Pitney Bowes FastPac DI900, FastPac DI950, FastPac DI950e Operator's Manual

DI900/DI950/DI950e

FastPac™ Document Inserting System

Operator Guide Addendum

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 modications 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.

SV62081 Rev. A 12/07 ©2007 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. FastPac, DM Series, DM800i,
DM1000, SwiftStart, SureTrac, Optiflow, IntelliLink and E-Z Seal are trademarks or registered trade­marks of Pitney Bowes.

DI900/DI950 Operator

Guide Addendum

Introduction .....................................................................................4

Meet the Inserting System ..............................................................4

Fixed Function Keys ..................................................................4

Basic Operation .............................................................................. 7

Powering Up ..............................................................................7

Making Pre-Run Adjustments ....................................................8

Creating a Job ...........................................................................9

Creating a Job that Uses the Universal Feeder .......................11

Job Options .............................................................................14

Selecting a Job ........................................................................24

Troubleshooting ............................................................................26

Reference ..................................................................................... 31

System Specifications .............................................................31

Universal Feeder .....................................................................31

Feeder Tower Sheet Specifications .........................................31

DI900/DI950 Input Transport (F733) ........................................32

Add Ons and Options ...................................................................33

Universal Feeder .....................................................................33

High Capacity Loader (Optional) .............................................34

DI900/DI950 Input Transport ...................................................35

Scanning.......................................................................................40

Scanning Features ..................................................................40

3SV62081 Rev. A

DI900/DI950/DI950e Operator Guide Addendum

Introduction

Meet the
Inserting
System

This document contains information about the new features and options
available for the DI900/DI950 Inserting System. This document should be
used in conjunction with the FastPac™ Document Inserting System Operator
Guide.

NOTE: The availability of add-ons and options for your inserting system varies by
region. Refer to your system supplier for availability details.

New Features

• The inserter can single fold up to 10 20 lb. sheets.

• The inserter supports multiple inserts into flat envelopes.

• The inserter supports mail pieces that include inflexible inserts in enve­lopes having a depth of 6 in. (152.4 mm) to 7 in. (177.8 mm).

• The inserter supports marking of every nth envelope if the Flats Sealer
is present on the system.

The information in this section is intended for use as a replacement or sup­plement to information contained in Chapter 2, Meet the Inserting System in
the DI900/DI950 FastPac™ Document Inserting System Operator Guide.

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.

4 SV62081 Rev. A

DI900/DI950/DI950e Operator Guide Addendum

Fixed Function
Keys (continued)

Reset Counters

The system has two
counters:

• Piece Counter

• Batch Counter

NOTE: If the Flats Sealer
is present on the system,
the “Mark Piece Count”
option will be available
on this screen. When the
“Mark Piece Count” option
is available, the “Both”
reset option changes to
“All”. Refer to Chapter 7
in the DI900/DI950 Fast-

Pac™ Document Inserting
System Operator Guide

for more information
about the Flats Sealer.

Reset Counters

Job Items

A

B

D

Job: ABC

Piece Count

Batch Count

Both

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".

SV62081 Rev. A

5

DI900/DI950/DI950e Operator Guide Addendum

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 the Mark Piece Count

The Mark Piece Count selection allows you to reset the counter for the en­velope edge mark to zero.

1. Press RESET COUNTERS to display the Reset Counters screen.

2. Select "Mark Piece Count".

3. You will be returned to the Home screen. The counter will be reset to
zero.

Resetting Both (or All) Counters

The 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".

NOTE: If the Mark Piece Count option is available, select “All.” The counter
for the envelope edge mark will be reset to zero as well.

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.

6 SV62081 Rev. A

DI900/DI950/DI950e Operator Guide Addendum

Basic Operation

Powering Up

The information in this section is intended for use as a replacement or
supplement to information contained in Chapter 3, Basic Operation in the
DI900/DI950 FastPac™ Document Inserting System Operator Guide. These
instructions explain how to:

• properly power up the inserting system;

• create a job using the Universal Feeder on the DI900/DI950 Inserting
System; and

NOTE: You should be thoroughly familiar with each component of the Uni­versal Feeder and the optional High Capacity Loader before creating a job
on the DI900/DI950 Inserting System (see the Model F731/F732 Universal

Feeder and the optional Model F734/F735 High Capacity Loader Operator
Guide supplied with the system).

