Pitney Bowes Relay 5000, Relay 8000, Relay 7000, Relay 6000 Operator's Manual
Shipping & Mailing
Inserter
Relay™
5000/6000/7000/8000
Document Inserting System
Operator Guide
International English Edition
SV63136 Rev. A
August 1, 2015
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 EMC Compliance
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.
It is certified that this system complies with all applicable Directives of the European
Union.
SV63136 Rev. A ©2015 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. Connect+, SwiftStart, 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 ................................................ v
USA Contacts .................................................................................v
Canada Contacts ............................................................................v
Contacts in other countries .............................................................v
1 • Introduction ............................................................1-1
A Note to the Operator ................................................................ 1-2
About Your System ..................................................................... 1-2
System Features ................................................................... 1-2
System Components ............................................................ 1-2
Standard Systems ...................................................................... 1-3
System Options .......................................................................... 1-4
Safety Information ....................................................................... 1-5
Warning Labels ........................................................................... 1-6
2 • Meet the Inserting System .....................................2-1
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
iSV63136 Rev. A
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 ......................................................3-1
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
Creating a Job .......................................................................... 3-26
Job Options ............................................................................... 3-30
Editing a Job ............................................................................. 3-40
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 High Capacity Envelope Feeder (HCEF) ........ 3-13
Adjusting the Envelope Openers ........................................ 3-18
Reviewing the Job Settings ................................................ 3-24
™
Jobs ........................................................................ 3-25
™
Using SwiftStart
............................................................... 3-26
Envelope Options ............................................................... 3-30
Fold Options ....................................................................... 3-32
Sheet Options ..................................................................... 3-33
Insert Options ..................................................................... 3-36
Modifying Job Settings ........................................................ 3-41
Editing an Item .................................................................... 3-41
Adding an Item .................................................................... 3-42
Moving an Item ................................................................... 3-44
Deleting an Item .................................................................. 3-45
4 • Advanced Operation ..............................................4-1
Overview ..................................................................................... 4-2
Using the Alphanumeric Matrix ................................................... 4-2
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
ii SV63136 Rev. A
Table of Contents
5 • Troubleshooting and Maintenance ....................... 5-1
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 ................................................................ 5-17
Daily Tasks .......................................................................... 5-17
Replacing the Moistener Wick ............................................ 5-17
Replacing the Moistener Brushes ....................................... 5-19
6• Specications .......................................................... 6-1
Overview ..................................................................................... 6-2
System Specifications ................................................................. 6-2
Component Specifications .......................................................... 6-4
Feeder Tower and Base Material Specifications ......................... 6-6
General Information .............................................................. 6-6
Outer Envelopes ................................................................... 6-6
Inserts ................................................................................... 6-9
Sheets ................................................................................. 6-10
High Capacity Sheet Feeder (HCSF) Material Specifications .. 6-11
General Information ............................................................ 6-11
Sheets ................................................................................. 6-11
Materials Not Certied for Use ............................................ 6-12
7 • Add-On Modules ..................................................... 7-1
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
File Based Processing .......................................................... 7-9
Exit Options ................................................................................ 7-9
Connect+ MMI .................................................................... 7-10
Vertical Power Stacker .......................................................7-13
Horizontal Belt Stacker ....................................................... 7-13
Exit Transport ......................................................................7-13
SV63136 Rev. A
iii
Table of Contents
8 • Scanning .................................................................8-1
Scanning Overview ..................................................................... 8-2
Setting Up a New Scan Configuration ...................................... 8-11
Editing a Scan Configuration .................................................... 8-18
Copying a Scan Configuration .................................................. 8-20
Deleting a Scan Configuration .................................................. 8-20
Reviewing a Scan Configuration ............................................... 8-21
Viewing the Job List .................................................................. 8-21
Assigning a Scan Configuration to an Existing Job ................. 8-22
Adjusting the Scan Heads ........................................................ 8-24
