Pitney Bowes DI950 Operator Guide
DI900/DI950 FastPac
™
Document Inserting System
Operator Guide
US/Canada English Version
Statement of FCC Compliance
This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to
part 15 of the FCC rules. These limits are designed to provide reasonable protection against interference when
the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate
radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause
interference to radio communications. Operation of this equipment in a residential area is likely to cause interference, in which case the user will be required to correct the interference at his own expense.
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.
SV61311 Rev. D ©2005 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 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. DM Series, DM800i, DM1000, SwiftStart, SureTrac,
Optiflow and E-Z Seal are trademarks or registered trademarks of Pitney Bowes. Tyvek is a registered trademark of Dupont.
Table of Contents
Contact Information List
USA Contacts .................................................................................v
Canada Contacts ............................................................................v
Chapter 1 - Introduction
A Note to the Operator ................................................................1-2
Viewing this Guide as a PDF File ...............................................1-2
About Your System ..................................................................... 1-3
Safety Information .......................................................................1-6
Warning Labels ........................................................................... 1-7
Basic Terms ...............................................................................1-8
Icon Glossary ............................................................................ 1-10
Envelope Icons ...................................................................1-10
Fold Icons ...........................................................................1-10
Sheet Icons .........................................................................1-11
Insert Icons .........................................................................1-12
Feeder Assignment Icons ...................................................1-13
Other Icons .........................................................................1-13
Book Contents ..........................................................................1-14
What's New ...............................................................................1-14
Chapter 2 - Meet the Inserting System
System Components ..................................................................2-2
Feeder Tower ..............................................................................2-4
Feeder Trays ...............................................................................2-5
Sheet Trays ...........................................................................2-5
Insert Trays ...........................................................................2-6
Manual Feeder ............................................................................2-7
Transport Deck ...........................................................................2-8
Mail Piece Path .....................................................................2-8
Pre-fold Accumulator ............................................................2-8
Folder ....................................................................................2-9
Post-fold Accumulator ..........................................................2-9
Insertion Area ........................................................................2-9
Folder Bypass Path ..............................................................2-9
Moistener, Closer, Sealer ......................................................2-9
About the Control Panel ............................................................2-10
Screen Option Keys ............................................................2-10
Fixed Function Keys ........................................................... 2-11
Machine Action Keys ..........................................................2-13
Screen Navigation Keys .....................................................2-13
iSV61311 Rev. D
Table of Contents
Display Screen ..........................................................................2-14
Access Rights ........................................................................... 2-19
About System Covers ............................................................... 2-21
About the Paper Release Knobs/Levers...................................2-23
Accounting ................................................................................2-24
About Add-On Modules .............................................................2-24
Chapter 3 - Basic Operation
Connecting to Power ..................................................................3-2
Powering Up ...............................................................................3-2
Home Screen .............................................................................. 3-3
Job Overview .............................................................................. 3-4
Selecting the Job ........................................................................3-5
Setting Up Feeders and Loading Materials ................................3-6
Making Pre-Run Adjustments ..................................................3-18
Running a Trial Piece ................................................................3-22
Starting the Job .........................................................................3-25
About SwiftStart
Creating a Job ..........................................................................3-27
Job Options ...............................................................................3-30
Editing a Job .............................................................................3-38
Header Area ........................................................................2-14
Status Area .........................................................................2-15
Logging In ...........................................................................2-20
Logging Out ........................................................................2-20
Opening the Covers ............................................................2-22
Closing the Covers .............................................................2-22
Attaching Trays to the Feeder Tower .................................... 3-6
Removing Trays from the Feeder Tower ...............................3-7
Loading Material into the Trays .............................................3-8
Loading the HCEF (High Capacity Envelope Feeder) ........3-13
Adjusting the Envelope Openers ........................................3-18
Reviewing the Job Settings ................................................3-24
™
......................................................................3-25
SwiftStart
Using SwiftStart
™
Jobs ..................................................................3-25
™
