Epic™ v3.1(ZVE0) Inserting System - Pitney Bowes€¦ · Print+ Messenger Digital Inkjet System Operator Guide (OG_APF_PRINT_020111) l. Hunkeler UW6 Unwinding Module Operator Guide

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Epic™ v3.1(ZVE0) Inserting SystemAuto Adjust Chassis

Operator Guide US English EditionSV63233 RevGMay 8, 2018

2018© 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.

The use of this information by the recipient or others for purposes other than the training of customers on Pitney Bowes equipment may constitute an infringement of intellectual property rights of Pitney Bowes, and Pitney Bowes assumes no responsibility for any such use of the information.

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.

Except as provided in writing, duly signed by an officer of Pitney Bowes, no license either express or implied, under any Pitney Bowes or third party’s patent, copyright or other intellectual property rights is granted by providing this information.

This guide is designed to support proper setup, operation, jam removal, troubleshooting, and basic maintenance activities associated with the Epic v3.1 Inserting System. This guide covers Epic v3.1 system components from the Buffer through the On Edge Stacker. System input content can be found in related operator guides listed here in the "Related Documentation" section.

Version History

Document Part Number Release Date Comments

SV63233 RevA DRAFT October 25, 2016 Draft release (Safety certification)

SV63233 RevA July 24, 2017 Initial release

SV63233 RevB September 15, 2017 Direct Connect section reworked for localization - content updated and reorganized

SV63233 RevC September 28, 2017 Changed product name to Epic v3.1

SV63233 RevD November 29, 2017 Added Booklet Feeder and operator adjustable horn content

SV63233 RevE December 8, 2017 Update to Booklet Feeder (side guide adjustment)

SV63233 RevF March 7, 2018 OES information added

SV63233 RevG May 8. 2018 Envelope specs updated - max changed to 2.5"

About this Book

Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page iii of 7

Related Documentation

l HPI Pinless Cutter (Y484/Y485) Operator Guide (OG-AF-INPU-102006)

l HPI Accumulator (Y470 ) Operator Guide (OG-ADFS-INPU-031005)

l HPI RAT/FIM (Y47EWP) Operator Guide (SV63088)

l Print+ Messenger Digital Inkjet System Operator Guide (OG_APF_PRINT_020111)

l Hunkeler UW6 Unwinding Module Operator Guide (OG-Hunk-Unwinder)

l Auto Buckle Chute (Y488, Y20R, Y20S) Operator Guide (OG-APF-INPU-011513)

l Y254 Vacuum Sheet Feeder Operator Guide (SV63223)

About this Book

Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page iv of 7

1 - Safety

Safety Information 2Power 3Operation 4Maintenance 5Warning Labels and Cautions 6Safety Features 10

2 - Product Overview

Epic v3.1 (ZVE0) Inserting System 14Component Overview - Epic v3.1 (ZVE0) 15Indicator Lights 17About the Remote Control 18

3 - Power the System On and Off

Powering Up the System 20Powering Down the System 22

4 - Using Direct Connect

Direct Connect Software Overview 26DC Main Screen 27Changing the UI Display Language 30

Powering Down the DC Computer 31Viewing DC Software Details 32Logging In and Logging Out of DC 33Loading a Mode 35Setting the Mail Date 37Checking Status with Job Manager 38Accessing Reports in DC 39Starting and Stopping the Inserter Using DC 40Assigning an MRDF File (File Based Jobs) 41Disabling (and Enabling) the Inserter 42Clear Deck Function 43About the Speed Indicators in DC 46About the DC Alarm Message Box 47

5 - Operator Adjustments

Operator Adjustments 51Adjusting the Envelope Feeder Separator Gap 52Adjusting the Envelope Fence 55Adjusting the Suction Cups in the Engine 56Adjusting the Engine Tongue Position 60Adjusting the Engine Tongue Height 63About Engine Horns 65Changing Engine Horns 66Envelope Settings 71Setting Up the RAT (Right Angle Transfer) 78Adjusting Amount of Sealer Fluid Applied 80

Table of Contents

Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page v of 7

Setting Up the Vertical Stacker 82Moving the Flat Stacker 84About the On Edge Stacker (OES) 88Setting Up the Entrance to the On Edge Stacker 90Centering Mail on the On Edge Stacker Conveyor Belt 94Adjusting the Belt Speed and Stack Pressure on the On Edge Stacker 96Adjusting On Edge Stacker Fingers 100Adjusting Chassis Material Center Deck Control Strap 102Adjusting Chassis Side Guide Control Straps 104Setting the Chassis Collation Length 105Setting the Chassis Speed 107Friction Feeder Mechanical Adjustments 109Adjusting the Friction Feeder Separator 110Adjusting the Friction Feeder Side Guides 113Adjusting the Feeder Pack Control Ramp 116Rotary Feeder Mechanical Adjustments 118Using Rotary Feeder Suction Cups 119Adjusting the Rotary Feeder Side Guide and Backstop 122Adjusting the Rotary Feeder Deck Position 124Setting the Rotary Feeder Feed Deck Angle 126Adjusting the Rotary Feeder Separator Pins 128Using the Wedge Accessory on the Rotary Feeder 131Using the Jog Function on the Rotary Feeder 133Booklet Feeder Mechanical Adjustments 137Changing Out the Booklet Feeder Separator Assemblies 138Adjusting the Booklet Feeder Separator Gap 145Adjusting the Booklet Feeder Side Guides 148Adjusting the Booklet Feeder Pack Control Ramp 151

Adjusting the Booklet Feeder Double Detect Feature 155Adjusting the Bulk Loader Hopper Deck 158Adjusting the Bulk Loader Hopper Side Guides 161Insert Feeder Software Adjustments 163Enabling and Disabling Feeders 164Document Information 165Setting Feeder Feed Modes 169Setting Backup Feeders (Backup Feed Mode) 171Transport Envelope Setup (Xport Setup) 174Setting Separator Options for Friction Feeders 175Recalibrating the Double Detect Feature 177Adjusting Buffer Upper O-ring Belt Height 178

6 - Job Changeover Guidelines

Job Changeover Guidelines 182Auto Adjustments - Engine and Chassis 185Manually Adjusting Engine and Chassis Auto Settings 187

7 - Running the System

Loading the Envelope Feeder 194Reloading the Envelope Feeder 196Loading the Insert Feeders 199Loading the Booklet Feeder 200Reloading Insert Feeders (with the system is running) 201Removing Finished Mail from the On Edge Stacker 202Removing Mail from the Flat Conveyor 205

Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page vi of 7

Adding Sealer Fluid 206

8 - Error Recovery

Error Recovery 210Alarms in Direct Connect 211Removing Material Jams in the Buffer 215Removing Material Jams Under the Nip Rollers 217Removing Material Jams in the Dump Station Exit 218Removing Material Jams on Chassis Deck 219Removing Material Jams in the Friction Feeder 221Removing Material Jams in the Rotary Feeder 224Removing Material Jams in the Booklet Feeder 227Removing Material Jams in the Engine 231Removing Material Jams in the Envelope Feeder 237Removing Material Jams in the Sealer or Vertical Stacker #1 240Removing Material Jams in the Turnover 241Removing Material Jams in the Vertical Stackers 242Removing Material Jams in the On Edge Stacker 243Removing Material Jams in the Flat Conveyor 244

9 - Troubleshooting

Troubleshooting 248Engine Troubleshooting 249Chassis Troubleshooting 252

Buffer Troubleshooting 258

10 - Maintenance

Operator Maintenance 260Replacing Suction Cups in the Engine 262Buffer Maintenance 266Rotary Feeder Maintenance 267Friction Feeder Maintenance 268Vertical Stacker Maintenance 269On Edge Stacker Maintenance 270

11 - Specifications

Epic V3 Description and Features 272Epic Material Specifications 274Epic v3.1 Engine (ZVE0) 276Envelope Specifications 281MPS/Epic Friction Feeder (Y554) 296Epic Rotary Feeder (Y558) 300Epic Universal Friction Feeder (ZVF1) 305Epic P2L Buffer with TNT (ZVB2) 309Epic Turnover (Y370) 312Epic V-Bin (Y31E, Y31F, Y31G, Y31H ) 314Epic On-Edge Stacker (Y396) 317Epic Shingling Stacker (Y32S) 320Epic Edge Markers (Y367, Y368, Y369 ) 321Environmental Operating Conditions 323Network and Power Requirements 324Air Requirements 326Expected Lifetime 327

Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page vii of 7

1 - Safety

In this sectionSafety Information 2Power 3Operation 4Maintenance 5Warning Labels and Cautions 6Safety Features 10

Safety Information

To avoid personal injury or damage to the equipment, familiarize yourself with proper procedures and methods before you operate the system. Read operator information before using this machine. Failure to follow operator instruction could result in serious injury.

Follow all applicable Lockout/Tagout procedures found in the most current version of the Lockout/Tagout (LOTO) Program and Procedures Guide (PG-APFS-INSR-080609)

Battery Handling (California Customers Only)

The battery used in this product contains perchlorate material. California requires perchlorate containing products to be accompanied by the following notice:

Perchlorate Material - special handling may apply. For more information refer to the following website: https://www.dtsc.ca.gov/hazardouswaste/perchlorate/.

Ear Protection/Noise Exposure GuidelinesEar protection is required if noise exposure exceeds OSHA standards. There are many factors to be taken into consideration in each individual work area when dealing with ear protection. Factors such as floor noise, length of exposure to noise, loss of hearing history in individual employees can all play a role in requirements. Analyze your specific work area environment to ensure safe practices. These are standard OSHA guidelines.

l 85dBA time weighted average over an 8-hour shift requires hearing protection be made available to employees and use is recommended. (European Union standard is 80dBA)

l 90dBA time weighted average over an 8-hour shift mandates hearing protection is used. (European Union standard is 85dBA)

Note:Local jurisdictions may have more stringent requirements. Refer to local regulations for standards and requirements in your area.

Safety

Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 2 of 328

https://www.dtsc.ca.gov/hazardouswaste/perchlorate/

Power

System Power

The inserter receives its power from a customer provided, single drop, external connection.

General Power Safety

l Use the power cord supplied with the machine chassis at the power entry and plug it into a properly grounded (earthed) and easily accessible wall outlet located near the machine. Failure to properly ground (earth) the machine can result in severe personal injury and/or fire.

l The power cord wall plug is the primary means of disconnecting the machine from the AC power supply for Lock Out/Tag Out (LOTO).

l Do not use an adapter plug on the line cord or wall outlet.

l Do not route the power cord over sharp edges or trap it between furniture.

l Ensure there is no strain on the power cord where it becomes jammed between the equipment, walls or furniture.

l Be certain the area in front of the wall receptacle into which the machine is plugged is free from obstruction.

l For input and output modules - power is distributed from the chassis. Use the AC connectors supplied with the modules to connect to system power. Do not connect external devices to the inserter.

Safety


Operation

l Only trained personnel are permitted to operate this equipment. Training must include instruction in operation under normal conditions and emergency situations.

l Read all instructions before attempting to operate the equipment.

l Use this equipment only for its intended purpose.

l Personnel working on or near this equipment must be instructed about the location and operation of emergency stop buttons (ESTOPs).

l Before starting the machine, check that:

o All persons are clear of the machine

o No maintenance work is being performed on the machine

o All covers and guards are in place

o The machine is free of scraps, jams, and foreign objects

l Never run the machine when any of the covers or guards are missing.

l Keep loose clothing, jewelry, long hair and neckties away from all moving parts. Make sure that clothing and hair fit closely to your body and remove all jewelry.

l When lifting covers, wait for all parts to stop moving before placing hands near paper path.

l Avoid touching moving parts or materials while the machine is in use. Before clearing a jam, be sure machine mechanisms come to a stop.

l When removing jammed material, avoid using too much force to prevent personal injury and damaging equipment.

l The machine will only be serviced by trained and authorized personnel. The main power source may need to be disconnected before servicing, depending on the type of service activity.

l It is essential that personnel employ safe working practices and observe all related regulations and legal requirements for safety when operating this product.

Safety


Maintenance

l Operators must understand and adhere to safety precautions when working with the equipment.

l Only qualified service personnel should service this equipment per local national requirements.

l Service that requires removal of protective covering is performed by qualified service personnel.

l Only setup maintenance, as described in the information provided, is to be performed by operators.

l A setup tool is supplied for adjustments to accommodate different size paper on the inserter.

l Use only Pitney Bowes approved printer ink and cleaners.

l To prevent overheating, do not cover the vent openings.

l Do not store flammable fluids inside this machine.

l Do not place any container with liquid on this machine, (i.e. coffee cups, soda, etc.)

l Do not use flammable cleaners in this machine.

l Do not use aerosol air canisters. It is recommended that a vacuum cleaner be used to remove dust and debris from the machine paper path. If you have to use shop air, turn the system off before you begin cleaning. Verify the shop air does not contain excessive oil or water.

l Do not spray liquid onto or into any part of the machine. Use a cloth to apply cleaning solution.

Safety


Warning Labels and Cautions

Pitney Bowes declines all liability in the event of material damage or bodily injury resulting from negligence in the application of these precautions in respect to handling, operating, or servicing, even if not expressly stated in these instructions.

Caution: Pinch Point Rotating ShaftPinch hazard; rotating shaft. Keep hands clear during operation.

Caution: Pinch Point RollersPinch hazard; moving belts and rollers in this area. Do not operate with cover open.

Caution: Hand EntanglementMoving belts; use caution. Keep hands clear during operation.

Caution: Rotating Roller HazardMoving rollers; use caution. Keep hands clear of this area during operation.

Safety


Caution: Hand Crush from LeftCrush hazard; force from the left. Use caution; keep hands clear during operation.

Caution: Hand Crush from AboveCrush hazard; force from above. Use caution; keep hands clear during operation.

Caution: Hand CrushCrush hazard; use caution when working in this area.

Caution: Hot SurfaceBurn hazard; hot surface inside. Allow to cool before servicing.

Caution: Motor Capacitor DischargeAllow six minutes for motor capacitors to discharge before servicing motor driver module.

Safety


Warning! Severe Shock HazardOnly authorized personnel should service this equipment. Turn power OFF before entry.

Caution: Hand AbrasionCaution, moving belts. Keep hands clear during operation to avoid hand abrasion.

Caution: Hair EntanglementCaution, rotating parts. Keep hair, jewelry, and loose clothing away during operation to prevent potential injury.

Caution: Cut HazardCaution, sharp blades. Keep hands clear during operation.

Caution: Sharp PointCaution, sharp points. Use care when working in this area; keep hands clear during operation.

Safety


Caution: Tip Over HazardWhen moving unit, push or pull in direction shown by arrow. Tipping over may cause injury or damage to equipment.

Caution: Refer to Operator GuideRead and understand operator information before using this machine. Failure to follow operator instruction could result in serious injury.

Additional Feeder Safety Risks

Although every effort has been made to reduce the hazards to a minimum, some residual risk remains. The feed station is open to allow for paper loading onto the feed hopper belts. Although these belts travel very slowly, always be aware of the moving belts and use proper caution in this area.

Caution: Entanglement in Feeder BeltsFeeder belts are moving when material is transported. Keep loose clothing, jewelry and hair away during operation to prevent potential injury.

Caution: Pinch Point - Infeed Envelope Conveyor GripperTo prevent potential injury do not put your hands near the infeed envelope conveyor gripper area.

Safety


Safety Features

Emergency Stop (ESTOP)

The ESTOP is used to stop the machine quickly in an emergency situation. Press down gently on the red ESTOP switch to activate it. Turn the red knob clockwise to deactivate it. If the ESTOP switch is pressed while the machine is running, the entire machine will come to an immediate stop. When the ESTOP is activated, the main DC screen will indicate this, as well as which location on the machine the ESTOP was engaged.

Only use ESTOPs for emergency situations with the potential of causing injury or machine damage.

ESTOP Switch (red)

There is an ESTOP icon on the Direct Connect main screen that indicates there is an ESTOP or interlock open, prohibiting the machine from starting.

ESTOP Icon - Main DC Screen (red)

Safety


Interlock Safety Connections

The interlock safety connection is a built-in safety feature. This system is equipped with covers that have an interlock mechanism to provide protection from injury to operators while the system is running. Each cover that can be opened or enables access to moving equipment while the system is running is connected to an interlock safety connection via a latch magnet.

The purpose of the interlock safety connection is to stop the machine so operators can safely access inside the module. The interlock feature stops potentially hazardous moving parts so operators can safely get inside the module to make adjustments or clear jams. Breaking the interlock safety connection should never be used as an emergency stop option.

The covers should not be opened while the machine is running. If an interlock cover is accidentally opened while the inserter is running, the connection is broken (via the latch magnet) and the system will immediately stop in the interlock area, while bringing the rest of the system to a controlled stop. The inserter will not start until that cover is closed and the interlock safety connection is satisfied.

Every operator accessible cover on the inserter that exposes an operator to a potential hazard while the machine is running is equipped with an interlock cover.

Note:

l Covers that require a tool for access are to be opened by trained Service personnel only.

l If the cover is partially closed, the icon on the main DC screen will not change color or indicate an open cover, but the machine will not start. If this occurs, verify the cover is fully closed.

Safety


Insert Rotary Feeder Interlock Switch

Each rotary feeder has one gray interlock switch that can be used to disable the rotary feeder locally. In this case, the feeder is disabled, with no power. The inserter system still has power but is not able to run when the feder interlock switch is engaged.

Insert Rotary Feeder Interlock Switch (gray)

Safety


2 - Product Overview

In this sectionEpic v3.1 (ZVE0) Inserting System 14Component Overview - Epic v3.1 (ZVE0) 15Indicator Lights 17About the Remote Control 18

Epic v3.1 (ZVE0) Inserting System

The Epic v3.1 (ZVE0) Inserter is capable of processing up to 21,000 transactional mailpieces per hour, depending on the application and configurations of the inserter. The system processes tri-fold (C-fold), half folds and flat material, and is controlled by Direct Connect (DC) software.

The Epic v3.1 (ZVE0) Inserter has all the auto adjustments features of the original Epic engine, plus auto adjusting chassis side guides and new buffer (ZVB4) design. These side guides work the same as the other engine auto adjust features, in that they automatically adjust to the measurements defined in the mode setting for each job. All of these auto adjust locations can be manually adjusted in DC.

Epic v3.1 (ZVE0) Inserting System

Note:The Epic v3.1 (ZVE0) Inserting system is capable of running flats. This is an optional feature that requires a software key to enable the functionality.

Product Overview


Component Overview - Epic v3.1 (ZVE0)

The Epic v3.1 (ZVE0) Inserting system consists of these main modules and sections.

Item Description Item Description

1 Input modules 7 Sealer

2 Buffer 8 Turnover

3 Chassis 9 Print+ Messenger Printer (optional)

4 Insert Feeders 10 Vertical Stacker (with flats stacker)

5 Engine 11 On Edge Stacker

6 Envelope Feeder

Product Overview


Component Descriptions

l Input Modules - Cut sheet or continuous forms can be cut and accumulated into collations. Material can be folded based job requirements. (Refer to specific input operator guides for details.)

l Buffer - Transports the collation from the input to the chassis. This area can rotate a collation from portrait to landscape (P2L) and / or change material from face up to face down (TNT).

l Chassis - Transports the collation under each feeder as it moves it towards the engine. The chassis supports sub setting. Side guides are automated based on mode configuration.

l Insert Feeders - This is where the inserts are added to the collation based on the mode configuration. Both friction and rotary style feeders can be intermixed.

l Booklet Feeder - A designated feeder designed to feed booklet style inserts 3 to 10 mm thick.

l Envelope Feeder - Envelopes are staged in this module and fed into the engine as needed.

l Engine - This is where the envelope flap is opened and the collation is inserted into the envelope. After insertion, the envelope (with collation inside) is transported to the sealer. There are both manual and automated adjustments in the engine.

l Sealer - This is where the envelope flap is moistened and closed to seal the envelope. The sealer module has a built-in Vertical Stacker (VS1).

l Turnover - This is used when the application requires postage to be printed on the envelope. The turnover turns the envelope from face down to face up, allowing you to print on the front of the envelope.

l Vertical Stackers - These stackers divert and stack good and bad mailpieces, based on application or system error. A stacker for flats can be installed under a vertical stacker, and is operator removable.

l On Edge Stacker - This is where the finished mailpieces are stacked vertically, until they are removed and placed in mail trays.

