Pitney Bowes DI800 Operator Guide

DI800 FastPac

Inserting System

™

SV40188-OG Rev. A

OPERATOR GUIDE

WARNING

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. It has been tested and found to comply with the limits for
a Class A computing device pursuant to Subpart B of Part 15 of
FCC Rules, which are designed to provide reasonable protection
against such interference when operated in a commercial envi­ronment. 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 take whatever measures are required
to correct this interference.

Trademark Notice

FastPac™ is a trademark 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.

FastPac™ Inserting System Contents

Chapter 1: Introduction................................... 1-1

In This Book .............................................................. 1-1

Introduction................................................................ 1-2

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

A Note to the Operator .............................................. 1-8

Material Specifications .............................................. 1-9

Chapter 2: The Base Unit ................................ 2-1

Overview.................................................................... 2-1

Controls and Indicators .............................................. 2-5

Setup and Adjustments ............................................ 2-19

Running Test Material ............................................. 2-38

Tips to Reduce Setup Time ...................................... 2-40

Clearing Material From the Base Unit.................... 2-41

Maintaining the Base Unit ....................................... 2-44

Chapter 3: The Single Feeder Modules ......... 3-1

Overview.................................................................... 3-1

Controls and Indicators .............................................. 3-7

Setup and Adjustments ............................................ 3-17

Running Test Material ............................................. 3-33

Tips to Reduce Setup Time ...................................... 3-34

Clearing Material From the Feeder.......................... 3-35

Maintaining the Feeder ............................................ 3-38

What is OMR? ......................................................... 3-40

ii

FastPac™ Inserting System — Contents

Chapter 4: The Folder...................................... 4-1

Overview.................................................................... 4-1

Controls and Indicators ............................................ 4-10

Setup and Adjustments ............................................ 4-16

Running Test Material ............................................. 4-25

Tips to Reduce Setup Time ...................................... 4-28

Clearing Material From the Folder ......................... 4-30

Maintaining the Folder ............................................ 4-32

Document Inverter Operation .................................. 4-33

Chapter 5: The Crossfolder ............................ 5-1

Overview.................................................................... 5-1

Controls and Indicators .............................................. 5-4

Setup and Adjustments ............................................ 5-11

Running Test Material ............................................. 5-32

Tips to Reduce Setup Time ...................................... 5-32

Clearing Material from the Crossfolder................... 5-34

Maintaining the Crossfolder .................................... 5-34

Chapter 6: The Burster Interface.................... 6-1

The Burster Interface ................................................. 6-1

Setup and Adjustments .............................................. 6-4

Chapter 7: Electronic Setup ........................... 7-1

Overview.................................................................... 7-1

Types of Operators ..................................................... 7-2

FastPac™ Inserting System — Contents

Control Panel ............................................................. 7-3

Job Numbers .............................................................. 7-4

Startup ........................................................................ 7-5

