Pitney Bowes DI350 Operator Guide

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DI350 OfficeRight

Inserting System

Operator Guide

SV40190-OG Rev. A

Contents

NOTE: This equipment has been tested and found to

comply with the limits for a Class A 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, at their own expense, will be required to correct the interference.

Trademark Notice

OfficeRight™ and EZ Seal® are trademarks of Pitney Bowes Inc.

First Edition, September 2002 ©2002 Pitney Bowes Inc. All rights reserved. This book may not be reproduced in whole or in part in any fashion or stored in a retrieval system of any type or transmitted by any means, electronically or mechanically, without the express written permission of Pitney Bowes.

We have made every reasonable effort to assure 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.

Contents

ABOUT THIS GUIDE

This guide explains how to setup and use the DI350 OfficeRight™ Inserting System . Please spend a few moments reading through it. Understanding what the inserter does, and how it does it, will keep problems to a minimum and help you get the best performance possible.

This Guide is organized into seven sections:

1. INTRODUCTION

To the Operator 1-5

Three-Station Model .................................................... 1-5

Two-Station Model ...................................................... 1-6

One-Station Model ...................................................... 1-6

Safety ................................................................................ 1-7

Machine Identification ....................................................... 1-8

Control Panel .................................................................. 1-10

Control Panel Buttons ............................................... 1-10

Display Symbols ........................................................ 1-12

2. OPERATION

Connecting Power ............................................................. 2-1

Selecting and Running a Job ............................................ 2-1

Select the Job.............................................................. 2-1

Run a Trial Piece ......................................................... 2-2

Start Machine Operation ............................................. 2-3

Setting the Sheet Feeders ................................................ 2-3

Setting the Envelope Feeder............................................. 2-4

Setting the Insert Feeder................................................... 2-5

Filling the Sealer ............................................................... 2-6

Programming Options By Model ....................................... 2-7

iii

Contents

3. CREATE A NEW NON-OMR JOB

Create New Non-OMR Job ............................................... 3-1

Entering the Setup Mode............................................. 3-1

Choosing the New Job Number .................................. 3-2

Selecting Non-OMR Option ......................................... 3-2

Flowchart for Non-OMR Job........................................ 3-3

Setting the Accumulation Function .............................. 3-5

Fold Type .................................................................... 3-6

Setting Sheet Feeder 1 ............................................... 3-7

Setting Sheet Feeder 2 ............................................... 3-8

Setting Insert Feeder ................................................... 3-9

Mode ........................................................................... 3-9

Sealer ........................................................................ 3-10

Paper Length ............................................................. 3-10

Fold A ........................................................................ 3-11

Fold B ........................................................................ 3-11

Envelope Depth ......................................................... 3-12

Envelope Stop ........................................................... 3-12

Batch Mode ............................................................... 3-13

Confirming the Job Setup .......................................... 3-13

Testing the Job .......................................................... 3-14

Changing an Existing Job ............................................... 3-15

Deleting a Job ................................................................. 3-15

Contents

4. WHAT IS OMR (OPTICAL MARK RECOGNITION)?

What is OMR? ................................................................... 4-1

What Do OMR Marks Look Like on Paper? ...................... 4-2

How are OMR Marks Read on the DI350? ....................... 4-3

How are OMR Marks Generated?..................................... 4-4

What OMR Marks are Used on the DI350? ...................... 4-5

OMR Group Combinations ................................................ 4-9

Details of Basic Level OMR ............................................ 4-10

Group 1 Marks (“OMR”) ............................................. 4-10

Details of Enhanced Level OMR ..................................... 4-14

Group 2 Marks (“Select Feed”) ................................... 4-14

Group 3 Marks (“Sequence”) ...................................... 4-17

Considerations When Implementing OMR ...................... 4-20

Contents

5. CREATE A NEW OMR JOB

Creating a New OMR job .................................................. 5-1

What Is OMR? ............................................................. 5-1

Entering the Setup Mode............................................. 5-1

Choosing the New Job Number .................................. 5-2

Selecting OMR Option................................................. 5-3

Flowchart for OMR Job ............................................... 5-4

Fold Type .................................................................... 5-6

Setting Main (Scanning) Sheet Feeder ....................... 5-7

Setting Other Sheet Feeder ........................................ 5-7

Setting Insert Feeder ................................................... 5-9

Sealer ........................................................................ 5-10

Paper Length ............................................................. 5-10

Fold A ........................................................................ 5-11

Fold B ........................................................................ 5-11

Envelope Depth ......................................................... 5-12

Envelope Stop ........................................................... 5-12

Batch Mode ............................................................... 5-13

Confirming the Job Setup .......................................... 5-13

Adjustment of OMR Scanner..................................... 5-14

Loading the Material .................................................. 5-17

Testing the Job .......................................................... 5-18

Changing an Existing Job ............................................... 5-19

Deleting a job .................................................................. 5-19

Contents

6. REFERENCE

Changing the Display Language ....................................... 6-1

Clearing Material ............................................................... 6-1

Hand Crank ................................................................. 6-1

Removal & Replacement of Sheet Feeder and

Envelope Trays ........................................................ 6-2

Removal & Replacement of the Fold Plates................ 6-2

Removal & Replacement of the Insert Tray ................ 6-3

Access to Carriage Assembly ..................................... 6-3

Access to Envelope Feeder Area ................................ 6-3

Access to the Envelope Exit Area ............................... 6-4

Access to the Envelope Inserting Area ....................... 6-4

Access to the Sheet Feed Area................................... 6-4

Troubleshooting ................................................................ 6-5

Error Messages ............................................................... 6-11

Paper Handling.......................................................... 6-11

OMR Errors ............................................................... 6-15

Material Specifications .................................................... 6-17

Sheet Feeders ........................................................... 6-17

Insert Feeder ............................................................. 6-17

Sealer ........................................................................ 6-18

Stacker ...................................................................... 6-18

Envelope Feeder ....................................................... 6-18

Material Requirements .............................................. 6-19

OMR Specifications (General) ........................................ 6-19

Machine Specifications ................................................... 6-20

Physical Dimensions: ................................................ 6-20

Noise Level................................................................ 6-20

Electrical/BTU Rating ................................................ 6-20

Speed ........................................................................ 6-20

Fold Modes................................................................ 6-20

Compliance ............................................................... 6-20

Usage ........................................................................ 6-21

Machine Life .............................................................. 6-21

Service ............................................................................ 6-21

vii

Contents

APPENDIX A – TRAINING CHECKLIST

Operator Training Checklist .............................................. A-1

Introduction..................................................................A-1

Operation.....................................................................A-1

Create (Program) Non-OMR Job ................................ A-1

What Is OMR? .............................................................A-2

Create (Program) OMR Job ........................................A-2

Reference ....................................................................A-2

INDEX

viii

Introduction

1. INTRODUCTION

To the Operator

Your Pitney Bowes DI350 Inserting System is a compact, desk top unit, which is simple to set up and run while offering the following features:

• Envelope seal/no seal option

• Semi-automatic single insert operation (not on single station model)

• Fully automatic material separation on sheet feeder(s)

• Fully automatic settings on fold plates

• Fully automatic envelope separation

• Fully automatic double document detection when selected

• Fold only option (fold without insertion)

• Semi-automatic insertion of single and multiple sheet Inserts

• Option of single fold, letter (C) fold, accordion (Z) fold or double fold

• Job recall, operator programmable (up to 20, depending on model)

• Switchable feeding

• Optical Mark Recognition (OMR) scanning for greater collation

integrity and additional feeding flexibility (3-station model only)

This guide covers all three models of the DI350 inserter system.

Three-Station Model

This model incorporates two sheet feeders and an insert feeder. It is the only model that has OMR and has the most setup options. For this reason, all illustrations in this guide show this model.

Sheet Feeder 1

Sheet Feeder 2

1-1

Insert Feeder

Introduction

Two-Station Model

This model incorporates a single sheet feeder and an insert feeder.

Insert Feeder

Sheet Feeder 1

One-Station Model

This model incorporates a single sheet feeder.

Sheet Feeder 1

All models are set up and operated in a very similar way. Procedures in this guide cover all models. If a function is model dependent, the accompanying text will explain this.

1-2

Introduction

Safety

Safety Precautions:

When using this machine, follow the normal safety precautions for all office equipment:

Keep loose clothing, jewelry and long hair away from all moving parts. Avoid touching moving parts or materials while the machine is in use. Before clearing a jam, be sure machine mechanisms come to a stop. When removing jammed material, avoid using too much force to

protect against minor personal injury and damaging equipment. Use the power cord supplied with the machine and plug it into a

properly grounded wall outlet located near the machine and easily accessible. Failure to properly ground the machine can result in severe personal injury and/or fire.

The power cord wall plug is the primary means of disconnecting the machine from 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 that are controlled by wall switches, or shared

with other equipment. DO NOT route the power cord over sharp edges or trapped between

furniture. Insure there is no strain on the power cord where it becomes jammed

between the equipment, walls or furniture. Be certain the area in front of the wall receptacle into which the

machine is plugged is free from obstruction. Do not remove covers. Covers enclose hazardous parts that should

only be accessed by Pitney Bowes Customer Service. Report any damage of covers to a Pitney Bowes Customer Service Representative.

To prevent overheating, do not cover the vent openings. Read all instructions before attempting to operate the equipment. Use this equipment only for its intended purpose.

In addition, follow any specific occupational safety and health standards for your workplace or area.

1-3

Introduction

Machine Identification

1 6

1 Sheet Feeder 1

This feeder is intended for feeding material that requires folding. If you are running addressed documents for insertion into window envelopes, feed them from this feeder.

In addition, sheet feeder 1 can be set to ‘manual feed’. In this mode, stapled sets of up to 5 sheets may be run. The machine waits for each set to be manually fed into sheet feeder 1 before folding and inserting the set automatically. See the specifications section of Chapter 6 (Reference) for full details of the sets possible.

2 Sheet Feeder 2

For feeding material that requires folding. Its functions are similar to sheet feeder 1 but ‘manual feed’ is NOT available from this feeder.

(three-station machine only)

1-4

Introduction

3 Insert Feeder

Use this feeder to add additional inserts to your envelope. Material fed from this feeder cannot be folded by the inserter. However, this feeder is especially suited to feeding pre-folded or thicker inserts.

4 Fold Plate 2 5 Fold Plate 1

These units are used to create the desired fold in material fed from the sheet feeder(s). The fold plates are automatically set from the control panel.

6 Display/Control Panel

This is where you enter commands and where the machine informs you of its status with the use of symbols and icons. Full details of each button function are given on the following page.

7 Stacker and Measuring Scale

Located at the right end, is the fold-down stacker. This unit can be latched against the right side of the machine when not in use to save space.

(two and three-station machines only)

A scale is located along the front edge of the stacker to aid measurement of material and envelopes.

8 Hand Crank

The hand crank is located behind a drop down cover at the left front. It can be used to manually turn the machine mechanisms to free a material stoppage.

9 Envelope Feeder

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

10 Envelope Inverter Unit

This unit exits the envelope into the stacker face up.11

1-5

Introduction

11 Sealer Water Bottle

The sealer water bottle is located behind a drop down cover at the right rear of the machine. It provides water or EZ Seal® solution to the envelope sealer unit.

12 Upper OMR Scanner

Scanner used to read OMR marks on sheet feeder 1 from above the sheet.

13 Lower OMR Scanner

Scanner used to read OMR marks on sheet feeder 2 from under sheet.