OMR Specifications .................................................................. 8-29
OMR Print and Placement Specifications ................................ 8-30
OMR Print and Placement Specifications ................................ 8-31
Barcode Specifications ............................................................ 8-32
Barcode Print and Placement Specifications ........................... 8-33
Barcode Print and Placement Specifications ........................... 8-34
Barcode Print and Placement Specifications ........................... 8-35
Barcode Print and Placement Specifications ........................... 8-36
Barcode Print and Placement Specifications ........................... 8-37
OMR ..................................................................................... 8-2
BCR ...................................................................................... 8-2
Physical Specications
for 2D Data Matrix Barcodes ................................................ 8-5
Supported Square and Rectangular Formats ....................... 8-5
Scanning Features ................................................................ 8-8
Supported ECC (Error Correction Code) Levels ................. 8-10
Setting Up an OMR Scan Conguration ............................. 8-11
Setting Up a BCR Scan Conguration ................................ 8-14
Editing an OMR Scan Conguration ................................... 8-18
Editing a BCR Scan Conguration ...................................... 8-19
Adjusting the Scan Heads for Ladder or
2D Orientation Marks .......................................................... 8-24
Adjusting the Scan Heads for Picket Orientation Marks ..... 8-27
OMR Placement Specications for Feeder Tower
(Ladder Orientation) ............................................................ 8-30
OMR Placement Specications for HCSF
(New Scan Kit F790250 - Ladder Orientation) ................... 8-31
1D Barcode Placement Specications for Feeder Tower ... 8-33
1D Barcode Placement Specications for HCSF ................ 8-34
1D Barcode Print and Placement Specications for HCSF 8-35
1D Barcode Placement Specications for HCSF ................ 8-36
2D Barcode Placement Specications for HCSF ................ 8-37
iv SV63136 Rev. A
Table of Contents
Setting the OMR Scanning Area ............................................... 8-38
Defining the First Mark Position and Code Length ................... 8-38
Defining the Clear Zone ............................................................ 8-39
Additional Information ............................................................... 8-40
BCR and OMR Mark Levels ..................................................... 8-40
Basic Level ......................................................................... 8-41
Enhanced Integrity Level .................................................... 8-43
Enhanced Integrity Level
Selective Operations Level ................................................. 8-45
Appendix A • Glossary ............................................... A-1
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
SV63136 Rev. A
v
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Contact Information List
USA Contacts
Product Name - Relay™ 5000/6000/7000/8000
• 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
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
Customer Support.
Canada Contacts
Product Name - Relay™ 5000/6000 or Relay™ 7000/8000
▪ 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.
™
at: 1.800.243.7824 or go to: www.
™
or go to: www.pb.com and click on
Contacts in other countries
Contact information will be given either on a sticker on the system or in a separate document
supplied with your system.
SV63136 Rev. A
v
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1 • Introduction
Contents
A Note to the Operator.................................................................1-3
About Your System ......................................................................1-3
System Features .........................................................................1-3
System Components ............................................................. 1-3
Standard Systems .......................................................................1-4
System Options ...........................................................................1-5
Safety Information .......................................................................1-6
Safety Information
Warning Labels ............................................................................1-7
(continued) ........................................................... 1-7
SV63136 Rev. A
This page is intentionally blank.
SV63136 Rev. A
Introduction • 1
A Note to the
Operator
About Your
System
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: The availability of add-ons and options for your inserting system
varies by region. Refer to your system supplier for availability details.
Relay™ 5000/6000/7000/8000 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.
System Features
• The inserter can fold up to a maximum of 10 sheets of 20 lb. (80 gsm)
with a single fold, subject to test.
• The inserter supports multiple inserts into flat envelopes.
• The inserter supports marking of every nth envelope if the flats sealer is
present on the system.
• The systems can be configured with four flexible feeder trays, that come
in two types:
- Sheet trays - capable of feeding sheets
- Insert trays - capable of feeding slip/insert materials, pre-folded
inserts, thin booklets, and envelopes.
• The Relay 7000/8000 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.
System Components
The systems are configured with two major components:
• Feeder Tower
• 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 into 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.
SV63136 Rev. A
1-3
1 • Introduction
Standard
Systems
Relay 8000
Relay 7000
Relay 5000
Relay 6000 (HCSF is optional)
Letter and Flats Drop Stacker
(standard on all systems)
IMPORTANT Model and feature availability varies by country. Contact your
machine supplier for more information. This guide covers all models and
features. Information included in this guide does not guarantee availability of a
particular model or feature within your country.
1-4 SV63136 Rev. A
Introduction • 1
System Options
(Furniture, designed
specifically for the
system, is also
available.)
Fold Expansion Kit
(Document Inverter)
Vertical Power
Stacker
High Capacity Sheet
Feeder (HCSF)
Connect+
Belt StackerTandem Belt Stacker
IMPORTANT Model and feature availability varies by country. Contact your
machine supplier for more information. This guide covers all models and features.
Information included in this guide does not guarantee availability of a particular
model or feature within your country.
SV63136 Rev. A
Exit Transport
Flats Sealer
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 SV63136 Rev. A
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.