Operator Functions .................................................... 7-6

Review any of the job settings: ...................... 7-7

Selecting another job to run: ........................ 7-11

Running test material and starting a run: ..... 7-12

Clearing the Deck: ....................................... 7-13

Resetting the Job Count: .............................. 7-14

Resetting the Base Cumulative Count: ........ 7-14

Key Operator, Module Functions ............................. 7-15

Module Options: .......................................... 7-16

Language:..................................................... 7-24

iii

Speed:........................................................... 7-25

Key Operator, OMR Setup ....................................... 7-26

Flowchart for OMR Setup Screens .............. 7-28

OMR Present/Off ......................................... 7-29

OMR Present/EOC Only.............................. 7-31

OMR Present/Multi Line ............................. 7-40

Chapter 8: Troubleshooting ............................ 8-1

Mechanical Problems................................................. 8-1

Messages on the Screen ............................................. 8-6

iv

FastPac™ Inserting System — Contents

Appendix A: The Twin Feeder Modules ........ A-1

Overview................................................................... A-1

Controls and Indicators ............................................. A-7

Setup and Adjustments ........................................... A-17

Running Test Material ............................................ A-33

Tips to Reduce Setup Time ..................................... A-34

Clearing Material From the Feeder......................... A-35

Maintaining the Feeder ........................................... A-38

What is OMR? ........................................................ A-40

Is the Module Equipped with OMR? ...................... A-41

Key Operator, Module Functions ............................ A-44

Key Operator, OMR Setup...................................... A-49

Messages on the Screen .......................................... A-50

Index .................................................................. I-1

Chapter 1: Introduction

In This Book

This book contains information that explains the FastPac™ Insert­ing System DI800. There are several chapters in this book.

The chapter you are now reading, Chapter 1, contains:
❑ System Introduction—describes the FastPac™ Inserting

System DI800 and how the system can fill your mailing needs.

❑ Safety—outlines safety practices that you should follow.
❑ A Note to the Operator—a reminder to read this manual

before operating your FastPac™ Inserting System DI800.

❑ Material Specifications—a listing of the kinds of material

appropriate to use in the FastPac™ Inserting System DI800.

Chapters 2 — 4 and Appendix A describe the Base Unit, the
Single Sheet Feeder and Insert Feeder, the Folder, and the Twin Sheet
Feeder and Insert Feeder. Chapters 5 and 6 describe the optional
Crossfolder Module and the Burster Interface. These chapters contain:

❑ An introduction to the module—a discussion of the module

and how it fits in the FastPac™ Inserting System DI800.

❑ Controls and Indicators—illustrates the various parts of the

modules and explains their usage.

❑ Mechanical Setup and Adjustments—step-by-step proce-

dures on how to make the necessary mechanical setup and
adjustments to the modules to get the system up and running.

❑ Running Test Material—how to test settings and adjustments.
❑ Maintaining the Module

Chapter 7 covers the electronic setup for the FastPac™ Inserting
System DI800. This chapter discusses the use of the Main Control
Panel located on the Base Unit. These functions are separated into
two categories: those functions available to all operators and those
available only to a key operator.

Chapter 8 covers troubleshooting for the FastPac™ Inserting
System DI800. Included are error messages, their meaning, and
suggestions for correcting the problem.

1-2

Chapter 1: Introduction

Introduction

This manual is about the FastPac™ Inserting System DI800. The
FastPac™ Inserting System DI800 is a modular system, one ma­chine made up of a group of compact, versatile, building blocks.
These building blocks, or “modules” work together to create a
“collation” or “mailpiece.” A collation or mailpiece is simply a
group of papers that go into one envelope to be mailed to one
addressee. That means the FastPac™ Inserting System DI800 must
have modules to feed paper, fold paper, add extra inserts to the
collation, insert that accumulated collation into an envelope, and
seal the envelope.

A FastPac™ Inserting System DI800 can also perform some more
complex tasks, such as “optical mark recognition” (OMR). That
means the system is equipped with a scanner, much like those used
for cash registers in check out lines, to read and process paper with
special dash mark codes.

The modular units of the FastPac™ Inserting System DI800 are
streamlined and compact. They are designed to fit on the top of
most work tables. Which components are included in your FastPac™
Inserting System DI800 depends on your application needs. Dur­ing installation, your Pitney Bowes representative will fully ex­plain all of the modules. During operator training, you will learn
what each module does and why it was included in your system.

The simplest configuration for a FastPac™ Inserting System
DI800 is a Base Unit and one feeding module, such as an Insert
Feeder. More elaborate configurations are possible to fill a wide
range of needs. The illustration on the next page shows a simple
FastPac™ Inserting System DI800. The modules shown, a Sheet
Feeder, Folder, Insert Feeder, and Base Unit are all explained in
this manual.

