This equipment has been tested and found to comply with the limits for a Class A
digital device, pursuant to part 15 of the FCC rules. These limits are designed to
provide reasonable protection against interference when the equipment is operated
in a commercial environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the instruction
manual, may cause interference to radio communications. Operation of this equipment in a residential area is likely to cause interference, in which case the user will
be required to correct the interference at his own expense.
CAUTION: Changes or modifications to this equipment not expressly approved by
the party responsible for compliance (Pitney Bowes) could void the user’s authority
to operate the equipment.
Canada
This class A digital apparatus complies with Canadian ICES-003.
Cet appareil numérique de la classe A est conforme á la norme NMB-003 du
Canada.
All rights reserved. This book may not be reproduced in whole or in part in any fashion
or stored in a retrieval system of any type or transmitted by any means, electronically or mechanically, without the express, written permission of Pitney Bowes. We
have made every reasonable effort to ensure the accuracy and usefulness of this
manual; however, we cannot assume responsibility for errors or omissions or liability
for the misuse or misapplication of our products.
Due to our continuing program of product improvement, equipment and material
specifications as well as performance features are subject to change without notice. OfficeRight and E-Z Seal are trademarks or registered trademarks of Pitney
Bowes.
Table of Contents
If You Need Assistance
Contact Information for the USA and Canada ......................iii
Customer Job Programming Record .................................5-1
Appendix A
Glossary of Terms ............................................................. A-1
Index
Index to the Operator Guide ....................................... Index-1
ii SV61656 Rev. A
Pitney Bowes Contact List
Table of Contents
If You Need Assistance
USA Contacts
▪ Product Name - OfficeRight™ Document Inserting System
▪ Model - DI380
▪ For frequently asked questions, go to:
www.pb.com and click on Customer Support.
▪ To place requests for service or training, go to:
www.pb.com and click on My Account.
▪ To order PB supplies and accessories, go to:
www.pb.com and click on Online Store.
▪ To view and pay invoices online, go to:
www.pb.com and click on My Account.
▪ To view inventory, go to:
www.pb.com and click on My Account.
▪ For direct questions, call: 1.800.522.0020. Customer Service
Representatives are available Monday through Friday, 8:00 AM
to 8:00 PM ET.
Canada Contacts
▪ Product Name - OfficeRight™ Document Inserting System
▪ Model - DI380
▪ For frequently asked questions or to order supplies, go to:
www.pitneybowes.ca
▪ For direct questions, call: 1.800.672.6937. Customer Service
Representatives are available Monday through Friday, 8:30 AM
to 4:00 PM ET.
iiiSV61656 Rev. A
Table of Contents
ivSV61656 Rev. A
Introduction • 1
Safety Notes
Follow these precautions whenever you use your inserting system:
• Read all instructions before you attempt to operate the system.
Keep the Operator Guide accessible for quick reference.
• Use this equipment only for its intended purpose.
• Place the system close to an easily accessible wall outlet.
• Place the system in an accessible location to allow for proper
venting of the equipment and to facilitate servicing.
• Use the power cord supplied with the machine and plug it into a
properly grounded wall outlet that is 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 the AC supply.
• DO NOT use a wall outlet controlled by a wall switch or one that
is shared with other equipment.
• DO NOT use an adapter plug on the line cord or wall outlet.
• DO NOT remove the ground pin from the line cord.
• Make sure the area in front of the wall outlet into which the machine is plugged is free from obstruction.
• DO NOT route the power cord over sharp edges or trap it between pieces of furniture. Make sure there is no strain on the
power cord.
• To reduce the risk of fire or electrical shock, DO NOT attempt
to remove covers or disassemble the control panel or its base.
The cabinet encloses hazardous parts. If you should damage
the unit, contact Your system supplier. Refer to the Contact Information List at the front of this guide for more information.
• If the unit becomes damaged, unplug it from the wall, then contact Your system supplier. Refer to the Contact Information List at
the front of this guide for more information.
• Keep fingers, long hair, jewelry and loose clothing away from
moving parts at all times.
• Avoid touching moving parts or materials while the machine is in
use. Before clearing a jam, be sure machine mechanisms come
to a complete stop.
• Remove jammed material gently and carefully.
1-1SV61656 Rev. A
1 • Introduction
Safety Notes (Continued)
• Do not place lighted candles, cigarettes, cigars, etc., on the system.
