Pitney Bowes relay 3000 User Manual Download Page 108

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7 • Troubleshooting and Error Messages

7-10

SV63138 Rev. A

Message

Action

CLEAR SEALER

Material is detected in the sealer brush area.
• Open the tinted plastic cover on left side of the

inserter and remove any material.

• Close cover and restart.

CLOSE COVER

Cover indicated is not fully closed. Close the

indicated cover and restart the inserter.

CLOSE MAN ADV

COVER

The manual advance knob door is not fully closed.

Close the door.

DEFLECTOR

ERROR

The function of half fold is not possible due to

a fault. Remove fold plates and check for any

material.

DOUBLE FEED

A double feed has been detected from the feed tray

indicated.
• Remove the material from the inserter and

restart.

• If double feeds persist, request another trial

piece.

DOUBLE FEED

CHECK STACKER

A double feed has been detected from the feed tray

indicated.
• Remove the double feed from the stacker
• Restart the inserter.

FOLD PLATES

NOT SET

The fold plates has not set to the correct position.
• Remove fold plates and check for any material.
• Install the fold plates and restart the inserter.

MANUAL FEED

TIMEOUT

Material feed has not been detected within a

predetermined time.
• In manual feed mode, you must feed material

within a set time.

• Restart the machine by pressing

Start

Summary of Contents for relay 3000

Page 1: ...Relay 3000 4000 User Guide International English Edition SV63138 Rev A August 1 2015 Document Inserting Systems with Touch Screen and Barcode Scanning Shipping Mailing Inserter ...

Page 2: ...ced in whole or in part in any fashion or stored in a retrieval system of any type or transmitted by any means electronically or mechanically without the express written permission of Pitney Bowes Wehavemadeeveryreasonableefforttoensuretheaccuracyandusefulness ofthismanual however wecannotassumeresponsibilityforerrorsoromissions or liability for the misuse or misapplication of our products Due to ...

Page 3: ...rnames 1 12 Change an Existing Operator Password 1 13 Recover an Existing Operator Password 1 13 Rename an Existing Default Job 1 14 Inserter Control Reports on the Touch Screen 1 15 Report Data 1 15 Access Reports 1 16 Archive Reports 1 17 Print Reports 1 17 Chapter 2 Program a Job Navigate Using the Touch Screen 2 3 Scanning and Non Scanning Jobs 2 4 Program a Job 2 5 Log In 2 5 Enter Supervisor...

Page 4: ... Trial Pieces and Linked Feeding 3 12 Material Changes or Double Detect Issues During Operation 3 12 Start and Stop the Inserter 3 13 Fill the Sealer 3 14 Adjust the Stacker 3 14 Chapter 4 OMR Scanning Optical Mark Recognition OMR 4 3 Accuracy 4 3 OMR and Feeders on the Inserter 4 3 OMR Scanning Types 4 4 Basic OMR 4 4 Enhanced OMR 4 4 OMR Mark Positions 4 4 OMR Specifications 4 5 Standard OMR Pos...

Page 5: ...R Error Messages 4 15 Chapter 5 Barcode Scanning Barcode Scanning 5 3 How Barcode Scanning Works 5 3 1D and 2D Barcode Scanning 5 3 Jobs with Barcode Scanning 5 4 Barcode Options 5 4 Basic Barcode Reading 5 4 Enhanced Barcode Reading 5 4 Barcode Placement Specifications 5 5 Barcode Placement Areas 5 5 Barcode Zones Clear and Blank 5 7 2D Barcode Camera Setup 5 8 Turn On the 2D Barcode Camera 5 8 A...

Page 6: ...and Replace 6 4 Access the Carriage Assembly 6 4 Access to Envelope Feeder Area 6 5 Access the Envelope Exit Area 6 5 Access the Envelope Inserting Sealing Area 6 6 Access to the Sheet Feed Area 6 6 Chapter 7 Troubleshooting and Error Messages General Troubleshooting 7 3 Changing the Sealer Unit Felts 7 7 Error Messages 7 9 Chapter 8 Material Specifications Material Specifications 8 3 Inserter Spe...

Page 7: ...r plug on the line cord or wall outlet DO NOT remove the ground pin from the line cord DO NOT route the AC adapter power cord over sharp edges or trap it between furniture Make sure there is no strain on the power cord If the unit becomes damaged unplug it from the wall Keep fingers long hair jewelry and loose clothing away from moving parts at all times Avoid touching moving parts or materials wh...

Page 8: ...lear of the inserter Immediately report to service any damaged or non functioning components that renders the unit unsafe Contact your system supplier for the following Supplies Material Safety Data Sheets If you should damage the unit Required maintenance service schedule If Your Stacker has an AC Adapter Use the AC power adapter included with this device Third party adapters may damage the devic...