...............................................................3-26
Envelope Options ...............................................................3-30
Fold Options .......................................................................3-32
Sheet Options .....................................................................3-32
Insert Options .....................................................................3-35
Adding an Item ....................................................................3-40
Moving an Item ...................................................................3-41
Deleting an Item ..................................................................3-42
ii SV61311 Rev. D
Table of Contents
Chapter 4 - Advanced Operation
Overview .....................................................................................4-2
Using the Alphanumeric Matrix ................................................... 4-2
Saving a Job .............................................................................. 4-3
Deleting a Job ............................................................................. 4-4
Using Accounting ........................................................................4-5
Creating an Account .............................................................4-5
Deleting an Account ..............................................................4-5
Enabling the Accounting Feature ..........................................4-5
Assigning User IDs and Passwords ............................................4-6
Chapter 5 - Troubleshooting and Maintenance
Adjusting Screen Brightness and Contrast .................................5-2
Setting the Time and/or Date ...................................................... 5-3
Changing the Language .............................................................5-4
Refilling the Sealing Solution ......................................................5-5
Handling Material Stoppages ......................................................5-5
Clearing a Stoppage .............................................................5-5
Resuming the Job .................................................................5-6
Handling Outsorts .................................................................5-6
Troubleshooting Tables ...............................................................5-7
Routine Maintenance ................................................................ 5-16
Daily Tasks ..........................................................................5-16
Replacing the Moistener Wick ............................................5-16
Replacing the Moistener Brushes .......................................5-18
SV61311 Rev. D
Chapter 6 - Reference
Overview .....................................................................................6-2
System Specifications .................................................................6-2
Component Specifications ..........................................................6-4
System Configurations ...............................................................6-6
Feeder Tower and Base Material Specifications .......................6-10
General Information ............................................................6-10
Envelopes ...........................................................................6-10
Inserts .................................................................................6-12
Sheets .................................................................................6-13
High Capacity Sheet Feeder (HCSF) Material Specifications ..6-14
General Information ............................................................6-14
Sheets .................................................................................6-14
Materials Not Certi ed for Use ............................................6-15
System Operating Modes ........................................................6-16
iii
Table of Contents
Chapter 7 - Add-On Modules
About the Add-On Modules .........................................................7-2
High Capacity Sheet Feeder (HCSF) .........................................7-2
Exit Options ................................................................................7-6
Chapter 8 - Scanning
Scanning Overview ..................................................................... 8-2
Setting Up a New Scan Configuration ........................................8-6
Editing a Scan Configuration ....................................................8-13
Copying a Scan Configuration ..................................................8-15
Deleting a Scan Configuration ..................................................8-15
Reviewing a Scan Configuration ...............................................8-16
Viewing the Job List .................................................................. 8-16
Assigning a Scan Configuration to an Existing Job .................8-17
Adjusting the Scan Heads ........................................................8-19
OMR Specifications ..................................................................8-24
BCR and OMR Mark Levels .....................................................8-28
Loading the HCSF ................................................................7-3
Adjusting the HCSF Guides ..................................................7-5
OMR .....................................................................................8-2
BCR ......................................................................................8-2
Scanning Features ................................................................8-4
Setting Up an OMR Scan Con guration ...............................8-6
Setting Up a BCR Scan Con guration ..................................8-9
Editing an OMR Scan Con guration ...................................8-13
Editing a BCR Scan Con guration ......................................8-14
Adjusting the Scan Heads for Ladder Orientation Marks ....8-19
Adjusting the Scan Heads for Picket Orientation Marks .....8-22
Setting the OMR Scanning Area .........................................8-26
De ning the First Mark Position and Code Length .............8-26
De ning the Clear Zone ......................................................8-27
Additional Information .........................................................8-28
Basic Level .........................................................................8-29
Enhanced Integrity Level ....................................................8-31
Selective Operations Level .................................................8-32
Index
Index ............................................................................................I-1
iv SV61311 Rev. D
Contact Information List
USA Contacts
Product Name - DI900 or DI950
▪ 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 supplies and accessories, call the Supply Line
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 - 8:00 PM ET.
• To obtain Material Safety Data Sheets, call the Supply Line
click on Customer Support.
at: 1.800.243.7824 or go to:
™
or go to: www.pb.com and
Canada Contacts
Product Name - DI900 or DI950
▪ 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 - 4:00 PM ET.