Product Overview


Indicator Lights

System indicator lights are located in various areas on the inserter. When an error occurs or operator intervention is needed, the indicator light will illuminate to a bright yellow (steady on or flashing) to help direct an operator to the appropriate area of the machine.

Indicator lights also alert operators when there is an open cover or ESTOP activated and when the material in the insert feeder gets low.

LED State Meaning

OFF Ready to run

Slow blink Feeder material low

Fast blink Interlock open

ON Jam

System Indicator Lights

System Indicator Lights

Product Overview


About the Remote Control

Direct Connect (DC) is the operating system software that controls the inserter. You make selections in DC using a mouse, keyboard, and computer monitor for setting up, running, and servicing the inserter. A DC touchscreen monitor is optional.

Although DC is used to control many aspects of the inserter, the remote control unit should be used as much as possible to operate the system.

Remote Control Functions

l Start and Stop - Press the Start and Stop buttons to start and stop the machine.

l Cycle - If the input is in Service mode, press the Cycle button to feed one sheet at a time.

l Clear Deck - To clear the deck (an operating sequence that clears the inserter deck of all mailpieces), press the Stop and Cycle buttons at the same time. Refer to the Clear Deck Function topic for more information.

Product Overview


3 - Power the System On and Off

In this sectionPowering Up the System 20Powering Down the System 22

Powering Up the System

There are specific instructions for powering up the system, both the inserter and the Direct Connect computer.

Power Up the Inserter

1. Locate the red and yellow ON/OFF power switch (near left most chassis feeder on lower cabinet).

ON/OFF Switch

Power the System On and Off


2. To turn the system ON, rotate the red section of the switch clockwise from the 9:00 position, so the arrow is facing up, in the 12:00 position.

Main Power Switch - OFF position and ON position

Power Up the Direct Connect Computer

1. When the DC computer completely boots up, at the Begin Login window hold down the [CTRL] and [ALT] keys at the same time and press the [Delete] key. The Login window opens.

2. To log into Windows, if the system is connected to a network, enter the system password. If it is not connected to a network, click OK.

Note:Depending on your site, the Windows log in may be automatic and you will not be prompted to perform this step.

3. Log in to DC.



Powering Down the System

When you power down the system, you cannot simply turn off the power. There are specific instructions for powering down the system, both the inserter and the Direct Connect computer.

Power Down the Direct Connect Computer

1. Clear all the material in the paper path.

2. Click Control > Power Down on the DC main menu bar.

3. When the Power Down window opens, click Yes. This powers down the DC computer.



Power Down the Inserter

After you log out of DC, the : It is now safe to turn off your computers message displays.

Note:After you power down the DC computer, wait about 30 seconds before proceeding; this gives time for other computers in the system to shut down safely.

1. Locate the red and yellow ON/OFF power switch (on the lower cabinet near the left most chassis feeder).

2. To turn the system OFF, rotate the red section of the switch counterclockwise from the 12:00 position, so the arrow is facing in the 9:00 position.

Main Power Switch - ON position and OFF position



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4 - Using Direct Connect

In this sectionDirect Connect Software Overview 26DC Main Screen 27Changing the UI Display Language 30Powering Down the DC Computer 31Viewing DC Software Details 32Logging In and Logging Out of DC 33Loading a Mode 35Setting the Mail Date 37Checking Status with Job Manager 38Accessing Reports in DC 39Starting and Stopping the Inserter Using DC 40Assigning an MRDF File (File Based Jobs) 41Disabling (and Enabling) the Inserter 42Clear Deck Function 43About the Speed Indicators in DC 46About the DC Alarm Message Box 47

Direct Connect Software Overview

Pitney Bowes inserters are controlled by Direct Connect™ (DC) software. This software provides centralized control that allows the DC PC to control operational areas on the inserter. The software can detect inserter issues while the machine is running. When material jams or inserter problems occur, the software pinpoints them swiftly to minimize machine downtime.

The inserting process is assembling mailpieces by feeding documents, envelopes and inserts into an inserter, and starting the machine so that it assembles the mailpiece. There are two main inserting processes - including direct scanning and file based scanning.

Direct Scanning

Direct scanning is when DC uses a barcode to control the inserter and provide real-time decision-making about mail processing. A document with a barcode (for example, a monthly statement) is fed into the inserter. DC reads and decodes the barcode, and the information is used to control the inserting process for the mailpieces.

File Based Scanning

Fle based scanning is when DC uses an Input file (also known as the MRDF or mail run data file) to control the inserter and provide real-time decision-making about mail processing. A document with a barcode (for example, a monthly statement) is fed into the inserter. DC reads and decodes the barcode, and the information is used to grab the instructions from the Input file for putting the mailpiece together. The Input file can store an unlimited number of instructions for assembling a mailpiece.

File based scanning with DC connects to a network and file server to communicate and store the Input file for the inserting process. Because the Input file is stored on a central server, it can be accessed by all of the inserters. This allows a mailing job to be run on any inserter or split among inserters.

Using Direct Connect


DC Main Screen

The DC main screen consists of machine operation buttons, icons, elements and animated objects designed to match the components on your actual machine. You can control operations of the system from this main screen.

Note:This screen is configurable. The items shown in this example are for reference only and may not match the DC screen on the inserter(s) at your site.




1 Main Menu Bar 6 Menu Button

2 Banner Area 7 Alarm Icon

3 Buttons 8 Alarm Message Box

4 Icons (may look different site to site) 9 Speed Indicators

5 Start Bar (Menu, Start/Stop, Cycle buttons) 10 Inserter Model



Screen Item Descriptions

l Main menu bar - power up and down, switch UI display language, and get software details

l Banner area - displays user, mode, and job name

l Buttons - options to log in, load a mode, access reports, set feeders

l Icons - configurable (i.e. ESTOP, Mailpiece Manager, etc.)

l Start bar - start and stop DC; includes Menu and Cycle buttons

l Menu button - options to start or stop a job, reset the count, load a mode, open a file or clear deck

l Alarm icon - indicates an error (click to view more error information)

l Alarm message box - displays specific error

l Speed indicators - displays sheets fed and sheets processed

l Inserter model - graphic representation of the inserter modules



Changing the UI Display Language

When you are logged in as an Operator, you can change the UI display language from the main menu bar on the main DC screen.

1. Click Control on the DC main menu bar.

2. Hover over Switch Languages and select the language you want.

Note:The UI display language is typically set by Service during the installation process.



Powering Down the DC Computer

When you are logged in as an Operator, you can power down the DC computer from the main menu bar on the main DC screen.

1. Click Control on the DC main menu bar.

2. Select Power Down and click Yes when prompted. This shuts down the DC computer.

Note:If you are logged in as an Operator, you cannot exit DC, you can only power down the DC computer.



Viewing DC Software Details

When you are logged in as an Operator, you can view details about the DC software from the main menu bar on the main DC screen.

1. Click About! on the main menu bar in DC, a dialog opens with software details (version, install date, ID number).

2. Click Close to exit.



Logging In and Logging Out of DC

There are a few different login levels in DC. Options and features you see or have access to vary depending on your user access level - Operator, Key Operator, Manager, Service, Administrator and Engineer.

Logging In

1. Click the Login button on the main DC screen.

2. Select Login from the drop-down menu.

3. When the User Login dialog opens, double-click Operator (or your login name).

4. When prompted, enter your password and click OK.

Logging Out

1. Click the Login button on the main DC screen.

2. Select Logout from the drop-down menu.

Note:

l When no one is logged in, the Login button shows a locked padlock icon.

l When a user is logged in, the Login button shows an unlocked padlock icon and the operator's name is displayed in the banner area of the screen.



Operator Login Access

When you log in as an operator, you can perform these activities in DC:

l Change UI display language

l Power down the DC computer

l View DC software details

l Load a mode

l Set the mail date

l Check status with Job Manager

l Access standard report

l Start and stop the inserter

l Assign an MRDF file

l Enable and disable inserter components

l Clear the deck

l Monitor speed indicators

l View and access alarm screens

l View Help dialogs

Note:Key Operators have the same access operators do, and they can get to some additional setup screens.



Loading a Mode

DC uses operating modes to run applications on the inserter. A mode contains the unique combination of system settings for processing a specific job. Some setting examples include timing parameters, file locations, scan code layout, forms length, and the icons displayed on the main DC screen.

Note:In order to see available modes you must be logged in to DC. Typically, operators load modes, they do not create them.

Loading a Mode

Before you run a job, load the mode.

1. Log in to DC.

2. Click the Mode button on the main DC screen.

3. Select Load Mode from the drop-down menu.



4. Highlight the mode for the job you are setting up and click OK.

Note:After you load the mode successfully, the mode name appears in the banner area at the top of the main DC screen.



Setting the Mail Date

If you are logged in as an Operator, you can set the mail date for the job, before you run it.

1. Click the JobMgr button on the main DC screen.

2. Select Set Mail Date from the drop-down menu.

3. When the dialog opens, type in the mail date. (It must be today's date or a date in the future.)

4. Click OK.



Checking Status with Job Manager

If you are logged in as an Operator, you can check job status information about the inserter you are working on, the current job, the operator, etc.

1. Click the JobMgr button on the main DC screen.

2. Select Status from the drop-down menu.

A Job Manager Status dialog opens and displays information about the machine, the current job, the operator, etc.

3. Click Close to exit.



Accessing Reports in DC

When you are logged in as an Operator, you can access a standard machine status report, which you can view, save or print.

1. Click the Reports button on the main DC screen.

2. Select Reports > Report from the drop-down menu.

3. When the dialog opens, you can click Print, Save or Close to exit.

Accessing Saved Reports Feature

To view the reports you may have previously saved:

1. Click the Reports button the main DC screen.

2. Select Reports > View Saved Reports from the drop-down menus.

3. When the folder opens, browse through the reports you saved and double-click the desired report to view details.

Note:The Direct Reports option is not available at an Operator log in access level.



Starting and Stopping the Inserter Using DC

When you are logged in as an Operator, you can start and stop the inserter using the buttons in the Start bar area on the bottom of the main DC screen.

Start Button

When you click the Start button, the inserter starts running and the Menu, Start, and Cycle buttons are replaced by the Stop button.

Stop Button

When you click the Stop button, the system stops at a predetermined state, to ensure all the mailpieces in process are controlled; this helps to avoid errors or jams. Also, when you click Stop, the Menu, Start, and Cycle buttons display again.

Note:You can also start or stop the inserter using the remote control.



Assigning an MRDF File (File Based Jobs)

If you are running a file based job, you need to assign an MRDF file to the job. The MRDF is a data file that contains a set of information used for processing the mail (i.e. number of pages, number of collations, etc.). If this is not a file based job, you can skip this step.

1. Click on the Menu button on the bottom of the main DC screen, near the Start bar.

2. Select Open File or Start Job from the drop-down menu.

3. In the Select Mailrun field, type in the name of the MRDF file or scan it from the work order.

4. When the file name populates the field, click OK to open it.



Disabling (and Enabling) the Inserter

When you are logged in as an Operator, you can disable the inserter from any run activity. Typically, you might only disable the system if directed by Service.

For example, if Service needs to perform diagnostic activity on the machine, they may ask you to disable the system, to avoid having to completely shut down. This freezes system activity, preserving data that may be helpful for diagnosing issues.

When you are ready to start running the job again, you can enable the system.

1. Click the Menu button on the bottom of the main DC screen, near the Start bar at the bottom of the screen.

2. Select Disable System. The inserter stops and cannot be started until it's enabled through DC.

3. When you are ready to run the inserter, click the Menu button and select Enable System. The inserter is enable to start when you are ready.



Clear Deck Function

The Clear Deck function starts an operating sequence that clears all the mailpieces from the paper path. Typically you use this option at the end of a job or before you start a new job, if the paper path is not clear.

How to Initiate Clear Deck

When you are logged in as an Operator, you can initiate clear deck. There are three ways to do this:

l Click the Menu button on the bottom of the main DC screen and select Clear Deck from the menu.

l Press and hold the Cycle button on the remote control (wait for about 1 second), and then press the Stop button while still holding down the Cycle button.

l Click the Chassis object on the main DC screen and select Clear Deck from the menu.

What Happens When Clear Deck is Initiated

l If the machine is running when Clear Deck is initiated, all the material in the paper path will be processed and cleared from the machine.

l If the machine is not running when Clear Deck is initiated, the next time the machine is started, all mail that was being processed is completed and then the system will stop.

Once initiated, the Clear Deck message flashes at the bottom of the screen.



Clear Deck and Feeders Function

The Clear Deck and Feeders function cycles all the mailpieces out from the paper path and, all the material in the armed area of the insert feeders. Clear Deck, only removes the mailpieces in the paper path, not the material in the insert feeders.

You can initiate Clear Deck and Feeders manually or set it up to run automatically whenever you initiate a Clear Deck function.

Initiate Clear Deck and Feeders Manually

1. Click the Chassis object on the main DC screen and select Clear Deck & Feeders from the drop-down menu.



Setting Up "Clear Deck and Feeders" to Run Automatically When Clear Deck is Initiated

You can set the system up so the feeders are automatically cleared every time you initiate Clear Deck.

1. Click the Chassis object on the main DC screen and select Setup from the drop-down menu.

2. When the Chassis Setup dialog opens, select the Clear feeders on clear deck checkbox. (Every time you initiate the Clear Deck function, the material in the armed area of the insert feeders is also cleared.)



About the Speed Indicators in DC

The speed indicators are located on either side of the Start bar on the bottom of the main DC screen.

The input speed indicator displays the input speed (the speed in which pages are fed) in number of mailpieces per hour (shown as 0 below) as well as the total number of pages fed (shown as 63 here).

The output speed indicator displays the output speed in numbers of mailpieces per hour (shown as 677 here), as well as the total number of mailpieces that reached the output stacker (shown as 12 here).



About the DC Alarm Message Box

Alarms are reasons why the inserter stops. When the machine stops because of a problem, the alarm message box opens at the bottom of the DC main screen over the start bar.

Alarm Message Box

When an alarm displays in the alarm message box, you can get more information about what and where the issue is, and suggestions on how to solve it..

Refer to the Alarm Recovery topic for more detailed information on how to manage DC alarms.




5 - Operator Adjustments

In this sectionOperator Adjustments 51Adjusting the Envelope Feeder Separator Gap 52Adjusting the Envelope Fence 55Adjusting the Suction Cups in the Engine 56Adjusting the Engine Tongue Position 60Adjusting the Engine Tongue Height 63About Engine Horns 65Changing Engine Horns 66Envelope Settings 71Setting Up the RAT (Right Angle Transfer) 78Adjusting Amount of Sealer Fluid Applied 80Setting Up the Vertical Stacker 82Moving the Flat Stacker 84About the On Edge Stacker (OES) 88Setting Up the Entrance to the On Edge Stacker 90Centering Mail on the On Edge Stacker Conveyor Belt 94Adjusting the Belt Speed and Stack Pressure on the On Edge Stacker 96Adjusting On Edge Stacker Fingers 100Adjusting Chassis Material Center Deck Control Strap 102Adjusting Chassis Side Guide Control Straps 104Setting the Chassis Collation Length 105Setting the Chassis Speed 107Friction Feeder Mechanical Adjustments 109Adjusting the Friction Feeder Separator 110Adjusting the Friction Feeder Side Guides 113Adjusting the Feeder Pack Control Ramp 116Rotary Feeder Mechanical Adjustments 118

Using Rotary Feeder Suction Cups 119Adjusting the Rotary Feeder Side Guide and Backstop 122Adjusting the Rotary Feeder Deck Position 124Setting the Rotary Feeder Feed Deck Angle 126Adjusting the Rotary Feeder Separator Pins 128Using the Wedge Accessory on the Rotary Feeder 131Using the Jog Function on the Rotary Feeder 133Booklet Feeder Mechanical Adjustments 137Changing Out the Booklet Feeder Separator Assemblies 138Adjusting the Booklet Feeder Separator Gap 145Adjusting the Booklet Feeder Side Guides 148Adjusting the Booklet Feeder Pack Control Ramp 151Adjusting the Booklet Feeder Double Detect Feature 155Adjusting the Bulk Loader Hopper Deck 158Adjusting the Bulk Loader Hopper Side Guides 161Insert Feeder Software Adjustments 163Enabling and Disabling Feeders 164Document Information 165Setting Feeder Feed Modes 169Setting Backup Feeders (Backup Feed Mode) 171Transport Envelope Setup (Xport Setup) 174Setting Separator Options for Friction Feeders 175Recalibrating the Double Detect Feature 177Adjusting Buffer Upper O-ring Belt Height 178

Operator Adjustments



There are several adjustments (both mechanical and through the software GUI) operators can make during job setup, running a job and troubleshooting activities. These adjustments are grouped by areas of the system to make it easier to find the procedures.

l Envelope Feeder

l Engine

l Sealer

l Vertical Stacker

l On Edge Stacker (OES)

l Chassis

l Friction Feeders (insert feeder)

l Rotary Feeders (insert feeder)

l Booklet Feeder

l Buffer

Note:After loading a mode, home the chassis by pressing the Start button once.

Job Changeovers

Changeover adjustments may be required if the new job you are about to run has material that is a different orientation (portrait or landscape), size or material thickness than the previous job.

Some of the adjustments for a job changeover the system makes automatically, and some you need to make manually. Refer to the "Job Changeover Guidelines" topic for detailed information.



Adjusting the Envelope Feeder Separator Gap

The envelope feeder separator sets the gap, so only one envelope feeds at a time. The size of the gap is set based on envelope thickness. If the gap is too tight, envelopes will not feed. If the gap is open too wide, multiple envelopes will feed.

1. Pull the separator access lever towards you until it stops and hold it in place.

Pull Back Separator Access Lever



2. While holding back the separator access lever, slide one envelope between the separator and the red belts, making sure it's between the separator rollers.

Item Description

1 Red Belt

2 Separator Roller Area (roller not seen in photo)

3 Separator Adjustment Knob

Insert Envelope Between Separator Rollers

3. Release the access lever.

4. Turn the separator knob to adjust for thickness. You should feel a very slight drag on the envelope as you try to remove it from the separator roller. (Adjust the separator knob only a few clicks and recheck the settings.)

a. If there is too much drag on the envelope, open the knob to reduce drag.

b. If there is not enough drag on the envelope, close the knob to increase drag.



5. Remove the envelope.

Note:This adjustment gets the feeder gap close to the final setting. During operation testing additional adjustments may be necessary if doubles or no envelopes are feeding.



Adjusting the Envelope Fence

The envelope fence supports the envelopes at the feed head and also keeps the envelopes aligned with the feed head.

1. Load a stack of envelopes (flap down and facing to the right) in the envelope hopper.

2. Loosen the lock down lever and slide the envelope fence up or down until the alignment arrow lines up with the top edge of the envelopes.

Loosen Lever and Use Alignment Arrows

3. When the fence is properly positioned, lock it in place.



Adjusting the Suction Cups in the Engine

The suction cups in the engine open up the throat of the envelope for insertion. They can be adjusted to accommodate different envelope throat sizes.

1. Lift the engine cover.

2. Lift the upper engine to access the vacuum deck.

3. Open the envelope and fold the flap inside, so the throat of the envelope is showing.

4. Align the top of the envelope (flap crease line) with the deck lines shown here. (This is where the envelope is staged. All adjustments should be made from this position.)

Align Envelope



5. Close the upper engine.

Close Upper Engine

Envelope Aligned - view from above



6. Use the operator setup tool to loosen the three suction cup lockdown screws.

Suction Cup Lockdown Screws



7. Slide the suction cup arm to position the suction cup approximately 1/8-inch (3 mm) from the envelope throat. (Do this for all three suction cups.)

