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Pitney Bowes Relay 5000 Operator'S Manual Download Page 5

SV63136 Rev. A   

iii

Table of Contents

5 • Troubleshooting and Maintenance .......................5-1

Adjusting Screen Brightness and Contrast ................................. 5-2
Setting the Time and/or Date ...................................................... 5-3
Changing the Language ............................................................. 5-4
Refilling the Sealing Solution ...................................................... 5-5
Handling Material Stoppages ...................................................... 5-5

Clearing a Stoppage ............................................................. 5-5
Resuming the Job ................................................................. 5-6
Handling Outsorted Material ................................................. 5-6

Troubleshooting Tables ............................................................... 5-7
Routine Maintenance ................................................................ 5-17

Daily Tasks .......................................................................... 5-17
Replacing the Moistener Wick ............................................ 5-17
Replacing the Moistener Brushes ....................................... 5-19

6• Specifications

 ..........................................................6-1

Overview ..................................................................................... 6-2
System Specifications ................................................................. 6-2
Component Specifications .......................................................... 6-4
Feeder Tower and Base Material Specifications ......................... 6-6

General Information .............................................................. 6-6
Outer Envelopes ................................................................... 6-6
Inserts ................................................................................... 6-9
Sheets ................................................................................. 6-10

High Capacity Sheet Feeder (HCSF) Material Specifications .. 6-11

General Information ............................................................ 6-11
Sheets ................................................................................. 6-11

Materials Not Certified for Use

 ............................................ 6-12

7 • Add-On Modules .....................................................7-1

About the Add-On Modules ......................................................... 7-2
High Capacity Sheet Feeder (HCSF) ......................................... 7-2

Loading the HCSF ................................................................ 7-3
Adjusting the HCSF Guides .................................................. 7-5

Flats Sealer ................................................................................. 7-7

Replacing the Envelope Edge Marker Roller ........................ 7-8
File Based Processing .......................................................... 7-9

Exit Options ................................................................................ 7-9

MMI .................................................................... 7-10
Vertical Power Stacker  ....................................................... 7-13
Horizontal Belt Stacker ....................................................... 7-13
Exit Transport ...................................................................... 7-13

Summary of Contents for Relay 5000

Page 1: ...Operator Guide International English Edition SV63136 Rev A August 1 2015 Relay 5000 6000 7000 8000 Shipping Mailing Inserter Document Inserting System ...

Page 2: ...2015 Pitney Bowes Inc All rights reserved This book may not be reproduced in whole or in part in any fashion or stored in a retrieval system of any type or transmitted by any means electronically or mechanically without the express written permission of Pitney Bowes We have made every reasonable effort to ensure the accuracy and usefulness of this manual however we cannot assume responsibility for...

Page 3: ...erting System 2 1 System Components 2 2 Feeder Tower 2 4 Feeder Trays 2 5 Sheet Trays 2 5 Insert Trays 2 6 Manual Feeder 2 7 Transport Deck 2 8 Mail Piece Path 2 8 Pre fold Accumulator 2 8 Folder 2 9 Post fold Accumulator 2 9 Insertion Area 2 9 Folder Bypass Path 2 9 Moistener Closer Sealer 2 9 About the Control Panel 2 10 Screen Option Keys 2 10 Fixed Function Keys 2 11 Machine Action Keys 2 13 S...

Page 4: ...acity Envelope Feeder HCEF 3 13 Making Pre Run Adjustments 3 18 Adjusting the Envelope Openers 3 18 Running a Trial Piece 3 22 Reviewing the Job Settings 3 24 Starting the Job 3 25 SwiftStart Jobs 3 25 Using SwiftStart 3 26 Creating a Job 3 26 Job Options 3 30 Envelope Options 3 30 Fold Options 3 32 Sheet Options 3 33 Insert Options 3 36 Editing a Job 3 40 Modifying Job Settings 3 41 Editing an It...

Page 5: ...fications 6 1 Overview 6 2 System Specifications 6 2 Component Specifications 6 4 Feeder Tower and Base Material Specifications 6 6 General Information 6 6 Outer Envelopes 6 6 Inserts 6 9 Sheets 6 10 High Capacity Sheet Feeder HCSF Material Specifications 6 11 General Information 6 11 Sheets 6 11 Materials Not Certified for Use 6 12 7 Add On Modules 7 1 About the Add On Modules 7 2 High Capacity S...

Page 6: ...ing the Scan Heads for Ladder or 2D Orientation Marks 8 24 Adjusting the Scan Heads for Picket Orientation Marks 8 27 OMR Specifications 8 29 OMR Print and Placement Specifications 8 30 OMR Placement Specifications for Feeder Tower Ladder Orientation 8 30 OMR Print and Placement Specifications 8 31 OMR Placement Specifications for HCSF New Scan Kit F790250 Ladder Orientation 8 31 Barcode Specifica...

Page 7: ...Information 8 40 BCR and OMR Mark Levels 8 40 Basic Level 8 41 Enhanced Integrity Level 8 43 Enhanced Integrity Level Selective Operations Level 8 45 Appendix A Glossary A 1 Basic Terms A 2 Material References A 2 Machine Functions A 3 Icon Glossary A 4 Envelope Icons A 4 Fold Icons A 5 Sheet Icons A 5 Insert Icons A 6 Feeder Assignment Icons A 7 Other Icons A 7 ...

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Page 9: ...m and click on My Account For direct questions call 1 800 522 0020 Customer Service Representatives are available Monday through Friday 8 00 AM 8 00 PM ET To obtain Material Safety Data Sheets call the Supply Line or go to www pb com and click on Customer Support Canada Contacts Product Name Relay 5000 6000 or Relay 7000 8000 For frequently asked questions or to order supplies go to www pitneybowe...

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Page 11: ...s A Note to the Operator 1 3 About Your System 1 3 System Features 1 3 System Components 1 3 Standard Systems 1 4 System Options 1 5 Safety Information 1 6 Safety Information continued 1 7 Warning Labels 1 7 1 Introduction ...

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Page 13: ...erts thin booklets and envelopes The Relay 7000 8000 system is equipped with a dedicated High Capacity Envelope Feeder HCEF that allows for greater speed and throughput The systems also accept material from optional upstream input devices System Components The systems are configured with two major components Feeder Tower Transport Deck The feeder tower sends material from the feeder trays to the t...

Page 14: ...tacker standard on all systems Standard Systems IMPORTANT Model and feature availability varies by country Contact your machine supplier for more information This guide covers all models and features Information included in this guide does not guarantee availability of a particular model or feature within your country ...

Page 15: ... Connect System Options Furniture designed specifically for the system is also available Flats Sealer IMPORTANT Model and feature availability varies by country Contact your machine supplier for more information This guide covers all models and features Information included in this guide does not guarantee availability of a particular model or feature within your country ...

Page 16: ... or trap it between pieces of furniture Make sure there is no strain on the power cord To reduce the risk of fire or electrical shock DO NOT attempt to remove covers or disassemble the control panel or its base The cabinet encloses hazardous parts If you should damage the unit contact your system supplier Refer to the Contact Information List at the front of this guide for more information If the ...

Page 17: ...isplay workplaces To avoid incommoding reflexions at visual display workplaces this device must not be placed in the direct field of view If your stacker has an AC adapter to power the stacker Use only the AC adapter designed specifically for the stacker Third party AC adapters may damage the stacker To protect against electrical shock plug the AC adapter power cord into a properly grounded wall o...

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Page 19: ...anel 2 11 Screen Option Keys 2 11 Fixed Function Keys 2 12 Fixed Function Keys continued 2 13 Machine Action Keys 2 14 Screen Navigation Keys 2 14 Display Screen 2 15 Header Area 2 15 Status Area 2 16 Status Area continued 2 17 Status Area continued 2 18 Status Area continued 2 19 Status Area continued 2 20 Access Rights 2 21 Access Rights continued 2 22 Logging In 2 22 Logging Out 2 22 About Syst...

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Page 21: ... the system System Components 1 Feeder Tower Trays feed sheets or inserts to the feeder tower NOTE If enabled the lower left tray is assigned with the letter A on the Mail Piece Icon Tree When a High Capacity Envelope Feeder is not part of the system configuration this Tray is the primary tray for feeding envelopes designated for a given job 2 Feeder Tower is a two sided tray holder material feede...

Page 22: ...to an outer envelope 8 Moistener Closer Sealer Brushes sweep across the envelope flap to wet the glued area of the flap The letter size envelope then moves through the Closer and Sealer areas of the unit to complete the mail piece 9 Sealing Solution Bottle is located inside an opening cover at the front right side of the machine It provides sealing solution to the envelope sealing system 10 Contro...