Control Panel

(three-station machine only)

Control Panel Buttons

Default Press this button to return the system to its

‘standard’ settings. These settings come preconfigured from the factory but can be modified to suit your needs by a Pitney Bowes Customer Service Representative.

Job Press to step through the jobs you have programmed

into the machine’s memory. Up to twenty (20) jobs can be held, depending on model (see page 2-9). See Chapters 3 or 5 for details on programming jobs.

1-6

Introduction

Reset Counter Press this button to reset the item counter. Clear Deck Pressing this button will jog material through and out

of the machine. It can be used to clear the machine ready for automatic operation after a stoppage has occurred etc.

Trial Piece This button is used to run a single test piece so that

you can check machine setup. A trial piece must be run before automatic operation can be commenced using the Start button. If double detection is in use, the machine sets itself automatically as it runs the trial piece. This envelope will be unsealed and counted as one item.

Start Starts automatic operation.

Stop Stops automatic operation at the end of the next

cycle.

Delete Used in setup mode to delete a programmed job

from memory.

Setup When pressed, the machine enters setup mode. This

mode allows you to program jobs into memory for instant recall using the Job button.

Change + – In setup mode, used to select options or set values

of machine settings.

Prev. In setup mode, used to step backwards/forwards

through the various machine settings.

1-7

Introduction

Display Symbols

. . 3 . .

Used on sheet feeders to signify that the feeder is on without double detection.

Used on sheet feeders to signify that the feeder is on with double detection.

Used on insert feeder to signify that the feeder is on without double detection.

Used on insert feeder to signify that the feeder is on with double detection.

Used on sheet feeder 1 to signify that the feeder is set for manual feed.

Used on envelope feeder to signify that the feeder is on.

Indicates the setting (from 1 to 5) of the envelope stop.

Indicates that the sealer water bottle needs refilling.

Indicates that the sealer unit is on (automatic envelope sealing).

Indicates a ‘C’ - Letter fold is selected.

Indicates a ‘Z’ - Accordion fold is selected.

Indicates a double fold is selected.

Indicates a single fold is selected.

Indicates a no-fold insert operation.

Indicates a material stoppage. The position of this symbol in the display indicates where the stoppage has occurred.

Indicates the envelope depth.

Indicates that the sealer unit is off (envelopes not sealed).

Used on any feeder to indicate feeder is not in use.

Call Pitney Bowes Service.

Indicates the paper size, address orientation and fold(s) set for sheet feeder.

1-8

Operation

2. OPERATION

This section explains operation of the DI350 inserter, assuming the job to be run is already programmed into the machine.

If the job has not been programmed, refer to “Create Non- OMR Job” on page 3-1 or “Create OMR Job” on page 5-1.

Connecting Power

Read the safety information on

Connect the power cord to the socket on the left side 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.

page 1-3 before connecting the machine.

Selecting and Running a Job

Select the Job

When the machine is turned ON, the display will show the last job run and ‘Trial Piece Required’.

Press the Job button until the job you require is displayed, or press Default if you want to run the machine with your ‘standard’ settings.

Note: The default job can be altered only by a Pitney Bowes Customer Service Representative.

2-1

Operation

If you have material loaded, press Trial Piece. The machine will set itself and run a test piece for you to check.

If you don’t have material loaded, do this now, then return to this section. Loading feeders etc. is covered on the following pages.

Note:

You may have selected a ‘manual feed’ job where sheet feeder 1 is set for manual feed of collated sets. If this is the case, the sheet feeder should not be loaded, as the collated sets are fed one at a time as required by the machine. However, the lever shown in the illustration should be pulled back to open the feed mechanism to ready the manual feed operation. Remember to return this lever to its normal position when you use the feeder for automatic operation.

Run a Trial Piece

Once material is in place, press Trial Piece so you can check that the setup is correct.

Note: In switchable mode both sheet feeders must be loaded. A

trial piece will be run for both feeders.

Minor changes to the job settings can be made at this stage if the trial piece needs ‘fine tuning’. Press Setup, then use the Prev ( ), Next ( ) and Change (+/-) buttons as required to modify job settings. When you have made the necessary changes, press Setup again to return to run mode. The job will be saved with the new settings.

2-2

Operation

Start Machine Operation

Press Start to begin automatic operation. The machine will operate until either material runs out or the Stop button is pressed.

Note: If the three station machine is set for switchable

feeding, the display will show:

Ready: 1 > 2 > 1

This confirms that feeding will automatically switch between sheet feeders. See page 3-8 or 5-7 for more details.

Setting the Sheet Feeders

1. Adjust the side guides to

the width of the material

being fed, then back-off a

quarter turn on the side

guide control. This will

set the correct clearance

between the guides and

the material.

2. Take the stack of paper

and aerate it to ensure

the individual sheets are

not stuck together.

2-3

Operation

3. Jog the stack back into alignment. The sheet feeders take the paper stack aligned in a similar way to a photocopier paper cassette.

4. The three possible choices for loading you documents with addresses are listed below. NOTE: The display will indicate the correct orientation of the paper in the first two cases only.

FACE UP HEAD FIRST

ABC

FACE DOWN

FEET FIRST

ABC

FACE UP

FEET FIRST

5. Place the paper stack onto the feed deck. Allow the deck to move down and the top of the paper stack to slide under the feed roller.

Note: When using both sheet feeders with

accordion

fold, sheet feeder 2 must be used for the prime (address bearing) document.

6. You can pull out the sliding supports from the end of the deck to help support long material.

2-4

Setting the Envelope Feeder

1. Adjust the side guides to the width of the envelopes being fed, then back-off half a turn on the side guide control. This will set the correct clearance between the guides and the envelopes.

2. Aerate the stack of envelopes to be run.

Operation

3. Place them on the feed deck with the flaps up and trailing. The lead

edge of the first envelope should be under the front feed roller.

Let the ‘wedge’ slide down behind the stack so that the envelopes are supported.

2-5

Operation

Setting the Insert Feeder

1. Adjust the side guides to the width of the material being fed, then back-off a quarter turn on the side guide control. This will set the correct clearance between the guides and the material.

2. Refer to the ‘label’ located on the insert feeder. Compare your insert with the diagram. Read off the settings for the insert feeder blue lever (numbers 1 to

9) and the separator shield (letters A to D).

Thin Material

Thicker Material

Thick Inserts/

Booklets etc.

3. Set the blue lever to the number required.

2-6

4. Set the separator shield to the letter required.

5. Fan the inserts to be run and place them onto the feed deck face up with their bottom edge feeding first.

Operation

Let the ‘wedge’ slide down behind the stack so that the inserts are supported.

2-7

Operation

Filling the Sealer

When the sealer unit needs refilling, the Add Fluid symbol will flash in the display.

Add Pitney Bowes EZ Seal® solution or water in the following way:

Note: EZ Seal® solution is recommended to minimize growth of algae and scale build-up.

Hinge open the Water Bottle Cover located at the rear right hand side of the machine. Remove the bottle

Fill the bottle up to the level indicated.

Replace the water bottle and close the cover.

If the sealer unit has been allowed to completely empty, you should allow time for water to soak through the sealer mechanism.

2-8

Operation

Programming Options By Model

The DI350 has the ability to be programmed by the operator with up to 20 jobs (depending on model) which can be recalled at the touch of a button. The following table shows which functions are available on a machine by the number of stations it has (

✓ = present on machine):

Function

Sheet Feeder 1 ✓✓✓On (with double detect), On (without

Insert Feeder ✓✓On (with double detect), On (without

Sheet Feeder 2 ✓ On (with double detect), On (without

Accumul Mode ✓✓✓Off or On (with 2, 3,4, or 5 pages) OMR Mode ✓ Off, On, OMR + Sequence, OMR +

Mode ✓✓✓Insertion Mode, Fold Only Mode Number of Jobs 10 10 20 Each job can be programmed by operator

Fold Type ✓✓✓C - Letter, Z - Accordion, Double or

Paper Length ✓✓✓any within machine specification limits Fold A ✓✓✓any within machine/fold specification

Fold B ✓✓✓any within machine/fold specification

Envelope Depth ✓✓✓any within machine specification limits Envelope Stop ✓✓✓1 to 5 Batch Mode ✓✓✓Off or On (from 50 to 99)

# of Stations 1 2 3

Possible Settings

double detect), Off, or Manual Feed

✓ In addition to above: Select Feed (with

double detect), or Select Feed (without double detect)

double detect), Off

✓ In addition to above: Select Feed (with

double detect), or Select Feed (without double detect)

double detect), Off, Select Feed (with double detect), or Select Feed (without double detect)

Select Feed and Sequence, OMR + Select Feed

Single

limits

2-9

Operation

2-10

Create Non-OMR Job

3. CREATE NON-OMR JOB

This section takes you step-by-step through the process of setting up a new (non-OMR) job and saving it in the memory.

Programming is carried out in the ‘Setup Mode’…

Entering the Setup Mode

Open the hinged cover to the right of the display. This will expose the setup buttons.

Press Setup. The indicator will light and the machine will ask for an access code. This code prevents the machine’s settings being changed by unauthorized personnel.

The Prev ( buttons are used to step forward or backwards through the settings available. Once the item is displayed, the Change (+/-) buttons are used to select the option or value you want.

Use the Change (+/-) buttons to select the access code 71.

Press Next ( to the next setting….

) and Next ( )

) to advance

3-1

Create Non-OMR Job

Choosing the new job number

The machine will ask for the job number you wish the new settings to be stored under (the default job number is 1). Use the Change (+/-) buttons to display the job number you want.

Notes:

• If you use an existing job number, the old settings will be overwritten by the new settings you are about to make.

• If you want to find a currently unused job number, press Change (+/-)until you see a job where the display shows no symbols alongside the feeders or in the fold setup area. This means the job is currently empty.

Press Next (

) to advance to the next setting…

Selecting Non-OMR Option

Press Change (+/-) until you see this option:

OMR off

Press Next (

The flowchart on the following pages describe the setup for a non-OMR job.

OMR is turned off for this job.

) to advance to the next setting... (see page 3-5)

3-2

Create Non-OMR Job

Flowchart for Non-OMR Job Setup

Open hinged cover on right side of

control panel and press Setup key

Use + / - keys to enter 71 for access code, then press > key

Use + / - keys to enter job number,

Base Level Enhanced

OMR off OMR on

Use + / - keys to select accumulation

Off or On, then press > key

Use + / - keys to select fold type

(c-letter, z-accordion, double, single),

then press > key

Use + / - keys to select OMR

function, then press > key

OMR +

Sequence

OnOff

Level Only

OMR + Select

Feed + Sequence

See Separate

Flowchart for

OMR Job

Use + / - enter keys to

select 2, 3, 4 or 5 pages,

then press > key

OMR + Select

Feed

Use + / - keys to select whether the main sheet feeder is:

• On Double Detect

• Manual Feed

• On

• Off

• Switchable - On Double Detect

• Switchable - On

then press > key

continued on next page

3-3

Create Non-OMR Job

Flowchart for Non-OMR Job Setup

continued from previous page

Use +/ - keys to select whether other

sheet feeder is Off, On with

double detect or On with no double

detect, then press > key

Use + /- keys to select whether insert

feeder is Off, On with

double detect or On with no double

detect, then press > key

Insert Feeder On

Use +/ - keys to select whether sealer

is Off or On, then press > key

Use +/ - keys to change paper length of

your sheets, then press > key

Use + /- keys to change Fold A setting

(if neccesary), then press > key to

continue

Single Fold

Use +/ - keys to change envelope depth,

then press > key

Insert Feeder Off

C, Z, Double Folds

Use +/ - keys to select

whether insert feeder is in insertion mode or fold only

mode, then press > key

Use +/- keys to change Fold B

setting (if neccesary), then

press > key to continue

continued on next page

3-4

Create Non-OMR Job

Flowchart for Non-OMR Job Setup

continued from previous page

Use +/ - keys to change envelope stop

setting, then press > key

Use +/ - keys to select whether batch

mode is Off or On, then press > key

Use +/ - keys to enter batch

Batch OnBatch Off

Job number displays (back at beginining)

Setting the Accumulation Function

Press Change (+/-) until you see the option you want:

counter (from 50 to 999),

then press > key

Accumulation: OFF

Accumulation is turned off for this job.