Item Description

1 Envelope Flap

2 Envelope Throat

3 Suction Cups

4 1/8-inch (3 mm) space

Position Suction Cups - 1/8-inch (3 mm) from throat

8. Tighten the suction cup lockdown screws.


10. Lower the upper engine.

11. Close the cover.



Adjusting the Engine Tongue Position

The engine tongue helps guide the collation into the open envelope and prevents it from catching on the envelope throat. The tongue position needs to be adjusted when the throat of the envelope changes.

To adjust the engine tongue position:


2. Lift the upper engine to access the vacuum deck.

3. Open the flap of the envelope and fold the flap inside, so the envelope throat is showing.

4. Align the top of the envelope (flap crease line) with the deck lines shown here. (This is where the envelope is staged. All adjustments should be made from this position.)

Envelope Flap Against Insert Ledge



5. Close the upper engine.

Close Upper Engine

6. Use the operator setup tool to loosen both horizontal tongue lockdown screws.

Tongue Lockdown Screws



7. Slide the tongue assembly so it is 1/8" (3 mm) from the edge of the envelope throat.

Item Description

1 Tongue Assembly

2 Envelope Throat

3 1/8" (3 mm) gap between tongue and throat

Position Tongue Assembly

8. Tighten the lockdown screws.



11. Close the engine cover.



Adjusting the Engine Tongue Height

You can adjust the tongue height to accommodate the thickness of the collation.

1. Identify the thickest collation or largest number of panels to be run in this job.

2. Open the engine top cover and open the upper engine.

3. Locate the lockdown screw to adjust the tongue height and loosen it.

Tongue Height Lockdown Screw



4. Place the thickest collation (or largest number of panels) under the tongue.

Tongue to Collation Location

5. Close the upper engine and with the collation under the tongue, adjust the tongue (up or down) so there is a no drag, to about a 1 to 2 mm gap.

Small Gap (1 to 2 mm) between Tongue and Collation

6. Remove all material from under the tongue and insert area.


8. Close the engine cover.



About Engine Horns

Engine horns are used to funnel the material from the insert area into the envelope. There are three different types of horns, based on size, that can be installed on the engine - standard, narrow and wide. Horn type is selected based on collation thickness or envelope size.

Horn Descriptions

Horn Types

Item Description

1 Narrow Horn (3 mm)

2 Standard Horn (standard 8 mm)

3 Thick Horn (13 mm)

l Narrow horn - used when the envelope is 8" or less and when the collation thickness is less than 3 mm. Used for applications with tight end clearance.

l Standard horn - used for all applications up to 8 mm in thickness. This is the middle size horn.

l Thick horn - this horn is used for applications running thicker collations, up to 13 mm.

Use the horn that is saved to the mode, otherwise timing and adjustments may not be properly completed.



Changing Engine Horns

Change engine horns based on the application you are running.

1. Loosen the short screw using the short setup tool.

Short Setup Tool (ZX84205)

The short screw is captured and will not come out of the horn assembly. When loosening the screw, do not hold the horn or you can damage it.

Short Screw - Horn Mounting Screw



2. Using the setup tool, loosen the single locking screw and remove the horn strap.

Item Description

1 Mounting Screw

2 Horn Strap

3 Horn

Remove the Horn Strap



3. Remove the horn you are going to use from the holder, and store the removed horn back in the holder.

Horn on Holder

4. Install the new horn by aligning the horn mounting with the horn mount.

Horn Mounting Screw



5. Tighten the horn in place. (NOTE: Don't hold the horn while you tightening it; it may cause damage.)

Item Description

1 Horn Mounting Screw

2 Horn Mount



6. Installing the horn strap:

a. If you are installing the narrow horns, install the narrow strap. If you are installing the standard or wide horns, install the wide strap.

b. Select the correct width and orientation (left or right) and slide the slotted mounting bracket under the mounting screw and between the horn opening.

c. Tighten the horn mounting screw in place and verify that the horn pivots freely without binds.

Item Description

1 Mounting Screw

2 Horn Strap

3 Horn

Install Horn Strap

7. Load the mode for the new application.



Envelope Settings

Envelope information is typically defined in the mode. If you are required to change envelope properties for any reason, this is where you would do that.

1. Log into DC as Key Operator access level or higher.

2. Click the Engine object on the main DC screen and select Setup from the drop-down menu.

Engine Object



3. When the Engine Setup screen opens, you can define your envelope properties in these fields.

l Length - measured across the envelope from left to right (required field)

l Height - measured with the flap closed from the top to the bottom of the envelope (required field)

l Flap height - length of flap at its largest point from crease (required field)

l Flap delta - difference in flap size at flapper exit sensors (i.e. how much shorter is the flap at the sealer). The sensor itself is about 2.9 inches (74 mm) off the flap center line. (required field)

l Weight - weight of the envelope (optional)

l Thickness - (referring to material thickness) the thickness of a single insert or document page that will be fed from this feeder. (optional)



Identify Envelope Flap Information

There are two ways to identify the flap delta of an envelope. The easiest way is to use the Flap Delta Envelope Guide Template. If the template is not available, you can use a scale and envelope measurements to identify the flap delta.

Use this information as a reference to enter the proper envelope settings into DC for your job.

Using the Flap Delta Envelope Guide Template

To identify the envelope flap delta using the flap delta envelope guide template (SV63174):

1. Lay the envelope flap template on a flat surface.



2. Fold the envelope in half and find the center width.

3. Open the envelopes flap.

4. Align the center of the envelope to the arrow on the top of the template.

5. Square up the envelope with the guidelines on the bottom of the template.

Item Description

1 Center line of template (aligned with center of envelope)

2 Bottom of envelope (parallel with template guides)



6. Hold the envelope in position (shown above) and locate the flap delta scale to either the right or left of the center. Record the measurement seen where the flap crosses this scale.

l Left side of the scale is in inches and should be recorded as .1, .2, .3, .4, .5, .6, .7, etc.

l Right side of the scale is in millimeters.

In this Example - Flap Delta is .7 inches

7. Enter the value of the Flap Delta (measured in step #6) in the Engine Setup screen.



Flap Height Measurement

1. Measure the flap height from the crease line to the edge of the center of the flap - that is your flap height measurement for entry into DC.

Envelope Information - Flap Height Measurement



Flap Delta Measurement

If you don't have the Flap Delta template, follow these steps.

1. Measure and mark 2.9 inches (74 mm) off of the center line.

2. Measure the height difference from the marked point to the top center of the flap - that is your flap delta measurement for entry into DC.

Envelope Information - Flap Delta Measurement



Setting Up the RAT (Right Angle Transfer)

The RAT changes the direction of the envelope 90 degrees to be transported downstream to the output.

Adjusting the Roller Tension

This is the only operator adjustment in the RAT area.

1. Open the engine and sealer top covers.

2. Locate the adjustable roller locking screw for the two exit rollers.

Item Description

1 Tensioner

2 Locking Screw

RAT Roller Tension and Locking Screw

3. Using a 3/16" setup tool, loosen the locking screw.

4. With the locking screw loose, adjust the tension of the roller. (The left side is lighter, press to the right is more pressure.)

5. Tighten the locking screw.



6. Perform on other roller if needed.

7. Close covers.



Adjusting Amount of Sealer Fluid Applied

The sealer is where the envelope flap is moistened and the flap is closed. Operators can adjust the amount of sealer fluid applied using DC. There are no mechanical adjustments available to operators on the sealer.

Adjusting Amount of Sealer Fluid

The default amount of fluid applied to the envelope is determined by the envelope parameters entered in the Engine Setup screen in DC. The amount of fluid used to seal the envelopes may need to be adjusted during mail processing based on the type of envelope material.

1. Click the Sealer object on the main DC screen and select Sealer Control from the drop-down.

Sealer Object



2. Use the adjustment bar slider to adjust the amount of fluid dispensed.

Pulse Water - when this parameter is selected, the sealer pump will pulse for the amount of time displayed in the field, up to 30 seconds. This feature is not active while the system is running.

Note:Make small changes with the slider checking often to see if you are getting the desired results. Excessive fluid will drain into the overflow tube into the overflow catch bin.



Setting Up the Vertical Stacker

The vertical stacker is primarily used to transport material. It can also be used as a diverter, depending on the application.

This adjustment is only performed when stacker material is changed or possibly after a service call.

1. Use the operator setup tool to loosen the screw that holds the wheel to the bracket to adjust the direction of travel of the envelope.

Vertical Stacker - Screws on Wheels

2. Angle the roller more to the right to direct the envelope toward the back wall of the vertical stacker. (Sliding the roller to the left will steer the envelope away from the back wall.)

3. Tighten the rollers.

Note:Rollers are used to correct small amounts of skew or misalignment only; adjustments should be slight. Always check upstream of where the skew / misalignment occurred to see if another area is the issue.



Remove or Add Vertical Stacker Side Guide

To remove or add a vertical stacker side guide:

1. Loosen both thumb screws that hold the guide in place.

2. Grasp the side guide and slide it to the left of the cross bars.

3. Lift the right side and remove the guide from the module.

Adjust a Vertical Stacker Side Guide

To adjust the position of a vertical stacker side guide:

1. Loosen both thumb screws and slide the guide on the bars to the desired position.

2. Tighten the thumb screws.

Note:When running flats, remove the guides from all vertical stackers before the flats conveyor stacker.



Moving the Flat Stacker

The flat stacker is used when flat envelopes (non-folded collations) are processed on the input. The stacker is mounted under the designated stacker that has the appropriate mounting features and electrical connections to make it work

When you are not running flat envelopes, the stacker can be removed from the work cell to increase access to the On Edge Stacker.

Note:The stacker can be removed and installed while the system is powered on.



Removing the Flat Stacker

1. Remove the three electrical connections on the non-operator side of the vertical stacker:

a. Unscrew the connector at the base.

b. Squeeze the top and bottom tab while gently pulling the connector free.

c. Pull the blue connector off the base.

Item Description

A Connector

B Tab

C Pull connector off

Remove Electrical Connections



2. Flip both black latches down to a horizontal position to unlatch them.

Unlatched

3. With the electrical connection disconnected and the latches down, grasp the handle on the other side of the module, and roll the unit out from under the vertical stacker.

4. Move the module to a secure location to prevent damage.



Adding the Flat Stacker

1. Roll the flats stacker up to the appropriate vertical stacker (use the handle) and align the locking latches to the mating holes in the stacker.

2. Once the latches and holes are aligned, latch them closed.

3. Connect the three electrical connections:

a. Align the starting tab and tighten the ring on the connector.

b. Align the connector so the starting tab is in the correct orientation, and then press the connector together until it locks in place.

c. Align the pin into the blue plug and press them together.

Item Description

A Connector

B Tab

C Align and press together

Electrical Connections



About the On Edge Stacker (OES)

Completed mailpieces are turned up on edge and prepared for stacking on the On Edge Stacker (OES).

Main OES Components

Item Description

1 Stacker Entrance Envelope Guides

2 Pack Pressure Adjustment Knob (on backside, not visible here)

3 Control Panel

4 OES Fingers (on backside, not visible here)

5 Bin Full Switch with 3/4 Full Sensor

On Edge Stacker (OES)



Control Panel

Item Description

1 ESTOP

2 Pack Pressure LED

3 Reset Button (not available)

4 Actuator Switch

5 Conveyor Speed

On Edge Stacker Control Panel



Setting Up the Entrance to the On Edge Stacker

To help make sure the On Edge Stacker (OES) stacks mail properly, use these setup guidelines.

1. For proper stacking height the envelope must be set to 1/2-inch (12.7 mm) off the deck.

Item Description

1 1/2-inch (12.7 mm) Offset from Deck

2 Paper Flow and Stacker Exit

Envelopes Set to 1/2-inch (12.7 mm) Off the Deck (shown here in closeup)

2. To adjust the height, move the actuator switch up or down.

3. After setting the proper height, adjust the entrance guides to keep the same height consistent.



4. Use the operator setup tool to loosen the four Allen screws (two on the non-operator side guide and two on the operator side guide) and slide the entrance guides open.

Item Description

1 Non-Operator Entrance Guide (loosen screw)

2 Operator Entrance Guide

Loosen Screws - loosening screw on non-operator side guide shown here



5. Place the setup envelope under the rollers of the vertical stacker - position half of the envelope under the rollers and half under the entrance of the OES.

Item Description

1 Vertical Stacker Rollers

2 Entrance to OES

Positioning the Envelope in the Vertical Stacker



6. Take the outer guide (non-operator side), position it 1/4-inch (12.7 mm) from the top seam of the envelope and use the operator setup tool to tighten the Allen screws.

Item Description

1 Non-operator Side Guide (outer)

2 Top Seam of Envelope

3 1/8-inch Gap

4 Operator Side Guide (inner)

Positioning of the Inner and Outer Guides

7. Take the inner guide (operator side) and position it 1/4-inch (6.3 mm) away from the bottom seam of the envelope and use the operator setup tool to tighten the cap head screws.



Centering Mail on the On Edge Stacker Conveyor Belt

When possible it is best to stack the mail in the center of the belt on the On Edge Stacker (OES) or as close to the center as possible.

Mail Centered



To make sure the mail is stacked properly :

1. If the lead or trail edge of the mail is not centered on the belt, loosen the top knob and adjust the mail stacking fence toward or away from the envelope as needed.

Item Description

1 Top Knob

2 Mail Stacking Fence

Mail Centering Adjustment

Note:If you are getting inconsistent stacking, it may be necessary to move the stacking fence left or right 1/8-inch to 1/4-inch to get a better stack.



Adjusting the Belt Speed and Stack Pressure on the On Edge Stacker

Adjust the speed of the belt and pack pressure to ensure the material stacks properly on the On Edge Stacker (OES). Properly stacked mail is perpendicular to the belt. Improper vertical stacking can cause jams at the stacker exit.

Proper Vertical Stacking - mailpieces are straight and even

Improper Vertical Stacking - mailpieces are uneven and not tightly packed



Adjust Belt Speed

As the mailpieces leave the turn up module they are driven onto the OES conveyor belt. The pulsing of the conveyor belt is what moves the mailpiece down the conveyor and determines how far the mailpiece advances with each pulse of the belt.

The conveyor speed dial controls the speed of the stacker conveyor belt. Adjust the conveyor speed by turning the speed dial clockwise to make the belt move faster or counterclockwise to make the belt move slower.

Speed Dial Adjustment Knob



Adjust Pack Pressure

Pack pressure refers to the stack of finished envelopes on the stack and how tightly they are packed. It is measured by a sensor. Proper pack pressure is important because the amount of pressure in the stack ensures adequate sealing of the envelopes.

You can control the pack pressure with the pack pressure adjustment knob, located on the backside of the OES. While the system is running it is possible to make small movements (about 20 increments turn on the scale) to adjust it.

Pack Pressure Adjustment Knob



If the stack is too loose and the envelopes are leaning back, turn the knob clockwise to adjust the pressure. If the stack is too tight (possibly causing jams) turn the knob counterclockwise to remove some of the pressure.

Item Description

1 Pack too loose (leaning back)

2 Pack too tight (possible jamming)

Note:Do not over adjust the knob in the clockwise direction or you will bend the pack pressure arm.



Adjusting On Edge Stacker Fingers

The On Edge Stacker (OES) finger guides assist in keeping the mail already on the stacker clear of mail entering onto the stacker conveyor from the turn up module. As the mail exits the turn up module, the fingers guide it to get in line behind the mailpieces that are already on the conveyor.

Note:It may be beneficial to remove the finger guides when stacking 6 x 9 and other types of envelopes.

If the fingers have been moved and need to be repositioned:

1. Loosen the four adjustment thumbscrews.

Finger Guides - Adjustment Thumbscrews



2. Align each finger guide so it is even with the tip of the D roller. (Verify the D roller is in run position.)

Item Description

1 Finger Guides

2 Tip of the D Roller

Aligned Finger Guides

3. Once aligned, tighten the four thumbscrews to set the new adjustment in place.

Note:Additional adjustments may be required when running.



Adjusting Chassis Material Center Deck Control Strap

Chassis material control straps are located in front of each feeder and they control the collation as it travels down the length of the chassis. The straps are adjusted to provide the proper amount of pressure on each mailpiece to prevent the collation from sliding when the chassis stops.

The default location will be the first notch from the right. To adjust the material center deck control strap:

1. Start the inserter and run a job.

2. When the chassis deck is full, stop the machine with the remote or using DC.

3. View the collations (mailpieces) resting underneath each feeder:

a. If collation / mailpiece is more than 1-inch away from the pushers, loosen the lockdown screw with the Operator setup tool and rotate the indicator lever to the right to tighten strap pressure.

b. If the collation / mailpiece is buckled at the pusher, loosen the lockdown screw with the Operator setup tool and rotate the indicator level to the left to loosen strap pressure.

Item Description

1 Lockdown Screw

2 Indicator Lever

Adjust Chassis Material Deck Center Control Strap



4. Run more material and adjust the straps as needed until the proper position is achieved.

Note:When you find a setting that works, note the location of the strap indicator tabs to use for future jobs.



Adjusting Chassis Side Guide Control Straps

1. Open the appropriate covers.

2. Raise the appropriate feeders to gain access.

3. Use a 3/16” Allen to loosen the adjustment locking nut on the appropriate straps. Provide guideline for default strap location (angle).

4. Rotate to adjust the strap as needed.

5. Use a 3/16” Allen to tighten the locking nut.

6. Lower the feeders.

7. Close all the covers.

Side Guide Strap -Loosen Locking Nut - Rotate Strap to Adjust



Setting the Chassis Collation Length

The chassis collation length is usually set in the mode and not required to be set manually.

1. Measure the length of the largest document to be run on the chassis. (This can be from the input or an insert feeder.)

2. Click the Chassis object on the main DC screen and select Setup from the drop-down.

Chassis Object



3. In the Chassis Setup dialog type the new collation length in the Collation length field.

4. Click OK.



Setting the Chassis Speed

If the chassis speed has to be adjusted during a job, follow these steps to change the speed while the inserter is running. (NOTE: This is a site specific setting, access permission to perform this function varies from site to site.)

1. Click the Chassis object on the main DC screen and select Chassis Speed from the drop-down.

Chassis Object



2. To change the speed in the Chassis Speed dialog:

l Use the mouse to click the Decrease and Increase buttons as needed to modify the chassis speed setting.

OR

l Use the mouse to click in the text field above the buttons and type a number to manually adjust the speed.

3. When the desired speed is set, click OK.

Note:If the speed of the chassis is changed while the system is running, the speed will gradually change after the new speed values are entered.



Friction Feeder Mechanical Adjustments

There are several mechanical adjustments operators will need to perform on the friction feeders to be prepared for successful job runs.

l Adjusting the Separator

l Adjusting the Side Guides

l Adjusting the Pack Control Ramp



Adjusting the Friction Feeder Separator

Each friction feeder has a separator that separates the material during the feed cycle. The separators can be adjusted to accommodate various insert thickness. The adjustment outlined here gets the setup very close to the final setting, but you may have to continue making adjustments at the start of the job.

Note:The belts shown in these photos are blue, but feeder belts can also be red, tan or black depending on the system configuration and the material being processed.

1. Loosen the feeder side guide locking knobs.

2. Turn the side guide adjustment knob clockwise until it stops (side guides all the way open).

Item Description

1 Locking Knobs

2 Side Guide Adjustment Knob

3 Separator Knob

Feeder Side Guide Control Knobs



3. Loosen the pack control knob and slide the pack control to the right.

Item Description

1 Pack Control Guide

2 Pack Control Knob (slides to the right)

Pack Control Knob

4. Place a single piece of insert material on the feeder belts and slide it to the left under the separator. (The separator knob is on the other side of the separator, it's not visible here.)

Position Material on the Feeder Belts - Separator Under Roller



5. If the material does not slide under the separator, turn the separator knob clockwise until it does. (The separator is on the other side of the knob shown here.)

Separator Knob

6. Pull the material under the separator to the right (as if you were trying to remove it); you should feel a slight drag.

l If there is no drag, turn the separator knob counterclockwise until you feel a slight drag

l If there is too much drag, turn the separator knob clockwise until you feel a slight drag.

7. When you have the correct drag, remove the insert material.



Adjusting the Friction Feeder Side Guides

The feeder side guides allow the material in the feeder to be stacked. You can adjust the side guides to accommodate different insert material sizes.

