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Operator Maintenance

There are a few routine inspection and maintenance activities operators need to perform daily to keep
the system operating at peak performance. These simple procedures help make sure that your
equipment is clean and free of debris.

Since a single list cannot address all applications and conditions, it is important to communicate with your
Pitney Bowes Customer Service Representative to develop a maintenance program for your system.

Safety Precautions

Before performing maintenance on any equipment, follow these safety precautions:

l

Remove all material and envelopes 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 Maintenance

Perform these system maintenance activities at every shift:

l

Remove dust and debris from the entire machine, either via air or vacuum

(the vacuum tip must be

non-metallic)

Note:

Follow eye safety protection policies in place at your site.

l

Refill the sealer brush reservoir bottle

l

Inspect suction cups and replace if necessary

l

Clean and ink the edge markers and mail machines (if equipped)

l

Clean system covers

(use only the approved cleaner - 902-F Polycarbonate cleaner - for top clear

Plexiglas covers)

Maintenance

Pitney Bowes

Epic Select Operator Guide

December, 2017

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Summary of Contents for Epic

Page 1: ...Shipping Mailing Inserting Epic Select Inserting System Operator Guide US English Edition SV63276 RevA December 10 2017 ...

Page 2: ...itute 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 accuracy and usefulness of this manual However we cannot assume responsibility for errors or omissions or liability for the misuse or misapplication of our products Except as provided in writing duly ...

Page 3: ...rt Number Release Date Comments SV63276 RevA December 10 2017 Initial release Related Documentation l HPI Pinless Cutter Y484 Y485 Operator Guide OG AF INPU 102006 l HPI Accumulator Y470 Operator Guide OG ADFS INPU 031005 l HPI RAT FIM Y47EWP Operator Guide SV63088 l Print Messenger Digital Inkjet System Operator Guide OG_APF_PRINT_020111 l Hunkeler UW6 Unwinding Module Operator Guide OG Hunk Unwi...

Page 4: ...essing Reports in DC 41 Starting and Stopping the Inserter Using DC 42 Assigning an MRDF File File Based Jobs 43 Disabling and Enabling the Inserter 44 Clear Deck Function 45 About the Speed Indicators in DC 47 About the DC Alarm Message Box 48 5 Operator Adjustments Operator Adjustments 51 Adjusting the Envelope Feeder Separator Gap 52 Adjusting the Envelope Fence 55 Adjusting the Suction Cups in...

Page 5: ...g the Wedge Accessory on the Rotary Feeder 136 Using the Jog Function on the Rotary Feeder 138 Insert Feeder Software Adjustments 142 Enabling and Disabling Feeders 143 Document Information 144 Setting Feeder Feed Modes 148 Setting Backup Feeders Backup Feed Mode 150 Transport Envelope Setup Xport Setup 153 Setting Separator Options for Friction Feeders 154 Recalibrating the Double Detect Feature ...

Page 6: ...234 Buffer Maintenance 239 Rotary Feeder Maintenance 240 Friction Feeder Maintenance 241 Vertical Stacker Maintenance 242 On Edge Stacker Maintenance 243 11 Specifications Epic Select Engine ZVE2 246 Envelope Specifications 251 MPS Epic Friction Feeder Y554 263 Epic Rotary Feeder Y558 267 Epic Buffer with TNT Y574 272 Epic Turnover Y371 275 Epic V Bin Y31E Y31F Y31G Y31H 277 Epic On Edge Stacker Y...

Page 7: ...1 Safety In this section Safety Information 2 Power 3 Operation 4 Maintenance 5 Warning Labels and Cautions 6 Safety Features 10 ...

Page 8: ... 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 area when dealing with ear protection Factors such as floor noise length of exposure to noise loss of hearing history in individual employees can all play a role in requirements Analyze your specific ...

Page 9: ... 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 there is no strain on the power cord where it becomes jammed between the equipment walls or furniture l Be certain the area in front of the wall receptacle into which the machine is plugged is free from...

Page 10: ...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 parts to stop moving before placing hands near paper path l Avoid touching moving parts or materials while the machine is in use Before clearing a jam be sure machine mechanisms come to a stop l When r...

Page 11: ...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 i e coffee cups soda etc l Do not use flammable cleaners in this machine l Do not use aerosol air canisters It is recommended that a vacuum cleaner be used to remove dust and debris from the machine ...

Page 12: ...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 cover open Caution Hand Entanglement Moving belts use caution Keep hands clear during operation Caution Rotating Roller Hazard Moving rollers use caution Keep hands clear of this area during operation ...

Page 13: ...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 Capacitor Discharge Allow six minutes for motor capacitors to discharge before servicing motor driver module Safety Pitney Bowes Epic Select Operator Guide December 2017 Page 7 of 288 ...

Page 14: ... 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 clear during operation Caution Sharp Point Caution sharp points Use care when working in this area keep hands clear during operation Safety Pitney Bowes Epic Select Operator Guide December 2017 Page 8 of...

Page 15: ...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 in this area Caution Entanglement in Feeder Belts Feeder belts are moving when material is transported Keep loose clothing jewelry and hair away during operation to prevent potential injury Caution Pin...

Page 16: ...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 potential of causing injury or machine damage ESTOP Switch red There is an ESTOP icon on the Direct Connect main screen that indicates there is an ESTOP or interlock open prohibiting the machine from starti...

Page 17: ...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 system will immediately stop in the interlock area while bringing the rest of the system to a controlled stop The inserter will not start until that cover is closed and the interlock safety connectio...

Page 18: ...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 Rotary Feeder Interlock Switch gray Safety Pitney Bowes Epic Select Operator Guide December 2017 Page 12 of 288 ...

Page 19: ...2 Product Overview In this section Epic Select Inserting System 14 Component Overview 17 Indicator Lights 19 About the Remote Control 20 ...

Page 20: ...onal mailpieces per hour depending on the application and configurations of the inserter The system process tri fold C fold and half folds material and is controlled by Direct Connect DC software Epic Select Inserting System Product Overview Pitney Bowes Epic Select Operator Guide December 2017 Page 14 of 288 ...

Page 21: ...lation thickness 0 32 8 mm uncompressed at insertion Minimum Maximum Depth 3 5 inch 89 mm 6 25 inch 158 mm Width 5 5 inch 140 mm 11 inch 279 4 mm Paper Width 16 lb bond 60gm sq m 28 lb bond 100 gm sq m Paper Weight 6 lbs linear inches n a Document Dimensions no input Minimum Maximum Depth 3 5 inch 89 mm 6 25 inch 158 mm Width 7 inch 177 mm 11 inch 279 4 mm Paper Weight 18 lb bond 70gm sq m 28 lb b...

Page 22: ...ature range of 65 85 l Material should be stored within a range of 40 60 relative humidity Paper Curl These paper curl guidelines apply to 8 5 width paper Curl Direction Toward Image Away from Image Short Direction Under 10 mm Under 5 mm Long Direction Under 20 mm Under 15 mm NOTE Diagonal Curl is considered unacceptable Short Direction Curl short edges of the sheet curl Long Direction Curl long e...

Page 23: ... 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 Edge Stacker 6 Envelope Feeder Epic Select System Product Overview Pitney Bowes Epic Select Operator Guide December 2017 Page 17 of 288 ...

Page 24: ...s 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 inside is transported to the sealer There are both manual and automated adjustments in the engine l Sealer This is where the envelope flap is moistened and closed to seal the envelope The sealer module has a built in Vertical Stacker VS1 l Turnover...

