Pitney Bowes D1500, D1600 User Manual

Document Inserting System

DI500/DI600

Operator Guide

US/Canada English Version

FCC Compliance

This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to part 15 of the FCC rules. These limits
are designed to provide reasonable protection against interference when
the equipment is operated in a commercial environment. This equipment
generates, uses, and can radiate radio frequency energy and, if not installed
and used in accordance with the instruction manual, may cause interference
to radio communications. Operation of this equipment in a residential area is
likely to cause interference, in which case the user will be required to correct
the interference at his own expense. Use only a shielded interface cable to
operate this equipment with a printer or other peripheral device.

CAUTION: Changes or modifications to this equipment not expressly
approved by the party responsible for compliance (Pitney Bowes) could void
the user’s authority to operate the equipment.

Canada EMC Compliance

This Class A digital apparatus complies with Canadian ICES-003.

Cet appareil numérique de la classe A est conforme à la norme NMB-003 du
Canada.

SV40221 Rev. A 9/04

©2004 Pitney Bowes Inc. All rights reserved. This guide 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 errors or omissions or liability for the misuse or misapplication of our
products.

Due to our continuing program of product improvement, equipment and
material specifications as well as performance features are subject to
change without notice. Your inserter system may not have some of the
features described in this book.

E-Z Seal and PacPilot are trademarks or registered trademarks of Pitney
Bowes Inc. ENERGY STAR is a reg is tered trademark of the United States
Environmental Pro tec tion Agency.

Printed in the USA or Canada.

Table of Contents

Pitney Bowes Contact Information List v

Chapter 1 Introduction

Safety ................................................................................1-2

To The Operator ................................................................1-3

Machine Configurations .....................................................1-4

Machine Identification ........................................................1-6

PacPilot™ Control Panel ...................................................1-8

Control Panel Keys .................................................... 1-8

Mail Piece Icon Tree ................................................ 1-10

Common Terms ...............................................................1-14

Chapter 2 Using the Menus

The Home Screen .............................................................2-2

The Menu Structure ...........................................................2-4

iSV40221 Rev. A

Table of Contents

Chapter 3 Operator Functions

About this Chapter .............................................................3-2

Connecting Power .............................................................3-2

Running a Job ...................................................................3-3

SwiftStart™ ........................................................................3-6

Manual Feed ......................................................................3-9

Setting the Sheet Feeders ...............................................3-12

Setting the Envelope Feeder ...........................................3-14

Setting the Insert Feeder(s) .............................................3-16

Filling the Envelope Sealer ..............................................3-18

Menu ................................................................................3-19

Language ................................................................. 3-19

Display Adjustments ................................................. 3-19

Safe Seal ................................................................. 3-19

System Information .................................................. 3-19

Chapter 4 Supervisor Functions

About this Chapter .............................................................4-2

Supervisor Access Code ................................................... 4-2

Create Job .........................................................................4-3

Edit Job ..............................................................................4-4

Create From ......................................................................4-6

Delete Job .........................................................................4-7

OMR Menu ........................................................................4-8

System Menu .....................................................................4-8

Manual Feed Option .................................................. 4-8

ii SV40221 Rev. A

Table of Contents

Chapter 5 Optical Mark Recognition (OMR)

OMR Availability ................................................................5-2

What is OMR? ...................................................................5-2

OMR Marks Available ........................................................5-3

OMR Mark Options ............................................................5-6

OMR Specifications ...........................................................5-8

Creating, Deleting and Viewing OMR Codes ..................5-10

Create New OMR Code ...................................................5-11

Delete OMR Code ...........................................................5-13

View OMR Code ..............................................................5-14

Creating an OMR Job ......................................................5-15

OMR Scanner Adjustments ............................................5-18

Chapter 6 Troubleshooting

Troubleshooting Tips .........................................................6-2

General Troubleshooting ...................................................6-3

Machine ..................................................................... 6-3

Envelopes .................................................................. 6-4

Sheets ........................................................................ 6-5

Inserts ........................................................................ 6-6

Double Detect ............................................................ 6-7

Clearing Material Stalls ......................................................6-8

The Manual Advance Knob ........................................ 6-8

Removal/Replacement of Sheet Feeder Trays .......... 6-9

Removal/Replacement of Insert Tray(s) .................... 6-9

Access to Internal Areas 1 to 5 ................................ 6-10

Access to Area 6 ...................................................... 6-12

Access to Areas 7 and 8 .......................................... 6-12

Access to Removeable Paper Path ......................... 6-13

Access to Top Cover (Sheet Feed Area) .................. 6-13

Access to Envelope Exit Area .................................. 6-14

Access to Envelope Inserting/Sealing Area ............. 6-14

Envelope Stop Position ............................................ 6-15

iiiSV40221 Rev. A

Table of Contents

Chapter 7 Reference

Specifications ....................................................................7-2

Sheet Feeders ........................................................... 7-2

Fold Type and Overall Thickness Limits .................... 7-3

Insert Feeders ............................................................ 7-4

Envelope Feeder ........................................................ 7-4

Envelope Sealer ......................................................... 7-6

Drop Stacker .............................................................. 7-6

Material Requirements ............................................... 7-6

Machine Specifications .............................................. 7-7

Changing the Envelope Sealer Unit Felts ..........................7-8

Service .............................................................................7-10

Index I-i

iv SV40221 Rev. A

Pitney Bowes Contact

t

Information Lis

USA Contacts

 Product Name - DI500 or DI600
 For frequently asked questions, go to:

www.pb.com and click on Customer Support.

 To place requests for service or training, go to:

www.pb.com and click on My Account.

 To order PB supplies and accessories, go to:

www.pb.com and click on Online Store.

 To view and pay invoices online, go to:

www.pb.com and click on My Account.

 To view inventory, go to:

www.pb.com and click on My Account.

 For direct questions, call: 1.800.522.0020. Customer

Service Representatives are available Monday through
Friday, 8:00 AM - 8:00 PM ET.

Canada Contacts

 Product Name - DI500 or DI600
 For frequently asked questions or to order supplies, go to:

www.pitneybowes.ca

 For direct questions, call: 1.800.672.6937. Customer

Service Representatives are available Monday through
Friday, 8:30 AM - 4:00 PM ET.

vSV40221 Rev. A

vi SV40221 Rev. A

1 • Introduction

This chapter pre sents important safety information and describes the
main controls and features of your machine.

Important Safety Notes ...................................................... 1-2

To The Operator ................................................................ 1-3

Machine Configurations ..................................................... 1-4

Machine Identification ........................................................ 1-6

PacPilot™ Control Panel ................................................... 1-8

Control Panel Keys ..................................................... 1-8

Mail Piece Icon Tree ................................................. 1-10

Common Terms ............................................................... 1-14

1-1SV40221 Rev. A

1 • Introduction

Important Safety Notes

Follow these basic safety precautions when operating this machine:

• Use only Pitney Bowes approved supplies, in particular aerosol
dusters. Improper storage and use of aerosol dusters or
flammable aerosol dusters, can cause an explosive-like condition
that could result in a personal injury and/or property damage.
Never use aerosol dusters labeled flammable and always read
instructions and safety precautions on the duster container.

• To obtain Pitney Bowes supplies, please contact our Supply
Line or on the web at PB.com (see the Pitney Bowes Contact
Information List at beginning of this guide). Material Safety Data
Sheets can also be acquired from the Supply Line or PB.com.

• Read all instructions before operating the equipment. Only use
the equipment for its intended purpose.

• Operation of this equipment without periodic maintenance will
inhibit optimum operating performance and could cause the
equipment to malfunction. Contact your Pitney Bowes Customer
Service Representative for required service schedule.

• Use the power cord supplied with the machine. Plug it and all
other supplied power cords into a properly grounded wall outlet
that is located near the machine and easily accessible, meaning
it is free from obstruction and there is enough room around the
unit for servicing.

• The power cord wall plug is the primary means of disconnecting
the machine from the AC supply.

• Do not use an adapter plug on the line cord or wall outlet. Do not
remove the ground pin from the line cord.

• Avoid using wall outlets controlled by wall switches or shared
with other equipment. Do not route the AC power cord over
sharp edges, or allow it to be trapped between furniture and/or
furniture and the wall.

• Avoid touching moving parts or materials while the machine is
in use. Keep hands, loose clothing, jewelry, and long hair away
from all moving parts.

• Do not remove covers. Covers enclose hazardous parts that
should only be accessed by properly trained service personnel.

1-2 SV40221 Rev. A

Introduction • 1

• Immediately report to Pitney Bowes Service any damaged or
nonfunctioning components. The unit may be unsafe for use.

• To prevent overheating, do not cover the vent openings. Allow
ample spacing around the unit for ventilation.

NOTE: Always follow the specific occupational safety and health
standards for your workplace.

To the Operator

Your new Folding/Inserting Machine has an easy to follow user
interface which makes it simple to set up, whilst offering the following
features:

• Envelope seal/no seal/safe seal.

• Fully automatic material separation on sheet feeders.

• Fully automatic fold adjustments.

• Fully automatic envelope separation.

• Fully automatic Double Detect, when selected.

• Fold only option (fold without insertion).

• Fully automatic insertion of single and multiple sheet inserts

(on models fitted with insert feeders only).

• Option of single fold, C fold, Z fold and double fold.

• 20 Job recall facility - User programmable.

• SwiftStart™ - allows you to quickly execute and save simple

jobs without programming.

• Linked Feeding - multiple feeders can be linked to allow

continuous operation.

• OMR functionality - storing up to 10 codes (on models where

OMR is enabled).

• Load on the fly operation.

• Manual Feed facility for occasional ‘one-off’ jobs.

1-3SV40221 Rev. A

1 • Introduction

Machine Configurations

The following machine configurations are available, depending on
your local market:

• Two Sheet Feeders Only

• Four Sheet Feeders Only

• Two Sheet Feeders and One Insert Feeder

• Two Sheet Feeders and Two Insert Feeders

• Four Sheet Feeders and One Insert Feeder

• Four Sheet Feeders and Two Insert Feeders

Each feeder location has its own letter designation which remains
the same irrespective of machine configuration. Therefore, machine
configurations with less than the full complement of feeders will use
feeder designations which are not in alphabetical sequence – this is
normal.

The processing speed will also vary depending on machine
configuration. See ‘Specifications’ in Chapter 7 for further details.

The illustration on the next page shows feeder locations and
designations.

In addition, an Optical Mark Recognition (OMR) option can be added

to any model. This allows control of machine functions and Mail
Piece make-up by ‘scanning’ material passing through the machine

for machine readable marks (OMR Marks). For further information,
refer to Chapter 5 of this guide.

This guide covers all models. If a function is dependent on machine
configuration, the accompanying text will explain this.

1-4 SV40221 Rev. A

Introduction • 1

Sheet Feeders

A

B

C

D

E

Envelope Feeder

Feeder Configuration

Insert Feeders

Manual Feeder

H

G

F

1-5SV40221 Rev. A

1 • Introduction

Machine Identification

32

1

9

8

7 6

Sheet Feeders

1

Use these feeders to feed sheets that require folding. They
automatically detect if more than one sheet feeds (double
detect), giving security to your mailings.