SV61311 Rev. D
v
Contact Information List
This page is intentionally blank.
vi SV61311 Rev. D
1 • Introduction
A Note to the Operator.................................................................1-2
Viewing this Guide as a PDF File ................................................1-2
About Your System ......................................................................1-3
Safety Information .......................................................................1-6
Warning Labels ............................................................................1-7
Basic Terms ................................................................................1-8
Icon Glossary.............................................................................1-10
Envelope Icons .................................................................... 1-10
Fold Icons ............................................................................ 1-10
Sheet Icons ...........................................................................1-11
Insert Icons .......................................................................... 1-12
Feeder Assignment Icons ....................................................1-13
Other Icons .......................................................................... 1-13
Book Contents ...........................................................................1-14
What's New ...............................................................................1-14
1-1SV61311 Rev. D
1 • Introduction
A Note to the
Operator
Viewing this
Guide as a PDF
File
It is important to be familiar with this guide as it will enable you to utilize the
system to its full potential, while keeping problems to a minimum.
NOTE: This guide applies to systems running software version 1.10.04. The software version is displayed on the control panel screen at power up.
There are several built-in features you can use to navigate through this
guide when viewing it as a pdf file:
• Topics highlighted by a blue rectangle are hyperlinks.
Using the Hand tool (
jump to the topic's location in the Help guide.
Highlighted Hyperlink
• Entries in the main Table of Contents and the table of contents at the
beginning of every chapter are hyperlinks, although they are not highlighted.
Move the Hand tool over a table of contents entry until it points, then
click to jump to the location of the entry in the Help guide.
), you can click anywhere within a hyperlink to
Table of Contents Hyperlink
• Page numbers in the Index are hyperlinks, although they are not highlighted.
Move the Hand tool over the page number until it points, then click on
the page number to jump to that page of the Help guide.
Index Hyperlink
1-2 SV61311 Rev. D
Introduction • 1
About Your
System
DI900/DI950 are high throughput, mail creation systems designed to handle
a broad range of applications with minimum operator setup adjustments.
These systems have the ability to feed, fold, and insert mail piece components into an outer envelope. The systems generate Letters or Flats as the
final mail piece. The systems also accept a variety of options that provide a
wide range of capacities and operating speeds.
Figure 1.1: The DI900 System
The systems can be configured with four flexible Feeder Trays. There are
two types of Feeder Trays:
• Sheet Trays, which are capable of feeding sheets; and
• Insert Trays, which are capable of feeding slip/insert materials, pre-folded inserts, thin booklets, and envelopes.
In addition, the DI950 system is equipped with a dedicated High Capacity
Envelope Feeder (HCEF) that allows for greater speed and throughput. The
systems also accept material from optional upstream input devices, such as
High Capacity Sheet Feeders.
Basic system features are summarized in this chapter. Refer to Chapter 6
for detailed equipment and material specifications.
The systems are configured with two major components:
• Feeder Tower, and
• Transport Deck.
The Feeder Tower sends material from the Feeder Trays to the Transport
Deck. Depending on the job parameters, the material may or may not need
to pass through the Folder in the Transport Deck. If it does, the system offers numerous types of folds and the ability to insert the folded material into
the appropriate position in the mail piece collation. The system can also seal
the envelope (Letter only) before sending the final mail piece to a stacking
unit.
SV61311 Rev. D
1-3
1 • Introduction
DI950C
DI900C
DI950H
DI900H
Letter and Flats Drop Stacker
(standard on all systems)
Standard Systems
Bottom Address Z Fold
Kit (Document Inverter)
Belt Stacker Tandem Belt Stacker DM Series™ Mailing System
* Furniture, designed specifically for the system, is also available.
High Capacity Sheet
Feeder (HCSF)
System Options*
OptiFlow™ Vertical
Power Stacker
DM800i™, DM1000
Exit Transport
™
1-4 SV61311 Rev. D
Introduction • 1
About Your
System
(continued)
The systems are software driven and are controlled by a Control Panel that
contains the following:
• Screen Option Keys (for screen choices)
• Screen Navigation Keys (for screen choices)
• Fixed Function Keys (for screen functions)
• Machine Action Keys (for running hardware)
• LED Status Indicator
For more information about the Control Panel, refer to About the Control
Panel in Chapter 2 of this guide.
LED Status Indicator
Figure 2-4: Control Panel
Screen Option Keys
Fixed Function Keys
Screen Navigation Keys
Machine Action Keys
SV61311 Rev. D
1-5
1 • Introduction
Safety
Information
Follow these precautions when ev er you use your inserting system:
• Read all instructions before you attempt to op er ate 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 ac ces si ble 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. Fail ure to prop er ly ground the machine can result in severe personal
injury and/or fire.
• The power cord wall plug is the primary means of dis con nect ing the
machine from the AC supply.
• DO NOT use a wall outlet con trolled by a wall switch or one that is
shared with other equip ment.