Page 25: ... 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 State Meaning OFF Ready to run Slow blink Feeder material low Fast blink Interlock open ON Jam System Indicator Lights System Indicator Lights Product Overview Pitney Bowes Epic Select Operator Guide ...

Page 26: ...ld 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 and running press the Cycle button to feed one sheet at a time l Clear Deck To clear the deck an operating sequence that clears the inserter deck of all mailpieces press the Stop and Cycle buttons at th...

Page 27: ...3 Power the System On and Off In this section Power Up the System 22 Power Down the System 24 ...

Page 28: ...the Direct Connect computer Power Up the Inserter 1 Locate the main power switch on the lower chassis cover left of the first feeder closest to the input and lift it up to the ON position Main Power Switch Power the System On and Off Pitney Bowes Epic Select Operator Guide December 2017 Page 22 of 288 ...

Page 29: ...The Login window opens 2 To log into Windows if the system is connected to a network enter the system password If it is not connected to a network click OK Note Depending on your site the Windows log in may be automatic and you will not be prompted to perform this step 3 Log in to DC Power the System On and Off Pitney Bowes Epic Select Operator Guide December 2017 Page 23 of 288 ...

Page 30: ...th 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 Down window opens click Yes This powers down the DC computer Power the System On and Off Pitney Bowes Epic Select Operator Guide December 2017 Page 24 of 288 ...

Page 31: ...0 seconds before proceeding this gives time for other computers in the system to shut down safely 1 Locate the main power switch on the system on the lower chassis cover left of the first feeder closest to the input and pull it down to the OFF position Main Power Switch Power the System On and Off Pitney Bowes Epic Select Operator Guide December 2017 Page 25 of 288 ...

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Page 33: ...ware Details 34 Logging In and Logging Out of DC 35 Loading a Mode 37 Setting the Mail Date 39 Checking Status with Job Manager 40 Accessing Reports in DC 41 Starting and Stopping the Inserter Using DC 42 Assigning an MRDF File File Based Jobs 43 Disabling and Enabling the Inserter 44 Clear Deck Function 45 About the Speed Indicators in DC 47 About the DC Alarm Message Box 48 ...

Page 34: ...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 Input file also known as the MRDF or mail run data file to control the inserter and provide real time decision making about mail processing A document with a barcode for example a monthly statement is ...

Page 35: ...ontrol certain operations of the system and software through this screen Note Graphics settings data and modes shown here are for reference only and may not match the custom mode settings object icons machine elements or data used for the inserter system in your facility Using Direct Connect Pitney Bowes Epic Select Operator Guide December 2017 Page 29 of 288 ...

Page 36: ...ing major areas Item Description 1 Banner Bar 2 Main Menu Bar 3 Menu Buttons 4 Icons 5 Start Bar 6 Alarm Icon 7 Alarm Message Box 8 Inserter Model Using Direct Connect Pitney Bowes Epic Select Operator Guide December 2017 Page 30 of 288 ...

Page 37: ...t the software l Control select Control to power down the system or change the language displayed on the screen l About select About to access software information that includes version copyright date library name installation date and system identification number Using Direct Connect Pitney Bowes Epic Select Operator Guide December 2017 Page 31 of 288 ...

Page 38: ...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 during the installation process Using Direct Connect Pitney Bowes Epic Select Operator Guide December 2017 Page 32 of 288 ...

Page 39: ... 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 you can only power down the DC computer Using Direct Connect Pitney Bowes Epic Select Operator Guide December 2017 Page 33 of 288 ...

Page 40: ... 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 Using Direct Connect Pitney Bowes Epic Select Operator Guide December 2017 Page 34 of 288 ...

Page 41: ...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 from the drop down menu Note l When no one is logged in the Login button shows a locked padlock icon l When a user is logged in the Login button shows an unlocked padlock icon and the operator s name is ...

Page 42: ...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 alarm screens l View Help dialogs Note Key Operators have the same access operators do and they can get to some additional setup screens Using Direct Connect Pitney Bowes Epic Select Operator Guide Dec...

Page 43: ...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 Mode Before you run a job load the mode 1 Log in to DC 2 Click the Mode button on the main DC screen 3 Select Load Mode from the drop down menu Using Direct Connect Pitney Bowes Epic Select Operator G...

Page 44: ...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 Select Operator Guide December 2017 Page 38 of 288 ...

Page 45: ...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 future 4 Click OK Using Direct Connect Pitney Bowes Epic Select Operator Guide December 2017 Page 39 of 288 ...

Page 46: ...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 the current job the operator etc 3 Click Close to exit Using Direct Connect Pitney Bowes Epic Select Operator Guide December 2017 Page 40 of 288 ...

Page 47: ...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 menus 3 When the folder opens browse through the reports you saved and double click the desired report to view details Note The Direct Reports option is not available at an Operator log in access leve...

Page 48: ... 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 controlled this helps to avoid errors or jams Also when you click Stop the Menu Start and Cycle buttons display again Note You can also start or stop the inserter using the remote control Using Direct Conn...

Page 49: ...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 3 In the Select Mailrun field type in the name of the MRDF file or scan it from the work order 4 When the file name populates the field click OK to open it Using Direct Connect Pitney Bowes Epic Selec...

Page 50: ...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 near the Start bar at the bottom of the screen 2 Select Disable System The inserter stops and cannot be started until it s enabled through DC 3 When you are ready to run the inserter click the Menu bu...

Page 51: ...l wait for abut 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 Once initiated the Clear Deck indicator flashes at the bottom of the screen What Happens When Clear Deck is Initiated l If the machine is running when Clear Deck is initiated all the material in the paper path will be...

Page 52: ...Once initiated the Clear Deck message flashes at the bottom of the screen Using Direct Connect Pitney Bowes Epic Select Operator Guide December 2017 Page 46 of 288 ...

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 per hour shown as 677 here as well as the total number of mailpieces that reached the output stacker shown as 12 here Using Direct Connect Pitney Bowes Epic Select Operator Guide December 2017 Page 47 ...

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 to the Alarm Recovery topic for more detailed information on how to manage DC alarms Using Direct Connect Pitney Bowes Epic Select Operator Guide December 2017 Page 48 of 288 ...

Page 55: ...l Stacker 82 About the On Edge Stacker OES 84 Setting Up the Entrance to the On Edge Stacker 86 Centering Mail on the On Edge Stacker Conveyor Belt 90 Adjusting the Belt Speed and Stack Pressure on the On Edge Stacker 92 Adjusting On Edge Stacker Fingers 96 Adjusting the Engine Observation Side Guides 98 Adjusting the Chassis Side Guides 101 Adjusting the Buffer Chassis Side Guides 105 Adjusting t...

Page 56: ...Rotary Feeder Separator Pins 133 Using the Wedge Accessory on the Rotary Feeder 136 Using the Jog Function on the Rotary Feeder 138 Insert Feeder Software Adjustments 142 Enabling and Disabling Feeders 143 Document Information 144 Setting Feeder Feed Modes 148 Setting Backup Feeders Backup Feed Mode 150 Transport Envelope Setup Xport Setup 153 Setting Separator Options for Friction Feeders 154 Rec...

Page 57: ... Rotary Feeders insert 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 are about to run has material that is a different orientation portrait or landscape size or material thickness than the previous job Some of the adjustments for a job changeover the system makes automatically a...

Page 58: ... 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 stops and hold it in place Pull Back Separator Access Lever Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 52 of 288 ...