Chapter 1: Introduction

Introduction

Single Sheet
Feeder (F583)

Single Insert

T
r
i
a
l
P

i
e
c
e

I
n
S
e
r

v
i
c
e

B
y

e
n
t
i
P

R
e
a
d
y

F
a
u
l
t

Feeder (F581)

s
e
w
o

R
e
R
s
e
e

t

v

/
i
e

w

T
r
i
a
l

P
i
e
c

e

J

S

J

t

o

a

b

r

t

P
a
u

A
s
e

d

d

W

a

t

e

r

C
l
e
a

r
D
e
c

k
S
e

a
l

S
e
t
u

p

R
e
p

o
r
t

E
x
i
t

Z
e
r
o

C
o
u

n
t

T
ri
al
P

i
e
c
e

I
n
S
e
r

v
i
c
e

F
a
u
l

t
R
e

a
d

y
I
n

R

S

e
a

e

d

r

y

v
i
c

e

F
a
u
l
t

T
r
i
a

P

l

i
e
c

e

T
ri
al
P

ie
c
e

In
S
e
r

v
i
c
e

s
e
w
o

B
y

e
n
t
i
P

R
e
a
d

y

F
a
u
l
t

T
ria
l
P

i
e
c
e

I
n
S
e
r

v
i
c
e

s
e
w
o

B
y

e
n
t
i
P

R
e
a
d

y

F
a
u
l
t

Folder
(F582)

Base Unit
(F580)

Figure 1-1—A Simple FastPac™ Inserting System DI800

1-3

F500_029

Complete FastPac™ Inserting System DI800s always include the F580
Base Unit. Which modules are included in addition to the Base Unit
depends on your needs. A FastPac™ Inserting System DI800 can consist
of any of the following modules, up to a total of five plus the Base Unit.

❑ Base Unit (F580)—Every FastPac™ Inserting System DI800

must have the Base Unit. Consult Chapter 2 of this manual for
a detailed explanation of the Base Unit. You can't operate the
FastPac™ Inserting System DI800 without thoroughly under­standing the Base Unit.

❑ Insert Feeder—The F581 Single Insert Feeder (Chapter 3)

and F587 Twin Insert Feeder (Appendix A) adds an insert to the
collation that is inserted in the envelope by the Base Unit. The
feeder is capable of feeding a wide variety of forms and
materials by moving the paper along with a belt and gate
system. The feeder holds material until the next module is
ready to accept it.

1-4

Introduction

❑ Sheet Feeder—The F583 Single Sheet Feeder ( Chapter

3) and F588 Twin Sheet Feeder (Appendix A) can feed a
supply of single sheets or collect a set (up to six sheets)
from another module. The sheet feeder passes a complete
set to the next module (usually a folder).

❑ OMR capability—The F504/F516 OMR is an optional

feature, that can be attached to either the F581 Single Insert
Feeder or the F583 Single Sheet Feeder (Chapter 3). The
OMR option continuously scans enclosures as they leave
a feeder deck. If an End of Collation (EOC) mark is
recognized, it passes the collation to the next downstream
module for processing.

❑ Folder (F582)—The Folder (Chapter 4) is included in a

system to accept paper (from one to six sheets) from
upstream modules, fold it into one of four common folds
(single fold, letter fold, accordion fold, or double fold) and
pass it downstream to the Base Unit. The folder also has a
bypass mechanism to let paper pass through the folder if
you do not want the paper folded.

Chapter 1: Introduction

❑ Cross Folder (F407)—The Cross Folder (Chapter 5)

handles large pieces of paper by single folding a sheet once
and then changing the direction of the paper so that a
second fold module can fold it again.

❑ Different “input devices” such as bursters and cutters can

also be added to the FastPac™ Inserting System DI800.
These attach to the FastPac™ Inserting System DI800 at
the opposite end from the Base Unit, at the furthest
upstream point, to feed special forms into the FastPac™
Inserting System DI800. The F422 Burster Interface is
covered in Chapter 6. The 3324 Burster is covered in
SV40025.

Chapter 1: Introduction

Introduction

Components do not have to be in a specific order, but logically,
certain functions must follow other functions (i.e., sheets must be
fed before they can be folded, and they need to be folded before they
can fit in an envelope).