• This device is not intended for use in the direct field of view at visual
display workplaces. To avoid incommoding reflexions at visual display
workplaces, this device must not be placed in the direct field of view.
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
SV63136 Rev. A
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.
CAUTION
Moving mechanism can result in
personal injury.
Keep hands, long hair, ties,
jewelry and loose clothing away
from moving parts.
NOTICE
CAUTION
Moving mechanism can result
in personal injury.
Keep hands, long hair, ties,
jewelry and loose clothing
away from moving parts.
1-7
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2 • Meet the Inserting
System
Contents
System Components ...................................................................2-3
System Components (continued) ................................................2-4
Feeder Tower ............................................................................... 2-5
Feeder Trays ...............................................................................2-6
Sheet Trays ........................................................................... 2-6
Insert Trays ............................................................................ 2-7
Manual Feeder ............................................................................2-8
Transport Deck ............................................................................2-9
Mail Piece Path ...................................................................... 2-9
Pre-fold Accumulator ............................................................. 2-9
Folder .................................................................................. 2-10
Post-fold Accumulator ......................................................... 2-10
Insertion Area ...................................................................... 2-10
Folder Bypass Path ............................................................. 2-10
Moistener, Closer, Sealer .................................................... 2-10
About the Control Panel ............................................................2-11
Screen Option Keys ..............................................................2-11
Fixed Function Keys ............................................................ 2-12
Fixed Function Keys (continued) ......................................... 2-13
Machine Action Keys ........................................................... 2-14
Screen Navigation Keys ...................................................... 2-14
Display Screen ..........................................................................2-15
Header Area ........................................................................ 2-15
Status Area .......................................................................... 2-16
Status Area (continued) ....................................................... 2-17
Status Area (continued) ....................................................... 2-18
Status Area (continued) ....................................................... 2-19
Status Area (continued) ....................................................... 2-20
Access Rights ............................................................................2-21
Access Rights (continued) .........................................................2-22
Logging In ............................................................................ 2-22
Logging Out ......................................................................... 2-22
About System Covers ................................................................2-23
Opening the Covers ............................................................. 2-24
Closing the Covers .............................................................. 2-24
About the Paper Release Knobs/Levers ...................................2-25
About Add-On Modules .............................................................2-25
SV63136 Rev. A
This page is intentionally blank.
Meet the Inserting System • 2
System
Components
The base system configuration includes a feeder tower, transport
deck, and envelope sealer; the Relay 7000/8000 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 Relay 5000/6000 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
Relay 7000/8000 only
SV63136 Rev. A
2-3
2 • Meet the Inserting System
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
7
intended 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 shown) or Power Stacker
(optional, not shown) - 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 (Relay 7000/8000 only) - holds
at least 500 letter-sized envelopes. It feeds directly to the Insertion
Area.
2-4 SV63136 Rev. A
Meet the Inserting System • 2
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
SV63136 Rev. A
2-5
2 • Meet the Inserting System
Feeder Trays
Sheet Trays
There are two types of feeder trays:
• Sheet Trays
• Insert Trays
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 this guide.
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.
2-6 SV63136 Rev. A
Figure 2.3.1: Sheet Trays
Meet the Inserting System • 2
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
SV63136 Rev. A
2-7
2 • Meet the Inserting System
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 inserter.
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.
2-8 SV63136 Rev. A
Meet the Inserting System • 2
Transport Deck
The transport deck accepts material from the feeder lower and moves it
through the various modules to produce a finished mail piece. The standard
transport deck consists of the following:
Moistener,
Closer,
Sealer
Pre-fold
Accumulator
Folder
Post-fold
Accumulator
Insertion
Area
Mail Piece Path
Pre-fold
Accumulator
Figure 2.5: Transport Deck
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.
SV63136 Rev. A
2-9
2 • Meet the Inserting System
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
Accumulator. The Folder offers these options:
• C Fold
• Z Fold
• Single Fold
• Double Fold
• No Fold
(An optional Inverter may be used for some address location/fold type
combinations.)
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
2-10 SV63136 Rev. A
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.
Meet the Inserting System • 2
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.
SV63136 Rev. A
2-11
2 • Meet the Inserting System
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 here:
Reset Counters
The system has two
counters:
• Piece Counter
• Batch Counter
NOTE: If the ats 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”.
Reset Counters
Job Items
Piece Count
A
Batch Count
B
D
Job: ABC
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 reads "0".
2-12 SV63136 Rev. A
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