Page 23: ...rollers This makes it easy to access media that may stop as it exits the tower Depending on the configuration the tower accepts two or four feeder trays Feeder Tower Figure 2 2 2 Two sided Feeder Tower Open for easy access to Feed Rollers Figure 2 2 1 Latch Opens Feeder Tower Push latch up to open Tower cover CAUTION Moving mechanism can result in personal injury Keep hands long hair ties jewelry ...

Page 24: ...pe of material selected for a given job Feeder Trays Sheet Trays Sheet trays feed flat unfolded material Use only the recommended materials Refer to the specifications in this guide NOTE Sheet trays have fill marks on their side walls Be sure to keep your stack of materials at or below these marks to avoid feed problems Figure 2 3 1 Sheet Trays ...

Page 25: ...lets slips and pre folded media into the system Insert Trays have a weighted sliding mechanism known as a sled that keeps pressure on the material for proper feeding Insert trays have two sets of maximum fill lines one set for slips and a second set for envelopes Insert Trays Figure 2 3 2 Insert Tray Sled mechanism ...

Page 26: ...he current job has to be defined as manual for the feature to work The job with the manual fed piece can also include items from other feeders including sheets or inserts To use the manual feeder 1 Select a job that uses the manual feeder 2 Push the Manual Feed lever up 3 Press TRIAL PIECE to start the inserter 4 Feed each set by pushing the edge into the rollers one at a time 5 Push the lever dow...

Page 27: ...shed mail piece that is dropped into a stacking bin or onto an optional high capacity output stacker A brief description of the function of each module in the paper path is presented next Mail Piece Path Pre fold Accumulator The pre fold accumulator is the first stop in the paper path The pre fold accumulator is a stacking place for the material that needs to be collated and folded When the approp...

Page 28: ...ts are present the stack moves to the insertion area Insertion Area The contents of the mail piece meet the outer envelope at the insertion area The envelope arrives at the insertion area with its front face down and flap open Envelope openers on the insertion area open the envelope wide enough to allow the contents to be slid inside Folder Bypass Path The outer envelope fed from the feeder that w...

Page 29: ...eft in the Display and to apply selections that you ve made Machine Action Keys control hardware components and mechanical movements LED Status Indicator About the Control Panel The screen option keys are the eight keys on the right side of the screen These keys correspond to options on the screen and therefore have no dedicated labels Use these keys to highlight an item in a displayed pick list a...

Page 30: ...or each completed mail piece If you run the same job but for a different customer and or use different materials you ll need to zero the counter and ready it for counting the completed mail pieces in the new run To reset the piece counter 1 Press RESET COUNTERS to display the Reset Counters screen 2 Select Piece Count 3 You will be returned to the Home screen The piece counter at the bottom of the...

Page 31: ...g Both Counters The Reset Both selection allows you to reset both the piece counter and the batch counter to zero 1 Press RESET COUNTERS to display the Reset Counters screen 2 Select Both 3 You are returned to the Home screen The piece counter at bottom of the screen will read 0 and the batch counter returns to original setting Help Select Help for information about the screen that currently displ...

Page 32: ...tem of materials currently in process in the paper paths NOTE Only press CLEAR DECK when prompted by the system to minimize lost material and manual mail piece generation Stop Press STOP to finish in process mail Machine Action Keys The four keys along the bottom of the control panel are called machine action keys Use these keys to run the system Screen Navigation Keys The screen navigation keys m...

Page 33: ...navigation directions Header Area Display Screen The display screen is divided into two major areas Header area Status area Display screen Header Area Status Area Home Job ABC Low Sealant Select Another Job SwiftStart Menu Loading Instructions and Pre Run Adjustments Run Trial Piece Job Items A B D Pieces 1658 The top blue band dis plays the name of the screen and Job The bottom green band display...

Page 34: ...t icon indicates that the seal feature is enabled Status Area Each icon has one darker edge either at the top or bottom that indicates the leading edge of the material The leading edge of an object is the edge that feeds into the machine first For example a sheet that must be loaded face up with the top of the sheet leading would be represented by a face up sheet icon containing a leading edge lin...

Page 35: ...rol of the OMR or Barcode marks and so a small letter n will appear in place of the number 3 Number of sheets in set Lines between the icons indicate the way the mailpiece is assembled The outer envelope is at the top of the icon tree Making any change to the job settings can cause the feeder tray assignments to change in the Mail Piece Icon Tree NOTE Any time the job set up changes be sure to che...

Page 36: ...umu lated together and the C Fold is applied to them An Insert see the Reply Envelope icon always appears as a single set within the Mail Piece Icon Tree Example Mail Piece Icon Tree Window Envelope loaded flap down flap last Envelope sealing turned on loaded into Feeder G C Fold selected Top address loaded Face Up fed Top First loaded into Feeder C Double Detect is on Additional Sheet No address ...

Page 37: ...t an icon in the Mail Piece Icon Tree to display information about the item that the icon represents In most instances an image appears in the status area of the screen and shows the required orientation for loading the item into the Tray Figure 2 6 Sample Material Orientation Picture Status Area continued ...

Page 38: ...elected item in the screen Selection of the available options is done via the screen option keys that were described earlier in this chapter See the example screens below Example Options Display Example Functions Display A D B C Jobs Job 123 Job Items A D B C Edit Current Job Review Current Job Save Current Job Create New Job Delete Saved Job Finished Select Job A D B C Edit Outer Envelope Job 123...

Page 39: ...perators have access to any of the function not listed as supervisor or manager functions System operators may be required to log in and out of the system if a security mode has been enabled Chapter 3 describes the steps involved with performing each of the non restricted procedures Supervisors have access to all operator functions and the following after logging in with the correct access code or...

Page 40: ...g in to perform operator functions 1 The Select User screen displays Select the appropriate user ID NOTE If necessary press Next to view additional user IDs 2 Enter your password NOTE Passwords are four digit numeric codes Numbers 1 2 3 4 and 5 display on the first screen Press Next to access numbers 6 7 8 9 and 0 3 Press Accept once you have entered your password The Home screen displays If Login...

Page 41: ... to paper release knobs Covers on the top of the transport deck open to provide access to the rollers in the main paper path Post fold Accumulator Cover Insertion Area Cover Figure 2 7 2 Top Covers Pre fold Accumulator Cover Folder Cover Figure 2 7 1 Front Covers Sealer Replacement Cover closed Tower Base Cover closed Main Transport Deck Cover open ...

Page 42: ...port deck cover 2 Pull down on the tower base cover handle The tower base cover interlocks with the main transport deck cover This means that you cannot open the tower base cover unless you open the main transport deck cover first Opening the Covers Closing the Covers To close the lower tower and or the main transport deck cover push the cover up until it is seated in place on the system deck CAUT...

Page 43: ...Each paper release lever opens an area of the system and allows you to clear any material that may have stalled The images here indicate the various knob lever locations as well as the areas each knob moves material through and each lever opens 1 7 8 2 4 9 6 1 4 2 7 8 9 6 Paper Release Knob Lever Locations and Related Areas Controlled by Knob 2 About Add On Modules The system accepts a number of a...

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Page 45: ... 3 14 Making Pre Run Adjustments 3 19 Adjusting the Envelope Openers 3 19 Running a Trial Piece 3 23 Reviewing the Job Settings 3 25 Starting the Job 3 26 SwiftStart Jobs 3 26 Using SwiftStart 3 27 Creating a Job 3 27 Job Options 3 31 Envelope Options 3 31 Fold Options 3 33 Sheet Options 3 34 Insert Options 3 37 Editing a Job 3 41 Modifying Job Settings 3 42 Editing an Item 3 42 Adding an Item 3 4...

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Page 47: ...plain how to Properly power up the inserting system and Select a job Connecting to Power Press the ON OFF switch located below the control panel to start the pow er up process NOTE If a High Capacity Sheet Feeder HCSF is present power on before you power on the base The system will automatically conduct a number of checks to verify the op erational integrity of the system If any problems are detec...

Page 48: ...means to select a different job edit settings for the displayed job use the SwiftStart feature and view loading instructions for the selected job Home Screen If you need to adjust the screen brightness or contrast refer to Chapter 5 for detailed procedures Home Screen Home Job ABC Low Sealant Select Another Job SwiftStart Menu Loading Instructions and Pre Run Adjustments Run Trial Piece Job Items ...

Page 49: ...k or pile of material loaded into a feeder Follow the loading instructions each time before you run a job The loading orientation may change depending on the Feeder assignment and job settings For instance one Feeder may need to be loaded bottom first and another top first Feeder assignments are determined by the machine to best optimize the job This means they are assigned only after a job is sel...