Page 9: ...f 1 10 Use the Touch Screen Keyboard 1 11 Change the Display Language 1 11 Touch Screen Usernames and Passwords 1 12 Rename or Create an Operator Username 1 12 Change or Create an Existing Operator Password 1 12 Recover an Existing Operator Password 1 13 Change a Job Name 1 13 Inserter Control Reports on the Touch Screen 1 14 Report Data 1 14 Access Reports 1 15 Archive Reports 1 16 Print Reports ...

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Page 11: ...ch is an option for both systems Touch screen technology makes it easy to set up jobs and use the inserter Enhanced barcode scanning decodes barcode information and enables the inserter to maintain the integrity of your mailpiece NOTE The Relay Inserter touchscreen is a WiFi enabled device If clients choose to utilize this network connection it is the responsibility of the client to ensure that th...

Page 12: ... this feeder to add additional inserts to your envelope Material fed from this feeder cannot be folded by the inserter However this feeder is especially suited to feeding pre folded or thicker inserts 4 Sealer Bottle The sealer bottle is located on the rear of the inserter on the right side It is under a hinged cover labeled with the sealer icon The sealer bottle provides sealing solution to the e...

Page 13: ...nob is located under a cover on the front left lower corner of the inserter Use it to turn the inserter mechanisms by hand to help clear a material 10 Power Switch This switch turns the inserter on and off 11 Side Guide Adjustment Knob Use this knob to adjust the side guides on the envelope feeder 12 Envelope Feeder Feeds envelopes into the inserting area where they are filled with material reques...

Page 14: ...mode only 3 Tap these icons to scroll through available options for job settings Supervisor function setup mode only 4 Tap these icons to scroll through available job settings Supervisor function setup mode only 5 Tap to delete a programmed job from the inserter memory Supervisor function setup mode only 6 Default Job Tap to return inserter to its default or standard settings which are pre configu...

Page 15: ...top automatic operation at the end of the next cycle 11 Start Tap to start automatic operation 12 Gold Star Helps guide you through the job settings by displaying next to the icon of the setting you are programming changing 13 Fold Type Icon Represents the selected fold option 14 Sheet Length Icon Indicates in millimeters the length of the unfolded sheet 15 Keyboard Icon Tap to display a full keyb...

Page 16: ...on Used on insert feeder to signify that the feeder is on with double detection Used on sheet feeder 1 to signify that the feeder is set for manual feed Indicates the setting from 1 to 5 of the envelope stop 3 Indicates that the sealer bottle needs refilling Indicates the envelope depth Indicates the sealer unit is off envelopes not sealed Indicates the sealer unit is off envelopes not sealed Indi...

Page 17: ...ected Indicates a no fold insert operation Indicates a material stoppage The position of this symbol in the display indicates where the stoppage has occurred Call Pitney Bowes for service ABC Indicates the paper size address orientation and fold s set for sheet feeder Indicates a material stoppage in a downstream device such as a power stacker ...

Page 18: ...serter is powered up before you turn on the touch screen 2 Press and hold the ON OFF power button for a few seconds The power button is located on the top eft frame of the touch screen NOTE If the touch screen is in sleep mode press the ON OFF button Touch Screen ON OFF Power Button ...

Page 19: ... tap the in the upper right corner Capital Letters For single caps tap the key once To turn Caps Lock on tap the key twice Change the Display Language To change the language on the touch screen display 1 Tap the icon on the opening screen 2 When the Operator List displays tap 3 Select Language Program from the menu bar A screen opens displaying country flags associated with available languages 4 T...

Page 20: ...his procedure can be used to rename an existing default operator username to a specific operator username A maximum of 10 operators can be programmed into the touch screen 1 Tap the icon twice 2 When the Operator List displays select a default Operator to rename typically indicated as Operator 1 Operator 10 3 To launch the keyboard tap the icon bottom right corner of the screen and enter either th...

Page 21: ...screen keyboard to enter the new password re enter the password to confirm 6 Tap 7 Tap Recover an Existing Operator Password This activity requires Supervisor level access 1 Tap the icon twice 2 When the Operator List displays select the Operator name associated with the lost password and tap 3 Tap the touch screen keyboard and enter the Supervisor password 71 in the field DO NOT tap 4 Select File...

Page 22: ...s select an Operator and tap 3 To launch the keyboard tap the icon on the bottom right corner of the screen and enter the Operator password in the field 4 Tap 5 At the main control screen tap the Name of jobs button in the upper left corner of the display 6 Highlight a job in the Name of jobs list and tap Change 7 Using the touch screen keyboard enter the new job name in the field 8 Tap to accept ...

Page 23: ...of time or for specific jobs Report Data When running an enhanced barcode scanning application the reports contain unique information found within the barcode Date mailpiece was processed Time mailpiece was processed Operator name Job name Expected number of sheets Actual number of sheets processed from feeder with barcode reader Missing sheets Total number of envelopes Mailpiece status correctly ...

Page 24: ...en desktop 2 To select a report from a specific date tap the Open by date icon at the top of the screen 3 Select the date on the calendar and the report data populates the screen 4 You can include information from additional dates in the report by repeating the date selection process Select by Job File To view and or print inserter reports by specific job s follow these steps 1 Tap the reports ico...

