Pitney Bowes DI950 User Manual
Operator Guide
US/Canada English Version
DI900/DI950 FastPac
™
Document Inserting System
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. E ©2006 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, IntelliLink 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
1 • Introduction
A Note to the Operator ................................................................ 1-2
Viewing this Guide as a PDF File ............................................... 1-2
About Your System ..................................................................... 1-3
Standard Systems ................................................................ 1-4
System Options* ................................................................... 1-5
Safety Information ....................................................................... 1-6
Warning Labels ........................................................................... 1-7
Book Contents ............................................................................ 1-8
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 ........................................................................... 2-20
Logging In ........................................................................... 2-21
Logging Out ........................................................................ 2-21
iSV61311 Rev. E
Table of Contents
About System Covers ............................................................... 2-22
About the Paper Release Knobs/Levers................................... 2-24
About Add-On Modules .............................................................2-24
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
SwiftStart™ Jobs ........................................................................ 3-25
Creating a Job ..........................................................................3-26
Job Options ............................................................................... 3-30
Editing a Job ............................................................................. 3-39
Opening the Covers ............................................................ 2-23
Closing the Covers ............................................................. 2-23
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 DI950 High Capacity Envelope Feeder
(HCEF) ................................................................................ 3-13
Adjusting the Envelope Openers ........................................ 3-18
Reviewing the Job Settings ................................................ 3-24
Using SwiftStart™ ............................................................... 3-26
Envelope Options ............................................................... 3-30
Fold Options ....................................................................... 3-32
Sheet Options ..................................................................... 3-33
Insert Options ..................................................................... 3-36
Modifying Job Settings ........................................................ 3-40
Editing an Item .................................................................... 3-40
Adding an Item .................................................................... 3-41
Moving an Item ................................................................... 3-43
Deleting an Item .................................................................. 3-44
4 • Advanced Operation
Overview ..................................................................................... 4-2
Using the Alphanumeric Matrix ................................................... 4-2
ii SV61311 Rev. E
Saving a Job .............................................................................. 4-3
Deleting a Job ............................................................................. 4-4
Assigning User IDs and Passwords ............................................ 4-5
Enabling and Disabling the High Capacity Sheet Feeder
(HCSF) ........................................................................................ 4-5
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 Outsorted Material ................................................. 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
Table of Contents
6• Reference
Overview ..................................................................................... 6-2
System Specifications ................................................................. 6-2
Component Specifications .......................................................... 6-4
Feeder Tower and Base Material Specifications ......................... 6-7
General Information .............................................................. 6-7
Outer Envelopes ................................................................... 6-7
Inserts ................................................................................. 6-10
Sheets ................................................................................. 6-11
High Capacity Sheet Feeder (HCSF) Material Specifications ..6-12
General Information ............................................................ 6-12
Sheets ................................................................................. 6-12
Materials Not Certied for Use ............................................ 6-13
7 • Add-On Modules
About the Add-On Modules .........................................................7-2
High Capacity Sheet Feeder (HCSF) .........................................7-2
Loading the HCSF ................................................................ 7-3
Adjusting the HCSF Guides .................................................. 7-5
Flats Sealer ................................................................................. 7-7
Replacing the Envelope Edge Marker Roller ........................ 7-8
SV61311 Rev. E
iii
Table of Contents
Attached Printer .......................................................................... 7-9
SureTrac™ Process Verification System ................................... 7-13
Exit Options ..............................................................................7-15
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
Barcode Specifications ............................................................ 8-26
Setting the OMR Scanning Area ............................................... 8-29
Defining the First Mark Position and Code Length ................... 8-29
Defining the Clear Zone ............................................................ 8-30
Additional Information ............................................................... 8-31
BCR and OMR Mark Levels .....................................................8-31
Loading the Attached Printer .............................................. 7-10
Adjusting the Printer Interface Guides ................................ 7-11
Printing a Cover Sheet to the Top of the Attached Printer .. 7-13
DM Series™ Mailing System Interface
(DM800i™ or DM1000™ only) .............................................. 7-15
OptiFlow™ Vertical Power Stacker ..................................... 7-18
OptiFlow™ Belt Stacker ....................................................... 7-18
Exit Transport ...................................................................... 7-18
OMR ..................................................................................... 8-2
BCR ...................................................................................... 8-2
Scanning Features ................................................................ 8-4
Setting Up an OMR Scan Conguration ............................... 8-6
Setting Up a BCR Scan Conguration .................................. 8-9
Editing an OMR Scan Conguration ................................... 8-13
Editing a BCR Scan Conguration ...................................... 8-14
Adjusting the Scan Heads for Ladder Orientation Marks .... 8-19
Basic Level ......................................................................... 8-32
Enhanced Integrity Level .................................................... 8-34
Selective Operations Level ................................................. 8-35
iv SV61311 Rev. E
Appendix A • Glossary
Basic Terms ...............................................................................A-2
Material References ..............................................................A-2
Machine Functions ................................................................A-3
Icon Glossary ..............................................................................A-4
Envelope Icons .....................................................................A-4
Fold Icons .............................................................................A-5
Sheet Icons ...........................................................................A-5
Insert Icons ...........................................................................A-6
Feeder Assignment Icons .....................................................A-7
Other Icons ...........................................................................A-7
Index
Index ...................................................................................... I-1
Table of Contents
SV61311 Rev. E
v
Table of Contents
This page is intentionally blank.