• select a job.

Press the ON/OFF switch (located below the Control Panel) to start the
power up process.

IMPORTANT:

• If additional modules are present (e.g. High Capacity Sheet Feeder, Universal
Feeder, DI900/DI950 Input Transport, Exit Transport), power on each module
from left to right.

• When powering the system off and on, be sure to power off all modules, from
left to right, then power them all back on from left to right.

The system will automatically conduct a number of checks to verify the op­erational integrity of the system. If any problems are detected, the system
will display information directing you to a solution to the problem.

SV62081 Rev. A

7

DI900/DI950/DI950e Operator Guide Addendum

Making Pre-Run
Adjustments

Adjusting the Manual Lever for Stiff Media Mode (DI950e Only)

Mail pieces with stiff inserts leave the machine through the flats exit. The
Stiff media feature requires manual lever (with sensor) to hold the flats gate
open. This hardware is included with DI950e inserters.

If the stiff media hardware is present, one or more of any insert type may be
designated “stiff”.

• Most common case is a single stiff insert from the Input Transport.

• Also possible is a job with multiple inserts from the tower that, taken to­gether, are stiff.

Once one or more inserts have been designated “stiff”, the job requires an
envelope of length 6 in. (152.4 mm) to 7 in. (177.8 mm) and the manual le­ver placed in the flats position.

• Envelopes must be fed from the Feeder Tower; the HCEF cannot be
used.

• Since mail piece components may be too short to leave the machine
through the flats exit when they are not in an envelope, CLEAR DECK
does not function in Stiff Media mode. Instead, you must clear the ma­chine manually.

To adjust the manual lever for Stiff Media mode:

1. Open the Sealer cover.

2. Adjust the lever to the stiff media position.

3. Close the Sealer cover.

Manual Lever

Position for Stiff Media

8 SV62081 Rev. A

DI900/DI950/DI950e Operator Guide Addendum

Creating a Job

The Stiff Media option is an addition to the “Menu Options” table on page
3-27 of the DI900/DI950 FastPac™ Document Inserting System Operator
Guide:

Reply Card

Reply Envelope

Pre-Folded Insert

Small Booklet

Slip

Generic Insert

Large Booklet

Stiff Media*

*The DI950e is required to feed this item.

a. If this is a scanning job, follow the steps below. Otherwise, go

to step b.

• The Scan Type screen displays. Select the appropriate
Scan Type (OMR, Code 3 of 9, or Interleaved 2 of 5.)

• The Scan Configuration screen displays. Select the
appropriate Scan Configuration.

• The Content - In Line with Marks screen displays. If there

is content in line with the scan marks, select "Yes". If there
is no content in line with the scan marks, select "No".

b. Select the appropriate options for the insert. Press “Accept”

when done.

Refer to the Insert Options table in Chapter 3 of the FastPac™
DI900, DI950 Operator Guide for specific information about each of
the related menu options.

The following definition is an addition to the “Menu Options” table on page
3-29 of the DI900/DI950 FastPac™ Document Inserting System Operator

Guide:

Mark Piece Count Select this option if you have a Flats Sealer and want to use

the envelope edge marker to mark every nth envelope. Use the
numeric matrix to enter the appropriate value.

NOTE: The Flats Sealer is a purchasable exit option. Only letter­sized envelopes can be marked using the envelope edge marker.
Refer to Chapter 7 of the FastPac™ DI900, DI950 Operator Guide
for more information about the Flats Sealer.

The following replaces the “Length of Clear Zone” definition on page 3-35 of
the DI900/DI950 FastPac™ Document Inserting System Operator Guide:

Additional Settings
(continued)

- Length of Clear Zone is the is the total length of the scan
marks plus the Clear Zones before and after the scan
marks.

The following replaces the “Insert Type” definition on page 3-36 of the

SV62081 Rev. A

9

DI900/DI950/DI950e Operator Guide Addendum

Creating a Job
(continued)

DI900/DI950 FastPac™ Document Inserting System Operator Guide:

Insert Type includes
all items that do not
need folding or have
been pre-folded.