Accumulation: ON

Accumulation is turned on for this job.

Accumulation = 2/3/4/5

Select how many pages you want to feed into each envelope. Either 2, 3, 4 or 5 pages can be selected.

Press Next (

) to advance to the next setting…

3-5

Create Non-OMR Job

Fold Type

Select the type of fold.

Press Change (+/-) until you see the option you want:

C - Letter

Z - Accordion

Double

Single

Folds your sheet into a standard ‘C’ or letter fold.

Folds your sheet into a ‘Z’ or accordion fold.

Folds your sheet in half and then in half again.

Folds your sheet once.

When the fold type is set as required, press Next ( ) to advance to the next setting…

3-6

Create Non-OMR Job

Setting Sheet Feeder 1 (Upper Feeder)

Select whether you want to use sheet feeder 1 and, if so, how it will be used.

Press Change (+/-) until you see the option you want:

On Double Detect

Manual Feed

Off

Switchable: On Switchable: On Dble Detect

Feeder on with the double detector operating. (The double detector stops the machine if more than one sheet simultaneously feeds from the feeder).

Feeder on without the double detector.

Allows you to manually feed collated sets (see notes below).

Feeder turned off for this job.

These functions are available only on the three-station machine. Feed will initially be from Sheet Feeder 1. When the feeder is empty, the machine will automatically switch to feeding from sheet feeder 2.

When a trial piece is requested, both feeders must be loaded as a trial piece will be fed from each feeder

Notes About Manual Feed:

1. The manual feed setting allows stapled sets of up to 5 sheets

of 20/24 lb (to a maximum of 120 lbs per set) to be run. The maximum compressed thickness of the set not exceed 2mm. The machine will wait for manual insertion of each set into sheet feeder 1 after which it will fold and insert the set automatically.

2. When running manual feed mode, sheet feeder 2 becomes

inoperable

3-7

after folding

must

Create Non-OMR Job

When sheet feeder 1 is set as required, press Next ( ) to advance to the next setting…

Setting Sheet Feeder 2 (Lower Feeder)

Select whether you want to use the sheet feeder 2. This function is available only on the three-station model.

Press Change (+/-) until you see the option you want:

On Double Detect

Off

Feeder on with the double detector operating. (The double detector stops the machine if more than one sheet simultaneously feeds from the feeder).

Feeder on without the double detector.

Feeder turned off for this job.

When sheet feeder 2 is set as required, press Next ( ) to advance to the next setting…

3-8

Create Non-OMR Job

Setting Insert Feeder

Select whether you want to use the insert feeder and, if so, how it will be used. This function is available only on the two and three-station models.

Press Change (+/-) until you see the option you want:

On Double Detect

Off

Feeder on with the double detector operating. (The double detector stops the machine if more than one insert simultaneously feeds from the feeder).

Feeder on without the double detector.

Feeder turned off for this job.

When the insert feeder is set as required, press Next ( ) to advance to the next setting…

Mode

This option only appears if you have the insert feeder turned off. In this case, the machine needs to know if the job requires inserting into an envelope or if it is a fold only job.

If the insert feeder has been set to ‘on’, the machine automatically sets itself to Insertion Mode and advances to the Sealer option on the next page.

If ‘Insertion Mode’ appears on the display, you must choose the machine’s mode of operation. Press Change (+/-) to switch between the options:

Insertion Mode

Fold Only Mode

Activates the Envelope Feeder for a normal inserting job.

Turns the Envelope Feeder off and makes the machine act as a folding machine.

When the mode is set as required, press Next ( ) to advance to the next setting…

3-9

Create Non-OMR Job

Sealer

This setting only appears if an insertion mode has been selected.

Select whether you want to seal envelopes or not.

Press Change (+/-) to switch the option on or off:

Off

Turns the sealer unit on for automatic sealing of envelopes. Make sure the sealer water bottle is full of EZ Seal® or water (see page 2-8).

Turns the sealer unit off. Envelopes will be ejected unsealed.

When the sealer is set as required, press Next ( ) to advance to the next setting…

If you have selected either of the sheet feeders, the next setting offered will be fold type. However, if you are using the insert feeder only, folding is not possible and the machine will advance directly to the envelope depth setting (page 3-12).

Paper Length

Select the paper length.

Use the scale on the edge of the stacker.

Quick reference:

US Letter length 11" (279mm)

A4 paper length 297mm

Press Change (+/-) until the length of your paper (in millimeters) is displayed.

When the paper length is correct, press Next (

) to advance

to the next setting…

3-10

Create Non-OMR Job

Fold A

Select the size of the first fold required.

Depending on the settings previously made for fold type and paper length, the machine will be suggesting the correct dimension for the first fold. Most times, therefore, this setting will not require alteration.

If you want to change the ‘standard’ setting, press Change (+/-) until the length of fold required is displayed. The symbol | –––– | shows the fold panel you are adjusting.

The machine will automatically limit your choices to what is physically possible within the machine specifications. (As you change the length of fold A, you will see the dimension of fold B automatically changing to keep within paper length and machine specifications.)

When the setting is correct, press Next ( the next setting…

) to advance to

Fold B

Select the size of the second fold required.

In a similar way to fold A, the machine will be suggesting the correct dimension for the fold.

If you want to change the ‘standard’ setting, press Change (+/-) until the length of fold required is displayed. The symbol | –––– | shows the fold panel you are adjusting.

When the setting is correct, press Next ( next setting…

3-11

) to advance to the

Create Non-OMR Job

If you are programming an inserting job the setting Envelope Depth will now appear. If you are programming a fold only job, the display will jump straight to the ‘Confirming the Job Setup’ section on the next page.

Envelope Depth

Select the depth of your envelopes (in millimeters).

Again, you can use the scale on the stacker to measure the depth of your envelopes. Press Change (+/-) until the correct dimension is displayed. When the envelope depth is set as required, press Next ( setting…

Envelope Stop

Select the position of the machine’s envelope stop.

) to advance to the next

The stop has five positions numbered 1 to 5. Setting 3 is the ‘standard’ setting for normal weight paper with standard folds. A thinner/ lighter envelope will require a lower setting and thicker/heavier envelope a higher setting.

Press Change (+/-) until the setting you want is displayed.

When the envelope stop is set as required, press Next ( advance to the next setting…

3-12

) to

Create Non-OMR Job

Batch Mode

The batch mode allows you to automatically process predefined batches of finished mailpieces. The system “counts down” from the number programmed for that job. When the batch is complete (has reached “0”), the machine will stop, allowing you to empty the stacker. Pressing Start will commence processing of the next batch.

If batch mode is not selected, the display counter will simply count the number of items processed until reset by pressing

Reset Counter.

Press Change (+/-) to switch batch mode On or Off.

When the setting is correct, press Next ( ).

If batch mode is turned On, the machine will now request the batch quantity. The default quantity is 50, but you may select any value up to 999 using the Change (+/-) buttons.

When the setting is correct, press Next (

Confirming the Job Setup

Job setup is now complete. The display will show the complete job setup for you to confirm. If you see a setting that is incorrect, use the Prev ( ) button to backtrack to the setting and correct it.

When you are satisfied with the program, press the Setup button. The machine will save the job into its memory and reset to the new job.

3-13

Create Non-OMR Job

When this is complete, the display will show the new job with the message ‘Trial Piece Required’.

Job settings will be retained by the machine

disconnected

until they are changed or deleted as described

even with power

on the following page.

Testing the Job

Load material and press Trial Piece so that you can check that the setup is correct.

Minor changes to the job settings can be made at this stage if the trial piece needs ‘fine tuning’. Press Setup, then use the Prev (

), Next ( ) and Change (+/-) buttons as

required to modify job settings. A chart is provided below to help ‘fine tune’ your fold settings.

FOLD TYPE ADDRESS TOO LOW ADDRESS TOO HIGH

“C” - Letter Fold Decrease Fold A Increase Fold A and

increase Fold B by the same amount

“Z” - Accordion Increase Fold A Decrease Fold A and

Fold increase Fold B

by the same amount

Single Fold Increase Fold A Decrease Fold A

Double Fold Decrease Fold A Increase Fold A

It is recommended that the folds are changed by 5mm each time and a new trial piece run to test the settings. When you have made the necessary changes, press Setup again to return to run mode. The job will be saved with the new settings.

3-14

Create Non-OMR Job

Changing an existing job

To change an existing job…

1. Enter the setup mode as described on page 3-1.

2. Use the Change (+/-) buttons to display the job you wish

to edit.

3. Use the Prev (

setting(s) you wish to change.

4. Use the Change (+/-) buttons to change the options/

dimensions you wish to amend.

5. Press the Setup button to leave setup mode and save

the changes.

) and Next ( ) buttons to display the

Deleting a job

To erase an existing job from memory, follow the steps below:

1. Enter the setup mode as described on page 3-1.

2. Use the Change (+/-) buttons to display the job you wish

to delete.

3. Press the Delete button. The display reads “Press again

to confirm”. Press Delete again. The display will briefly read ‘Deleting Job’ as the job is erased.

4. Press the Setup button to leave setup mode.

3-15

Create Non-OMR Job

3-16

What is OMR?

4. WHAT IS OMR?

DI350 inserters that are 3-station models have an Optical Mark Recognition (OMR) scanner installed on the upper and lower sheet feeders. This section describes what OMR is and how it can be used to enhance your use of the machine for your inserting needs. Once you understand the OMR concepts (and you have printed your documents with the proper OMR marks), go to Chapter 5 for instructions on setting up an OMR job and adjusting the OMR scanners.

What is OMR (Optical Mark Recognition)?

OMR (Optical Mark Recognition) is a system whereby marks are pre-printed on all pages that make up a document, statement, advertisement, etc. These pages are fed into the machine and their OMR marks “read” by the system, whose job is to interpret the marks and do the prescribed tasks associated with those marks (such as feeding sheets or verifying the end of a document).

The tracking of these OMR marks by the system assures that sheets of a document which belong together (a collated set) actually stays together throughout the inserting process. This is known as are printed and read, the better the collated set integrity. However, more space and programming is required to print additional marks on a document, so you will need to weigh the trade-off between more integrity and the space you have available on your document.

The OMR mark itself is normally a dark solid line on a sheet of light-colored paper (usually white) that is horizontally positioned so it matches the direction of travel of the paper. This line must be printed to certain specifications in width, length, and separation to be read by the OMR scanner on the system. Normally, there are several of these OMR marks printed in a group in one area on the paper (away from any text, pictures, or other lines) where the OMR scanner “reads” or scans them.

collation set integrity

4-1

. The more OMR marks that

What is OMR?

What Do OMR Marks Look Like on Paper?

The example below shows OMR marks that may be typically used on a document for the DI350:

Example of OMR Marks on a Document (not drawn to scale)

Feed Direction (for this example)

OMR Marks

This is a test last page for a collation. This is a test page for a

{

collation. This is a test page for a collation.

This is a test page for a collation. This is a test page for a collation. This is a test page for a collation.