To adjust the friction feeder side guides:

1. Loosen the feeder side guide lockdown knobs.

Item Description

1 Lockdown Knobs

2 Side Guide Adjustment Knob

Side Guide Lockdown Knobs



2. Turn the side guide adjustment knob clockwise until it stops.

Side Guides Opened Wide

3. With the side guides opened as wide as they can go, place a 1-inch (25.4mm) stack of insert material from the job in the selected feeder and hold it between the side guides just above the adjustment knob.

Position Material in Side Guides



4. Turn the side guide adjustment knob counterclockwise until the guides are against the insert material. (Allow a 1/16-inch (1.6mm) gap between each side of the material and side guide.)

Adjusting the Side Guides (1/16-inch / 1.6mm gap)

5. Tighten the side guide lockdown knobs.

6. Remove the material.



Adjusting the Feeder Pack Control Ramp

The pack control ramp helps relieve weight off the inserts as they are fed into the separator. It also keeps the material at a consistent angle for feeding into the separator. There is one feeder pack control ramp in each friction feeder.

To adjust the pack control ramp:

1. Loosen the pack control knob.

Item Description

1 Pack Control Guide

2 Pack Control Knob (slides to the right)

Pack Control Knob

2. Slide the pack control guide to the right.

3. Place a 1-inch (25 mm) stack of material between the side guides at the same height as the top of the pack control ramp.



4. Slide the pack control guide to between 1/32 "(.79 mm) and 1/16" (1.5 mm) from the material.

Position Material - 1/32-inch (.7 mm) to 1/16-inch (1.5 mm) gap

5. Tighten the pack control knob.



Rotary Feeder Mechanical Adjustments

There are several mechanical adjustments operators will need to perform on the rotary feeders to be prepared for successful job runs.

l Using Rotary Feeder Suction Cups

l Adjusting the Side Guide and Backstop

l Adjusting the Deck Position

l Adjusting the Feed Deck Angle

l Adjusting the Separator Pins

l Using the Wedge

l Using the Jog Function



Using Rotary Feeder Suction Cups

The suction cups in the rotary feeder pull the insert material from the stack in the rotary feeder down into the drum of the feeder, preparing it for insertion.

Rotary Feeder Suction Cups



About Suction Cup Types and Positions

There are two different types of suction cups - short and tall . The type of cup you use dependents on the type of material you are running.

Suction cup position is also determined by the type of material you are running. Refer to the table included here to determine the proper suction cup type and position for your job.

Material Type Cup Type Cup Position

Single sheet - #10, A4 (single sheet) short, blue ring 0

Half-fold, non-glossy (single sheet) short, blue ring 0

Half-fold, glossy (single sheet) short, blue ring 0-1

Folded, perfume tall, red ring 1

BRE tall, red ring 0

Booklet (thick .125" max) tall, red ring 1

Booklet (thin) short, blue ring 1



Setting the Suction Cup Position

1. Jog the feeder so the arm is in the horizontal position.

2. Loosen the suction cup arm locking screw.

3. Using the scale on the suction cup arm, move the arm to get the suction cups in the proper position.

Item Description

1 Locking Screw

2 Suction Cup Arm

3 Scale

Position Suction Cup



Adjusting the Rotary Feeder Side Guide and Backstop

1. Place the material on the deck against the feed center gate.

2. Loosen the backstop locking knob.

3. Push the backstop (forward or backward) against the material and lock the knob in place. (Do not move the backstop too close to the material as it can restrict the material from dropping to the deck naturally.)

Item Description

1 Center Gate

2 Backstop

3 Backstop Locking Knob

4. Loosen the side guide locking knobs.



5. Turn the control knob counterclockwise to close the side guides against the material. (Do not move the side guides too close to the material as it can restrict the material from dropping to the deck naturally.)

Item Description

1 Side Guide

2 Side Guide Locking Knobs

3 Control Knob

Adjust the Side Guides

6. Lock the side guides in place.



Adjusting the Rotary Feeder Deck Position

The rotary feeder deck holds the material. You can adjust the position of the deck so the material is properly positioned for inserting.

Rotary Feeder Deck Position Settings

The position of the rotary feeder deck depends on the type of material you are running. Use this table as a reference when setting the deck position.

Material Type Deck Position

#10, A4 (single sheet) 3

Half-fold, non-glossy (single sheet) 4

Half-fold, glossy 3, 4

Folded, perfume 2

BRE 2

Booklet (thick .125" max) 1

Booklet (thin) 1



To set the rotary deck in the proper position:

1. Loosen both outer deck blue locking knobs.

2. Slide the deck to the appropriate setting (use table here as a reference).

Slide the Deck to the Setting

3. Tighten the outer deck locking knobs.



Setting the Rotary Feeder Feed Deck Angle

The angle of the rotary feeder feed deck can be adjusted up and down to accommodate different size material.

Rotary Feeder Deck Angle Settings

Use this table as a reference to adjust the rotary feeder deck to the proper angle.

Material Type Deck Position

#10, A4 (Single Sheet) 1

Half-fold, non-glossy (single sheet) 1

Half-fold, glossy 0

Folded, perfume 3

BRE 1

Booklet (thick .125" max) 4

Booklet (thin) 0



To adjust the rotary feeder deck angle:

1. Turn the middle two blue angle adjustment knobs clockwise or counterclockwise to adjust the angle up or down.

Item Description

1 Angle Adjustment Knob

2 Angle Adjustment Marks

Adjust the Rotary Feeder Deck Angle

2. Use the angle adjustment marks on the side frame for reference.



Adjusting the Rotary Feeder Separator Pins

The separator pins in the rotary feeder prevent multiple pieces of material from being pulled into the feeder at once.

There are four separator pins located on the center gate. The two inner pins are closest to the center of the gate and the two outer pins are closer to the suction cups.

l Inner pins - used for most material

l Outer pins - used for unusual inserts (booklets) to allows the staple to miss the pins

Rotary Feeder Separator Pins (outer pins shown here)



Rotary Feeder Separator Pin Settings

The position of the rotary feeder separator pins is based on the type of material you are running. Use this table for reference when adjusting the separator pins.

Material Type Pins

Single Sheet (#10, A4, half-fold non-glossy, half-fold glossy) inner fuly in (toward stack)

Folded, perfume inner fuly in (toward stack)

BRE inner fuly in (toward stack)

Booklet (thick .125" max) all pins fully out (away from stack)

Booklet (thin) inner fully in (toward stack)



Adjutsing Rotary Feeder Separator Pin Positions

Separator pins are adjusted to be more or less exposed. To adjust their position:

1. Turn the knurled knobs located on the back of the center gate to adjust each separator pin.

2. Use the table in this topic to determine the proper pin setting based on the type of material you are running.

Separator Pin Adjustment Screws

Note:The pins are all the way exposed for most applications.



Using the Wedge Accessory on the Rotary Feeder

The wedge is an optional accessory that can be used to help support certain types of material as it is fed into the inserter from the rotary feeder. The wedge lifts the trail edge of the material to give the material more support.

Refer to the table included here to see if the material you are running requires the use of the wedge.

Material Type Wedge

(Single Sheet (#10, A4, half-fold non-glossy, half-fold glossy) optional

Folded, perfume optional

BRE optional

Booklet (thick .125" max) yes

Booklet (thin) yes

Installing the Wedge on the Rotary Feeder

1. Lift the wedge off the back wall of the feeder.

Wedge



2. Slide the wedge over the "goal posts" on the rotary feeder until it rests on the feeder deck.

Slide Wedge

3. Load the material into the feeder as usual.

4. When the job is finished, slide the wedge off the feeder and return to the back wall.



Using the Jog Function on the Rotary Feeder

The jog function slowly cycles material out of the rotary feeder for clearing jams or checking feeder setup.

Jog Features

There are two Jog functions you can use with the rotary feeder:

l Jog Only - This jog feature is for clearing jams. It turns the feeder drum one cycle so you can easily remove jammed material.

l Feed with Jog - This jog feature can help verify feeder setup. It clears all the material in the feeder drum and then acquires and feeds another insert to confirm correct setup.



Clearing Jams Using the "Jog Only" Function

In the event of a jam, you initiate the Jog Only function from DC and then use the mechanical Jog button on the rotary feeder to move the material out of the feeder.

Note:When you are clearing material jams from the rotary feeder, do not physically pull the material from the transport belts. Use the Jog button to move the material to the deck for easy removal.

1. Click the desired Rotary Feeder object on the main DC screen.

Feeder Objects

2. Select Jog Only from the drop-down list. (If Jog Only is not in the drop-down list, select Feed with Jog; click the Feeder object again and Jog Only is now listed. )



3. Once Jog Only mode is initiated in DC, press the mechanical Jog button on the feeder and the jammed material feeds out.

Jog Button on the Rotary Feeder



Verifying Feeder Setup Using "Feed with Jog" Function

You can verify rotary feeders are set up propelry using the Feed with Jog function.

1. Click the desired Rotary Feeder object on the main DC screen.

Feeder Objects

2. Select Feed with Jog from the drop-down menu. (If Feed with Jog is not in the drop-down list, select Jog Only; click the Feeder object again and Feed with Jog is now listed.)

3. Once the Feed with Jog mode is initiated in DC, press and hold the Jog button on the feeder.

The material in the feeder drum is cleared and another insert is acquired and fed to confirm correct setup.



Booklet Feeder Mechanical Adjustments

There are several mechanical adjustments operators will need to perform on the booklet feeder to be prepared for successful job runs.

l Swapping the Separator (stone or stripper bar)

l Adjusting the Separator Gap

l Adjusting the Side Guides

l Adjusting Pack Control Ramp

l Adjusting the Double Detect Feature

Booklet Feeder with Bulk Hopper

Booklet feeders that are mounted in the most upstream position can have an additional bulk loading hopper installed. These procedures are for this optional bulk hopper.

l Adjusting the Pack Control Ramp

l Adjusting the Bulk Loader Hopper Side Guides

l Adjusting the Bulk Loader Hopper Deck



Changing Out the Booklet Feeder Separator Assemblies

Note:This procedure is for standard booklet feeders or booklet feeders with a bulk loader hopper.

Each booklet feeder has a separator assembly that separates the insert material during the feed process.

The separator can be adjusted to accommodate various insert thickness. There are two separator options for the booklet feeder, a stone or a stripper bar.

You can switch between the two separator options depending on the type of insert material you are running. If the stone separator is not working, try using the stripper bar. Both styles are removed or replaced the same way.



Removing the Separator Assembly (Stone or Stripper Bar)

1. Turn the separator knob so at least 5/16" (8 mm) of thread is showing above the knob. This makes it easier to remove the separator assembly.

Separator Knob



2. Locate the 3/16" locking screw on the operator side of the separator assembly and use a setup tool to loosen and remove the screw and wedge block.

Locking Screw Location

Closeup View of Screw and Wedge Block

Item Description

1 Locking Screw

2 Wedge



3. With the screw and wedge block removed, slide and pivot the separator assembly out.

Removing the Separator Assembly

Note:Take care not to lose or damage a spring or photocell wires while removing the assembly.



Installing the Separator Assembly (Stone or Stripper Bar)

1. Turn the separator knob so at least 5/16" (8 mm) of thread is showing above the knob. This makes it easier to install the separator assembly.

Separator Knob

2. If the 3/16" screw and wedge block are installed on the operator side of the assembly, remove them at this time.

3. Angle and slide the separator assembly in place. Help guide the assembly into position, taking care not to lose or damage a spring or photocell wires.

4. With the separator assembly in place, install the 3/16" screw and wedge block on the operator side.



5. While pushing the assembly to your left, fully seat in in place and tighten the 3/16" screw using the setup tool.

The separator assembly needs to be fully installed to your left.

The wedge block must be sitting in the groove when the screw is tightened, otherwise the separator assembly might come loose.

Wedge Block Seated Correctly (left) and Wedge Block Seated Incorrectly (right)



6. Adjust the separator gap for the insert material in the job. (Refer to the Adjusting the Separator Gap topic for more information.)



Adjusting the Booklet Feeder Separator Gap

The separator gap is the space between the separator stone or stripper bar and material. This space can be adjusted to accommodate different types and thicknesses of material.

The adjustment outlined here gets the gap very close to the final setting, but additional fine tuning may be required.

1. Loosen the feeder side guide thumbscrews and slide the guides to their widest position.

2. Loosen the pack control knob and slide the pack control ramp to the left.



3. Place the insert material under the separator roller or stripper bar.

Stripper Bar

4. If the material does not slide under the roller or bar, turn the separator knob clockwise until it does.



5. With the insert material under the roller or bar, adjust the gap so there is very little (almost no) drag on the insert. The goal is that the gap be tight enough for one piece to easily fit under, but not two or more pieces.

l If there is no drag, turn the separator knob counterclockwise until you feel a slight drag

l If there is too much drag, turn the separator knob clockwise until you feel a slight drag.

6. When you have the correct amount of drag , remove the sample insert material.

7. Adjust the position of the pack control ramp. (Refer to the topic on Adjusting the Booklet Feeder Pack Control Ramp for details.)



Adjusting the Booklet Feeder Side Guides

The feeder side guides allow the material in the feeder to be stacked square and evenly. You can adjust them to accommodate different insert material sizes.

To adjust the booklet feeder side guides:

1. Measure the width of the insert for the job using the scale on the chassis deck.

2. Open the booklet feeder top cover.

3. Using a setup tool, loosen the side guide position mounting and height adjustment screws for each side guide.

Item Description

1 Height Adjustment Screws

2 Position Mounting Screws

Position Mounting and Height Adjustment Screws

4. Raise the side guide to its upper most position, and lightly tighten the two side guide height adjustment screws for each side guide.

5. Using the scale provided, slide the side guide so the inner edge of the side guide aligns with the width of the measured insert.

6. Using the scale provided, slide the other side guide to align with the width of the measured insert.



7. Tighten the position mounting screw for each side guide.

8. Loosen the two side guide height adjustment screws and lower them down.

l If the bottom of the guide is over the belt or roller, adjust the height of the side guide so there is a 2 mm gap.

l If the bottom of the guide is not over a belt or roller, lower the side guide to its lowest position.

Height Adjustment

9. Tighten both height adjustment screws for each side guide.



10. Using an insert, test the adjustment:

l The default setup for the side guides is centered and straight, no taper.

l Side guides should only be 1/16" to 1/8" (1.6 mm to 3.1 mm) larger than the insert.

Item Description

1 Adjust guides to insert width

2 Gap 1/16 to 1/8" gap (use insert)



Adjusting the Booklet Feeder Pack Control Ramp

Note:This procedure is for standard booklet feeders.

The pack control ramp helps relieve weight off the inserts as they are fed into the separator. This allows inserts to be placed continuously into the separator of the feeder.

Note:Prior to doing this, it's easier if the separator gap has already been set. If not, the separator gap may need to be adjusted (opened) to get the material to fit between the separator roller and lower feed roller.



To adjust the pack control ramp:

1. Loosen the pack control thumb screw and slide the ramp to the left.



2. Place the lead edge of the material from the job over the center of the lower feed roller, and hold in place.

Material Centered Over the Blue Roller (even with front of separator, not shown here)



3. Adjust the edge of the pack control ramp so it just touches the booklet, positioned over the center of the feed roller. (The pack control ramp just touches the trail edge of the booklet.)

Pack Control Ramp Adjusted to Trail Edge of Booklet

4. Tighten the pack control thumb screw.



Adjusting the Booklet Feeder Double Detect Feature

The double detect feature detects when more than one piece of material is fed from the insert feeder. If the double detect feature is not working properly, try adjusting it. For example, if you are running material that runs about 50% thinner or thicker than the material from the previous job, you should adjust the booklet feeder double detect.

Adjusting Double Detect

Note:

l When you check the double detect it's important to set the double detect for the insert material for the job.

l Also, use the same location on the insert that the double detect roller will make contact with. For example, don't set the double detect on the thickest portion of the insert if that section will not be under the double detect roller once the feeder is properly set up.

1. Loosen both mounting screws using the setup tool, and slide the double detect bracket to its highest position.



Item Description

1 Mounting Screws

2 Adjustment Knob

2. Secure the mounting screws in this position temporarily.

3. Turn the double detect knob to adjust the space between the bracket and the mount, about 1/2"(13 mm) to 5/8" (16mm).



4. Place an insert from the job under the double detect roller.

5. With the insert under the roller, loosen both double detect bracket screws and lower the assembly so the double detect roller touches the insert.

6. Next, keep the bracket square and tighten the two bracket screws.

7. Now, place two inserts under the double detect roller. The light on the left side of the feeder should illuminate. (NOTE: If the light does not illuminate, turn the double detect adjustment knob counterclockwise until it comes on.)

8. Remove the two inserts, and the light should turn off.

9. Place a single insert under the double detect roller and the light should stay off.

Note:If the light does not go off, try repeating steps 7 and 8.

10. To check the adjustment, remove the single insert and put two inserts back under the roller, the light should turn on.



Adjusting the Bulk Loader Hopper Deck

Adjust the pack control ramp before adjusting the hopper deck.

1. Open both buffer side covers.

2. While holding the hopper deck in place, loosen both lockdown knobs under the deck. This lets you slide the deck.

Bulk Loader Hopper Deck Lockdown Knobs (one of two visible here)



3. Loosen the five blue locking knobs for both side guides and slide the guides to the center (towards the flat belts).

Locking Knobs



4. With the pack control ramp set for the job material you are running, adjust the deck to the right, so the red hopper belts are 1/8" (3 mm) away from the trail edge of the booklet.

Red Hopper Belts 1/8" (3 mm) Away from Ramp

5. Tighten the lockdown knobs under the bulk loader hopper deck.

6. Adjust the bulk loader hopper side guides. (Refer to the Adjusting Bulk Loader Hopper Side Guides topic for details.)



Adjusting the Bulk Loader Hopper Side Guides

There are two side guides on the bulk loading hopper, one on the operator side and one on the non-operator side.

The guide on the operator side is a short guide, held in place by two blue locking knobs. The guide on the non- operator side is a long guide, held in place by three blue locking knobs.

Both side guides need to be straight and inside the booklet feeder side guides, or a catch point will occur.

1. Be sure the bulk loader hopper deck is properly adjusted. (Refer to the Adjusting the Bulk Loader Hopper Deck for details.)

2. With the bulk loader hopper deck and booklet feeder side guides properly adjusted, slide the operator and non-operator side guides so they are tight to the inside of the booklet feeder side guides.

Bulk Loader Hopper Side Guides (inside booklet feeder side guides)

3. Continue to align the side guides, keeping them parallel to the two red drive belts. (There is a scale to help with this adjustment.)



4. Tighten the five blue locking knobs on the side guides.

Note:The booklet must move freely between both side guides on the bulk loader hopper. If the space is too tight, they will into feed into the booklet feeder.



Insert Feeder Software Adjustments

There are several software adjustments operators will need to perform on the friction feeders to be prepared for successful job runs. Some of these activities are available to operators and some activities are for key operator levels and higher.

The activities for each access level are grouped here. Be sure you are logged into DC at the correct level to access these features.

Adjustment Friction Feeder Rotary Feeder Access Level

Enable and Disable Feeders • • Operator

Document Information • • Key Operator

Feed Modes • • Key Operator

Backup Feed Mode • • Key Operator

Xport Setup • • Key Operator

Separator Control • Operator

Recalibrate Double Detect • • Operator



Enabling and Disabling Feeders

Individual feeders can be enabled or disabled (turned on and off) for various reasons. For example, if a particular feeder is not being used for a job you can disable it so it will not operate while processing that particular mail run.

To enable or disable feeders during a job:

1. Visually check the status of the feeder on the main DC screen.

Item Description

1 Enabled (feeder object is gray)

2 Disabled (feeder object is white)

Feeder Objects - Check Feeder Status

2. Click a Feeder object and select Disable or Enable from the drop-down menu.

3. Repeat this for all feeders that require the change.



Document Information

Material details like width, length, and weight for the inserts in each specific feeder is generally saved in the mode, but if you have to, you can enter the width of inserts for specific feeders.

Setting Document Width, Length, Weight (Friction, Rotary, Booklet Feeders)

Width and length are mandatory fields and must be done for every feeder if it is not included in the mode.