Page 25: ... Tap Browse and set the Backup field to the SD drive usually D 5 Tap All reports are automatically archived by date on the SD drive Print Reports You can print reports directly through the touch screen if it is connected to an external printer on your wireless network 1 Populate the screen with report data either by date or job 2 Tap the print icon to print the report NOTE If clients choose to pri...

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Page 27: ...uch Screen 2 3 Scanning and Non Scanning Jobs 2 4 Program a Job 2 5 Log In 2 5 Enter Supervisor Access Code 2 5 Select the Job Number New or Existing Job 2 5 Program a Scanning Job 2 6 Program a Non Scanning Job 2 14 Modify an Existing Job 2 23 Delete a Job 2 23 ...

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Page 29: ...Touch Screen To help visually guide you through the programing sequence a icon appears on the display next to the area being set Tap the icons to scroll through and select available settings Once the desired setting displays tap the icons to scroll through available options or values for the selected setting Tap to accept the selection and advance to the next setting NOTE For icon locations and de...

Page 30: ...ng Job Non Scanning Jobs Enable scanning OMR On or Off Disable scanning OMR Off if available on your inserter Skip if you inserter does not have scanning Set fold type Set fold type Set main scanning sheet feeder Set accumulation Set select supplementary sheet or insert feeder Set first main sheet feeder Set the sealer Set second supplementary sheet feeder Set paper length Set insert feeder Set fo...

Page 31: ...eld displays over the inserter model on the touch screen display 2 Tap the icons to increase or decrease to 71 3 Tap to accept the access code and advance to the job settings Select the Job Number New or Existing Job When prompted for the job number follow these steps to select or create the job You can select an existing job and overwrite its current settings or you can select an unused job and p...

Page 32: ...v A Program a Scanning Job Enable Scanning OMR or Barcode 1 When prompted tap the icons to select one of the OMR on settings Refer to the OMR Settings table included here 2 Tap to accept the selection and advance to the next setting ...

Page 33: ...MR scanning Select Feed Autobatch Wrap Around Sequence OR Enhanced barcode scanning is enabled for this job with standard OMR mark positioning OMR Offset on OMR scanning is turned on for this job with offset OMR mark positioning OMR Offset Sequence OMR scanning Wrap Around Sequence scanning is enabled for this job with offset OMR mark positioning OMR Offset Select feed OMR scanning Select Feed Aut...

Page 34: ...on of the paper for loading into the feeders FACE UP HEAD FIRST ABC FACE DOWN FEET FIRST A B C Set the Main Scanning Sheet Feeder 1 Tap the icons to scroll through the options 2 Tap to accept the option and advance to the next setting Main Sheet Feeder 1 Options Scanning Jobs Icon Option Description On Double Detect Feeder on with the double detector operating The double detector stops the inserte...

Page 35: ...SF Double Detect not shown on single or Z folds Select feeder on with the double detector operating The double detector stops the inserter if more than one sheet simultaneously feeds from the feeder On SF not shown on single or Z folds Select feeder on without the double detector Off Feeder turned off for this job On not shown on single or Z folds Feeder on without the double detector or select fe...

Page 36: ...ns Icon Option Description On Turns the sealer unit on for automatic sealing of envelopes Make sure the sealer water bottle is full of E Z Seal or water Off Turns the sealer unit off Envelopes will be ejected unsealed Set Paper Length 1 Use the scale on the side of the inserter cover to measure the paper US letter 279mm 11 inches A4 paper 297mm 2 Tap the icons to scroll through paper lengths displ...

Page 37: ...o keep within the correct paper length and inserter specifications 3 Tap to accept the fold value and advance to the next setting Set Fold B 1 Select the size of the second fold required NOTE Similar to setting fold the inserter suggests the correct dimension for fold B 2 To change the standard setting tap the icons until the length of fold required displays A icon displays next to the fold panel ...

Page 38: ... begin processing the next batch 2 Tap the icons to toggle the batch mode to On or Off NOTE If the batch counter is turned on the inserter prompts for the batch quantity The default quantity is 50 but you may select any value up to 999 by tapping the icons 3 Tap to accept the setting Confirm Job Setup Job setup is now complete Using the inserter model and icons the touch screen display shows all t...

Page 39: ...n another trial piece to test the modified settings NOTE Any time you modify settings you must run a trial piece Incorrect Address Position Adjust Fold Settings When you run a trial piece if the address is not in the correct position refer to the Adjust Fold Settings table to help you fine tune your folds settings Adjust Fold Settings Table Fold Type Address Too Low Address Too High C Letter Fold ...

Page 40: ...o select OMR off 2 Tap to accept the selection and advance to the next setting Set the Fold Type 1 Tap the icons to scroll through the fold types 2 Tap to accept the fold type and advance to the next setting Fold Types C Letter Z Accordion Double Single When the fold type is selected the display indicates the correct orientation of the paper for loading into the feeders FACE UP HEAD FIRST ABC FACE...