Page 59: ...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 separator knob only a few clicks and recheck the settings a If there is too much drag on the envelope open the knob to reduce drag b If there is not enough drag on the envelope close the knob to increase...

Page 60: ...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 Select Operator Guide December 2017 Page 54 of 288 ...

Page 61: ...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 Lever and Use Alignment Arrows 3 When the fence is properly positioned lock it in place Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 55 of 288 ...

Page 62: ...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 deck lines shown here This is where the envelope is staged All adjustments should be made from this position Align Envelope Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Pag...

Page 63: ...5 Close the upper engine Close Upper Engine Envelope Aligned view from above Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 57 of 288 ...

Page 64: ...6 Use the operator setup tool to loosen the three suction cup lockdown screws Suction Cup Lockdown Screws Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 58 of 288 ...

Page 65: ... 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 envelope 10 Lower the upper engine 11 Close the cover Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 59 of 288 ...

Page 66: ...osition 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 envelope flap crease line with the deck lines shown here This is where the envelope is staged All adjustments should be made from this position Envelope Flap Against Insert Ledge Air Operator Adjustments ...

Page 67: ... 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 Select Operator Guide December 2017 Page 61 of 288 ...

Page 68: ...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 engine cover Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 62 of 288 ...

Page 69: ...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 it Tongue Height Lockdown Screw Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 63 of 288 ...

Page 70: ...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 insert area 7 Lower the upper engine 8 Close the engine cover Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 64 of 288 ...

Page 71: ...riptions Horn Types Item Description 1 Narrow Horn 3 mm 2 Standard Horn standard 8 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 horn used for all applications up to 8 mm in thickness Use the horn that is saved to the mode otherwise timing and adjustments may not be properly complete...

Page 72: ...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 Horn Mounting Screw Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 66 of 288 ...

Page 73: ... 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 Select Operator Guide December 2017 Page 67 of 288 ...

Page 74: ...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 Select Operator Guide December 2017 Page 68 of 288 ...

Page 75: ... 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 Select Operator Guide December 2017 Page 69 of 288 ...

Page 76: ...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 binds Item Description 1 Mounting Screw 2 Horn Strap 3 Horn Install Horn Strap 7 Load the mode for the new application Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 7...

Page 77: ...change envelope properties for any reason this is where you would do that 1 Log into DC as Key Operator or higher 2 Click the Engine object on the main DC screen and select Setup from the drop down menu Engine Object Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 71 of 288 ...

Page 78: ... 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 74mm off the flap center line required field l Weight weight of the envelope optional l Thickness referring to material thickness the thickness of a single insert or document page that will be fed from this feeder option...

Page 79: ...se the Flap Delta Envelope Guide Template If the template is not available you can use a scale and envelope measurements to identify the flap delta Using the Flap Delta Envelope Guide Template To identify the envelope flap delta using the flap delta envelope guide template SV63174 1 Lay the envelope flap template on a flat surface Operator Adjustments Pitney Bowes Epic Select Operator Guide Decemb...

Page 80: ...o the 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 envelope parallel with template guides Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 74 of 288 ...

Page 81: ...lap crosses this scale l Left side of the scale is in inches ans 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 value of the Flap Delta measured in step 6 in the Engine Setup screen Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 75 of 288 ...

Page 82: ...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 Select Operator Guide December 2017 Page 76 of 288 ...

Page 83: ... 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 Delta Measurement Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 77 of 288 ...

Page 84: ...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 locking screw 4 With the locking screw loose adjust the tension of the roller The left side is lighter press to the right is more pressure 5 Tighten the locking screw Operator Adjustments Pitney Bowes E...

Page 85: ...6 Perform on other roller if needed 7 Close covers Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 79 of 288 ...

Page 86: ...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 need to be adjusted during mail processing based on the type of envelope material 1 Click the Sealer object on the main DC screen and select Sealer Control from the drop down Sealer Object Operator Adjus...

Page 87: ...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 Excessive fluid will drain into the overflow tube into the overflow catch bin Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 81 of 288 ...

Page 88: ...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 will steer the envelope away from the back wall 3 Tighten the rollers Note Rollers are used to correct small amounts of skew or misalignment only adjustments should be slight Always check upstream of...

Page 89: ... 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 desired position 2 Tighten the thumb screws Note When running flats remove the guides from all vertical stackers before the flats conveyor stacker Operator Adjustments Pitney Bowes Epic Select Operator G...

Page 90: ...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 Switch with 3 4 Full Sensor On Edge Stacker OES Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 84 of 288 ...

Page 91: ...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 Select Operator Guide December 2017 Page 85 of 288 ...

Page 92: ...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 actuator switch up or down 3 After setting the proper height adjust the entrance guides to keep the same height consistent Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Pag...

Page 93: ... 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 guide shown here Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 87 of 288 ...

Page 94: ... 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 Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 88 of 288 ...

Page 95: ... 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 away from the bottom seam of the envelope and use the operator setup tool to tighten the cap head screws Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 89 of 288 ...

Page 96: ...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 Select Operator Guide December 2017 Page 90 of 288 ...

Page 97: ...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 stacking fence left or right 1 8 inch to 1 4 inch to get a better stack Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 91 of 288 ...

Page 98: ... 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 Improper Vertical Stacking mailpieces are uneven and not tightly packed Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 92 of 288 ...

Page 99: ...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 to make the belt move faster or counterclockwise to make the belt move slower Speed Dial Adjustment Knob Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 93 of 288 ...

Page 100: ...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 it is possible to make small movements about 20 increments turn on the scale to adjust it Pack Pressure Adjustment Knob Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 9...

Page 101: ...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 clockwise direction or you will bend the pack pressure arm Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 95 of 288 ...

Page 102: ...module 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 If the fingers have been moved and need to be repositioned 1 Loosen the four adjustment thumbscrews Finger Guides Adjustment Thumbscrews Operator Adjustments Pitney Bowes Epic Select Operator Guide D...

Page 103: ...ion 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 required when running Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 97 of 288 ...

Page 104: ...t collation 1 Log in to DC 2 Load a mode 3 Click the Engine object on the main DC screen and select Position Horns from the drop down menu Engine Object The horns automatically relocate to the new position based on the material sizes set in the mode Note All interlocks and covers must be satisfied for this auto feature to work Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2...

Page 105: ...en both observation guide locking levers Note Guides should be as straight as possible funneled slightly is acceptable Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 99 of 288 ...

Page 106: ... by using the deck scales Item Description 1 Observation Guide Indicator and Horn Mount Lined Up 2 Deck Scale Observation Guide Indicator Lined Up with Horn Mount 6 Tighten the locking levers 7 Repeat these steps on the non operator side Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 100 of 288 ...

Page 107: ...bservation side guides are properly set into position 2 Open the feeder doors 3 Grasp the left and right sides of the operator chassis side guide and begin moving the guide so it sits about 1mm inside the engine observation guide where they meet This setup creates a funnel like effect so the material does not get caught on the observation side guide entrances when exiting the chassis Adjust Chassi...

Page 108: ...he observation guide that the guides meet with the proper alignment 6 Place the widest document in the job between the guides and center it leaving about 1 8 inch 3 1mm on each side 7 Do this for any additional upstream chassis sections maintaining the 1 8 inch 3 1 mm gap on either side of the material 8 Close the feeder covers Operator Adjustments Pitney Bowes Epic Select Operator Guide December ...

Page 109: ...sitting approximately 1 mm inside the observation guides The paper path direction is indicated here l Correct If the chassis side guides are narrower than the observation guides the paper will flow without jamming Chassis Side Guides Positioned 1mm Inside Observation Side Guides Correct Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 103 of 288 ...