• DO NOT use an adapter plug on the line cord or wall out let.
• 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 ob struc tion.
• 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 pan el or its base. The cabinet encloses haz ard ous parts. If you should dam age 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 ma chine is in use.
Before clearing a jam, be sure machine mechanisms come to a complete stop.
• Remove jammed material gently and carefully.
• Do not place lighted candles, cigarettes, cigars, etc., on the system.
• To prevent overheating, do not cover vent open ings.
• 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.
1-6 SV61311 Rev. D
Introduction • 1
Safety
Information
(continued)
• 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 pan el or its base. The cabinet encloses haz ard ous parts. If you should dam age 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.
Warning Labels
The following warning labels are attached to modules on the system to alert
you to potential injury that could occur with careless operating procedures.
These same labels will be shown throughout the manual as they apply to
the various modules that are discussed in that section.
SV61311 Rev. D
1-7
1 • Introduction
Basic Terms
The following table lists and defines standard terms used in the system's
screens and this Operator Guide.
Material References
Sheet A single piece of paper that will require folding by the machine
before it is placed into an envelope. In the Mail Piece Icon Tree, the
sheet icon represents a stack of single sheets, or a stack of precollated sets of sheets.
Additional Sheet Additional sheet(s) can be added to the Mail Piece. Each will be
placed into the envelope behind the Control Document.
Stack A pile of paper as received from the printer. A Stack might consist of
numerous individual Sheets or numerous Pre-collated Sets.
Control
Document
Print Order • Sheets that have been printed in a collated sequence, (i.e.,
Manual Feed Stapled or unstapled sets of sheets that are fed by hand.
This sheet normally contains the destination address. This sheet
will be positioned closest to the envelope window, or to the front
face of a windowless envelope.
Relates to:
• OMR and Barcode use, and
• Addressed piece on non-OMR jobs.
page 1, page 2, page 3; page 1, page 2, page 3; etc.), or
• Single sheets printed in a predefined mail order.
Insert An item that doesn't require folding before being placed into an
envelope. There are five kinds of inserts:
• Reply Envelope - An envelope placed into the Outer Envelope
with the other Mail Piece contents
• Booklet - An item with a stapled and folded binding edge.
• Slip - A single thickness piece of paper or card. Double detect
is turned ON by default for this item.
• Reply Card - A single thickness piece of paper. Double detect
is turned OFF by default for this item.
• Pre-Folded Insert - A sheet that has been folded prior to
loading and requires no further folding by the machine.
Fold Types The folder offers these options:
• C Fold - Also known as "standard" fold.
• Z Fold - Also known as "accordion" fold.
• Single Fold - One fold applied (usually folded in half).
• Double Fold - Folded in half and then in half again.
• No Fold - No fold present.
Outer Envelope The envelope which contains all the items placed into it by the
machine.
Mail Piece A single assembled article of mail, usually an envelope and its
correctly ordered contents.
Fan The process of flicking through a stack of material to separate the
items prior to loading.
Shingle The method of loading inserts into a Feeder in a partially overlapped
manner, like tiles on a roof.
1-8 SV61311 Rev. D
Introduction • 1
Basic Terms
(continued)
Material References
Tray A removable holder of items. For example, sheets or inserts..
Feeder Object that material is loaded into to be pulled into the folder/
inserter for processing.
Machine Functions
Home Screen The initial screen displayed after turning power on. From this
screen, you can run the machine, select a pre-programmed
Job, and enter the menu functions.
Mail Piece Icon Tree A graphic that runs down the left side of the display and
contains icons/small pictures that represent the items that
make up the currently selected mail piece. It also indicates the
location of the feeder where each item needs to be placed.
Trial Piece(s) Test piece(s) run by the machine before automatic operation
can be started. Trial Piece(s) allow the machine to calibrate
itself and the Mail Piece make-up to be checked. Trial Piece(s)
that do not go into the stacker are not counted.
Personalized Refers to the top sheet that contains the address that will
show the in the windowed envelope and/or a sheet or insert
that contains unique information.
OMR Marks The lines on the Sheets/Inserts corresponding to the system
control commands. OMR marks ensure that Sheets/Inserts
that belong together in a mail piece stay together as they
make their way through the paper path and into the outer
envelope.
Barcode A printed code used to convey information to the system
through optical scanning of the document.
Double Detect Detects the incorrect feeding of a single sheet or insert. The
system detects if it feeds two or more sheets when only one
should have been fed.