As paper moves through the FastPac™ Inserting System DI800 we
say it is flowing “downstream.” The Base Unit is always located at
the most downstream position, the position all the way to the right
when facing the operator side of the machine (the side with the
control panels). The furthest upstream module, usually a sheet
feeder, is all the way to the left.

In many of the messages displayed on the main control panel on the
Base Unit, modules are referred to by number. These are the
numbers that the FastPac™ Inserting System DI800 assigns to each
module based on its position in the system. The Base Unit is not
numbered and the most upstream module is always number one.
The numbers increase as you move downstream toward the Base
Unit. See Figure 1-2 below.

1-5

Sheet Feeder

Module

Number 1

Folder

Module

Number 2

Insert

Feeder

Module

Number 3

Base Unit

The Base Unit is

Not Numbered

UPSTREAM DOWNSTREAM

Figure 1-2—Paper flows downstream

1-6

Chapter 1: Introduction

Introduction

Additional capabilities include Fold Only, Daily Mail, Continu­ous/Batching stacking modes, and Double Detect reference meth­ods.

• Fold Only allows you to process material through the FastPac™
Inserting System DI800, but not insert it into an envelope.

• Daily Mail is a feature which allows you to interrupt a job to
process a small job, and then go back to the original job. Note
that new setup may be required for the Daily Mail and then a
return to the original setup.

• Continuous/Batching stacking modes allow you to process one
piece after another (Continuous), a counter counting continu­ously, or in batches of 25 with a counter counting the batches
from 25 down to zero (Maximum batch count is 250).

• Double Detection can be set up on Start where thickness of the
first piece through is measured and then used as a reference for
subsequent sheets. It can also be set up by using the Trial Piece
method. In Trial Piece, the envelope is not sealed, allowing you
to examine the collation to be sure it is correct.

Chapter 1: Introduction

Safety

The Tabletop Inserting System is equipped with safety interlocks
that prevent operation under certain circumstances. Never attempt
to defeat these devices; you’ll endanger yourself and co-workers.

• Keep loose clothing, jewelry, and long hair away from all

moving parts.

• Avoid touching moving parts or materials while machine is in

use. Before clearing a jam, be sure 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 an

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

• The power cord is the primary means of disconnecting the

machine from the AC supply.

• DO NOT use an adapter plug on the line cord or wall outlet.

• DO NOT remove the ground pin from the line cord.

• Avoid using wall outlets that are controlled by wall switches or

shared with other equipment.

• DO NOT route the power cord over sharp edges or trap it between

furniture.

• Ensure there is no strain on the power cord where it becomes

jammed between the equipment, walls, or furniture.

• Be sure 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 your 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.

1-7

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

1-8

Chapter 1: Introduction

A Note to the Operator

The instructions in this guide explain how to set up and use the
modules in a basic FastPac™ Inserting System DI800. Being
familiar with the information in this manual helps you keep
problems to a minimum and achieve the best possible performance
from your system.

Before setting up and using the system, you should be completely
familiar with the modules used in your application. Read each
chapter of this manual as your system may include any of the
available modules. This operating guide is meant to help you use
the equipment to its full potential. For additional assistance, contact
your Pitney Bowes Customer Service Representative.

Note that some of the instructions that follow tell you to use the
scales provided on the FastPac™ Inserting System DI800 to take
measurements. Always use these scales as instructed.

Chapter 1: Introduction

Material Specifications

These material specifications apply to the FastPac™ Inserting
System DI800.

Envelopes for the F580 Base Unit:

• Envelopes must be flat, straight, and not glued together.

• Envelopes can be standard side seam, diagonal side seam,

executive, die cut, and closed window. The FastPac™
Inserting System DI800 does not run open window envelopes.

• Envelopes must be made from at least 16 lb. bond and no more

than 24 lb. bond material.

