Pitney Bowes W660, W680 User Manual

Notice
The use of this information by the recipient or others for purposes other than the repair, adjustment or operation of Pitney Bowes equipment may constitute an infringement of patent and/or other intellectual property rights of Pitney Bowes or others. Pitney Bowes assumes no
responsibility for any such use of the information.
Except as provided in writing, duly signed by an officer of Pitney Bowes, no license, either express or implied, under any Pitney Bowes or any third party’s patent, copyright, or other intellectual property rights is granted by providing this information.
SV60702C
Third edition, January, 2002. ©2002 Pitney Bowes Inc. All rights reserved. This book may not be reproduced in whole or in part in any fashion or stored in a retrieval system of any type or transmitted by any means, electronically or me­chanically, without the express written permission of Pitney Bowes.
We have made every reasonable effort to assure the accuracy and usefulness of this manual, however we can not assume responsibility for errors or omissions or liabil­ity for the misuse or misapplication of our products.
Envelope Designer and SmartMailer are registered trademarks of Pitney Bowes, Inc. Microsoft and Windows are trademarks or registered trademarks of Microsoft Cor­poration.
NOTE: W660/W680
The similarity of the W660 and W680 printers allows their features and operation to be documented together. The principle difference in these printers is that the W680 is a color printer that uses both a black and color ink cartridge. The W660 only uses a black ink cartridge.
The photos and illustrations in this document are of the W680 printer, but represen­tative of each printer.

Table of Contents

Chapter 1, W660/W680 Overview
Welcome to the W660/W680 .................................................... 1-2
Using This Guide ....................................................................... 1-2
System Requirements ................................................................ 1-3
Getting Help .............................................................................. 1-3
Online Help......................................................................... 1-3
Phone Support .................................................................... 1-4
Before You Call .................................................................... 1-4
The World Wide Web ......................................................... 1-4
Printer Options .......................................................................... 1-4
Ordering Supplies ...................................................................... 1-5
Chapter 2, Setting Up the W660/W680 Printer
Unpacking the Printer ............................................................... 2-2
Package Contents ................................................................ 2-3
Setting Up the W660/W680 ...................................................... 2-4
Choosing a Location for Your Printer ...................................... 2-5
Important Safety Notes ............................................................. 2-5
Assembling the W660/W680..................................................... 2-6
1. Attach the Wireframe to the Printer .............................. 2-7
2. Install the Sliding Fence .................................................. 2-8
3. Position the Output Stacker Tray ................................... 2-9
4. Connect the Parallel Cable or Serial Cable .................... 2-10
5. Connect the Power Cord ................................................ 2-12
6. Install the Ink Jet Cartridges (Color & Black) ............... 2-13
Removing the Ink Jet Cartridges ............................................... 2-15
Chapter 3, W660/W680 Basics
Printer Features.......................................................................... 3-2
Speed ................................................................................... 3-2
Print Qualities ..................................................................... 3-2
Internal Fonts...................................................................... 3-2
Font Size .............................................................................. 3-2
Material Thickness .............................................................. 3-3
Media Size ........................................................................... 3-3
Approved Media Types ....................................................... 3-3
Pitney Bowes W660/W680 Operator Guide i
Table of Contents
Setting Up a Job ......................................................................... 3-4
1. Set the Separator Gap ..................................................... 3-6
2. Center the Wireframe under the Material ..................... 3-9
3. Set the Feed Angle ........................................................... 3-10
4. Position the Sliding Fence .............................................. 3-11
5. Load Material .................................................................. 3-12
6. Adjust the Position of the Feed Ramp ........................... 3-13
7. Adjust the Media Thickness Lever ................................. 3-14
8. Adjust the Exit Rollers .................................................... 3-15
9. Print a Test Piece ............................................................. 3-16
Chapter 4, Using the W660/W680 With Your Computer
Installing the Printer Driver ...................................................... 4-2
Selecting Printer Properties....................................................... 4-10
Using the Printer Properties Window ...................................... 4-11
Selecting the W660/W680 Printer from a Windows
Application .......................................................................... 4-25
Envelope Designer™.................................................................. 4-26
Chapter 5, Printer Maintenance
Preventive Maintenance ............................................................ 5-2
Cleaning ..................................................................................... 5-2
Print Quality Problems ............................................................. 5-2
Exit Rollers ................................................................................. 5-3
Sensor ......................................................................................... 5-3
Floor Assembly and Top Cover ................................................. 5-3
Chapter 6, Troubleshooting
Problems and Solutions ............................................................ 6-2
Feed Problems ..................................................................... 6-2
Print Quality Problems....................................................... 6-3
Interface Problems .............................................................. 6-4
Connector Diagram ............................................................ 6-5
Motor Problems .................................................................. 6-6
ii
Pitney Bowes W660/W680 Operator Guide
Table of Contents
Barcode Problems ............................................................... 6-6
Other Problems................................................................... 6-7
Appendix A, Control Panel Menus
Using the Control Panel ............................................................ A-2
Using the Menus ........................................................................ A-3
Using the Main Menu ................................................................ A-5
Main Menu Diagram................................................................. A-6
1. Address Layout ................................................................ A-7
2. Print Quality ................................................................... A-10
3. Font Selection.................................................................. A-12
4. Barcode ............................................................................ A-14
5. Address Recovery ............................................................ A-16
6. Clear Counter.................................................................. A-18
7. Job Settings...................................................................... A-18
Using the Setup Menu ............................................................... A-20
Setup Menu Diagram ................................................................ A-21
1. Heavy Media Mode ......................................................... A-22
2. Test Print Head................................................................ A-22
3. Purge Print Head ............................................................ A-23
4. Lines Per Address ............................................................ A-23
5. Communications ............................................................ A-24
6. Hex Dump Mode ............................................................ A-26
7. Language.......................................................................... A-28
8. Envelope Feed Delay ....................................................... A-30
9. Auto Envelope Eject ........................................................ A-30
10. ROM Revision Number ................................................ A-31
Appendix B, Specifications
W660/W680 Specifications ....................................................... B-1
Index
Index to the Contents of this Manual....................................... i-1
Pitney Bowes W660/W680 Operator Guide iii
Chapter
1
The W660/W680 Printer Overview
The Pitney Bowes W660/W680 is a versatile, easy-to-use desk­top printer designed for ad­dressing applications.
This chapter explains what's in this guide, and tells you how to order supplies and where to get more information about using your W660/W680.
In this chapter:
Welcome to the W660/W680 Ink Jet
Printer ................................................. 1-2
Using This Guide............................... 1-2
System Requirements .................... 1-3
Getting Help ......................................1-3
Printer Options ................................. 1-4
Ordering Supplies .............................1-4
1 • W660/W680 Printer - Overview

Welcome to the W660/ W680 Ink Jet Printer

Using This Guide

The Pitney Bowes W660/W680 ink jet printer is a desktop printer used to print addresses, graphics and other information, in color (W680), on a wide range of material of various sizes, construc­tion and composition. With the W660/W680 you can define the font, placement, print quality and bar code characteristics for your addresses.
This Operator Guide shows you how to:
Set up the W660/W680 printer
Connect it to your computer
Define your envelope layout
Print a test mail piece
Send a mail job to the printer from your computer
application.
Refer to this guide for information about printer setup, operation and troubleshooting. It is divided into the following chapters:
Chapter 1, Introduction
Contains an overview of the W660/W680 Operator Guide, information about ordering supplies and a list of help resources.
Chapter 2, Setting Up the the printer.
Contains instructions for assembling your printer.
Chapter 3, Printer Basics
Explains how to set up your printer to run a job.
Chapter 4, Using the Printer With Your Computer
Contains instructions for installing the printer driver, selecting the printer from your software program and sending a mail job from your computer.
Chapter 5, Printer Maintenance
Describes how to keep the printer clean and functioning prop­erly.
Chapter 6, Troubleshooting
Contains a list of possible problems and their solutions.
1-2 Pitney Bowes W660/W680 Operator Guide
W660/W680 Printer - Overview • 1
Appendix A, Control Panel Menus
Explains the Main Menu and Setup Menu options available on the W660/W680 control panel.
Appendix B, Specifications
Provides hardware and material specifications. Your printer will run at its best when your material conforms to our specifications.

System Requirements

Getting Help

In order to operate the W660/W680 with your computer, your system must meet the following requirements:
CPU 80486 or Pentium recommended
8 MB RAM recommended; 16 MB or more preferred
Operating System Windows 95/98/2000/NT/ME
Parallel Cable A parallel cable is supplied with your
printer. If you choose to use another cable, make sure it isn't any longer than 10 feet.
Or Serial Cable To use the serial port, a serial cable of no
more than 15 feet in length is required.
As you use your printer, there may be times when you need help to solve a specific application problem, or you may want addi­tional information about printer operation. Pitney Bowes pro­vides several information resources.
Online Help
The W660/W680 Print Driver has a built-in help system. To get to the driver, click on Properties from Windows print dialog box. Right- click on items in question for the "What's This" Help button.
If you're using Pitney Bowes programs such as Envelope De­signer or SmartMailer™, press the F1 key while you're using the program to display information about the open screen. Select the Help menu to display a list of topics or search for a term. Refer to the documentation supplied with these programs for more information.
Pitney Bowes W660/W680 Operator Guide 1-3
1 • W660/W680 Printer - Overview
Getting Help (continued)
Phone Support
If you need technical support, call the Pitney Bowes National Diagnostic Center at:
(800) 253-6565
Before You Call...
Please see Chapter 6, Troubleshooting, for a description of common problems and their solutions. If you need to call, please
have the following information at hand:
Product name: W660/W680.
Serial number: See back of unit.
Nature of problem: What happens and when does it
happen?
The steps you've already taken to solve the problem and
the results.
The World Wide Web
We encourage you to visit our web site at:
http://www.pb.com
You'll find the latest information about our products and services as well as answers to frequently asked technical questions.

