time of envelope manufacture during finished goods transit or develop as the r...

Page 283: ...ximately 2 500 letter envelopes or 1 000 flat envelopes l Vacuum valve and Servo feed head mechanism to feed and separate the envelopes l Envelope feed assist l Transport and Servo flapper device to d...

Page 284: ...ity The seal quality is highly material dependent If further characterization is needed sample material application details and detail on the MOS configuration will have to be provided to the team in...

Page 285: ...12 7 mm total collation 120 sheets uncompressed 24lb 90 gsm total collation Prime Doc Size Depth 3 5 89 mm 6 25 158 mm 9 5 241 mm Width 7 0 178 mm 11 279 4 mm 12 0 305 mm Thickness 18 lb 70 gsm 28 lb...

Page 286: ...is 8 stage TNT buffer is 6 5 SCFM System Air Consumption Case 1 Case 2 10 21K SCFM subset flats at 7 2K SCFM Engine 6 44 2 98 21 station chassis 0 10 0 292 8 stage TNT buffer 0 001 0 159 Engine chassi...

Page 287: ...ngle 17 V Bin rear Y31G Epic Flats ZX29 Dual 17 V Bin rear Y31H Engine Light Tower Y56L 17 V Bin Meter Combo Y31J TNT and P2L Buffer ZBV2 Print Messenger Color Y360 Engine Scan Y55E Print Messenger Mo...

Page 288: ...l or twist should not exceed 25 6 4 mm when the envelope is placed on a flat surface l The envelope throat should be a maximum of 25 6 4 mm below the crease line at 75 19 mm from the side edges Envelo...

Page 289: ...83 221 2 8 71 ZVE0 Engine Horn Matrix End Clearance End clearance is the difference between the dimension of the largest insert and the length of the envelope when measured with all inserts in the en...

Page 290: ...Diagonal Seam Envelopes Letter Mode Specifications Pitney Bowes Epic v3 1 ZVE0 Operator Guide May 2018 Page 283 of 328...

Page 291: ...Diagonal Seam Envelopes Flats Mode Specifications Pitney Bowes Epic v3 1 ZVE0 Operator Guide May 2018 Page 284 of 328...

Page 292: ...part of the side of the patch material is within 1 0 25 mm from any envelope side edge the following applies o If the top of the patch material falls within 375 9 6 mm of the crease score line the pa...

Page 293: ...Executive Envelopes Letter Mode Specifications Pitney Bowes Epic v3 1 ZVE0 Operator Guide May 2018 Page 286 of 328...

Page 294: ...Executive Envelopes Flat Mode Specifications Pitney Bowes Epic v3 1 ZVE0 Operator Guide May 2018 Page 287 of 328...

Page 295: ...velope s front panel then the envelope must be tested l In those cases where any part of the side of the patch material is within 1 0 25 mm from any envelope side edge the following applies o If the t...

Page 296: ...l For speeds higher than 18 5K or 10 or DL envelopes a truncated flaps is required see specifications indicated here Specifications Pitney Bowes Epic v3 1 ZVE0 Operator Guide May 2018 Page 289 of 328...

Page 297: ...Side Seam Envelopes Letter Mode Specifications Pitney Bowes Epic v3 1 ZVE0 Operator Guide May 2018 Page 290 of 328...

Page 298: ...Side Seam Envelopes Flats Mode Specifications Pitney Bowes Epic v3 1 ZVE0 Operator Guide May 2018 Page 291 of 328...

Page 299: ...m the side edges This is required to prevent the throat openers from tearing the patch l Envelope curl or twist should not exceed 25 6 4 mm when envelope is placed on a flat surface l In open window e...

Page 300: ...a minimum of 25 6 4 mm larger than the opening on all sides The glue line should be no more than 125 3 2 mm from the inside of the opening on all sides All window patches should be flat ripple free an...

Page 301: ...quirements can be reviewed by PB Engineering to determine the ability of a particular envelope to run Mailpiece The mailpiece l Is measured with the maximum collation size inserted into the envelope a...

Page 302: ...2 2 50 44 21K 10 4 10 105 9 500 241 1 25 32 2 50 44 21K ISO DL 4 30 110 8 7 220 1 25 32 2 50 44 21K C6 5 4 50 114 9 0 229 2 25 57 2 75 70 21K 14 5 00 127 11 5 292 1 25 32 2 50 44 19K 6 x 9 6 00 152 9...

Page 303: ...d Features l Servo controlled l Double detection and Fail to Feed detection l Easy operator setup for material changeover l Backup feeding option standard Cycling Speed Enclosure Length Depth Cycling...

Page 304: ...fications Folded Enclosure Specifications l Folds that result in an even overall thickness of enclosure will give the best feeding performance l Folds that are made parallel to the paper grain directi...

Page 305: ...l Die cut envelope must be fed with window down flap leading Die Cuts l Die cut holes with and without windows are allowed as long as there is an area under the hole that is not die cut l Die cut pre...

Page 306: ...n Curled Edges Banding l Bands should be loose enough to prevent scoring or creasing the paper l Paper bands are preferred to rubber bands l Cardboard chips at the top and bottom of each banded stack...

Page 307: ...uble detection and Fail to Feed detection l Easy operator setup for material changeover l Backup feeding option standard Cycling Speed Enclosure Length Depth Cycling Speed Max MPS Epic 4 102 mm 26K 21...

Page 308: ...enclosure is placed on a flat surface Folded Enclosure Specifications l Folds that result in an even overall thickness of enclosure will give the best feeding performance l Folds that are made paralle...