Depending on the job being run and availability of feeders,
there also is an option to ‘link’ these feeders so that when
the first feeder runs out of material, feed will automatically
switch to the next linked feeder. This allows a higher volume of
material to be processed before refilling is required.

PacPilot™ Control Panel

2

This is where you enter commands to run the machine or
configure Job Settings. The control panel display also shows
you the machine status, loading instructions and details of the
job. See 'Control Panel' on the page 1-8 for more details.

4

5

1-6 SV40221 Rev. A

Introduction • 1

Manual Feeder (also known as Convenience Feeder or Daily

3

Mail Feeder)
Use this feeder to manually feed stapled or unstapled sets of
up to 5 sheets (see specifications, page 7-2). The machine
waits for each set to be manually fed before folding and
inserting the set automatically into the envelope. A Supervisor
can also configure the machine to place insert(s) within the set
if Insert Feeder(s) are fitted.

Insert Feeder(s) (not on all model configurations)

4

Use these feeders to add additional inserts to your envelope.
Inserts fed from these feeders cannot be folded by the
machine, so they must already be folded or be a size that
does not require folding.

Drop Stacker (not illustrated)

5

A fold down stacker is located at the exit from the machine
to collect the finished Mail Pieces. This unit can be latched
against the machine when not in use.

Power stacker (not illustrated)

This is an optional extra which automatically collects and
neatly stacks finished Mail Pieces. It locates at the exit of the
machine, in place of the Drop Stacker.

Sealer Bottle

6

The sealer bottle is located inside an opening cover at the
front right side of the machine. It provides sealing solution to
the Envelope Sealer.

Manual Advance Knob

7

The Manual Advance Knob is located inside an opening cover
at the lower center of the machine. It can be used to manually
turn the machine mechanisms to assist in clearing a material
stoppage.

Measuring Scale

8

The scale is located on the left side of the machine near the
sheet feeders as an aid in measuring material and envelopes.

Envelope Feeder

9

This feeder feeds envelopes into the inserting area where they
are filled with the material requested from the other feeder(s).

1-7SV40221 Rev. A

1 • Introduction

PacPilot™ Control Panel

Control Panel Keys

Screen Keys

Navigation Keys

Reset Counters

If only piece count is displayed, press this key to reset the piece
count to zero. If both piece and batch counters are displayed,
pressing this key allows either or both counters to be reset.

Help (not available in some markets)

Press this key to view an electronic Quick Reference Guide giving
you quick access to basic information regarding operation of your
machine.

Cancel

Press this key to take you back to the previous screen. If you have
made changes or defined settings on the screen you are cancelling,
these will be lost. Multiple presses of the Cancel key will step you
back through the screens you have visited until you get back to the
Home Screen.

1-8 SV40221 Rev. A

Introduction • 1

Home

Press this key to take you back to the Home Screen. The Home
Screen is where you can run jobs and is the start point for accessing
the menus.

Start

Starts automatic operation.

Trial Piece

Press this key to run test piece(s) so that you can check the machine
setup. Trial Piece(s) must be run before automatic operation can be
commenced using the Start key. If double detection is in use, the
machine calibrates itself automatically as it runs the Trial Piece(s).
If the job includes an Outer Envelope, it will be unsealed so that the
contents can be easily checked.

Clear Deck

Press this key to drive the material through and out of the system. It
can be used to clear the machine ready for automatic operation after
a stoppage has occurred, etc.

Stop

Stops automatic operation at the end of the next cycle.

Navigation Keys (▲▼◄► OK)

These keys are used to move a highlighted area around the display.
Once the desired area is highlighted, press the OK key to select it.
The ▲ and ▼ navigation keys can also be used to change values of
machine settings.

Screen Keys

These are the six round keys located directly to the right of the
display. These keys correspond to the changeable options on the
display alongside them and therefore are not labelled.

1-9SV40221 Rev. A

1 • Introduction

Mail Piece Icon Tree

The Mail Piece Icon Tree is located on the left side of the display.
It displays the Mailing Object Icons required, based on the Job
Definition.

The icons inform you which feeders to load, the type of object (sheet,
insert, etc.) to be loaded into each designated feeder and the loading
orientation of each object. It is therefore extremely important that you
become familiar with the icons themselves and the make-up of the
Mail Piece Icon Tree.

Loading Instructions

The ▲ and ▼ navigation keys can be used to scroll through the Mail
Piece Icon Tree. When an item is highlighted, the machine will give
you the loading instructions associated with that item.

When you have viewed the loading instructions, press Home or
Cancel to return to the Home Screen or press Start or Trial Piece to
immediately begin processing.

1-10 SV40221 Rev. A

Introduction • 1

Mail Piece Icon Tree Icons

Each Mailing Object Icon has one darker edge either at the top or
bottom that indicates the leading edge of the object when loaded into
the assigned feeder. 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” line on top.

A feeder assignment letter (A to G) will be placed
alongside the Mailing Object Icon to indicate which
feeder the object should be loaded into.

Two or more feeder assignment letters alongside a
single Mailing Object Icon indicate that linked feeders
have been selected. The item should be loaded in
all the feeders indicated. When one feeder becomes
empty, feed will automatically switch to the next
linked feeder and so on, in a continuous cycle.

If Double Detect is in use, the Double Detect Icon will
appear immediately to the left of the relevant Mailing
Object Icon.

If any Sheet Feeder(s) are programmed to feed
Pre-Collated Sets (multiple sheets), a modified icon
indicating multiple sheets will appear, together with
a number showing the number of sheets in the Pre­Collated Set.

On an Optical Mark Recognition (OMR) job, a
variable number of pages might be fed under
control of the OMR marks and so a small letter ‘n’
will appear in place of the number. Also, an asterisk
(*) will be displayed in the Mail Piece Icon Tree to
remind you that the job is an OMR job.

Lines between the Mailing Object Icons indicate the flow of material
through the machine.

3

n

Refer to the table on the following page as a reference to all the
icons that might appear on the Mail Piece Icon Tree.

1-11SV40221 Rev. A

1 • Introduction

Envelope Icons

No Window,
Flap side up,
Flap Last

Window,
Flap side up,
Flap Last

Seal Icons

Seal On

Safe Seal On

Fold Icons

C Fold
(letter fold)

Z Fold
(accordion fold)

Single Fold

Double Fold

Insert Icons

Reply envelope,
Flap side down,
Flap First

Booklet,
Face Down,
Bound Edge First

Slip,
Face Up,
Bottom First

Pre-Folded Insert,
Closed Side First

Sheet Icons

No address,
Face Down,
Bottom First

No address,
Face Down,
Top First

No address,
Face Up,
Bottom First

No address,
Face Up,
Top First

Top address,
Face Down,
Bottom First

Top address,
Face Down,
Top First

Top address,
Face Up,
Bottom First

Top address,
Face Up,
Top First

Bottom address,
Face Down,
Bottom First

Bottom address,
Face Down,
Top First

Bottom address,
Face Up,
Bottom First

Bottom address,
Face Up,
Top First

Other Icons

A

Double Detect On

H

Feeder Designators

to

1-12 SV40221 Rev. A

Introduction • 1

Mail Piece Icon Tree Example

An example Mail Piece Icon Tree is shown below. This explains the
information that is available and how it assists you in loading and
running a job.

Window Envelope
loaded Flap Side Up
fed Flap Last
Envelope sealing turned on
loaded into feeder E

C Fold selected

Prime Sheet with Top Address
loaded Face Up
fed Top First
loaded into feeders A and B
feeders A and B Linked
Double Detect turned on

Additional Sheet
loaded Face Up
fed Top First
loaded into feeders C and D
feeders C and D Linked

Reply Envelope
loaded Flap Side Down
fed Flap First
loaded into feeder G

Booklet
loaded Face Down
fed Bound Edge First
loaded into feeder F

1-13SV40221 Rev. A

1 • Introduction

Common Terms

Throughout the machine screens and this guide, standard terms are
used to describe the elements of the Mail Piece and functions of the
equipment.

It is therefore important that you fully understand the following basic
terms to get the best from your machine:

MATERIAL

Sheet A single piece of paper that will require folding

by the machine before it is placed into an
envelope.

Pre-Collated Set A set of sheets printed in a collated sequence

i.e. sheet 1, sheet 2, sheet 3, etc.

Stack A pile of paper as received from the printer

that will be loaded into a feeder (or feeders)
on the machine. A stack might consist of

numerous individual Sheets or numerous
Pre-Collated Sets, depending on how it was

printed.

Prime Sheet or
Prime Set

Additional Sheet
or Additional Set

Fold Type The style of fold to be applied:

This sheet or set normally contains the
address. It will be positioned closest to the
envelope window, or the front face of a
windowless envelope.

Additional sheet(s) or set(s) can be added
to the Prime Sheet or Prime Set. They will
be fed from other Sheet Feeder(s) and are
placed into the envelope behind the Prime.

C Fold

Z Fold

Single Fold

Double Fold

1-14 SV40221 Rev. A

also know as ‘standard’

fold.

also known as

‘accordion’ fold.

one fold applied (usually

folded in half).

folded in half and then

in half again.

Introduction • 1

MATERIAL (continued)

Insert An item that doesn’t require folding before

being placed into an envelope. There are four
kinds of Inserts:

Reply Envelope A return 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.

Pre-Folded Insert A sheet that has

been folded prior to
loading and requires
no further folding by
the machine.

Outer Envelope The envelope which contains all the items

placed into it by the machine.

Mail Piece A single assembled article of mail, usually an

envelope with correct contents.

Fan The process of flicking through a stack of

material to separate the items prior to loading.

Shingle The method of loading Inserts into a feeder in

a partially overlapped manner, like tiles on a
roof.

1-15SV40221 Rev. A

1 • Introduction

MACHINE FUNCTIONS

Home Screen The initial screen displayed after turning

power on. From this screen you can select

pre-programmed Job Definitions, enter the

menu functions or run the machine.

Pressing the Home key on the Control Panel
will return you to this screen at any time.

Job Definition The collection of settings that define how a

Mail Piece is to be created by the machine.
Up to 20 Job Definitions can be stored for

instant recall.

Mail Piece Icon
Tree

Trial Piece Test piece run by the machine before

Safe Seal A modified sealing mode that allows better

Linked Feeders Allows more than one feeder to be configured

Optical Mark
Recognition
(OMR)

Situated down the left side of the display.
A graphical representation of the items that

make up the currently selected Job Definition.

automatic operation can be started. A Trial
Piece allows the machine to calibrate itself

and the Mail Piece make-up to be checked.

sealing of ‘poor’ envelopes. Safe Seal will
allow more time for the envelope flap gum to
soften, but will slow machine operation.

to run the same Stack. When the first feeder

runs out of material, feed will automatically
switch to the next ‘linked’ feeder, and so on,
in a continuous cycle. This allows empty
feeder(s) to be loaded while another linked
feeder is feeding material.

The process of controlling machine functions

and Mail Piece make-up by ‘scanning’

material passing through the machine for
machine readable marks (OMR Marks).

1-16 SV40221 Rev. A

2 • Using the Menus

This chapter explains the Home Screen and the menu structure
accessed via the PacPilot™ Control Panel

The Home Screen ............................................................. 2-2

The Menu Structure ........................................................... 2-4

2-1SV40221 Rev. A

2 • Using the Menus

The Home Screen

The Home Screen is the first screen shown on the display after the
machine has finished powering up.

