Pitney Bowes DI400 Operator Guide
DI400 FastPac
Inserting System
Operator Guide
TM
SV40191-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
FastPac™ 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.
ii
Contents
ABOUT THIS GUIDE
This guide explains how to setup and use the DI400
FastPac™ 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
Safety ................................................................................ 1-6
Machine Identification ....................................................... 1-7
Control Panel .................................................................... 1-9
Control Panel Buttons ................................................. 1-9
Display Symbols ........................................................ 1-11
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
iv
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 DI400? ....................... 4-3
How are OMR Marks Generated?..................................... 4-4
What OMR Marks are Used on the DI400? ...................... 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
v
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
vi
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
Changing the Sealer Unit Felts ................................... 6-5
Troubleshooting ................................................................ 6-8
Error Messages ............................................................... 6-14
Paper Handling.......................................................... 6-14
OMR Errors ............................................................... 6-18
Material Specifications .................................................... 6-20
Sheet Feeders ........................................................... 6-20
Insert Feeder ............................................................. 6-20
Sealer ........................................................................ 6-21
Stacker ...................................................................... 6-21
Envelope Feeder ....................................................... 6-21
Material Requirements .............................................. 6-22
OMR Specifications (General) ........................................ 6-22
Machine Specifications ................................................... 6-23
Physical Dimensions: ................................................ 6-23
Noise Level................................................................ 6-23
Electrical/BTU Rating ................................................ 6-23
Speed ........................................................................ 6-23
Fold Modes................................................................ 6-23
Compliance ............................................................... 6-23
Usage ........................................................................ 6-24
Machine Life .............................................................. 6-24
Service ............................................................................ 6-24
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 DI400 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)
• Switchable feeding
• Optical Mark Recognition (OMR) scanning for greater collation
integrity and additional feeding flexibility
The DI400 Inserting System is a three-station machine, so
named because it incorporates two sheet feeders and an
insert feeder.
Sheet
Feeder 1
Sheet
Feeder 2
1-1
Insert Feeder
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.
1-2
Machine Identification
Introduction
12
2
1 6
11
3
5
9
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.
8
13
4
10
7
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 automatic-
ally. 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.
1-3
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.
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
1-4
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
Introduction
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. See Chapters 3 or 5 for details on
programming jobs.
1-5
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
Next
through the various machine settings.
1-6
Display Symbols
Introduction
. . 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.
1-7
Introduction
1-8
Operation
2. OPERATION
This section explains operation of the DI400 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 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
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 Features At A Glance
The DI400 has the ability to be programmed by the operator
with up to 20 jobs which can be recalled at the touch of a
button. The table below shows the other functions and settings
that are available.
Function
Sheet Feeder 1 On (with double detect), On (without double detect), Off, or
Insert Feeder On (with double detect), On (without double detect), Off,
Sheet Feeder 2 On (with double detect), On (without double detect), Off,
Accumul Mode Off or On (with 2, 3,4, or 5 pages)
OMR Mode Off, On, OMR + Sequence, OMR + Select Feed and Se-
Mode Insertion Mode, Fold Only Mode
Number of Jobs Up to 20; each job can be programmed by the operator
Fold Type C - Letter, Z - Accordion, Double or Single
Paper Length any within machine specification limits
Fold A any within machine/fold specification limits
Fold B any within machine/fold specification limits
Envelope Depth any within machine specification limits
Envelope Stop 1 to 5
Batch Mode Off or On (from 50 to 99)
Possible Settings
Manual Feed, Select Feed (with double detect), or Select
Feed (without double detect)
Select Feed (with double detect), or Select Feed (without
double detect)
Select Feed (with double detect), or Select Feed (without
double detect)
quence, OMR + Select Feed
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
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
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