This is a test page for a collation. This is a test page for a collation. This is a test page for a collation. This is a test page for a collation. This is a test page for a collation. This is a test page for a collation.

This is a test page for a collation. This is a test page for a collation. This is a test page for a collation.

Sincerely,

John Smith, Solicitor General

OMR Marks Being Read by a DI350 Scanner

4-2

What is OMR?

How are OMR Marks Read on the DI350?

There are two OMR scanners (the devices that “read” the OMR marks) on the DI350 inserter. One is top-mounted on sheet feeder 1 and the other is bottom-mounted on the sheet feeder 2 (see figures below).

Top-Mounted OMR Scanner on Sheet Feeder 1 (upper)

BottomMounted OMR Scanner on Sheet Feeder 2 (lower )

4-3

What is OMR?

The top-mounted scanner reads the marks from on top of the sheet, while the bottom-mounted scanner reads the marks from underneath the sheet of paper. This configuration allows you the maximum flexibility for your document folding needs when processed through the system. Specifically:

• the top-mounted scanner supports C-fold and double fold documents so the address can be visible in window envelopes

• that bottom-mounted scanner supports Z and half-fold documents so the address can be visible in window envelopes

How are OMR Marks Generated?

There are several ways to print the special OMR marks on a document. Pitney Bowes offers a PC-based product called PB FIRST™ that enables you to add the OMR marks to your documents so they can be read by the DI350 inserter (it also allows you to setup OMR marks for the DI400 and DI800 inserters). What’s nice is that once you’ve setup PB FIRST™ correctly to generate the marks, the marks are printed to the proper specifications – no “experimentation” is necessary.

If you have a computer/IT department in your organization, you may be able to use them also as a resource to create and print the OMR marks for you, based on the DI350 OMR specifications given in this chapter (see pages 4-25 and 4-26).

Additional information on implementing OMR marks can be found in Pitney Bowes publication SV40193 and the OMR template that are included with your DI350 inserter.

IMPORTANT: Unless you (or your organization) has had previous experience working with OMR marks or PB FIRST™, we recommend that you have a Pitney Bowes Consultant setup your OMR marks for you (at a cost to be estimated).

Pitney Bowes does not cover the implementation of OMR marks on your documents under the standard support agreements for the DI350 inserter.

4-4

What is OMR?

What OMR Marks are Used on the DI350?

The DI350 has two feature levels of OMR – the feature level you have depends on the level installed on your machine.

Basic Level OMR

the ability to have variable-sized collation sets (a different number sheets may be fed for each document based on what the marks on those sheets indicate to the system). It consists of these marks, known as Group 1:

Group 1 (“OMR”)

• Benchmark

• Safety

• Not EOC (end-of-collation)

• Not BOC (beginning-of-collation)

• Parity [even]

• Retime Mark

Enhanced Level OMR

size collation sets as well as greater collation set integrity. The Enhanced OMR Level allows for two additional groups of marks, which consist of:

Group 2 (“Select Feed”)

• SF1 (feed from the other sheet feeder)

• SF2 (feed from the insert feeder)

• Auto-Batch

• Retime Mark

– provides basic collation set integrity and

– allows more flexibility in variable-

Group 3 (“Sequence”)

• WAS3 (wrap-around sequence)

• WAS2 (wrap-around sequence)

• WAS1 (wrap-around sequence)

• Retime Mark

NOTE: Each group of OMR marks must be treated as one unit when programing and printing the marks for your documents (that is, space must be allocated for every mark within each group, whether the mark is used or not). Also, Basic OMR (Group 1) is always used; Group 2 and 3 marks are optional.

4-5

What is OMR?

Overview of Group 1 OMR Marks

Group 1 (Mandatory)

Benchmark (BM) Identifies the start of the

Safety Determines the line

Not EOC (End-of-Collation)

Not BOC (Beginning-ofCollation)

Parity Helps in the detection of

Retime Indicates the end of

Description How it Works When You Would

OMR marks on a sheet

spacing of the OMR marks.

Identifies the last sheet (as fed into the system) of a collated set

Identifies the first sheet (as fed into the system) of a collated set

misread OMR marks on a sheet

OMR marks for Group 1

Mark always appears at beginning of OMR marks

The measurement of the space between the BM and the Safety marks becomes the standard of what the system should expect in the space between all the subsequent OMR marks on that document. Mark always appears.

When mark appears on a sheet, indicates to system the end of a collated set

When mark appears on a sheet, indicates to system the start of a new collated set

Verifies that the number of OMR marks is even.

Mark always appears. Helps the systems avoid “losing its place” when tracking the marks

Use Mark

Mandatory for OMR on DI350

OMR Group 1 Marks (Basic)

Feed Direction (for this example)

BM Safety Not EOC Not BOC

Parity Retime

Group 1 Marks - Mandatory

}

4-6

Overview of Group 2 OMR Marks

What is OMR?

Group 2 (Optional)

Select Feed 1 (SF1)

Select Feed 2 (SF2)

Auto-Batch Instructs the system to

Retime Indicates the end of

Description How it Works When You Would

Dynamically turns on and off the other sheet feeder as necessary for each collated set.

Dynamically turns on and off the insert feeder as necessary for each collated set.

stop (but not end) the job when it encounters a collated set which contains this mark

OMR marks for Group 2

Presence of a mark indicates that the other sheet feeder feeds one sheet. The absence of the mark indicates that other feeder will operate in passthrough mode for the indicated collated set.

Presence of a mark indicates that the insert feeder feeds one sheet. The absence of the mark indicates that the insert feeder will operate in passthrough mode for the indicated collated set.

Presence of a mark indicates that system should stop after this collated set. This mark must be on all pages within the collated set.

Mark always appears. Helps the systems avoid “losing its place” when tracking the marks

Use Mark

For feeding additional fullpage sheets from the other sheet feeder as necessary to add to collated sets

For feeding inserts from the insert feeder as necessary to add to collated sets

For separating collated sets that may need special handling (like a mail tray) within the same job run

Mandatory when using this OMR Group on DI350

OMR Group 1 and 2 Marks (Enhanced Level)

Feed Direction (for this example)

BM Safety Not EOC Not BOC

Parity Retime

SF1 SF2

Auto-Batch Retime

Group 1 Marks - Mandatory

}

Group 2 Marks (“Select Feed” ) - Optional

}

4-7

What is OMR?

Overview of Group 3 OMR Marks

Group 3 (Optional)

Wrap-Around Sequence (WAS3)

Wrap-Around Sequence (WAS2)

Wrap-Around Sequence (WAS1)

Retime Indicates the end of

Description How it Works When You Would

Allows the system to track each sheet from the feeder by a number sequence. The numbers repeat, or "wrap-around", when they come to the end of the sequence, with the sequence repeating as more sheets are fed. The system reads the marks in ascending order (as in 0, 1, 2, 3, 4, 5, 6, 7, 0, 1, 2, 3, 4...).

Part of above Mark appears as

OMR marks for Group 3

The sequence of numbers (from 0-7) is based on the combinations that can be created in binary format from three OMR marks (see chart).With the proper sequence printed on all mailpieces, the system easily detects when a sheet is not fed in the proper order. Mark appears as necessary to create binary number sequence.

necessary to create binary number sequence

Mark always appears. Helps the systems avoid “losing its place” when tracking the marks.

Use Mark

For greater collated set integrity, such as in high-sensitivity jobs.

Part of above

Mandatory when using this OMR Group on DI350

OMR Group 1, 2, and 3 Marks (Enhanced Level)

Feed Direction (for this example)

BM Safety Not EOC Not BOC

Parity Retime

SF1 SF2

Auto-Batch Retime

WAS3 WAS2

WAS1 Retime

Group 1 Marks - Mandatory

}

Group 2 Marks (“Select Feed” ) - Optional

}

Group 3 Marks (“Sequence”) - Optional

}

4-8

What is OMR?

OMR Group Combinations

Under Enhanced Level OMR, you have the option of adding Group 2 marks, Group 3 marks, both groups, or no groups to Basic OMR (Group 1). Groups must be contiguous, that is, if you are not using Group 2, Group 3 marks must immediately follow Group 1 (see figure below). In every case, you must always select Basic Level OMR before choosing the optional Group 2 and/or Group 3 marks.

OMR Group 1 and 3 Marks (Enhanced Level)

Feed Direction (for this example)

BM Safety Not EOC Not BOC

Parity Retime

WAS3 WAS2

WAS1 Retime

Group 1 Marks - Mandatory

}

Group 3 Marks (“Sequence”) - Optional

}

The table below lists the combination of OMR groups that may be used together.

OMR Group Combinations Table

Basic OMR Enhanced OMR

Group 1

Marks

✔ ✔✔ ✔✔ ✔ ✔✔

Group 2

Marks

Group 3

Marks

4-9

What is OMR?

Details of Basic Level OMR

Basic Level OMR consists of six OMR marks, which make up Group 1. Space must be allocated for every mark in the group, whether the mark is used or not. In the OMR job setup on the system control panel, Group 1 is referred as simply “OMR”.

OMR Group 1 Marks (Basic)

Feed Direction (for this example)

BM Safety Not EOC Not BOC Parity Retime

Group 1 Marks (“OMR”)

• Benchmark (BM)

The Benchmark (BM) is the first OMR mark scanned and must be on every page in a collated set. This mark indicates to the system the start of the OMR marks on a page.

Group 1 Marks - Mandatory

}

• Safety

The Safety mark is the second OMR mark scanned and must be on line spacing of the OMR marks. Specifically, the measurement of the space between the BM and the Safety marks becomes the standard of what the system should expect in the space between all the subsequent OMR marks on that document.

• Not End-Of-Collation (EOC)

The Not End-Of-Collation (EOC) mark is the third OMR mark scanned and must be on every page in a collated set, except the last page fed into the system (which is the first printed page of a document). When the system reads a Not EOC mark on a sheet, it knows that this is the not the last page of a collated set. However, when it doesn’t see a Not EOC mark, it knows this is the last page of a collated set. This feature allows different size collated sets to be processed on the DI350 inserter.

every page in a collated set. It used to determine the

4-10

What is OMR?

While the feeders within the system have double detection sensors, a combination of paper slippage and other variables could result in two full collated sets being mailed as one. The Not EOC configuration adds the benefit in that it avoids putting two documents into a single envelope if the Not EOC mark is ever missed by the scanner.

• Not Beginning-Of-Collation (BOC)

The Not Beginning-Of-Collation (BOC) mark is the fourth OMR mark scanned and must be on set, except the first page fed into the system (which is the last printed page of a document). When the system reads a Not BOC mark on a sheet, it knows that this is the not the first page of a collated set. However, when it doesn’t see a Not BOC mark, it knows this is the first page of a collated set. This provides additional verification that a collated set is not being split or combined with another collated set into one package.

• Parity (even)

The Parity mark is the fifth OMR mark scanned, but because of how it is used, it may or may not be printed on every page in a collated set. The Parity mark is used to ensure that the total number of OMR marks read by the scanner on one piece of paper is always an even number. This provides an internal check on the scan set of marks on a single sheet and helps detect sensitivity problems associated with the scanner or excessive paper skew. Because the system checks for an even number of marks, it is known as “even” parity (if the system checked for an odd number, it would be called “odd” parity).

every page in a collated

4-11

What is OMR?

For example, for a one-page document, the marks printed on the page are:

BM 1 mark Safety 1 mark Not EOC 0 mark (not printed, as it is the end of document) Not BOC 0 mark (not printed, as it is the start of document) Retime 1 mark (see description below)

-----------------------Total = 3 marks (odd number; needs Parity mark)

Parity + 1 mark

-------------------------New total= 4 marks (even number; all OK)

In this example, the Parity mark is printed on this page to make the number of marks go from odd (3) to even (4).