• To prevent overheating, do not cover vent openings.
• Use only approved supplies, in particular aerosol duster.
Improper storage and use of aerosol dusters or flammable aerosol dusters, can cause an explosive-like condition that could
result in a personal injury and/or property damage. Never use
aerosol dusters labeled flammable and always read instructions
and safety precautions on the duster container label.
• To obtain supplies and/or Material Safety Data Sheets, contact
your system supplier. Refer to the Contact Information List at the
front of this guide for more information.
• Operation of this equipment without periodic maintenance will
inhibit optimum operating performance and could cause the
equipment to malfunction. Contact your system supplier for the
required service schedule.
• Always follow specific occupational safety and health standards
for your workplace.
• To reduce the risk of fire or electrical shock, DO NOT attempt
to remove covers or disassemble the control panel or its base.
The cabinet encloses hazardous parts. If you should damage
the unit, contact your system supplier. Refer to the Contact Information List at the front of this guide for more information.
If your stacker has an AC adapter to power the stacker:
• Use only the AC adapter designed specifically for the stacker.
Third-party AC adapters may damage the stacker.
• To protect against electrical shock, plug the AC adapter power
cord into a properly grounded wall outlet.
• Do not route the AC adapter cable over sharp edges or trap it
between furniture.
1-2 SV61656 Rev. A
Introduction • 1
To the Operator
Your new folding/inserting machine has an easy-to-follow user interface which makes it simple to set up, while offering the following
advanced features:
• Envelope seal/no seal option
• Fully automatic material separation on sheet feeders
• Fully automatic settings on fold plates
• Fully automatic envelope separation
• Fully automatic double document detection when selected
• Fold-only option (fold without insertion)
• Manually fed, semi-automatic insertion of single and multiple
sheet collations
• Option of single fold, letter (C-fold), accordion (Z-fold) or
double fold
• Job recall facility
• Linked feeding (three-station machines only)
• Optical Mark Recognition (OMR) scanning (some models)
Machine Configurations
The following machine configurations are available:
• 1 Station – One sheet feeder only
• 2 Station – One sheet feeder and an insert feeder
• 3 Station – Two sheet feeders and an insert feeder
IMPORTANT: Machine configurations may vary. Some features
and options may not be available. This operator guide covers all
models and features. However, inclusion in this guide does not
guarantee the availability of a particular model, feature or option.
1-3SV61656 Rev. A
1 • Introduction
Processing speed will vary, depending on machine configuration.
See Specifications in Chapter 4 for further details.
Some models are equipped with OMR (Optical Mark Recognition)
scanning.
An OMR mark is normally a dark solid line on a sheet of light colored
paper that is perpendicular to the direction of paper travel. This line
must be thick and dense enough to trigger the system’s OMR scanner.
The scanner, working with the OMR system software, checks for one
or more different OMR marks on a document as it feeds through the
system. Tracking of these marks enhances mail piece integrity by
assuring that documents that belong together (a set) stay together
throughout the inserting process.
OMR-equipped models have scanning heads located on each of the
sheet feeders.
Instructions for using OMR functions appear in Chapter 3 of this
guide.
Top Sheet
Feeder Scanner
Bottom Sheet
Feeder Scanner
1-4 SV61656 Rev. A
Machine Identification
1
2
Introduction • 1
36
5
9
8
11
4
Sheet Feeder 1 — This feeder is intended for feeding material
1
that requires folding.
In addition, you can set sheet feeder 1 to Manual Feed. In this
mode, you can run stapled sets of up to five sheets. 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 this guide for full details of the sets
possible.
Sheet Feeder 2 — For feeding material that requires folding.
2
Its functions are similar to sheet feeder 1, but manual feed is
NOT available from this feeder.
10
12
7
1-5SV61656 Rev. A
1 • Introduction
Machine Identification (Continued)
36
5
9
10
12
8
7
11
4
1-6 SV61656 Rev. A
Introduction • 1
Insert Feeder — Use this feeder to add additional inserts to
3
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 Plates 1 and 2 — These create the desired fold in
material fed from the sheet feeder(s). The fold plates are auto-
5
matically set from the control panel.
Display/Control Panel — This is where you enter commands
6
and where the machine informs you of its status with the use
of symbols and icons. Each button function is explained on the
following page.