Page 110: ...t caught on the observation side guide entrance and jam Chassis Side Guides Positioned Outside Observation Side Guides Incorrect Item Description 1 Chassis Side Guides 2 Collation 3 Observation Side Guide Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 104 of 288 ...

Page 111: ...uides 1 Verify the document coming from the input is centered 2 Open the buffer covers 3 Align the buffer guide to be slightly inside the chassis side guide but wide enough for the collation to fit through Align them so the buffer guides are approximately 1 mm inside the chassis guides Item Description 1 Buffer Chassis Guide 2 Chassis Side Guide Align Buffer Side Guide with Chassis Side Guides Ope...

Page 112: ...t 5 16 inch wider than the document on both sides Item Description 1 Buffer Chassis Guides 5 16 inch wider 2 Buffer Chassis Side Guides narrowing 3 Paper Path Buffer Chassis Side Guides Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 106 of 288 ...

Page 113: ...llation the brush may have to be raised slightly If the collation is pushed ahead of the chassis pushers causing stoppages of the system the brush may have to be lowered To adjust the height of the brush 1 Open the right buffer cover to access the brush 2 Use an operator tool to adjust the brush height screw o Clockwise raises the brush o Counterclockwise lowers the brush Item Description 1 Chassi...

Page 114: ... collations mailpieces resting underneath each feeder a If collation mailpiece is more than 1 inch away from the pushers loosen the lockdown screw with the Operator setup tool and rotate the indicator lever to the right to tighten strap pressure b If the collation mailpiece is buckled at the pusher loosen the lockdown screw with the Operator setup tool and rotate the indicator level to the left to...

Page 115: ...ial the roller should be in the up position which reduces shingling in the collation Lowering a center nip roller 1 Open all the feeder doors 2 Locate the release ring to the right of the roller 3 Pull the release ring to the right until the nip roller is in the down lowered position Item Description 1 Nip Roller 2 Release Ring Adjust Nip Roller Release Ring Operator Adjustments Pitney Bowes Epic ...

Page 116: ... nip roller 1 Open all the feeder doors 2 Lift the roller up until it locks approximately 1 2 inch up 3 Close the feeder doors Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 110 of 288 ...

Page 117: ...ent 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 the drop down menu Chassis Object 3 In the Chassis Setup dialog type the new collation length in the Collation length field 4 Click OK Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 111 of 288 ...

Page 118: ...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 Speed from the drop down Chassis Object Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 112 of 288 ...

Page 119: ...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 is running the speed will gradually change after the new speed values are entered Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 113 of 288 ...

Page 120: ...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 Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 114 of 288 ...

Page 121: ...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 feeder side guide locking knobs 2 Turn the side guide adjustment knob clockwise until it stops side guides all the way open Item Description 1 Locking Knobs 2 Side Guide Adjustment Knob 3 Separator Kno...

Page 122: ...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 here Position Material on the Feeder Belts Separator Under Roller Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 116 of 288 ...

Page 123: ...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 turn the separator knob clockwise until you feel a slight drag 7 When you have the correct drag remove the insert material Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Pa...

Page 124: ...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 Adjustment Knob Side Guide Lockdown Knobs Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 118 of 288 ...

Page 125: ...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 Material in Side Guides Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 119 of 288 ...

Page 126: ...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 Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 120 of 288 ...

Page 127: ...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 the pack control guide to the right 3 Place a 1 inch 25 mm stack of material between the side guides at the same height as the top of the pack control ramp Operator Adjustments Pitney Bowes Epic Select...

Page 128: ...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 Select Operator Guide December 2017 Page 122 of 288 ...

Page 129: ...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 Pins l Using the Wedge l Using the Jog Function Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 123 of 288 ...

Page 130: ...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 Epic Select Operator Guide December 2017 Page 124 of 288 ...

Page 131: ...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 short blue ring 0 Half fold glossy single sheet short blue ring 0 1 Folded perfume tall red ring 1 BRE tall red ring 0 Booklet thick 125 max tall red ring 1 Booklet thin short blue ring 1 Operator Adju...

Page 132: ...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 Suction Cup Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 126 of 288 ...

Page 133: ...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 Center Gate 2 Backstop 3 Backstop Locking Knob 4 Loosen the side guide locking knobs Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 127 of 288 ...

Page 134: ...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 the side guides in place Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 128 of 288 ...

Page 135: ...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 3 Half fold non glossy single sheet 4 Half fold glossy 3 4 Folded perfume 2 BRE 2 Booklet thick 125 max 1 Booklet thin 1 Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page...

Page 136: ...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 Bowes Epic Select Operator Guide December 2017 Page 130 of 288 ...

Page 137: ...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 glossy 0 Folded perfume 3 BRE 1 Booklet thick 125 max 4 Booklet thin 0 Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 131 of 288 ...

Page 138: ...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 for reference Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 132 of 288 ...

Page 139: ...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 inserts booklets to allows the staple to miss the pins Rotary Feeder Separator Pins outer pins shown here Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 133 of 288 ...

Page 140: ...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 Booklet thick 125 max all pins fully out away from stack Booklet thin inner fully in toward stack Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 134 of 288 ...

Page 141: ...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 Screws Note The pins are all the way exposed for most applications Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 135 of 288 ...

Page 142: ...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 Folded perfume optional BRE optional Booklet thick 125 max yes Booklet thin yes Installing the Wedge on the Rotary Feeder 1 Lift the wedge off the back wall of the feeder Wedge Operator Adjustments Pit...

Page 143: ...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 Pitney Bowes Epic Select Operator Guide December 2017 Page 137 of 288 ...

Page 144: ... 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 setup It clears all the material in the feeder drum and then acquires and feeds another insert to confirm correct setup Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page ...

Page 145: ...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 Feeder Objects 2 Select Jog Only from the drop down list If Jog Only is not in the drop down list select Feed with Jog click the Feeder object again and Jog Only is now listed Operator Adjustments Pitn...

Page 146: ... 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 Select Operator Guide December 2017 Page 140 of 288 ...

Page 147: ...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 press and hold the Jog button on the feeder The material in the feeder drum is cleared and another insert is acquired and fed to confirm correct setup Operator Adjustments Pitney Bowes Epic Select Operat...

Page 148: ... and some activities are for key operator levels and higher The 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 Document Information Key Operator Xport Setup Key Operator Separator Control Operator Operator Adjustments Pitney Bowes Epic Select Operator Guide December...

Page 149: ...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 Feeder Objects Check Feeder Status 2 Click a Feeder object and select Disable or Enable from the drop down menu 3 Repeat this for all feeders that require the change Operator Adjustments Pitney Bowes Ep...

Page 150: ...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 feeder 2 Log in as Key Operator access level or higher 3 Click the desired Feeder object on the main DC screen and select Setup from the drop down Feeder Objects Operator Adjustments Pitney Bowes Epic Sel...

Page 151: ...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 Select Operator Guide December 2017 Page 145 of 288 ...

Page 152: ...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 Epic Select Operator Guide December 2017 Page 146 of 288 ...

Page 153: ...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 Select Operator Guide December 2017 Page 147 of 288 ...

Page 154: ... 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 break when this mode is selected the Feeder object is blue l Priority Fill the feeder provides an insert when all other feed modes always data select and priority select have been processed and the wei...

Page 155: ... 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 Feeder Feed Mode topic for more instructions 4 Click OK Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 149 of 288 ...