Printer Options

1-4 Pitney Bowes W660/W680 Operator Guide
Pitney Bowes offers several very useful options for your W660/ W680:
Envelope Designer lets you create a professional looking envelope in a matter of seconds—you don't have to bother with the print driver or make manual settings.
The W853 Ink Dryer helps to eliminate smudging on difficult materials like glossy stock.
The W760 Power Stacker holds up to 300 #10 envelopes. It helps maintain a neat stack in ZIP Code order when you run long jobs.
SmartMailer software refines and presorts mailing list entries to enable faster mail delivery at the lowest pos­sible rates.
W660/W680 Printer - Overview • 1

Ordering Supplies

You can order supplies for your W660/W680 printer directly through the Pitney Bowes Supply Line. To place an order, call:
(800) 243-7824
The following supplies are available for your W660/W680 printer:
Single Black Ink Cartridge (order number 711-1)
Single Color Ink Cartridge (W680 only) (order number
660-5)
4 Pack of Black Ink Cartridges (order number 660-9)
Pitney Bowes W660/W680 Operator Guide 1-5
1 • W660/W680 Printer - Overview
1-6 Pitney Bowes W660/W680 Operator Guide
Chapter
2
Setting Up the W660/W680 Printer
This chapter explains how to unpack, assemble and connect your new printer.
In this chapter:
Unpacking the Printer ..................... 2-2
Package Contents ............................ 2-3
Setting Up the W660/W680 .......2-4
Choosing a Location ....................... 2-5
Important Safety Notes ................ 2-5
Assembling the W660/W680 ..... 2-6
Attaching the Wire Frame .............. 2-7
Installing the Fence ........................ 2-8
Positioning the
Output Stacker ............................... 2-9
Connecting the Parallel or
Serial Cable ..................................... 2-10
Connecting the Power Cord .......... 2-12
Installing the Ink Jet Cartridge .. 2-13
Removing the Ink Jet Cartridge .. 2-15
2 Setting Up the W660/W680 Printer

Unpacking the Printer

As you remove the W660/W680 contents from the box, check the parts against the list on the opposite page.
1
2
3 4
(Shipped Assembled)
7
65
2-2 Pitney Bowes W660/W680 Operator Guide
Setting Up the W660/W680 Printer • 2
Unpacking the Printer
Package Contents
1. W660 or W80 Printer
2. Output Stacker
3. Wire Frame with Feed Ramp, Washer and Retaining Knob (Input Material Stacker assembled)
4. Long Sliding Fence
5. Power Cord
6. Short Sliding Fence
7. Parallel Cable
Not Shown:
Printer Driver Software (SAPS)
Ink Jet Cartridges (Color - W680 only, and Black -
both models)
Quick Setup Instructions
Printer Operating Guide
Operator Training Guide
PostNet Certificate
Installation Quality Report
Operator Safety Tip Card
Pitney Bowes W660/W680 Operator Guide 2-3
2 Setting Up the W660/W680 Printer

Setting Up the W660/W680

The assembled printer should look like the picture below. The parts you have to put together are identified.
Wireframe
Input Stacker
Feed Ramp
and Lock Knob
Sliding
Fence
Output Stacker
Refer to this picture as you set up your printer. Follow the steps on pages 2-7 through 2-15. The following product orientation will be useful in performing these steps:
Front is the area of the printer housing the LCD. Rear is the area of the printer with the cable interface panel. Left side is the input area of the printer. Right side is the output area of the printer.
2-4 Pitney Bowes W660/W680 Operator Guide
Setting Up the W660/W680 Printer • 2

Choosing a Location for Your Printer

Important Safety Notes

Follow these guidelines and safety precautions when selecting a location for your printer.
Place the printer on a table or other stable, level surface within the cable's length (Parallel 10 feet max. - Serial 15 feet max.) of your computer.
Allow for adequate space. The W660/W680 is 14.7 inches high, 16.2 inches wide and 21.7 inches deep, without the wire frame input stacker.
Allow for adequate ventilation around the base and rear of the printer.
Protect the printer from heat, dust and moisture. Avoid placing the printer in direct sunlight.
To protect against electric shock, plug the machine into a properly grounded wall outlet. DO NOT use an adapter plug. Use of an adapter could compromise the ground and cause a possible shock hazard or damage to the equipment in the event of a short circuit.
DO NOT remove the ground pin from the line cord.
Avoid using outlets controlled by wall switches. Someone
could accidently shut your printer off.
The power cord wall plug is the primary means of disconnecting the machine from the AC power. The wall outlet should be near the machine and easily accessible.
DO NOT route the power cord over sharp edges or trap it between pieces of furniture.
Insure that there is no strain on the power cord where it passes between the equipment, walls or furniture.
Be certain the area in front of the wall receptacle into which the machine is plugged is free from obstruction.
Pitney Bowes W660/W680 Operator Guide 2-5
2 Setting Up the W660/W680 Printer
Important Safety Notes

Assembling the W660/W680

Do not remove covers. The machine covers serve to enclose hazardous parts. If the machine has been dropped or has otherwise had the covers stressed in any way, report it to your Pitney Bowes Customer Service Representative.Keep fingers, loose clothing, jewelry and long hair away from the moving parts.
To reduce the risk of fire and/or electrical shock, do not attempt to disassemble this machine. If service is re­quired, contact your Pitney Bowes Customer Service Representative.
Use only Pitney Bowes approved supplied ink cartridges and cleaners. Read all instructions before attempting to operate the equipment.
In addition, follow any specific occupational safety and health standards for your workplace or area.
Once you've placed the printer in a suitable location, assemble the printer components in the following order:
NOTE: Do not plug the printer into the power source until you've completed steps 1-4.
1. Install the wireframe input stacker (page 2-7).
2. Install the sliding fence (page 2-8).
3. Position the output stacker (page 2-9).
4. Connect the parallel or serial cable (page 2-10).*
5. Attach the power cord and turn the printer ON (page 2-11).
6. Install the ink jet cartridges (page 2-13).
Instructions for installing each of these components start on the next page.
* Requires use of a small flat-head screwdriver.
2-6 Pitney Bowes W660/W680 Operator Guide
Setting Up the W660/W680 Printer • 2
Assembling the W660/W680 (continued)
1. Attach the Wire Frame to the Printer.
1. Hook the bottom edge of the wire frame under the tabs in the frame slide.
2. Rotate the wire frame and insert the curved metal bar on the bottom of the frame into the height adjustment slot. See photos below.
Tabs
Height
Adjustment
Slot
Curved
metal Bar
3. Adjust the height of the wireframe so it's positioned at about a 45 degree angle. Turn the lock knob on the side of the slide clockwise to hold the wireframe in position.
Wire Frame
Bottom
Edge
Lock
Lever
Lock
Knob
You can adjust both the height and side-to-side position of the wireframe to accommodate the size and type of the material you're running. We talk about this in the next chapter.
Pitney Bowes W660/W680 Operator Guide 2-7
2 Setting Up the W660/W680 Printer
Assembling the W660/W680 (continued)
2. Install the Sliding Fence
The W660/W680 has two fencesa long one and a short one. Use the short fence when printing material smaller than a #10 envelope. Use the long fence for larger material.
Slide the square edge of the sliding fence into the slots on the frame slide as shown below. The fence fits snugly in the slots to ensure accurate positioning during operation. The next chapter explains how to set the fence to the width of the material you're running.
Sliding Fence
in Position
2-8 Pitney Bowes W660/W680 Operator Guide
Setting Up the W660/W680 Printer • 2
Assembling the W660/W680 (continued)
3. Position the Output Stacker Tray
Printed material is deposited in the output stacker tray. The tray can stack up to 150 #10 envelopes. Slide it under the output area of the printer as shown below, then center it on the output area. Right to left placement of the tray varies with the size of the media being printed.
Output Stacker
Tra y
Pitney Bowes W660/W680 Operator Guide 2-9
2 Setting Up the W660/W680 Printer
Connecting the W660/W680 to Your Computer
4. Connecting the Parallel Cable or Serial Cable
Use the parallel cable supplied to connect the W660/W680 to your computer, or use an approved serial cable.
Each end of the parallel cable has a connector. One end is labelled Printer and the other is labelled “Computer.
1. To connect the Parallel Cable to the printer, align the end of the cable connector labelled “Printer” with the parallel port on the interface panel at the rear of the printer. (See the figure below.) Push the cable connector into the port.
Serial Port
Parallel Port
Power Switch
Power Receptacle
2-10 Pitney Bowes W660/W680 Operator Guide
Fuse
Setting Up the W660/W680 Printer • 2
2. Secure the connector by snapping the two wire clips over the corresponding tabs on the connector, as shown in the figure below.
3. Align the end of the cable connector labelled “Computer with the printer port on your computer, then push the cable connector into the port. Secure the connection by tightening the screws on either side of the connector.
4. To connect a Serial Cable to the printer, align the 25 pin male connector end of the cable with the serial port on the left side of the printer's interface. Attach the cable to the printer and the computer's hex jack screws using the thumb screws in the connectors.
5. Initialize the W660/W680's communication port by sending data to either the parallel or serial port. When the serial interface is used, the W660/W680 Communica­tions menu settings must be configured to match the computer settings. Configure the computer to use either the XON/XOFF or DTR handshaking settings to commu­nicate with the W660/W680. Use the following sub menus to change the W660/W680 serial communica­tions: A. Baud Rate, B. Parity, C. Word Length and D. Line Termination.
Pitney Bowes W660/W680 Operator Guide 2-11
2 Setting Up the W660/W680 Printer