Page 41: ...g Inserter Accumulation Settings Setting Description Accumulation OFF Accumulation is turned off for this job Accumulation From Main Accumulation is turned on with sheets feeding from the main feeder This feeder normally contains the address sheet Accumulation From Suppl Accumulation is turned on with sheets feeding from the supplementary feeder one address sheet from the main feeder followed by m...

Page 42: ...st Main Sheet Feeder Options Non Scanning Jobs Icon Option Description On Double Detect Feeder on with the double detector operating The double detector stops the inserter if two or more sheets feed simultaneously Off Feeder turned off for this job On Feeder on without the double detector Manual Feed see the description following this table Able to manually feed collated sets Only available on she...

Page 43: ...eed option is only available when Accumulation is set to OFF Set Second Supplementary Sheet Feeder If you want to use the second sheet feeder use these settings 1 Tap the icons to scroll through the options Refer to the Second Supplementary Sheet Feeder Options Non Scanning Jobs table for descriptions 2 Tap to accept the option and advance to the next setting Second Supplementary Sheet Feeder Opti...

Page 44: ...inserter if two or more sheets feed simultaneously On Feeder on without the double detector Off Feeder turned off for this job Set the Mode Type Insertion or Fold Only This setting only appears if Accumulation is not turned on The inserter needs to know if the job requires inserting material into an envelope or if it is a fold only job To set the mode type 1 Tap the icons to toggle between the opt...

Page 45: ...nsert feeder only folding is not possible skip to the Set Envelope Depth setting Sealer Options Icon Option Description On Turns the sealer unit on for automatic sealing of envelopes Make sure the sealer water bottle is full of E Z Seal or water Off Turns the sealer unit off Envelopes will be ejected unsealed Set Paper Length 1 Use the scale on the side of the inserter cover to measure the paper U...

Page 46: ...p within the correct paper length and inserter specifications 3 Tap to accept the fold value and advance to the next setting Set Fold B 1 Select the size of the second fold required NOTE Similar to setting fold A the inserter suggests the correct dimension for fold B 2 To change the standard setting tap the icons until the length of fold required displays A icon displays next to the fold panel you...

Page 47: ... begin processing the next batch 2 Tap the icons to toggle the batch mode to On or Off NOTE If the batch counter is turned on the inserter prompts for the batch quantity The default quantity is 50 but you may select any value up to 999 by tapping the icons 3 Tap to accept the setting Confirm Job Setup Job setup is now complete Using the inserter model and icons the touch screen display shows all t...

Page 48: ...n another trial piece to test the modified settings NOTE Any time you modify settings you must run a trial piece Incorrect Address Position Adjust Fold Settings When you run a trial piece if the address is not in the correct position refer to the Adjust Fold Settings table to help you fine tune your folds settings Adjust Fold Settings Table Fold Type Address Too Low Address Too High C Letter Fold ...

Page 49: ... 7 Tap the icons to scroll through the options or desired values 8 Tap to accept the job setting 9 Tap the Setup button to save the changes and exit setup mode Delete a Job To delete an existing job from the inserter system follow these steps This requires Supervisor level access 1 Tap the Setup button to enter setup mode 2 The Enter Access Code field displays over the inserter model on the touch ...

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Page 51: ...l Feed Jobs 3 6 Load Material 3 7 Adjust and Load the Sheet Feeders 3 7 Adjust and Load the Envelope Feeder 3 8 Adjust and Load the Insert Feeder 3 10 Run a Trial Piece 3 12 Trial Pieces and Linked Feeding 3 12 Material Changes or Double Detect Issues During Operation 3 12 Start and Stop the Inserter 3 13 Fill the Sealer 3 14 Adjust the Stacker 3 14 ...

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Page 53: ...ors perform with the touch screen to run a previously programmed job Verify the inserter has power Turn on the touch screen Log into the system Select a job Load material Adjust and load the sheet feeders Adjust and load the envelope feeders Adjust and load the insert feeders Run a trial piece Run the job Fill the sealer if needed Adjust the stacker if needed Read the safety information in this gu...

Page 54: ...touch screen 2 Press and hold the ON OFF power button for a few seconds The power button is located on the top left rim of the touch screen NOTE If the touch screen is in sleep mode press the ON OFF button Touch Screen ON OFF power button Log In 1 Tap the icon twice 2 Highlight the operator name from the list and tap 3 To launch the keyboard tap the icon in the bottom right corner of the screen an...

Page 55: ...Job button to scroll through the jobs until the job you want displays OR tap the Default button if you want to run the inserter with your default job settings NOTE Only a PB Service Representative can modify default job settings 2 Load material refer to the Loading Material section in this guide 3 If material is already loaded tap the Trial Piece button The inserter sets itself and runs a test pie...

Page 56: ... collated sets DO NOT load the sheet feeder Instead you will feed collated sets one at a time by hand as required Before you run a manual feed job pull back the lever shown here This opens the feed mechanism for manual feed operation NOTE Return this lever to its normal position when you use the feeder for automatic operation ...