Page 50: ...ble in that category 4 Select the desired job from the list If the job does not appear on the first page use the UP DOWN arrow keys to scroll through the list As any job is highlighted in the list the Mail Piece Icon Tree for the job appears on the display so that it can be identified Selecting the Job If the job that you want to run is the one that currently displays in the Home screen proceed to...

Page 51: ...der is present you will need to load material into it Refer to Adjusting the HCSF Guides in Chapter 7 for more information Setting Up Feeders and Loading Materials The procedure for attaching either type of tray to the feeder tower and the loading instructions for either type of tray are essentially the same NOTE Use both hands when attaching or removing a tray 1 Align the back end of the tray wit...

Page 52: ... at the angle at which the Tray sits to ensure it is securely attached If it isn t repeat the procedure until the tray seats properly and securely Figure 3 1 2 Check Tray Seating Figure 3 1 2 Tray Seated Properly in Tray Mount bottom view Notch on Tray Groove on tray mount Removing Trays from the Feeder Tower The procedure for removing a sheet or insert tray consists of the following 1 Grasp the o...

Page 53: ...g information will display Graphic of the document media type Tray type into which the document media should be loaded Orientation of the document in the tray It is important to loosen fan any items in the stack that may be stuck together BEFORE you place the material in the tray To do this 1 Hold one end of the stack in one hand 2 Flip through the opposite end of the stack with your other hand 3 ...

Page 54: ... against the side guide adjustor at the open end of the tray 2 Use the palm of your hand to turn the side guide adjustor Turn the adjustor counterclockwise to move the side guides in towards the material Turn the adjustor clockwise to move the side guides out and away from the material 3 When the side guides contact the material in the tray remove your hand from the adjustor The guides will automa...

Page 55: ...ng a Sheet Tray NOTE To view a demo of the sheet tray loading and side guide adjustment processes go to the Home screen and select Loading Instructions and Pre Run Adjustments Use the UP DOWN arrow keys to select a Sheet being fed by the Feeder Tower from the Mail Piece Icon Tree then select Feeders Setup Demo To load media into a sheet tray 1 Using the side guide adjustor open the sides of the tr...

Page 56: ... the sides of the tray beyond the width of the material 3 Stand a stack of material straight up and against the front end of the tray and in the orientation specified on the Mail Piece Icon Tree and Home screen loading instructions 4 Using the side guide adjustor bring the sides of the Tray lightly against the material then release the adjustor The guides will automatically spring back to a positi...

Page 57: ...Allow the sled to move forward 8 Slide the sled until it contacts the end piece in the stack of material and then release your hold on the material NOTE Items in the Mail Piece Icon Tree on the display represent the material in the selected job Use the arrow keys to highlight any icon to view a picture of the orientation of material in the tray and the designated location of that tray on the feede...

Page 58: ... Run Adjustments Use the UP DOWN arrow keys to select the envelope being fed by the HCEF then select Feeders Setup Demo Adjusting the HCEF Side Guides 1 Place an envelope between the side guides 2 Using the adjustor knob bring the side guides in to lightly touch the envelope 3 Release the knob The guides will spring back to the correct position to allow free sliding of the envelope between the sid...

Page 59: ...TE Ensure the envelope is centered not angled on the center guide to obtain correct positioning If the position of the envelope is incorrect the separator gap adjustment will be incorrect as well 2 Push up and release the blue wedge locking lever 3 Slide the wedge toward the envelope until the top edge of the envelope fits into the center slot of the wedge Loading the HCEF continued Figure 3 7 1 A...

Page 60: ...6 SV63136 Rev A 3 Basic Operation Loading the HCEF continued 4 Push down on the trail prop locking lever to lock the wedge into place and remove the envelope Figure 3 7 2 Corner of Envelope in Center Slot ...

Page 61: ...efer to Adjusting the HCEF Wedge in this chapter for more information 1 Prepare an envelope for the separator gap adjustment a Cut a strip of 20 lb 80 gsm paper to fit inside an envelope b Insert the strip of paper into the envelope NOTE Tap the envelope lightly against a hard surface to ensure the strip of paper rests all the way down at the bottom of the envelope c Close the envelope flap 2 Push...

Page 62: ...s or Adjusting the Printer Interface Guides in Chapter 7 of this guide for more information If you are using scanning you may need to adjust the scan head to ensure the bar code or OMR mark is read Refer to Adjusting the Scan Heads in Chapter 8 of this guide for more information 3 Place the envelope bottom edge first into the separator so the top edge flap crease lines up with the edge of the tab ...

Page 63: ... Instructions from the Home screen and then select Pre Run Adjustments and finally select Envelope Opener Settings NOTE The system will automatically select the feeder when only one outer envelope is being used If multiple outer envelopes are to be used you need to select an envelope Feeder 3 Press TRIAL PIECE to feed one envelope to the insertion area 4 Open the insertion area cover and observe t...

Page 64: ...ers with the outer edges of the envelope Push down on the thumbscrews to ensure the outer envelope openers align with the envelope If using small envelopes less than 7 5 inches 194mm wide move the outer envelope openers out and away from the outer edges of the envelope If using windowed envelopes ensure the outer envelope openers do not touch the edges of the window 3 Tighten the thumbscrew on the...

Page 65: ...Envelope Opener Thumbscrews a Position the inner envelope openers so they do not touch the edge of the window In unusual circumstances i e vertical windows it may be necessary to place the opener on the window to prevent the opener from catching on the window s edge b Tighten the thumbscrews for the adjusted openers 2 Press down then pull one of the knobs on the top of the frame to deter mine how ...

Page 66: ...o Envelope Insertion Edges of Inner Envelope Openers Adjusting Manual Lever for Stiff Media Mode Relay 8000 Only Mail pieces with stiff inserts leave the machine through the flats exit The Stiff Media feature requires manual lever with sensor to hold the flats gate open This hardware is included with Relay 8000 inserters Once one or more inserts have been designated stiff the job requires an envel...

Page 67: ... the material in the Tray and loca tion of the tray on the feeder tower 2 Load the mail piece components into the feeder trays 3 Press TRIAL PIECE The system collates all contents of the mail piece according to the job parameters The resulting mail piece is fed to the upper divert area waiting for your inspection It does not go through the sealer The Trial Piece Complete screen displays 4 Examine ...

Page 68: ...r to a document s in the mail piece run Trial Piece again to verify machine function and mail piece accuracy Any edits you make are NOT saved unless a Supervisor Manager specifically saves them d If you need to check verify the job settings access the Review Job screen select Home Menu Jobs Review Job 5 Depending on your findings choose one of the following options listed on the Trial Piece screen...

Page 69: ...ct Jobs Review Current Job 3 Use the arrow keys to scroll through the settings for the job and each of the included items Select Edit Job to access screens for making changes Select Finish to return to the Menu screen Press HOME to return to the Home screen NOTE Make sure that the materials in the mail piece meets material specifications Refer to the Specifications listed in Chapter 6 Review Job S...

Page 70: ... four sheets and three inserts Relay 50000 6000 or four sheets and four inserts Relay 7000 8000 Fold will be determined by sheet length and envelope depth NOTE The maximum content options are available only when two HCSFs are present Maximum sheet length is 11 5 8 inches 297mm Only envelope depths of 4 1 4inches to 6 3 8 inches 109mm 111mm 114mm 121mm and 162mm can be used Cannot be used to run fo...

Page 71: ... from loaded Trays Feeders have been fed the system produces a sample mail piece 4 Check the trial piece and then make any needed adjustments Repeat the trial piece run until the mail piece meets your specifications 5 Press START to run your job 6 If you wish to save this job you will need supervisor or manager access to enter a name in the save job screen Creating a new job involves defining the ...

Page 72: ...pt when done NOTE If this is a scanning job and you will be using dynamic envelope selection you must select No Two Outer Envelopes 5 The Create Select Next Item screen displays Select the appropriate option Menu Options Associated Options Actions Reply Card Reply Envelope Pre Folded Insert Small Booklet Slip Generic Insert Large Booklet Stiff a If this is a scanning job follow the steps below Oth...

Page 73: ...figuration The Content in Line with Marks screen displays If there is content in line with the scan marks select Yes If there is no content in line with the scan marks select No If you selected Yes the Mark Locations Settings screen appears Follow the steps below to enter the various mark related measurements Select an option then use the UP DOWN arrow keys to enter the appropriate measurement in ...