The last Job Definition selected is displayed with the relevant Mail
Piece Icon Tree on the left hand side.

The ▲ and ▼ navigation keys can be used to scroll through the
icon tree and highlight individual items. As you do this, the loading
instructions associated with the highlighted item will be shown.

From this screen you can run the job displayed. Alternatively, press
the relevant Screen Key to:

 Select Another Job from those already programmed into

the machine. See page 3-3.
 Initiate the SwiftStart™ feature. See page 3-6.
 Select the Menu Screen Key to access:
Operator Functions. See page 3-19.
Supervisor Functions. See page 4-2.
 You can also use the Manual Feed feature. See page 3-9.

2-2 SV40221 Rev. A

Using the Menus • 2

Machine
Status

Screen
Name

Home Piece Count:
READY Batch Count:

Invoice Job
Use ▼, ▲ to view loading
instructions

Name of
selected Job

Counter(s)

Job comments
text area

Select Job

SwiftStart

Menu

Instructional
Text

>

>

>

Screen
Key
Selections

Mail Piece Icon Tree Machine Graphic

The Home Screen

2-3SV40221 Rev. A

2 • Using the Menus

The Menu Structure

The diagram on the facing page shows the menu structure available
when you press the Menu Screen Key.

You will see that the menu follows a logical structure with similar
functions grouped together.

The menu structure is split into two sections:

 The first section is available to all Operators and contains

settings and adjustments that might be required when

running jobs on the machine.
 The second section is only available to a 'Supervisor' upon

entry of a Supervisor Access Code. This section allows

supervisors to create, edit and delete jobs as well as set

more advanced features.

The following two chapters in this guide; 'Operator Functions' and
'Supervisor Functions' give details of the functions available to each
level of user.

Use this diagram as a quick reference to find the function(s) that you
require, then refer to the relevant page in this guide.

Each screen can be identified by its title located in the top left corner.

2-4 SV40221 Rev. A

Home Screen

Select Job (p.3-3) >
SwiftStart (p.3-6) >
Menu (p.3-19) >

Language (p.3-19) >

OPERATOR FUNCTIONS SUPERVISOR FUNCTIONS

Display Adjustments (p.3-19) >
Safe Seal (p.3-19) >
System Information (p.3-19) >
Supervisor Functions (p.4-1) >

Create Job (p.4-3) >
Edit Job (p.4-4) >
Create From (p.4-6) >
Delete Job (p.4-7) >
OMR Menu (p.4-8) >
Systems Menu (p.4-8) >

Using the Menus • 2

Menu items

below this

line require

a Supervisor

Access Code

The Menu Structure

Manual Feed Option (p.4-8) >

2-5SV40221 Rev. A

2 • Using the Menus

2-6 SV40221 Rev. A

3 • Operator Functions

This chapter lists the functions that can be carried out by an
Operator. Primarily, this includes selecting Job Definitions, running
the various operator modes and loading material.

About this Chapter ............................................................. 3-2

Connecting Power ............................................................. 3-2

Running a Job ................................................................... 3-3

SwiftStart™........................................................................ 3-6

Manual Feed ..................................................................... 3-9

Setting the Sheet Feeders ............................................... 3-12

Setting the Envelope Feeder ........................................... 3-14

Setting the Insert Feeder(s) ............................................. 3-16

Filling the Envelope Sealer .............................................. 3-18

Menu ............................................................................... 3-19

Language .................................................................. 3-19

Display Adjustments .................................................. 3-19

Safe Seal .................................................................. 3-19

System Information ................................................... 3-19

3-1SV40221 Rev. A

3 • Operator Functions

About this Chapter

This chapter explains functions on the machine that can be carried

out by an Operator. This includes:

• Selecting and running a pre-programmed Job Definition

• Using the SwiftStart™ mode

• Using the Manual Feeder

• Loading the feeders

• Filling the sealer

Functions that can only be carried out after entry of a Supervisor
Access Code are described in the next chapter, ‘Supervisor
Functions’.

Connecting Power

Read the safety information on
page 1-2 before connecting the machine.

Connect the power cord to the socket on the back of the machine.

Plug the power cord into a suitable power outlet. Make sure the
power outlet is near the machine and is easily accessible.

Turn the machine power switch
ON.

3-2 SV40221 Rev. A

Operator Functions • 3

Running a Job

Selecting a Job

This section assumes the job to be run has already been created by
a Supervisor. If the job has not been created, refer to Create Job on
page 4-3.

When the machine is turned ON, a ‘ Startup Screen’ showing details
of your machine and contact details will be displayed for a short time.

After a few seconds, the Home Screen will appear. The last Job
Definition selected will be loaded, with the message ‘Trial Piece
Required’ displayed at the top of the screen.

If the job loaded is not the one required, press the Select Job

Screen Key. A list of Job Definitions that have been created will
appear alphabetically on the screen. Then...

• If you are certain which job you want, press the Screen Key
alongside the desired job to select it immediately.

• If you need confirmation of the job details, use the ▲ and
▼ keys to scroll through the list. As each job is highlighted,
the Mail Piece Icon Tree and Job Comments (if entered) will
change to reflect the highlighted job. When you are certain
which job you want, press the corresponding Screen Key to
select it.

TIP: In either case, if the job you require is not on the
first screen, use the ◄ and ► keys to move to the
screen containing the required job.

The selected job’s Mail Piece Icon Tree will now be
displayed. This shows the job make-up and the loading
orientation of material in the feeders. The message
‘Trial Piece Required’ will be shown at the top of the
display.

TIP: Once a job is selected, you can use the ▲ and ▼
keys to scroll through the icons on the Mail Piece Icon
Tree. As each icon is highlighted, loading instructions
related to the particular item will be displayed.

3-3SV40221 Rev. A

3 • Operator Functions

Load material into all the feeders as indicated by the Mail Piece Icon
Tree (refer to setting the feeders on pages 3-12 to 3-17).

If required, reset the item and/or batch counters by pressing the
Reset Counters key.

If necessary, fill the Sealer with sealing solution or water (see page
3-18).

If you are running an Optical Mark Recognition (OMR) job, the OMR
Scanner must be aligned to the OMR marks on the material being
run. Refer to page 5-18 for instructions.

Now run a Trial Piece as described in the following section.

Running a Trial Piece

A Trial Piece is required to enable you to check the Mail Piece
contents and to allow the machine to calibrate itself for the material
being run.

Press the Trial Piece key. The machine runs a single Mail Piece
which exits the machine unsealed so that you can check the
contents. The machine then asks if the Trial Piece is OK.

If the Trial Piece is OK, select Yes and follow the instructions in the
section ‘ Automatic Processing’ on the following page.

If the Trial Piece is NOT OK, select No and follow the on-screen
instructions to correct the error. You can adjust the address position,
fold panel length and/or the envelope stop position. The envelope
stop position will rarely need adjusting - for more information, see
page 6-15.

Once the adjustment is made and any further Trial Piece is OK, you
will be asked if you wish to save the changed settings as part of the
Job Definition.

If you choose Yes...

The machine will save the changed setting(s) as part of the

current job. Next time the original Job Definition is selected,
the modified adjustment(s) will be remembered.

A Supervisor Access Code (see page 4-2) will be requested,

as you are editing an existing Job Definition.

3-4 SV40221 Rev. A

Operator Functions • 3

If you choose No...

The adjustment(s) you have just changed will only be

retained while you are running the current job. If another Job
Definition is selected or if power is turned off, next time the
original Job Definition is selected, the modified adjustment(s)
will have returned to the value saved within the Job
Definition.

TIPS:

If you reload material during a run which seems to have
different characteristics (weight, colour shade, etc.), or if
you have any problems with double detect, run another
Trial Piece. This allows the machine to recalibrate the
double detect function for the new material in case the
batches vary slightly.

When loading a C-folded insert into feeder F or G,
load it with the open edge last and the double sheet
thickness face up.

Automatic Processing

After confirming a Trial Piece is OK...

Press the Start key to commence automatic operation.

The machine will operate until:

 material runs out
 the Stop key is pressed
 the batch count is reached (if batch count is being used)

Batch Count

If the Batch Count function was set when the job was created, the
machine will stop automatically after processing the required number
of Mail Pieces. Remove the batch of Mail Pieces and press Start to
recommence processing.

3-5SV40221 Rev. A

3 • Operator Functions

SwiftStart™

SwiftStart™ allows you to load material into the feeders and run a
simple job with minimal setup information.

The job can then either be run without saving it to the machine’s
memory, or a Supervisor can name and save the Job Definition for
future recall as and when required.

TIP:

SwiftStart™ can be used as a way to quickly program a
new Job Definition. Load material and run SwiftStart™.
A Supervisor can save the new job and then use
the Edit Job function (see page 4-4) to make minor
changes, if necessary.

Constraints and Requirements

• Only use closed flap envelopes.

• Feeds only single sheets from each Sheet Feeder.

• This mode cannot be used to run fold only or inserts only.

• You cannot link Sheet Feeders in this mode.

• The Envelope Sealer is always on (except for the Trial
Piece).

• The Batch Count is always off.

• The Maximum Sheet Length is 11”.

• Can run #10 and 6” x 9” sized envelopes.

• This mode will not work with OMR.

Loading Material for SwiftStart™

Loading Sheet Feeders

Depending on your envelope depth, the machine will automatically
select the fold type – Single or C (standard) fold.

For example, an 8-1/2” x 11” sheet inserted into a #10 envelope will
receive a C fold, whereas a 8-1/2 x 11” sheet inserted into a 6” x 9”
envelope will only require a Single Fold.

3-6 SV40221 Rev. A

For a C fold Job: Load the

Sheet Feeders from the
top feeder downwards, in
sequence (first sheet in top
feeder).

Load Sheets Face Up and Top
First.

For a Single fold job: Load the

Sheet Feeders from the bottom
feeder upwards, in sequence
(first sheet in bottom feeder).

Load Sheets Face Down and
Bottom First.

Operator Functions • 3

Loading Insert Feeder(s)

If either or both Insert Feeders are loaded with material when
SwiftStart is selected, the machine will feed the Inserts and make
them part of the SwiftStart™ job.

For a single Insert, load Insert Feeder F. For two Inserts, load Insert
Feeders F and G.

Booklets must be loaded into Insert Feeder F only and should be
loaded with the binding edge first.

Pre-folded Inserts should be fed with the open edge last.

Loading Envelope Feeder

Envelopes are loaded into Envelope
Feeder E flap side up, flap last.

3-7SV40221 Rev. A

3 • Operator Functions

SwiftStart™ Operation

Load material as previously described and select SwiftStart. The
machine will feed an envelope and depending on the depth of the
envelope, will automatically select the fold type – Single or C fold.

A Trial Piece is automatically produced, enabling you to check the
job and to allow the machine to calibrate itself for the material being
run.

During this process, if the material in any of the feeders is too
heavy, the Double Detect for the relevant feeder(s) will be turned off
automatically. This will be indicated by a message on the display.

The machine will ask if the Trial Piece is OK.

If the Trial Piece is OK, select Yes and follow the instructions in the
section ‘Saving a SwiftStart™ Job’ below.

If the Trial Piece is NOT OK, select No and follow the on-screen
instructions to correct the error. You can adjust the address position,
fold panel length and/or the envelope stop position. The envelope
stop position will rarely need adjusting - for more information, see
page 6-15.

