Pitney Bowes DI200 User Manual

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Inserting System

Statement of 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.

Canada

This class A digital apparatus complies with Canadian ICES-003. Cet appareil numérique de la classe A est conforme á la norme NMB-003 du Canada.

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.

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.

OfficeRight is a trademark and E-Z Seal is a registered trademark of Pitney Bowes.

Contents

1. Introduction

Important Safety Information ...................................................... 2

About Your Machine .................................................................... 3

Machine Configurations .............................................................. 3

Machine Controls, Indicators and Features ................................ 4

The Controls ............................................................................... 6

2. Preparing and Loading

Connecting Power and Turning On ............................................. 8

Filling the Moistener ................................................................... 9

Loading the Sheet Feeders (Feeders A1 and A2) .................... 10

Loading the Envelope Feeder (Feeder B)................................. 11

Loading the Insert Feeder (Feeder C) ...................................... 12

3. Running Jobs

Job Listing ................................................................................ 13

Job 1: One Folded Sheet into an Envelope ............................ 15

Job 2: One Folded Sheet, No Envelope (Fold Only) .............. 16

Job 3: One Folded Sheet + One Insert into an Envelope ....... 17

Job 4: One Insert into an Envelope ........................................ 19

Job 5: Two Folded Sheets into an Envelope........................... 20

Job 6: Two Collated, Folded Sheets into an Envelope ........... 21

Job 7: Two Folded Sheets, No Envelope (Fold Only) ............. 22

Job 8: Two Collated, Folded Sheets, No Envelope

(Fold Only) ................................................................... 23

Job 9: Two Folded Sheets and an Insert into an Envelope .... 24

Job 10: Two Collated, Folded Sheets and an Insert into an

Envelope ...................................................................... 26

The Manual Feeder M .............................................................. 28

4. Advanced Menu Options

Reset Counter .......................................................................... 29

Change Paper Size................................................................... 30

Move the Address in the Window ............................................. 30

Sheet Double Detect On/Off ..................................................... 31

Insert Double Detect On/Off ..................................................... 32

Safe Seal On/Off....................................................................... 32

5. Reference

Error Messages ................................................................... 33-36

General Troubleshooting ........................................................... 37

Clearing Material Jams ............................................................. 38

Getting Help............................................................................. 39

Ordering Supplies ..................................................................... 40

Material Specifications.............................................................. 41

Machine Specifications ............................................................. 42

Index ....................................................................................... 43

Page

OfficeRight™ DI200

Operator’s Guide

Safety

1. INTRODUCTION

Important Safety Information

• Please read all the instructions in this manual operate your OfficeRight™ DI200. Save all instructions for future use.

WARNING! Always use the power cord supplied with your machine and plug it into a outlet that's located near the machine and easily accessible. Failure to properly ground the machine can result in severe personal injury and/or fire.

• DO NOT use a wall outlet controlled by a wall switch or one that is shared with other equipment.

• Do not use an adapter plug on the line cord or wall outlet.

• Do not remove the ground pin from the line cord.

• Make sure the area in front of the wall outlet into which the machine is

plugged is free from obstruction.

• DO NOT route the power cord over sharp edges or trap it between pieces of furniture. Make sure there is no strain on the power cord.

• To reduce the risk of fire or electrical shock, DO NOT attempt to remove covers or disassemble the inserter. The cabinet encloses hazardous parts. Refer servicing to qualified personnel.

• Keep fingers, long hair, jewelry and loose clothing away from moving parts at all times.

• Never reach into the machine while it is running. Avoid touching moving parts or materials while the machine is in use. Before clearing a jam, be sure all machine mechanisms come to a complete stop.

• Know your equipment, especially

emergency.

• When removing jammed material, avoid using too much force to protect against minor personal injury and damage to the equipment.

• Use the equipment only for its intended purpose.

• Always follow the specific occupational safety and health standards

prescribed for your workplace.

CAUTION! If you relocate an OfficeRight™ DI200 that has the optional Second Sheet Feeder A2 installed, remove it from the Second Sheet Feeder first—that is, as you lift it clear, make sure it fully disengages from the Second Sheet Feeder. Obtain help if necessary.

how to stop it in the event of an

before

you attempt to

properly grounded

wall

OfficeRight™ DI200

Operator’s Guide

Introduction

About Your Machine

Your new OfficeRight™ DI200 is a compact folding and inserting machine designed to speed the process of mail creation.

It has a minimal number of user adjustments and an intuitive, easy-to-use control panel. This greatly simplifies machine operation and will enhance the productivity of your mailing operation.

Machine Configurations

There are two configurations of the OfficeRight™ DI200 available. The basic model is supplied with an insert feeder and one sheet feeder. The second configuration is supplied with an insert feeder and two sheet feeders.

insert feeder

Configuration 1

Basic machine with insert

feeder and one sheet feeder

OfficeRight™ DI200

Operator’s Guide

2nd sheet

feeder

Configuration 2

Machine with insert feeder

and a 2nd sheet feeder added

Introduction

Machine Controls, Indicators and Features

1 2

9 8

1. Insert Cover E Release Button (Blue Button Marked E)

Press this button to release the insert cover if a jam occurs in this area of the machine. The display prompts you if you need to open this cover to remove jammed material.