Page 74: ...t mailing system via a USB connection The system sends start and stop signals to the mailing system and the mailing system can send error messages back to the inserter to stop feeding Toggle Off means this feature will not function for this job or On means this feature is active NOTE The MMI is a purchasable exit option Only letter sized envelopes can be used with this interface Refer to Connect M...

Page 75: ...ce of windowed envelope Standard Flap is a regular envelope Forward Flap means the window and flap are on the same side of the envelope Bottom Flap means the flap is at the bottom instead of the top of the envelope Seal refers to using the Moistener unit to close the envelope Off means the envelope will not be sealed closed or On means the envelope will be sealed closed Safe Seal means the envelop...

Page 76: ...location must be at least 2 inches 5mm away from the edge of the window if present at least 2 inches 5mm away from the edge of flap and cannot lie on top of a seam For best results be sure to avoid areas that overlap with the window flap or seams Action On Double allows you to select where the items should be fed to if a double is detected Feeder Type allows you to change the Feeder setting when m...

Page 77: ...een for each fold type address combination Use the UP DOWN Arrow Keys to select desired length Press Accept when done Fold Options Envelope Options continued Menu Item Associated Options and Actions Additional Settings continued Envelope Select Feed allows you to indicate when the envelope should be used Toggle Main Alternate NOTE This option is enabled only when the Scan feature is activated two ...

Page 78: ...ct Accept when done NOTE Quantity is always set to Variable n for scanning jobs Page Order identifies the feeding pattern of multiple sheets that are not identical Forward indicates page 1 is on top and pages 2 3 4 etc follow in that order Reverse indicates that the last page for example page 4 is first followed by pages 3 then 2 then 1 NOTE This menu option appears as a read only field when the j...

Page 79: ...uble allows you to select where the items should be fed to if a double is detected Feeder Type allows you to change the Feeder setting when material is problematic or to indicate that the job requires a Custom Feeder NOTE This menu option is not available when the job requires an Attached Printer Normal is used for most items Manual Feed is used when items will be fed into the system by hand Refer...

Page 80: ...ar Zones before and after the scan marks Refer to OMR Specifications in Chapter 8 for more information on the Clear Zone and mark location settings Item Over Count Quantity is the number of sheets to be accumulated before the system takes an alternate action Item Over Count Action indicates what will happen to items that exceed the item over count quantity Choices include Divert Select this option...

Page 81: ...dia must be placed in the flats position to run the job Refer to Making Pre Run Adjustments for more information Personalized means the insert contains information customized to a specific recipient NOTE This menu option is not available when Large Booklet is the selected insert Yes means there is unique information on this insert or No means the insert does not contain unique information Quantity...

Page 82: ...t length Use the UP DOWN Arrow Keys to select number Select Accept when done NOTE If the job requires a Large Booklet you must enter the sheet length using this Custom Length option The job will not be valid if the booklet length is not entered Custom Length Large Booklet Only allows selection of large booklet size 8 5 inch x 11 inch 216mm x 279mm or 5 5 inches x 8 5 inches 140mm x 216mm NOTE If t...

Page 83: ...to if a double is detected Feeder Type allows you to change the Feeder setting when material is problematic or to indicate that the job requires a Custom Feeder NOTE This menu option is not available when the job requires an Attached Printer The custom feeder is selected automatically when Large Booklet is the selected insert Normal is used for most items Manual Feed is used when items will be fed...

Page 84: ...ne Length of Clear Zone is the distance from the top of the Clear Zone to the first mark Refer to OMR Specifications in Chapter 8 for more information on the Clear Zone and mark location settings Item Over Count Quantity is the number of inserts that cannot be run normally NOTE At this time only a single insert can be added to each mail piece When using a flat envelope the insert must be a Reply E...

Page 85: ...an item to a different position in the mail piece collation Modifying settings for the job NOTE The options available in the Edit Job screen vary and depend on the item selected and the number of available Trays on the Feeder Tower Edit Job Screen Edit Job Job 123 A B C D Press to highlight an item to edit Job Items Edit Job Settings Edit Highlighted Item Move Highlighted Item Delete Highlighted I...

Page 86: ...an Item You can edit items to your mail piece one at a time using the procedure de scribed below To edit an item in a mail piece 1 From the Home screen select Menu Jobs Edit Current Job The Edit Job screen will display 2 Use the UP DOWN arrow keys to select the item A highlight will appear around the selected item 3 Select Edit Highlighted Item 4 The next screen that displays depends on the item y...

Page 87: ...t Add Insert or Add Large Booklet the Add Item Location screen displays Adding an Item a Use the UP DOWN arrow keys to indicate where in the Mail Piece Icon Tree the mail piece collation to place the new item An insert marker highlights the selected area b Press Accept Highlighted Location when you are done c Depending upon the item you selected the Add Sheet Add Insert or Add Booklet screen appea...

Page 88: ...cide that you don t want the changes that you ve made press CANCEL The Confirm Cancel prompt displays Press Don t Keep Changes to discard the new entries You will be returned to the Edit Job screen 8 To retain your changes for this job select Accept in the Edit Job screen 9 To store the job changes permanently select Save Job in the Menu screen This requires supervisor or manager access to save a ...

Page 89: ...e Move Item Location screen displays 4 Use the UP DOWN arrow keys to move the red insert marker to the area in the collation where you want to relocate the item 5 Select Accept Highlighted Location You will be returned to the Edit Job screen NOTE Recheck the Mail Piece Icon Tree Moving an item can cause the feeder assignment to change If it does be sure to load the designated item into the correct...

Page 90: ...plays 2 Use the UP DOWN arrows to select the item to be deleted A highlight will appear around the selected item 3 Select Delete Highlighted Item 4 Select Yes Delete Item You will be returned to the Edit Job screen NOTE Re check the Mail Piece Icon Tree Deleting an item can cause the feeder assignment to change If it does be sure to load the designated item into the correct feeder ...

Page 91: ...A 4 Advanced Operation Contents Overview 4 3 Using the Alphanumeric Matrix 4 3 Saving a Job 4 4 Deleting a Job 4 5 Assigning User IDs and Passwords 4 6 Enabling and Disabling the High Capacity Sheet Feeder HCSF 4 6 ...

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Page 93: ...s Overview The alphanumeric matrix allows you enter text for naming items and job for entering job comments and for logging in and out of the system Using the Alphanumeric Matrix 1 Use the UP DOWN and LEFT RIGHT Screen Navigation Arrow keys to select any of the following Desired character Add a blank space in the Job Name and or Job Comments Backspace to delete the character that appears immediate...

Page 94: ... Select Save Current Job from the Job Screen Refer to Editing a Job in Chapter 3 of this guide for more information NOTE If you are not logged in with supervisor or manager access rights you will be prompted to enter an access code 2 The Save Job screen displays Select Finished to save updates and edits made to the current job To Save Current Job as a Different Job new or replace existing job 1 Se...

Page 95: ...with supervisor or manager access rights you will be prompted to enter an access code 4 Select the name of the job you want to delete 5 Select Delete Job to confirm the delete command NOTE Selecting Delete causes permanent deletion of this job from the sys tem s memory However if this is the current job the job name will appear on the Home screen as it is still in the system s working memory Addit...

Page 96: ...l screen displays a Use the UP DOWN arrow keys to select the appropriate access level operator supervisor or manager NOTE Refer to Access Rights in Chapter 2 of this guide for more infor mation b Select Accept User Level when done 7 The Enter Password screen displays a Enter the password NOTE Passwords are four digit numeric codes Numbers 1 2 3 4 and 5 display on the first screen Press Next to acc...

Page 97: ...e 5 5 Refilling the Sealing Solution 5 6 Handling Material Stoppages 5 6 Clearing a Stoppage 5 6 Resuming the Job 5 7 Handling Outsorted Material 5 7 Troubleshooting Tables 5 8 Routine Maintenance 5 18 Daily Tasks 5 18 Replacing the Moistener Wick 5 18 Replacing the Moistener Brushes 5 20 5 Troubleshooting and Maintenance ...

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Page 99: ...ntrast screen Press the UP DOWN arrow key s to increase decrease screen brightness Press the LEFT RIGHT arrow key s to decrease increase screen contrast To return to the default settings select Restore Defaults 6 When you are done Press Finished to back through the configure system screens and return to the Home screen Your settings will be saved OR Press HOME to save your adjustments and return d...

Page 100: ... will be prompted to enter an access code 5 Press the LEFT RIGHT arrow key s to select the item you want to change i e Month Day Year Hour or Minute The items highlight as you press the LEFT RIGHT arrow key s 6 Press the UP DOWN arrow key s to select the desired number 7 When you are done Press Finished to back through the configure system screens to the Home screen Your settings will be saved OR ...