1. Measure the width and length of the insert for each feeder.

2. Log in as Key Operator access level or higher.

3. Click the desired Feeder object on the main DC screen and select Setup from the drop-down.

Feeder Objects



4. Enter the material width and length in the Width and Length fields.

5. Enter the weight in the Weight field if you have that information.

6. Click OK.



Set the "Booklet / Fold Style Insert" Setting (Rotary Feeder only)


2. Click the desired Feeder object from the main DC main and select Setup from the drop-down.

Feeder Objects



3. Select the Booklet/Folded style inserts checkbox if you are running that type of material. If not, verifythis box is not selected.

4. Click OK.



Setting Feeder Feed Modes

About Feeder Feed Modes

Feeders can be set for a variety of feed modes, they are usually predefined in the mode. The Feeder objects on the main DC screen change color based on the selected feed mode.

l Always: the feeder provides an insert for every mailpiece; when this mode is selected the Feeder object is white.

l Data Select: the feeder provides an insert based on a feed select code as dictated by scan data or MRDF information; when this mode is selected the Feeder object is gray.

l Priority Select: the feeder provides an insert when a feed select code is present and the weight of the insert does not cause the total weight of the mailpiece to exceed its current weight break; when this mode is selected the Feeder object is blue.

l Priority Fill: the feeder provides an insert when all other feed modes (always, data select, and priority select) have been processed and the weight of the insert does not exceed postal regulations; when this mode is selected the Feeder object has purple stripes.


1 Backup 3 Priority Select

2 Priority Fill 4 Data Select



Setting Feed Modes



Feeder Objects

3. In the Feed Mode field select the desired feed mode from the drop-down list.

Note:Backup feed mode requires additional setup. If you select this mode, refer to the Backup Feeder (Feed Mode) topic for more instructions.

4. Click OK.



Setting Backup Feeders (Backup Feed Mode)

You can select a feeder to back up a primary feeder when it runs low on material during a job run. When this mode is selected the Feeder object has green stripes.

About Backup Feeder Locations

The backup feeder must be downstream (the direction the paper travels) of the primary feeder. In this example the following feeders are assigned:

l Feeder #3 is the primary feeder and set in backup mode

l Feeder #2 (downstream) is set to back up Feeder #3

l When Feeder #3 runs low on material, Feeder #2 takes over until Feeder #3 is reloaded and in a ready state

Item Description

1 Feeder #3

2 Backup Feeder #2

3 Backup Feeder (green stripes)

Backup Feeder Locations



Setting a Backup Feeder

To set a feeder as a backup feeder:



Feeder Objects



3. In the Feeder Setup dialog, set your backup feeder:

a. In the Feed mode field select Backup from the drop-down list.

b. In the Backup for field, select the feeder to use as a backup from the drop-down list.

4. Click OK.



Transport Envelope Setup (Xport Setup)

Note:This setup is used only when the envelope flap measure 3/4-inch (19 mm) or less.

When the friction feeder is armed (material is ready to feed) the envelope is not driven out far enough. It prevents the pushers from hitting or opening the envelope flap.

To adjust the transport envelope setup:



3. Click the Xport Setup tab.

4. Select the Flap first, short-flap return envelope checkbox.

5. Click OK.



Setting Separator Options for Friction Feeders

For different reasons, not all material will make it through the entire system properly (for example, warped or bent paper). You can set specific options in the friction feeders to help run compromised material. These settings help with known types of challenging material at the beginning of a job, or if you see continued issue with feeding inserts during a job.

1. Visually inspect the insert material you are loading into the friction feeders. If you find twisted or compromised material, you want to try a feeder setting to help feed the material



Feeder Objects



4. When the dialog opens, click the Sep Setup tab.

5. Select the appropriate separator setup options for the friction feeders:

l Enable Backup: this option casues the separator roller to rotate slightly with each piece to avoid flat spots. (This feature must be turned off if a stone separator is being used.)

l Synchronous Mode: this option helps with difficult inserts that tend to shingle or skew; with this option they are separated without stopping, before the lead edge reaches the nips.

l Twisted Return Envelopes: this setting can help if you are having trouble feeding badly twisted envelopes; when set, inserts are fed further out from under the weight of the stack when separating.

l Acceleration: this feature controls how fast the separator belts spin at startup.

o The lower the number, the slower the belts turn

o The higher the number, the faster the belts turn

6. After you make your selections, click OK.



Recalibrating the Double Detect Feature

The double detect feature detects when more than one piece of material is fed from the insert feeder. The system calibrates this with the first piece fed. If the first piece is a double, then all single pieces will be reported as too thin and recalibration is necessary.

If the double detect feature needs to be calibrated:

1. Log in as Operator.

2. Click the desired Feeder object on the main DC screen.

Feeder Objects

3. Select Recalibrate from the drop-down menu.



Adjusting Buffer Upper O-ring Belt Height

Two Ways to Measure Buffer O-ring Height

l A 2 mm gap between the upper and lower O-ring belts at the entrance of the buffer

OR

l The upper O-rings are even with the bottom of the upper P2L idler rollers

O-ring Even with Bottom of Upper P2L Idler Roller



Adjusting the O-ring Belt Height

If the height is incorrect, you can adjust the height of the buffer upper O-ring belts. In most cases, once they are set, these belts do not need to be adjusted.

1. Locate the adjustment screw.

2. Using the 3/16" operator setup tool, turn the screw as needed to raise or lower to achieve correct height adjustment.




6 - Job Changeover Guidelines

In this sectionJob Changeover Guidelines 182Auto Adjustments - Engine and Chassis 185Manually Adjusting Engine and Chassis Auto Settings 187

Job Changeover Guidelines

There may be areas of the system that you need to adjust when you are preparing to changeover to another job with different material. Changeover adjustments may be required if the new job you are about to run has material that is a different orientation (portrait or landscape), size or material thickness than the previous job.

Use this table as a guideline to help identify what, if any, adjustments you need to make for a job changeover. Some of these adjustments the system performs automatically, and some an operator performs manually. Refer to the "Operator Adjustments" chapter in this guide for detailed procedures.

* - auto adjustx = manual adjustment

Mailer Envelope - changes size or style

Insert - changes size or thickness

Control Document - changes length, width, thickness

Envelope Feeder

Separator Gap x

Fence Rollers x

Engine Setup GUI Screen x

Engine

Pocket Width *

Horn Position *

Horns Style / Thickness x x x

Suction Cup Location x

Tongue Position x

Tongue Height x x

Observation Guides

*

Backwall *







Chassis

Side Guide * * *

Control Straps x x

Buffer Chassis Side Guides *

Center Deck Nip Rollers *

Friction Feeder

Side Guides x

Pack Control Ramp x

Separator x

Feeder Setup GUI Screen x

Rotary Feeder

Suction Cups x

Deck x

Deck Angle / Side Guides x

Separator Pins x

Feeder Setup GUI Screen x

Buffer

Deck Height *







O-ring Belt Height x

Vertical Stacker

Side Guide Adjustment x

Flat Stacker x


Entrance Setup x

DC

Load Mode x x x



Auto Adjustments - Engine and Chassis

The most common adjustments in the Epic v3.1 inserter are adjusted automatically, based on mode settings and entries operators make in DC. These default adjustments settings will be sufficient for most standard material, but occasionally minor adjustments are needed.

Note:Areas of the Epic v3.1 system that auto adjust are identified in the Job Changeover Guidelines section.

Auto Adjust Engine Settings

Engine Settings

The entrance nip rollers and the pocket stops adjust to the length of the envelope in the mode. Both the pocket width offset and pocket center offset settings can be manually adjusted in the Engine Setup screen.

Horns Settings

The horns adjust to be centered on the envelope. The width of the horns uses the widest measurement of either the envelope or material on the chassis. The horn width offset setting can be manually adjusted in the Engine Setup screen.

Insert Blower Offset

The amount of vacuum on the vacuum deck can be increased or decreased. It is not normally necessary to change this setting, but it can be manually adjusted in the Engine Setup screen if needed.

Backwall Settings

The backwall adjusts based on the depth of the envelope, to set the crease line of the envelope consistent with the sealer brush (which stays in a fixed position). The backwall offset position setting can be manually adjusted in the Engine Setup screen.



Auto Adjust Engine Settings

Chassis Side Guide Settings

The chassis (engine observation, chassis and buffer exit) side guides are adjusted to the width of the largest document from either the input or the insert feeder for the collation. The side guides can be manually adjusted for guide width and center offset in the Chassis Side Guide Setup screen.



Manually Adjusting Engine and Chassis Auto Settings

Some auto adjust settings can be manually adjusted if necessary. You can make these adjustments using the Engine Setup and Chassis Setup screens, which can both be accessed by clicking on their associated objects on the main DC screen.

Item Description

1 Engine Object

2 Chassis Object

Engine and Chassis Object - Main DC Screen



Manually Adjust Engine Settings

1. Click the Engine object on the main DC main screen and select Adjust Engine Setup from the drop-down menu.

When the Engine Adjustment window opens, you can make the following adjustments:

l Horns Width Offset - to move horns closer together select Close to move the slider towards -.9 or drag the slider to the left; to move horns farther apart select Open to move the slider towards +.9 or drag the slider to the right. (You can make this change for all adjustments using the sliders.)

l Pocket Width Offset - to narrow the pocket select Close to move the slider towards - .9; to widen the pocket select Open to move the slider towards +.9.

l Pocket Center Offset- to move the pocket to the left select Left to move the slider towards -1.4; to move the pocket to the right select Right to move the slider towards + 1.4.

l Insert Blower Offset - to increase the amount of vacuum select the Increase button to move the slider towards 20%; to decrease the amount of vacuum select Decrease to move the slider towards -20%

l Backwall - to move the envelope flap closer to the sealer brush select Move In to move the slider towards -1.0; to move it farther away select Move Out to move the slider towards +1.0



Note:

l Adjustments should only be made in small increments (0.06 -inch to 0.12-inch). If the adjustments made in this screen differ from the settings in the mode, the changed field turns yellow to indicate a change has been made. Changes made here are temporary unless saved to mode.

l Clicking Zero returns the adjustable axis to its default location, based on mode parameters.



Manually Adjust Chassis Settings

1. Click the Chassis object on the main DC main screen and select Side Guide Setup from the drop-down list.



When the Chassis Adjustment window opens you can make these adjustments:

Chasssis Guide Width Offet

To move the guides closer together, click Close to move the slider towards the -1.0". To move tthe guides further apart, click Open to move the slider towards the 1.0".

Engine Guides Width Offset

To move the guides closer to each other (narrower), click Close and move the slider towards the left -1.0". To move the guides farther away from each other, move the slider to the right 1.0".

All Guides Center Offset

To move the center of the guides (away from operator side) to the left, click Left to move the slider towards the -.9". To move the center of the guides to the right (towards the operator) click Right to move the slider to the .9". Click Open to move the slider towards 1.0".

Note:Clicking Zero returns the adjustable axis to its default location based off the material parameters in the mode.




7 - Running the System

In this sectionLoading the Envelope Feeder 194Reloading the Envelope Feeder 196Loading the Insert Feeders 199Loading the Booklet Feeder 200Reloading Insert Feeders (with the system is running) 201Removing Finished Mail from the On Edge Stacker 202Removing Mail from the Flat Conveyor 205Adding Sealer Fluid 206

Loading the Envelope Feeder

Outside carrier envelopes need to be loaded on the envelope feeder correctly for the feeder to work right.

To load the envelope feeder:

1. Raise the envelope feeder paddle and slide it down toward the right side of the feeder (facing it).

2. Place envelopes in the feeder, flap side down, with the flap facing out to the right.

Envelopes Positioned in the Feeder

3. Verify the tops of the envelopes are squared up and no envelopes are sticking out from the stack or stuck together.

Running the System


4. Lower the envelope feeder paddle into position at the end of the stack. Do not drop the paddle.

Lower the Envelope Feeder Paddle

Caution:Do not drop the paddle.

Running the System


Reloading the Envelope Feeder

As the envelope feeder empties, the feeder paddle keeps constant pressure on the envelope stack and moves it toward the envelope feed head. When the stack reaches approximately the last 500 envelopes, a “BIN LOW” warning displays on the DC main screen. At this point, when the operator adds more envelopes to the feeder, the system will continue to run and the warning message turns off.

Follow these steps to reload envelopes while the inserter is running.

Caution: Pinch PointThe envelopes rest on rotating bars while the machine is running. Do not allow your fingers to come into contact with these bars while the machine is running.

Running the System


1. Place additional envelopes on the right side of the feeder paddle, flap down facing to the right.

Item Description

1 Paddle

2 Envelopes to right of paddle

Add Envelopes

2. Lift up the feeder paddle and slide it over to the end of the envelope stack.

Slide Feeder Paddle Over

Running the System


3. Lower the feeder paddle into position at the end of the stack. Do not drop the paddle.

Lower the Paddle

Running the System


Loading the Insert Feeders

1. Place one piece of material on the feeder belts.

Initial Loading

2. Shingle about a 1-inch (25 mm) stack of material and place it on top of the single piece.

3. Continue this until the stack is just about even with the top of the pack control ramp and then stack to desired height.

Stack the Feeder - do not shingle beyond the point noted in this image

Running the System


Loading the Booklet Feeder

1. Place one booklet flat on the feeder belts.

Booklet Flat on Feeder Belts

2. Shingle a few more booklets and place them on top of the first booklet.

3. Continue to stack the booklets until the feeder is about halfway full.

Running the System


Reloading Insert Feeders (with the system is running)

1. Fill the feeder without shingling the material if the feeder is still filled above the pack control ramp.

2. If the feeder is low or empty, refer to the Loading Insert Feeders topic.

Low Material Level

Running the System


Removing Finished Mail from the On Edge Stacker

The On Edge Stacker is equipped with a control paddle to aid in the stacking of finished mailpieces. The paddle is able to move the full length of the stacker conveyer belt and it also pivots up vertically.

When finished mailpieces reach the stacker belt the paddle will slowly move down the conveyor belt, allowing more mail to be stacked on the belt. As the belt becomes full of finished mail, the mail is ready to be placed into a mail tray.

Stacker Paddle

Running the System


To remove the finished mail from the On Edge Stacker:

1. Place your left hand on the end of the mail stack to support it as you lift the paddle.

Item Description

1 Paddle

2 Raise and slide the paddle in this direction

Move Paddle

2. Lift the paddle with your right hand.

3. Slide the paddle to the left for a distance equal to the amount of mail that will fit into a mail tray.

Running the System


4. Lower the paddle back to the belt between the two mailpieces and then slide that stack of mail to the right of the paddle into the mail tray.

Item Description

1 Paddle

2 Mail to be moved to mail tray

Remove Mail

On Edge Stacker Paddle and Switch

The On Edge Stacker signals the operator when the stacker belt is about three quarters full with a message on the bottom of the main DC screen in the alarm message box.. When the paddle reaches the switch located on the stacker, the machine will come to a controlled stop and indicate the stacker is full by displaying a message on the screen.

l The machine will not start while the paddle is pressing on the switch.

l This feature works only when the paddle is in the down position and the inserter is running.

Running the System


Removing Mail from the Flat Conveyor

Flat material will be stacked on the flat conveyor usually located under the last vertical stacker. (The flat conveyor can be positioned under any vertical stacker, generally it is located under the last one.)

During the job the finished flat mailpieces are stacked under the vertical stacker onto the conveyor. As more mail is processed the conveyor transfers the finished material out from the under the vertical stacker.

To manually remove the mailpieces from the conveyor:

1. Press the button located on the end of the conveyor to turn the belt on and move the flat mailpieces out from under the vertical stacker and down the belt.

2. Neatly stack the mail and remove it from the belt.

Flat Conveyor - Button

Running the System


Adding Sealer Fluid

The sealer uses water to seal envelopes. the sealer tank holds five gallons of water. DC displays a Supply Low [Water Tank] @ Sealer message when the sealer tanks needs to be refilled.

If the sealer tank is not refilled, eventually the sealer brush detects no water flow, and the system stops.

1. Fill a container (that has a funnel or spout) with fluid.

2. Open the sealer reservoir cover.

3. Carefully pour water into the reservoir; do not overfill the container.

4. Close the sealer reservoir cover.

Item Description

1 Sealer Reservoir (cover open)

2 Overflow Reservoir (partially pulled out)

Sealer and Overflow Reservoirs

Running the System


Emptying the Overflow Reservoir

l The overflow tray should be inspected every day and drained when it is half full.

l Slide the overflow reservoir from the bottom of the system and empty if excess water is present. (The water from this tank may evaporate faster than it accumulates and never require emptying.)

Overflow Reservoir

Note:Do not reuse water emptied from the overflow reservoir to fill the sealer reservoir; use only clean water. If you mix in used water, you may cause damage to the system.

Running the System



8 - Error Recovery

In this sectionError Recovery 210Alarms in Direct Connect 211Removing Material Jams in the Buffer 215Removing Material Jams Under the Nip Rollers 217Removing Material Jams in the Dump Station Exit 218Removing Material Jams on Chassis Deck 219Removing Material Jams in the Friction Feeder 221Removing Material Jams in the Rotary Feeder 224Removing Material Jams in the Booklet Feeder 227Removing Material Jams in the Engine 231Removing Material Jams in the Envelope Feeder 237Removing Material Jams in the Sealer or Vertical Stacker #1 240Removing Material Jams in the Turnover 241Removing Material Jams in the Vertical Stackers 242Removing Material Jams in the On Edge Stacker 243Removing Material Jams in the Flat Conveyor 244

Error Recovery

When an error or material jam occurs that stops the system while the job is processing, there are indicators on the DC main screen (in the form of alarm messages) telling you what the issue is. The indicator lights mounted on the system can also flash, showing you where the issue is.

In this section, learn how to view and clear alarm messages (errors) and how to access areas of the system to remove material jams.

Alarm Messages in DC

If you get an alarm message (error) on the bottom of the main DC screen, refer to the Alarms in Direct Connect topic for more information on how to view, resolve and clear them.

Material Jams

Material jams can be caused by things liked blocked photocells, paper dust, worn belts, poor material condition, etc. When a material jam occurs, in addition to a message or flashing object on the DC screen, the indicator lights on the inserter will flash to show the area where the material jam has occurred.

Learn how to access and remove material jams from the various areas of the system in this section.

Note:Take care when removing jams in any area of the system. Belts and straps can be moved or fall off during this process. Be sure to check all parts are in the right spot after clearing the jams to prevent further jamming issues.

Error Recovery


Alarms in Direct Connect

There are several alarms (error messages) that may display on the main DC screen. Things like double feeds, out of ink, interlock open, scanner errors can cause alarms. Also, material jams, can show up as alarms. An alarm causes the machine to stop running.

In this section, learn how to:

l View alarm details

l Resolve and clear alarms

l View alarm history

Error Recovery


View Alarm Details

If an alarm displays on the bottom of the DC main screen, follow these steps to get more information on the cause and resolution.

1. When an alarm displays on the bottom of the DC main screen, double-click it or click View. The Alarm History window opens.

This window has information about where the error occurred (Device), error details (Information), and a suggested course of action (Suggestion).

Item Description

1 Device (where the error occurred)

2 Information (details about the error)

3 Suggestion (suggested course of action)

Error Recovery


Resolve and Clear Alarms

1. After you review the details, close the Alarm History with details dialog.

2. Take the appropriate action to resolve the error.

3. Click Clear on the Alarm message box at the bottom of the screen to clear the alarm.

4. Click Start on the main DC main screen to start running again.

5. If the error still occurs, repeat the error recovery process.

6. If after repeating the process the error remains, contact Service.

Error Recovery


View Alarm History

It is possible to view the history of alarms that have occurred during the current job run. The alarm history can be helpful when troubleshooting persistent problems.

To view the alarm history:

1. Click the Alarm icon and select History from the drop-down menu. The Alarm History dialog opens.

Alarm Icon

Alarm History - (Alarms with a "stop sign" next to them indicate events that stopped the inserter)

2. To view details about a specific alarm, double-click it or highlight it, and click View.

3. Click Close and Close again, to exit out of alarm history and back to the maIn DC screen.

Error Recovery


Removing Material Jams in the Buffer

There are three covers that provide access to different areas of the buffer to help when clearing jams. Lift these covers to access and remove the jammed material.