vi SV61311 Rev. E
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™ at: 1.800.243.7824 or 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 - 8:00 PM ET.
• To obtain Material Safety Data Sheets, call the Supply Line™ or go to: www.pb.com and
click on Customer Support.
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. E
v
Contact Information List
This page is intentionally blank.
vi SV61311 Rev. E
1 • Introduction
A Note to the Operator.................................................................1-2
Viewing this Guide as a PDF File ................................................1-2
About Your System ......................................................................1-3
Standard Systems ................................................................. 1-4
System Options ..................................................................... 1-5
Safety Information .......................................................................1-6
Warning Labels ............................................................................1-7
Book Contents .............................................................................1-8
1-1SV61311 Rev. E
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.
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 ( ), you can click anywhere within a hyperlink to
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.
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. E
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, Attached Printer, and other devices.
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. E
1-3
1 • Introduction
Standard Systems
DI950C
DI950H
DI900C
DI900H
Letter and Flats Drop Stacker
(standard on all systems)
1-4 SV61311 Rev. E
Introduction • 1
DI900/DI950 Document Printing Options - Beta
System Options*
*Furniture, designed
specifically for the
system, is also
available.
Fold Expansion Kit
(Document Inverter)
OptiFlow™ Vertical
Power Stacker
High Capacity Sheet
Feeder (HCSF)
DM Series™ Mailing System
DM800i™, DM1000
Belt StackerTandem Belt Stacker
™
SV61311 Rev. E
Exit Transport
Flats Sealer
Attached Printer
1-5
1 • Introduction
Safety Information
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.
• 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.
1-6 SV61311 Rev. E
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 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.
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.
NOTICE
CAUTION
Moving mechanism can result
in personal injury.
Keep hands, long hair, ties,
jewelry and loose clothing
away from moving parts.
CAUTION
Moving mechanism can result in
personal injury.
Keep hands, long hair, ties,
jewelry and loose clothing away
from moving parts.
SV61311 Rev. E
1-7
1 • Introduction
Book Contents
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.
• Appendix A, Glossary - contains definitions for commonly used terms,
and explanations of the icons you'll see on the display screen.
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.
1-8 SV61311 Rev. E
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 ............................................................................2-20
Logging In ............................................................................ 2-21
Logging Out ......................................................................... 2-21
About System Covers ................................................................2-22
Opening the Covers ............................................................. 2-23
Closing the Covers .............................................................. 2-23
About the Paper Release Knobs/Levers ...................................2-24
About Add-On Modules .............................................................2-24
SV61311 Rev. E
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 conguration, 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. E
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 letter-size 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. E
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.
CAUTION
Moving mechanism can result in
personal injury.
Keep hands, long hair, ties,
jewelry and loose clothing away
from moving parts.
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. E
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. E
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. E
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
dened 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. Select a job that uses the Manual Feeder.
2. Push the Manual Feed lever up.
3. Press TRIAL PIECE to start the machine.
4. Feed each set by pushing the edge into the rollers one at a time.
5. Push the lever down when you are done.
Push the
Manual Feed
lever up.
Figure 2.4: Manual Feed Lever.
SV61311 Rev. E
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. E
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.
Meet the Inserting System • 2
Folder
Post-fold Accumulator
Insertion Area
The stack of collated sheets exits the Pre-fold Accumulator into the Folder.
The Folder then applies a fold to the stack and sends it to the Post-fold Ac-
cumulator. The Folder offers these options:
• C Fold,
• Z Fold,
• Single Fold,
• Double Fold, and
• No Fold.
An optional Inverter may be used for some address location/fold type combi-
nations.