Page 101: ...3 The Change Language screen displays the list of available languages If necessary use the Next and Previous options to view additional lan guages on the list then select the appropriate language 4 Select Finished when done 5 Press HOME to return directly to the Home screen Change Language Screen Change Language English International English North American Français Canada Deustch Español Français ...

Page 102: ...will require a brief waiting period to allow the wick to get moist Handling Material Stoppages If a stoppage occurs the system immediately stops the run and displays an error message Follow the instructions on the Display screen to get your system running again The procedure s involved with removing material that has caused the stop page resuming the run and handling the outsorts are explained nex...

Page 103: ...se The job will resume counting from the last complete mail piece that it produced During the recovery from jams and other machine stoppages the system will automatically clear material from the transport deck that cannot be completed by the inserter The system counts all mail pieces that it has successfully completed trial pieces included but partially assembled pieces are not counted and are tra...

Page 104: ...utton to restart system If problems persist call your system supplier Display timeout Press the OK key turn on the display Display is too light or dark contrast and or readability problem Poor contast brightness adjustment Adjust contrast and or brightness settings See Adjusting Screen Brightness and Contrast in this chapter The system will generate an error message when a problem occurs The messa...

Page 105: ...prevent material from feeding Check that material is loaded in the correct feeder and in the proper orientation Paper fragments or debris in tray rollers or tower transport Inspect feed rollers and transport path Remove paper fragments before running a clear deck Double or multiple feeds stream feeding Material not within specifications Check that all material meets published specifications Refer ...

Page 106: ...piece again Refer to Sheet Options or Insert Options and Running a Trial Piece in Chapter 3 for more information If the problem persists turn double detect off Tray is feeding a mix of different thickness sheets paper e g some 20 lb and 24 lb sheets mixed If the material is consistently a certain weight i e printer was initially loaded with 20 lb 80gsm paper then accidentally loaded with 24 lb 90g...

Page 107: ... Check Side Guide adjustment on Trays Skewed material is a common cause of problems in the Tower area Refer to Adjusting Tray Side Guides in Chapter 3 of this guide for instructions Paper fragments or other obstruction in transport Inspect Clean Flexible plastic material guides in Tower area are broken or displaced Open Tower cover and inspect If replacement is necessary call your system supplier ...

Page 108: ...n is five fingers three inner envelope openers and two outer envelope openers The alternative configuration is three fingers three inner envelope openers To obtain the alternative configuration slide the fingers outside of the envelope If the envelope is too wide to have the fingers completely out of the envelope take the lower part of the outside fingers off Envelope Size Fulls Size Booklet Sheet...

Page 109: ...to feed direction Refer to Adjusting the Envelope Openers in Chapter 3 for setup adjustment instructions Insufficient edge clearance Check clearance envelope width must be at least 5 inch 13mm greater than the sum of the width of the widest insert plus the insert pack thickness NOTE For the special case of a single piece into a standard business envelope 9 mm clearance is sufficient Insertion pack...

Page 110: ...set the Envelope Width and Widest Enclosure Width to the exact dimensions of the insertion pack 1 From the Home screen select Menu then Jobs 2 Select Edit Current Job Edit Job Settings Advanced 3 Select Aligner then On with Custom Settings The Customer Aligner Settings screen displays 4 Select Envelope Width Use the UP DOWN arrow keys to increase or decrease the measurement as necessary Select Acc...

Page 111: ...From the Home screen select Menu then Jobs 2 Select Edit Current Job Edit Job Settings then Advanced 3 Select Aligner then On with Custom Settings The Customer Aligner Settings screen displays 4 Select Envelope Width Use the UP DOWN arrow keys to increase or decrease the measurement as necessary Select Accept 5 Select Widest Enclosure Width Use the UP DOWN arrow keys to increase or decrease the me...

Page 112: ...ons in Chapter 3 First piece following trial piece is a false double The initial trial piece was likely a real double Run the trial piece again Refer to Running a Trial Piece in Chapter 3 Envelopes stop in flapper OR Envelopes stop in the transport beyond the flapper and are not flapped or partially flapped Incorrect loading of envelopes Ensure envelopes are properly oriented per the loading instr...

Page 113: ...OR A single collation is broken in two and inserted into two envelopes OR System stops and declares an error NOTE Recommended OMR thickness is 0 012 0 33mm to 0 49 12mm For general information on scanning see Chapter 8 Scanner head position improperly adjusted Check position adjustment of scanner head See instructions in Chapter 8 Selected scan definition is incorrect for job Select correct scan d...

Page 114: ... towels on the Sealer deck to the left of the reservoir The towels will capture any water that may drip from the old wick car tridge This section outlines the maintenance tasks you can perform on the system Be sure to schedule routine service with your system supplier at the appro priate intervals Remove any excess paper dust that has accumulated on or around the system modules Use a damp cloth to...

Page 115: ...u Replacing the Moistener Wick continued b Place the index finger of the other hand on other latch closest to you c Slide the latches away from each other until both latches are free of the wick cartridge below them 4 Pull the old wick cartridge straight up and out of the reservoir and place it on the paper towels Figure 5 2 Releasing the Rear Latch Figure 5 3 Removing the Old Wick Cartridge ...

Page 116: ...ss down on the ends of the cartridge to make the two bump features of the cartridge sit below the top edges of the reservoir 8 Slide the plastic latches toward each other and over the new wick car tridge until they snap into place 9 Close the Insertion Area cover Replacing the Moistener Brushes Replace the moistener brushes when they show wear To do this 1 Open the Insertion Area cover Figure 5 4 ...

Page 117: ...istortion of the bristles will prevent envelopes from sealing correctly a Hold the blue brush holder in place with one hand b Insert the metal edge of the new brush into the channel opening in front of the brush holder c Slightly push the brush into the channel of the brush holder to start it d Slide the new brush completely into the holder by its bristles until it stops NOTE The brush is complete...

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Page 119: ...ations 6 5 Feeder Tower and Base Material Specifications 6 7 General Information 6 7 Outer Envelopes 6 7 Inserts 6 10 Sheets 6 11 High Capacity Sheet Feeder HCSF Material Specifications 6 12 General Information 6 12 Sheets 6 12 Materials Not Certified for Use 6 13 6 Specifications ...

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Page 121: ...Exit Transport 20 508 mm 16 406 mm 52 lbs 24 kg Flats Sealer 12 5 317mm 16 406 mm 82 lbs 180 4 kg Environmental Limits Temperature F C Humidity Wet Bulb Temp F C Minimum Maximum Minimum Maximum Maximum Normal Operating Conditions 60 16 75 24 30 60 N A Extended Operating Conditions 50 10 95 35 08 85 85 29 Storage Conditions 15 09 120 49 05 95 85 29 Shipping Conditions 40 40 140 60 05 100 85 29 This...

Page 122: ...5 368 mm 89 LOA 2261 mm 38 75 984 mm 31 787 mm 60 5 1537 mm 10 254 mm 29 737 mm 118 LOA 2997 mm 14 5 368 mm 28 6 726 mm 14 356 mm Drop Stacker 33 5 851 mm 31 787 mm NOTE System depth is 22 8 in 579 mm Drawings are not to scale All dimensions approximate The Relay 5000 6000 does not include the High Capacity Envelope Feeder ...

Page 123: ...r Stacker 250 pieces letter mail assumes single sheet insert Production Power Stacker At least one USPS mail tray two feet of finished mail Moistener Closer Sealer 8 000 letters before refilling Component Specifications Folder Fold Types Top address documents C fold Z fold single and double fold Maximum number of sheets per collation 8 20 lb 80 gsm Bottom address documents see Notes below C fold Z...

Page 124: ...ctive feeding feeder to feeder matching force divert mark for special handling Barcode Formats Supported Code 39 3 of 9 Interleaved 2 of 5 2D Datamatrix barcode Notes The horizontal position of the scanner is operator adjustable Documents from any feeder can be scanned Documents should be printed on a laser printer for scanning Photo copied documents and documents printed on an ink jet printer may...

Page 125: ...d made of glassine or polystyrene material Patches shall be glued within 0 06 inch 1 6 mm from the top edge of the patch material to the window cutout Envelope materials shall include new or recycled white wove manila and lithographic material Non woven or synthetic envelopes e g Tyvek or envelopes with external fasteners are not permitted Envelopes with re moistenable flap adhesives made of starc...