As another example, for the last page fed of a two-page collated set, the marks printed on the page are:

BM 1 mark Safety 1 mark Not EOC 0 mark (not printed, as it is the end of collated set) Not BOC 1 mark Retime 1 mark

-----------------------Total = 4 marks (even number; all OK, no Parity mark)

Parity + 0 mark (not printed, as it is not needed)

-------------------------New total= 4 marks (even number; all OK)

In this example, the Parity mark is not printed on this page because the total number of marks is even (4) to begin with.

• Retime

The Retime mark is the last OMR mark scanned and must be on

every page in a collated set. This mark indicates to the system the end of OMR marks for Group 1 and helps the systems avoid “losing its place” when tracking the marks.

4-12

Example of Group 1 Marks Printed on Several Documents for Feeding from Sheet Feeder 1

Retime Parity Not BOC Not EOC

Safety BM

Feed Direction (for this example)

Page 1 of Document 1

Page 2 of Document 1 (fed first from feeder)

Page 2 of Document 3

Page 3 of Document 3

Document 2 (one page)

page for a collation. test last page for a collation. This is a test last This is a test last page for a collation. This is a

page for a collation. test last page for a collation. This is a test last

ABC Company

This is a test last page for a collation. This is a

page for a collation.

Respectfully Yours,

test last page for a collation. This is a test last This is a test last page for a collation. This is a

page for a collation.

Dear Mr. Customer:

test last page for a collation. This is a test last This is a test last page for a collation. This is a

Anytown, USA 11111 111 Maple St.

page for a collation.

Mrs. Jane Hancock

test last page for a collation. This is a test last This is a test last page for a collation. This is a

page for a collation. test last page for a collation. This is a test last This is a test last page for a collation. This is a

What is OMR?

Page 1 of Document 3 (fed last from feeder)

page for a collation. test last page for a collation. This is a test last This is a test last page for a collation. This is a

page for a collation.

ABC Company

Respectfully Yours,

page for a collation. test last page for a collation. This is a test last

ABC Company

Respectfully Yours,

llation. This is a test last page for a collation. page for a collation. test last page for a collation. This is a test last This is a test last page for a collation. This is a

page for a collation. test last page for a collation. This is a test last

This is a test last page for a collation. This is a

Dear Mr. Customer:

Anytown, USA 11111 111 Maple St. Mrs. Jane Hancock

Retime

Parity Not EOC Not BOC Safety BM

This is a test last page for a collation. This is a

page for a collation. test last page for a collation. This is a test last This is a test last page for a collation. This is a

page for a collation. test last page for a collation. This is a test last

This is a test last page for a collation. This is a

Retime Parity Not EOC Not BOC Safety BM

test last page for a collation. This is a test last This is a test last page for a collation. This is a

page for a collation. test last page for a collation. This is a test last This is a test last page for a collation. This is a

page for a collation. a test last page for a collation. This is a test last

This is a test second page for a collation. This is

Retime Parity Not EOC Not BOC Safety BM

page for a collation. test last page for a collation. This is a test last This is a test last page for a collation. This is a

page for a collation. test last page for a collation. This is a test last

This is a test last page for a collation. This is a

Dear Mr. Customer:

Anytown, USA 33333 333 Marble Dr. Mr. John Doe

Retime Parity Not EOC Not BOC Safety BM

Feed Direction

Retime Parity Not EOC Not BOC Safety BM

4-13

What is OMR?

Details of Enhanced Level OMR

Enhanced Level OMR adds the availability of two additional groups of marks, Groups 2 and 3. Like Group 1 marks, space must be allocated for every mark within each group, whether the mark is used or not.

Under Enhanced Level OMR, you have the option of adding Group 2 marks, Group 3 marks, both groups, or no groups to Basic OMR (Group 1). Groups must be contiguous, that is, if you are not using Group 2, Group 3 marks must immediately follow Group 1. In every case, you must always select Basic Level OMR before choosing the optional Group 2 and/or Group 3 marks. The table below lists the combination of OMR groups that may be used together.

OMR Group Combinations

Basic OMR Enhanced OMR

Group 1

Marks

✔ ✔✔ ✔✔ ✔ ✔✔

Group 2

Marks

Group 3

Marks

Group 2 Marks (“Select Feed”)

In the OMR job setup on the system control panel, Group 2 marks are referred to as “Select Feed”.

OMR Group 2 Marks (“Select Feed” ) - Optional

Feed Direction (for this example)

SF1 SF2

Auto-Batch Retime

4-14

What is OMR?

• Selective Feed 1 (SF1)

Selective Feed marks in general are used in applications where some pages are not fed as part of the initial collated set for certain mailpieces (e.g., perhaps confidential or restricted information should not be sent to each individual in a mailing). The Select Feed 1 mark specifically allows you to dynamically turn on and off the other sheet feeder for each collated set. For example, if you are feeding your control (also known as the main or prime) document from the upper sheet feeder, SF1 would allow you to feed from the lower sheet feeder as necessary.

Presence of a mark indicates that the other sheet feeder feeds one sheet. The absence of the mark indicates that other feeder will operate in pass-through mode for the indicated collated set. NOTE: The pattern must be on all sheets within a collated set.

• Selective Feed 2 (SF2)

You can use also dynamically turn on and off the insert feeder as necessary for each collated set using the Selective Feed 2 mark on the control document. Presence of a mark indicates that the insert feeder feeds one sheet. The absence of the mark indicates that the insert feeder will operate in pass-through mode for the indicated collated set. NOTE: The same selective feed mark pattern must be on all sheets within a collated set.

same selective feed mark

• Auto-Batch

An Auto-batch mark instructs the system to stop (but not end) the job after it processes a collated set which contains the Auto-batch mark. This allows you to separate collated sets that may need special handling (like a mail tray) within the same job run. NOTE: The on all sheets within a collated set.

• Retime

This Retime mark must be on It indicates to the system the end of this group of OMR marks on a page and helps the systems avoid “losing its place” when tracking the marks.

same Auto-batch marks must be

every page within a collated set.

4-15

What is OMR?

Example of Group 1 and 2 Marks Printed on Several Documents for Feeding from Sheet Feeder 1

Retime Auto-batch SF2

SF1 Retime Parity

Not BOC

Not EOC Safety BM

Feed Direction (for this example)

Document 2 (one page)

Page 1 of Document 1

Page 2 of Document 1 (fed first from feeder)

Feed Direction

Page 2 of Document 3

Page 3 of Document 3

ABC Company

Respectfully Yours,

llation. This is a test last page for a collation. page for a collation. test last page for a collation. This is a test last This is a test last page for a collation. This is a

page for a collation. test last page for a collation. This is a test last

page for a collation. test last page for a collation. This is a test last This is a test last page for a collation. This is a

page for a collation. test last page for a collation. This is a test last

ABC Company

Respectfully Yours,

page for a collation. test last page for a collation. This is a test last This is a test last page for a collation. This is a

This is a test last page for a collation. This is a

page for a collation. test last page for a collation. This is a test last

This is a test last page for a collation. This is a

Dear Mr. Customer:

Anytown, USA 11111 111 Maple St. Mrs. Jane Hancock

Retime Auto-Batch SF2 SF1 Retime Parity Not EOC Not BOC Safety BM

This is a test last page for a collation. This is a

Dear Mr. Customer:

Anytown, USA 11111 111 Maple St. Mrs. Jane Hancock

Retime Auto-Batch SF2 SF1 Retime Parity Not EOC Not BOC Safety BM

Legend of OMR Features on Documents

Feature Document 1 Document 2 Document 3

Select Feed 1-SF1 (feed page from supplementary feeder)

Select Feed 2-SF2 (feed page from insert feeder)

Auto-Batch (stop job after processing this document)

Page 1 of Document 3 (fed last from feeder)

page for a collation. test last page for a collation. This is a test last This is a test last page for a collation. This is a

ABC Company

Respectfully Yours,

page for a collation. test last page for a collation. This is a test last This is a test last page for a collation. This is a

page for a collation. test last page for a collation. This is a test last

This is a test last page for a collation. This is a

Retime Auto-Batch SF2 SF1 Retime Parity Not EOC Not BOC Safety BM

page for a collation. test last page for a collation. This is a test last This is a test last page for a collation. This is a

page for a collation. a test last page for a collation. This is a test last

This is a test second page for a collation. This is

Retime Auto-Batch SF2 SF1 Retime Parity Not EOC Not BOC Safety BM

✔✔

page for a collation. test last page for a collation. This is a test last This is a test last page for a collation. This is a

page for a collation. test last page for a collation. This is a test last

This is a test last page for a collation. This is a

Dear Mr. Customer:

Anytown, USA 33333 333 Marble Dr. Mr. John Doe

Retime

Auto-Batch SF2

SF1 Retime Parity Not EOC

Not BOC

Safety

Retime Auto-Batch SF2

SF1 Retime Parity Not EOC Not BOC Safety BM

✔

4-16

What is OMR?

Group 3 Marks (“Sequence”)

In the OMR job setup on the system control panel, Group 3 marks are referred to as “Sequence”.

OMR Group 3 Marks (“Sequence”) - Optional

Feed Direction (for this example)

WAS3 WAS2 WAS1 Retime

• Wrap-Around Sequence (WAS) - 3 mark positions

Wrap-Around Sequence (WAS) marks add to mailpiece integrity by allowing the system to track each sheet from the feeder by a number sequence. The numbers repeat, or "wrap-around", when they come to the end of the sequence, with the sequence repeating as more sheets are fed. The system reads the marks in ascending order (as in 0, 1, 2, 3, 4, 5, 6, 7, 0, 1, 2, 3, 4...).

With the proper sequence printed on all mailpieces, the system easily detects when a sheet is not fed in the proper order. After an out-of-sequence feeding or an OMR scan error is detected and cleared, the system will begin fresh with the sequence number of the next document that is fed.

This sequence of numbers (from 0-7) is based on the combinations that can be created in binary format from three OMR marks. The figure on the next page shows how the number combinations are created by the three marks within the space allocated to WAS.

• Retime

This Retime mark must be on every page within a collated set. It indicates to the system the end of this group of OMR marks on a page and helps the systems avoid “losing its place” when tracking the marks.

4-17

What is OMR?

Sequence Creation Using Wrap-Around Sequence (WAS) Marks

Feed Direction (for this example)

WAS3 WAS2 WAS1

Sequence #0

}

Sequence #1

}

Sequence #2

}

Sequence #3

}

Sequence #4

}

Sequence #5

}

mark not printed (position left blank)

WAS3 WAS2 WAS1

Sequence #6

}

Sequence #7

}

4-18

What is OMR?

Example of Group 1, 2, and 3 Marks Printed on Documents for Feeding from Sheet Feeder 1

Retime WAS1 WAS2 WAS3

Retime Auto-Batch

SF2 SF1

Retime Parity Not BOC Not EOC Safety

Feed Direction (for this example)

Page 1 of Document 1

Page 2 of Document 1 (fed first from feeder)

Feed Direction

Page 2 of Document 3

Page 3 of Document 3

Document 2 (one page)

page for a collation. test last page for a collation. This is a test last This is a test last page for a collation. This is a

page for a collation.