Saving a SwiftStart™ Job

After confirming a Trial Piece is OK, you will be given the option to
save the current SwiftStart™ setup as a Job Definition for recall in
future. This function requires Supervisor level access (see page 4-2).

If you do NOT save the SwiftStart™ setup, it will only be retained
while you are running the current job. If another Job Definition is
selected or if power is turned off, the SwiftStart™ settings will be lost.

Automatic Processing

Whether you have chosen to save the SwiftStart™ job or not, you
can now commence automatic processing in the normal way:

Press the Start key to commence automatic operation.

The machine will operate until either material runs out or the Stop
key is pressed.

3-8 SV40221 Rev. A

Operator Functions • 3

Manual Feed

Manual Feed allows you to feed stapled or unstapled sets of up
to 5 sheets of 20 lb. (80g/m2) to a maximum total weight of
100 lb. (400g/m2). The sets are fed by hand, one set at a time, for

processing by the machine.

Using the Manual Feed automatically turns off all Sheet Feeders.
You can, however, use the Insert Feeder(s) if they have been
enabled by a Supervisor using the Manual Feed Option explained
on page 4-8.

Constraints and Requirements

• Only use closed flap envelopes.

• This mode cannot be used to run fold only or inserts only.

• Sheet Feeders do not operate in this mode.

• The Envelope Sealer is always on (except for the Trial
Piece).

• The Batch Count is always off.

• Sets should contain sheets of the same length.

• This mode will not work with OMR.

Loading Material for Manual Feed Mode

Loading Insert Feeder(s)

Insert Feeder(s) will only operate if they have been enabled by a
Supervisor using the Manual Feed Option explained on page 4-8 of
this guide.

For a single Insert, load Insert Feeder F. For two Inserts, load Insert
Feeders F and G.

Booklets must be loaded into Insert Feeder F only and should be
loaded with the binding edge first.

Pre-folded Inserts should be fed with the open edge last.

Loading Envelope Feeder

Envelopes are loaded into Envelope Feeder E flap side up, flap last.

3-9SV40221 Rev. A

3 • Operator Functions

Manual Feed Operation

Make sure Envelopes and Inserts (if required) are loaded as
previously described.

You must now decide which way round to feed the set into the
Manual Feeder, as this depends on the type of fold the set requires.

Depending on your Envelope depth and Sheet length, the machine
will automatically select the fold type – Single, C or double fold.

For example:

8-1/2” x 11” sheets inserted into a #10 envelope will receive a C fold.

5-1/5” x 8-1/2” sheets inserted into a 6” x 9” envelope will only
require a Single fold.

Sheets over 12” (305mm) long inserted into a #10 envelope will need
a Double fold.

Use the following list as a guide for feeding the Manual Feed set:

C Fold Feed the set Face Up, Top First

Single Fold Feed the set Face Down, Bottom First

Double Fold Feed the set Face Up, Top First

Set the Manual Feeder side
guides to control the sets to
be fed. The guides are self­centering.

Take one set and feed it gently
into the Manual Feeder until the
machine automatically starts
and draws the set from you.

A Trial Piece is produced, enabling you to check the job setup. The
machine will ask if the Trial Piece is OK.

If the Trial Piece is OK, select Yes and refer to ‘Manually Feeding
Further Sets’ on the next page.

If the Trial Piece is NOT OK, select No and follow the on-screen
instructions to correct the error. You can adjust the address position,
fold panel length and/or the envelope stop position. The envelope
stop position will rarely need adjusting - for more information, see
page 6-15.

3-10 SV40221 Rev. A

Operator Functions • 3

Manually Feeding Further Sets

After confirming a Trial Piece is OK, the machine will remember it’s
settings and process further manually fed sets automatically.

While the motor runs, the machine will remain in Manual Feed mode.
If no further sets are fed whilst the motor is running, after a brief
delay, the motor stops and the machine reverts to the previous Job
Definition selected.

If you wish to leave Manual Feed mode while the motor is running,
press Cancel twice.

The Manual Feed settings will be lost once a pre-programmed Job
Definition is selected or SwiftStart™ is operated.

3-11SV40221 Rev. A

3 • Operator Functions

Setting the Sheet Feeders

Sheet Feeders A to D feed sheets that require folding by the
machine.

The Mail Piece Icon Tree for the job being run will show which
feeders need to be loaded and the sheet orientation. If you need help
understanding the sheet icons, refer to page 1-11 of this guide.

The First Sheet or Set (normally containing the address) will be fed
from the top feeder for C or Double Fold jobs and from the bottom
feeder for single or Z fold jobs. This will be indicated by the Mail
Piece Icon Tree.

Sheet Feeders can feed single Sheets or Pre-Collated Sets,
depending on job setup. The Mail Piece Icon Tree will tell you the
quantity of sheets that the machine is programmed to run from
each feeder if Pre-Collated sets are programmed. If you need help
understanding the terms Sheet or Pre-Collated Set, refer to page
1-14 of this guide.

1. Adjust the side guides to
the width of the material
being fed using the Side
Guide Adjustment Knob,
then back-off 1/4 of a turn.

This will set the correct

clearance between the
guides and sheets.

2. Take the relevant Stack of
sheets and fan it to ensure
individual sheets are not
stuck together.

3-12 SV40221 Rev. A

Operator Functions • 3

3. Jog the stack back into
alignment.

4. The Mail Piece Icon Tree will show the correct orientation of the
sheets in the Stack. Make sure you load sheets in the orientation
indicated.

5. The Sheet Feeders take
the paper Stack in a similar
way to a photocopier paper
cassette.

Place the Stack onto the

deck of the feeder.

Depress the Stack and

slide it fully under the feed
roller.

3-13SV40221 Rev. A

3 • Operator Functions

Setting the Envelope Feeder

Envelope Feeder E feeds the Outer Envelope for the inserting job
being run.

The Mail Piece Icon Tree for the Job Definition being run will show
if the feeder needs to be loaded and the envelope orientation. If you
need help understanding the envelope icons, refer to page 1-12 of
this guide.

1. Press the Envelope
Feeder loading switch to
lower the feeder tray ready
for loading.

2. Adjust the side guides to
the width of the envelopes
being fed using the Side
Guide Adjustment Knob,
then back-off 1/4 of a turn.

This will set the correct

clearance between the
guides and envelopes.

3. Take the stack of
envelopes and fan it
to ensure individual
envelopes are not stuck
together.

3-14 SV40221 Rev. A

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 raise the envelope
stack to the normal feeding
position.

Operator Functions • 3

TIP:

To quickly load envelopes during a run, without the need
to stop and start the machine...

• Press the Envelope Feeder loading switch to
lower the feeder tray.

• Load envelopes as described above.

• Press the Envelope Feeder loading switch
again. The envelope stack will rise to the normal
feeding position and processing will continue
automatically.

3-15SV40221 Rev. A

3 • Operator Functions

Setting the Insert Feeder(s)

Insert Feeders F and G feed items that do not require folding by the
machine. Depending on configuration, your machine may have no
Insert Feeders, one Insert Feeder or two Insert Feeders.

Insert Feeder F is capable of feeding thicker Inserts than Insert
Feeder G. Therefore, booklets must only be fed from Feeder F.

The Mail Piece Icon Tree for the job being run will show if the feeder
needs to be loaded and the Insert orientation. If you need help
understanding the Insert icons, refer to page 1-12 of this guide.

1. Adjust the side guides to
the width of the Inserts
being fed using the Side
Guide Adjustment Knob,
then back-off 1/4 of a turn.

This will set the correct

clearance between the
guides and Inserts.

2. Refer to the labels located on each Insert Feeder. Match your
insert type (Slip, Reply Envelope, Pre-Folded or Booklet) with the
relevant icon and colour indicator on each label. Where a range
of settings is indicated on the label, the thicker the insert, the
higher the number or letter that should be selected.

i.e., The blue Booklet range runs from 6 to 9 and from C to D.

A thin Booklet might be set to 6 or 7 and C, whereas a thick
booklet might need settings 9 and D to run effectively.

3. Set the blue separator
gap lever to the number
required.

3-16 SV40221 Rev. A

4. Set the blue separator
shield lever to the letter
required.

5. Take the stack of inserts
and fan it to ensure
individual Inserts are not
stuck together.

6. ‘Shingle’ the inserts to be
run so that they look like
the photograph on the right
and place them onto the
feed deck.

The Mail Piece Icon Tree

will show the correct
orientation of the Inserts.

Operator Functions • 3

7. Let the Wedge slide down
behind the stack so that
the Inserts are supported.

Note: If Insert Feeders F and G are linked (running the same

inserts), make sure the lever settings in steps 3 and 4 are
set the same on both feeders.

3-17SV40221 Rev. A

3 • Operator Functions

Filling the Envelope Sealer

Make sure the Envelope Sealer is filled with sealing solution before
running a job that has sealing turned on.

When the sealer needs refilling, a warning message will
automatically appear on the display and, if sealing, the sealing icon
will flash.

Add sealing solution (EZ-Seal™ is recommended) in the following
way:

Hinge open the Sealer Bottle
Cover located at the front right
hand side of the machine.
Remove the bottle.

Unscrew the cap and fill the bottle with sealing solution (EZ-Seal™).

Refit the cap and place the bottle back into the machine.

Close the Sealer Bottle Cover.

TIPS:

If filling the Envelope Sealer for the first time, or if the
sealer has been allowed to completely empty, you
should allow time for the solution to soak through the
sealer mechanism before processing material.

The use of water in the sealer is not recommended.
We recommend EZ-Seal™ as it improves sealing
performance and minimises growth of algae and scale
build-up. It can be purchased directly from Pitney
Bowes.

When refitting the Sealer Bottle cap, the ‘pointed’ part of
the cap fits into the bottle neck and the cap screws into
place.

3-18 SV40221 Rev. A

Operator Functions • 3

Menu

Select the Menu Screen Key to access the following Operator
Options within the menu structure:

• Language

• Display Adjustments

• Safe Seal

• System Information

Language

When this option is selected, a choice of languages will be displayed.
Choose the required language from the list and all display text will
change to the selected language.

This is a temporary setting. Switching the machine Off and then back
On will revert to the default language. (The default language is set to
your preference by your local service engineer at installation).

Display Adjustments

Select this option and follow the simple on-screen instructions to
change the contrast or brightness levels of the display to suit your
needs.

Safe Seal

This option allows you to switch Safe Seal on or off. When on, the
Safe Seal icon appears on the Mail Piece Icon Tree alongside

the Outer Envelope icon.

Safe Seal allows more time for moisture to soften the gum on the
Outer Envelope, allowing it to become more sticky. This function
therefore improves sealing of certain types of envelope but will slow
the machine down.

System Information

This screen displays information such as machine serial number,
your local service and supplies telephone number, software versions
and total item count.

3-19SV40221 Rev. A

3 • Operator Functions

3-20 SV40221 Rev. A

4 • Supervisor Functions

This chapter lists the functions that can be carried out by a
Supervisor. Primarily this includes creating, editing and deleting jobs.