• Maximum acceptable envelope size is 6-7/16" (163mm) deep

by 10-3/8" (263mm) wide.

• Minimum acceptable envelope size is 3-1/2" (89mm) deep by

6-3/8" (162mm) wide.

1-9

• Flaps must be between 1-1/4" (32mm) and 2-1/4" (57mm) and

all envelopes must always have at least 1/4" (7mm) clearance
on each side, and a 1/4" (7mm) clearance between the crease
line of the flap and the edge of the insert.

Material for other system modules:

• Sheets for the F583 and F588 Sheet Feeder must be at least

5-1/2" (140mm) wide and no more than 9-7/8" (250mm) wide.

• Sheets for the F583 and F588 Sheet Feeder must be at least 4"

(102mm) deep, but no more than 14" (355mm) deep.

• Sheets must be made from at least 16 lb. bond and no more than

24 lb. bond material.

1-10

Chapter 1: Introduction

Material Specifications

• The thickness of the full collation feeding through the sheet
feeder must not exceed .072" (2.0mm). If sheets are to be
folded, thickness must not exceed .024" (0.6mm) or 6 sheets.

• Inserts for the F581 and F587 Insert Feeder must be at least
5-1/2" (140mm) wide and no more than 9-7/8" (250mm) wide.

• Inserts for the F581 and F587 Insert Feeder must be at least 2­1/2" (64mm) deep, but no more than 6" (152mm) deep.

• Insert thickness must not exceed .100" (2.5mm).

• The depth of all material must be within 1/2" (12mm) of each

other in the accumulator section of the Insert Feeder.

• The depth of all inserts must be within 1/2" (12mm) of the depth
of a folded sheet.

• The folder is limited to six sheets of 20 lb. bond, or if the fold
desired is a Double Fold, then only 3 sheets may be folded.

• If input includes a crossfolded document, only a single sheet
may be added before the fold is made.

• Material to be fed and read by an OMR kit installed on an F583
and F588 Sheet Feeder is a single sheet of material within the
specification of the F583 and F588 Sheet Feeder.

• If the OMR is installed on an F581 and F587 Insert Feeder,
depth and width of material is the same as specified for F581
and F587.

• The thickness of the material when scanning cannot exceed
.020" (0.5mm). The thickness when not scanning can reach
.100" (2.5mm).

Chapter 2: The Base Unit

Overview

The F580 Base Unit is the primary and required component of the
FastPac™ Inserting System DI800. The primary functions of the
Base Unit are to insert the collation into an envelope, process that
envelope, and control the system from commands entered at the
Main Control Panel.

The Base Unit consists of several main sections; see Figure 2-1,
next page:

• the envelope feeder

• the flapper

• the insert station

• the turner/ejection station

• the sealer

• the Main Control Panel

Other modules in the system are always located to the left (or
“upstream”) of the Base Unit. Paper flows from these modules
toward the Base Unit—often referred to as flowing “downstream”—
flowing toward the Base Unit.

!

WARNING: As we've stated, the Base Unit is just one
component of the entire FastPac™ Inserting System
DI800. Each module was “docked” to the other
modules in the system by your service representative
when it was installed.

Never attempt to separate the modules. This is for
service personnel only.

2-2

Overview

Incoming
Collation Path

T
r
i

a
l

P
ie

c
e

I
n

S
e

r
v
i
c
e

R
e

a
d

y

F
a
u
l

t

Chapter 2: The Base Unit

Flapper Area

Envelope
Feeder

Bridge

Turner

Sealer

Reset/
Review

Trial Piece

JJob

Start

Pause

Add
Water

Clear Deck

Seal

Insert Station

Main Control Panel

Figure 2-1—The Base Unit (F580)

Setup

Report

Exit

Zero Count

Eject Station

F500_043

Chapter 2: The Base Unit

Overview

The following describes how paper moves through the Base Unit.