ABC Company

Respectfully Yours,

page for a collation. test last page for a collation. This is a test last This is a test last page for a collation. This is a

test last page for a collation. This is a test last

This is a test last page for a collation. This is a

Dear Mr. Customer:

Anytown, USA 11111 111 Maple St. Mrs. Jane Hancock

Retime WAS1 WAS2

WAS3 Retime Auto-Batch SF2 SF1 Retime Parity Not EOC Not BOC Safety BM

4-19

Page 1 of Document 3 (fed last from feeder)

page for a collation. test last page for a collation. This is a test last This is a test last page for a collation. This is a

ABC Company

Respectfully Yours,

page for a collation. test last page for a collation. This is a test last This is a test last page for a collation. This is a

ABC Company

Respectfully Yours,

llation. This is a test last page for a collation. page for a collation. test last page for a collation. This is a test last This is a test last page for a collation. This is a

page for a collation. test last page for a collation. This is a test last

This is a test last page for a collation. This is a

Dear Mr. Customer:

Anytown, USA 11111 111 Maple St. Mrs. Jane Hancock

Retime

WAS1

WAS2 WAS3 Retime Auto-Batch SF2 SF1 Retime Parity Not EOC Not BOC Safety BM

page for a collation. test last page for a collation. This is a test last This is a test last page for a collation. This is a

Feature Document 1 Document 2 Document 3

Select Feed 1-SF1 (feed page from supplementary feeder)

Select Feed 2-SF2 (feed page from insert feeder)

Auto-Batch (stop job after processing this document)

Wrap-Around Sequence - WAS1, WAS2, WAS3 (sequential numbering of pages from 0 to 7)

page for a collation. test last page for a collation. This is a test last This is a test last page for a collation. This is a

page for a collation. a test last page for a collation. This is a test last

This is a test second page for a collation. This is

Retime WAS1 WAS2 WAS3 Retime Auto-Batch SF2 SF1 Retime Parity Not EOC Not BOC Safety BM

Retime

WAS1 WAS2 WAS3

Retime

Auto-Batch SF2

SF1 Retime Parity Not EOC

Not BOC

Safety

Legend of OMR Features on Documents

✔✔

✔

Page 2 = "0" Page 1 = "1"

page for a collation. test last page for a collation. This is a test last This is a test last page for a collation. This is a

page for a collation. test last page for a collation. This is a test last

This is a test last page for a collation. This is a

Dear Mr. Customer:

Anytown, USA 33333 333 Marble Dr. Mr. John Doe

Retime WAS1 WAS2 WAS3 Retime Auto-Batch SF2 SF1 Retime Parity Not EOC Not BOC Safety BM

Retime WAS1 WAS2 WAS3 Retime Auto-Batch SF2

SF1 Retime Parity Not EOC Not BOC Safety BM

✔

Page 1 = "3"✔Page 3 = "4"

Page 2 = "5" Page 1 = "6"

What is OMR?

Considerations When Implementing OMR

Before implementing any of the DI350 OMR marks, you must consider various aspects of document preparation, OMR mark combinations, and system feeding. By being aware of the mechanical and electronic interaction of the system with OMR scanning, you can select the OMR features that work best with your applications.

Document Page Order from Creation to Final Output from DI350

Multi-Page Document Created in

Application (pages in normal

order, address page first)

Document Loaded onto Feeder as Printed (in reverse order)

Completed Document in Envelope in Normal Order, Address Page on Top or in Window (figure doesn't show folding)

Document Printed (pages in reverse order, address page on bottom)

Machine Feeds Pages from Top and Reverses Order When Collating (figure doesn't show folding)

4-20

BM Safety Not EOC Not BOC

Parity Retime

SF1 SF2

Auto-Batch Retime

WAS3 WAS2

WAS1 Retime

What is OMR?

View of Mark Order and Position on Page as Printed for Sheet Feeder 1

Head of Page

Group 1 Marks - Mandatory

}

Group 2 Marks (“Select Feed” ) - Optional

}

Group 3 Marks (“Sequence”) - Optional

}

Foot of Page

4-21

What is OMR?

View of Mark Order and Position on Page as Loaded for Sheet Feeder 1 (Face-Up, Head-First)

Foot of Page

Group 3 Marks (“Sequence”) - Optional

Group 2 Marks (“Select Feed” ) - Optional

Group 1 Marks - Mandatory

{ {

{

Retime

WAS1 WAS2 WAS3

Retime

Auto-Batch

SF2 SF1

Retime

Parity Not BOC Not EOC

Safety

Head of Page, Face-Up

Feed Direction

4-22

Scanner

What is OMR?

View of OMR Mark Order and Position on Page as Printed for Sheet Feeder 2

Head of Page

Group 1 Marks - Mandatory

Group 2 Marks (“Select Feed” ) - Optional

Group 3 Marks (“Sequence”) - Optional

{

Retime

WAS1

WAS2

WAS3

Retime

Auto-Batch

SF2 SF1

Retime

Parity Not BOC Not EOC

Safety

Foot of Page

4-23

What is OMR?

View of Mark Order and Position on Page for Sheet Feeder 2 (Face-Down, Feet-First)

Head of Page

Retime

WAS1 WAS2 WAS3

Retime

Auto-Batch SF2

SF1

Retime

Parity

Not BOC

Not EOC Safety BM

Group 3 Marks (“Sequence”) - Optional

}

Group 2 Marks (“Select Feed” ) - Optional

}

Group 1 Marks - Mandatory

}

as Loaded

Scanner

Foot of Page, Face-Down

Feed Direction

denotes mark is on other side of paper

4-24

What is OMR?

OMR Printing/Feeding Considerations Based on Fold Type

Fold Type Area Required

C-Fold 4.5 inches

Double Fold 4.5 inches

Z-Fold 4 inches

Single Fold (Half Fold)

on Paper for Printing OMR Marks and Leaving Space Around Them

(115mm) long and 3/4” (14 mm) wide column

(100mm) long and 3/4” (14 mm) wide column

4 inches (100mm) long and 3/4” (14 mm) wide column

Where OMR Marks are Printed on Paper

Upper left side of the paper

Lower right side of the paper

Order of Pages When PrInting and Presenting to Feeder

Reverse (address

page is last page printed and last page fed for each document set)

Reverse Sheet Feeder 1

Reverse Sheet Feeder 2

Maximum Sheets Per Collation Set

Sheets Fed from Control Document Feeder

1 to 5 1 1 up to 7

Sheets Fed from Supplementary Feeder

Sheets Fed from Insert Feeder

Loading of Documents on to System

Sheet Feeder 1 (face up,

head first )

(face up, head first )

(face down, feet first )

Total Sheets Permissible in Collation Set (Envelope)

4-25

What is OMR?

SV40193

9/02

side

_____

)

_____

)

_____

)

(

)

(

Bracket

OMR Printing Specifications Template

(see SV40193-TM for full-size version of this template)

DI350/DI400 Inserting System

Scanning Templat

4mm mi

DI350/DI400 OMR INFORMATION

IMPORTANT: Unless you (or your organization) has ha

previous experience working with OMR marks or PB FIRS software, we recommend that you have a Pitney Bowe consultant set up your OMR marks for you (at a cost to b estimated). Pitney Bowes does not cover the implementatio of OMR marks on your documents under the standar support agreements for the DI350/DI400 systems.

Before using template, read the accompanying guidelines. OMR is available on the three station machines ONLY The minimum scan line requirement is all of Group 1

DI350/DI400 SCAN MARK POSITIONIN

ANNOT DO PAR T OF A GROUP - ALL OR NOTHIN

Benchmar _____ Safet _____ NOT-End of Collation (NOT-EOC

Group

_____ NOT-Beginning of Collation (NOT-BOC) _____ Parity (even)

Re-time mark _____ Select Feed 1 (SF1 _____ Select Feed 2 (SF2

Group

Auto-batc _____ Re-time mark (Fixed if this group is in use _____ Wrap Around Sequence 3 (WAS3 _____ Wrap Around Sequence 2 (WAS2 _____ Wrap Around Sequence 1 (WAS1 _____ Re-time mark (Fixed if this group is in use

Vertically Cente Group withi Brack

2mm White Spac

on both sides of mark

mm ma

115mm mi

c rk

MARK SPECIFICATION

A clear area of 115mm is required from the top left corne of the form (top scan) and 100mm from the bottom right corne of the form (bottom scan

- black ink on a white background

- 10mm mi

- 1 pt min / 2 pt ma

Spacing - 3mm min between mark

learance - 2mm min on either

-TM Rev. A

100mm mi

on both sides of m

Vertically Cente

mm ma

27mm mi

2mm White Sp

Group withi

4-26

Create OMR Job

5. CREATE OMR JOB

This section takes you step-by-step through the process of setting up a new OMR job and saving it in the memory. The OMR function is available only on the three-station model. This model can be programmed with up to 20 jobs.

What is OMR (Optical Mark Recognition)?

An OMR mark is normally a dark solid line on a sheet of light colored paper that is horizontally printed so it matches the direction of travel of the paper. This line must be sufficiently thick and dense to trigger the OMR scanner on the system.

The OMR scanner, working with the OMR system software, checks for one or more different OMR marks on a document while it is fed through the system. The tracking of these OMR marks by the system increases the chance that a set of sheets which belong together (a collation set) actually stays together throughout the inserting process. See Chapter 3, “What is OMR?” for more information.

Programming is carried out in the ‘Setup Mode’…

Entering the Setup Mode

Open the hinged cover to the right of the display. This will expose the setup buttons. Press Setup. The indicator will light and the machine will ask for an access code. This code prevents the machine’s settings being changed by unauthorized personnel.

The Prev ( forward or backwards through the settings available. Once the item is displayed, the Change (+/-) buttons are used to select the option you want.

) and Next ( ) buttons are used to step

5-1

Create OMR Job

Use the Change (+/-) buttons to select the access code 71.

Press Next ( to the next setting…

) to advance

Choosing the New Job Number

The machine will ask for the job number you wish the new settings to be stored under (the default job number is 1). Use the Change (+/-) buttons to display the job number you want.

Notes:

• If you use an existing job number, the old settings will be overwritten by the new settings you are about to make.

• If you want to find a currently unused job number, press Change (+/-) until you see a job where the display shows no symbols alongside the feeders or in the fold setup area. This means the job is currently empty.

Press Next (

) to advance to the next setting…

5-2

Create OMR Job

Selecting the OMR Functions

Press Change (+/-) until you see the option you want:

OMR off

OMR on

this job.

If your machine has the Enhanced level of OMR, these options will also display:

OMR + Sequence

scanning for this job (OMR Groups 1 and 3).

OMR + Select feed + Sequence –

Select Feed/Auto-Batch + Page sequence scanning for this job (OMR Groups 1, 2, and 3).

OMR + Select feed

Auto-Batch scanning for this job (OMR Groups 1 and 2).

See Chapter 3, “What is OMR?” for more information on the OMR marks and groups and what they mean.

NOTE: A maximum of FIVE pages per set can be fed from either sheet feeder 1 or 2 when using the OMR function.

– OMR is turned off for this job.

– OMR (OMR Group 1 marks) is turned on for

– Basic scanning + page sequence

Basic scanning +

– Basic scanning + Select Feed/

Press Next (

The flowchart on the following pages describe the setup for the various OMR functions.