The accumulation of folded sheets exits the Folder onto the Post-fold
Accumulator area. Other components of the mail piece, such as a Business
Reply Envelope or a pre-folded insert, are added to the accumulation in the
Post-fold Accumulator area. When all components are present, the stack
moves to the Insertion Area.
The contents of the mail piece meet the outer envelope at the Insertion
Area. The envelope arrives at the Insertion Area with its front face down and
flap open. Envelope Openers on the Insertion Area open the envelope wide
enough to allow the contents to be slid inside.
Folder Bypass Path
Moistener, Closer, Sealer
SV61311 Rev. E
The outer envelope, fed from the Feeder, that will contain the collated media
runs through the bottom part of the Transport Deck. The route this envelope
travels is known as the Folder Bypass Path.
As the envelope passes over the Moistener, brushes sweep across the top
of the flap to wet the glued area of the flap. The envelope is then inverted
and slid through the Closer and Sealer portion of the system to complete the
mail piece. From there, the mail piece is dropped onto a stacker.
2-9
2 • Meet the Inserting System
About the Control Panel
The Control Panel consists of the following components:
• Screen Option Keys allow you to define settings for up to 24 jobs that
you can store in the system’s memory. These keys also provide the
means to edit any of the stored jobs.
• Fixed Function Keys allow you to access the system’s built-in tools that
appear on the screen (such as the system’s help file).
• Screen Navigation Keys allow you to move UP/DOWN and right/left in
the Display and to apply selections that you’ve made.
• Machine Action Keys control hardware components and mechanical
movements.
• LED Status Indicator
LED Status Indicator
Screen Option Keys
Screen Option Keys
Reset
Counter
Start
Help
Trial
Piece
Cancel
Home
Clear
Deck
OK
Stop
Fixed Function Keys
Screen Navigation Keys
Machine Action Keys
Control Panel
The Screen Option Keys are the eight keys on the right side of the screen.
These keys correspond to options on the screen, and therefore have no
dedicated labels. Use these keys to highlight an item in a displayed pick list
and/or to select the associated menu, item, action, or option.
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Meet the Inserting System • 2
Fixed Function Keys
The Fixed Function Keys are the top row of keys under the screen. Each
of these keys has an assigned function that is enabled or disabled based
on the screen that displays. Use of each of these keys is explained next in
more detail.
Reset Counters
The system has two
counters:
• Piece Counter
• Batch Counter
Reset Counters
Job Items
Piece Count
A
Batch Count
B
D
Job: ABC
Both
SV61311 Rev. E
Reset Counters Screen
Resetting the Piece Counter
The Piece Counter appears in the bottom portion of the Display screen. It is
a cumulative counter, i.e., it increments for each completed mail piece.
If you run the same job but for a different customer and/or use different
materials, you'll need to zero the counter and ready it for counting the completed mail pieces in the new run.
To reset the Piece Counter:
1. Press RESET COUNTERS to display the Reset Counters screen.
2. Select "Piece Count".
3. You will be returned to the Home screen. The Piece Counter at the bottom of the screen will read "0".
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2 • Meet the Inserting System
Fixed Function
Keys (continued)
Resetting the Batch Counter
The Batch Counter counts up to a set number. It increments one count for
each completed mail piece that the system detects. The system stops when
it reaches the batch count.
To reset the desired number for the job you are running:
1. Press RESET COUNTERS to display the Reset Counters screen.
2. Select "Batch Count".
3. You will be returned to the Home screen. The Batch Counter at the bottom of the screen will return to its original setting.
NOTE: The original setting for the Batch Counter cannot be less than “5” or
greater than “9999”.
Resetting Both Counters
The Reset Both selection allows you to reset both the Piece Counter and the
Batch Counter to zero.
1. Press RESET COUNTERS to display the Reset Counters screen.
2. Select "Both".
3. You will be returned to the Home screen. The Piece Counter at the bottom of the screen will read "0" and the Batch Counter will return to its
original setting.
Help
Select "Help" for information about the screen that currently displays and for
access to the entire Help file.
Cancel
Select "Cancel" to return to the previous screen.
NOTE: If you made changes to a job before pressing "Cancel", you are prompted
to save the changes. Press "Yes" to save the changes; press "No" to delete the
changes and to return to the last screen in which you saved changes. Be aware
that once you delete the changes, they are permanently gone.
Home
Select "HOME" to return to the Home screen for the current job. The current
job will automatically include any changes made while editing the job. Although the job can be run now, the changes are not saved until you choose
"Save Job" from the menu. Jobs that have been changed but not saved
have an asterisk next to the job name at the top of the Home screen.
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