Drop Stacker or Output Device (not illustrated)
7
A fold down stacker is located at the exit from the machine
to collect the finished mail pieces. This unit can be latched
against the machine when not in use. Alternatively, a range of
power stackers are available which offer greater capacity than
the standard drop stacker.
A mailing machine interface can be installed in place of a
stacker. This device automatically transports mail pieces to a
Pitney Bowes mailing machine for postage imprinting.
8
Manual Advance Knob —The manual advance knob is locat-
ed inside an opening cover at the lower center of the machine.
Use it to turn the machine mechanisms by hand to help clear a
material stoppage.
Envelope Feeder — This feeder feeds envelopes into the
9
inserting area where they are filled with material requested
from the other feeder(s).
Sealer Bottle — The sealer bottle is located inside an opening
10
cover at the front right side of the machine. It provides sealing
solution to the envelope sealer.
11
Measuring Scale — The scale is located on the left side
of the machine near the sheet feeders. Use it as an aid in
measuring material and envelopes.
12
Envelope Inverter — This unit transports the envelope into
the stacker face up.
1-7SV61656 Rev. A
1 • Introduction
Control Panel
Control Panel Buttons
Default — Press this button to return the machine to its default or
‘standard’ settings. These settings come pre-configured from the
factory but can be modified to suit your needs by a Pitney Bowes
Service Representative.
Job — Press to step through the jobs you’ve programmed into the
machine’s memory. The machine will store up to 20 jobs. See page
2-9 for details of programming jobs.
Reset Counter — Press to reset the item or batch counter.
Clear Deck — Press to jog material through and out of the system.
Use clear deck to clear the machine and make it ready for automatic
operation after a stoppage has occurred.
Trial Piece — Press to run a single test piece so that you can
check machine setup. You MUST run a trial piece before you begin
automatic operation by pressing the Start button. If you’re using
double detection, 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 — Use in setup mode to delete a programmed job from
memory.
Setup — Press to enter the machine setup mode. This mode allows
you to program jobs into memory for instant recall using the Job
button.
Change + – In setup mode, press + or - to select options or set
values of machine settings.
Prev. ◄ ► Next — In setup mode, use these keys to step backward
or forward through the various job settings.
1-8 SV61656 Rev. A
Display Symbols
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.
Introduction • 1
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 bottle needs refilling.
Indicates the envelope depth.
Indicates that the sealer unit is off (envelopes not
sealed).
1-9SV61656 Rev. A
1 • Introduction
!"#
Display Symbols (Continued)
Indicates that the sealer unit is on (automatic envelope sealing).
Indicates a C-fold (letter) fold is selected.
Indicates a Z-fold (accordion) 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.
Call for service.
Indicates the paper size, address orientation and
fold(s) set for sheet feeder.
Indicates a material stoppage in a downstream device, such as a power stacker or mailing machine
Interface (MMI).
1-10 SV61656 Rev. A
Operation • 2
About this Chapter
This chapter explains operation of the machine, assuming the job
you want to run is already programmed into the system.
If you haven’t programmed the job, please go to Programming Jobs
on page 2-9.
Connecting Power
IMPORTANT! Read the safety information on
pages 1-1 and 1-2 of this guide before you
connect the machine.
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 power switch ON.
2-1SV61656 Rev. A
2 • Operation
Select a Job
When the machine is turned ON,
the display shows 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 job
settings.
Note: Only a Pitney Bowes Service Representative can modify the
default job.
If you have material loaded, press
Trial Piece. The machine sets
itself and runs a test piece for you
to check.
If you don’t have material loaded,
do this now, then return to this
section. Loading feeders and related instructions are covered on pages 2-4 to 2-7.
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, DO NOT load
the sheet feeder; you will feed collated sets one at a time by hand as
required by the machine.
For manual feed jobs, pull back
the lever as shown in the illustration, right. This opens the feed
mechanism, making it ready for
manual feed operation.
Remember to return this lever to
its normal position when you use
the feeder for automatic operation.
2-2 SV61656 Rev. A
Operation • 2
Run a Trial Piece
Once material is in place, press Trial Piece so you can check that
setup is correct.