Page 156: ...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 Feeder 3 runs low on material Feeder 2 takes over until Feeder 3 is reloaded and in a ready state Item Description 1 Feeder 3 2 Backup Feeder 2 3 Backup Feeder green stripes Backup Feeder Locations Ope...

Page 157: ... 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 Epic Select Operator Guide December 2017 Page 151 of 288 ...

Page 158: ... 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 Select Operator Guide December 2017 Page 152 of 288 ...

Page 159: ...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 screen and select Setup from the drop down 3 Click the Xport Setup tab 4 Select the Flap first short flap return envelope checkbox 5 Click OK Operator Adjustments Pitney Bowes Epic Select Operator Guide ...

Page 160: ... 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 compromised material you want to try a feeder setting to help feed the material 2 Log in as Key Operator access level or higher 3 Click the desired Feeder object on the main DC screen and select Setup from th...

Page 161: ... 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 set inserts are fed further out from under the weight of the stack when separating l Acceleration this feature controls how fast the separator belts spin at startup o The lower the number the slower th...

Page 162: ... 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 desired Feeder object on the main DC screen Feeder Objects 3 Select Recalibrate from the drop down menu Operator Adjustments Pitney Bowes Epic Select Operator Guide December 2017 Page 156 of 288 ...

Page 163: ...6 Job Changeover Guidelines In this section Job Changeover Guidelines 158 Auto Adjustments 161 Transfer Interface Module TIM Setup 164 ...

Page 164: ...over 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 manual adjustment Mailer Envelope changes size or style Insert changes size or thickness Control Document changes length width thickness Envelope Feeder Separator Gap x Fence Rollers x Engine Setup GUI ...

Page 165: ...ntrol Straps x x Buffer Chassis Side Guides x Buffer Brush x Center Deck Nip Rollers x Friction Feeder Side Guides x Pack Control Ramp x Separator x Feeder Setup GUI Screen x Rotary Feeder Suction Cups x Deck x Deck Angle Side Guides x Separator Pins x Feeder Setup GUI Screen x Buffer Job Changeover Guidelines Pitney Bowes Epic Select Operator Guide December 2017 Page 159 of 288 ...

Page 166: ...s size or thickness Control Document changes length width thickness TIM Module Deck Height x Vertical Stacker Side Guide Adjustment x On Edge Stacker OES Entrance Setup x DC Load Mode x x x Job Changeover Guidelines Pitney Bowes Epic Select Operator Guide December 2017 Page 160 of 288 ...

Page 167: ...pocket center offset settings can be manually adjusted in the 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 to set the horns The horn width offset setting can be manually adjusted in the Engine Setup screen Insert Blower Offset The amount of vacuum on the vacuum...

Page 168: ...y adjust any of the auto adjustments 1 Click the Engine object on the DC main screen and select Adjust Engine Setup from the drop down menu Engine Object Job Changeover Guidelines Pitney Bowes Epic Select Operator Guide December 2017 Page 162 of 288 ...

Page 169: ...ds 2 5 l Insert Blower Offset to increase the amount of vacuum select the Increase button to move the slider towards 20 to decrease the amount of vacuum select the Decrease button to move the slider towards 20 l Backwall to move the envelope flap closer to the sealer brush select the Move In button to move the slider towards 2 5 to move it farher away select the Move Out button to move the slider ...

Page 170: ... changing jobs the TIM module may or may not be needed depending on whether the job calls for a fold application Part of the job setup may require you to install or remove the TIM Depending on the style buffer you have manual or switch installation and removal of the TIM will be slightly different TIM Module Job Changeover Guidelines Pitney Bowes Epic Select Operator Guide December 2017 Page 164 o...

Page 171: ...e first buffer cover 2 Remove the fold plates that are in upper positions 1 and 3 Item Description 1 Fold Plate position 1 2 Fold Plate position 3 Fold Plates Positions 1 and 3 Job Changeover Guidelines Pitney Bowes Epic Select Operator Guide December 2017 Page 165 of 288 ...

Page 172: ...n both sides with the alignment pins lined up with fold plate slot 1 Item Description 1 Alignment Pin 1 2 Alignment Pin 2 Alignment Pins Job Changeover Guidelines Pitney Bowes Epic Select Operator Guide December 2017 Page 166 of 288 ...

Page 173: ... slot 1 Fold Plate Slot First Pin In 5 After the first pins are in slide the TIM down so the second alignment pins go into the slots Both Pins in Slot first pin not visible in slot Job Changeover Guidelines Pitney Bowes Epic Select Operator Guide December 2017 Page 167 of 288 ...

Page 174: ...osition the TIM to be fully seated in fold plate slot 1 Spring Loaded Locking Pin Handles 7 Release the two locking pin handles to lock the TIM module in place TIM Locked in Position Job Changeover Guidelines Pitney Bowes Epic Select Operator Guide December 2017 Page 168 of 288 ...

Page 175: ...y there is no gap between the nut and the locking pin handle If there is a gap the TIM is not seated correctly Gap incorrect No Gap correct Job Changeover Guidelines Pitney Bowes Epic Select Operator Guide December 2017 Page 169 of 288 ...

Page 176: ...ds to be placed in its up position a Pull the buffer release handle toward the folder until the buffer rises to the up position Buffer Release Handle Job Changeover Guidelines Pitney Bowes Epic Select Operator Guide December 2017 Page 170 of 288 ...

Page 177: ...place the buffer in the down position 2 Pull the buffer release handle toward the folder and push the buffer down into the fold position Pull Buffer Release Handle Push the Buffer Down into the Fold Position Job Changeover Guidelines Pitney Bowes Epic Select Operator Guide December 2017 Page 171 of 288 ...

Page 178: ...hile holding the spring loaded locking pin handles pull the TIM module up and out of fold plate slot 1 6 Once the locking pins clear the top of the fold plate slot the handles may be released 7 Install the fold plates as necessary Note When you are not using the TIM module store the assembly safely to avoid damage Job Changeover Guidelines Pitney Bowes Epic Select Operator Guide December 2017 Page...

Page 179: ...elope Feeder 174 Reloading the Envelope Feeder 176 Loading the Insert Feeders 179 Reloading Insert Feeders with the system is running 180 Removing Finished Mail from the On Edge Stacker 181 Removing Mail from the Flat Conveyor 184 Adding Sealer Fluid 185 ...

Page 180: ...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 the tops of the envelopes are squared up and no envelopes are sticking out from the stack or stuck together Running the System Pitney Bowes Epic Select Operator Guide December 2017 Page 174 of 288 ...

Page 181: ...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 Select Operator Guide December 2017 Page 175 of 288 ...

Page 182: ...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 running Caution Pinch Point The envelopes rest on rotating bars while the machine is running Do not allow your fingers to come into contact with these bars while the machine is running Running the Syst...

Page 183: ...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 the System Pitney Bowes Epic Select Operator Guide December 2017 Page 177 of 288 ...

Page 184: ...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 Select Operator Guide December 2017 Page 178 of 288 ...

Page 185: ...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 shingle beyond the point noted in this image Running the System Pitney Bowes Epic Select Operator Guide December 2017 Page 179 of 288 ...

Page 186: ... 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 System Pitney Bowes Epic Select Operator Guide December 2017 Page 180 of 288 ...

Page 187: ...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 belt As the belt becomes full of finished mail the mail is ready to be placed into a mail tray Stacker Paddle Running the System Pitney Bowes Epic Select Operator Guide December 2017 Page 181 of 288 ...

Page 188: ...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 amount of mail that will fit into a mail tray Running the System Pitney Bowes Epic Select Operator Guide December 2017 Page 182 of 288 ...