• The envelope feeder holds a supply of envelopes and feeds
them to the flapper area of the Base Unit. Like the feeder
modules described later, the envelope feeder has a separat­ing mechanism that separates individual envelopes from
the stack loaded in the feeder. The separating mechanism
peels them away, one at a time, from the stack and feeds
them down to the paper path.

• The flapper section of the Base Unit opens the flap on the
envelope. As the envelope feeds into the flapper, the lead
edge of the envelope, opposite the flap edge, enters a pair
of rollers. The bottom roller rotates, wrapping the envelope
around until the downstream edge of the envelope contacts
the flap openers. As the envelope continues to move, the
flap openers pull the flap away from the body of the
envelope. Once the flap is pulled open, the envelope enters
the insert station where a sensor detects its arrival. Another
sensor detects if the flap is open.

2-3

• In the insert station the envelope throat is opened to receive
the collation being fed from upstream modules. Three
throat openers (two located on either side of the envelope
and one in the center), are rotated into the throat of the
envelope, pulling the envelope open to receive a collation.
When the body of the envelope is open to receive the
collation, a signal is sent that the envelope is ready, and the
collation is fed from the upstream module into the open
envelope.

continued-->

2-4

Overview

Chapter 2: The Base Unit

• A sensor verifies that the collation is inserted, causing the
Base Unit to pass the filled envelope to the turner section
where it is rotated 90˚. As the mailpiece exits the insert
station, the turner stops are raised to stop the mailpiece in
the turner area. When the leading edge of the mailpiece hits
the stops at the downstream end of the turner, the envelope
stops and is turned 90° to be properly aligned for the sealer.

• Defective pieces are ejected by an eject mechanism. This
provides a way to sort out unstuffed envelopes or incom­plete collations. Ejection is done just after the insert
station, preventing the mailpiece from being turned, sealed,
and counted.

• The turned envelope feeds into the sealer where the flap is
guided back toward a partially closed position and then
passed over a moistener where moisture is applied to the
glue on the flap. The envelope then passes through a pair
of rollers that apply pressure to the wet, gummed surface
of the envelope flap, sealing the envelope. When you select
the no-seal option, the diverter prevents the flap from
passing over the moistener.

A drawer pulls out of the front of the Base Unit for adding
water to the sealer. A mechanical float is located in the
reservoir to indicate the water level and help avoid over
filling. A light on the Main Control Panel warns when the
water level is low.

• The Base Unit also houses the Main Control Panel with the
operator interface for all the modules in the system; these
are the buttons you use to perform electronic setup on the
entire FastPac™ Inserting System DI800.

• The On/Off power switch is also located on the front of the
Base Unit. This controls power for the entire system.

Chapter 2: The Base Unit

Controls and Indicators

Controls and indicators on the Base Unit are described next. Each
illustration is labeled with numbers pointing out specific items in
the picture. An explanation of how the numbered control works or
what the indicator shows you is provided below the illustration.

Review these descriptions before you go on to the setup instruc­tions that follow. Understanding where everything on the equip­ment is located will help you keep your FastPac™ Inserting System
DI800 running smoothly and help you set the machine properly to
get the most from it.

This section of the chapter is intended to show you where things are,
not necessarily how to use them. Study the illustrations to see where
things are located and use the section on Setup and Adjustments to
learn how to operate the controls.

2-5

2-6

Controls and Indicators

T
r
i

a
l
P

i
e
c

e

I
n

S
e

r
v

i
c
e

R
e

a
d
y

F
a
u
lt

R

e

R

s

e

e

t

v

/
i
e

w

T
r

ia
l

P
i
e

c
e

J

S

J

t

o

a

b

r

t

P
a

u

A
s
e

d

d
W
a

t

e

r

C

le
a

r

D
e

c

3

1

k

S
e

a

l

2

Chapter 2: The Base Unit

S
e

t
u

p

R

e
p

o
r

t

E

x
i

t

Z

e

r
o

C

o
u

n
t

F500_043

Figure 2-2—Major Controls

1. Power Switch—A rocker switch that controls power to the

Base Unit and the entire FastPac™ Inserting System DI800.