) to advance to the next setting...(see page 5-6)

5-3

Create OMR Job

Flowchart for OMR Job Setup (Both Levels)

Open hinged cover on right side of control panel and press Setup key

Use +/ - keys to enter 71 for access code, then press > key

Use +/ - keys to enter job number,

Use +/- keys to select OMR

function, then press > key

Base Level Enhanced

OMR off OMR on

See Separate

Flowchart for

Non-OMR Job

Non-Select Feed Options Select Feed Options

Use + / - keys to select whether other

sheet feeder is Off, On with

double detect or On with no double

detect, then press > key

Sequence

Use +/ - keys to select fold type

(c-letter, z-accordion, double, single),

Use + / - keys to select whether the

main (scanning) sheet feeder is On with

double detect or On with no double

detect, then press > key

then press > key

OMR +

Feed + Sequence

then press > key

Use +/ - keys to select whether other sheet feeder is: Off On with double detect On with no double detect On with select feed On with select feed and double detect, then press > key

Level Only

OMR + Select

Feed

continued on next page

5-4

Create OMR Job

Flowchart for OMR Job Setup (Both Levels)

continued from previous page

Non-Sequence Options

Use +/- keys to select whether insert

feeder is Off, On with

double detect or On with no double

detect, then press > key

Use +/- keys to select whether sealer

is Off or On, then press > key

Use +/- keys to change paper length of

your sheets, then press > key

Use +/- keys to change Fold A setting

(if neccesary), then press > key to

continue

Single Fold C, Z, Double Folds

Use + / - keys to change envelope depth,

then press > key

Sequence Options

Use +/- keys to select whether insert feeder is: Off On with double detect On with no double detect On with select feed On with select feed and double detect, then press > key

Use + / - keys to change Fold B

setting (if neccesary), then

press > key to continue

Use +/ - keys to change envelope stop

setting, then press > key

Use +/ - keys to select whether batch

mode is Off or On, then press > key

Batch OnBatch Off

Job number displays (back at beginining)

Use + / - keys to enter batch

counter (from 50 to 999),

then press > key

5-5

Create OMR Job

Fold Type

Select the type of fold.

Press Change (+/-) until you see the option you want:

C - Letter

Z - Accordion

Double

Single

Folds your sheet into a standard ‘C’ or letter fold.

Folds your sheet into a ‘Z’ or accordion fold.

Folds your sheet in half and then in half again.

Folds your sheet once.

When you select either C-Letter fold or a double fold, the machine will automatically select the TOP Sheet Feeder 1 as the scanning feeder. If you select either a Z-Accordion Fold or a single fold, the machine will automatically select the BOTTOM Sheet Feeder 2 as the scanning feeder.

When the fold type is set as required, press Next ( ) to advance to the next setting…

5-6

Create OMR Job

Setting the Main (Scanning) Sheet Feeder

Press Change (+/-) until you see the option you want:

On Double Detect

with the double detector operating. (The double detector stops the machine if more than one sheet simultaneously feeds from the feeder).

Feeder on without the double detector.

When the Sheet Feeder is set as required, press Next ( ) to advance to the next setting…

Feeder on

Setting Other Sheet Feeder

Select whether you want to use the other sheet feeder (it may be feeder 1 or 2, depending on what feeder was chosen as the main sheet feeder based on fold type in the previous step). This function is available only on the threestation model.

Press Change (+/-) until you see the option you want.

If you had chosen OMR or OMR + Sequence as your OMR option earlier, the following choices are available:

On Double Detect

operating. (The double detector stops the machine if more than one sheet simultaneously feeds from the feeder).

Feeder on without the double detector

Off

select feeder turned off for this job.

Feeder on with the double detector

5-7

Create OMR Job

If you had chosen OMR + Select Feed or OMR + Select Feed + Sequence as your OMR option earlier, the following choices are available:

On Double Detect

operating. (The double detector stops the machine if more than one sheet simultan-eously feeds from the feeder).

Feeder on without the double detector.

Off

select feeder turned off for this job.

On SF Double Detect

detector operating. (The double detector stops the machine if more than one insert simultaneously feeds from the feeder).

On SF

When the feeder is set as required, press Next ( advance to the next setting…

Select feeder on without the double detector.

Feeder on with the double detector

Select feeder is on with the double

) to

5-8

Create OMR Job

Setting Insert Feeder

Select whether you want to use the insert feeder. This function is available only on the two and three-station models.

Press Change (+/-) until you see the option you want.

If you had chosen OMR or OMR + Select Feed as your OMR option earlier, the following choices are available:

On Double Detect

operating. (The double detector stops the machine if more than one sheet simultan-eously feeds from the feeder).

Feeder on without the double detector.

Off

select feeder turned off for this job.

If you had chosen OMR + Sequence or OMR + Select Feed + Sequence as your OMR option earlier, the following choices are available:

On Double Detect

operating. (The double detector stops the machine if more than one sheet simultan-eously feeds from the feeder).

Feeder on without the double detector.

Off

select feeder turned off for this job

On SF Double Detect

detector operating. (The double detector stops the machine if more than one insert simultaneously feeds from the feeder).

Feeder on with the double detector

Select feeder is on with the double

On SF

When the other feeder is set as required, press Next ( advance to the next setting…

Select feeder on without the double detector.

5-9

) to

Create OMR Job

Sealer

Select whether you want to seal envelopes or not.

Press Change (+/-) to switch the option on or off:

Off

Turns the sealer unit on for automatic sealing of envelopes. Make sure the sealer water bottle is full of EZ Seal® or water (see page 2-8).

Turns the sealer unit off. Envelopes will be ejected unsealed.

When the sealer is set as required, press Next ( ) to advance to the next setting…

If you have selected either of the Sheet Feeders, the next setting offered will be Fold Type. However, if you are using the Insert Feeder only, folding is not possible and the machine will advance directly to the Envelope Depth setting (page 5-12).

Paper Length

Select the paper length.

Use the scale on the edge of the stacker.

Quick reference:

US Letter length 11" (279mm)

A4 paper length 297mm

Press Change (+/-) until the length of your paper (in millimeters) is displayed.

When the paper length is correct, press Next (

) to advance

to the next setting…

5-10

Create OMR Job

Fold A

Select the size of the first fold required.

If you want to change the ‘standard’ setting, press Change (+/-) until the length of fold required is displayed. The symbol | –––– | shows the fold panel you are adjusting.

The machine will automatically limit your choices to what is physically possible within the machine specifications. (As you change the length of Fold A, you will see the dimension of Fold B automatically changing to keep within paper length and machine specifications.)

When the setting is correct, press Next ( the next setting…

) to advance to

Fold B

NOTE: This setting does not display when Single fold has been chosen. Select the size of the second fold required.

In a similar way to fold A, the machine will be suggesting the correct dimension for the fold.

If you want to change the ‘standard’ setting, press Change (+/-) until the length of fold required is displayed. The symbol | –––– | shows the fold panel you are adjusting.

When the setting is correct, press Next ( next setting…

5-11

) to advance to the

Create OMR Job

Envelope Depth

Select the depth of your envelopes (in millimeters).

Envelope Stop

Select the position of the machine’s envelope stop.

) to

Press Change (+/-) until the setting you want is displayed.

When the envelope stop is set as required, press Next ( advance to the next setting…

5-12

) to

Create OMR Job

Batch Mode

The Batch Mode allows you to automatically process predefined batches of finished mailpieces. The system “counts down” from the number programmed for that job. When the batch is complete (has reached “0”), the machine will stop, allowing you to empty the stacker. Pressing Start will commence processing of the next batch.

If Batch Mode is not selected, the display counter will simply count the number of items processed until reset by pressing

Reset Counter.

Press Change (+/-) to switch Batch Mode On or Off.

When the setting is correct, press Next ( ).

If Batch Mode is turned On, the machine will now request the batch quantity. The default quantity is 50, but you may select any value up to 999 using the Change (+/-) buttons.

When the setting is correct, press Next (

Confirming the Job Setup

Job setup is now complete. The display will show the complete job setup for you to confirm. If you see a setting that is incorrect, use the Prev ( ) button to backtrack to the setting and correct it.

When you are satisfied with the program, press the Setup button. The machine will save the job into its memory and reset to the new job.

5-13

Create OMR Job

When this is complete, the display will show the new job with the message ‘Trial Piece Required’.

Job settings will be retained by the system

disconnected

on page 5-18.

until they are changed or deleted as described

even with power

Adjustment of OMR Scanner (for first-time use or if a change in OMR has been made)

In order for the OMR scanning to function correctly, it is important to ensure that the scanning heads are positioned in line with the scan dash marks printed on the material.

In order to locate the scanning head for the top sheet feeder 1, open the top cover. The scanning head can be found at the rear of the machine.

In order to locate the scanning head for the bottom sheet feeder 2, remove both sheet feeder 2 and the fold plate situated below sheet feeder 2. The scanning head can be found mounted to the front of the machine.

Top Sheet Feeder Scanner

Bottom Sheet Feeder Scanner

5-14

Create OMR Job

Fold a sheet of material in half and measure the distance from the side of the form to the middle (for an 8-1/2” x 11” form, this measurement is 4-1/4”).

Now measure the distance from the edge of the form to the middle of the scan dash marks (see figure on next page), and subtract this measurement from the half fold measurement. Use the table (also on the next page) to convert this measurement into the setting for the scanning head.

For example, on an 8-1/2” x 11” form, the half fold measurement is 4-1/4”. If the distance from the edge of the form to the middle of the scan dash marks is 3/8”, the scanning head distance is 3-7/8” (4-1/4 – 3/8). For 3-7/8”, this translates to a setting of 98 on the scan head.

Loosen the knurled locking knob and set the appropriate scanning head to the correct setting. If the machine is turned on, you will notice a blue color emanating from the scanner. For the top scanner, the blue light shines on top of the paper; while on the bottom scanner, the light shines from beneath the paper. This is normal and will help you determine the correct position of the scanner.

Ruler for Setting Scanner Position

Scanner Head Locking Knob

When finished, retighten the locking knob.

If you have adjusted the bottom sheet feeder scanner, refit both sheet feeder 2 and the fold plate situated below sheet feeder 2.

5-15

Create OMR Job

Example of Measuring Distance of OMR Marks on 8-1/2” x 11” Paper for Proper Setting of Scan Head

Top Scanning

3/8”

10mm

3-7/8”

105mm

4-1/4”

Distance between center of OMR marks and center of page (in inches)

3-1/2" 89 3-5/8" 92 3-3/4" 95 3-7/8" 98

4" 102

5-16

Bottom Scanning

3-7/8”

Scanner Head Setting

10mm

3/8”

Create OMR Job

Loading the Material

Material for all OMR jobs are loaded in reverse order to which they are printed. This allows the address page for the document set to be the last page fed but the first page showing on top of the set after it has been collated and folded. See the table below.

Fold Type Order of Pages When

Presented to Feeder

C-Fold Reverse

(address page is last page printed and last page fed for each document set)

Double Fold Reverse Sheet Feeder 1- upper

Z-Fold Reverse Sheet Feeder 2 - lower

Single Fold (Half Fold)

Reverse Sheet Feeder 2 - lower

Loading of Documents on to System

Sheet Feeder 1 - upper (face up, head first )

(face up, head first )

(face down, feet first )

When preparing material for use in the lower feeder (for OMR jobs using a single fold or Z-fold), it is suggested that you place the sheets from the printer face down on a table and then take from the top of this inverted stack to load the machine. When the OMR feeder becomes empty in mid-job, you can just take another batch from the top of the stack, put it into the feeder and press Start, even if the last set is incomplete because part of it is in the stack rather than in the machine.

If you load from a face-up stack, the machine will not run unless the stack is split at exactly a set boundary. Also if sequence checking is active and the feeder becomes empty, you cannot just re-load and press Start because the machine will likely fail due to sequence error. Neither of these problems occurs if you load the machine from a face-down stack.

5-17

Create OMR Job

Testing the Job

Load material and press Trial Piece so that you can check that the setup is correct.