SV61311 Rev. D
1-9
1 • Introduction
Icon Glossary
The tables in this section provide descriptions of the various icons you will
see on the display screen.
NOTE: Where applicable, the darkest edge of an icon is the edge that feeds rst
into the system.
Envelope Icons
Tower Feeder
Orientation: flap side down,
flap first.
Non-Window Letter
Envelope
Window Standard Flap
Envelope
Window Forward Flap Letter
Envelope
Window Bottom Flap
Letter Envelope
Non-Window Flat
Envelope
HCEF*
Orientation: flap side down,
flap last.
N/A
Window Standard Flap Flat
Envelope
Window Forward Flap Flat
Envelope
Window Bottom Flap Flat
Envelope
*High Capacity Envelope Feeder
Fold Icons
No Fold
C Fold
Z Fold
Single Fold
N/A
N/A
N/A
Double Fold
1-10 SV61311 Rev. D
Introduction • 1
Icon Glossary
(continued)
Sheet Icons
Sheet, Not
Personalized
Sheet, Top
Address
Sheet, Middle
Address
Sheet, Bottom
Address
Multiple Sheets, Not
Personalized
Orientation:
face up, top
first.
Orientation:
face up, bottom
first.
Orientation:
face down, top
first.
Orientation:
face down,
bottom first.
Multiple Sheets, Top
Address
Multiple Sheets,
Middle Address
Multiple Sheets,
Bottom Address
SV61311 Rev. D
1-11
1 • Introduction
Icon Glossary
(continued)
Insert Icons
Orientation:
face up, top
first.
Slip or Generic
Insert
Reply Envelope N/A N/A N/A
Reply Card
Multiple Slips or
Generic Inserts
Multiple Reply
Envelopes
Orientation:
face up,
bottom first.
N/A N/A N/A
Orientation:
face down, top
first.
Orientation:
face down,
bottom first.
Multiple Reply Cards
Pre-Folded Insert
Multiple
Pre-Folded Inserts
Orientation:
closed edge
first.
Orientation:
bound edge
first.
Letter Booklet
Multiple Letter
Booklets
1-12 SV61311 Rev. D
Introduction • 1
Icon Glossary
(continued)
Feeder Assignment Icons
Feeder assignment is indicated by a letter in a grey square to the right of the
job item icon in the Mail Piece Icon Tree. The letter that appears in the grey
square will vary, depending upon the assigned feeder.
• Single Feeder Assignment is indicated by one grey square.
• Linked Feeder Assignment is indicated by two grey squares.
NOTE: The table below provides a list of all possible Feeder assignments. The
Feeders available to you will vary, depending upon your system con guration.
Feeder Letter Location Position
A Feeder Tower Bottom left feeder
B Feeder Tower Bottom right feeder
C Feeder Tower Top left feeder
D Feeder Tower Top right feeder
G High Capacity Envelope Feeder (HCEF) N/A
J High Capacity Sheet Feeder 1 (HCSF) Bottom feeder
K High Capacity Sheet Feeder 1 (HCSF) Top feeder
L High Capacity Sheet Feeder 2 (HCSF) Bottom feeder
M High Capacity Sheet Feeder 2 (HCSF) Top feeder
A
A
C
SV61311 Rev. D
Other Icons
Error Icon - appears in pop-up messages on display screen.
Indicates message is an error message.
Warning Icon - appears in pop-up messages on display screen.
Indicates message is a warning message.
Seal On Icon - appears in Mail Piece Icon Tree if sealing is on.
Double Detect Icon - appears in Mail Piece Icon Tree if double
detect is on.
1-13
1 • Introduction
Book Contents
What's New
This remaining chapters in this book contain setup, operation, troubleshooting and reference information about your document inserting system.
• Chapter 2, Meet the Inserting System - orients you to system software
and hardware components.
• Chapter 3, Basic Operation - explains basic steps for running a job.
• Chapter 4, Advanced Operation - describes advanced procedures.
• Chapter 5, Troubleshooting - explains screen adjustment procedures,
lists errors and their corrective actions, and describes routine maintenance procedures.
• Chapter 6, Reference - lists system specifications.
• Chapter 7, Add-On Modules - provides a brief description of each add-
on module.
• Chapter 8, Scanning - explains scanning options.
NOTE: Machine Keys will appear in all capital letters. Option Keys will appear in
Initial Caps in quotes ("). Variables within options will appear in quotes (") and in
the same case as shown on the screen.