2. Main Control Panel—The Main Control Panel has fourteen

push buttons on the keypad, two status lights, and a display
screen. Use the keys to perform setup for the Base Unit and the
entire FastPac™ Inserting System DI800. If the LED on a key
is lit, that function is available; if the LED is dark, that function
is not currently available.

3. Mini Control Panel—A small control panel ( located on each

of the FastPac™ Inserting System DI800 modules) which
indicates if the module is on or off, ready, or has a fault. Use this
control panel to run a single trial piece through a specific
module.

Chapter 2: The Base Unit

Controls and Indicators

2-7

1

Review Trial Piece Start

5

Figure 2-3—Main Control Panel, Left Side of Display

2

Stop Clear DeckJob

6

3

Add
Water

Seal

7

4

8

1. Review—Press for module-by-module review of the system

settings for the selected job.

2. Trial Piece—Press to assemble one complete inserted mail-

piece for inspection. The mailpiece will be ejected.

3. Start—Press to start continuous processing.

4. Add Water Light—Lights when the sealer requires more

water or sealing solution.

F400_096

5. Job—Press to change the selected job. Press as many times as

needed to display the desired job number. Up to ten different
jobs (groups of electronic setup commands) can be stored.

6. Stop—Press to halt the system.

7. Clear Deck—Always press before turning off the machine to

end a run or a job. The machine will cycle until all pieces on the
transport deck have been fully assembled, inserted and stacked.
Only pieces needed to complete collations will feed so that the
deck is clean when the machine stops.

8. Seal Light—Lights when the seal option is activated.

2-8

Controls and Indicators

Chapter 2: The Base Unit

1

Setup Exit Zero Count

3

Figure 2-4—Main Control Panel, Right Side of Display

2

Report

4

5

1. Arrow Keys—Use as indicated on the display to move from

one choice to another or to make a selection.

2. Report—Press to display the current reading of the cumulative

counter. The cumulative counter keeps track of the number of
valid collations (pieces of mail) processed by the system. The
count is independent and not affected by the Zero Count key
(see below). You can use the cumulative counter as a general
purpose counter to track the daily piece count, an operator
piece count, or as a backup to the job counter.

3. Setup—After the job number you want is displayed on the

screen, press this key to enter the setup mode, then use the
arrow keys. A code is required to access the job setup functions.

4. Exit—Press to exit the setup mode.

5. Zero Count—Press to reset the piece counter to zero, e.g., at

the beginning of a new job or run.

Chapter 2: The Base Unit

Controls and Indicators

5

Trial Piece In Service

2-9

3

2

Ready

Fault

4

F500_030

Figure 2-5—Mini Control Panel

1

1. Fault Light—Lights to indicate a fault has occurred at this

module.

2. Ready Light—Lights to indicate the module is ready for

operation.

3. In Service Light—Lights to indicate if the module is in

service, that is on, for the job being run.

4. In Service Control—Press this key to take the module in and

out of service (i.e., turns the feeder function on and off). The
unit is in service when the light (Item 3 above) is illuminated.
Turn the module off when using Fold Only mode (documents
not inserted into envelope, but material will still pass through).

5. Trial Piece—Press this key to cycle the module once.

2-10

Controls and Indicators

Chapter 2: The Base Unit

4

5

T
r
ia

l P

ie
c
e

I
n

S
e

r
v

i
c
e

R
e
a

d
y

F
a

u
l
t

3

R

e

R

s
e

e

t

v

/

i

e

w

T

r
i

a

l
P

i
e
c

e

J

S

J

t

o

a

b

r
t

P
a

u

A

s

e

d

d
W
a

t

e

r

C

l

e

a

r
D

e
c

k

S

e

a

l

F500_043

Figure 2-6—Envelope Feeder

1. Envelope Feeder—Holds supply of envelopes.

1

2

2. Feeder Guides—Adjust these guides to hold the envelopes in

place as they feed down to the deck.