Page 57: ...t clearance between the guides and the material 2 Aerate fan the stack of paper to ensure that individual sheets are not stuck together 3 Jog stack back into alignment The display indicates the correct orientation of the paper FACE UP HEAD FIRST ABC FACE DOWN FEET FIRST A B C 4 Place the paper stack onto the feed deck Allow the deck to move down and the top of the paper stack to slide under the fe...

Page 58: ...ide guides to the width of the envelopes Once adjusted back off the adjustment knob 1 4 turn This sets the correct clearance between the guides and envelopes 3 Take the stack of envelopes aerate and fan it to ensure that individual envelopes are not stuck together 4 Place the stack of envelopes into the feeder with the flap side UP and flap LAST 5 Press the envelope feeder loading switch again to ...

Page 59: ...erter 1 Press the envelope feeder loading switch to lower the feeder tray 2 Load envelopes as described earlier in this section 3 Press the envelope feeder loading switch again The envelope stack rises to the normal feeding position and processing continues automatically ...

Page 60: ...e adjusted back off the adjustment knob 1 4 turn This sets the correct clearance between the guides and inserts 2 Refer to the labels located on the insert feeder and match your insert type slip reply envelope pre folded booklet with the icon and color Identifying Your Insert If the label indicates a range of settings we recommend you select a higher number or letter for a thicker the insert 3 Set...

Page 61: ...g orientation can vary depending on the inserts As a general rule load inserts using the orientation guidelines in the table below 7 Let the wedge material prop slide down behind the stack to support the inserts Orientation Table for Loading Inserts Insert Type Orientation Slip Face up bottom edge first Reply Envelope Face up top edge first Pre Folded Face up closed edge first Booklet Face up boun...

Page 62: ...ing and return to run mode The inserter saves the job with the new settings 4 Run another trial piece to test the modified settings Trial Pieces and Linked Feeding If you are using linked feeding load both sheet feeders before running a trial piece Two trial pieces are produced when linked feeding is enabled When running the inserter the display shows 1 2 1 This confirms feeding automatically swit...

Page 63: ...V63138 Rev A Start and Stop the Inserter 1 Tap the Start button on the touch screen to begin automatic operation 2 The inserter runs until it runs out of material or you tap the Stop button on the touch screen Stop Start ...

Page 64: ...d close the cover NOTE If the sealer unit was completely empty allow time for the fresh solution or water to soak through the sealer before you resume operation This helps assure a good seal NOTE We recommend Pitney Bowes E Z Seal to minimize algae growth and scale build up Adjust the Stacker If necessary adjust the drop stacker to accommodate the job material 1 Lift the lever at the rear of the s...

Page 65: ... OMR Marks 4 8 Benchmark 4 8 Safety 4 8 End of Collation EOC 4 8 Beginning of Collation BOC 4 8 Parity 4 8 Re timing Mark 4 8 Select Feed SF1 SF2 4 9 Auto Batch 4 9 Wrap Around Sequence WAS1 WAS2 WAS3 4 9 OMR Mark Grouping 4 10 C Fold and Double Fold Jobs 4 10 Z Fold and Single Fold Jobs 4 11 Adjust the OMR Scanner 4 12 OMR Troubleshooting 4 14 Error Recovery for OMR Jobs 4 14 Error Recovery for A...

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Page 67: ...is means insertion accuracy is very high the probability of the wrong set of sheets being inserted into an envelope is low OMR and Feeders on the Inserter OMR equipped models have scanning heads on each sheet feeder One of the sheet feeders holds sheets with OMR marks and they feed multiple sheets per envelope Sheet feeder 1 for C fold and double fold Sheet feeder 2 for Z fold and single fold You ...

Page 68: ... address sheet has been inserted Enhanced OMR Allows you to stop feeding sheets at selected points in a run and or select whether the other feeders are used It provides a higher level of mailpiece integrity so that sensitive documents are not sent to the wrong customer OMR Mark Positions For the inserter scanners to read the printed OMR marks correctly they must be located within a defined range o...

Page 69: ...e area around the marks the clear zone should be kept clear from print and any other marks that the scanner might read in error There should be no print on the opposing face of the sheet immediately behind the clear zone Note diagram is not to scale 42mm maximum 3mm minimum pitch 10mm minimum 1pt to 2pt 0 35mm to 0 7mm thick 2mm minimum 2mm minimum see following diagrams for more detail of this ar...

Page 70: ... Single Fold bottom scanning bottom right corner Standard OMR Positions 54mm min 96mm max 20mm min Clear Zone 20mm x 115mm min 69mm max 27mm min 20mm min Clear Zone 20mm x 100mm min Feed Direction for Top Scanning C and Double Fold Feed Direction for Bottom Scanning Z and Single Fold 115mm min 100mm min Vertically center group within area indicated ...