Page 126: ...tered at the center line C 25 inch 6 mm Minimum throat depth within a 4 inch 100 mm area centered at the center line D 08 inch 2 mm Minimum distance from top of window to the envelope throat measured at a distance of 5 3 inches 135 mm centered at the center line A C 5 3 in 135 mm Centered at Center Line Center Line B D 4 in 100 mm Centered at Center Line Envelope Throat Definitions NOTE Diagram is...

Page 127: ... 37 162 mm HCEF 8 9 225 mm Feeder Tower 10 5 266 mm HCEF 10 4 264 mm Depth Feeder Tower 3 5 89 mm HCEF 3 9 98 mm 6 5 165 mm Throat Depth 0 25 6 35 mm 1 49 38 mm executive 1 61 41 mm Paper Weight 18 lb 70 gsm 24 lb 90 gsm Flap Depth 1 2 30 mm 2 5 63 mm within 1 4 35 mm of Center 1 85 47 mm outside 1 4 35 mm off center See Envelope Throat Definitions in this chapter for more information Feeder Tower...

Page 128: ...e Material Substrates Acceptable paper types include new or recycled bond text laser and offset Offset coatings include matte dull or gloss NOTE Use of glossy material may degrade system performance Grain Material may be short or long grain Printing Printing may be simplex one side or duplex both sides with no restriction on color Coating Varnish applied to sheets to modify finish is allowed Feede...

Page 129: ...TE Use of glossy material may degrade system performance Grain Material may be short or long grain Printing Printing may be simplex or duplex with no restriction on color Coating Varnish applied to sheets to modify finish is allowed Laser Printed Material Freshly laser printed material which meets the curl requirements is acceptable Feeder Tower Sheet Specifications Parameter Minimum Value Maximum...

Page 130: ...e Grain Material may be short or long grain Printing Printing may be simplex or duplex with no restriction on color Coating Varnish may be applied to sheets to modify finish Laser Printed Material Freshly laser printed material which meets the curl requirements is acceptable For reliable operation all materials must conform to published specifications Feed problems and high stall rates are often d...

Page 131: ...length Maximum material thickness for feeders 0 007 0 18 mm when scanning otherwise 0 25 mm 0 009 Contaminants Materials with visible material loss loose powder ink surface glaze etc when hung free over a clean surface and struck sharply with a standard wood ruler should not be used Special Materials Do not use materials that are sensitive to heat such as thermal papers Do not use materials that a...

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Page 133: ... HCSF 7 3 Loading the HCSF 7 4 Adjusting the HCSF Guides 7 6 Flats Sealer 7 8 Replacing the Envelope Edge Marker Roller 7 9 File Based Processing 7 10 Exit Options 7 10 Connect MMI 7 11 Vertical Power Stacker 7 14 Horizontal Belt Stacker 7 14 Exit Transport 7 14 7 Add On Modules ...

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Page 135: ...ined order and travel down the vertical paper path and into the horizontal transport Depending on the job setup individual sheets are either transported directly into the main unit or they accumulate in the horizontal transport into a pre determined packet before being transported into the main unit When Feeder Linking is en abled you can reload and empty the inactive Feeder Tray that is the Tray ...

Page 136: ...indicator letter Loading the HCSF 2 Load approximately 1 inch of material into the Tray in the orientation specified in the loading instructions on the Home screen Green lights on the front panel of the HCSF indicate that the material is loaded and that the HCSF is operable 3 Turn the Feeder Tray s Side Guide Adjustor clockwise until the side guides touch the material and then back off slightly TI...

Page 137: ...Ready to Feed 4 Load the remaining paper up to the fill line 5 Repeat steps 2 5 for each remaining HCSF Tray 6 Press the button on the front of the HCSF for each of the Trays The loaded Tray s will move into position for feeding Figure 7 3 HCSF Loaded with Material Max fill line ...

Page 138: ... to Enabling and Disabling the High Capacity Sheet Feeder HCSF in Chapter 4 for more information 1 From the Home screen select Loading Instructions then Pre Run Adjustments and finally HCSF Guide Settings 2 Select the Feeder that you will be setting up 3 Press TRIAL PIECE 4 Open the front and top covers of the enabled HCSF accumulation area Adjusting the HCSF Guides Figure 7 6 HCSF Front and Top C...

Page 139: ...et the Width Guides a Turn the right hand knob on the side of the sheet transport to move the Width Guides b Move the Width Guides until they just make contact with the sides of the sheet then back off slightly approximately 1 3 of a turn The sheet should lay flat and not buckle 7 Close the front and top covers of the HCSF accumulation area 8 Press CLEAR DECK to remove any material in the paper pa...

Page 140: ...ats Sealer closes the flap seals the envelope and sends it on to the next module downstream While the Flats Sealer is designed specifically to seal flat envelopes it has an exit path for sealed letter envelopes exiting the Moistener Sealer Clos er module Flats Sealer Downstream Attachments Letter Exit Path Drop Stacker Letter Mail Vertical Power Stacker Belt Stacker Exit Transport Mail Machine Int...

Page 141: ...sing through the letter exit path Replacing the Envelope Edge Marker Roller Follow the steps below to remove and replace the Envelope Edge Marker Roller NOTE Avoid touching the ink roller as it is covered in ink 1 Open the Flats Sealer cover 2 Grasp the tab at the top of the old ink roller and lift to remove 3 Grasp the tab at the top of the new ink roller and slide it onto the spin dle 4 Release ...

Page 142: ...oblems When material jams or inserter problems occur the soft ware pinpoints them swiftly to minimize machine downtime The solution uses bar coded documents that enable a dedicated computer to keep track of the piece during the process and tell the inserter how to build each mailpiece to the specified completion This is known as file based processing which provides mail piece integrity to the mail...

Page 143: ...g the Inserter and operating the Connect normally without inserter control When the mailing machine is processing mail and the inserter has a MMI job loaded the UIM will display Postage Meter Not Available Once the Connect returns to the Run Mail screen and no job is being run the inserter then displays Ready To Run NOTE Once you have completed processing mail in standalone mode press the Stop key...

Page 144: ...for you mailing system for more informa tion about processing mail 5 Adjust the side guide to the width of an envelope that will be used See figures below for Connect requirements NOTE The MMI does not support flats Figure 7 16 Clearance Between Envelope and Side Guide 1 8 1 4 Clearance between en velope and Side Guide ...

Page 145: ...nserting system The inserting system begins to assemble pieces of mail which the mail ing system will then accept and process The mailing system sends the inserting system a message for each exiting piece of mail Clearing a Jam If a jam occurs on the mailing system while processing mail with the MMI the Connect displays the area of the jam along with user instructions Follow the on screen instruct...

Page 146: ...cker is a compact powered bottom feed stacker that connects to the output of several Pitney Bowes Document Inserting Systems including the Relay inserters It neatly stacks the mail pieces fed from the inserter and keeps them in the same order as they were originally loaded Sensors in the stacker monitor the mail pieces fed into it if a mail piece should stall or the stacker fills up the inserter s...

Page 147: ...eads for Ladder or 2D Orientation Marks 8 25 Adjusting the Scan Heads for Picket Orientation Marks 8 28 OMR Specifications 8 30 OMR Print and Placement Specifications 8 31 OMR Placement Specifications for Feeder Tower Ladder 8 31 OMR Print and Placement Specifications 8 32 OMR Placement Specifications for HCSF New Scan Kit F790250 Ladder Orientation 8 32 Barcode Specifications 8 33 Barcode Print a...

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Page 149: ...ria Normally a dark solid line s that is printed on a sheet of white or light colored paper prior to being delivered to the system for folding and inserting functions to make the mail pieces The line runs is printed perpendicular to the direction of travel of the paper The line is sufficiently thick and dense enough to trigger the OMR scan ner on the system as it passes the scanner OMR marks are g...

Page 150: ...uired Interleaving allows the charac ters to overlap creating a higher density barcode than the Code 3 of 9 The symbology uses bars to represent the first character and the interleaved white spaces to represent the second character Each character has two wide elements and three narrow elements The Interleaved 2 of 5 uses combinations of 2 of the 5 bars or spaces to cre ate characters The odd and e...

Page 151: ...of the barcode measured by the number of modules A module is either a black or white square module The data encoding method used when the barcode is generated The three most common data encoding types are Numeric just numbers highest data density Alphanumeric numbers and letters Binary just numbers 0 and 1 BCR continued ...

Page 152: ...s The code should not intersect any perforation The printer should be set for printing at 600 DPI or higher Codes must be Barcode Quality Grade of A using an ISO15415 standard barcode grader Supported Square and Rectangular Formats The following Square Data Matrix formats are supported by the HCSF and the corresponding data capacity Supported Square Code Formats Size Max Numeric Capacity Max alpha...