• A single Reply Envelope (BRE) can now be added to a flats insertion
job. When creating the job, you must select the "Reply Envelope" insert
option for the job to validate correctly. The BRE will be accumulated with
the flat set in the Pre-fold Accumulator prior to insertion into the flat envelope.
• DI950 systems (with or without High Capacity Sheet Feeders) are now
capable of dynamic envelope selection. These systems can selectively
insert mail piece contents into either flats envelopes or letter envelopes
based on sheet count, or the presence of Envelope Select scan mark
(requires Selective Operations level of scanning). Refer to Scanning
Features in Chapter 8 for more information.
• An intelligent interface between the inserting system and the
DM Series™ DM800i™ and DM1000™ mailing systems is now available. Refer to Chapter 3 for more information about creating a job that
uses the Mail Machine Interface.
NOTE: The interface requires version 15 of the mailing machine IntelliLink®
Control Center software.
• Sheet feeders can be linked vertically in both the High Capacity Sheet
Feeder and base tower. Feeders must be loaded on collation breaks.
• Full feeder-to-feeder Match Code verification between scanned items in
a job is available. The feature is limited to six matched feeders.
• When creating a job, you can elect to have sheets diverted to the lower
divert area based on either the presence of the Divert Sheets scan mark
(requires Selective Operations level of scanning), or an overcount condition in the Pre-fold Accumulator. Refer to Scanning Features in Chapter
8 for more information about divert sheet functionality.
1-14 SV61311 Rev. D
2 • Meet the Inserting
System
System Components ...................................................................2-2
Feeder Tower ...............................................................................2-4
Feeder Trays ...............................................................................2-5
Sheet Trays ...........................................................................2-5
Insert Trays ............................................................................ 2-6
Manual Feeder ............................................................................2-7
Transport Deck ............................................................................2-8
Mail Piece Path ...................................................................... 2-8
Pre-fold Accumulator .............................................................2-8
Folder .................................................................................... 2-9
Post-fold Accumulator ........................................................... 2-9
Insertion Area ........................................................................ 2-9
Folder Bypass Path ............................................................... 2-9
Moistener, Closer, Sealer ...................................................... 2-9
About the Control Panel ............................................................2-10
Screen Option Keys ............................................................. 2-10
Fixed Function Keys .............................................................2-11
Machine Action Keys ........................................................... 2-13
Screen Navigation Keys ...................................................... 2-13
Display Screen ..........................................................................2-14
Header Area ........................................................................ 2-14
Status Area ..........................................................................2-15
Access Rights ............................................................................2-19
Logging In ............................................................................ 2-20
Logging Out ......................................................................... 2-20
About System Covers ................................................................2-21
Opening the Covers ............................................................. 2-22
Closing the Covers .............................................................. 2-22
About the Paper Release Knobs/Levers ...................................2-23
Accounting .................................................................................2-24
About Add-On Modules .............................................................2-24
SV61311 Rev. D
2-1
2 • Meet the Inserting System
System
Components
The base system configuration includes a Feeder Tower, Transport Deck,
and Envelope Sealer; the DI950 features an additional integrated High Capacity Envelope Feeder. Additional modules can be added to utilize the full
potential of the system.
3
4
5
6
7
2
8
1
10
9
Figure 2.1: The DI900 System
Feeder Tower Trays - feed sheets or inserts to the Feeder Tower.
1
NOTE: If enabled, the lower left Tray is assigned with the letter "A" on
the Mail Piece Icon Tree. When a High Capacity Envelope Feeder is not
part of the system con guration, this Tray is the primary Tray for feeding
envelopes designated for a given job.
Feeder Tower - is a two-sided Tray holder/material feeder.
2
11
DI950 only
2-2 SV61311 Rev. D
Meet the Inserting System • 2
System
Components
(continued)
Manual Feeder - allows you to manually feed stapled or unstapled
3
sets of up to 5 sheets of 20 lb (80gsm) paper. The machine waits for
each set to be manually fed before folding and inserting the set automatically into the envelope. The Manual Feed option is available
during job creation. Inserts and/or Sheets from other Trays can also
be added to the job.
Pre-fold Accumulator - is a staging area for the material that
4
needs to be collated together and then sent to the Folder unit.
Folder - applies one of the available fold types to Sheets.
5
Post-fold Accumulator - is a staging area for the folded Sheets to
6
meet any inserts that are to be included.