Page 189: ...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 indicate the stacker is full by displaying a message on the screen l The machine will not start while the paddle is pressing on the switch l This feature works only when the paddle is in the down posi...

Page 190: ...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 Press the button located on the end of the conveyor to turn the belt on and move the flat mailpieces out from under the vertical stacker and down the belt 2 Neatly stack the mail and remove it from the b...

Page 191: ... 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 the container 4 Close the sealer reservoir cover Item Description 1 Sealer Reservoir cover open 2 Overflow Reservoir partially pulled out Sealer and Overflow Reservoirs Running the System Pitney Bowes ...

Page 192: ...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 fill the sealer reservoir use only clean water If you mix in used water you may cause damage to the system Running the System Pitney Bowes Epic Select Operator Guide December 2017 Page 186 of 288 ...

Page 193: ......

Page 194: ...8 Error Recovery Error Recovery Pitney Bowes Epic Select Operator Guide December 2017 Page 188 of 288 ...

Page 195: ...ing Material Jams in the Engine 202 Removing Material Jams in the Envelope Feeder 207 Removing Material Jams in the Sealer or Vertical Stacker 1 210 Removing Material Jams in the Turnover 211 Setting Up the Vertical Stacker 212 Removing Material Jams in the On Edge Stacker 214 Removing Material Jams in the Flat Conveyor 215 Error Recovery Pitney Bowes Epic Select Operator Guide December 2017 Page ...

Page 196: ...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 in addition to a message or flashing object on the DC screen the indicator lights on the inserter will flash to show the area where the material jam has occurred Learn how to access and remove material...

Page 197: ...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 Resolve and clear alarms l View alarm history Error Recovery Pitney Bowes Epic Select Operator Guide December 2017 Page 191 of 288 ...

Page 198: ...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 Item Description 1 Device where the error occurred 2 Information details about the error 3 Suggestion suggested course of action Error Recovery Pitney Bowes Epic Select Operator Guide December 2017 Page ...

Page 199: ...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 process 6 If after repeating the process the error remains contact Service Error Recovery Pitney Bowes Epic Select Operator Guide December 2017 Page 193 of 288 ...

Page 200: ... 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 specific alarm double click it or highlight it and click View 3 Click Close and Close again to exit out of alarm history and back to the maIn DC screen Error Recovery Pitney Bowes Epic Select Operato...

Page 201: ...aring jams 1 Open the appropriate cover s to get to the area of the buffer necessary to clear the jam Item Description 1 Folder Cover buffer entrance 2 Buffer Cover center 3 Buffer Cover downstream Buffer Access 2 Remove the jam 3 Close the cover Error Recovery Pitney Bowes Epic Select Operator Guide December 2017 Page 195 of 288 ...

Page 202: ...stream buffer cover To remove jams from the dump station area follow these steps 1 Open the downstream buffer cover 2 Pull up on the handle to access the dump station deck Dump Station Handle Error Recovery Pitney Bowes Epic Select Operator Guide December 2017 Page 196 of 288 ...

Page 203: ...r bridge l Transport Feeder Deck To remove jams from the friction feeder deck 1 Pull out the locking pin and lift up the feeder slowly until the pin latches in 2 Remove the jam 3 Close the feeder Separator Bridge To remove jams from the separator bridge Error Recovery Pitney Bowes Epic Select Operator Guide December 2017 Page 197 of 288 ...

Page 204: ...e two locking knobs away from you and lift the friction feeder separator bridge Rotate Knob Lift Separator Bridge 3 Release the locking knobs 4 Remove the jam 5 Close the separator bridge make sure both locking knobs latch closed Error Recovery Pitney Bowes Epic Select Operator Guide December 2017 Page 198 of 288 ...

Page 205: ...Pull the transport knob out 3 Pivot the transport to the left while holding the knob out Transport Knob 4 Remove the jam 5 Close the transport make sure it locks in the closed position 6 Close the feeder cover Error Recovery Pitney Bowes Epic Select Operator Guide December 2017 Page 199 of 288 ...

Page 206: ...rs where jams may occur l Feeder deck l Feeder drums Rotary Feeder Deck To remove jams from the rotary feeder deck 1 Pull out the locking pin and lift up the feeder 2 Remove the jam 3 Close the feeder Error Recovery Pitney Bowes Epic Select Operator Guide December 2017 Page 200 of 288 ...

Page 207: ...1 With all doors shut press 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 Select Operator Guide December 2017 Page 201 of 288 ...

Page 208: ...ing area l Lower engine Upper Engine Area To remove jams from the upper engine area 1 Lift the engine cover 2 Grasp the upper engine handle and lift up for access to the insertion area Lift Upper Engine Handle Upper Engine Raised Error Recovery Pitney Bowes Epic Select Operator Guide December 2017 Page 202 of 288 ...

Page 209: ...en the engine cover and lift the upper engine 2 Remove the jam by pulling the edge of the envelope and sliding it out toward the engine exit This releases the rollers add arrow Pull the Envelope Toward the Engine Exit 3 Close the cover Error Recovery Pitney Bowes Epic Select Operator Guide December 2017 Page 203 of 288 ...

Page 210: ...ne cover and lift 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 Select Operator Guide December 2017 Page 204 of 288 ...

Page 211: ...he lower engine opens 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 down Error Recovery Pitney Bowes Epic Select Operator Guide December 2017 Page 205 of 288 ...

Page 212: ...e running there can be up to two envelopes in the lower engine that need to be removed whenever the lower pocket is opened Pocket Envelope and Flapper Envelope Error Recovery Pitney Bowes Epic Select Operator Guide December 2017 Page 206 of 288 ...

Page 213: ...y occur l Envelope transport l Envelope separator for jam access Envelope Transport To remove jams in the envelope transport 1 Pull down on the envelope feeder transport handle and to push it open Envelope Feeder Handle Error Recovery Pitney Bowes Epic Select Operator Guide December 2017 Page 207 of 288 ...

Page 214: ... 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 Select Operator Guide December 2017 Page 208 of 288 ...

Page 215: ... the spring tension on 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 Error Recovery Pitney Bowes Epic Select Operator Guide December 2017 Page 209 of 288 ...

Page 216: ...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 straps or belts if needed 4 Close the cover Error Recovery Pitney Bowes Epic Select Operator Guide December 2017 Page 210 of 288 ...

Page 217: ...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 Select Operator Guide December 2017 Page 211 of 288 ...

Page 218: ...ection 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 will steer the envelope away from the back wall 3 Tighten the rollers Note Rollers are used to correct small amounts of skew or misalignment only adjustments should be slight Always check upstream ...

Page 219: ...ide 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 desired position 2 Tighten the thumb screws Note When running flats remove the guides from all vertical stackers before the flats conveyor stacker Error Recovery Pitney Bowes Epic Select Operator Guid...

Page 220: ...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 Select Operator Guide December 2017 Page 214 of 288 ...

Page 221: ...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 Select Operator Guide December 2017 Page 215 of 288 ...

Page 222: ... 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 Select Operator Guide December 2017 Page 216 of 288 ...

Page 223: ...Foam Roller Raised for Jam Removal Error Recovery Pitney Bowes Epic Select Operator Guide December 2017 Page 217 of 288 ...

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Page 225: ...9 Troubleshooting In this section Troubleshooting 220 Engine Troubleshooting 221 Chassis Troubleshooting 224 Buffer Troubleshooting 229 ...