You can make minor changes to the job settings at this stage if the
trial piece needs fine tuning. Enter setup as described on page
2-9, then use the Prev (◄), Next (►) and Change (+/-) buttons as
required to modify job settings. When you’ve made the necessary
changes, press Setup again to return to run mode. The inserter
saves the job with the new settings.
Notes:
1. When using linked feeding,* load both sheet feeders before running a trial piece.
2. If you load material during a run which seems to have different
characteristics (weight, color shade, etc.), or if you have any
problems with double detection, run another trial piece. This
forces the machine to recalibrate the double detect function for
the new material in case the batches vary slightly.
Start Machine Operation
Press Start to begin automatic operation.
The machine runs until either material runs out or you press the
Stop button.
Note: If the machine is set for linked feeding, the display shows: 1 > 2 > 1
This confirms that feeding will automatically switch between
sheet feeders. See page 2-13 for more details.
* “Linking” is a method of using two feeders such that when one feeder
runs out of material, the next “linked” feeder automatically starts feeding.
Linking feeders allows you to process a higher volume of material before
reloading. Linked feeders are sometimes referred to as “cascading”
feeders.
2-3SV61656 Rev. A
2 • Operation
Setting the Sheet Feeders
1. Adjust the side guides to the
width of the material you’re
running, then back-off a
quarter turn on the side guide
control. This sets the correct clearance between the
guides and the material.
2. Take the stack of paper and
aerate it to ensure that individual sheets are not stuck
together.
3. Jog the stack back into alignment. The sheet feeders accept the paper stack aligned
in a manner similar to that
of a photocopier paper cassette.
4. The display shows the correct orientation of the paper.
FACE UP
HEAD FIRST
2-4 SV61656 Rev. A
ABC
ABC
FACE DOWN
FEET FIRST
Operation • 2
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
for an accordion fold job, always
use sheet feeder 2 for the prime (address-bearing) document.
2-5SV61656 Rev. A
2 • Operation
Setting the Envelope Feeder
The envelope feeder feeds the outer envelope for the inserting job
you’re running.
1. Adjust the side guides to the
width of the envelopes you’re
running, then back off half a
turn on the side guide control.
This sets the correct clearance between the guides and
the envelopes.
2. Aerate (fan) the stack of envelopes you’re running.
3. Place envelopes on the feed
deck with their flaps up and
trailing.
IMPORTANT ! Check that
lead edge of the first envelope is under the front feed
roller and that the stack of
envelopes is shingled on the
deck as shown.
Let the wedge slide down
behind the stack so that the
envelopes are supported.
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 sets the correct clearance between the
guides and the material.
2-6 SV61656 Rev. A
Operation • 2
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.
4. Set the separator shield to
the letter required.
5. Fan the inserts and place
them onto the feed deck.
Loading orientation can vary
depending on the actual
inserts you’re running. For
many applications we suggest the following:
• Slip — Face up, bottom edge first
• Reply Envelope — Face up, top edge first
• Pre-Folded — Face up, closed edge first
• Booklet — Face up,
bound edge first
Let the wedge slide down
behind the stack so that the
inserts are supported.
2-7SV61656 Rev. A
2 • Operation
Filling the Sealer
When the sealer unit needs refilling, the Add Sealing
Solution symbol flashes in the display.
Add E-Z Seal® or water in the following way:
Note: We recommend E-Z Seal® to minimize scale buildupand the growth of algae.
Hinge open the sealer bottle cover located at the rear right hand
side of the machine. Remove the
bottle.
Fill the bottle up to the level indicated.
Put the sealer bottle back in position and close the cover.
Note: If the sealer unit has emptied completely, allow enough time
for the solution to soak through the sealer mechanism. This
helps assure good seals.
Adjusting the Stacker
Adjust the drop stacker to suit the
material you’re running.
Lift the lever at the rear of the
stacker and adjust the stacker
to one of the preset positions.
Lower the lever to lock the stacker into position.
When not in use, you can raise
and latch the stacker vertically against the exit area of the machine
as shown in the photo above.
2-8 SV61656 Rev. A
Operation • 2
Programming Jobs
You can program your machine with jobs that you can recall at the
touch of a button.
All models have 20 operator-programmable jobs plus one default job
that your Pitney Bowes Service Representative normally sets.
Creating a New Job
This section takes you step-by-step through the process of setting
up a new job and saving it in memory.