Page 309: ...envelopes are allowed Overall thickness may not be more that 50 greater in the center than at the leading edge i e if leading edge is two paper thicknesses center can not be more that three thickness...

Page 310: ...uneven stacking can result in unacceptable edge curl Uneven stacking with offset edges can result in unacceptabe curl see diagram Stacking with Offset Edges Results in Curled Edges Banding l Bands sho...

Page 311: ...s The Rotary Feeder can be configured with these scanning options Option PCN Moving Beam Scanner Y556 Area Scan Camera Y55A Specifications Pitney Bowes Epic v3 1 ZVE0 Operator Guide May 2018 Page 304...

Page 312: ...position and in this position it comes with an extended feed hopper located over the top of the buffer additional loading capacity l Can be mounted in any other chassis position but without extended...

Page 313: ...ineering Group in Danbury if an application falls outside the specifications Folded Enclosures Specifications l Folds should be sharply creased flat and free of edge curl Curl at Fold l Folds must not...

Page 314: ...h a backing sheet are allowed l Die cut labels without a backing sheet such as remoistenable adhesive stickers are not allowed Glue l Any enclosure with glued features must not allow stray glue to att...

Page 315: ...ring or creasing the paper l Paper bands are preferred to rubber bands l Cardboard chips at the top and bottom of each banded stack greatly reduce the chance of enclosure damage and allow for tighter...

Page 316: ...s job setup is done through the Direct Connect operating system The module operates at 21 000 cycles per hour tri fold 18 000 cycles per hour in half fold mode and 14 000 cycles per hour in flat mode...

Page 317: ...ore rotation 7 179 mm 9 229 mm Thickness Single sheet 10 sheets 20 lb 80 gsm Folded TNT Active or Pass Thru Minimum Maximum Paper Length before rotation 3 5 89 mm 6 5 165 mm Paper Width trimmed before...

Page 318: ...195 cm l Width 34 86 cm l Height 50 4 128 cm l Heat Dissipation 1260 watts 4300 BTU Hr l Weight 520 lbs 234 kg l Air Consumption 0 3 SCFM when in P2L mode Specifications Pitney Bowes Epic v3 1 ZVE0 Op...

Page 319: ...output modules The turnover contains all the necessary connections to integrate to the Epic sealer or adjacent V Bin modules It also handles the entire range of Epic folded material and handles flats...

Page 320: ...cs Thickness 10 C5 C6 single sheet 14 sheets 4 3 mm Thickness 6x9 5 C5 single sheet 24 sheets 5 mm Thickness 9x12 C4 single sheet 50 sheets Thickness 10x13 custom C4 single sheet 70 sheets Physical Ch...

Page 321: ...stified face up post Turnover configurations Available Modules Pre Turnover l Y31E Single V Bin Front Justified l Y31F Dual V Bin Front Justified Post Turnover l Y31G Single V Bin Rear Justified l Y31...

Page 322: ...speed l Mail tray for outsorted mail pieces Material Specifications The Epic V Bins can handle the entire range of folded and flat materials of an Epic Physical Characteristics Single Dual Length 17...

Page 323: ...er Y32S Output Area Scan Top Y55FT Output Area Scan Bottom Y55FB Output Line Scan Top Y55LT Output Line Scan Bottom Y55LB Manual Hand Feed OSSO Y55FT image on left and Manual Hand Feed image on right...

Page 324: ...n Edge Stacker is configured standard with a sliding drawer just under the belt stacker where mail trays can be placed for fast and easy unloading from either side of the stacker The main components o...

Page 325: ...by tray zip code or count breaks l Available in one configuration Y396 On Edge Stacker Epic Standard Features l 7 2 1 m conveyor belt holds approximately 750 1000 10 envelopes C6 5 stacker two gate t...

Page 326: ...s l 1 The On Edge Stacker will not process stepped mail applications such as CDs DDA check applications license plates or credit cards l 2 Envelopes with external side seams require the External Side...

Page 327: ...n The Shingling Stacker is comes standard with a system clear button which helps to clear all envelopes from the belt for easy unloading Standard Features l 78 0 2 m conveyor belt stacker l Sponge rol...

Page 328: ...arkers Described by PCN Y367F Front Edge Markers 1st Position l Located in the engine prior to the first output V Bin or turnover l Includes two edge markers on the same side Y368F Front Edge Markers...

Page 329: ...Y367F and or Y367B This adds back rear edge markers to one of the other sets for a total of four edge markers refer to the image here to see the four markers Specifications Pitney Bowes Epic v3 1 ZVE...

Page 330: ...t bulb l Shipping refers to product prepared for shipping All requirements assume that the equipment is drained of all the aqueous liquids and any device with an open sump l Include condensation exclu...

Page 331: ...eptacle Hubbell 8450A or equivalent l Export 3 phase 230VAC or 240VAC phase to neutral 400 VAC or 415 VAC phase to phase 50Hz 50 amps per phase L1 L2 L3 N Earth l Power plug for 5 wire export connecti...

Page 332: ...Power Requirements l Powered on and at idle approximately 8 amps 1 614KVA BTUs l Heat Dissipation 2000 watts 7825 BTU hr Specifications Pitney Bowes Epic v3 1 ZVE0 Operator Guide May 2018 Page 325 of...

Page 333: ...resently released PB air compressor satisfies the requirements of the Epic inserting system The recommended vendor will provide the equipment and service required to maintain a compressed air system t...

Page 334: ...nce at the appropriate intervals has been performed Every 100M cycles a detailed mechanical inspection of the system must be done to identify any potential breakdowns This audit could identify parts r...

Page 335: ...This page intentionally left blank...

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Pitney Bowes Epic v3.1, Operator'S Manual

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