Connecting to Po w e r

Turning On the W660/W680

5. Connect the Power Cord
1. Connect the female end of the power cord to the power receptacle in the interface panel. Refer to the figure on page 2-10.
2. Plug the male end of the power cord into a grounded outlet. Please review the safety information on pages 2-9 and 2-10.
Once you've connected the cable, press the printers power switch to the “|” (ON) position. The switch is located next to the power cord receptacle.
When you turn the printer on:
The LCD menu shows the "STARTUP" and "INITIALIZ­ING" screens.
After the print head carriage moves to the right and parks in the maintenance station, the LCD shows the "ON LINE" screen.
2-12 Pitney Bowes W660/W680 Operator Guide
Setting Up the W660/W680 Printer • 2

Installing and Removing the Ink Jet Cartridges

6. Install the Ink Jet Cartridges (Color & Black).
The printer uses Ink Jet Cartridges for printing. You must install a black only cartridge (W660), or a black and a color cartridge (W680), before you can print. To begin:
1. With the printer on, press the On Line key until the display reads OFF LINE.
2. Open the Transport Door of the printer.
3. Press the Cartridge+ key on the control panel to move the carriage to the middle of the printer.
4. Remove the color (W680 only) or black cartridge (both models) from its shipping container by peeling the top cover off. Be careful not to touch the copper ribbon.
WARNING! The ink in the cartridge may be harmful if swallowed. Keep new and used car­tridges out of reach of children. Discard empty cartridges immediately.
5. Gently remove the tape covering the ink nozzles on the print cartridge. Be careful not to touch the copper nozzles.
6. Gently insert the cartridge (color to the right, black to the left) into the carriage at approximately a 20 degree angle with copper strip to the bottom and in first. Press down on the cartridge until it is seated.
Note: The print cartridge photos in this section are of the W680 printer. The W660 has only one cartridge.
Pitney Bowes W660/W680 Operator Guide 2-13
2 Setting Up the W660/W680 Printer
Installing and Removing the Ink Jet Cartridges (continued)
7. Push the cartridge forward (away from you) until it snaps in place.
8. Close the Transport Door.
9. The prompt asks about resetting the ink level. Select "YES" if you have installed a new cartridge. Otherwise, select "NO".
10. Press Enter. The display returns to the "OFF LINE" screen.
Note: The print cartridge photos in this section are of the W680 printer. The W660 has only one cartridge.
2-14 Pitney Bowes W660/W680 Operator Guide
Setting Up the W660/W680 Printer • 2
Installing and Removing the Ink Jet Cartridges (continued)
Removing the Ink Jet Cartridges
To remove or replace the ink jet cartridges, follow these steps:
1. With the printer on, press the On Line key until the display reads OFF LINE.
2. Open the Transport Door of the printer.
3. Press the Cartridge key on the control panel. This moves the carriage to the middle of the printer.
4. To remove the ink jet cartridge (color or black), place your thumb on the grooved surface and press down until it pops loose.
5. Lift the print cartridge out of the cradle.
Pitney Bowes W660/W680 Operator Guide 2-15
2 Setting Up the W660/W680 Printer
2-16 Pitney Bowes W660/W680 Operator Guide
Chapter
3
W660/W680 Basics
In this chapter you'll learn about key features of the W660/W680 printer and how to adjust it to meet the re­quirements of your print jobs.
In this chapter:
Printer Features ...............................3-2
Set Up the Job ................................ 3-4
Set the Separator Gap ................. 3-6
Center the Wireform....................... 3-9
Set the Feed Angle ........................ 3-10
Position the Feed Fence ................. 3-11
Load Materials ............................... 3-12
Adjust Feed Ramp ......................... 3-13
Adjust Media Thickness Lever .... 3-14
Adjust Upper Exit Rollers ............ 3-15
Print a Test Piece ...........................3-16
3 W660/W680 Basics

Printer Features

The W660/W680 has the following features:
Speed (pieces per hour): 9000 # 10 envelopes, 3 lines,
10 pt, Black
Print Qualities Draft, Letter, Executive Internal Fonts: 13 (14 including Code 39
Barcode)
Optional Font Card Font Point Size: 4 to 30 Material Thickness: 0.003" to .118"
Speed
Printer speed refers to the number of pieces of mail that can be processed in an hour. The W660/W680 can process 9000 number 10 envelopes per hour, depending on the address content and configuration. Printer speed depends on the number of charac­ters per line, the number of lines, character size, font, interface, barcode, material size and graphics.
Print Qualities
The printer has three selectable print qualities: Draft (fastest speed), Letter (medium speed) and Executive (slowest speed).
Internal Fonts
A font is a set of characters (letters, numbers and symbols) that use the same typeface. The W660/W680 has thirteen (plus Code 39 barcode) different typefaces: Courier, Sans Serif, Roman, OCR A, Quincy, Springer, Hancock, Alpine, Baxter, Marina, Stencil, Windmill, and Silicon. You can select these fonts from the printer control panel menus.
If you set up a print job from your computer, you can use any font that is available from your software application.
Font Size
Font size refers to the size of each typeface. The W660/W680 uses from 4 to 30 point size for internal or downloaded fonts.
3-2 Pitney Bowes W660/W680 Operator Guide
W660/W680 Basics • 3
Printer Features (continued)
Material Thickness
Thickness refers to the size of the material that is processed through the printer. The W660/W680 can handle material from .003" up to .118" thick.
Media Size
The W660/W680 can print on the following range of material sizes.
Width Height Thickness
Maximum 12.5" 15" .118"
(317.5 mm) (381 mm) (3.0 mm)
Minimum 3 " 5" .003"
(76 mm) (127 mm) (.0762 mm)
For envelope addressing purposes, the W660/W680 is compatible with any word processor or database application that can print a mailing label.
Approved Media Types
The printer can be used with the following types of material:
Envelopes Postcards
Booklets-Tabbed Self Mailers
Catalog envelopes Paper
All envelopes must be without windows, empty and unsealed. Any folded material needs to be tabbed.
Refer to Appendix B, Specifications, for detailed specifications for the W660/W680, including specific requirements for using each type of material.
Other printer features include:
Ink Jet technology with shuttling head.
Interface to a standard IBM® compatible computer.
Pitney Bowes W660/W680 Operator Guide 3-3
3 W660/W680 Basics
Prints USPS POSTNET certified bar code.
LCD menu display available in seven languages.
Memory capable of storing up to eight jobs.
Printing virtually anywhere on an envelope.
Graphic printing capability.

Setting Up A Job

Setting up a print job means adjusting the printer to accommo­date the width, height, thickness and weight of your material. There are two things that determine how reliably your printer feeds: the setup adjustments and the quality of your material. A good setup minimizes misfeeds and jams. And your printer will perform at its best when you run material that falls within our published specifications. Please see Appendix B for complete material specifications.
The figure on the next page calls out key machine components, each of which is briefly described in the text that follows. Refer to the figure on the next page for component location.
1. H-Block Separators
Adjust to the thickness of your material. The gap between the H­Block separator fingers and the feed rollers should be just enough to allow a single piece to feed through the printer.
2. Input Area
Where you stack material for printing. You'll make most setup adjustments in this general area.
3. Interface Panel (Not Shown)
Located on the lower part of the rear cover, the panel has the ON/ OFF switch, parallel cable connector and power cord receptacle.
4. Wire Frame
Supports the material stack. Adjust the feed angle to accommo­date the weight of the material you're running. Adjust its side-to­side position so it's centered under the stack.
3-4 Pitney Bowes W660/W680 Operator Guide
W660/W680 Basics • 3
Setting Up A Job (continued)
5. Feed Ramp and Lock Knob
The feed ramp adds a gentle slope to the stack to help feeding. Lower the feed ramp until the top of the bottom piece in the stack reaches the middle of the feed ram. Secure the feed ramp with the lock knob.
6. Wireframe Slide
Slides the wireframe side to side. Lock in position with the lock lever (Item 7).
7. Wireframe Slide Lock Lever (Not Shown)
Locks the wireframe slide in position.
3
5
124
13 12
10
6
7
11
9
8
8. Feed Fence
Helps confine the stack. Adjust to the width of your material plus 1/16" clearance.
9. Control Panel
Use the control panel buttons to access printer menus, define print options, run the print job, position the print carriage and turn the printer on and off line. See Appendix A, Printer Menus,
Pitney Bowes W660/W680 Operator Guide 3-5
3 W660/W680 Basics
Setting Up A Job (continued)
for detailed instructions. If you have the W660/W680 print driver loaded on your computer, you can easily perform these functions from within your application.
10. OutputStacker Tray
Printed material is deposited in the stacker (catch) tray. The tray holds about 5" of material.
11. Output Area
Where printed material is ejected from the printer.
12. Exit Rollers (Not Shown)
Guides the printed material as it exits the printer. Adjust so that each roller overlaps the edge of the material by 1/4".
13. Transport Door
Open to gain access to the print cartridge and exit rollers.
The following procedure describes the steps for setting up a job.