Page 71: ...ft margin Z Fold and Single Fold bottom scanning right margin Offset OMR Positions 125mm min 20mm min 80mm max 20mm min Feed Direction for Top Scanning C and Double Fold Feed Direction for Bottom Scanning Z and Single Fold 95mm max 65mm min 40mm min Bench Mark 65mm min 115mm min diagram is not to scale ...

Page 72: ...the absence of this mark that is the action will take place if the mark is not read by the scanner It is therefore indicated on the OMR code as Not EOC Beginning of Collation BOC This mark indicates this sheet is the first sheet fed within the collation set Your system operates on the absence of this mark that is the action will take place if the mark is not read by the scanner It is therefore ind...

Page 73: ...aterial from the insert feeder For C and double fold the primary feeder is sheet feeder 1 For Z and single fold the primary feeder is sheet feeder 2 Auto Batch This mark identifies the last set of a batch when the batch function is in use It must appear on all sheets of the OMR set that requests this function Wrap Around Sequence WAS1 WAS2 WAS3 This is a numbering system which uses a sequential bi...

Page 74: ...uses Group 1 plus Group 2 and or Group 3 as needed for a particular job C Fold and Double Fold Jobs Place marks in the upper left corner of the sheet Print marks in top to bottom order Printing Print sheets in reverse collation order When you do this the last sheet processed in each set is the address sheet and the first sheet processed is the last of each set Benchmark fixed Safety fixed Not EOC ...

Page 75: ...t sheet processed in each set is the address sheet and the last sheet processed is the last of each set Re timing fixed if this group is in use Wrap Around Sequence 1 WAS1 Wrap Around Sequence 2 WAS2 Wrap Around Sequence 3 WAS3 Re timing fixed if this group is in use Auto Batch Select Feed 2 Select Feed 1 Re timing fixed Parity Not BOC Not EOC Safety fixed Benchmark fixed Group 3 Group 2 Group 1 M...

Page 76: ...for the bottom sheet feeder 2 remove both sheet feeder 2 and the fold plate situated below sheet feeder 2 The scanning head is mounted to the front of the inserter 3 Fold a sheet of material in half and measure the distance from the side of the sheet to the middle A4 size sheet this measurement is 105mm Letter size sheet 8 5 x 11 inches 108mm 4 Next measure the distance from the edge of the sheet ...

Page 77: ...middle of the scan dash marks is 10mm the scanning head setting will be 95mm 105mm 10mm 105mm 10mm 10mm Locking Knob 5 Loosen the locking knob and set the relevant scanning head to the correct setting 6 Retighten the locking knob 7 If you adjusted the bottom sheet feeder scanner install both sheet feeder 2 and the fold plate situated below sheet feeder 2 ...

Page 78: ...4 Tap the Start button to resume operation Start Stop Clear Deck Error Recovery for Accumulation Jobs If the inserter stops during an accumulation job follow these steps 1 Tap the Clear Deck button on the control panel 2 The envelope at the insertion area ejects into the stacker You must manually remove the remaining pages of the set from the feeder 3 Fold insert the remaining pages into the envel...

Page 79: ... 4 was absent when it was expected Pages other than the first page of the set were expected OMR Parity Error The code doesn t have an even number of marks OMR Sequence Error The sequence number is not sequential with the previous page fed Therefore sheets are in the wrong order or missing OMR SF marks Inconsistent The Selective feed and Autobatch marks at positions 7 to 9 are different from those ...

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Page 81: ...5 4 Enhanced Barcode Reading 2D barcodes only 5 4 Barcode Placement Specifications 5 5 Barcode Placement Areas 5 5 Barcode Zones Clear and Blank 5 7 2D Barcode Camera Setup 5 8 Turn On the 2D Barcode Camera 5 8 Adjust the Position of the 2D Barcode Camera 5 9 2D Barcode Scanning Final Checklist 5 10 Barcode Error Messages 5 11 2D Barcode Specifications 5 12 Paper Specifications 5 12 2D Barcode Spe...

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Page 83: ...t to the inserter The inserter checks this information and verifies that the correct sheet is fed and inserted in the envelope If a sheet is skipped or if the sheets get out of sequential order the inserter stops processing and displays an error 1D and 2D Barcode Scanning 1D barcode scanners read barcode characters in a straight line and then translates that data into instructions for the inserter...

Page 84: ...within the barcode to determine when to insert into a new envelope Enhanced 2D barcodes only uses additional information within the barcode to aid the integrity of your mailing Basic Barcode Reading 1D barcodes only Basic barcode reading is made up of 1D ladder format barcodes and can only be read by 1D scanners Basic barcode reading is used only to identify a change of the unique identification n...

Page 85: ...ent Specifications Barcode Placement Areas The barcode can be positioned anywhere within the barcode placement area shown in this diagram The areas identified here are at the bottom trail edge of the sheet The diagram below is for an 8 5 x 11 inch sheet ...

Page 86: ...5 Barcode Scanning 5 6 SV63138 Rev A The diagram below is for an A4 sheet ...