Note:This image shows an inserter without a booklet feeder. If a booklet feeder was installed here, only the front side covers would pivot up to help you gain access to the buffer and dump station.

Item Description

1 Folder Cover / Buffer Entrance

2 Left Buffer Cover (closed)

3 Right Buffer Cover (closed)

Non-Booklet Feeder Option

Error Recovery


Item Description

1 Folder Cover / Buffer Entrance

2 Left Buffer Cover

3 Right Buffer Cover

4 Bulk Load Hopper

Booklet Feeder Option

Error Recovery


Removing Material Jams Under the Nip Rollers

1. Open either the left or right buffer side cover depending on where the jam is located.

2. Locate the nip where the jam is located.

3. Lift up on the nip levers (blue handle) above the nip to remove material located under the nip.

Nip Levers

4. Once the material is removed lower nip arm.

5. Close the cover.

Note:When you remove a jam be sure the orange O-ring belting is still intact on both the left and right pulleys.

Error Recovery


Removing Material Jams in the Dump Station Exit

The dump station is located under the downstream buffer cover.

1. Open the right most buffer side cover.

2. Locate the black knob on the dump station latch.

3. Pull the dump station latch toward you approximately 1" (25 mm).

4. Lift up on the dump station.

5. To close the dump station push down on the dump station cross brace to lower the unit.

6. Press the dump station down to the lock position making sure the latch completely latches.

Dump Station Closed - Black Knob Dump Station Open

Error Recovery


Removing Material Jams on Chassis Deck

1. Lower the front feeder cover where the indicator light is flashing.

2. Raise the feeder by pushing up and away on the side guide. The feeder pivots up and away, allowing access to the bottom of feeder and chassis deck area.

Raise the Feeder; Material Access

Caution:Do not press on the LED lens cover when lifting the feeder.

3. Remove the jammed material.

Error Recovery


4. Lower the feeder down being cautious not to allow feeder to drop onto deck.

5. Close any opened front feeder covers.

Error Recovery


Removing Material Jams in the Friction Feeder

There are three areas in the friction feeder where material jams may occur:

l Feeder deck

l Separator bridge

l Transport

Feeder Deck


2. Raise the feeder by pushing up and away on the side guide. The feeder pivots, allowing access to the bottom of feeder and chassis deck area. DO NOT press on LED lens cover when lifitng feeder.

Feeder Lifted; Material Access Area


Error Recovery




Separator Bridge

1. Pull the two locking knobs towards you.

2. Rotate the separator bridge to the left while continuing to pull on the two locking knobs away from you and lift the friction feeder separator bridge.

Rotate Knob - Lift Separator Bridge

3. Release the locking knobs.

4. Remove the jam.

5. Close the separator bridge; make sure both locking knobs latch closed.

Error Recovery


Transport (Clamshell)

1. Open the appropriate feeder cover.

2. Pull the transport knob out.

3. Pivot the transport to the left while holding the knob out.

Transport Knob

4. Remove the jam.

5. Close the transport; make sure it locks in the closed position. ( Be sure the knob is pushed all the way in towards the non-operator side of the machine.)

6. Close the feeder cover.

Error Recovery


Removing Material Jams in the Rotary Feeder

There are two areas in the rotary feeders where material jams may occur:

l Feeder deck

l Feeder drums

Error Recovery


Rotary Feeder Deck


2. Raise the feeder by pushing up and away on the side guide.

Lift Feeder - Feeder Pivots Giving Access to Jammed Material

Caution:Do not press on the LED cover when lifitng the feeder.




Error Recovery


Rotary Feeder Drums

1. With all doors shut, press the Cycle button on the feeder so the drum rotates and feeds damaged insert to the deck.

Cycle Button

2. Open the feeder deck door.

3. Clear the piece from the deck.

Error Recovery


Removing Material Jams in the Booklet Feeder

You may encounter material jams in the mid or exit areas of the booklet feeder.

Mid Area

1. Open the Booklet Feeders top and chassis access doors.

Booklet Feeder Access Doors

Error Recovery


2. Lift the center blue roller up to remove pressure on the booklet - put one finger behind the roller and lift it.

Center Blue Roller - Booklet Feeder

3. With the roller up, slide the booklet out towards you and release the blue roller.

4. Close the covers.

Error Recovery


Exit Area

1. Open the Booklet Feeders chassis access door.

Chassis Access Door - Booklet Feeder

2. Locate the exit roller pivot latch and press it down to raise the blue rollers; this removes pressure off the booklet.

Exit Roller Pivot Latch

3. With the rollers up, slide out the booklet out towards you.

Error Recovery


4. Release the exit roller pivot latch.

5. Close the cover.

Error Recovery


Removing Material Jams in the Engine

The several areas in the engine where material jams may occur:

l Upper engine

l Engine exit

l Arming area

l Lower engine

Error Recovery


Upper Engine


2. Grasp the upper engine handle and lift up for access to the insertion area.

Lift Upper Engine Handle

Upper Engine Raised

3. Remove the jam.

4. Close the engine handle.

5. Close the cover.

Error Recovery


Engine Exit

1. Open the engine cover .

2. Remove the jam by pulling the edge of the envelope and sliding it out, toward the engine exit. This releases the rollers.

Pull the Envelope Toward the Engine Exit

3. Close the cover.

Error Recovery


Arming Area

1. Open the engine cover and lift the upper engine.

Lift Upper Engine

2. Lift the arming area.

Lift Arming Area

3. Remove the jam.

4. Lower the upper engine; it will press down and close the arming area.

Error Recovery


Lower Engine

1. Press and hold both buttons on the engine deck and the lower engine opens.

Engine Deck Buttons

2. Remove the jam.

3. Press and hold both buttons until the lower engine is completely closed. (If you release the buttons before the engine is fully closed, the engine will drop back down.)

Error Recovery


Note:Depending on the material size you are running, there can be up to two envelopes in the lower engine that need to be removed whenever the lower pocket is opened. (Arrows in this image indicate location.)

Pocket Envelope and Flapper Envelope

Error Recovery


Removing Material Jams in the Envelope Feeder

There are two areas in the envelope feeder where material jams may occur:

l Envelope transport

l Envelope separator

Envelope Transport

1. Pull down on the envelope feeder transport handle and to push it open.

Envelope Feeder Handle

Error Recovery


Envelope Transport Open

2. Remove the jam.

3. Grasp and press the feeder transport handle upwards to close.

Caution! Pinch PointThe feeder handle snaps shut, keep hands away from the inside when closing.

Error Recovery


Envelope Separator

1. Pull the lever towards you to release the spring tension on the separator roller. (The separator is spring loaded, so hold the lever with one hand and reach in with the other hand.)

Separator Lever

2. Remove the jam.

3. Release the lever to engage the separator.

Error Recovery


Removing Material Jams in the Sealer or Vertical Stacker #1

Note:The monitor stand may need to be pivoted out of the way in order to open the sealer cover.

1. Pull up on the interlocked handles to lift the cover.

Item Description

1 Sealer Cover Handle

2 Vertical Stacker #1 Cover Handle

Cover Handles

2. Remove the jam.

3. Realign any straps or belts if needed.

4. Close the cover.

Error Recovery


Removing Material Jams in the Turnover

1. Lift the turnover cover.

Cover Opened

2. Remove the jam.

3. Close the cover.

Error Recovery


Removing Material Jams in the Vertical Stackers

Caution!The vertical stackers will run while the covers are open. Use caution when removing jams in this area.

1. Lift the vertical stacker covers.

2. Hold the cover up while accessing the area.

Vertical Stacker Cover

3. Remove the jam.

4. Lower the cover.

Error Recovery


Removing Material Jams in the On Edge Stacker

1. Pull open the latch on the On Edge Stacker door.

On Edge Stacker Latch

2. Remove the jam.

3. Close the door.

Note:Be careful not to accidentally pull the belts off the pulleys.

Error Recovery


Removing Material Jams in the Flat Conveyor

1. Press and hold the button at the end of the flat conveyor to start the belt and move the material out from under the vertical stacker.

Flat Conveyor Button

Error Recovery


2. If there is any material jammed under the vertical stacker on the flat conveyor deck lift the foam roller by the handle to gain access to the jammed mailpieces.

Foam Roller Down

Lifting the Foam Roller

Error Recovery


Foam Roller Raised for Jam Removal

Error Recovery


9 - Troubleshooting

In this sectionTroubleshooting 248Engine Troubleshooting 249Chassis Troubleshooting 252Buffer Troubleshooting 258

Troubleshooting

Here are some simple troubleshooting activities operators can perform to try and resolve system issues and stoppages. This includes things like material jamming, double feeds, material skew, etc.

Troubleshooting


Engine Troubleshooting

Envelope Feeder

Issue Cause Resolution

Double Feeds Separator gap is too wide Adjust the separator

Nested envelopes Check material

Fence rollers not adjusted to envelope height

Adjust the fence rollers

Envelopes glued / stuck together Check / fan / jog material

Jams Improper envelope length set in DC Enter proper envelope length

Fence rollers not adjusted to envelope height

Adjust the fence rollers

Separator too tight Adjust the separator

Dust or debris in paper path Remove and clean

Lower Pocket


Not flapping Envelopes loaded incorrectly Reload envelopes

Flap glued closed Check material

Excessive paper curl Check material

Troubleshooting


Insertion


Not inserting Worn suction cups Replace suction cups

Improper envelope length set in DC Enter proper envelope length

Suction cup placement Adjust suction cup

Tongue location Adjust tongue

Observation guide alignment Check observation side guide setup

Bad or improper fold Folder Setup,

Chassis side guides

Observation side guides

Envelope side seam damage

Horns set too wide for envelope Decrease horn width

Engine Exit


Missing or late / skew Strap location or tension Adjust strap

Troubleshooting


Sealer


High seals Constant bad folds Adjust fold, refer to associated Folder Operator Guide

Incorrect backwall setting Engine setup

Tongue location Adjust tongue

Suction cup placement Adjust suction cup

Horn width Increase horn spacing

Observation guide alignment Check observation side guide setup

Flap not Sealed Incorrect backwall setting Engine setup

Not enough fluid applied to flap Adjust sealer fluid



Jam High seals Inspect for high seals and refer to Sealer

Belt adjustment / envelope positioning Adjust the OES entrance setup

Stacking too tight on belt Increase speed of conveyor belt

Troubleshooting


Chassis Troubleshooting

Chassis


Jams Straps Check drag on straps

Side guides Verify side guides are set to the correct width for the collation

Side Guides Not adjusting to proper size Check material dimensions; check if there any side guide offsets

In DC, click Chassis > Setup and make sure Enable Automatic Setup is not checked. Manually adjust the side guides as needed.

Troubleshooting


Friction Feeder


Shingled or Double Feeds Separator gap Tighten the separator; to a firm drag

Stack height Reduce stack height; do not load enclosures to the top

Material Fan material; reload in a different orientation

Belt contamination Clean belts and feed rollers with denatured alcohol (L-6079)

Skew Ramp Set ramp close - within 1 mm of the enclosure length; adjust the ramp toward skewing side

Side guide Set side guide close - 1 mm space on each side


Excessive delays or Out of material errors

Ramp Loosen ramp - no more tha 3 mm larger than the encloure length

Stack height Reduce stack height; do not load enclosures to the top

Peeling Material Fan material; reload in a different orientation

Stack height Check material dimensions; check if there any side guide offsets

Separator gap Loosen separator, to a light drag

Troubleshooting


Rotary Feeder

Single Sheet (#10, A4, half-fold non-glossy, half-fold glossy)


Double feeds Material orientation Curl up (if applicable)

Too much stack weight on the separation pins

Move deck toward lead edge and/or increase deck angle to remove excess weight

Back guide is set too loose Reset back guide and verify the lead edge of the material is at the font wall

Fail to feed Material orientation Curl up (if applicable)

Material is not at the pins; backstop/side guides may be too tight or deck angle

Loosen guides or reduce deck angle

Warp in material may cause sheet(s) to rest above the pins

Switch to tall cups and/or move cups away from the lead edge

Material rips out of gripper Reduce stack height or move deck away

Move each away from lead edge to next lower integer setting

Troubleshooting


Folded, Perfume, BRE


Double feeds Material orientation Folded: closed and first, curl upBRE: flap up and leadingPerfume: flap up

Backstop set to loose Reset backstop and verify the lead edge of the material is at the front wall

Move deck toward lead edge to stiffen the material

Fail to feed Material orientation Folded: closed and first, curl upBRE: flap up and leadingPerfume: flap up

Lead edge is poorly justfied Tamp lead edges even prior to loading

Material is pinched at separation pins Increase deck angle to remove excessive weight from pins

Backstop / side guides set too tight, preventing material from falling onto the pins

Reset and/or loosen side guides

Material too stiff Move deck away from the lead edge to the next greater setting

Troubleshooting


Booklet (thick, .125 max or thin)


Double feeds Material orientation Closed end first, curl up

Booklet too flimsy Turn inner pins fully in

Fail to feed Material orientation Closed end first, curl up

Lead edge is poorly justified Tamp lead edges even prior to loading

Backstop, side guides set too tight Loosen guides

Troubleshooting


Booklet Feeder


Shingled or Double Feeds Separator gap Tighten the separator so there is no drag on one booklet and so the two documents will not fit under separator

Stack height Reduce stack height; do not load enclosures as high

Material Fan material; reload in a different orientation


Skew Ramp Set ramp close to trail edge of the booklet

Side guide Set side guide close - 1 mm space on each side; make sure side guides are straight and not toed in at the bottom


Excessive delays or Out of material errors

Ramp Loosen ramp - no more than 3 mm larger than the enclosure length

Stack height Reduce stack height; do not load enclosures as high

Peeling Material Fan material; reload in a different orientation

Stack height Check material dimensions; reduce stack height

Separator gap Loosen separator - set to little or no drag

Troubleshooting


Buffer Troubleshooting

Buffer


Jams and skews Deck height Verify the deck height is properly adjusted to the folder

O-ring belts Check the height off the deck of the belts; be sure that all O-ring belts are properly aligned and on the pulleys

Fold plates Check fold quality

Troubleshooting


10 - Maintenance

In this sectionOperator Maintenance 260Replacing Suction Cups in the Engine 262Buffer Maintenance 266Rotary Feeder Maintenance 267Friction Feeder Maintenance 268Vertical Stacker Maintenance 269On Edge Stacker Maintenance 270

Operator Maintenance

There are a few routine inspection and maintenance activities operators need to perform daily to keep the system operating at peak performance. These simple procedures help make sure that your equipment is clean and free of debris.

Since a single list cannot address all applications and conditions, it is important to communicate with your Pitney Bowes Customer Service Representative to develop a maintenance program for your system.

Safety Precautions

Before performing maintenance on any equipment, follow these safety precautions:

l Remove all material and envelopes from the system before performing any maintenance activity.

l Use an industrial vacuum cleaner equipped with a non-metallic tip to remove paper dust and debris from the system.

Overall System Maintenance

Perform these system maintenance activities at every shift:

l Remove dust and debris from the entire machine, either via air or vacuum (the vacuum tip must be non-metallic)

Note:Follow eye safety protection policies in place at your site.

l Refill the sealer brush reservoir bottle

l Inspect suction cups and replace if necessary

l Clean and ink the edge markers and mail machines (if equipped)

l Clean system covers (use only the approved cleaner - 902-F Polycarbonate cleaner - for top clear Plexiglas covers)

Maintenance


Module Maintenance

Hera ere some step-by-step, daily operator maintenance activities for various Epic system modules:

l Buffer

l Friction Feeder

l Rotary Feeder

l Engine

l Vertical Stacker

l On Edge Stacker

Note:Any required maintenance activities for the input modules not included here, can be found in either the associated operator guide or on the system via the on-system support tool.

Maintenance


Replacing Suction Cups in the Engine

Part of your daily maintenance activities include inspecting the suction cups in the engine. If during inspection the suction cups are worn or cracked, you will need to replace them.

Replacing Insert Suction Cups (Upper Platform)

1. Lift the top engine cover.

2. Lift the upper engine handle to access the upper insertion area.

Lift Upper Engine Handle

3. Locate the three suction cups.

Suction Cups

Maintenance


4. Remove the suction cup by firmly grasping the bellow and pulling the cup straight down.

Grasp the Suction Cup

5. Replace the suction cup by aligning the hole in the suction cup with the suction cup adapter and then gently push the suction up onto the adapter. (You may have to hold the adapter while pushing the suction cup on.)

Replace the Suction Cup

Maintenance


Replacing Feed Assist Suction Cups (Envelope Feeder)

1. Click on the Engine object and select Feeder Cup Out from the drop-down menu.

Feeder Objects

2. Remove the envelopes away from the feed head.

3. Reach in and grasp the suction cup and pull it to your right until it pops off.

Maintenance


4. Press the new suction cup in place until it is fully seated (just below the surface of the deck).

5. In the dialog, click Feeder Cup In.

Maintenance


Buffer Maintenance

Perform these buffer maintenance activities daily.

Note:All routine maintenance must be performed with the system logged off.

Required Tools

l Denatured alcohol

l Polycarbonate cover cleaner (902-F)

l Clean cloths

l Shop air

Cleaning Covers and Clearing the Paper Path

1. Wipe down the top buffer covers with PB approved cleaner (polycarbonate cover cleaner, 902-F).

2. Open the top buffer covers.

3. Use low pressure shop air to blow dust and debris out of the paper path and remove any toner buildup on the deck.

4. Close the buffer covers.

Maintenance


Rotary Feeder Maintenance

Perform these maintenance activities daily.


Required Tools

l Shop air

Cleaning and Replacing Rotary Feeder Suction Cups

If a suction cup is torn or worn, it will need to be replaced.

1. Remove material from the hopper.

2. Remove, inspect, and replace suction cups if damaged.

3. Use low pressure shop air to blow dust and debris out of the paper path and remove any toner buildup on the deck.

4. If you need to replace the suction cup, pull it off the cup holder.

5. Remove the old suction cup from the ring.

6. Place the new suction cup on the ring.

7. Return the cup into the cup holder.

Maintenance


Friction Feeder Maintenance



Required Tools

l Polycarbonate cover cleaner (902-F)

l Shop air

Cleaning Covers and Clearing Paper Dust and Debris

1. Wipe down the covers with PB approved cleaner (polycarbonate cover cleaner).

2. Open the feeder covers.

3. Remove material from the feeder hopper.

4. Open the clam shell.

5. Pull out on the two spring latches and pivot the one attached to the bridge assembly up to open the bridge; remove any material if present.

6. Use the shop air with the blower attachment to blow dust and debris out of the bridge.

7. Close the bridge assembly.

8. Use the shop air with the blower attachment to blow dust and debris out of the clam shell.

9. Raise the feeder.

10. Use the shop air with the blower attachment to blow dust and debris from the feeder deck.

11. Lower the feeder.

12. Close the clam shell.

13. Close the feeder cover.

Maintenance


Vertical Stacker Maintenance



Required Tools

l Soapy water

l Clean cloths

l Shop air

Cleaning Stacker Cover and Clearing Paper Path

1. Lift the vertical stacker cover.

2. Inspect the deck and rollers for glue buildup and toner; wipe down with damp, clean cloth and soapy water.

3. Use shop air with the blower attachment to blow dust and debris out of the paper path.

4. Close the cover.

Maintenance


On Edge Stacker Maintenance



Required Tools

l Soapy water

l Clean rags

l Shop air

Clearing Paper Path and Cleaning Components

1. Open both On Edge Stacker doors.

2. Use the shop air with the blower attachment to blow dust and debris out of the paper path.

3. Wipe down the rollers with a clean, damp cloth (soapy water).

4. Wipe down the back plate with a clean, damp cloth (soapy water).

5. Close the doors.

Maintenance


11 - Specifications

In this sectionEpic V3 Description and Features 272Epic Material Specifications 274Epic v3.1 Engine (ZVE0) 276Envelope Specifications 281MPS/Epic Friction Feeder (Y554) 296Epic Rotary Feeder (Y558) 300Epic Universal Friction Feeder (ZVF1) 305Epic P2L Buffer with TNT (ZVB2) 309Epic Turnover (Y370) 312Epic V-Bin (Y31E, Y31F, Y31G, Y31H ) 314Epic On-Edge Stacker (Y396) 317Epic Shingling Stacker (Y32S) 320Epic Edge Markers (Y367, Y368, Y369 ) 321Environmental Operating Conditions 323Network and Power Requirements 324Air Requirements 326Expected Lifetime 327

Epic V3 Description and Features

Description

The Chassis is comprised of three or four modular stations capable of building up to 21 stations. The chassis is the bed that accommodates the enclosure feeders and input buffer. The chassis uses two pusher belts that move the material to the engine. The Chassis is also fitted with a central belt with actuated nip rollers under every enclosure feeder. These smart nip rollers will dynamically actuate to maintain an optimum material handling for all size and thickness. During chassis stops (acceleration and de-acceleration), the paper is stopped while under a nip, reducing the dependence on straps to hold the paper against chassis pushers.