1. Set the Separator Gap

Switching from one material type to another requires setting the gap between the separators and the feed roller before printing begins. To find the correct spacing, refer to the figure on the next page and follow the instructions below:
1. Loosen the lock knobs to unlock all three H-Blocks.
2. Lift all three H-Blocks to their highest position and lock in place.
3. Place a sample piece of material into the input area. Align the sample with the left wall of the input area, then place it between the separator fingers (the lower section of the H-Blocks) and the feed roller.
4. Lower only the H-Blocks that come in direct contact with the sample material. Make sure the material is between the separator fingers and the feed rollers, and that the separator fingers do not directly contact the feed rollers.
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W660/W680 Basics • 3
Setting Up A Job (continued)
5. Lock each separator in place.
NOTE: If the separator gap is not set properly, the printer will misfeed or jam. If the gap is to big, the printer will feed doubles (two or more pieces at the same time). If the gap is too small, material will jam at the feed roller entrance. If you're running post cards and have feeding problems, set a smaller gap between the H-Block separators and feed rollers, or use thinner media.
Setting the Separator Gap
H-Block Separator
Lock Knob
Support Plate
Place a sample piece against the input wall and between the separator fingers and the feed roller
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3 W660/W680 Basics
Setting Up A Job (continued)
Setup Example Using # 10 Envelopes:
When you set the feed gap for a number 10 envelope, the width of the envelope will fall completely under the inside and middle H-Blocks, but only half way under the outer H-Block.
In this case, remove the sliding fence, then follow this procedure:
1. Slide the #10 envelope over until it is under both fingers of the outermost H-Block.
2. Lower the outer H-Block so it contacts the material, then lock the H-Block in place.
3. With all H-Blocks locked in position, slide the envelope back to its original position.
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W660/W680 Basics • 3
Setting Up A Job (continued)

2. Center the Wireform under the Material

1. Place a sample piece of material in the feed area, up against the support plate.
2. Push down on the wireframe lock lever to free the wireframe slide.
3. Center the wireframe under your sample piece of mate­rial.
4. Pull up on the lock lever to secure the wireframe in position.
Lock Lever
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3 W660/W680 Basics
Setting Up A Job (continued)

3. Set the Feed Angle

The feed angle of the wireframe input stacker depends on the type of material you're running:
Heavy materialadjust to a low angle
Standard materialadjust to the center (45 degree angle)
Light materialadjust to a high angle
To make the adjustment:
1. Loosen the lock knob on the wireframe slide.
2. Move the wireframe up or down as required.
3. Tighten the lock knob to secure the wireframe.
Wire Frame
Lock Knob
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W660/W680 Basics • 3
Setting Up A Job (continued)

4. Position the Sliding Fence

Your printer comes with two sliding fencesa long one and a short one. Use the long fence for number 10 envelopes and larger materials. Use the short fence for materials smaller than a num­ber 10 envelope.
To position the fence:
1. Place a sample piece or trial stack of material in the input area.
2. Slide the fence until it almost touches the stack of material.
3. Check that there's about 1/16" clearance (the thickness of adime) between the fence and the stack.
NOTE: Proper clearance is important. If you push the fence tight up against the stack, it could retard feeding and cause jams. If the clearance is too great, pieces could skew as they feed into the printer.
Sliding Fence
Pitney Bowes W660/W680 Operator Guide 3-11
3 W660/W680 Basics
Setting Up A Job (continued)

5. Load Material

Once your printer is set up, you can load material and make a test print. Avoid misfeeds by following these precautions:
1. Make sure the input area is free of dust and other matter.
2. Take a manageable amount of material and while holding it as shown, fan all sides of the material to separate each piece. This step helps keep misfeeds to a minimum.
3 Tamp the material on a flat surface, making sure that the
stack is square.
4 Shingle the stack as you load it into the input area. Load
envelopes so the side to be printed faces up. Flaps should be down and oriented away from the feed roller (flaps trailing).
5. Position the right edge of the envelopes flush against the support plate. Begin with just a few envelopes to start the stack and get the proper contour, then add several more pieces. Then, add the remainder of the stack.
NOTE: Envelope feeding is generally more reliable if there are more than just a couple of envelopes in the input bin.
6. Adjust the position of the feed ramp as described on the next page.
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W660/W680 Basics • 3
Setting Up A Job (continued)

6. Adjust the Position of the Feed Ramp

With a stack of material loaded:
1. Loosen the lock knob that holds the feed ramp in posi­tion.
2. Lower the feed ramp until the top of the bottom piece of the stack reaches the middle of the feed ramp.
3. Tighten the feed ramp's lock knob to hold it in position.
Feed Ramp
At this point, it's a good idea to recheck your setup adjustments:
Is the separator gap adjustment correct?
Is the wireframe centered under the material?
Is the feed angle okay?
Is there a slight clearance between the sliding fence and
the edge of the stack?
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3 W660/W680 Basics
Setting Up A Job (continued)

7. Adjust the Media Thickness Lever

The media thickness lever sets the distance between the printhead and the material. Use it to compensate for different material thicknesses. The lever is located inside the printer under the transport door, as shown below.
Set for approximate material thickness. Up position for thicker material (.118"), down position for paper or card stock (.010").
Media Thickness
Lever
Print a test piece (page 3-16) with the lever in the middle posi­tion. If the address appears blurred or too light, lower the lever; if the address appears smeared, raise the lever
A Note about Print Quality
The W660/W680 is designed to feed and print on a range of materials with various finishes and coatings. However, the sharpness of the print may vary with different materials, depend­ing on how absorbent the surface is, as well as other qualities.
You'll get best results using white wove bonded stock. Printing is less sharp on Tyvek, recycled and glossy material. It is also possible that ink may not dry thoroughly on certain very glossy materials. Always test high gloss materials for their drying qualities before you buy them in quantity and attempt to run a print job.
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W660/W680 Basics • 3
Setting Up A Job (continued)

8. Adjust the Upper Exit Rollers

Adjust the upper exit rollers so the outside edge of the rollers overlap the left and right edges of the material by 1/4". Slide the rollers from side to side to make the adjustment.
IMPORTANT: Make sure the rollers do not touch any printed area of the material. If this happens, the rollers will act like a printing press and imprint a faint impression at incremental distances on the material. If this happens, move the roller or rollers toward the nearest clear zone, that is, an area free of printing.
Output Stack Height
The output stacker holds up to five inches of material before it becomes necessary to remove the stack from the bin. The op­tional W760 stacker increases capacity to 300 #10 envelopes.
NOTE: As the stack approaches the 5" limit, there is a poten­tial for stacking misfeed (pieces not neatly stacked one on top of the other). This can cause envelopes to stack out of ZIP Code sequence.
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3 W660/W680 Basics
Setting Up A Job (continued)

9. Print a Test Piece

1. Make sure material is loaded properly. (Or you can use a single test piece if you'd like to check your setup adjust­ments.)
2. Turn the printer ON. The On/Off switch is located on the interface panel at the rear of the machine. Wait for the printer to finish its startup routine and for the "ON LINE" screen to appear on the LCD.
3. Press the On Line button on the printer control panel until the LCD display reads OFF LINE.
4. Press the "Test Env." button. A single envelope will feed and a sample address should print.
5. Check the print quality. If it's not what you want, adjust the media thickness lever (page 3-14) as required and run another test piece by pressing the Test Env. button on the interface panel at the rear of the machine.
On Line
Display
Test Env.
When you're satisfied with the setup adjustments, you're ready to run the job. The next chapter explains use of the printer with your computer.
3-16 Pitney Bowes W660/W680 Operator Guide
Chapter
4
Using the W660/ W680 With Your Computer
This chapter has instructions for installing the W660/W680 printer driver and selecting the printer from a computer appli­cation.
In this chapter:
Installing the Printer Driver .........4-2
Selecting Printer Properties...... 4-10
Using Printer Properties
Windows ......................................... 4-11
Selecting the W660/W680
from a Windows® Application..........
....................................................... 4-25
Using Envelope Designer with
the W660/W680 .......................4-26
NOTE: Graphics that show the W680 also represent the W660.
4 Using the W660/W680 with Your Computer