Page 226: ...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 Select Operator Guide December 2017 Page 220 of 288 ...

Page 227: ...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 paper path Remove and clean Lower Pocket Issue Cause Resolution Not flapping Envelopes loaded incorrectly Reload envelopes Flap glued closed Check material Excessive paper curl Check material Trouble...

Page 228: ...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 for envelope Decrease horn wIdth Engine Exit Issue Cause Resolution Missing or late skew Strap location or tension Adjust strap Troubleshooting Pitney Bowes Epic Select Operator Guide December 2017 Page...

Page 229: ...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 Resolution Jam High seals Inspect for high seals and refer to Sealer Belt adjustment envelope positioning Adjust the OES entrance setup Stacking too tight on belt Increase speed of conveyor belt Troubleshooti...

Page 230: ...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 not checked Manually adjust the side guides as needed Troubleshooting Pitney Bowes Epic Select Operator Guide December 2017 Page 224 of 288 ...

Page 231: ...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 Loosen ramp no more tha 3 mm larger than the encloure length Stack height Reduce stack height do not load enclosures to the top Peeling Material Fan material reload in a different orientation Stack heig...

Page 232: ...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 deck angle Warp in material may cause sheet s to rest above the pins Switch to tall cups and or move cups away from the lead edge Material rips out of gripper Reduce stack height or move deck away Move...

Page 233: ...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 angle to remove excessive weight from pins Backstop side guides set too tight preventing material from falling onto the pins Reset and or loosen side guides Material too stiff Move deck away from the...

Page 234: ... 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 too tight Loosen guides Troubleshooting Pitney Bowes Epic Select Operator Guide December 2017 Page 228 of 288 ...

Page 235: ...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 quality Troubleshooting Pitney Bowes Epic Select Operator Guide December 2017 Page 229 of 288 ...

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Page 237: ... section Operator Maintenance 232 Replacing Suction Cups in the Engine 234 Buffer Maintenance 239 Rotary Feeder Maintenance 240 Friction Feeder Maintenance 241 Vertical Stacker Maintenance 242 On Edge Stacker Maintenance 243 ...

Page 238: ...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 Maintenance Perform these system maintenance activities at every shift l Remove dust and debris from the entire machine either via air or vacuum the vacuum tip must be non metallic Note Follow eye safety pro...

Page 239: ...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 guide or on the system via the on system support tool Maintenance Pitney Bowes Epic Select Operator Guide December 2017 Page 233 of 288 ...

Page 240: ...f during inspection the 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 area Lift Upper Engine Handle Maintenance Pitney Bowes Epic Select Operator Guide December 2017 Page 234 of 288 ...

Page 241: ... suction cups Suction Cups 4 Remove the suction cup by firmly grasping the bellow and pulling the cup straight down Grasp the Suction Cup Maintenance Pitney Bowes Epic Select Operator Guide December 2017 Page 235 of 288 ...

Page 242: ...on 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 suction cup on Replace the Suction Cup Maintenance Pitney Bowes Epic Select Operator Guide December 2017 Page 236 of 288 ...

Page 243: ...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 Maintenance Pitney Bowes Epic Select Operator Guide December 2017 Page 237 of 288 ...

Page 244: ...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 Select Operator Guide December 2017 Page 238 of 288 ...

Page 245: ...air Cleaning Covers and Clearing the Paper Path 1 Wipe down the top buffer covers with PB approved cleaner polycarbonate cover cleaner 2 Open the top buffer covers 3 Use a clean damp rag denatured alcohol to wipe down all the orange belts 4 Use an airline with the blower attachment to blow dust and debris out of the paper path 5 Close the buffer covers Maintenance Pitney Bowes Epic Select Operator...

Page 246: ...eplaced 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 the deck 4 If you need to replace the suction cup pull it off the cup holder 5 Remove the old suction cup from the ring 6 Place the new suction cup on the ring 7 Return the cup into the cup holder Ma...

Page 247: ...clam 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 airline with the blower attachment to blow dust and debris out of the bridge 7 Close the bridge assembly 8 Use the airline with the blower attachment to blow dust and debris out of the clam shell 9 Raise the feeder 10 Use the airline with ...

Page 248: ... Compressed 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 3 Use the airline with the blower attachment to blow dust and debris out of the paper path 4 Close the cover Maintenance Pitney Bowes Epic Select Operator Guide December 2017 Page 242 of 288 ...

Page 249: ...ed air Clearing Paper Path and Cleaning Components 1 Open both On Edge Stacker doors 2 Use the airline with the blower attachment to blow dust and debris out of the paper path 3 Wipe down the rollers with a clean damp cloth soapy water 4 Wipe down the back plate with a clean damp cloth soapy water 5 Close the doors Maintenance Pitney Bowes Epic Select Operator Guide December 2017 Page 243 of 288 ...

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Page 251: ...554 263 Epic Rotary Feeder Y558 267 Epic Buffer with TNT Y574 272 Epic Turnover Y371 275 Epic V Bin Y31E Y31F Y31G Y31H 277 Epic On Edge Stacker Y396 279 Epic Shingling Stacker Y32S 281 Epic Edge Markers Y367 Y368 Y369 282 Environmental Operating Conditions 284 Network and Power Requirements 285 Air Requirements 287 ...

Page 252: ...Standard Features l Envelope Hopper capacity of approximately 2 500 letter 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 detect envelope skew and open the envelope flap l Ability to re feed envelopes not flapped l Insertion engine capable of processing letter envelopes l Up to 32 8 mm or 70 s...

Page 253: ...ded here approximates the maximum system throughput based on a mathematical model of the Epic modules Lower throughput can be caused by failure to follow the guidelines outlined in product specifications and or poor material quality Specifications Pitney Bowes Epic Select Operator Guide December 2017 Page 247 of 288 ...

Page 254: ...humidity extremes These problems can originate at the time of envelope manufacturing during finished goods transit or as the result of poor environmental controls at either the manufacturing site or the storage facility or both Pitney Bowes equipment is designed to handle a certain range of material Envelopes that fall outside these specified ranges might run poorly or not at all l Store materials...

Page 255: ...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 0 010 0 292 8 stage TNT buffer 0 001 0 159 Engine chassis buffer total consumption 6 45 3 43 Case 1 21K 10 deck nips operate 1 of time for stop conditions Subset stops and jogger inactive Case 2 Flats mode two subsets of five pages each Chassis speed of 7...

Page 256: ...Stacker Epic Y396 Single 17 V Bin rear Y31G Engine Light Tower Y56L Dual 17 V Bin rear Y31H Engine Scan Y55E 17 V Bin Meter Combo Y31J Print Messenger Color Y360 Print Messenger Mono Y361 Engine Dual Edge Markers Y367 Stacker Dual Edge Markers Y368 Add l Dual Edge Markers Y369 Specifications Pitney Bowes Epic Select Operator Guide December 2017 Page 250 of 288 ...

Page 257: ...laps l Envelope curl 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 Envelope Measurements Minimum Maximum Folded Width 7 178 mm 11 50 292 mm Length 3 88 98 mm 6 38 162 mm Weight 20 lb bond 75 gsm 28 lb bond 105 gsm End Clearance See End Clearance and Horn...

Page 258: ... 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 envelope A 75 19 mm end clearance is recommended to achieve maximum throughput for all categories Experience has shown that end clearance requirements increase with the height of the collation and or with the number of pages comprising the ...

Page 259: ...Diagonal Seam Envelopes Letter Mode Specifications Pitney Bowes Epic Select Operator Guide December 2017 Page 253 of 288 ...