About this Chapter ............................................................. 4-2

Supervisor Access Code ................................................... 4-2

Create Job ......................................................................... 4-3

Edit Job ............................................................................. 4-4

Create From ...................................................................... 4-6

Delete Job ......................................................................... 4-7

OMR Menu ........................................................................ 4-8

System Menu .................................................................... 4-8

Manual Feed Option ................................................... 4-8

4-1SV40221 Rev. A

4 • Supervisor Functions

About this Chapter

This chapter describes the functions available within the Supervisor
Functions menu.

All of the functions are set by following a sequence of screens and
answering simple questions presented on the display. Therefore,
this chapter does not take you through every function step by step. It
gives you background information on the function and offers helpful
tips to get the best out of your machine.

Supervisor Access Code

Before you can access any of the functions in this menu you must
enter a Supervisor Access Code. This prevents unauthorised access
to functions mainly related to administration of jobs and OMR.

Your installing engineer will tell you the Supervisor Access Code. If
you wish, you can write it in the box on this page as a reminder.

However, please be aware that this is then available to anyone
using this Operator Guide and so you may wish to make a note
of it and keep it in a more secure location.

The Supervisor Access Code cannot be changed from the one given
to you by the installing engineer.

Supervisor Access Code:

Entering the Code

When asked to enter the Supervisor Access Code, use the ▲▼◄►
keys to highlight the first digit of the code on the Numeric Matrix
displayed, and confirm this digit by pressing OK. Repeat for the
second digit. When complete, select Finished.

4-2 SV40221 Rev. A

Supervisor Functions • 4

Create Job

What is it?

This function allows a Supervisor to create new Job Definitions to be
stored within the machine’s memory for easy access by an Operator.
The machine can store a maximum of 20 Job Definitions.

Where is it?

From the Home Screen...

select Menu
select Supervisor Functions
enter the Supervisor Access Code (see page 4-2)
select Create Job

Action…

The machine will ask you a number of specific easy to answer
questions about the make up of the finished Mail Piece in order to
create the Job Definition.

Some of the questions asked will be based on the answers
previously given and so the sequence will vary from job to job. As
you create the job, the Mail Piece Icon Tree will be built on the left
side of the display. This shows how to load material into each feeder.

Once the job is created, named and any comments entered, you
must select Save to store it in the machine’s memory.

TIPS:

Placing a job description in the job comments will make
it easy for an Operator to select the correct job.

Use the Batch Counter if you want to automatically
process a pre-defined number of Mail Pieces. When the
Batch Count is complete, the machine will stop, allowing
the Operator to empty the stacker. Pressing Start will
commence processing of the next batch.

If you are using OMR within a job, an OMR code must
be pre-programmed into the machine’s memory. For
details of programming OMR codes, refer to Chapter 5.

OMR jobs cannot utilise linked feeders.

4-3SV40221 Rev. A

4 • Supervisor Functions

Edit Job

What is it?

Edit Job allows a Supervisor to add and delete items within an
existing Job Definition. It also lets a Supervisor alter the job setup
such as batch count, job comments and job name.

The Edit Job function is used to change a Job Definition, and so

always over-writes the original Job Definition in the machine’s
memory (even if the Job Name has been edited). If you wish to
create a NEW Job Definition which is similar to an existing job and
leave the existing Job Definition untouched, use the Create From
function described on page 4-6.

Where is it?

From the Home Screen...

select Menu
select Supervisor Functions
enter the Supervisor Access Code (see page 4-2)
select Edit Job

Action…

Once Edit Job has been selected, choose the Job Definition you
wish to edit from the alphabetical job list using the ▲▼◄► keys in
the normal way.

Edit Job allows a Supervisor to modify all Job Definition parameters
except for adding or removing the Outer Envelope and the First
Sheet or Set.

Highlight the item you wish to edit by scrolling through the Mail Piece
Icon Tree using the ▲▼ keys.

To add an Additional Sheet/Set or a second Insert, highlight the icon
in the Mail Piece Icon Tree immediately adjacent to the point you
wish to add the new item, then select Add Item After or Add Item
Before as applicable.

To add an Insert to a job currently without Inserts, select Add Insert.

4-4 SV40221 Rev. A

Supervisor Functions • 4

TIPS:

Highlight the Job Name to edit the following items:
Job Name
Job Comments
Batch Counter
Maximum Sheet Length
OMR set up

Highlight the Envelope icon to edit envelope and
sealing settings.

The Outer Envelope and First sheet cannot be added or
deleted.

Don’t forget to edit the job comments to correspond to
your revised job setup!

When editing a job, it is recommended that you
start at the top of the Mail Piece Icon Tree and work
downwards.

OMR jobs cannot utilise linked feeders.

4-5SV40221 Rev. A

4 • Supervisor Functions

Create From

What is it?

A Supervisor can use the Create From function to create a NEW Job
Definition which is SIMILAR to an existing job and leave the existing
Job Definition untouched. This can save time programming a new
Job Definition when it is almost identical to an existing job but for a
small change such as an extra Insert or Sheet, etc.

The machine will copy the existing Job Definition and ask for the new
job to be named. It will then allow you to edit the new job to meet the
slightly changed requirements.

Where is it?

From the Home Screen...

select Menu
select Supervisor Functions
enter the Supervisor Access Code (see page 4-2)
select Create From

Action…

Once Create From has been selected, choose the Job Definition
you wish to use as the basis of the new job from the alphabetical job
list using the ▲▼◄► keys in the normal way.

Once the Job Definition that you are ‘creating from’ has been
selected, the machine will prompt you to enter a new Job Name (as
no two Job Definitions can have the same name).

After the Job Name has been entered, the machine will ask you to
enter the Job Comments. The following screens will then be as in

Edit Job described on page 4-4.

TIPS:

The machine’s memory holds a maximum of 20 Job
Definitions.

All the tips for Edit Job (page 4-5) also apply.

4-6 SV40221 Rev. A

Supervisor Functions • 4

Delete Job

What is it?

Delete Job allows a Supervisor to remove a stored Job Definition
permanently from the machine’s memory.

Where is it?

From the Home Screen...

select Menu
select Supervisor Functions
enter the Supervisor Access Code (see page 4-2)
select Delete Job

Action…

Once Delete Job has been selected, choose the Job Definition you
wish to delete from the alphabetical job list using the ▲▼◄► keys
in the normal way.

Once the required Job Definition is selected, a message will be
displayed which requires confirmation before the job is deleted.

TIP:

Make sure the Job Definition you are deleting is the
correct job! Once deleted, it cannot be retrieved.

4-7SV40221 Rev. A

4 • Supervisor Functions

OMR Menu

This function lets a Supervisor setup Optical Mark Recognition
(OMR) codes for inclusion within Job Definitions.

All OMR functions are explained fully within Chapter 5 - OMR.

System Menu

What is it?

This menu lets a Supervisor adjust the following system setting:

 Manual Feed Option

Where is it?

From the Home Screen...

select Menu
select Supervisor Functions
enter the Supervisor Access Code (see page 4-2)
select System Menu

Manual Feed Option

This function lets a Supervisor choose whether or not the Insert
Feeder(s) are active when a Manual Feed operation is carried out.

The default setting is for both Insert Feeders to be ignored with a
Manual Feed. Changing this setting will feed Insert(s) from either or
both Insert Feeders, if they are loaded.

For more details of Manual Feed see page 3-9 of this guide.

4-8 SV40221 Rev. A

5 • Optical Mar

k

Recognition (OMR)

This chapter gives background and setup information for using
Optical Mark Recognition (OMR) on a machine equipped with the
OMR option.

OMR Availability ................................................................ 5-2

What is OMR? ................................................................... 5-2

OMR Marks Available ........................................................ 5-3

OMR Mark Options ............................................................ 5-6

OMR Specifications ........................................................... 5-8

Creating, Deleting and Viewing OMR Codes .................. 5-10

Create New OMR Code ...................................................5-11

Delete OMR Code ........................................................... 5-13

View OMR Code .............................................................. 5-14

Creating an OMR Job ...................................................... 5-15

OMR Scanner Adjustments ............................................ 5-18

5-1SV40221 Rev. A

5 • Optical Mark Recognition (OMR)

OMR Availability

Your machine can be equipped with Optical Mark Recognition
(OMR) functionality either on installation or as an added option after
purchase. The machine can store up to 10 different codes for you to
select when creating Job Definitions that use OMR.

What is OMR?

An OMR mark is normally a dark solid
line on a sheet of light coloured paper
that is perpendicular to the direction of
travel of the paper. This line must be
sufficiently thick, dense and placed in the
correct area to trigger the OMR scanner
on the system.

There are many different OMR options
available to you, from a Single Mark
option to Multi-Mark options, which have
a maximum of 24 marks.

The OMR scanner, working with the
OMR system software, checks for one or
more different marks on the sheets while they are being fed through
the system. The tracking of these OMR marks by the system will aid
the integrity of your mailing through error checking, so generally the
more marks you use, the better the integrity of your Mail Piece.

As mentioned on page 7-3 of this guide, there are limits on how
many sheets the machine can fold at one time. These limits are
dependent on the paper weight of your sheets, and fold type
selected, and should not be exceeded. It is therefore strongly
recommended that, when programming your system to print your
OMR sheets, these limits are taken into account. If these limits are
exceeded, it could result in a material stoppage or damage to the
material and the machine.

Typical
OMR marks

5-2 SV40221 Rev. A

Optical Mark Recognition (OMR) • 5

OMR Marks Available

This section gives brief descriptions of the OMR Marks that can be
allocated to an OMR Code and lists the options available for use with

each mark. The section following, OMR Mark Options on page 5-6

then gives greater detail of each option.

NOTE: Some marks within this section are available as added
features which expand OMR capability. Contact your machine
supplier for details. OMR features available will vary depending on
the country you are in.

BM - Benchmark

This is a mandatory mark within the Multi-Mark option, it must be

either the first or last mark of the code and will appear on every page

within the first set.

This mark may only be selected once within the code.

SAF - Safety

This mark improves the integrity of your Mail Piece. It can be placed
anywhere within the code but benefits from being at the opposite end
of the code to the Benchmark.

When the Safety mark is placed in this position with the option

Always Present, and No other marks other than the OMR code
in the margin is chosen when creating the job, the machine will

automatically work out the length of the code. This makes creating
jobs using this code easier. Otherwise, the machine will ask for a
code length when creating a job.

This mark may appear more than once within the code.

Options available:

• Always Present or Never Present

BOC - Beginning of Collation

This mark indicates that it is the first sheet fed within a set. This mark
may only be selected once within the code.

Options available:

• Present or Absent

5-3SV40221 Rev. A

5 • Optical Mark Recognition (OMR)

EOC - End of Collation

This is a mandatory mark which indicates that it is the last sheet fed
within the OMR set. This can only be selected once within the code

and is the only mark used when using the Single Mark option.

Options available:

• Present or Absent

STP - Stop

This mark is a processing feature which tells the machine to stop
once the completed Mail Piece has exited the machine.

Options available:

• Present or Absent

• All Sheets, Page 1 Only or Last Page Only

• Marked Piece to be left Unsealed (Yes or No)

SF(n) - Select Feed

These marks instruct the machine to select material from specified
feeders.

This feature is only available to select sheets when C fold is used

and the material is under 12“ (305mm) in length.
Selectively fed inserts are available for all types of folds and sheet

lengths within the specifications of the machine.