Page 87: ...o the barcode This area represented by letter A in the diagram below includes the size of the barcode plus 5mm on each side 10mm and 5mm on the top and bottom 10mm There should be no print of any kind in this area Blank Zone B The blank zone refers to a more extended area around the barcode represented by the letter B in the diagram below In this diagram the blank zone is 100mm x 60mm No other bar...

Page 88: ... on the features available on your system 1 To enable 2D barcode scanning turn the 2D barcode camera on using the On Off switch 2 To disable 2D barcode scanning turn the 2D barcode camera off using the On Off switch Barcode Camera On Off Switch When the 2D barcode camera is powered On all LEDs flash once The blue LED located where the cable enters the 2D barcode camera indicates the reader is powe...

Page 89: ... adjustment arms 4 Move the barcode scanner directly above the barcode on the sheet 5 Once the camera is positioned correctly a green light flashes on the barcode 6 Be sure the center point of the green light is to the right of the barcode when looking from the front of the machine NOTE If you adjust the camera position too far to the right the green light changes to a red light 7 When the camera ...

Page 90: ...l Checklist Confirm that you have the correct job selected Make sure that the barcode camera switch is in the ON position Verify the barcode camera is positioned correctly above the barcode adjust if necessary Follow the inserter operation procedures in this guide ...

Page 91: ...t detected by barcode scanner Add missing page s Correct sheet sequence Not a new envelope First sheet of set was detected rest of sheets were expected Add missing sheets and or correct your sheet sequence OMR Sequence error Sequence number in barcode is not sequential with the previous page fed Add missing sheets and or correct the sheet sequence OMR SF Marks Inconsistent n a Not used for barcode...

Page 92: ... only 2D Barcode Specifications Print quality Minimum requirement ANSI Grade B Recommended ANSI Grade A Black print on white paper Barcode resolution 0 20 mm Module size 0 35 mm minimum and 0 50 mm maximum Maximum 18 characters Uses ECC 200 standards Barcode cannot be printed over any text or graphics Barcode should not intersect any perforation Cells should all be identical in size ...

Page 93: ...oval 6 3 Sheet Feeders Trays Remove and Replace 6 3 Fold Plates Remove and Replace 6 4 Insert Tray Remove and Replace 6 4 Access the Carriage Assembly 6 4 Access to Envelope Feeder Area 6 5 Access the Envelope Exit Area 6 5 Access the Envelope Inserting Sealing Area 6 6 Access to the Sheet Feed Area 6 6 ...

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Page 95: ... need to use the manual advance knob to manually feed paper out of the grip of feed rollers The manual advance knob is located behind the drop down cover at the left front of the inserter Access Areas of the Inserter for Jam Removal Sheet Feeders Trays Remove and Replace To remove the sheet feeder trays 1 Lift the rear of the tray slightly and pull it straight out from the inserter NOTE If the tra...

Page 96: ... plate outward to release 2 Slide the plate into its location guides and release the catches to lock the plate in position Insert Tray Remove and Replace To remove the insert tray pull the insert tray straight out from the inserter To replace the insert tray slide the tray into the location guides push until it clicks into place Access the Carriage Assembly Pull out the carriage assembly to access...

Page 97: ...access to the jam To relatch the feed rollers 1 Release the envelope area feed rollers and let them rest in position 2 Push the rollers firmly down until they latch into position NOTE You can get better access to this area by removing fold plate 1 and sheet feeder 2 Access the Envelope Exit Area 1 Pull down the access door shown here to gain access to the jammed material 2 When you close the acces...

Page 98: ...terial Access to the Sheet Feed Area Unlatch the blue handles to access a jam in the sheet feeder area 1 Open the top cover 2 Squeeze the two blue handles together and pivot the guide assembly to the right to gain access to the jammed material To relatch the blue handles 1 Squeeze the two blue handles together and pivot the guide assembly back to its closed position 2 Release the two blue handles ...

Page 99: ...SV63138 Rev A 7 1 7 1 7 Troubleshooting and Error Messages Contents General Troubleshooting 7 3 Changing the Sealer Unit Felts 7 7 Error Messages 7 9 ...

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Page 101: ...hat all covers are closed check display for cover information Feed trays fold plates not located correctly Remove and relocate all feeders and fold plates Verify they are in the correct positions and fully seated Insertion Problems Outer envelope contents do not enter the envelope correctly Check the envelope troubleshooting information Check that the fold selected is correct for the material size...

Page 102: ...es loaded incorrectly Load envelopes flap side up with the flap feeding last Envelopes Fail to Open Envelopes loaded incorrectly Load envelopes flap side up with the flap feeding last Poor envelope quality Check the envelopes are not stuck due to excessive dampness Try a new box of envelopes Envelope Sealing Problems No sealing solution Refill the sealer unit Seal mode not selected Check job setup...

Page 103: ...when One Sheet is Expected Manual feed mode is selected Check job setup and manual feed lever position Sheets loaded incorrectly Make sure to fan stack before loading Address in Wrong Position in Envelope Window Address bearing sheets incorrectly loaded Load sheets so that the address appears through the envelope window Folds incorrectly set Check job setup Poor Folding A fold is almost correspond...