Minor changes to the job settings can be made at this stage if the trial piece needs ‘fine tuning’. Press Setup, then use the Prev ( required to modify job settings. A chart is provided below to help ‘fine tune’ your fold settings.

FOLD TYPE ADDRESS TOO LOW ADDRESS TOO HIGH

“C” - Letter Fold Decrease Fold A Increase Fold A and

“Z” - Accordion Increase Fold A Decrease Fold A and

Fold increase Fold B

Single Fold Increase Fold A Decrease Fold A

), Next ( ) and Change (+/-) buttons as

increase Fold B by the same amount

by the same amount

Double Fold Decrease Fold A Increase Fold A

5-18

Create OMR Job

Changing an existing job

To change an existing job, follow the steps below:

1. Enter the setup mode as described on page 5-1.

2. Use the Change (+/-) buttons to display the job you wish

to edit.

3. Use the Prev (

setting(s) you wish to change.

4. Use the Change (+/-) buttons to change the options/

dimensions you wish to amend.

5. Press the Setup button to leave setup mode and save

the changes.

) and Next ( ) buttons to display the

Deleting a job

To erase an existing job from memory, follow the steps below:

1. Enter the setup mode as described on page 5-1.

2. Use the Change (+/-) buttons to display the job you wish

to delete.

3. Press the Delete button. The display reads “Press again to confirm”. Press Delete again. The display will briefly read ‘Deleting Job’ as the job is erased.

4. Press the Setup button to leave setup mode.

5-19

Create OMR Job

5-20

Reference

6. REFERENCE

Changing the Display Language

To change the language of the display…

1. Enter the setup mode as described on page 3-1 or 5-1.

2. Use the Change (+/-) buttons to select the access code

99.

3. Press Next (

4. Use the Change (+/-) buttons to scroll through the languages. When your required language is displayed, press the Setup button to select the language and leave setup mode

) to select the languages option.

Clearing Material

Note: All the following illustrations show the three-station

machine, although all models are similar.

The inserter has been designed to assure maximum performance. In the event of a material stoppage, the display will flash the symbol indicating where the stoppage has occurred. First press Clear Deck to attempt to feed the material through the machine. If not successful, the sections below tell you how to remove the trays and plates to gain access to the material.

The Hand Crank

Having located the material, you may need to use the hand crank to manually feed paper out of the grip of rollers etc.

6-1

Reference

The hand crank is located behind the drop down cover at the left front of the machine.

Removal & Replacement of the Sheet Feeder and Envelope Trays

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 Fold Plates

To remove…

Pull the two catches on the underside of the plate outwards to release them. Pull the plate straight out from the machine.

To replace…

Pull the two catches on the underside of the plate outwards to release them. Slide the plate into its location guides and release the catches to lock the plate in position.

6-2

Removal & Replacement of the Insert Tray

To remove…

Open the top cover. 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.

Access to Carriage Assembly

The carriage assembly can be pulled outwards to gain access. The insert feeder and Fold Plate 2 must be removed first.

Reference

Access to Envelope Feeder Area

To gain access…

Pull the release lever in the direction of the arrow.

Lift the envelope area feed rollers to gain access.

To relatch feed rollers…

Release the envelope area feed rollers and let them rest in position.

Push the rollers firmly down until they latch into position.

Note: Access to this area can be improved by removing Fold Plate

1 and sheet feeder 2.

6-3

Reference

Access to the Envelope Exit Area

Pull down the access door as shown to gain access to jammed material.

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

Access to the Envelope Inserting Area

Access can also be gained to the insertion area by lifting the tinted plastic cover.

Access to the Sheet Feed Area

To gain access…

Open the top cover.

Squeeze the two blue handles together and pivot the guide assembly to the right to gain access.

To relatch…

Squeeze the two blue handles together and pivot the guide assembly back to its closed position. Release the two blue handles making sure the assembly is securely latched into position.

Close the top cover.

6-4

Reference

Troubleshooting

SYMPTOM POSSIBLE REMEDY PAGE

CAUSE REF.

MACHINE

Blank Screen No Display

Machine will not operate

ENVELOPES

Envelopes fail to feed

a) No Power

b) Machine not

switched on

a) Cover open

b) Feed trays/fold

trays not in correctly

a) Envelope side

guides too tight

a) Check power cord is

firmly connected at each end, and the wall socket is switched ON.

b) Switch machine on.

Switch located on left side of machine.

a) Check that all covers

are closed - check display for cover location.

b) Remove and relocate

all feeder and fold trays firmly.

a) Adjust width of

envelope side guides. Adjust the side guides up to envelopes then back-off setting knob half a turn.

2-1

6-2

2-5

b) Poor envelope

quality

b) Check envelopes are

not curled. If excessive try a new batch/box. Make sure the

6-5

2-5

Reference

SYMPTOM POSSIBLE REMEDY PAGE

CAUSE REF.

ENVELOPES

(Continued)

envelopes have been fanned and aerated before loading.

Envelopes fail to feed (cont.)

More than one envelope feeds

c) Envelope guides

too loose

d) Wedge set

incorrectly

e) Envelopes

incorrectly loaded.

a) Poor envelope

quality

b) Envelopes

incorrectly loaded.

c) Adjust width of

envelope side guides. Adjust the side guides up to envelopes then back-off setting knob half a turn.

d) Position wedge to

support envelope stack.

e) The lead edge of the

first envelope should be under the front feed rollers.

a) Check envelopes are

not curled, if excessive try a new box/batch. Make sure the envelopes have been fanned and aerated before loading.

b) The lead edge of the

first envelope should be under the front feed rollers.

2-5

Envelope failed to open

a) Envelopes

incorrectly loaded

a) Load envelopes on feed

deck with flaps up and trailing.

6-6

2-5

Reference

SYMPTOM POSSIBLE REMEDY PAGE

CAUSE REF.

ENVELOPES

(Continued)

Make sure the envelopes are loaded in feeder squarely.

Envelope failed to open (continued)

Envelopes not sealing

b) Poor envelope

c) Envelope feed

a) No water

b) Seal mode not

SHEET FEEDER

Sheets fail to feed

a) Feeder not

quality

unit not latched down correctly

selected

selected to feed

b) Check envelopes are

not stuck due to being damp. If excessive try a new batch/box.

c) Check envelope jam

access area, is latched down firmly, located at the envelope feeding area.

a) Remove water bottle

and fill up to indicated level, replace bottle. Bottle is located on right side of machine at rear.

b) Check job set up.

Activate seal mode.

a) Check job set up

2-5

6-3

2-8

5-7,

5-9

b) Side guides too

tight

b) Adjust width of material

side guides. Adjust the side guides up to material then back-off setting knob a quarter turn.

6-7

2-3

Reference

SYMPTOM POSSIBLE REMEDY PAGE

CAUSE REF.

SHEET FEEDER

(Continued)

c) Paper not

More than one sheet is fed

a) Daily mail

b) Paper not

INSERT FEEDER

Inserts fail to feed

a) Insert guides

b) Feeder not

loaded correctly

(manual feed mode) is selected

loaded correctly

too tight

selected to feed

c) Aerate the stack of

paper, making sure that individual sheets are not stuck together.

a) Check job set up and

manual feed lever.

b) Aerate the stack of

paper, making sure that they are not stuck together.

a) Adjust width of

material side guides. Adjust the side guides up to material then back-off setting knob a quarter turn.

b) Check job set up.

2-3

2-2

2-3

2-6

5-7,

5-9

c) Poor

separation

d) Side guides

too loose

e) Wedge set

incorrectly

c) Check Lever setting is

correct. Check stone shield is in correct position.

d) Adjust side guides.

e) Rest wedge behind

material to support it.

6-8

5-9

2-4

2-5

Reference

SYMPTOM POSSIBLE REMEDY PAGE

CAUSE REF.

INSERT FEEDER

(Continued)

More than one insert is fed

Failure to insert

a) Poor separation

a) Wrong envelope

b) Side guides set

c) Poor fold

d) Poor quality

envelope

a) Check Lever setting is

correct. Check stone shield is in correct position. Reduce lever setting by 1.

a) Check that you are

using the correct envelope for the job selected. If problems still occur change envelope stop position.

b) Check ALL feeder side

guides, are not set too wide.

c) Check the fold selected,

in job set up is the correct one for the material length you are using.

d) Check window of

envelopes are not stuck down due to excessive glue. Try a new batch/ box.

2-6

5-12

2-3 to

2-8

5-6

6-9

Reference

SYMPTOM POSSIBLE REMEDY PAGE

CAUSE REF.

Error Recovery for Empty Feeders

If feeder runs out of material and stops

a) Ran out of

material

a) Press Stop (and then

Clear Deck if material is in transit), re-fill empty tray, and press Start to continue.

Error Recovery for Normal Job (non-OMR)

If the machine stops during an accumulation of a job (nonOMR)

a) Too many

sheets or a jam

a) Press the Clear Deck key.

The envelope at the insertion area will eject into the stacker. MANUALLY remove the remaining pages of the set from the appropriate feeder and fold/insert into the envelope. Once the cause of the stoppage has been determined, press

Start to continue.

Error Recovery for OMR Job

If the machine stops during an OMR Job

a) OMR Error

message (as listed on page 6-15)

a) Press the Clear Deck key.

The envelope at the insertion area will eject into the stacker. The remaining pages of the current set will feed/fold and eject into the stacker, and can be manually inserted into the envelope. The FIRST page of the NEXT set will prefeed into the feed rollers and stop. Press Start to continue.

1-7

6-10

Reference

Error Messages - Paper Handling

MESSAGE ACTION

CALL SERVICE Power machine off and on. If

message is still displayed Call service.

CHECK /CLEAR FEEDER Feeder indicated has failed to

feed material. Remove material from the feed tray, reload and restart machine.

CHECK FEEDER Feeder indicated is not located

correctly. Remove tray and relocate.

CHECK FOLD PLATE Fold plate indicated is not

located correctly. Remove Fold Plate and relocate.

CHECK INVERTER Envelope inverter unit has not

set to it’s correct position. Open inverter cover and check for any material. Close cover and restart.

CHECK LAST MAIL PIECE Envelope has failed to open.

Check envelopes are loaded correctly. Reload envelopes and restart machine.

CLEAR FOLD PLATE Material has been detected

inside the Fold Plate indicated on the display. Remove Fold Plate and check for any material. Replace Fold Plate.

CLEAR INSERTION AREA Material has been detected in

the inserting area. Open tinted plastic cover on right hand side of machine and remove any material. Close cover and restart.

6-11

Reference

MESSAGE ACTION

CLEAR MOISTENER Material has been detected in

the sealer brush area. Open tinted plastic cover on right hand side of machine and remove any material. Close cover and restart.

CLEAR SEALER Material has been detected in

the sealer brush area. Open tinted plastic cover on right hand side of machine and remove any material. Close cover and restart.

CLOSE COVER Cover indicated is not fully

closed. Close indicated cover and restart.

CLOSE HAND CRANK The hand crank door not fully DOOR closed. Close cover located at

front left of machine.

DEFLECTOR ERROR The function of half fold is not

possible due to a fault. Remove Fold Plates and check for any material.

DOUBLE FEED A double feed has been

detected being fed from the feed tray indicated. Remove the material from the machine and restart. If double feeds persist, request another trial piece.

DOUBLE FEED CHECK A double feed has been STACKER detected being fed from the

feed tray indicated. Remove the double feed from the stacker. Restart machine.

6-12

Pitney Bowes DI350 Operator Guide

Specifications and Main Features

Frequently Asked Questions

User Manual