Standard Features

l Modular chassis - three or four modular stations capable of building up to 21 stations

l Collation gathering mechanism

l Smart jam clearance under insert feeders for quick jam removal and increased productivity

l Simplified center drive mechanics

l Automatic side guides

l Smart nip to nip control

Specifications


Chassis Configuration Details

Epic Chassis Configuration

PCN Module Order

3-station ZV03 B-3-E

4-station ZV04 B-4-E

6-station ZV06 B-3-3-E



9-station ZV09 B-3-3-3-E



14-station ZV14 B-3-3-4-4-E

16-station ZV16 B-4-4-4-4-E

18-station ZV18 B-3-3-4-4-4-E

20-station ZV20 B-4-4-4-4-4-E

21-station ZV21 B-3-3-3-4-4-4-E

B = Buffer

E = Engine

Options

The Epic v3.1 inserter can be configured with these options:

Kit Part #

Flats / Folded Rotary Feeder Y558

Friction Feeder Y554

Specifications


Epic Material Specifications

Maximum collation thickness = 0.5" (12.7 mm) uncompressed at the insertion.

Minimum Maximum

Depth 3.5-inch (89 mm) 8.5-inch (216 mm)

Width 5.5-inch (140 mm) 12-inch (305 mm)

Paper Width 16 lb bond (60gm/sq m) 28 lb bond (100 gm/sq.m)

Paper Weight 6 lbs/linear inches n/a

Document Dimensions (no input)

Minimum Maximum

Depth 3.5-inch (89 mm) 9.5-inch (241 mm)

Width 7-inch (177mm) 12-inch (305mm)

Paper Weight 18 lb bond (70gm/sq. m) 28 lb bond (100 gm/sq.m)

Perforation Strength 6 lbs linear inches n/a

Document Dimensions (when supplied from the input)

General Paper Requirements

These material guidelines are recommended to achieve performance goals and apply to all documents processed on the system.

l Store material in a controlled environment away from moisture

l Paper moisture content should be within 4% - 6% by weight

l Material should be stored within a temperature range of 65 - 85° (+/- 2% humidity

l Material should be stored within a range of 40% - 60% relative humidity

Specifications


Paper Curl

These paper curl guidelines apply to 8.5" width paper.

Curl Direction Toward Image Away from Image

Short Direction* Under 10 mm Under 5 mm

Long Direction** Under 20 mm Under 15 mm

NOTE: Diagonal Curl is considered unacceptable.

* Short Direction Curl: short edges of the sheet curl

** Long Direction Curl: long edges of the sheet curl

Material Handling - General Guidelines

Envelope and material handling problems in automatic mail inserting equipment are often due to envelope distortion (warping, curl, deformation, etc.). This can occur as a result of poor packaging, improper handling and storage as well as temperature and humidity extremes.

These problems can originate at the time of envelope manufacture, during finished goods transit or develop as the result of poor environmental controls either at the manufacturing site or the storage facility, or both.

Pitney Bowes equipment is designed to handle a certain range of material. Envelopes that fall outside these specified ranges might run poorly or not at all.

Handle with care

l Transfer cartons from the storage area to the work area no more than several hours before using.

l Do not remove envelope boxes from their cartons until ready to load them on the worktable.

Specifications


Epic v3.1 Engine (ZVE0)

The ZVE0 Epic v3.1 Engine / Sealer / Takeaway modules consists of the three areas described here. The engine supports letter and flat envelopes.

Description

The Engine / Sealer / Takeaway modules include:

l Envelope Hopper

l Envelope Feeder and Separator

l Envelope Flapper

l Insertion Engine

l 90° transfer module (changes direction of envelope to be transported downstream to output; adjusts automatically)

l Sealer modules

l Programmable and automatic setup features

l V-Bin (one, integrated)

Standard Features

l Envelope Hopper - capacity of approximately 2,500 letter envelopes or 1,000 flat envelopes

l Vacuum valve and Servo feed head mechanism to feed and separate the envelopes

l Envelope feed assist

l Transport and Servo flapper device to detect envelope skew and open the envelope flap

l Ability to re-feed envelopes not flapped

l Insertion engine capable of processing letter envelopes and flat envelopes (flat is an option)

l Up to .5” (12.7 mm) or 120 sheets 24 lb (90 gsm) of total collation thickness

l The sealer moistens the flap of the envelope, closes the envelope flap, and transports the mailpiece to the next module

l An integrated Vertical Stacker outsorts mail pieces before final stacking in the stacker

Specifications


Epic Throughput

Epic Epic Flats

#10 - DL application up to 21K up to 21K

6 x 9 application up to 18K up to 18K

9 x 12 - C4 application* up to 14K**

10 x 13 - B4 application* up to 14K**

* requires flat key ZX29

** the 14K flat speed can be met for collations up to 1 mm or 10 sheets thick. Past that speed the maximum speed may have to be reduced to maintain seal and stack quality. The seal quality is highly material dependent. If further characterization is needed, sample material, application details, and detail on the MOS configuration will have to be provided to the team in Danbury.

Note:The "Epic Throughput" table (included here) approximates the maximum system throughput based on a mathematical model of the Epic modules. Lower throughput can be caused by failure to follow the guidelines outlined in product specifications and/or poor material quality.

Specifications


Collation Size

Minimum Maximum Maximum Epic Flats

With Input

Trifold/Half Single page 18 lb (80 gsm) .5" (12.7 mm) total collation .5" (12.7 mm) total collation120 sheets uncompressed - 24lb (90 gsm) total collation

Flats Single page 24 lb (90 gsm) .5" (12.7 mm) total collation .5" (12.7 mm) total collation120 sheets uncompressed - 24lb (90 gsm) total collation

Prime Doc Size

Depth 3.5" (89 mm) 6.25" (158 mm) 9.5" (241 mm)

Width 7.0" (178 mm) 11" (279.4 mm) 12.0" (305 mm)

Thickness 18 lb (70 gsm) 28 lb (110 gsm) 28 lb (110 gsm)

No Input

Depth 3.5" (89 mm) 6.25" (158 mm) 8.5" (216 mm)

Width 5.5" (140 mm) 11" (279.4 mm) 12.0" (305 mm)

Thickness 18 lb (70 gsm) 28 lb (110 gsm) 28 lb (110 gsm)

Collation Size

Specifications


Physical Characteristics

The physical characteristics of the Epic system:

l Length (along chassis): 88" (226 cm)

l Width (along output): 101" (257 cm)

l Height: 44" (112 cm)

l Heat Dissipation: 2000 watts (6824 BTU/hr)

l Air requirements: 6.3 SCFM @ 70 PSI

l Total Weight: 1790 lbs (812 kg)

o Engine = 1000 lbs

o Sealer / VBin = 455 lbs

o Envelope Feeder = 335 lbs

Air Consumption

Worse case air consumption for a ZVE0, 21-station chassis, 8-stage TNT buffer is 6.5 SCFM.

System Air Consumption Case #1 Case #2

#10@21K (SCFM) subset flats at 7.2K (SCFM)

Engine 6.44 2.98

21-station chassis 0.10 0.292

8-stage TNT buffer 0.001 0.159

Engine, chassis, buffer total consumption 6.45 3.43

Case #1: 21K, #10, deck nips operate 1% of time for stop conditions. Subset stops and jogger inactive.

Case #2: Flats mode, two subsets of five pages each. Chassis speed of 7.2K, jogger activates 2x per collation. Subset stops activate 1x per collation. All deck nips go up and down 1x per cycle.

Specifications


Options

The engine can be configured with these options:

Option PCN Option PCN

Single 17" V-Bin (front) Y31E Standard Turnover Y370

Dual 17" V-Bin (front) Y31F On-Edge Stacker (Epic) Y396

Single 17" V-Bin (rear) Y31G Epic Flats ZX29

Dual 17" V-Bin (rear) Y31H Engine Light Tower Y56L

17" V-Bin/Meter Combo Y31J TNT and P2L Buffer ZBV2

Print+ Messenger - Color Y360 Engine Scan Y55E

Print+ Messenger - Mono Y361

Engine Dual Edge Markers Y367

Stacker Dual Edge Markers Y368

Add'l Dual Edge Markers Y369

Specifications


Envelope Specifications

Envelopes whose characteristics fall outside of these construction guidelines must be evaluated by testing of customer samples.

Primary Envelope Requirements The Epic system processes the following types of envelopes:

l Executive envelopes (to achieve maximum productivity, truncated flap is recommended)

l Diagonal cut envelopes

l Side seam envelopes

l McIntyre side seam envelopes (if examined and approved by Pitney Bowes)

Envelope Guidelines

l All seams should be securely bonded to the bottom flap without exhibiting any curl or ripple between the flaps.

l Envelope curl or twist should not exceed .25" (6.4 mm) when the envelope is placed on a flat surface.

l The envelope throat should be a maximum of .25" (6.4 mm) below the crease line at .75" (19 mm) from the side edges.

Envelope Measurements

Minimum Maximum Maximum Epic Flats

Width* 7" (178 mm) 11.50" (292 mm) 13.9" (353 mm)

Length** 3.88" (98 mm) 6.38" (162 mm) 10" (259 mm)

Weight 20 lb bond (75 gsm) 28 lb bond (105 gsm) 28 lb bond (105 gsm)

End Clearance See End Clearance 1.25" (32 mm) 1.25" (32 mm)

Bottom of Flap to crease line 1.25" (32 mm) 1.75" (44 mm) standard2.50" (64 mm) custom

1.75" (44 mm) standard2.50" (64 mm) custom

* Width is defined as the dimension parallel to the address direction* * Length is defined as the dimension perpendicular to the address direction

Specifications


Horns

Three sets of horns are provided.

Maximum Collation Thickness

Minimum End Clearance, Total

Minimum Envelope Width (mm)

Left Horn Right Horn

mm inches mm inches mm inches

Narrow Envelopes

ZY56464 ZY56465 3 0.12 10 0.37 177.6 6.99

Standard Envelopes

ZY56452 ZY56451 9 0.35 15 0.58 194.8 7.67

Thick Envelopes

ZV51233 ZV51233 12.7 0.50 21 0.83 221.2 8.71

ZVE0 Engine Horn Matrix

End Clearance

End clearance is the difference between the dimension of the largest insert and the length of the envelope when measured with all inserts in the envelope.

A .75" (19.1 mm) end clearance is recommended to achieve maximum throughput for all categories.

Experience has shown that end clearance requirements increase with the height of the collation and / or with the number of pages comprising the input document.

Specifications


Diagonal Seam Envelopes - Letter Mode

Specifications


Diagonal Seam Envelopes - Flats Mode

Specifications


NOTES - Diagonal Seam Envelope Notes

l Envelope dimensions should not vary more than + .062" (1.6 mm).

l All side flaps should be securely bonded to the bottom flap without exhibiting any curl or ripple between the bottom flap and side seams.

l Maximum depth flap on minimum length envelope is 2.25" (57 mm).

l All window patches should be flat, ripple free and bonded within .062" (1.6 mm) of the top edge of the patch material and top edge of the window cut out(s). If the window patch area is 1/3 or more of the total area of the envelopes front panel, the envelope must be tested.

l In cases where any part of the side of the patch material is within 1.0" (25 mm) from any envelope side edge, the following applies:

o If the top of the patch material falls within .375" (9.6 mm) of the crease score line, the patch material should be raised to within .062" (1.6 mm) of the crease line.

o In addition, the throat should be a maximum of .25" (6.4 mm) below the crease line at .75" (19.05 mm) from the side edges.

l Envelope curl or twist should not exceed .25" (6.4 mm) when envelope is placed on a flat surface.

l Paper stock may range from 20 lb. (75 gsm) minimum to 28 lb. (105 gsm) maximum, but 24 lb. (90 gsm) is suggested.

l Envelopes whose characteristics fall outside of these construction guidelines must be evaluated by Pitney Bowes.

Specifications


Executive Envelopes - Letter Mode

Specifications


Executive Envelopes - Flat Mode

Specifications


NOTES - Executive (Monarch Style) Envelopes

l Envelope dimensions should not vary more than + .062" (1.6 mm).

l Side flaps should be securely bonded to bottom flap without any curl or ripple between the flaps.

l Open window envelopes cannot have any part of the window above the "V" in the back panel of the envelope. In open window envelopes (no patch), the window should be located .75" (19 mm) minimum from either side, top and bottom of the envelope.

l All window patches should be flat, ripple free and bonded within .062" (1.6 mm) of the top edge of the patch material and top edge of the window cut out(s). If the window patch area is one third or more of the total area of the envelope's front panel, then the envelope must be tested.

l In those cases where any part of the side of the patch material is within 1.0" (25 mm) from any envelope side edge, the following applies:

o If the top of the patch material falls within .375 (9.6 mm) of the crease score line, the patch material should be raised to within .062" (1.6 mm) or closer to the crease line.

o The throat should be a maximum of .25" (6.4 mm) below the crease line at .75" (19 mm) from the side edges.


l Paper stock may range from 20 lb (75 gsm) minimum to 28 lb (105 gsm) maximum, but 24 lb (90 gsm) is suggested.


Specifications


l For speeds higher than 18.5K or #10 or DL envelopes, a truncated flaps is required, (see specifications indicated here).

Specifications


Side Seam Envelopes - Letter Mode

Specifications


Side Seam Envelopes - Flats Mode

Specifications


NOTES - Side Seam Envelopes

l Envelope dimensions should not vary more than .0625" (1.6 mm).

l Side seams should be securely bonded to the back flap without any curl or ripple between back flap and side seams.

l Side seams should have the adhesive line within .0625" (1.6 mm) of the top edge of the back and within .25" (6.4 mm) of the inner edge of the side seam.

l All window patches should be flat, ripple free and bonded within .0625" (1.6 mm) of the top edge of the patch material and top edge of the window cut out(s). If the window patch area is one third or more of the total area of the envelope's front panel, then the envelope must be tested.

l In those cases where any part of the side of the patch material is within 1.0" (25 mm) from any envelope side edge, the following apply:

o If the top of the patch material falls within .375" (9.6 mm) of the crease score line, the patch material should be raised to within .0625" (1.6 mm) or closer to the crease line.

o The throat should be at least .25" (6.4 mm) below the crease line at .75" (19 mm) from the side edges. This is required to prevent the throat openers from tearing the patch.


l In open window envelopes (no patch), the window should be located .75" (19 mm) minimum from either side, top and bottom of the envelope.

l Paper stock may range from 20 lb (75 gsm) minimum to 28 lb (105 gsm) maximum, but 24 lb (90 gsm) is suggested.

l Top edge of the side seam should be even with or up to .0625" (1.6 mm) above top edge of the back panel.

l Maximum flap depth on minimum length envelopes is 2.75" (69.8 mm).

l The length of the enclosure should not be equal to the distance between the side seam edges. When possible, the enclosure length should be greater than this dimension, with consideration that the correct end clearance is maintained.


l Distance between the glue line and the envelope edge should be .125" (3.17 mm) or less.

McIntryre Side Seam Envelopes

These envelopes must be provided to PB Engineering to ensure the design is acceptable.

Specifications


Window Requirements

Open window envelopes are not supported. Patched window types cannot have any part of the window above the "V" in the back panel of the envelope. In these envelopes, the window should be located .75" (19 mm) minimum from side, top and bottom of the envelope.

Bottom window envelopes are becoming more prevalent due to current US security concerns. The automated processing requirements for this type of envelope need to be researched.

The patch should be a minimum of .25" (6.4 mm) larger than the opening on all sides.

The glue line should be no more than .125" (3.2 mm) from the inside of the opening on all sides. All window patches should be flat, ripple free and bonded within .0625" (1.6 mm) of the top edge of the patch material and top edge of the window cut out(s). If the window patch area is 1/3 or more of the total area of the envelope's front panel, the envelope must be tested.

For front / back double window envelopes, the window patches cannot be in opposite positions or the photocells will see through the envelopes, (see the example here).

Specifications


Throat GeometryIt is assumed that the flap defines the envelope throat geometry. The maximum flap depth is 2.5" (64 mm) and the minimum distance from the lowest point on the flap to the base of the envelope is 1.5 " (38 mm). Any flap / envelope dimension which does not meet these requirements can be reviewed by PB Engineering to determine the ability of a particular envelope to run.

Mailpiece

The mailpiece:

l Is measured with the maximum collation size inserted into the envelope and the envelope sealed

l Is measured by laying the sealed envelope on a flat surface and measuring from the surface to the highest point of the envelope

l Thickness will not exceed 0.32" (8 mm)

Specifications


Cycling Speed Specifications

This table approximates the maximum system throughput based on a mathematical model of the MPS insertion engine.

Envelope Depth Envelope Width Flap Dimension (Min)

Flap Dimension (Max)

MaximumCycle Rate(env/hr)

Envelope inches mm inches mm inches mm inches mm

#7 3/4 or Monarch 3.95 98 7.500 191 1.25 32 2.50 44 21K

#10 4.10 105 9.500 241 1.25 32 2.50 44 21K

ISO DL 4.30 110 8.7 220 1.25 32 2.50 44 21K

C6/5 4.50 114 9.0 229 2.25 57 2.75 70 21K

#14 5.00 127 11.5 292 1.25 32 2.50 44 19K

6 x 9 6.00 152 9.00 229 1.25 32 2.50 44 18K

C5 6.40 162 9.00 229 1.25 32 2.50 44 18K

9 x 12 9.00 229 12.0 305 1.75 44 2.25 57 14K

C4 9.00 229 12.8 324 1.75 44 3.25 83 14K

B4 9.80 250 13.8 350 1.75 44 5.25 133 14K

10 x 13 10.0 254 13.0 330 1.75 44 4.25 108 14K

Specifications


MPS/Epic Friction Feeder (Y554)

The Y554 Friction Feeder brings specialized friction feeding technology to the MPS/Epic platform.

Standard Features

l Servo-controlled

l Double detection and Fail to Feed detection

l Easy operator setup for material changeover

l Backup feeding option standard

Cycling Speed

Enclosure Length (Depth)

Cycling Speed Max

MPS Epic

<4" (102mm) 26K 21K

>4" (102mm) 22K 21K

Specifications


Enclosure Specifications

Measurements Minimum Maximum

Length 3.0" (76 mm) .6.25" (159 mm)

Width 5.5" (140 mm) 10.0" (254 mm)

Total Enclosure Thickness - Max Speed

.0038" (0.1 mm) .125" (3 mm)

l Enclosure dimensions should not vary more than +/- .03125" (1 mm).

l Enclosure curl or twist should not exceed .125” (3 mm) when enclosure is placed on a flat surface.

l Contact PB Engineering if an application falls outside the specifications.

Folded Enclosure Specifications

l Folds that result in an even overall thickness of enclosure will give the best feeding performance.

l Folds that are made parallel to the paper grain direction are preferred. This results in a cleaner, straighter fold with less thickness increase at the fold.

l Folds should be sharply creased, flat, and free of edge curl (see diagram).

Curl at Fold

l Folds must not result in the free ends being greater than .25" (6 mm) from a fold (see diagram).