Page 153: ...ule Size mm 8 x 18 10 6 3 0 33 0 635 8 x 32 20 13 8 0 33 0 5842 12 x 26 32 22 14 0 33 0 635 12 x 36 44 31 20 0 33 0 4826 16 x 36 64 46 30 0 33 0 4826 16 x 48 98 72 47 0 33 0 381 Can be read but software ignores any data beyond the 32nd character Direction of Travel Example of Short Edge of Barcode in Travel Direction Rectangular data matrix barcodes can be put on the page in several orientations L...

Page 154: ... Max Numeric Capacity Max Alpha numeric capacity Max Binary capacity Min Supported Module Size mm Max Supported Module Size mm 8 x 18 10 6 3 0 33 0 635 8 x 32 20 13 8 0 33 0 453 12 x 26 32 22 14 0 33 0 559 12 x 36 44 31 20 0 33 0 432 16 x 36 64 46 30 0 33 0 432 16 x 48 98 72 47 0 33 0 330 Can be read but software ignores any data beyond the 32nd character NOTE There are some combinations that are ...

Page 155: ...scanning Setting the Item Overcount Action to Use Alternate Envelope Refer to Creating a Job in Chapter 3 or Assigning a Scan Configuration to an Existing Job in this chapter for more information Jobs using dynamic envelope selection must be set up with two outer envelopes The first set in the job must contain the information necessary to make the envelope selection either the Envelope Select scan...

Page 156: ...fer to Creating a Job in Chapter 3 or Assigning a Scan Configuration to an Existing Job in this chapter for more information Jobs using the divert sheet functionality will send diverted sets to the lower divert area The remaining parts of the mail piece will be processed inserted into an outer envelope and sent to the upper divert area NOTE If the mail piece contains only a single set which has be...

Page 157: ...correction is known as the ECC level The use of ECC allows for codes to be partially damaged but remain read able The amount of error correction built into a Data Matrix barcode does not limit the data capacity of the barcode The HCSF supports Data Matrix barcodes for all ECC levels New Applications ECC 200 the current industry standard Legacy Applications ECC 140 ECC 130 ECC 120 ECC 100 ECC 080 E...

Page 158: ...and or Manager is required for use of these functions Refer to Access Rights in Chapter 2 in this guide for more information about logging in using the two security modes Setting Up a New Scan Configuration To setup an OMR Scan Configuration 1 From the Home screen select Menu Tools 2 Select Configure System Scan Configuration Setup NOTE If you are not logged in with supervisor or manager access ri...

Page 159: ... list c Press Finished when you are done 9 The Create OMR screen displays Use the UP DOWN arrows to highlight an item in the OMR Marks list 10 Select Set Options for Highlighted Item NOTE The options that appear vary depending upon the selected function Menu Option Associated Options Actions Increase Count for Highlighted Item MC WAS only Allows you to increase the number of marks for the function...

Page 160: ...ssing job then MC must be controlling This tells the inserter that file based processing will provide the control instructions to the inserter based on the MC read on each document and defines this as a closed loop scan code definition Wrap At Multi bit only Displays Wrap At numeric entry screen where you enter the maximum code value in decimal format If the count direction is Up the next code aft...

Page 161: ... unique across all scan types That is a BCR Scan Configuration name cannot be the same as an OMR Scan Configuration name Setting Up a BCR Scan Configuration Setting Up an OMR Scan Configuration continued Menu Option Associated Options Actions LSB Allows you to specify the least significant bit Toggles Last default farthest from top of page or First When First is selected for the Least Significant ...

Page 162: ...ction column Enter the associated character information in the C column the bit information in the B column and if necessary the size information in the S column Bit 0 is the right most bit least significant in each character For Code 3 of 9 barcodes bits are 5 4 3 2 1 and 0 For Interleaved 2 of 5 barcodes bits are 2 1 0 2D Items with character set to zero will no be included in the final code For...

Page 163: ...e The minimum value is 2 and the maximum value is 43 The default value is 32 For codes that span more than one character this sets the value where each character resets to zero and carries to the next character Code Type Select the appropriate code type BIN for most single bit functions CCD for most multi bit functions XCD for minimum code size this selection allows multibit fields to span partial...

Page 164: ...default farthest from start of code or First When Last is selected for the Least Significant Bit option the code is in the normal order with the least significant bit is closest to the right hand end of the string When First is selected which is very uncommon the bits are reversed 8 Select Finished once you have set all of the necessary options for the function 9 Repeat steps 6 to 8 for each addit...

Page 165: ...il all necessary items have been added to the Selected list c Press Accept when you are done Once you have added the mark be sure to set the appropriate options Refer to the Set Options table in the Setting Up a OMR Scan Configuration section of this chapter for more information NOTES Items that can be added appear in the Available list Items that have been added appear in the Selected list Use th...

Page 166: ...Allows you to increase the selected character bit or size for a function a Use the UP DOWN and LEFT RIGHT arrow keys to highlight the character C bit B or size S within the grid b Press Increase to edit the info for the highlighted item Decrease Allows you to decrease the selected character bit or size for a function a Use the UP DOWN and LEFT RIGHT arrow keys to highlight the character C bit B or...

Page 167: ...can configuration cannot be deleted if it is a library scan configuration associated with a library job or if it is used by a saved job NOTE To see which jobs use a given scan configuration view the job list Refer to Viewing the Job List in this chapter for more information You can remove the association with a saved job via the Edit Job function for the job s listed in the dialog and then delete ...

Page 168: ...ation appear in the Functions list Use the UP DOWN arrow keys to select the function you want to review 7 Select Finished once you have reviewed the list Viewing the Job List View the jobs associated with the selected scan configuration NOTE This option is not available if there are no jobs associated with the se lected Scan Configuration 1 From the Home screen select Menu Tools 2 Select Configure...

Page 169: ...r insert in the Mail Piece Icon Tree 4 Select Edit Highlighted Item 5 Select Additional Settings 6 Select Scan Item and toggle Yes 7 Select Scan Settings 8 The Select Scan Type screen displays Select the appropriate scan type OMR Code 3 of 9 or Interleaved 2 of 5 9 Select the appropriate scan configuration name from the list that appears If necessary select Next or Previous to move forward or back...

Page 170: ...ning each of the above measurements refer to OMR Specifications in this chapter Item Over Count Quantity Allows you to select the number of items that cannot be run normally a Use the UP DOWN arrow keys to enter the item over count quantity b Select Accept when you are done NOTE At this time only a single scanned insert can be added to each mail piece The scanned insert must be a Reply Envelope BR...

Page 171: ...ad the marks correctly Additionally material must be jogged back into place and loaded as an even stack to ensure the Scan Head and marks align properly Refer to Loading Material into the Trays in Chapter 3 of this guide for more information To adjust the scan heads 1 Fold one of the sheets to be scanned in half vertically side with mark facing up 2 Draw two arrows one at the top of the mark and o...

Page 172: ...eeder J K L M open the HCSF tower cover TIPS Remove the left feeder trays from the feeder tower to allow the HCSF tower cover to open freely If you have two HCSFs on your system the first HCSF Tower will pre vent the second tower farthest from opening fully For best results be sure you have proper lighting when adjusting the scan head in the second tower 7 Determine the direction the scan head nee...

Page 173: ... on your system may appear different but operation concepts are the same 9 If additional scan heads are to be used repeat step 1 to 8 for each 10 To verify the adjustment is correct a From the home screen select Loading Instructions and Pre Run Adjustments canner Setup b Use the UP DOWN arrow keys to select a feeder to run c Press TRIAL PIECE to feed a piece from the highlighted feeder d Select Fi...

Page 174: ...ver Use the ruler to measure the distance from the center of the sheet lined up at 0 on the ruler to the center of the marks 5 Refer to the loading instructions to determine The scan head location to be used for this sheet left or right If the sheet will be loaded top or bottom first 6 Open the HCSF Tower cover TIPS Remove the left feeder Trays from the feeder tower to allow the HCSF tower cover t...

Page 175: ... move the scan head Blue thumbwheel Figure 8 3 Use the Blue Thumbwheel to Adjust Scan Head Position Move the thumbwheel until the pointer lines up with the measurement distance from the center of the page to the center of the mark defined in step 7 9 If additional scan heads are to be used repeat step 1 to 8 for each 10 To verify the adjustment is correct a From the home screen select Loading Inst...

Page 176: ...w the relative differ ence between acceptable and unacceptable OMR mark thicknesses Each mark position must be evenly spaced and at least 0 125 3 175 mm and no more than 0 167 4 2 mm apart The maximum number of mark positions allowed within the code is 19 this includes ignored marks The total length of the OMR code should not exceed 3 5 89 mm On the HCSF the center line of the marks must fall with...