Page 260: ...e 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 top of the patch material falls within 375 9 6 mm of the crease score line the patch material should be raised to within 062 1 6 mm of the crease line o In addition the throat should be a maximum of 25 6 4 mm below the crease line at 75 from the side edges l Envelope curl or ...

Page 261: ...Executive Envelopes Letter Mode Specifications Pitney Bowes Epic Select Operator Guide December 2017 Page 255 of 288 ...

Page 262: ...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 top of the patch material falls within 375 9 6 mm of the crease score line the patch material should be raised to within 062 1 6 mm or closer to the crease line o The throat should be a maximum of 25 6...

Page 263: ...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 Select Operator Guide December 2017 Page 257 of 288 ...

Page 264: ...Side Seam Envelopes Letter Mode Specifications Pitney Bowes Epic Select Operator Guide December 2017 Page 258 of 288 ...

Page 265: ... from 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 envelopes no patch the window should be located 75 19 mm minimum from either side top and bottom of the envelope l Paper stock may range from 20 lb 75 gsm minimum to 28 lb 105 gsm maximum but 24 lb...

Page 266: ...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 and bonded within 0625 1 6 mm of the top edge of the patch material and top edge of the window cut out s If the window patch area is 1 3 or more of the total area of the envelope s front panel the envel...

Page 267: ...quirements can be reviewed by PB Engineering to determine the abiity of a particular envelope to run Mailpiece The mailpiece l Is measured with the maximum collation size inserted into the envelope and the envelope sealed l Is measured by laying the sealed envelope on a flat surface and measuring from the surface to the highest point of the envelope l Thickness will not exceed 0 32 8 mm Specificat...

Page 268: ...2 1 75 44 21K 10 4 10 105 9 500 241 1 25 32 1 75 44 21K ISO DL 4 30 110 8 7 220 1 25 32 1 75 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 1 75 44 19K 6 x 9 6 00 152 9 00 229 1 25 32 1 75 44 18K C5 6 40 162 9 00 229 1 25 32 1 75 44 18K 9 x 12 9 00 229 12 0 305 1 75 44 2 25 57 14K C4 9 00 229 12 8 324 1 75 44 3 25 83 14K B4 9 80 250 13 8 350 1 75 44 5 25 133 14K 10 x...

Page 269: ...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 Speed Max MPS Epic 4 102mm 26K 21K 4 102mm 22K 21K Specifications Pitney Bowes Epic Select Operator Guide December 2017 Page 263 of 288 ...

Page 270: ...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 direction are preferred This results in a cleaner straighter fold with less thickness increase at the fold l Folds should be sharply creased flat and free of edge curl see diagram Curl at Fold l Folds must n...

Page 271: ...han 50 greater in the center than at the leading edge i e if leading edge is two papers thick center cannot be more than three papers thick 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 pressure sensitive labels with a backing sheet are allowed l Die...

Page 272: ...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 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 greatly reduce the chance of enclosure damage and allow for t...

Page 273: ...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 21K 4 102 mm 22K 21K 6 25 159 mm n a 18K 6 25 159 mm n a 14K Specifications Pitney Bowes Epic Select Operator Guide December 2017 Page 267 of 288 ...

Page 274: ...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 parallel to the paper grain direction are preferred This will result in a cleaner straighter fold with less thickness increase at the fold l Cannot feed Z folds l Closed end first see diagram l Folds should ...

Page 275: ... 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 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 276: ...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 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 greatly reduce the chance of enclo...

Page 277: ...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 Select Operator Guide December 2017 Page 271 of 288 ...

Page 278: ... and includes l Buffers and synchronizes the collated material to optimize the performance of the input l The 8 Stage Buffer stages finished collations and subsequently reduce the number of dry cycles per hour depending on the collation size thus optimize chassis utilization l When activated the TNT module twists the collated material 180 degree l When not activated the collation passes through th...

Page 279: ...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 rotation 7 179 mm 12 305 mm Thickness Single sheet 16 sheets 20 lb 80 gsm half fold 10 sheets 20 lb 80 gsm tri fold The TNT does not support twisting of flat materials any rotation is limited to 14 0...

Page 280: ...168 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 Select Operator Guide December 2017 Page 274 of 288 ...

Page 281: ... 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 envelope up to 70 panels Standard Features l Parts include o Cabinet o Servo powered turnover belt o Turn bar guide o Exit nip roller l DC controlled linear speed Specifications Pitney Bowes Epic Sel...

Page 282: ...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 Characteristics l Length 55 140 cm l Width 26 66 cm l Height 46 117 cm l Heat Dissipation 117 KW 400 BTU Hr Specifications Pitney Bowes Epic Select Operator Guide December 2017 Page 276 of 288 ...

Page 283: ...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 Y31H Dual V Bin Rear Justified l Y31J Single V Bin DM Infinity Meter Combo For the most cost effective solution dual V Bin modules should be used wherever possible unless an odd number of V Bins is requi...

Page 284: ...ntire range of Epic folded and flat materials Physical Characteristics Single Dual Length 17 140 cm 34 140 cm Width 32 66 cm 32 66 cm Height 39 117 cm 39 117 cm Options The V Bin can be configured with these options Options PCN Shingling Conveyor Y32S Output Area Scan Top Y55FT Output Area Scan Bottom Y55FB Output Line Scan Top Y55LT Output Line Scan Bottom Y55LB Specifications Pitney Bowes Epic S...

Page 285: ...under the belt stacker where mail trays can be placed for fast and easy unloading from either side of the stacker Description l Parts include turn up belt a 7 2 1 m belted stacker a sliding drawer l Conveyor belt holds approximately 750 1000 10 envelopes C 6 5 two page tri fold documents and two inserts l Can be equipped with an optional Offset Kit to provide a visible break in the material flow f...

Page 286: ...h 6 5 169 mm see note 2 11 5 292 1 mm Width 3 88 98 mm 6 5 165 mm Basis Weight 20 lb 75 gsm 28 lb 105 gsm Range of Thickness 25 0 6 4 mm Notes 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 Seam kit Options The On Edge Stacker can be configured with...

Page 287: ...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 roller to improve envelope sealing l Integrated with DC l Holds approximately 750 1000 9x12 C4 envelopes with 10 page flats and no inserts l Continuous unloading l NRTL approved Specifications Pitney Bow...

Page 288: ...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 Last Position l Located just prior to the On Edge Stacker l Includes two edge markers on the same side Y367B Front Edge Markers 1st Position l Located in the engine prior to the first output V Bin or ...

Page 289: ... 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 Select Operator Guide December 2017 Page 283 of 288 ...

Page 290: ...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 excluding rain l The system should satisfy performance requirements over the normal operating range of conditions A loss of performance may occur at environmental conditions outside the normal operation ra...

Page 291: ...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 connection l Power plug for 5 wire connection is not provided A suitable power connector rated at 240 415V 50A minimum and inlet wiring that conforms to local wiring standards must be chosen by the customer C...

Page 292: ... 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 Select Operator Guide December 2017 Page 286 of 288 ...

Page 293: ...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 to work with PB equipment l Air requirements 6 3 SCFM 70 PSI l 375 quick disconnect fitting included on the system Specifications Pitney Bowes Epic Select Operator Guide December 2017 Page 287 of 288 ...

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Page 295: ...SV63276 RevA 2017 Pitney Bowes Inc All Rights Reserved 3001 Summer Street Stamford Connecticut 06926 www pitneybowes com ...

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