2. Insert Feeder (Not on All Models)

Use this feeder to add additional inserts to your envelope. Material fed from this feeder feeder is especially suited to feeding pre-folded or thicker inserts.

3. Operating Guide Slot

Store this Operating Guide in the slot provided so that it doesn’t get lost and is readily available when you need it.

4. Control Panel

This is where you enter commands and where the machine informs you of its status. See pages 6 and 7 for a full explanation of what each button does.

cannot

be folded by the inserter. However, this

OfficeRight™ DI200

Operator’s Guide

Introduction

5. Moistener Tank

This tank contains E-Z Seal® solution or water to moisten and seal envelope flaps. It slides out to the right for refilling and has an oval level indicator window at the front so you can easily check fluid level.

6. Lifting Handles (One Each Side)

Always lift the OfficeRight™ DI200 using the side handles. DO NOT lift the machine by any of the feeders or the stacker.

7. Second Sheet Feeder A2 (Optional)

You can add this feeder to the machine to enable folding and inserting of a second sheet into the envelope. It functions in exactly the same way as the standard sheet feeder, A1.

IMPORTANT: When you use both sheet feeders A1 and A2 together, always load the address bearing sheet into sheet feeder A2. If you fail to do this, the address won’t show in the envelope window. Always load sheets into feeder A2

first,

that is, with the bottom edge of the sheet furthest into the

machine.

8. Standard Sheet Feeder A1

This feeder enables folding and inserting of a sheet into the envelope. Always load sheets into this feeder

face down

and

bottom edge

and

bottom edge first.

9. Manual Feeder M

Use this feeder to manually feed stapled sets of

each.

The machine waits for you to feed each set by hand into this feeder before it folds and inserts the set automatically. Always feed sheets into this feeder the bottom edge of the sheet furthest into the machine.

10. Stacker

The machine delivers finished pieces to this area.

11. Front Cover D Release Button (Blue Button Marked D)

Press this button to release the front cover if a jam occurs in this area of the machine. The display prompts you if you need to open this cover to remove jammed material.

12. Envelope Feeder B

This feeder feeds envelopes into the inserting area where they are filled with sheets or inserts from other feeders.

OfficeRight™ DI200

Operator’s Guide

face down

and

bottom edge first,

up to three sheets

that is, with

Introduction

The Controls

Menu / Enter

no yes

Feeder A1

Seal No Seal

Trial Piece Stop

Feeder A2 2nd Page

Envelope Fdr B Insert Fdr C Fold Only

Start

1. Display

Shows the current status of your OfficeRight™ DI200 and displays prompts or error messages which help you in operating the machine.

2. Menu/Enter

Press this button to enter the menu options. Options available are:

• Reset Counter

• Change Paper Size. Choose 11” (letter size) or 14” (legal size)

• Move Address in Window

• Turn Sheet Double Detection On/Off

• Turn Insert Double Detection On/Off

• Turn Safe Seal On/Off

3. yes and no buttons

Once you’ve entered the menu using Menu/Enter, press these buttons to answer yes or no to prompts. You also use them to change (increase or decrease) settings offered by menu options.

OfficeRight™ DI200

Operator’s Guide

Introduction

4. Selection Buttons and Indicator Lights

Press these buttons to step through the feeders and options that are available on your machine.

Depending on your model configuration, some indicator lights and associated feeders may be inoperable. If your model doesn’t have a second sheet feeder, for example, the indicators associated with this feeder will not light. This is normal.

green indicator

red indicator

combination of functions. Simply correct the error in selection and the indicator(s) will change back to green.

unlit indicator

5. Trial Piece

After you’ve set up a job using the control panel, you piece. If you press Start before running a trial piece, the machine display will prompt you to run a trial piece first.

Press this button to run one fully collated piece as programmed via the control panel. The envelope will not seal regardless of whether the system has been told to seal or not. This allows you to inspect the processed job to make sure that everything is inserted correctly and that the address appears in the window.

The trial piece also allows the system to calibrate itself and set its double detect feature, if selected.

6. Start

Press to begin automatic operation.

7. Stop

Press to stop automatic operation at the end of the next cycle.

shows that a feeder or function is selected for use.

shows that you selected an invalid (impossible)

means that the feeder or function is turned

must

IMPORTANT: Running the trial piece is an function for the machine to perform. You before a start every time you use a new batch of material. This allows the system to re-calibrate in case different batches of material vary slightly.

must

OFF.

run a trial

essential

do it

About the Sleep Mode

After 10 minutes of inactivity, the system enters a power-saving “sleep mode” and displays Powersave On. Pressing any button will wake the machine up. The machine remembers the last job setup.

OfficeRight™ DI200

Operator’s Guide

2. PREPARING AND LOADING

This chapter explains how to connect and load the machine. Once you understand the subjects covered in this chapter, you can quickly

set up and use the machine for a variety of jobs as explained later in Chapter 3,

IMPORTANT: Before running a job, make sure your material meets our published specifications (see assure reliable operation and greatest productivity.