Up to 8 Select Feed Marks can be within to the code. 5 of these
marks can be allocated to specified feeders when creating a Job
Definition. The other 3 marks will be automatically ignored. Allowing
8 Select Feed Marks to be used gives greater flexibility in reusing
existing codes from production type machines which may have
greater Select Feed capability.

Options available:

• Present or Absent

• All Sheets, Page 1 Only or Last Page Only

5-4 SV40221 Rev. A

Optical Mark Recognition (OMR) • 5

PAR - Parity

This mark is a security feature, that when printed always makes

the number of marks total an odd or even number. If any one of the
marks within the code is missed during scanning, the machine will

stop functioning, allowing the error to be rectified. No more than 1

Parity mark can be used within the code.

Options available:

• Odd or Even

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 processing and declare an error message. Up to
6 Wrap Around Sequence marks can be within the code.

Options available:

• Increment (Ascending) or Decrement (Descending)

• Include or Omit Zero (0) as a value within the sequence

• Continuous Sequence or Page 1 Reset

• Least or Most Significant Mark nearest to Bench Mark
(code orientation)

• Number of Wrap Around Sequence Marks

TM - Timing

This mark is needed by some other machines to read OMR marks

correctly. This machine does NOT need Timing marks, but the

mark(s) may be left within an existing code and will add integrity to
your Mail Piece.

Timing mark(s) may appear more than once within the code and, if
used, must always be present within the code.

IGN - Ignore

This feature is used to ignore a mark within the code. It may be used
more than once within the code.

This can be useful to enable existing codes from other equipment to
be used, as certain marks might not be applicable to this machine.

5-5SV40221 Rev. A

5 • Optical Mark Recognition (OMR)

OMR Mark Options

This section gives brief descriptions of the OMR Mark Options that

can be allocated to relevant OMR marks. The previous section, OMR
Marks Available on page 5-3 lists which options can be selected with

each mark.

Present or Absent

When Present the machine will act upon scanning the relevant
mark.

When Absent the machine will act upon NOT scanning the relevant

mark.

Increment or Decrement

When choosing Increment the relevant code’s binary value will

increase.
If you choose to use Decrement, the relevant code’s binary value

will decrease.

Include Zero or Omit Zero (0) as a Value

If Include Zero is chosen, the relevant code’s binary value would

allow zero, which is represented by no marks being printed within

that section of the code.

When choosing to use Omit Zero the relevant code’s binary value

will NOT include zero as a value. Therefore, a mark will ALWAYS be

printed within that section of the code.

Continuous Sequence or Page 1 Reset

When using Continuous Sequence, the binary value within the

relevant part of the code increments or decrements continuously on
every sheet fed, irrespective of set boundaries.

If Page 1 Reset is used, the first page of each set has a binary value
of 1, therefore the count always stays within the boundaries of the

set.

5-6 SV40221 Rev. A

Optical Mark Recognition (OMR) • 5

Least or Most Significant Mark nearest to Benchmark

This option gives the choice of orientation of the binary digit count

within the relevant part of the OMR code.

When Least Significant Mark is chosen, the mark within the
relevant part of the code nearest to the Benchmark would be

represented by the lowest binary digit within that part of the code.

When Most Significant Mark is chosen, the mark within the relevant
part of the code nearest to the Benchmark would be represented by

the highest binary digit within that part of the code.

All Sheets, Page 1 Only, Last Page Only

If All Sheets is selected, the relevant code is expected on all sheets
within that set.

When using Page 1 Only or Last Page Only, the relevant code

will only be expected on the first or last page fed, depending on the

option chosen.

Marked Piece to be left Unsealed (Yes or No)

If Yes is selected, the machine will stop when it sees the Stop mark

with the relevant unsealed envelope in the stacker.

If No is selected, the machine will also stop with the envelope in the
stacker when it sees the Stop mark, but envelope sealing will be

processed as programmed in the relevant Job Definition.

Odd or Even

This is an option used in conjunction with the Parity mark. When

the Parity mark is printed, this option defines whether the number of

marks should be odd or even. If any mark is missed during scanning,

the machine will stop indicating a problem.

Always Present or Never Present

This option is used in conjunction with the Safety mark only. When

Always Present is selected, the Safety mark must be printed on all
pages within the first set.

If Never Present is selected, the Safety mark will not be printed and
this mark position must be kept blank.

5-7SV40221 Rev. A

5 • Optical Mark Recognition (OMR)

OMR Specifications

The mark must be a solid black line between 1pt and 2pts thick 1/64”
(0.35mm to 0.7mm) and at least 3/8” (10mm) wide.

Each mark position must be evenly spaced and at least 1/10”
(2.54mm) apart.

The maximum amount of mark positions allowed within the code is
24; this includes ignored marks. The total length of the OMR code
should not exceed 2-3/4” (70mm).

The center line of the marks must fall within a range from 2-3/8”
(59mm) to 4-3/4” (108mm) from the center line of the sheet. The
OMR marks should not be closer than 3/4” (20mm) from the Lead
Edge or 1-3/16” (30mm) from the Trail Edge of the sheet.

An area around the marks should be kept clear from print, etc. that
may be read by the scanner in error, this area is called the Clear
Zone. The Clear Zone must be at least 1/8” (3mm) each side of the
marks, 3/4” (20mm) before the first mark and 3/4” (20mm) after the
last mark.

There should be no print on the reverse of the sheet immediately
behind the Clear Zone.

Clear Zone

min 1/10” pitch

(10 lines/inch)

1pt to 2pt

1/64” (0.35mm to

0.7mm) thick

1/8” (3mm)

min

5-8 SV40221 Rev. A

3/8”

(10mm)

min

3/4” (20mm) min

2-3/4” (70mm) max

3/4” (20mm) min

1/8” (3mm)
min

Diagrams NOT to scale

3/4”

(20mm)

min

Optical Mark Recognition (OMR) • 5

LEADING EDGE

2-3/8”

(59mm)

min

4-3/4” (108mm)

max

2-3/8”

(59mm)

min

4-3/4” (108mm)

max

1/8” (3mm) min 1/8” (3mm) min

Place marks in
this area for:

C/Double Fold
Rear Top Scanner

Single/Z Fold
Rear Bottom
Scanner

Place marks in
this area for:

C/Double Fold
Front Top Scanner

Single/Z Fold
Front Bottom
Scanner

1-3/16”

(30mm)

min

The white areas in the diagram show the
possible areas where OMR marks can be
placed and depend on the physical location
of the scanners fitted to the machine.

5-9SV40221 Rev. A

5 • Optical Mark Recognition (OMR)

Creating, Deleting and Viewing OMR Codes

The OMR Menu contains functions which allow a Supervisor to
create, delete and view OMR Codes.

Where is it?

From the Home Screen…

Select Menu

Select Supervisor Functions

Enter the Supervisor Access Code (see page 4-2)

Select OMR Menu

Action…

Once the OMR Menu has been selected, the three following options
will appear:

• Create New OMR Code

• Delete OMR Code

• View OMR Code

Note that some options will be unavailable if you have no current
OMR code(s) stored in the machine’s memory.

5-10 SV40221 Rev. A

Optical Mark Recognition (OMR) • 5

Create New OMR Code

This function lets a Supervisor create a new OMR code to be stored
in the machine’s memory so that it can be used when creating a Job
Definition that uses OMR.

Action…

Select Create New OMR Code from the OMR Menu screen and the
machine will ask if you are creating a Single Mark or Multi-Mark
Code:

If Single Mark is selected...

The machine automatically assigns the End of Collation mark

as this is the only ‘single mark’ the machine uses.

You will then be asked to set the End of Collation mark options,

i.e. will the mark be Present or Absent?

Once a mark is selected, a representation with its abbreviation

will appear on the left hand side of the screen.

When complete you will be asked to name the OMR Code (see

tips on following page).

If Multi-Mark is selected...

You will be able to select from the available OMR Marks in the

list on the screen. This is done by scrolling up or down the list by
using the ▲ and ▼ navigation keys.

The marks must be selected in the correct order, starting with the

mark located towards the top (head) of the page first.

Once the required mark is highlighted, press the OK key to

select it.

Certain marks may have a number of options associated with

them as described in the previous sections.

Some marks will disappear once selected, as they can only be

used once within the code. Other marks can be used multiple
times and so will remain available in the list.

Once a mark is selected, a representation with its abbreviation

will appear on the left hand side of the screen.

If you press Cancel whilst in this screen, the last selected mark

will be removed.

5-11SV40221 Rev. A

5 • Optical Mark Recognition (OMR)

The Benchmark is a mandatory mark and must be either the

first or last mark within the code. The End of Collation Mark is
the only other mandatory mark and so must also be selected,
but it can be placed anywhere within the code. If either of the
mandatory marks are not selected, the Finish screen key will not
be activated.

After all the required marks have been entered, select the Finish

screen key.

You will now be asked to name the OMR code. Once the name

of the code has been entered correctly, select the Save screen
key to save the code within the machine’s memory.

TIPS:

The representation of the OMR mark on the left hand

side of the screen will display as a dashed line if the
‘Absent’ option is selected.

Up to 9 characters can be used to name an OMR code.

10 codes can be stored in the machine’s memory.

All codes to be saved must be named.

No two codes can have the same name.

5-12 SV40221 Rev. A

Optical Mark Recognition (OMR) • 5

Delete OMR Code

This function lets a Supervisor delete a current OMR code which is
stored in the machine’s memory.

Action…

Select Delete OMR Code from the OMR Menu screen.

A list of all the current OMR Codes will be displayed. Select the OMR
code you wish to delete from the list using the ▲▼◄► keys in the
normal way.

Once selected, a message will be displayed asking you to confirm
that you want to delete the selected code.

Either...

• Select Yes to confirm deletion.

• Select No to return you to the OMR Menu without deleting
any codes.

TIPS:

Make sure that the code you are deleting is the correct

code! Once deleted, it cannot be retrieved.

This function is not available if there are no OMR codes

to delete.

Any code that is being used within a saved Job

Definition cannot be deleted. You must first either delete
the relevant Job Definition(s), or edit the affected Job
Definition(s) to use a different OMR code.

5-13SV40221 Rev. A

5 • Optical Mark Recognition (OMR)

View OMR Code

This function lets a Supervisor view any current OMR codes, which
are stored in the machine’s memory.

Action…

Select View OMR Code from the OMR Menu screen.

A list of all the current OMR Codes will be displayed. Select the OMR
code you wish to view from the list using the ▲▼◄► keys in the
normal way.

The highlighted OMR code will then be displayed on the left side of
the screen.

If you require more detailed information about the code, either select
the relevant screen key for that code or press the OK key once the
relevant code has been highlighted.

Scroll up and down the selected OMR code by using the ▲ and ▼
navigation keys to review detailed information about the selected
code.

From this screen you can select the corresponding screen key to:

• Delete this Code

• View another Code

• Return to OMR Menu

TIPS:

The representation of the OMR mark on the left hand

side of the screen will display as a dashed line if the
‘Absent’ option is selected.

This function is not available if there are no OMR codes
to view.

5-14 SV40221 Rev. A

Optical Mark Recognition (OMR) • 5

Creating an OMR Job

Before you Start

Before creating a Job Definition using OMR, make sure that the
required OMR code has been set up as described in Create New
OMR Code on page 5-11.