Page 104: ...lp to change the orientation of the insert stack Insert feeder wedge used incorrectly Let the wedge slide down behind the insert stack to support it Inserts out of specification Check the specifications in this guide DOUBLE DETECT Inserter Stops for Doubles that Aren t There or Feeds Doubles without Stopping Double detect is not turned ON Check double detect status Double detect icon appears along...

Page 105: ... Operators can change them as necessary 1 Open the water bottle cover located at rear right side of the inserter and remove the bottle 2 Open the envelope inverter access door and lift the insertion area plastic cover 3 Squeeze both blue tabs A together and lift one tab B to gain access to the sealer unit felts B A 4 Push the latch A back grasp the upper sealer felt B and slide it towards the fron...

Page 106: ... sure it has fully latched into position 7 Using the plastic tweezers provided in the kit remove all four felts from the sealer tank Discard these old felts 8 Install the four new felts into the sealer tank They will only fit one way Push them fully down into the tank 9 Push down on the blue tab to return the upper felt assembly to its operating position Make sure that the blue latches A spring ou...

Page 107: ... to its correct position Open the inverter cover and check for material Close the cover and restart CHECK LAST MAIL PIECE Envelope has failed to open Check the envelopes are loaded correctly Reload the envelopes and restart machine CLEAR FOLD PLATE Material was detected inside the fold plate indicated on the display Remove the fold plate and check for any material Install fold plate CLEAR INSERTIO...

Page 108: ...plates and check for any material DOUBLE FEED A double feed has been detected from the feed tray indicated Remove the material from the inserter and restart If double feeds persist request another trial piece DOUBLE FEED CHECK STACKER A double feed has been detected from the feed tray indicated Remove the double feed from the stacker Restart the inserter FOLD PLATES NOT SET The fold plates has not...

Page 109: ...incorrect position for the mode of running Move the manual feed lever to the correct position left position manual right automatic STREAM FEED The inserter detected two sheets fed together from the feed tray indicated Remove the material from the inserter Reload and restart the inserter STREAM FEED CHECK STACKER The inserter detected two sheets fed together from the feed tray indicated Remove the ...

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Page 111: ...pecifications Contents Material Specifications 8 3 Sheet Feeders 8 3 Number of sheets 8 4 Paper Weights in Pounds 8 4 Insert Feeder 8 5 Sealer 8 5 Stacker 8 5 Material Requirements 8 5 Envelope Feeder 8 6 Inserter Specifications 8 7 ...

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Page 113: ...hes 201mm 14 inches 356mm Double fold 12 inches 305mm 16 inches 406mm Double Document Detector Material Range Minimum 16 lb 60gsm Maximum 32 lb 120gsm Feed Tray Capacity maximum of 325 sheets of 20 lb bond 80gsm Manual Feed Mode Inserter processes stapled sets of up to five sheets of 20 lb bond 80gsm up to a maximum total weight of 100 lbs 400gsm per set NOTE For manual feed applications you may u...

Page 114: ...MPORTANT Do not program jobs that exceed these maximums or impose them by OMR code printing and or OMR selective feed NOTES You can use the sheet limits above with one additional sheet from the supplementary feeder plus one insert only if total mail piece contents do not exceed 0 078 in 2mm total compressed thickness For single fold only using 16 lb to 20 lb 60 75gsm paper only you can place a max...

Page 115: ...le panel inserts should be fed from the insert feeder Double Document Detector Material Range 16 lbs 60gsm minimum 32 lbs 120gsm maximum Feed Tray Capacity Up to a maximum of 300 inserts Sealer The inserter seals up to a maximum of 1 200 envelopes between refills Stacker The envelope stacker accommodates up to 150 filled envelopes depending on size and contents of the envelope Material Requirement...

Page 116: ...472 inches 12mm overall Take this measurement with all documents placed in the envelope Depth Clearance The insert must allow a minimum clearance of 0 118 in 3mm for unfolded documents and 0 236 in 6mm for folded documents below the flap crease after it is fully inserted into the envelope Envelope Flap and Throat Requirements DEPTH WIDTH 19mm Min 1 6mm Max 6mm throat depth at 19mm in from edge of ...

Page 117: ... 20 75 inches 525mm Weight 143 lbs 65kg Noise Level system running 73dBA Electrical USA and Canada 120V 60Hz 6 0A Europe 220 240V 50Hz Japan 100V 50 60 Hz Speed Up to a maximum of 3 500 cycles per hour depending on inserter condition operator skill fold type and material quality Fold Modes Single fold C Letter fold Z Accordion fold Double fold ...

Page 118: ...ave questions about your inserter or require service or assistance with your application refer to the Contact List at the front of this guide Pitney Bowes also offers a service maintenance agreement to keep your inserter in top condition For further information contact your local Pitney Bowes office or authorized dealer ...

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