• Reply Envelope - is also called a Business Reply Envelope.

• Reply Card - is a thick slip.

• Pre-folded Insert - is a sheet or set of sheets already folded
together.

• Small Booklet - is a type of insert that typically has a bound or
stapled edge.

• Slip - is single thickness document that fits into the outer
envelope without folding.

• Generic - is an undeclared type of insert used by SwiftStart™
jobs.

• Large Booklet - is a type of insert that typically has a bound or
stapled edge.

NOTE: A Custom Feeder is required to feed this item.

• Stiff Media - is a type of insert that is inflexible.

NOTE: The DI950e is required to feed this item. Once one (or

more) Stiff Media insert has been selected, the job requires an
outer envelope length of 6 in. (152.4 mm) to 7 in. (177.8 mm).
In addition, the manual lever for Stiff Media must be placed in
the flats position in order to run the job. Refer to Making Pre-
Run Adjustments in this document for more information.

The following replaces the “Quantity” definition on page 3-36 of the DI900/
DI950 FastPac™ Document Inserting System Operator Guide:

Quantity is the
number of this
particular insert to
include in each mail
piece.

NOTE: This menu
option is not available
when “Large Booklet”
is the selected insert.

• 1, 2, 3, 4, 5, 6

• Custom Quantity

- Use UP/DOWN arrow keys to select number.

- Select "Accept" when done.

• Variable - used with scanning-controlled jobs.

The following replaces the “Item Over Count Quantity” definition on page
3-38 of the DI900/DI950 FastPac™ Document Inserting System Operator
Guide:

Additional Settings
(continued)

• Item Over Count Quantity is the number of inserts that cannot
be run normally.

The following replaces the “Batch Mode” definition on page 3-39 of the
DI900/DI950 FastPac™ Document Inserting System Operator Guide:

Batch Mode Toggle:

• Off means this feature will not function for this job, or

• On means this feature is active.

10 SV62081 Rev. A

DI900/DI950/DI950e Operator Guide Addendum

Creating a Job
that Uses the
Universal Feeder

Creating a new job involves defining the contents of a new mail piece, and
optionally, saving the job for future use. This process consists of identifying
each item in the mail piece and selecting settings for the job. A Mail Piece
Icon Tree automatically builds on the screen as you add items.

To access the Create New Job screen:

1. From the Home screen, select “Menu”, then “Jobs”, and finally “Create
New Job.” The Create Job screen displays.

2. Enter the Job Name using the alphanumeric matrix.
a. Use the UP/DOWN and LEFT/RIGHT arrow keys to select a letter.
b. Press OK to add the letter to the job name. Highlight the arrow char-

acter and press OK to move the cursor within the job name.

c. Select “Accept Name” when done.

3. If scanning is present on the system, the Create - Job Type screen dis­plays.

• If the new job does not require scanning, select "Normal Type" to

continue.

• If the new job requires scanning, select "Scanning Job".

4. The Create Outer Envelope screen displays.

• If the job does not require an Outer Envelope, select "No".

• If the job requires an Outer Envelope, select “Yes.”

- Select the appropriate Outer Envelope options for the job. Refer
to the Envelope Options table in this document for more informa­tion about each of the related menu options.

- Press “Accept” when done.

- If the job is a scanning job, the Create - Only One Envelope
screen displays. If the job requires only one envelope, select
"Yes" and proceed to step 5.

- If the job requires an additional envelope, select "No, Two Outer
Envelopes". Validate the available options, and press "Accept"
when done.

SV62081 Rev. A

NOTE: If this is a scanning job, and you will be using dynamic enve­lope selection, you must select “No, Two Outer Envelopes”.

11

DI900/DI950/DI950e Operator Guide Addendum

Creating a Job
that Uses the
Universal Feeder
(continued)

5. The Create - Select Next Item screen displays. Select the appropriate
option.

NOTE: These instructions apply to items being fed by the Universal Feeder.

Menu Options Associated Options/Actions

Reply Card

Reply Envelope

Pre-Folded Insert

Small Booklet

Slip

Generic Insert

Large Booklet

Stiff Media

Sheet a. Select the “Custom Feeder” option. The Sheet - Personalized

a. If this is a scanning job, follow the steps in this section.