Setting the Type of OMR

During the Create Job process, the machine will ask whether OMR
is being used within the job being programmed. If you reply yes, you
must select the type of OMR code you wish to use: Selective Feed
or Non Selective Feed. If either of these options are greyed out, it
means an OMR code of the required type has not yet been created
and saved into the machine’s memory.

When creating a Job Definition using Select Feed marks, additional
questions will be asked to assign feeders to required Select Feed
mark(s).

TIP:

Note that a Selective Feed code can be used in a non­Selective Feed Job Definition by not allocating any of
the Select Feed (SF) marks to a feeder when creating
the Job Definition.

Setting the OMR Scanning Area

Material is scanned as it feeds through the machine. This means that
the OMR Scanner reads a vertical strip or margin down the page,
defined by the OMR Specifications on pages 5-8 and 5-9.

The machine must now be told if the entire OMR margin (the strip
down the page that is scanned for OMR marks) is clear of any other
printing or punched holes, etc.

If the area IS clear, the machine can normally detect the OMR marks
with no further setup.

If the entire margin is NOT clear, or the machine cannot set itself
automatically, it will ask questions to ascertain where it needs to look
for OMR marks and where it should ignore other printed matter.

Depending on the type of OMR 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...

5-15SV40221 Rev. A

5 • Optical Mark Recognition (OMR)

Defining the first mark position and code length

Take a sheet that has at least the FIRST and LAST OMR mark
printed on it.

When requested by the machine, measure and enter the distance
(A) from the top edge of the sheet to the FIRST OMR mark, in
millimetres.

Again, when requested by the machine, measure and enter the
distance (B) from the FIRST OMR mark to the LAST OMR mark, in
millimetres.

TOP OF SHEET

A

B

5-16 SV40221 Rev. A

Optical Mark Recognition (OMR) • 5

Defining the Clear Zone

When requested by the machine, measure and enter the distance
(A) from the top edge of the sheet to the point after the printed matter
where you wish the machine to START scanning.

Again, when requested by the machine, measure and enter the
distance (B) from the start point just set, to the point you wish the
machine to STOP scanning. This is called the Clear Zone.

Note that setting the Clear Zone closer to the beginning and end
of the OMR marks decreases the possibility of any poor print or
imperfections on the material being interpreted as OMR marks.
Conversely, setting the Clear Zone too close to the beginning
and end of the OMR marks could cause problems if the position
(registration) of the printing on the material varies. A good guide is
to limit the Clear Zone, but always allow at least 3/4” (20mm) before
and after the OMR marks.

TOP OF SHEET

A

Grey area
indicates
printed matter

B

on material

5-17SV40221 Rev. A

5 • Optical Mark Recognition (OMR)

OMR Scanner Adjustments

The machine can be fitted with one Top Scanner and one Bottom
Scanner. If the sheet(s) bearing OMR marks are loaded face up,
the Top Scanner will be used. If they are loaded face down, the
Bottom Scanner will be used. The loading orientation required for the
particular job will be shown on the Mail Piece Icon Tree and depends
on fold type, etc.

Aligning the Scanners

It is essential that the OMR Scanner being used is correctly aligned
over the OMR marks printed on the sheet(s). Failure to align the
scanner will result in scanning errors. It is therefore essential that the
scanner alignment is checked before commencing any OMR job.

Measure the OMR mark position

Take a sheet printed with the OMR marks to be used and fold it in
half in the direction of feed to locate the sheet’s center line. Now

measure from the center line to the center of the OMR marks in

millimetres. Take a note of this measurement (X).

OMR marks
(position used
depends on
scanner location)

X mm

5-18 SV40221 Rev. A

X mm

Folded
center line

Optical Mark Recognition (OMR) • 5

Setting the Top Scanner Position

This scanner position is used for C and Double Folds.

Open the Top Cover and locate the blue Top Scanner adjusting knob
and adjustment scale for the side the scanner is fitted.

Rotate the adjusting knob until the indicator is aligned with the
measurement (X) you just made.

The Top Scanner will now be aligned.

Top Scanner
Adjusting Knob

Adjustment
Scale

Rear Adjustment
Scale

Indicator

Front Adjustment
Scale

NOTE: Illustration shows adjustment for a front scanner. If using a
rear scanner, refer to the scale towards the rear of the machine.

5-19SV40221 Rev. A

5 • Optical Mark Recognition (OMR)

Setting the Bottom Scanner Position

This scanner position is used for Z and Single Folds.

Open the upper central front door and locate the blue Bottom
Scanner adjusting knob and adjustment scale.

Rotate the adjusting knob until the indicator is aligned with the
measurement (X) you just made.

The Bottom Scanner will now be aligned.

Adjustment

Bottom Scanner
Adjusting Knob

Scale

Indicator

5-20 SV40221 Rev. A

Optical Mark Recognition (OMR) • 5

Once the Bottom Scanner is aligned, the Top Scanner (or paper
guide if a corresponding Top Scanner is not fitted) must be
positioned so that the sheet being scanned is kept at a controlled
distance from the scanner.

This is achieved by adjusting the Top Scanner as described on page
5-19, but to a setting 10mm (3/8”) different to the Bottom Scanner
setting. For example, if the Bottom Scanner is set to 70mm, set the
Top Scanner to 80mm.

When setting the Top Scanner, use the appropriate adjustment scale
depending on the location of the Bottom Scanner: The front scale
for a Front Bottom Scanner and the rear scale for a Rear Bottom
Scanner.

Top Scanner

Bottom
Scanner

Top Scanner
position

60 70 80

10mm
(3/8”)

Bottom
Scanner
position

5-21SV40221 Rev. A

5 • Optical Mark Recognition (OMR)

5-22 SV40221 Rev. A

6 • Troubleshootin

g

Refer to this chapter if you have problems with your machine.

Troubleshooting Tips ......................................................... 6-2

General Troubleshooting ................................................... 6-3

Machine ...................................................................... 6-3

Envelopes ................................................................... 6-4

Sheets ......................................................................... 6-5

Inserts ......................................................................... 6-6

Double Detect ............................................................. 6-7

Clearing Material Stalls ..................................................... 6-8

The Manual Advance Knob ......................................... 6-8

Removal and Replacement of Sheet Feeder Trays .... 6-9

Removal and Replacement of Insert Tray(s) .............. 6-9

Access to Internal Areas 1 to 5 ................................. 6-10

Access to Area 6 ....................................................... 6-12

Access to Areas 7 and 8 ........................................... 6-12

Access to Removeable Paper Path .......................... 6-13

Access to Top Cover (Sheet Feed Area) ................... 6-13

Access to Envelope Exit Area ................................... 6-14

Access to Envelope Inserting/Sealing Area .............. 6-14

Envelope Stop Position ................................................... 6-15

6-1SV40221 Rev. A

6 • Troubleshooting

Troubleshooting Tips

In most cases, the machine will generate an Error Message when a
problem occurs, and the display will offer advice on how to rectify the
problem immediately.

An on-line guide is also available in many countries. Press the Help
key and use the Screen Keys to select the information you require.

This Operating Guide contains additional troubleshooting information
which, with the troubleshooting sources above, should resolve most
problems.

If problems related to material handling persist, make sure your
material conforms to the machine specifications given in Chapter 7 of
this guide.

If you still cannot resolve the problem, call your machine supplier for
help. Contact details can be found:

• on the back cover of this guide

• In the System Information option in the menus:
At the Home Screen, select Menu.
Then select System Information.

6-2 SV40221 Rev. A

Troubleshooting • 6

General Troubleshooting

Problem Remedy Page

MACHINE

Blank Screen

No power. Check power cord is firmly

connected and wall socket is
switched ON.

Machine not
switched ON.

Display adjustment
set incorrectly.

Performance

Machine runs
slowly.

Turn power switch (located on
lower front) ON.

Reset the Display Adjustment to an
acceptable setting.

Is Safe Seal selected? ( icon
in Icon Tree). Safe Seal provides
improved sealing of 'difficult'
envelopes, but slows machine
operation.

3-2

3-2

3-19

3-19

Insertion Problems

Outer Envelope
contents do not
enter the envelope
correctly.

Check envelope troubleshooting
table.

Check envelope depth setting for
the job is correct within the Edit Job
function.

If running heavy or light material,
the Envelope Stop Adjustment
might need changing.

6-4

4-4

6-15

6-3SV40221 Rev. A

6 • Troubleshooting

Problem Remedy Page

ENVELOPES

Poor Envelope Feed

Envelope side
guides set
incorrectly.

Poor envelope
quality.

Envelopes loaded
incorrectly.

Envelopes Fail to Open

Envelopes loaded
incorrectly.

Poor envelope
quality.

Set guides to envelope width and
back off 1/4 turn.

Check envelopes are not curled.
Try a new box of envelopes.
Make sure stack has been fanned
before loading.

Load envelopes flap side up with
the flap feeding last.

Load envelopes flap side up with
the flap feeding last.

Check envelopes are not stuck due
to excessive dampness.
Try a new box of envelopes.

3-14

3-14

3-15

3-15

Envelope Sealing Problems

No sealing
solution.

Seal mode not
selected.

Envelope flaps
spring open.

Poor Sealing It’s possible that the sealing felts

Refill Sealer Unit. 3-18

If selected, Mail Piece Icon Tree will
show Seal icon ( ) alongside the

Envelope icon.

Try using Safe Seal. Safe Seal
provides improved sealing of
‘difficult’ envelopes, but slows
machine operation.

need replacing. Contact your
machine supplier for more details.

1-13

3-19

7-8

6-4 SV40221 Rev. A

Troubleshooting • 6

Problem Remedy Page

SHEETS

Poor Sheet Feed

Sheet Feeder
side guides set
incorrectly.

Sheets loaded
incorrectly.

Multiple sheets feed when one is expected

Sheet Feeder
is programmed
to feed a Pre­Collated Set.

Address in wrong position in envelope window

First Sheet/Set
incorrectly loaded.

Address Position
incorrectly set.

Set guides to Sheet width and back
off 1/4 turn.

Make sure stack has been fanned
before loading.

Check Mail Piece Icon Tree to see
if relevant feeder is set to feed pre­collated sets.

Correct loading or have Supervisor
correct Job Definition as necessary.

Load First (address bearing) Sheet
or Set in the correct orientation as
shown by the Mail Piece Icon Tree.

Run a Trial Piece. Say No to Trial
Piece OK? and adjust the address
position.

3-12

3-12

1-11

4-4

1-11,
1-12

3-4

Poor Folding

A fold is almost

corresponding with
a perforation on
the sheet, causing
a ‘box fold’ or third
fold.

Run a Trial Piece. Say No to Trial
Piece OK? and slightly change the
fold positions.

3-4

6-5SV40221 Rev. A

6 • Troubleshooting

Problem Remedy Page

INSERTS

Poor Insert Feed

Insert Feeder
side guides set
incorrectly.

Insert Feeder
separator
adjustments
incorrect.

Inserts loaded
incorrectly.

Insert Feeder
Wedge used
incorrectly.

Booklets not
feeding correctly.

Inserts out of
specification.

Set guides to Insert width and back
off 1/4 turn.

Make sure the two Insert Feeder
adjustments (number and letter
settings) are set correctly for the
type of Insert being run.