Throughout the programming sequence, an asterisk (*) will flash on
the display next to the item you’re setting. Use the Prev (◄) and
Next (►) buttons to step forward or backward through the available
settings. Once an option displays, use the Change (+/-) buttons to
select the option or value you want.
Note: Your machine may be equipped with OMR (Optical Mark
Recognition) scanning, depending on the model you pur-
chased. To program an OMR job, go to page 3-10 of this
guide. To program a non-OMR job, continue by entering the
Setup Mode…
Entering the Setup Mode
Open the hinged cover to the
right of the display. This exposes
the setup buttons.
Press Setup. The indicator lights
and the machine asks for an access code. This code prevents
the machine’s settings being
changed by unauthorized personnel.
Use the Change (+/-) buttons to
select the access code 71.
Press Next (►) to advance to the
next setting…
2-9SV61656 Rev. A
2 • Operation
Choosing the New Job Number
The machine asks for the job
number you wish the new settings
to be stored under.
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 number is currently unused.
Press Next (►) to advance to the next setting…
OMR
On models equipped with OMR ONLY, the machine will ask you to
select the OMR mode. For a non-OMR job, use Change (+/-) to select OMR off (if you wish to program an OMR job, see page 3-10).
Press Next (►) to advance to the next setting…
2-10 SV61656 Rev. A
Operation • 2
Fold Type
Select the type of fold. See the
illustrations below.
Press Change (+/-) until you see
the option you want:
C (Letter) Z (Accordion) Double Single
Note: For accumulation jobs, DO NOT manually change the
fold length dimensions at the “Fold A” and “Fold B” settings
(pages 2-17 and 2-18). The machine sets these automati
cally.
When you’ve selected the fold type, the display shows the correct
orientation for loading paper into the feeders:
FACE UP
HEAD FIRST
ABC
ABC
FACE DOWN
FEET FIRST
When you’ve set the fold type as required, press Next (►) to advance to the next setting…
2-11SV61656 Rev. A
2 • Operation
Setting the Accumulation Function
Accumulation, if selected, allows
multiple sheets to be fed from the
same feeder into the envelope.
Press Change (+/-) until you see
the option you want.
Accumulation: OFF
Accumulation is turned off for this job.
1- and 2-station machines...
Accumulation: ON
Accumulation is turned on for this job.
3-station machines...
Accumulation From Main
Accumulation is turned on with sheets feeding from the main
feeder. This feeder normally contains the address sheet.
Accumulation From Suppl
Accumulation is turned on with sheets feeding from the
Supplementary feeder (that is, one address sheet from the
main feeder followed by multiple sheets from the supplementary feeder.
Press Next (►) to advance to the next setting…
Accumulation = (2 to 10)
Select how many pages you want to feed into each envelope
using Change (+/-).
Important:The number of sheets the machine can accumulate is limited by machine specifications. Exceeding this
limit can cause the machine to malfunction. See
page 4-14 for details.
2-12 SV61656 Rev. A
Operation • 2
Setting the First/Main Sheet Feeder
The machine automatically selects the first feeder to set, depending
on the fold type selected.
Note: If you’re collating different sheets using both sheet feeders,
you must load the prime (addressed) document into sheet
feeder 1 for C and Double folds, and into sheet feeder 2
for Z- or single folds. If you’re using a single sheet only, you
may use either sheet feeder or you can use both by choos
ing the linked feeder option described below.
Press Change (+/-) until you see
the option you want:
On Double Detect
Feeder on with the
double detector operating. (The double detector stops the machine if two or more
sheets feed simultaneously from the feeder).
Off
Feeder turned off for this job.
On
Feeder on without the double detector.
Manual Feed
Allows you to manually feed collated sets (only available on
sheet feeder 1; also see notes on following page).
Linked: On
Linked: On Double Detect
These functions are available only on the three-station ma-
chine. Feed will initially be from the first sheet feeder. When
the feeder is empty, the machine automatically switches to
feeding from the second sheet feeder.
Load both feeders before running a trial piece. This is neces-
sary because each feeder will feed a trial piece.
continued...
2-13SV61656 Rev. A
2 • Operation
Notes about manual feed:
1. The manual feed setting allows you to run stapled sets of up
to five sheets to a maximum of 100 lbs. (400g/m2 per set). The
maximum compressed thickness of the set after folding must
not exceed 0.08 inches (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.