Free Ends at 1/4" (6 mm) Maximum

Specifications


l Short folds that result in either the lead or trail edge being 1.5 times as thick as or thicker than the opposite edge are not allowed (see diagram).

Short Folds - Thickness

Ink and Surface Condition

l Ink should be dry or set sufficiently to prevent enclosures from sticking together (blocking).

l Ink should not smudge when enclosures are rubbed together.

l Powder should not be used to prevent enclosures from sticking together (blocking).

Envelopes (BRE)

l All types of envelopes are allowed. Overall thickness may not be more than 50% greater in the center than at the leading edge (i.e. if leading edge is two papers thick, center cannot be more than three papers thick).

l Die cut envelope must be fed with window down, flap leading.

Die Cuts

l Die cut holes with and without windows are allowed as long as there is an area under the hole that is not die cut.

l Die cut pressure sensitive labels with a backing sheet are allowed.

l Die cut labels without a backing sheet (such as remoistenable adhesive “stickers”) are not allowed.

Glue

l Any enclosure with glued features must not allow stray glue to attach enclosures together.

l Exposed “remoistenable” adhesive is not allowed.

Attached Cards

l Cards must be attached with at least two glue lines to a carrier sheet.

l Cards should be centered on the carrier sheet in both side-to-side and lengthwise orientations.

l Carrier sheet must not exceed two times the length of the card. Requires application review.

Specifications


Packaging

Packaging of enclosures should not result in curling, creasing, folding or damage to edges of enclosure.

Stacking

Enclosures should be packaged in a way that will hold stacks even on the edges – uneven stacking can result in unacceptable edge curl.

Uneven stacking with offset edges can result in unacceptabe curl (see diagram).

Stacking with Offset Edges Results in Curled Edges

Banding

l Bands should be loose enough to prevent scoring or creasing the paper.

l Paper bands are preferred to rubber bands.

l Cardboard chips at the top and bottom of each banded stack greatly reduce the chance of enclosure damage and allow for tighter bands to be used.

l Enclosures should be free of paper shards, excessive dust, and powder.

Options

The Friction Feeder can be configured with these scanning options:

Option PCN

Barcode Scanner Y551

Area Scan Camera Y55B

Specifications


Epic Rotary Feeder (Y558)

The Y558 Rotary Feeder brings rotary feeding technology to the Epic platform.

Standard Features

l Servo-controlled



l Backup feeding option standard

Cycling Speed

Enclosure Length (Depth)

Cycling Speed Max

MPS Epic

<4" (102 mm) 26K 21K

>4" (102 mm) 22K 21K

<6.25" (159 mm) n/a 18K

>6.25" (159 mm) n/a 14K

Specifications




Length 3.0" (76 mm) 8.5" (216 mm)

Width 5.5" (140 mm) 12.0" (305 mm)

Total Enclosure Thickness - Speed Reduced

.0025" (0.064 mm) .125" (3.2 mm)


.0032" (0.81 mm) .10" (2.54 mm)


l Enclosure curl or twist should not exceed .125” (3 mm) when enclosure is placed on a flat surface.

Folded Enclosure Specifications

l Folds that result in an even overall thickness of enclosure will give the best feeding performance.

l Folds that are made parallel to the paper grain direction are preferred. This will result in a cleaner, straighter fold with less thickness increase at the fold.

l Cannot feed "Z" folds.

l Closed end first (see diagram)

l Folds should be sharply creased, flat, and free of edge curl(see diagram).

Curl at Fold

Specifications


l Folds must not result in the free ends being greater than .25" (6mm) from a fold (see diagram).

Free Ends at 1/4-inch (6 mm) Maximum

l Short folds that result in either the leading or trailing edge being one and one half times as thick or thicker than the opposite edge are not allowed (see diagram).





Envelopes (BRE)

l All types of envelopes are allowed. Overall thickness may not be more that 50% greater in the center than at the leading edge (i.e. if leading edge is two paper thicknesses, center can not be more that three thickness).


Die Cuts




Glue



Specifications


Attached Cards




Packaging

In general, packaging of enclosures should not result in curling, creasing, folding or otherwise damaging of the edges of the enclosure.

Stacking


Uneven stacking with offset edges can result in unacceptabe curl (see diagram).


Banding





Air Supply Requirements

Each Rotary Feeder requires:

l Air Pressure: 70PSI (4.9 bar)

l Flow: 1.8 SCFM (51 l/min)

Specifications


Options

The Rotary Feeder can be configured with these scanning options:

Option PCN

Moving Beam Scanner Y556

Area Scan Camera Y55A

Specifications


Epic Universal Friction Feeder (ZVF1)

The Universal Friction Feeder (ZVF1), also known as the "booklet feeder," is designed with a specialized, full range of material feeding technology including booklets.

Standard Features

l Servo controlled



l Single booklet feeder typically mounts in most upstream chassis position and in this position it comes with an extended feed hopper (located over the top of the buffer), additional loading capacity

l Can be mounted in any other chassis position but without extended feed hopper

l Takes two to three feeder positions (depending on chassis position)

Cycling Speed

Enclosure Length (Depth) Cycling Speed (Max)

<4" (102 mm) up to 21K

4" (102 mm) - 6.25" (159 mm) up to 18K

6.25" (159 mm) up to 14K

* Actual cycling speed will be insert and application dependent; see section 6 in the Performance Guide

Specifications




Length (Depth) 3.0" (76 mm) 9.0" (229 mm)

Width 5.5" (140 mm) 12.0" (305 mm)


.0038" (0.81 mm) .375" (10 mm)


l Enclosure curl or twist should not exceed .125” (3 mm) when enclosure is placed on a flat surface. Contact the Engineering Group in Danbury if an application falls outside the specifications

Folded Enclosures Specifications

l Folds should be sharply creased, flat, and free of edge curl

Curl at Fold

l Folds must not result in the free ends being greater than .25" (6 mm) from a fold

Free Ends at 1/4-inch (6 mm) Maximum

l Short folds that result in either the leading or trailing edge being one and one half times as thick or thicker than the opposite edge are not allowed (see diagram).

Specifications






Envelopes (BRE)

l All types of envelopes are allowed. Overall thickness may not be more that 50% greater in the center than at the leading edge (i.e. if leading edge is two paper thicknesses, center can not be more that three thickness).


Die Cuts




Glue



Attached Cards




Packaging

In general, packaging of enclosures should not result in curling, creasing, folding or otherwise damaging of the edges of the enclosure.

Stacking


Specifications


Uneven stacking with offset edges can result in unacceptable curl.


Banding





Specifications


Epic P2L Buffer with TNT (ZVB2)

Description

The Buffer with TNT module synchronizes the collated material to optimize the performance of the input. The 8-stage buffer will buffer finished collations and reduce the number of dry cycles per hour depending on the collation size.

The TNT module, when activated, twists the collated material 180°. When it's not activated, the collation passes through the TNT. This job setup is done through the Direct Connect operating system.

The P2L module (portrait to landscape), when activated, rotates the collated material 90° (left or right). When it's not activated, the collation passes through the gate. This job setup is done through the Direct Connect operating system.

The module operates at 21,000 cycles per hour tri-fold, 18,000 cycles per hour in half-fold mode, and 14,000 cycles per hour in flat mode (rotation / P2L mode).

Standard Features

The Y575 Epic Buffer with TNT includes:

l An integrated Servo 8-stage buffer that transports and stages collations from the folder output to the Twist No Twist (TNT)

l Hand-off station that transfers the collations to the chassis

l Automated subset stops for faster changeovers

l Smart dynamic skew correction

l Nip to nip hand-off between the buffer dump station and the chassis increases feed reliability

l Improved jam clearance in the dump station and buffer gates

l P2L module that rotates the collation +/- 90°

Specifications


Material Specifications

Flats - Pass Thru Minimum Maximum

Paper Length 8" (203 mm)* 9" (229 mm)

Paper width (trimmed) 7" (179 mm) 12" (305 mm)

Thickness Single sheet 20 sheets 20 lb (80 gsm)

Flats - P2L 90° (TNT Pass Thru) Minimum Maximum

Paper Length (before rotation) 8" (203 mm)* 12" (305 mm)

Paper width (trimmed, before rotation) 7" (179 mm) 9" (229 mm)

Thickness Single sheet 10 sheets 20 lb (80 gsm)

Folded - TNT Active or Pass Thru Minimum Maximum

Paper Length (before rotation) 3.5" (89 mm) 6.5" (165 mm)

Paper Width (trimmed, before rotation) 7" (179 mm) 12" (305 mm)

Thickness Single sheet 16 sheets 20 lb (80 gsm) half-fold10 sheets 20 lb (80 gsm) tri-fold

* The TNT does not support twisting of flat materials; any rotation is limited to 14,000.

Specifications



l Length: 77" (195 cm)

l Width: 34" (86 cm)

l Height: 50.4" (128 cm)

l Heat Dissipation: 1260 watts/4300 BTU/Hr

l Weight: 520 lbs (234 kg)

l Air Consumption: 0.3 SCFM when in P2L mode

Specifications


Epic Turnover (Y370)

Description

The Epic Turnover (Y370) is a Servo powered turnover belt. The turnover takes mail pieces from the output of the Epic sealer, turns the mail piece over (from face down to face up), and presents it face up to the downstream output modules.

The turnover contains all the necessary connections to integrate to the Epic sealer or adjacent V-Bin modules. It also handles the entire range of Epic folded material and handles flats envelope up to 70 panels.

Standard Features

l Parts include:

o Cabinet

o Servo-powered turnover belt

o Turn bar guide

o Exit nip roller

l DC-controlled linear speed

Specifications



Minimum Maximum

Depth - Height Refer to Epic specs Refer to Epic specs

Width - Length Refer to Epic specs Refer to Epic specs

Flap Refer to Epic specs Refer to Epic specs

Thickness (#10 - C5/C6) single sheet 14 sheets (4.3 mm)

Thickness (6x9.5 - C5) single sheet 24 sheets (5 mm)

Thickness (9x12 - C4) single sheet 50 sheets

Thickness (10x13 - custom C4) single sheet 70 sheets


l Length: 55” (140 cm)

l Width: 26” (66 cm)

l Height: 46” (117 cm)

l Heat Dissipation: 117 KW (400 BTU/Hr)

Specifications


Epic V-Bin (Y31E, Y31F, Y31G, Y31H )

The Y31 series V-Bin modules are optional output devices used on the Epic platform and on non-turnover MSE/Rival systems. It diverts finished envelopes out of the mailstream prior to the On-Edge Stacker.

When the divert gate is activated, the V-Bin diverts a single envelope from the mailstream. The diverted envelopes are stacked in a tray located below the V-Bin transport. When the divert gate is not activated the envelope is transported to the next downstream module. Setting up the V-Bin is part of the job setup and is done through the Direct Connect operating system.

The V-Bins are available in both single and dual configurations and are factory configured for front justified, face down (pre-Turnover) and rear justified, face up (post-Turnover) configurations.

Available Modules

Pre-Turnover

l Y31E (Single V-Bin, Front Justified)

l Y31F (Dual V-Bin, Front Justified)

Post-Turnover

l Y31G (Single V-Bin, Rear Justified)

l Y31H (Dual V-Bin, Rear Justified)

l Y31J (Single V-Bin/DM Infinity Meter Combo)

For the most cost-effective solution, dual V-Bin modules should be used wherever possible, unless an odd number of V-Bins is required. In this case, a single module can be used at the end. For example, to get three output V-Bins pre-Turnover we would use one Y31F followed by one Y31E. If we require four V-Bins in a row, we would use two Y31F. Same rules apply for post-Turnover V-Bins.

The V-Bin modules provide the mounting base and electrical connections for top or bottom scanning or the Shingle Conveyor. These options are mutually exclusive and therefore only one option per V-Bin is permitted.

Specifications


Standard Features

l Servo-powered transport

l Adjustable drive rollers for slight skew correction

l Air-actuated divert gate

l DC-controlled linear speed

l Mail tray for outsorted mail pieces


The Epic V-Bins can handle the entire range of folded and flat materials of an Epic.


Single Dual

Length 17" (43 cm) 34" (86 cm)

Width 32" (81 cm) 32" (81 cm)

Height 39" (99 cm) 39" (99 cm)

Specifications


Options

The V-Bin can be configured with these options:

Options PCN

Shingling Stacker Y32S

Output Area Scan Top Y55FT

Output Area Scan Bottom Y55FB

Output Line Scan Top Y55LT

Output Line Scan Bottom Y55LB

Manual Hand Feed OSSO

Y55FT (image on left) and Manual Hand Feed (image on right)

Specifications


Epic On-Edge Stacker (Y396)

The On-Edge Stacker is a labor savings output device that simplifies the handling of finished mail pieces to optimize production workflow and efficiencies. Finished mail pieces are stacked on edge for greater stacking density, allowing less frequent unloading of the output stacker. Unloading occurs without stopping inserter operation, thereby maintaining high system throughput.

The On-Edge Stacker is configured standard with a sliding drawer just under the belt stacker where mail trays can be placed for fast and easy unloading from either side of the stacker.

The main components of the On-Edge Stacker include the belt turn-up, a 7’ (2.1 m) belted stacker and a sliding drawer.

The On-Edge Stacker can also be equipped with an optional Offset Kit to provide a visible break in the material flow, automating the production workflow even more. This Offset Kit can be activated to identify tray, zip or count breaks.

Specifications


Description

l Parts include: turn-up belt , a 7’ (2.1 m) belted stacker, a sliding drawer

l Conveyor belt holds approximately 750-1000 #10 envelopes (C 6/5), two-page tri-fold documents, and two inserts

l Can be equipped with an optional Offset Kit to provide a visible break in the material flow, further automating the production workflow. The Offset Kit enables the system to identify and sort by tray, zip code or count breaks.

l Available in one configuration - Y396 On Edge Stacker (Epic)

Standard Features

l 7’ (2.1 m) conveyor belt (holds approximately 750-1000 #10 envelopes, C6/5 stacker, two-gate tri-fold document and two inserts)

l Automated envelope height adjustment mechanism

l Continuous unloading

l Sliding drawer with dual sided access for storage and loading of mail trays

l Automatic operator visual notification for “Stacker Full” and “3/4 Full”

l Jam and stoppage detection

l UL, CE approved

Specifications



Envelope Specifications Minimum Maximum

Length 6.5" (165 mm) see note 2 11.5" (292.1mm)

Width 3.88" (98 mm) 6.5" (165 mm)

Basis Weight 20 lb (75 gsm) 28 lb (105 gsm)

Range of Thickness 25.0" (635 mm)

Notes

l (1) The On Edge Stacker will not process stepped mail applications, such as CDs, DDA check applications, license plates or credit cards

l (2) Envelopes with external side seams require the External Side Seam kit

Options

The On Edge Stacker can be configured with these optional kits:

Kit Part #

Offset Kit Y49B

Side Seam Kit Y490011

Specifications


Epic Shingling Stacker (Y32S)

The Shingling Stacker is designed to handle finished flat mailpieces. Integrated into a 17.0" V-Bin, the stacker puts finished mailpieces on a 78.0" (2 m) belt.

Unloading the finished mail pieces occurs without stopping inserter operation. The Shingling Stacker is comes standard with a system clear button, which helps to clear all envelopes from the belt for easy unloading.

Standard Features

l 78.0" (2 m) conveyor belt stacker

l Sponge roller to improve envelope sealing

l Integrated with DC

l Holds approximately 750-1000 9x12 (C4) envelopes with 10 page flats and no inserts

l Continuous unloading

l NRTL approved

Specifications


Epic Edge Markers (Y367, Y368, Y369 )

The edge marker is an accessory on inserters that marks the edge of envelopes to help with sorting mail.

Y367 and Y368 are dual edge markers that include two rollers for applying ink to the envelope edge. Both edge markers are controlled through Direct Connect as independent devices.

l F = Front - also referred to as operators side and within the work cell

l B = Back - also referred to as non-operators side and outside the work cell

Edge Markers Described by PCN

Y367F - Front Edge Markers 1st Position

l Located in the engine prior to the first output V-Bin or turnover

l Includes two edge markers on the same side

Y368F - Front Edge Markers Last Position

l Located just prior to the On-Edge Stacker


Y367B - Front Edge Markers 1st Position

l Located in the engine prior to the first output V-Bin or turnover


Y368B - Front Edge Markers Last Position

l Located just prior to the On-Edge Stacker


Specifications


Y369 - Additional Dual Edge Markers (child of Y367F and/or Y367B)

This adds back/rear edge markers to one of the other sets, for a total of four edge markers, (refer to the image here to see the four markers).

Specifications


Environmental Operating Conditions

The Epic Inserting system meets the environmental requirements in PB Standard G2605 "Operating Conditions" (June 1985, revised April 1986). The Epic is RoHS compliant.

Temperature and Humidity

Temperature Humidity (%) Max Wet Bulb Temp

°F °C

Min Max Min Max Min Max °F °C

Normal 55 95 13 35 30 80 80 27

Storage 15 120 -9 49 5 95 85 29

Shipping -40 140 -40 60 0.5 100 (3.6) 85 29

Temperature and Humidity Tips

l Humidity control is not required below 33° C (1° C wet bulb)

l Shipping refers to product prepared for shipping. All requirements assume that the equipment is drained of all the aqueous liquids and any device with an open sump.

l Include condensation, excluding rain.

l The system should satisfy performance requirements over the normal operating range of conditions. A loss of performance may occur at environmental conditions outside the normal operation range. Performance may degrade at environmental extremes.

l Paper has different humidity control requirements for normal operating conditions, storage, and shipping.

l 100% relative humidity up to 85° F.

Specifications


Network and Power Requirements

The following network and power requirements apply to the Epic inserting system.

Network Requirements

l Data concentrator ethernet hub (min. 4-port)

l CAT5 cable from each DC and RTP PC to data concentrator hub

l CAT5 cable from data concentrator hub to data concentrator (modified PIDA server provided)

l Internet connect to data concentrator (LAN)

Power Requirements

l Domestic power (Canada, US, and Mexico)

l 3 Phase, 208VAC, 60Hz, 50 amp 4-wire connection (L1, L2, L3, Earth)

l Power plug for 3-wire plus earth domestic connection supplied

l Power plug supplied - NEMA 15-50P (Hubbell 8451C or equivalent)

l Power receptacle required: NEMA 15-50R receptacle (Hubbell 8450A or equivalent)

l Export 3 phase, 230VAC or 240VAC phase to neutral (400 VAC or 415 VAC phase to phase), 50Hz, 50 amps per phase, (L1, L2, L3, N, Earth)

l Power plug for 5-wire export connection

l Power plug for 5 wire connection is not provided. A suitable power connector rated at 240/415V, 50A minimum and inlet wiring that conforms to local wiring standards must be chosen by the customer. (Connections are made by the customer to terminals inside the MPS power inlet assembly. Wiring diagram shown on inside of removable front cover of the inlet assembly.)

l Typical cutsheet MPS configuration (powered on and processing work) - 3 phase approximate 31A total (6.448KVA)

l Typical continuous MPS configuration (powered on and processing work) - 3 phase approximate 36A total (7.448KVA)

Specifications


Idle Power Requirements

l Powered on and at idle – approximately 8 amps (1.614KVA)

BTUs

l Heat Dissipation: 2000 watts (7825 BTU/hr)

Specifications


Air Requirements

The correct compressed air supply for the Epic inserter is critical to the operation of the system. Follow these guidelines or contact PB Service or Engineering with questions.

No presently released PB air compressor satisfies the requirements of the Epic inserting system. The recommended vendor will provide the equipment and service required to maintain a compressed air system to work with PB equipment.

l Air requirements: 6.3 SCFM @ 70 PSI

l .375" quick disconnect fitting included on the system

Specifications


Expected Lifetime

The Epic Inserter design will meet a minimum life expectancy of 250M cycles or the equivalent of 10 yrs from the time of manufacture. This expectation can be met or exceeded when the recommended preliminary maintenance at the appropriate intervals has been performed.

Every 100M cycles a detailed mechanical inspection of the system must be done to identify any potential breakdowns. This audit could identify parts replacement for non-standard parts. In this case, there would be a proposal made to the customer to provide this 100M service above the standard support.

Specifications



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