Make sure stack has been fanned
before loading.
Changing the orientation of the
Insert stack may help.

Let the Wedge slide down behind
the Insert stack to support it.

Booklets must only be run from
Insert Feeder F.

Check the Mail Piece Icon Tree
loading instructions.

Check specifications in this guide. 7-4

3-16

3-16

3-17

3-17

1-15,
3-16

1-12,
1-13

Inserts won’t feed when using Manual Feeder

By default, Insert
Feeder(s) are
disabled in Manual
Feed mode.

A Supervisor can change this
default setting to allow Insert
Feeders to operate in Manual Feed
mode using the Manual Feed
Option.

4-8

6-6 SV40221 Rev. A

Troubleshooting • 6

Problem Remedy Page

DOUBLE DETECT

The machine keeps turning Double Detect OFF

Double Detect
cannot calibrate
itself properly.

Machine stops for ‘doubles’ that aren’t there or feeds ‘doubles’
without stopping

Double Detect is
not turned ON.

Double Detect
is not correctly
calibrated.

Double Detection might not be
possible with certain very thick
or heavily printed material. Either
change material or choose to run
with Double Detect OFF.

Check Double Detect status.
Double Detect icon will appear
alongside all items where Double
Detect is operational.

Correct loading or have Supervisor
correct Job Definition as necessary.

Run a Trial Piece whenever a
new batch of material is loaded to
recalibrate Double Detect. The new
batch might be of slightly different
thickness.

1-11,
1-12

4-4

3-4

6-7SV40221 Rev. A

6 • Troubleshooting

Clearing Material Stalls

Your machine has been designed to assure maximum performance.
In the event of a material stall, the display will indicate where the stall
has occurred and will suggest remedial action.

First press Clear Deck to attempt to feed the material through the
machine. If not successful, the sections below tell you how to gain
access to the material.

The Manual Advance Knob

Having located the material,
you may need to use the
Manual Advance Knob to
manually feed material out of
the grip of rollers, etc.

The Manual Advance Knob
is located behind the lower
door at the center front of the
machine.

6-8 SV40221 Rev. A

Troubleshooting • 6

Removal & Replacement of the Sheet Feeder Trays A to D

To remove…

Lift the rear of the tray slightly
and pull it straight outwards
from the machine.

Note: If the tray is loaded,
gently hold the material in
place to prevent it sliding
forward as the tray is removed.

To replace…

Place the tray into its location guides in the side frames. Lift the
rear of the tray slightly and push it into the machine. The tray will
automatically drop into its correct location.

Removal & Replacement of the Insert Tray(s) F and G

To remove…

Pull the Insert Tray straight
outwards from the machine.

To replace…

Slide the tray into its location
guides and push until it ‘clicks’
into place.

6-9SV40221 Rev. A

6 • Troubleshooting

Access to Internal Areas 1 to 5

If material stalls within the internal areas of the machine, the display
will indicate an area or areas (labelled 1 to 5) where the stalled
material is located.

Open both central front doors and the access points, as shown
below, will be exposed.

3

4

5

2

1

The illustrations on the next page show each area in more detail...

6-10 SV40221 Rev. A

Troubleshooting • 6

Area 1

Pull upwards to unlatch.
Relatch by pressing assembly
firmly down at the center.

Area 3

Rotate counterclockwise to unlatch.
Push assembly back into position
and relatch by rotating lever fully
clockwise.

Area 2

Rotate clockwise to unlatch.
Relatch by rotating lever fully
counterclockwise.

Area 4

Rotate counterclockwise to unlatch.
Push assembly back into position
and relatch by rotating lever fully
clockwise.

Area 5

Rotate clockwise to unlatch.
Push assembly back into position
and relatch by rotating lever fully
counterclockwise.

6-11SV40221 Rev. A

6 • Troubleshooting

Access to Area 6

Area 6 is located under Sheet
Feeder D, where envelopes
are fed into the system.
Therefore, before access can
be gained to a material stall
in this area, Sheet Feeder
Tray D should be removed as
described on page 6-9.

Once the tray is removed, access to stalled material can be gained
by unlatching the lever shown in the illustration above.

Access to Areas 7 and 8

Areas 7 and 8 are located at
the inner ends of the Insert
Feeders F and G. Therefore,
before access can be gained
to a material stall in these
areas, the Insert Trays must
be removed as described on
page 6-9.

Once the trays are removed,
access to stalled material can
be gained by unlatching the
access covers shown.

Area 7

Area 8

6-12 SV40221 Rev. A

Troubleshooting • 6

Access to the Removeable Paper Path
(under Insert Feeder F)

This removeable plate is located immediately below Insert Feeder
F. Therefore, before access can be gained to a material stall in this
area, Insert Tray F must be removed as described on page 6-9.

Access can be gained by
lifting the blue handle and then
pulling the plate outwards.

When refitting the plate, make
sure it is fully latched into
position.

Access to the Top Cover (Sheet Feed Area)

Access can be gained to this
area by unlatching the blue
handle on the Top Cover and
raising the cover.

When closing the cover, make
sure it is fully latched into
position.

6-13SV40221 Rev. A

6 • Troubleshooting

Access to the Envelope Exit Area

Pull down the envelope exit
area door, as shown, to gain
access to stalled material.

When closing the door, make
sure it is firmly latched into
position.

Access to the Envelope Inserting/Sealing Area

Access can be gained to the
insertion and sealing areas
by lifting the plastic cover and
lowering the envelope exit area
door.

Points arrowed in the
illustration can be unlatched
to allow access to stalled
material.

6-14 SV40221 Rev. A

Troubleshooting • 6

Envelope Stop Position

This function lets you adjust the position where the Outer Envelope
is held, waiting for material to be placed into it. It is accessed by
running a Trial Piece and replying ‘No’ when asked if the Trial Piece
is OK.

This adjustment will only be needed in unusual situations where
material is not being placed fully into the envelope, or is being driven
too far, causing damage to the envelope or material.

The Envelope Stop has five positions...

0 Standard setting for normal weight material.

-1, -2 Places the material further into the mailing envelope,

which may be useful for light or thin material.

+1, +2 Reduces how far the material goes into the
envelope, which may be useful for thicker or heavier
material.

After carrying out this adjustment, you will be offered two options:

1. You can save the adjustment as part of the current Job Definition
so that it is automatically recalled in future. This requires
a Supervisor Access Code to be entered because the Job
Definition is being edited.

2. You can run the current job with the adjustment applied
temporarily. Once a new Job Definition is selected, or if power is
turned off, this temporary adjustment will be lost.

When the Envelope Stop

is set to any position other
than its standard (0) position,

a warning icon showing
the modified setting will be
displayed beneath the Machine
Graphic.

Envelope Stop Icon

6-15SV40221 Rev. A

6 • Troubleshooting

6-16 SV40221 Rev. A

7 • Reference

This chapter lists the specifications of your machine and describes
operations that may only need to be carried out occasionally.

Specifications .................................................................... 7-2

Sheet Feeders ............................................................ 7-2

Fold Type and Overall Thickness Limits ..................... 7-3

Insert Feeders ............................................................. 7-4

Envelope Feeder ......................................................... 7-4

Envelope Sealer .......................................................... 7-6

Drop Stacker ............................................................... 7-6

Material Requirements ................................................ 7-6

Machine Specifications ............................................... 7-7

Changing the Envelope Sealer Unit Felts ......................... 7-8

Service ............................................................................ 7-10

7-1SV40221 Rev. A

7 • Reference

Specifications

Sheet Feeders A, B C and D

Minimum sheet size: 5" (127mm) Width (non OMR)
8" (203mm) Width (with OMR)
6-7/8" (175mm) Length

Maximum sheet size: 9" (229mm) Width
16" (406mm) Length

Paper weights: 16 lb. (60g/m2) Minimum (non OMR)
20 lb. (75g/m2) Minimum (with OMR)
32 lb. (120g/m2) Maximum

Fold configurations : Sheet length limits before folding
Single fold: 6-7/8"- 12" (175mm - 305mm)
C fold: 9-1/2"- 13-5/8" (242mm - 347mm)
Z fold: 9-1/2"- 13-5/8" (242mm - 347mm)
Double fold: 12-1/2" - 16" (319mm - 406mm)

Double Document Detector
Material range: 16 lb. (60g/m2) Minimum
32 lb. (120g/m2) Maximum

Sheet Feed tray capacity: Up to a maximum of
325 sheets of 20 lb. (80g/m2)

Manual Feed mode: Stapled or unstapled sets up to 5
sheets of 20 lb. (80g/m2) to a
maximum total weight of 100 lb.
(400g/m2) per set can be
processed in the Manual Feed
mode. Glossy/coated sheets are
not recommended.

7-2 SV40221 Rev. A

Reference • 7

Fold Type and Overall Thickness Limits

The table below shows the maximum number of sheets up to 12"
(305mm) in length that can be accumulated or collated for each fold
type, based on different weights of paper.

It is important that jobs exceeding these maximums are NOT
programmed into the machine or imposed by OMR code
printing and/or OMR selective feed.

Number of

sheets

16, 18, 20 22, 24, 26 28, 30, 32

1 C,Z,S,D C,Z,S,D C,Z,S,D

2 C,Z,S,D C,Z,S,D C,Z,S

3 C,Z,S,D C,Z,S,D C,Z,S

4 C,Z,S,D C,Z,S,D

5 C,Z,S,D D

6 S,D D

7 S

8 S

9 S

10 S

Fold Types: C = C Fold, Z = Z Fold, S = Single Fold, D = Double Fold

Sheets above 12" (305mm) in length can only be folded C, Z and
D up to 5 sheets.

All the above sheet limits can be used with Inserts from
feeders F and G only if the total Mail Piece contents are up to a
maximum of 1/8" (3mm) total compressed thickness.

Paper Weights in lbs.

For applications within this

shaded area, contact your

machine supplier for advice.

ALL SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT

NOTIFICATION AND ARE SUBJECT TO TEST

7-3SV40221 Rev. A

7 • Reference

Insert Feeders F and G

Minimum Insert size: 5" (127mm) Width

3-1/4" (82mm) Depth

Maximum Insert size: 9" (230mm) Width

6" (152mm) Depth

2

Paper Weights: 20 lb. (75g/m
(single sheet/slip)

16 lb. (60g/m2) Minimum
(folded material)

48 lb. (180g/m2) Maximum
(single sheet/slip)

Maximum compressed
thickness of insert: .08" (2mm) from feeder F
.06" (1.5mm) from feeder G

Double Detect material range: 16 lb. (60g/m2) Minimum
32 lb. (120g/m2) Maximum

) Minimum

Insert feed tray capacity: Up to a maximum of 300 Inserts
in each feeder, dependent on
thickness and weight of inserts.

Envelope Feeder

Minimum envelope size: 3-7/8" (98mm) Depth
8-5/8" (220mm) Width

Maximum envelope size: 6-1/2" (164mm) Depth
9-1/2" (242mm) Width

Envelope depths for

SwiftStart™ and Manual Feed: 4-1/4" to 6-3/8" (109mm, 111mm,
114mm, 121mm, 162mm)

Envelope weights: 16 lb. (65g/m2) Minimum
26 lb. (100g/m2) Maximum

7-4 SV40221 Rev. A

WIDTH

DEPTH