Insertion Area - is the part of the transport where the collation in-
7
tended for a single addressee is inserted into an outer envelope.
Moistener, Closer, Sealer - Brushes sweep across the envelope
8
flap to wet the glued area of the flap. The envelope then moves
through the Closer and Sealer areas of the unit to complete the mail
piece.
Sealing Solution Bottle - is located inside an opening cover at the
9
front right side of the machine. It provides sealing solution to the
envelope sealing system.
10
11
Drop Stacker (available on all units, not illustrated) or Power Stacker
(Optional, not illustrated) - collects and neatly stacks the finished mail
pieces that exit the system. The drop stacker can be unlatched from the
system when it is not needed. The power stacker is mounted to the system.
Control Panel - allows you to run the machine and configure job
settings. It also displays the machine status and shows loading instructions and details of the job. See the following pages for more
information on the controls and screen.
High Capacity Envelope Feeder (DI950 only) - holds at least 500
letter-sized envelopes. It feeds directly to the Insertion Area.
SV61311 Rev. D
2-3
2 • Meet the Inserting System
Feeder Tower
The Feeder Tower is a two-sided Tray holder/material feeder that stands at
one end of the unit. Unlocking a latch on the left side of the Tower opens it to
expose Feeder Exit and Tower Transport Rollers. This makes it easy to access media that may stop as it exits the Tower. Depending on the Configuration, the Tower accepts two or four Feeder Trays.
Push latch up to
open Tower cover
Figure 2.2.1: Latch Opens Feeder Tower.
Figure 2.2.2: Two-sided Feeder Tower: Open for easy
access to Feed Rollers.
2-4 SV61311 Rev. D
Meet the Inserting System • 2
Feeder Trays
Sheet Trays
There are two types of Feeder Trays:
• Sheet Trays
• Insert Trays
The required Tray type is based on the type of material selected for a given
job.
Sheet Trays feed flat, unfolded material. Use only the recommended materials. Refer to the specifications in Chapter 6.
NOTE: Sheet Trays have ll marks on their side walls. Be sure to keep your stack
of materials at or below these marks to avoid feed problems.
SV61311 Rev. D
Figure 2.3.1: Sheet Trays
2-5
2 • Meet the Inserting System
Insert Trays
Insert Trays feed items that do not need folding (envelopes, cards, booklets,
slips and pre-folded media) into the system. Insert Trays have a weighted
sliding mechanism known as a Sled that keeps pressure on the material for
proper feeding.
Insert Trays have two sets of maximum fill lines: one set for slips, and a
second set for envelopes.
Sled mechanism
Figure 2.3.2: Insert Tray
2-6 SV61311 Rev. D
Meet the Inserting System • 2
Manual Feeder
Use the Manual Feeder to hand feed stapled or unstapled sets of up to five
sheets. The machine waits for each set to be manually fed before folding
and inserting the set into the envelope.
NOTES:
• The feeder type of the item (to be fed manually) in the current job has to be
de ned as Manual for the feature to work.
• The job with the manual fed piece can also include items from other feeders,
including sheets or inserts.
To use the Manual Feeder:
1. Push the Manual Feed lever up.
2. Feed each set by pushing the edge into the rollers one at a time.
3. Push the lever down when you are done.
Push the
Manual Feed
lever up.
Figure 2.4: Manual Feed Lever.
SV61311 Rev. D
2-7
2 • Meet the Inserting System
Transport Deck
The Transport Deck accepts material from the Feeder Tower and moves it
through the various modules to produce a finished mail piece. The Standard
Transport Deck consists of the following:
Pre-fold
Accumulator
Figure 2.5: Transport Deck
Folder
Post-fold
Accumulator
Insertion
Area
Moistener,
Closer,
Sealer
Mail Piece Path
Pre-fold
Accumulator
2-8 SV61311 Rev. D
Material from the Feeder Trays comes down the Feeder Tower in a pre-defined order. Material moves rapidly from one station to the next in the Transport Deck to produce a finished mail piece that is dropped into a stacking
bin or onto an optional high capacity output stacker. A brief description of the
function of each module in the paper path is presented next.
The Pre-fold Accumulator is the first stop in the paper path. The Pre-fold
Accumulator is a stacking place for the material that needs to be collated
and folded. When the appropriate components for one mail piece finish collating on the Pre-fold Accumulator, they move into the Folder.
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