Otherwise, go to step b.

The Scan Type screen displays. Select “External Scan

Definition”.

NOTE: The External Scan Definition option is only available

if the Universal Feeder is present on the system. If the job
requires a Universal Feeder, External Scan Definition is the
only available option.

b. Select the appropriate options for the insert. Press “Accept”

when done.

Refer to the Insert Options section in this document for specific
information about each of the related menu options.

Create screen appears. Select the appropriate personalization
option. The Create - Verify Sheet screen appears.

b. If this is a scanning job, follow the steps below. Otherwise, go

to step c.

• The Scan Type screen displays. Select “External Scan
Definition”.

NOTE: The External Scan Definition option is only

available if the Custom Feeder is present on the system.
If the job requires a Custom Feeder, External Scan
Definition is the only available option.

• The Scan Configuration screen displays. Select the
appropriate Scan Configuration.

• The Content in Line with Marks screen displays. If there is

content in line with the scan marks, select "Yes". If there is
no content in line with the scan marks, select "No".

• If you selected "Yes", the Mark Locations Settings screen
appears. Follow the steps below to enter the various
mark-related measurements:

- Select an option, then use the UP/DOWN arrow keys

to enter the appropriate measurement (in millimeters).

- Press "Accept" when done entering the

measurement.

- Once all measurements have been entered, select

"Accept".

c. Select the appropriate Sheet options for the job. Press

"Accept" when done.

NOTE: If this is a scan job, set the Select Feed setting.

Refer to the Sheet Options table in this document for more

information about each of the related menu options.

d. Select the appropriate Fold options for the sheet. Press

"Accept" when done.

Refer to the Fold Options table in this document for specific

information about each of the related menu items.

12 SV62081 Rev. A

DI900/DI950/DI950e Operator Guide Addendum

Creating a Job
that Uses the
Universal Feeder
(continued)

6. Once you have finished adding a Sheet or Insert, the Add New Item
screen appears.

• Select "Yes" to add additional items to the job. Repeat step 4 as nec-

essary.

• Select "No" if you have finished adding items to the job.

7. The Create - Edit Job Settings screen displays. Select the appropriate
options.

Menu Options Associated Options/Actions

Job Comments Use the alphanumeric matrix to enter any additional information

related to the job. If the job will be saved by a supervisor or
manager, you can make it easy for operators to identify/select the
correct job in the future by entering a job description in the job
comments area.

NOTE: Job comments can contain up to 120 characters.

Batch Mode Toggle:

• Off means this feature will not function for this job, or

• On means this feature is active.

Batch Count Use the numeric matrix to enter the batch count value.

NOTE: The batch count can contain up to four digits. The

minimum is "5" and the maximum is "9999".

Set Over Max Count Indicates what will happen to sets that exceed the set over count

quantity. Choices include Divert and Stop.

Use Postage Meter Select this option if you will be using the Mail Machine Interface

(MMI). This interface enables communication between the Inserting
System and either a DM Series™ DM800i™ or DM1000™ mailing
system via a USB connection.

The system sends start and stop signals to the mailing system, and
the mailing system can send error messages back to the inserter to
stop feeding.

Toggle:

• Off means this feature will not function for this job, or

• On means this feature is active.

NOTE: The MMI is a purchasable exit option. Only letter-sized
envelopes can be used with this interface.

Refer to Chapter 7 of the FastPac™ DI900, DI950 Operator Guide
for more information about the MMI.

Mark Piece Count Select this option if you have a Flats Sealer and want to use

the envelope edge marker to mark every nth envelope. Use the
numeric matrix to enter the appropriate value.

NOTE: The Flats Sealer is a purchasable exit option. Only letter­sized envelopes can be marked using the envelope edge marker.
Refer to Chapter 7 of the FastPac™ DI900, DI950 Operator Guide
for more information about the Flats Sealer.

Advanced Allows access to advanced job settings.

IMPORTANT: Do not change the advanced job settings unless

instructed to do so. Changing settings may affect machine
performance.

SV62081 Rev. A

13