Installing the W660/W680 Printer Driver

Before using the W660/W680 printer with your computer, you must install the W660/W680 printer driver. The driver gives your computer information about the printer you're using, and tells the printer about the settings you want to use in your print job.
To install the W660/W680 printer driver, follow these steps:
1. Turn on your computer and wait for it to finish booting.
2. Insert the Pitney Bowes Stand Alone Printing (Envelope Designer Plus) software into the CD-ROM drive. After a few seconds, the ADDRESSRIGHT Printing System Welcome message displays on the monitor. If it doesn't, do the following:
Click the Start menu, then select the Run option.
Click "Browse" and type D:\setup.exe ("D" equals the
CD-ROM drive letter). If your CD-ROM drive is designated by a different drive letter, type the correct letter in the command line.
Click "OK" in the Run window. The Run window
closes and the ADDRESSRIGHT Printing System Welcome window appears.
3. When you are ready, click "OK" to proceed with the installation.
4-2 Pitney Bowes W660/W680 Operator Guide
Using the W660/W680 with Your Computer • 4
Installing the W660/W680 Printer Driver (continued)
An install update message displays briefly, followed by the Install window which displays a prompt for restarting the system.
4. Click "OK" to restart the computer.
5. When the Applications Running window appears, shut down any running applications, then click "OK".
The Options List window displays.
6. Select the desired components, then click "OK".
Pitney Bowes W660/W680 Operator Guide 4-3
4 Using the W660/W680 with Your Computer
Installing the W660/W680 Printer Driver (continued)
An install update message window displays briefly, followed by the Destination Directory window.
7. Select the desired directory, then click "OK".
An install update message window displays briefly, followed by the Program Folder window.
8. Select the desired folder, then click "OK".
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Using the W660/W680 with Your Computer • 4
Installing the W660/W680 Printer Driver (continued)
An install update message window displays briefly, followed by a prompt to create a printer.
9. Click "OK" to enter the program for adding a printer to your computer setup.
An install update message displays briefly, followed by the first window in the Add Printer Wizard. It prompts you to begin installing the printer.
10. Click "Next" to begin the installation process.
Pitney Bowes W660/W680 Operator Guide 4-5
4 Using the W660/W680 with Your Computer
Installing the W660/W680 Printer Driver (continued)
The window for designating the printer connection displays.
11. Select from the available options, then click "Next".
The window for identifying the printer manufacturer and model displays.
12. Select Pitney Bowes from the Manufactures area and Pitney Bowes W660 or W680 from the Printers area. Then, click the "Next" button.
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Using the W660/W680 with Your Computer • 4
Installing the W660/W680 Printer Driver (continued)
The window for selecting the port displays. The default port is highlighted
13. If applicable, change the default settings, then click "Next".
When the next window displays, Pitney Bowes W660 or W680 appears in the printer name area. The prompt asks you to indi­cate if you want to use this printer as the default setting.
14. Select "Yes" if you plan to dedicate your system to mailings. Otherwise, select "No". After making the desired selection, click "Finish".
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4 Using the W660/W680 with Your Computer
Installing the W660/W680 Printer Driver (continued)
The Envelope Printer Accelerator Setup window displays.
15. Select "Proceed with installation" if you intend to use non-Pitney Bowes applications and refer to step 17 on the next page for additional instructions. Otherwise, select "Cancel".
If you selected "Cancel", the Update Complete window displays.
16. Remove the printer CD-ROM, then click "OK". The system automatically restarts and the installation process is finished.
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Using the W660/W680 with Your Computer • 4
Installing the W660/W680 Printer Driver (continued)
If you selected "Proceed with installation", the 3rd Party Envelope Printing Setup window displays.
17. Select the printer to be targeted by the Accelerator, then click "Next".
The Successful Configuration window displays.
18. Click "OK" to complete the installation process.
Pitney Bowes W660/W680 Operator Guide 4-9
4 Using the W660/W680 with Your Computer

Selecting Printer Properties

This section describes printer properties and use of the windows for selecting the available options. To access the main properties window, follow these steps:
1. Click the "Start" button in the task bar, then select "Settings".
2. Click "Printers." The Printer window displays.
3. Right click the Pitney Bowes icon, then left click the Properties option.
The Properties window opens and displays eight tabs, each of which allows access to different printer options. Note that the General tab window displays when the Properties window opens.
To access another option, left click on the appropriate tab. A window for the selected option displays.
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Using the W660/W680 with Your Computer • 4

Using the Printer Properties Window

NOTE: An explanation of items in the tab windows is also available by doing the following:
Right click an item to display the "What's This" button.
Right or left click this button to display the information
about the selected item.
Use of the window for each tabbed item follows, starting with the General tab window.
If the General tab window is not currently active, left click the General tab.
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4 Using the W660/W680 with Your Computer
Using the Printer Properties Window
Use the Comment area to make a statement about the printer. For example, you might want to indicate what the printer should be used for and when it is available. If this printer is shared, the comment entered in this area displays on the computers sharing this printer.
Use the Separator page area to insert a page between each printed document. Options for this item are available through the pull­down menu and include: none; Full; and Simple. To insert a page that includes a graphic, select Full. To insert a page that has text only, select Simple.
To look for and select the file that you want to use as the separa­tor page, click the "Browse" button
To print a test page to ensure that the printer is set up correctly, click the "Print Test Page" button.
The "OK, "Cancel", and "Apply" buttons display at the bottom of each tab window and work the same way in each window. Note that the "Apply" button is active only after a setting in the tab window is changed.
To save the selected settings and close the Properties window, click the "OK" button.
To save the selected setting and keep open the Properties window, click the "Apply" button.
To close the dialog box without saving any changes made to the options in a tab window, click the "Cancel" button.
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Using the Printer Properties Window
Using the W660/W680 with Your Computer • 4
To display the Details window, left click the Details tab in the Properties window.
Use the Print to the following port area to select the port to which the printer is connected or the path to your network printer. Options for designating the port include the following:
Type in the path.
Selecting a path from the drop-down list.
Click on "Add Port" to select the type of port you want to
add.
The "Delete Port" option allows point and click removal of unwanted port designations.
Use the Print using the following drive area to display the type of printer in use. A drop-down menu shows the available op­tions. The selected driver must match the printer or be compat­ible with it.
To change or update the printer driver, click the "New Driver" option.
Pitney Bowes W660/W680 Operator Guide 4-13
4 Using the W660/W680 with Your Computer
Using the Printer Properties Window
Use the "Capture Printer Port" option to map a path to the network drive.
Use the "End Capture" option to remove the mapping of a port from a network drive.
Use the Timeout Settings in the following manner:
Choose the "Not Selected" area to specify the time (in seconds) that Windows will wait for the printer to be online before reporting an error.
Choose the "Transmission retry "area to specify the time (in seconds) that Windows will wait for the printer to be ready to print before reporting an error.
Use "Spool Settings" to specify how the document is sent to the printer, ". Use the "What's This" feature to clarify the choices available in the Spool Settings menu.
Use "Port Settings" to change the printer port settings.
If you make any changes to the original settings, click "Apply" to save the settings and keep the Properties window open. Click" OK" to save the settings and close the Properties window.
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Using the Printer Properties Window
Using the W660/W680 with Your Computer • 4
To display the Color Management window, left click the Color Management tab in the Properties window.
Choosing "Automatic" allows the system to select the best colors from the available profile. The "Automatic" option is the manu­facturer-recommended choice.
Choosing "Manual" allows you to choose the desired colors.
If you make any changes to the original settings, click "Apply" to save the settings and keep the Properties window open. Click "OK" to save the settings and close the Properties window.
Pitney Bowes W660/W680 Operator Guide 4-15
4 Using the W660/W680 with Your Computer
Using the Printer Properties Window
To display the Paper window, left click the Paper tab in the Properties window.
Use the Paper Size area to select the size or envelope that is to be printed. Click on the desired size from the selection that includes three paper sizes, eight envelope sizes, and an option to customize the size.
Use the Orientation area to select how the document is posi- tioned on the paper when it is printed. Options for this item are Portrait and Landscape.
Use the Paper source area to specify the location of the paper to be used in the print job. Different printers support different paper sources and offer options such as, upper tray, envelope feed, and manual feed. For the W660/W680 the only paper source option is Auto sheet feeder.
4-16 Pitney Bowes W660/W680 Operator Guide
Using the W660/W680 with Your Computer • 4
Using the Printer Properties Window
Use the "Restore Defaults" button to return the printer to the manufacturer recommended paper settings
If you make any changes to the original settings, click "Apply" to save the settings and keep the Properties window open. Click "OK"" to save the settings and close the Properties window.
Pitney Bowes W660/W680 Operator Guide 4-17
4 Using the W660/W680 with Your Computer
Using the Printer Properties Window
To display the Graphics window, left click the Graphics tab in the Properties window.
Use the Resolution area to select the DPI (dots per square inch) for the printer. The setting for the W660/W680 is 300 DPI.
Use the Dither area to select one of the following options to blend pure colors into patterns:
Select None for no dithering.
Select Fine for resolution settings of 200 DPI or less.
Select Coarse for resolution settings of 300 DPI or higher.
Select Line art for well-defined borders of graphic art
with black, white, and gray shadings.
Select Error diffusion for photographs or pictures without sharp, well-defined edges.
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Using the W660/W680 with Your Computer • 4
Using the Printer Properties Window
Use the Intensity scale to select the desired level of darkness for the printed document.
Use the "Color" button to display the color and rendering con­trols. Use the "What's This" feature for help in selecting the options best suited to do the job.
Use the "Restore Defaults" button to return the printer to the manufacturer-recommended graphic settings.
If you make any changes to the original settings, click "Apply" to save the settings and keep the Properties window open. Click "OK" to save the settings and close the Properties window.
Pitney Bowes W660/W680 Operator Guide 4-19
4 Using the W660/W680 with Your Computer
Using the Printer Properties Window
To display the Fonts window, left click the Font tab in the Properties window.
Use the Download True Type fonts as bitmap fonts: options for maximum printing speed. With this option selected, each character is sent to the printer and remembered and doesn't need to be sent again for the rest of the job.
Use the Print True Type as graphics option to print graphics over text. With this option selected, all text is sent as graphics and resent on every page, thus greatly reducing print speed.
Use the "Restore Defaults" button to return the printer to the manufacturer-recommended font settings
If you make any changes to the original settings, click "Apply" to save the settings and keep the Properties window open. Click "OK" to save the settings and close the Properties window.
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Using the Printer Properties Window
Using the W660/W680 with Your Computer • 4
To display the Device Options window, left click the Device Options tab in the Properties window.
Use the Image Control option to change the way graphics and text are printed. Three options are available. Right click on each option to use the "What's This" feature to determine the option best suited to the job
The Printer Memory areas specify use of the printer memory. The first area indicates the amount of available memory. For the W660/W680, it is unchangeable at 2.5MB.
While the Printer memory tracking permits user adjustment of the printer memory to the level of complexity of the document being printed, the recommended setting is the manufacturer default.
Pitney Bowes W660/W680 Operator Guide 4-21
4 Using the W660/W680 with Your Computer
Using the Printer Properties Window
Use the "Restore Defaults" button to return the printer to the manufacturer-recommended settings
If you make any changes to the original settings, click "Apply" to save the settings and keep the Properties window open. Click "OK" to save the settings and close the Properties window.
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Using the Printer Properties Window
Using the W660/W680 with Your Computer • 4
To display the Settings window, left click the Settings tab in the Properties window.
Use the Print Quality area to select the desired level of reproduc- tion of the printed documented. Three levels are available:
Draft prints readable documents of low contrast at the fastest printing speed.
Letter prints documents with acceptable contrast. Printing speed with option is slower than Draft printing, but faster than Executive printing.
Executive prints documents of high contrast. With this option selected, printing is slower than that of the other two options.
Use the Feed Delay area to select the time (in seconds) that the printer will pause before feeding the next mailpiece. Settings for this option range from 0 to 30 seconds.
Pitney Bowes W660/W680 Operator Guide 4-23
4 Using the W660/W680 with Your Computer
Using the Printer Properties Window
Use the Heavy Media option when the job consists of stuffed or thick envelopes, newsletters, or multi-page catalogs. Selecting this option decreases printer throughput, as the heavier media feeds 25% slower than regular weight envelopes. Also, more torque is applied to the motor, which ultimately prolongs the motor's life.
Use the Inverted Printing option to do the following:
print of the left side of an oversized envelope
when the printer head cannot reach the far end of an
oversized envelope (larger than 9 1/4"). Note that envelopes must be fed flap first into the printer to have the addresses line up properly.
When the Auto Eject option is checked, the last piece of media in a stack automatically ejects itself from the printer.
When the "About" button is clicked, a window displays and indicates the Pitney Bowes W660/W680 Printer Driver version and copyright information.
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Using the W660/W680 with Your Computer • 4