Connecting Power and Turning On

Running Jobs

Specifications

on page 41). This helps

WARNING! Read all the safety information on page 2 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 power switch ON. After a few seconds, the display shows When turned ON, the machine remembers the last job setup, but resets

the item counter back to zero automatically.

before

connecting

Ready.

OfficeRight™ DI200

Operator’s Guide

Filling the Moistener

Refill the moistener when the fluid gets low. Check fluid level through the oval viewing window (figure, below right).

Slide the moistener out to the right.

IMPORTANT: Never open the moistener while the machine is processing material.

Carefully fill the moistener with E-Z

Seal

solution or water up to the “Max”

mark in the filler funnel.

We recommend E-Z Seal® to minimize algae growth and scale buildup.

Slide the moistener back into the machine.

From the dry state, the moistener will take about five minutes to become fully wet and ready for use.

OfficeRight™ DI200

Operator’s Guide

Loading the Sheet Feeders (Feeders A1 and A2)

Sheet Feeder A1 is common to all models and is located immediately below the Manual Feeder M. Sheet Feeder A2 is an option on all models. It allows the machine to insert a second folded sheet into an envelope.

Both feeders are used for sheets that require folding before inserting. Load both feeders in exactly the same way.

Always fan (aerate) sheets before you load them. This prevents them from sticking together.

Then tap the stack of sheets onto a firm surface to align the edges.

Place the sheets into Sheet Feeder A1 or A2 as required.

IMPORTANT: Always load sheets into these feeders

bottom edge first.

bottom edge of the

sheet is furthest into the machine.

face down

and

The

If you’re using both Sheet Feeders A1

and

A2 at the same time, you

the document printed with the address into Sheet Feeder A2. If you load the address-bearing document into Sheet Feeder A1,

in the envelope window.

Slide the back stop in until it just touches the paper stack.

the address won’t be visible

must

load

OfficeRight™ DI200

Operator’s Guide

Loading the Envelope Feeder (Feeder B)

Always fan (aerate) envelopes before you load them. This prevents them from sticking together.

Then tap the stack of envelopes onto a firm surface to align the edges.

IMPORTANT:

Load envelopes right way up and facing you. This means that the envelope flap is on the back of the envelope and at the top. Any other orientation will prevent the machine from inserting properly.

Place the envelope stack into Feeder B with the back envelope flat against the feed belts. There’s no need to “shingle” or stagger the envelope stack.

Slide the two side guides up to the envelope stack then off. Use the blue handles at the rear of the guides when moving them.

The correct setting is achieved when the guides control the envelopes but in no way restrict their feed into the machine or cause them to feed at an angle (skew).

IMPORTANT: If the guides are too tight, envelopes may not feed reliably; if the guides are too loose, envelopes may skew as they feed into the machine.

OfficeRight™ DI200

slightly

Operator’s Guide

back them

Loading the Insert Feeder (Feeder C)

Insert Feeder C is only available on certain machine configurations. Use

do not

this feeder to add additional inserts to your envelope that folding by the machine. Feeder C is especially suited to feeding pre-folded or thicker inserts such as business reply envelopes (BREs), response cards and similar materials.

Always fan (aerate) inserts before you load them. This prevents them from sticking together.

Then tap the stack of inserts onto a firm surface to align the edges.

Place the insert stack into Feeder C.

IMPORTANT: The orientation of the insert stack depends on the nature of the material being run. For pre-folded inserts, it’s normally best to load with the “closed” edge feeding first. You can usually load business reply envelopes right way up and facing you. However, if the flaps are pulled open when feeding, try loading the envelopes with the flaps down and facing you.

require

Slide the two side guides up to the insert stack then Use the blue handles at the rear of the guides when moving them.

IMPORTANT: The setting is correct when the guides control the inserts but in no way restrict their feed into the machine or cause them to feed at an angle (skew). If the guides are too tight, inserts may not feed reliably; if they are too loose, inserts may skew as they feed into the machine.

slightly

back them off.

OfficeRight™ DI200

Operator’s Guide

1 folded sheet no envelope (fold only)

envelope

1 insert

Running

3. RUNNING JOBS

Chapter 1 explained the main features of the machine and how to use the control panel. Chapter 2 described how to turn the machine ON and load the feeders and moistener unit.

This chapter assumes you understand the content of the previous chapters. It includes illustrations that identify the various jobs you can run on your OfficeRight™ DI200, and then gives a table of quick steps to set up and run each job.

Once you’re familiar with the machine, use this chapter as a quick reference when you have to change a job setup.

The Manual Feeder M is used to feed stapled sets of up to three sheets by hand. See page 28 for an explanation of how to set up and use this feeder.

Job Listing

ALL MODELS

1 folded sheet

MODELS with an INSERT FEEDER C

OfficeRight™ DI200

envelope

JOB 1 Page 15

1 insert

1 folded sheet

envelope

JOB 3 Page 17 JOB 4 Page 19

Operator’s Guide

JOB 2 Page 16

+ 34 hidden pages