Page 177: ...one dotted line 20 mm min to first mark Trailing Edge 3 mm min 3 mm min 9 mm min 9 mm min 3 mm min Diagram is not to scale Feeder Tower 125 mm max Feeder Tower 20 mm min 10 mm min OMR Placement Specifications for Feeder Tower Ladder Orientation 11 mm min to clear zone dot ted line 20 mm min to last mark Requires F7TB Tower Scanning ...

Page 178: ...m min 11 mm min to clear zone dotted line 20 mm min to last mark Requires F7HD Scanner F790250 Scanner Install Kit At the time of this writing we recommend that any scan codes within 45 mm of document trail edge be validated first to avoid scanning issues Scan codes containing BOC as a Controlling function should be located within the first 1 3rd of the lead edge of the document OMR Placement Spec...

Page 179: ...the HCSF the center line of the barcode must fall within a range of 1 25 32 mm to 4 125 105 mm from the center line of the sheet On the Feeder Tower the center line of the barcode must fall within a range of 0 787 20 mm to 4 92 125 mm from the center line of the sheet The 2D barcode should not be closer than 79 20 mm from the Lead Edge nor closer than 79 20 mm from the trail edge of the sheet NOTE...

Page 180: ...ear Zone Leading Edge Trailing Edge 3 mm min 3 mm min 3 mm min 3 mm min 3 mm min Diagram is not to scale Feeder Tower 125 mm max Feeder Tower 20 mm min 12345 12345 12345 12345 12345 12345 12345 12345 12345 16 point font min 17 mm min to clear zone dotted line 20 mm min to barcode 17 mm min to clear zone dotted line 20 mm min to barcode Requires F7TB Tower Scanning ...

Page 181: ...dotted line 20 mm min to barcode Requires F7HD Scanner F790250 Scanner Install Kit At the time of this writing we recommend that any barcodes within 45 mm of document trail edge be validated first to avoid scanning issues Applications containing narrow barcodes may not scan reliably with the barcode in this location Scan codes containing BOC as a Controlling function should be located within the f...

Page 182: ...ne dotted line 20 mm min to barcode 17 mm min to clear zone dotted line 20 mm min to barcode At the time of this writing we recommend a minimum of 45 mm between trail edge and barcode 1D Barcode Print and Placement Specifications for HCSF Original Scan Kit F790050 Picket Fence Orientation Diagram is not to scale Barcode Print and Placement Specifications Leading Edge Trailing Edge Requires F7FB Sc...

Page 183: ...mm min to clear zone dot ted line 20 mm min to barcode 17 mm min to clear zone dotted line 20 mm min to bar code Requires F7MB Scanner F790250 Scanner Install Kit At the time of this writing we recommend that any barcodes within 45 mm of document trail edge be validated first to avoid scanning issues Applications containing narrow barcodes may not scan reliably with the barcode in this location Sc...

Page 184: ...tions 2D Barcode Placement Specifications for HCSF New Scan Kit F790250 Horizontal Vertical Orientation Direction of Feed Clear Zone Leading Edge Trailing Edge 6 mm min 6 mm min 6 mm min 6 mm min Diagram is not to scale Requires F72D Scanner F790250 Scanner Install Kit ...

Page 185: ...t will ask questions to ascertain where it needs to look for marks and where it should ignore other printed matter Depending on the type of code being used the machine will ask you to define either the first mark position and code length OR the Clear Zone as described on the following pages 1 Take a sheet that has at least the FIRST and LAST mark printed on it 2 When requested by the machine measu...

Page 186: ...called the Clear Zone NOTES Setting the Clear Zone closer to the beginning and end of the OMR marks de creases the possibility of any poor print or imperfections on the material being interpreted as marks Conversely setting the Clear Zone too close to the beginning and end of the marks could cause problems if the position registration of the printing on the material varies A good guide is to limit...

Page 187: ...le The About My Machine screen shows the level of scanning that has been enabled on your system Follow the steps below to navigate to the screen 1 From the Home screen select Menu Tools 2 Select About My Machine One of the following marks must be present and must be marked as Is controlling in the system EOC BOC PC or MC EOC is most frequently marked as Is controlling Additional restrictions apply...

Page 188: ...is case the scan configuration should indicate Content in Line with Marks be set to Yes to enable the functionality Additionally the HCSF furthest upstream must be used Currently if the BOC mark is controlling the Content in Line with Marks option must be set to Yes and the mark locations settings must be entered into the system EOC End of Collation This normal controlling mark indicates that it i...

Page 189: ...dd number of marks Parity should be set to odd No more than one Parity mark can be used within the code SAF Safety OMR Only This mark improves the integrity of your mail piece It should be at the end of the code that is opposite to the Benchmark When the Safety mark is added the machine will automatically work out the length of the code This makes creating jobs using this code easier Otherwise the...

Page 190: ...mber within a collation The system checks the order of pages and for missing or extra pages within the collation NOTE The Page Count and Page Number marks can be used together to ensure internal collation integrity WAS Wrap Around Sequence This is a numbering system which uses a sequential binary coding If a page becomes missing or the set becomes out of sequential order the system will stop proce...

Page 191: ...e is pressed the Job ID will be read from the first piece and then compared to the job ID numbers of the rest of the run If the Job ID number changes within the same job the system will stop processing the material and display a error stating a Job ID mismatch USR User Data Use the User Defined scan code function to ignore customer data at the end of a barcode Example a customer could place an acc...

Page 192: ... the Seal mark will not be sealed If Seal is set to absent and the Seal mark is on an item the Mail Piece will not be sealed An item that doesn t have the Seal mark will be sealed TIP This mark is useful when materials need to be hand stuffed into an envelope SF n Select Feed These marks instruct the machine to select material from specific feeders Up to nine Select Feed marks can be within the co...

Page 193: ...ntents Basic Terms A 3 Material References A 3 Machine Functions A 4 Icon Glossary A 5 Envelope Icons A 5 Fold Icons A 6 Sheet Icons A 6 Insert Icons A 7 Feeder Assignment Icons A 8 Other Icons A 8 Appendix A Glossary ...

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Page 195: ...uire folding before being placed into an en velope There are five kinds of inserts Reply Envelope An envelope placed into the Outer Envelope with the other Mail Piece contents Booklet An item with a stapled and folded binding edge Slip A single thickness piece of paper or card Double detect is turned ON by default for this item Reply Card A single thickness piece of paper Double detect is turned O...

Page 196: ...een The initial screen displayed after turning power on From this screen you can run the machine select a pre programmed Job and enter the menu functions Mail Piece Icon Tree A graphic that runs down the left side of the display and contains icons small pictures that represent the items that make up the currently selected mail piece It also indicates the location of the feeder where each item need...

Page 197: ...dard Flap Flat Envelope N A Window Forward Flap Flat Envelope N A Window Bottom Flap Flat Envelope N A High Capacity Envelope Feeder The tables in this section provide descriptions of the various icons you will see on the display screen Dark lines within an icon represent features you can plainly see Where applicable the darkest edge of an icon is the edge that feeds first into the system Light gr...

Page 198: ...Orientation face down top first Orientation face down bottom first Sheet Not Personalized Sheet Top Address Sheet Middle Address Sheet Bottom Address Multiple Sheets Not Personalized Multiple Sheets Top Address Multiple Sheets Middle Address Multiple Sheets Bottom Address Fold Icons No Fold C Fold Z Fold Single Fold Double Fold ...

Page 199: ...down top first Orientation face down bottom first Slip or Generic Insert Reply Envelope N A N A N A Reply Card Multiple Slips or Generic Inserts Multiple Reply Envelopes N A N A N A Multiple Reply Cards Orientation closed edge first Pre Folded Insert Multiple Pre Folded Inserts Orientation bound edge first Letter Booklet Multiple Letter Booklets ...

Page 200: ...ower Bottom left feeder B Feeder Tower Bottom right feeder C Feeder Tower Top left feeder D Feeder Tower Top right feeder G High Capacity Envelope Feeder HCEF N A J High Capacity Sheet Feeder 1 HCSF Bottom feeder K High Capacity Sheet Feeder 1 HCSF Top feeder L High Capacity Sheet Feeder 2 HCSF Bottom feeder M High Capacity Sheet Feeder 2 HCSF Top feeder X Custom Feeder N A Z Attached Printer N A ...

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Page 202: ...3001 Summer Street Stamford CT 06926 0700 www pitneybowes com SV63136 Rev A 2015 Pitney Bowes Inc All Rights Reserved ...

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