Selecting the W660/W680 Printer From a Windows Application

The following steps explain how to select the W660/W680 printer from a Windows software application. The steps are similar for most applications. You can also refer to your application's documentation for specific instructions on installing selecting printers.
1. Start the software application that you use when printing envelopes with the W660/W680 printer and open the file you want to use.
2. From the File menu, select Print. The Print dialog box appears.
3. Click on the arrow in the Printer Name box. When you click on the arrow, a drop-down list box appears contain­ing the names of the available printers.
The illustration below shows a typical print dialog box with the W660 or W680 selected.
4. Click OK to send the job to the printer.
Pitney Bowes W660/W680 Operator Guide 4-25
4 Using the W660/W680 with Your Computer
Selecting the W660/W680 Printer From a Windows Application (continued)

Envelope Designer

Once you've made this selection, your print job will automati­cally go to the W660/W680 printer when you select File/Print provided the W660/W680 is selected as the default printer). Remember to change the printer selection back to your regular printer for your other printing jobs.
The Pitney Bowes Envelope Designer™ is an easy-to-use pro- gram that helps you create professional-looking envelope layouts quickly. With Envelope Designer, you can create and position a mailing address, return address, single-line message, barcode and graphics. Envelope Designer has an extensive online help system and a Wizard that guides you through the entire design process. Envelope Designer virtually eliminates the need for setting up your envelope manually, using either the print driver options or the printer's control panel menu options.
To access Envelop Designer, follow these steps:
1. Click Start in the task bar, then select Programs.
2. Select Pitney Bowes Printing, then left click Envelope Designer (TM) Plus. The program displays a sample envelope for you to customize.
4-26 Pitney Bowes W660/W680 Operator Guide
Chapter
5
Printer Maintenance
This chapter describes the maintenance procedures you should perform on a regular basis to keep your printer run­ning trouble-free.
In this chapter:
Preventive Maintenance ..................5-2
Cleaning .............................................5-2
Print Quality Problems....................5-2
Exit Rollers ....................................... 5-3
Sensor .............................................. 5-3
Floor Assembly and Top Cover ..... 5-3
5 Printer Maintenance

Preventive Maintenance

Print Quality Problems

The Pitney Bowes W660/W680 Ink Jet Printer is designed for trouble- free service with a minimal amount of care. You should schedule regular cleaning of the Feed Rollers, Exit Rollers and Lower Guide.

CautionCleaning

Clean print head, cartridge, ink surfaces and covers with plain water only. (Water works best!)
Clean all rubber rollers with isopropyl, denatured and rubbing alcohol only.
Use of any other cleaning solvents will void all warranties.
Keep petroleum based cleaning solvents away from rubber or plastic parts. Anything but alcohol will cause premature break­down of the rubber compound.
The print head performs a self cleaning cycle periodically. If print quality is unacceptable, try the following:
Adjust the media thickness lever (page 3-13) to see if print quality improves.
Clean the print head cartridge: dampen a soft cotton cloth with water and wipe the nozzles clean.
Install a new ink cartridge (page 2-13).
From the Setup Menu, select 3. Purge Printhead. The
purging process clears any clogged ink on the print nozzle. Often this returns the print quality to a normal level. See Appendix A, Control Panel Menus, for informa- tion on using this feature.
5-2 Pitney Bowes W660/W680 Operator Guide
Printer Maintenance • 5

Exit Rollers

Sensor

Floor Assembly and Top Cover

If the right and left exit rollers are misaligned, that is, contact printed surfaces, they can become contaminated with ink. Use water to dampen a soft cloth and remove the ink from the rollers.
A film and/or dust can build up on the sensors and cause misfeeds of the material. Lift the transport door and use com­pressed air to blow dust from the sensors. Cans of compressed air are available from many computer supply houses.
Sensor Location
Periodically wipe the cover and floor assembly (feed deck) with a soft cotton cloth, dampened with water only.
Pitney Bowes W660/W680 Operator Guide 5-3
Chapter
6
Troubleshooting
This chapter lists some common printer problems and offers sug­gestions on how to fix them.
In this chapter:
Problems and Solutions .......6-2
Feed Problems ........................ 6-2
Print Quality Problems......... 6-3
Interface Problems ................6-4
Serial Pin Connector
Diagram ...................................6-5
Motor Problems .................... 6-6
Barcode Problems ................. 6-6
Other Problems ..................... 6-8
6 Troubleshooting

Problems and Solutions

Feed Problems

Before calling our National Diagnostic Center or your Pitney Bowes Customer Service Representative, look for your problem below. If you can solve the problem yourself, you will be able to resume printing sooner.
Problem Intermittent Feed
Reason: Feed ramp not used.
Solution: The feed ramp adds a gentle slope to the stack
and helps feeding. If you're using the prop, check the H-Block gap for proper separation. Also make sure the wire frame is centered under the material. See pages 3-9 and 3-13.)
Reason: Dirty feed rollers.
Solution: Clean the feed roller with denatured alcohol. DO
NOT use any other solvents or detergents. They could damage the feed rollers.
Reason: Paper dust present (yellow or white residue),
blocking feed sensor.
Solution: Clean sensor with compressed air (see page 5-3).
Problem Multifeed (Feeds Doubles) or Skewing
Reason: Separators (H-blocks) not set correctly. Also
sliding fence set incorrectly.
Solution: Adjust H-blocks to thickness of material. See
page 3-6. Check sliding fence position. See page 3-11.
6-2 Pitney Bowes W660/W680 Operator Guide
Troubleshooting 6

Print Quality Problems

Problem No Print
Reason: Ink cartridge problem.
Solution: Purge ink cartridge (pg A-23).
Clean cartridge jets with soft cotton cloth and water (in line with colors as shown). Change to a new cartridge.
Problem Gray or Light Print - Black Ink
Off Color or Low Intensity - Color Ink - W680 only
Reason: Ink supply is low. Solution: Check adjustment of the media thickness lever
(page 3-14). If this fails to correct the problem, replace ink cartridge (pages 2-13, 2-15).
Problem Address Smudging
Reason: Incorrect media thickness lever setting.
Ink may not dry on very high gloss material.
Solution: Check whether media thickness lever is adjusted
too low (page 3-13). Try using less glossy material. Check exit rollers.
Problem Address Printing is not Sharp
Reason: Incorrect media thickness lever setting. Also,
unsuitable material.
Solution: Check whether envelope thickness lever is
adjusted too high (page 3-14). Print quality is less sharp when using Tyvek, recycled or glossy media.
Pitney Bowes W660/W680 Operator Guide 6-3
6 Troubleshooting
Print Quality Problems (continued)
Problem Unwanted Bolding
Reason: Escape sequence turning on bold or bold
selection in printer's menu options is set to bold.
Solution: Turn off bolding in software and/or turn bold
selection in printer menu OFF. See Appendix A for instructions. If problem still exists, call Pitney Bowes for service.
Problem Addresses "Walking"
Reason: Incorrect Address Setup.
Solution: Count carriage returns and line feeds and adjust
Lines Per Address to the same number. Also check line termination: Typical, CR=CR; LF=LF. Other choices, (CR=CR+LF;LF=LF), (CR=CR; LF=CR+LF), (CR=CR+LF;LF=CR+LF), double spacing.