3. Feeder Guides Lock Lever—Blue lever pushes in to release

side guides so they can be adjusted.

4. Envelope Feeder Bridge—The piece that covers the separa-

tor gap. The main feed roller is located below this bridge.

5. Roller Release Lever—This is used to access paper under the

Main feed roller.

Chapter 2: The Base Unit

Controls and Indicators

3

T
r
i
a

l
P
i
e

c
e

I
n
S

e
r
v
i

c
e

R
e

a
d
y

F
a
u

l
t

R

e

R

s

e

e

t

v

/
i
e

w

T
r
i
a
l

P
i

e
c

e

J

S

J

t

o

a

b

r

t

P

a
u

A
s
e

d

d
W
a
t

e
r

C

l
e

a
r

D

e
c
k

S
e

a
l

2-11

S
e

t
u
p

R

e
p

o

r
t

E
x

i
t

Z
e

r
o

C
o
u

n
t

1

Figure 2-7—Stone and Shield

1. Envelope Feeder Stone—Works with the Main Feed Roller

to create the necessary friction for peeling one envelope at a
time away from the stack in the envelope feeder.

2. Envelope Feeder Stone Shield—Adjust to reveal more or

less of the stone.

3. Envelope Feeder Stone Shield Adjuster—Slide back and

forth to adjust the amount of shield which affects how much
friction is used to feed envelopes.

2

F500_048

2-12

Controls and Indicators

1

T
r
i

a
l
P
i

e
c
e

I
n
S

e
r
v

i
c
e

R

e
a
d

y

F

a
u

l
t

R

e

R

s

e

e

t

v

/

i

e
w

T
r

i
a

l
P

i
e

c
e

J

S

J

t

o

a

b

r
t

P
a
u

A

s

e

d

d

W

a

t
e
r

C

l
e
a

r

D
e

c

k

S

e
a
l

Chapter 2: The Base Unit

S
e

t
u

p

R

e
p

o
r

t

E

x
i

t

Z

e
r
o

C

o

u
n

t

2

F550_010

Figure 2-8—Separating Mechanism

1. Envelope Feeder Prefeed Rollers—Help move one envelope

to the separating stone and main feed roller.

2. Envelope Feeder Main Feed Rollers—Move envelopes one

at a time down from the feeder to the flapper.

3. Separator Gap Adjustment Wheel—Raises and lowers the

main feed rollers to adjust the “separating gap.” To adjust for
better separation, turn the adjustment wheel clockwise to raise
the rollers and counterclockwise to lower them.

3

Chapter 2: The Base Unit

Controls and Indicators

3

1

2-13

4

Figure 2-9—Envelope Flapper Unit

1. Envelope Flapper Unit Safety Cover—Flip open to access

envelope flapper unit to remove envelope misfeeds.

2. Envelope Flapper Cover Lock Lever—Pull this lever to

release flapper unit. Flapper unit gently pivots when unlocked.

3. Recessed Area on Flapper Unit—Pull here after flapper unit

is unlocked to expose more of the flapper unit.

4. Tab on Flapper Unit—Pull here to gain access to the inside of

the flapper.

2

2-14

a

Controls and Indicators

10

1

2

0

1

2

3

4

190

180

170

100

0

2

1

90

0

3

1

0

4

1

1

6

0

150

Chapter 2: The Base Unit

1

3

R

e

v

ie

w

T

r

i

Figure 2-10—Insert Station Envelope Side Guides

1. Envelope Side Guides—Guides in the insert area that hold the

envelope in place after it’s opened. The two guides keep the
envelope lined up with the oncoming mailpiece for insertion
(only one guide is visible here).

2. Envelope Side Guides Setting Knob—Small blue knob lo-

cated on the side frame of the module, under the cover. Turn the
knob to move the scale until the pointer indicates the measured
width of the envelope.

3. Scale and Pointer—Match the pointer to the measured width

of the envelope on the scale.

F400_133