Interface Problems

6-4 Pitney Bowes W660/W680 Operator Guide
Problem No Communications; Printer Does Not Re-
spond
Reason: Incorrect print driver, bad parallel or serial cable,
bad printer controller board.
Solution: Use W660/W680 print driver; replace parallel or
serial cable. Make sure cable connections are tight, and that they are correct. Refer to serial pin diagram on the next page. If the problem still persists, call Pitney Bowes for service.
Clear memory (pg A-16).
Cycle power.

Connector Diagram

CHS GND
TXD
RXD
CTS
DSR
SIG GND
DTR
CHS GND
TXD
RXD
CTS
DSR
DTR
SIG GND
Troubleshooting 6
Serial Pin Connector Diagram
PRINTER COMPUTER DB25 DB25
1 2 3 5 6 7
20
DB25 DB9
1 2 3 5 6
20
7
1 3 2
20
7 5 6
2 3 4 6 8 5
CHS GND RXD TXD DTR SIG GND CTS DSR
RXD TXD DTR DSR CTS SIG GND
Pitney Bowes W660/W680 Operator Guide 6-5
6 Troubleshooting

Motor Problems

Barcode Problems

Problem Motor Turning but no Feed Roller Movement
Reason: Mechanical problem.
Solution: Call Pitney Bowes for Service.
Problem Barcode (Lower Right) is not Printing
Reason: Barcode not enabled
Solution: Turn barcode ON using Envelope Designer, or
the W660/W680 print driver or the printer’s control panel menus.
Reason: Missing ZIP Code.
Solution: Insert ZIP Code.
Reason: Invalid ZIP Code format.
Solution: Check ZIP Code for invalid character. Example:
Zero (0) can only be the number, not the letter (O). Verify that there is a dash inserted between the 5 + 4 ZIP Code Per DMM manual specifica­tions.
Reason: Address too low.
Solution: Verify the bottom of the last line of the address
field is not less than 5/8" from bottom edge of the media.
6-6 Pitney Bowes W660/W680 Operator Guide
Troubleshooting 6
Barcode Problems (continued)

Other Problems

Problem Address too High
Reason: Address field is within 1/10" of the top edge of
the media.
Solution: Move address field down to within DMM
specifications.
Problem Paper Out or Paper Jam
Reason: Input area is empty.
Solution: Refill the input area.
Reason: H-Block separators not adjusted correctly.
Solution: Adjust the H-Blocks to the thickness of the
material you're running. See page 3-6.
Reason: Paper jam obstructing paper path.
Solution: Clear obstructed path.
Reason: Dirty paper feed sensor.
Solution: Clean sensor with compressed air. See page
5-3.
Problem Shuttle Jam
Reason: Envelope thickness lever is set too low for
material.
Solution: Open the transport door and adjust the media
thickness lever. See page 3-14.
Pitney Bowes W660/W680 Operator Guide 6-7
6 Troubleshooting
Other Problems (continued)
Reason: Lower rail shaft dirty.
Solution: Wipe lower rail shaft clean.
Problem Memory Card Error
Reason: The card was removed while the printer was
reading it.
Solution: Do not remove the card while the printer is in
use. If the card has been removed, insert the card, turn the printer off, then turn the printer on again.
Problem Out of Memory
Reason: The printer can run out of memory when
downloading fonts or graphics.
Solution: This generally means you’re trying to use a
graphic (artwork) thats too big or you have too many fonts or too large a font size. If the out-of­memory message appears, try reducing the size of your art and limiting the number and size of your fonts. Then shut the printer OFF, then ON and retry.
6-8 Pitney Bowes W660/W680 Operator Guide
Appendix
A
Using the Control Panel Menus
The printer menus are used to control how your printed mate­rial looks. This chapter de­scribes each menu and its options.
In this Appendix:
Using the Control Panel ................. A-2
Using the Menus............................. A-3
Main Menu........................................ A-5
Setup Menu ................................... A-20
Appendix A Control Panel Menus

Using the Control Panel

Use the buttons on the control panel to get to the printer menus, define the print options, run a print job, position the print carriage and turn the printer on line and off line.
If you’ve installed the W660/W680 printer driver on your computer, you’ll normally perform these actions from within the application you’re using to set up your envelope layout.
The buttons on the control panel perform the following func­tions:
This Button... Does This... On Line Toggles (switches) between ON LINE
(communicates with host) and OFF LINE (no communications with host). Note that the functions of two buttons, Eject/- and Cartridge/+, vary, depend ing on whether the printer is ONLINE or OFFLINE.
Eject/- When printer is offline, press to eject (minus) the last printed piece from the printer.
When printer is online, press to scroll through menu items from bottom to top.
A-2 Pitney Bowes W660/W680 Operator Guide
Appendix A Control Panel Menus
Menu Displays the options on the Main
Menu and the Setup Menu. The printer must be OFF LINE to access the menus.
Enter Press to select the currently displayed
menu option.
Cartridge/+(plus) With the printer OFFLINE, press
to move the ink cartridge holder to the center of the printer. This makes it easy to remove the cartridge.
With the printer ONLINE, press to scroll forward through the menu options.

Using the Menus

Test Env. Prints a test envelope. This is very
useful when you set up a print job.
The W660/W680 has two menus, both displayed on the LCD:
Use the Main Menu to control how your printed
material looks.
Use the Setup Menu to configure your printer so it
will function correctly with your computer.
NOTE: The printer must be OFFLINE to access the menu options.
To select an option:
Pitney Bowes W660/W680 Operator Guide A-3
Appendix A Control Panel Menus
Using the Menus (continued)
To select an option:
1. Press the On Line button until the LCD message displays “OFF LINE”.
2. To access the MAIN MENU, press the Menu button.
3. To access the SETUP MENU, press and hold the Menu button for four (4) seconds.
4. Press the plus (+) or minus (–) buttons to move through the list of menu options.
5. When the appropriate menu option appears, press the Enter button to display the choices associated with that option.
6. Press + or – to scroll through the choices. When an option has an asterisk (*) in front of it, means that option is presently selected.
Upon receipt of the printer from the factory, the asterisk is typically the default setting.
When you press the Enter button to define a new option, an asterisk will appear before the selected option.
7. Press the Menu button several times to back out of the Menu until the printer displays OFF LINE. Then press the ON LINE button to print
A-4 Pitney Bowes W660/W680 Operator Guide
Appendix A Control Panel Menus

Using the Main Menu

The Main Menu options are:
1. Address Layout
2. Print Quality
3. Font
4. Barcode
5. Address Recovery
6. Clear Counter
7. Job Settings
NOTE: The settings you define in a software application such as SmartMailer override any settings you choose in the printer menus.
Pitney Bowes W660/W680 Operator Guide A-5
Appendix A Control Panel Menus
Using the Main Menu (continued)
Main Menu Menu Options
1. ADDRESS LAYOUT
2. PRINT QUALITY
3. FONT
4. BARCODE
5. ADDRESS RECOVERY
A. DISTANCE TO RIGHT B. DISTANCE TO BOTTOM C. LINE SPACING D. ORIENTATION E. ORIENTATION CONTROL
DRAFT EXECUTIVE LETTER
A. NAME B. SIZE C. WIDTH D. BOLD E. ITALIC F. OUTLINE
A. LOCATION B. 5 DIGIT ON/OFF C. 9 DIGIT ON/OFF
A. GET ADDRESS B. CLEAR MEMORY
6. CLEAR COUNTER
7. JOB SETTINGS
CLEAR ADDRESS (YES/NO) PIECE COUNTERS
A. LOAD B. SAVE
NOTE: To print a list of the Main Menu and Setup Menu settings, press the test button when ROM REV is displayed ­in the Setup Menu.
A-6 Pitney Bowes W660/W680 Operator Guide
Appendix A Control Panel Menus

1. Address Layout

Use the Address Layout option to set up the way an address appears on the printed material. The printable width is limited to 9.4” from the right side of the mail piece. The printable height is 15 measured from the bottom edge of the mail piece.
Define the following options from this menu:
A. Distance to Right (Left Margin)
This option sets the start of the address (the left side of the address) as measured from the right side of the envelope. For # 10 envelopes this should be about 5.5”.
Press the + or – buttons to increase or decrease the Distance to Right, ( + MORE or – LESS) defined in inches or millimeters. The left margin is the distance measured from the right edge of the material to the first printable character. Press the Enter button to select the desired measurement.
Pitney Bowes W660/W680 Operator Guide A-7
Appendix A Control Panel Menus
1. Address Layout (continued)
B. Distance to Bottom (Bottom Margin)
Use this option to set the distance from the top address line to the bottom of the envelope. For #10 envelopes this should be about two inches.
Press the + or – buttons to increase or decrease the Distance to Bottom, (+ MORE or – LESS) defined in inches or millimeters. The bottom margin is the distance between the bottom edge of the material and base of first line of the address. Minimum distance between the last line of the address and the bottom edge of the material is 5/8 inches. If less than 5/8 inches, the lower right barcode will not be printed. Press the Enter button to enable the desired measurement.
C. Line Spacing
Press the + or – buttons to increase or decrease the Line Spacing (i.e., 3, 4, 6, 8 lines/inch or Automatic), defined in lines per inch. Automatic line pitch selection is based on industry-standard definitions for line spacing for each print pitch and style se­lected. The printer will automatically select the correct setting for the font and size of the characters being printed.
D. Orientation
The choices are Normal and Inverted. Select Normal for most applications. This tells the printer that the bottom edge of the material feeds first, with the right side running against the right side of the printer.
The Inverted option tells the printer that the top edge of the material feeds first. Select this option if, for example, you need to feed envelopes flap first.
E. Orientation Control
The choices are Automatic and Manual. When Orientation Control is set to Automatic, the printer acknowledges the orientation commands sent from the computer. Setting Orien­tation to Manual notifies the printer to use the menu settings for orientation.
A-8 Pitney Bowes W660/W680 Operator Guide
Appendix A Control Panel Menus
1. Address Layout (continued)
To use the Address Layout option:
1. Press the On Line button until the display reads OFF LINE.
2. Press the Menu button to display the Main Menu.
3. Press the + or - buttons to scroll through the Main Menu options until 1. ADDRESS LAYOUT appears on the LCD panel.
4. Press the Enter button to select this option.
5. Press the + or – buttons to scroll through the ADDRESS LAYOUT options.
6. Press the Enter button to select the desired option (A, B, C, D or E).
7. Press the + or - buttons to scroll through the choices associated with each option.
8. When you’ve finished making selections, press the menu button several times to back out of the menu until the printer displays OFF LINE. Then press the On Line button to enable the printer.
Pitney Bowes W660/W680 Operator Guide A-9
Appendix A Control Panel Menus

2. Print Quality

Use the print quality option to select the resolution of the printed addressesExecutive, Letter or Draft.
Note: All color print quality specifications only apply to the W680.
A. Executive Quality
Black - 600 x 600 DPI - Color 300 x 300 DPI
This is the darkest of the three print qualities. It prints at the slowest speed, uses the most ink and delivers the best quality printout. Executive quality prints envelopes that require a professional appearance.
B. Letter Quality
Black - 300 x 600 DPI - Color 300 x 200 DPI
Letter quality is used for envelopes that require a finished, polished appearance.
C. Draft Quality (150 DPI)
Black - 300 x 300 DPI - Color 300 x 150 DPI
This is the lightest of the three and prints at the fastest speed. Draft quality prints envelopes at the highest speed and saves ink.
To use the Print Quality option:
1. Press the ON LINE button until the display reads OFF LINE.
2. Press the Menu button to display the Main Menu.
3. Press the + or – buttons to scroll through the Main Menu options until the Print Quality option is displayed on the LCD panel.
4. Press the Enter button to select the option you want.
A-10 Pitney Bowes W660/W680 Operator Guide
Appendix A Control Panel Menus
2. Print Quality (continued)
5. Press the + or – buttons to scroll through the Print Quality options, until the desired option (Executive, Letter or Draft) is displayed on the LCD panel.
6. Press the Enter button to select the desired option.
7. After you’ve made your selection, press the Menu button several times to back out of the Menu until the printer displays OFF LINE. Then, press the On Line button to enable the printer.
Pitney Bowes W660/W680 Operator Guide A-11
Appendix A Control Panel Menus

3. Font Selection

The W660/W680 has thirteen available fonts (typefaces, plus barcode): Courier, Sans Serif, Roman, OCR A, Quincy, Springer, Hancock, Alpine, Baxter, Marina, Stencil, Windmill, and Silicon. All fonts are scalable from 4 to 30 point size, and can be printed in regular, bold, italic. and outline style. The W660/W680 also supports downloaded fonts. This means that if you are using Windows, all the fonts installed in Windows are available. This also applies to any DOS can download fonts.
The options on this menu are Name, Width, Bold and Italic.
applications that
A. Name
The printer has thirteen internal fonts as described above, and one barcode font.
B. Size
The font size (internal or external) can be set from 4 to 30 point.
C. Width
The font width is Normal (100%), thin (75%), condensed (50%), wide (125%) or expanded (150%).
D. Bold
This is the darkest imprint because character stroke weight (thickness of print) is increased. Use Bold to emphasize or highlight text in an address.
A-12 Pitney Bowes W660/W680 Operator Guide
Appendix A Control Panel Menus
3. Font Selection
(continued)
E. Italic
Italic characters have decreased stroke weight, print at an oblique angle and print somewhat lighter than standard or bold typefaces. Use italic to provide emphasis and add flair to address text that requires a finished, polished appearance.
F. Outline
Use this option to print only the outline or the edge of the fonts shape. All records printed using Outline will appear as hollow text.
To select the font options:
1. Press the + or – buttons to scroll through the Main Menu options until the “FONT” option displays on the LCD panel.
2. Press the + or – buttons to scroll through the Font options until the desired option appears on the LCD panel.
3. Press the Enter button to select the desired option (A, B, C, D, E or F).
4. After making your selections, press the Menu button several times to back out of the Menu until the printer displays OFF LINE. Then, press the On Line button to enable the printer.
Pitney Bowes W660/W680 Operator Guide A-13
Appendix A Control Panel Menus

4. Barcode

Use this option to include a USPS-certified barcode on your mailpieces. The W660/W680 can print a 5- or 11-digit barcode. If you select Off, it means that if the computer sends a 5-digit ZIP Code, it won’t print a barcode; only the 9-digit ZIP Codes and Delivery Points will print.
The options on the barcode menu are Location and 5-Digit On/ Off.
A. Location
Press the Enter and + buttons to select the Location where you want the barcode to print. (Lower Right Corner, Above Address, Below Address or turn Barcode Off).
B. 5-Digit On / Off
If a 5-digit barcode is required, selecting the 5-digit barcode option (5-Digit ON) lets you print either 5-digit or 11-digit barcodes as requested by the computer.
1. Press the + or – buttons to scroll through the Main Menu options until the BARCODE option displays on the LCD panel.
2. Press the Enter button to select this option.
3. Press the + or – buttons to scroll through the Barcode options, until the desired option (A. Location and B. 5­Digit On/Off) displays on the LCD panel.
4. Press the Enter button to select an option. Use this option to define where the U.S. Postal Service POSTNET Barcode will print.
A-14 Pitney Bowes W660/W680 Operator Guide
Appendix A Control Panel Menus
4. Barcode (continued)
5. Press the Enter button at the 5-digit barcode prompt and use + or – to turn the option ON or OFF.
6. After making your selections, press the Menu button several times to back out of the menu until the printer displays OFF LINE. Then, press the On Line button to enable the printer.
Pitney Bowes W660/W680 Operator Guide A-15
Appendix A Control Panel Menus

5. Address Recovery

Use this option to direct the printer’s memory to go back a certain number of addresses when an error occurs in order to reprint the address. The options on this menu are A. Get Ad­dresses and B. Clear Memory.
A. Get Addresses
Select Get Addresses after a jam is cleared and you want to restart printing at the point where the printer left off just before the jam occurred. To retrieve any address in the data buffer, press the Enter button. The first 16 characters of the first line of the last address printed will be displayed on the LCD. Press the + or – buttons to scroll through the addresses. When the desired address appears, press the Enter button to print that address plus the remaining addresses in the buffer.
B. Clear Memory
Select Clear Memory before you start a new batch printing. This is required because the memory will contain up to twenty addresses from the previous batch.
To use this menu option:
1. Press the + or – buttons to scroll through the Main Menu options until the ADDRESS RECOVERY option displays on the LCD panel.
2. Press the Enter button to select this option.
3. Press the + or – buttons to scroll through the Address Recovery options until the desired option (A. Get Address or B. Clear Memory) displays on the LCD panel.
A-16 Pitney Bowes W660/W680 Operator Guide
Appendix A Control Panel Menus
5. Address Recovery (continued)
4. Press the Enter button to select the desired option.
5. After making your selection, press the Menu button several times to back out of the Menu, until the printer displays OFF LINE. Then, press the On Line button to enable the printer.
Pitney Bowes W660/W680 Operator Guide A-17
Appendix A Control Panel Menus

6. Clear Counter

7. Job Settings

Use this option to clear the piece (batch) counter.
1. Press the + or – buttons to scroll through the Main Menu options until the 6. CLEAR PIECE COUNTER option displays on the LCD panel.
2. Press the Enter button to select this option.
3. Press the + or – button to select CLEAR PIECE COUNTER, (+ YES or – NO).
4. After you’ve made your selection, press the Menu button several times to back out of the Menu, until the printer displays OFF LINE. Then, press the On Line button to enable the printer.
The W660/W680 Printer can hold eight job presets in memory. This eliminates the need for changes to the printer setup when you change print jobs. The options on this menu are A. LOAD and B. SAVE.
A. Load
Select this option to retrieve a previous job setup. Press + (for more) or – (for less) to increase or decrease the desired job number. Press the Enter button to select the desired option.
B. Save
Use this option to save the current envelope setup (address position, barcode position, number of lines per inch, and so on). The printer saves the setup as a job number (1 through 8). You must keep a record of these setups and the number you as­signed. Press + (MORE) or – (LESS) to increase or decrease the desired job number. Press the Enter button to select the desired option.
A-18 Pitney Bowes W660/W680 Operator Guide
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