Pitney Bowes F625 User manual

Operating Guide
F625
Conveyor
Stacker

1
Contents
Before setting up and using the F625, you should be thoroughly familiar with its
controls and setup procedure. You should also be thoroughly familiar with each
component of the Inserting system the F625 is being used with.
This Guide is organised into three sections:
1. INTRODUCTION
Gives basic details of your F625. This section includes: page
1.1 Safety............................................................................................. 2
1.2 What the Conveyor Stacker
Does ..................................................3
1.3 Main Components...........................................................................3
1.4 The Control Panel...........................................................................6
1.5 Principle of Operation .....................................................................6
2. OPERATION
Gives the basic steps required to process documents. It explains:
Use with the DI800
2.1 Setting up for operation with the DI800 Inserter.............................7
2.2 Operation with the DI800 Inserter ...................................................9
2.3 Setting up for DI800 and optional In-Line Kit ...............................11
2.4 Operation with the DI800 and optional In-Line Kit .......................12
Use with the DI875
2.5 Setting up for operation with the DI875........................................13
2.6 Operation with the DI875..............................................................15
2.7 Setting up for DI875 and optional In-Line Kit ...............................17
2.8 Operation with the DI875 and optional In-Line Kit .......................18
3. REFERENCE
Covers subjects that may only be required occasionally. It includes:
3.1 Troubleshooting ............................................................................19
3.2 Service..........................................................................................19
3.3 Specifications ................................................................................20
CONTENTS

2
Introduction
General
• Know your equipment, especially how to stop it in the event of an
emergency.
• Never reach into the machine while it is on; always wait until the machine
has come to a full stop.
• Never touch moving parts.
• Keep fingers, long hair, jewellery and loose clothing away from moving
parts at all times.
• Use the equipment only for its intended purpose.
• Don’t remove machine covers. Refer servicing to qualified personnel.
Mains Electrical Connection
In some countries the F625 is supplied with a moulded mains lead. In
other countries, or if the supplied lead is not used, the following information
applies:
1. An approved mains lead for the country concerned must be used.
2. The wires in the supplied mains lead are coloured in accordance with
the following code: Green and Yellow -
Earth
Blue - Neutral
Brown - Live
3. As the colours of the wires in the mains lead of this equipment may not
correspond with the coloured markings identifying the terminals in your
plug, proceed as follows:
The wire which is coloured green and yellow must be connected to the
terminal in the plug which is marked with the letter “E” or by the earth
symbol or coloured green or green and yellow.
The wire which is coloured blue must be connected to the terminal
which is marked with the letter “N” or coloured black.
The wire which is coloured brown must be connected to the terminal
which is marked with the letter “L” or coloured red.
1. INTRODUCTION
1.1 Safety
WARNING:
This equipment must be earthed.
The socket outlet should be near to the equipment
and should be easily accessible.

3
Introduction
The Model F625 Conveyor Stacker is a belt stacker designed as output device
for the DI800 and DI875 inserting systems, but also as general output device for
other machines.
The Conveyor Stacker operates at a right or left angle and also in-line with
optional parts. The product can easily be changed over without any tools. The
control panel, which can be hooked up on either side of the stacker, incorporates
variable speed control, run-out button, power switch and power supply.
Take a few minutes to become familiar with the components of the Conveyor
Stacker.
2
3
6
4
1
Side guides 5
2 Control panel box
3 Leg assembly
4 Lockable castors
5 Height adjustment knobs
6 Stacking tray
7 Entry guide
8 Front end side guide adjustment knobs
9 Rear end side guide adjustment knobs (underneath, not visible)
1.2 What the Conveyor Stacker Does
1.3 Main Components
8
7
1
9

4
Introduction
Adjustable brushes
Used to prevent material
bouncing back
Entry Guide Kit
Is used in conjunction
with DI875 Inserting
System
Start sensor adjustment knob
The sensor position determines
material overlap
Sensor bracket 1
Exit Rollers for the DI875 Inserter
For a secure transport of heavy envelopes
Docking plate for the DI800 Inserter
Helps positioning the Stacker to the inserter
1.3 Main Components (Continued)

5
Introduction
Optional In-line Kit
The In-Line Kit is used when the material enters the Conveyor Stacker at the
short end. This is the preferred configuration when running heavy, large envelopes.
Start sensor adjustment knob
The sensor position determines
material overlap
Sensor bracket 2 Idler roller position
adjustment knob
Optional Low-Profile Feet
Lowers the unit by 60 mm (2 3/8”). The Low Profile Feet replace the castors.
The kit contains four feet, for one Conveyor Stacker.

6
Introduction
The control panel can be positioned either side of the unit, depending on system
configuration.
Power switch
For switching
on/off main
power
Speed selector
For setting belt
speed
Run-out button
Runs the belt at
full speed - when
you want to gather
the material on the
belt
The belt will start as soon as the Start sensor is covered. When the material has
moved out of the sensor area the belt will stop again. The Start sensor position
is adjustable, which allows the material overlap to be adjusted.
The speed of the belt can be adjusted in order to optimise the stacking function
for various materials.
The Run-out button is used to gather the material after a job is finished. The belt
moves at the highest speed, independent of the Speed Selector setting.
1.5 Principle of Operation
1.4 The Control Panel

7
Operation
1. Place the Docking plate under the
DI800 Inserter. The feet should go
through the oblong cut-outs and
position the plate correctly.
2. The plate should be in the inner position
for 90 degree operation. Lift the inserter
slightly to be able to position the plate.
3. For right hand stacker configuration the
two studs of the Conveyor Stacker
should be positioned into the two holes
(A) and vice versa.
This illustration shows the Conveyor
Stacker correctly docked to a DI800
Inserter.
2. OPERATION
2.1 Setting up for operation with the DI800 Inserter
A
Plate at inner position
for 90
°
operation.

8
Operation
4. Check the correct height of the Stacker.
Place the Stacker close to the Inserter
and check whether the studs on the
side of the Stacker fit into the openings
in the Docking plate. If not, loosen the
height adjustment knobs (B) and
readjust.
5. Position the Conveyor Stacker as close
to the inserter as possible and lock all
four castors.
6. Loosen the front and rear end knobs
(C) of the side guide closest to the
inserter output and move the side
guide as close as possible to the
inserter. (The picture shows the inserter
removed for clarity).
Retighten the front and rear end knobs.
7. Install the rear support (D).
8. For right hand operation; install the
Sensor and Sensor Bracket (E) as
shown in the picture.
For left hand operation the parts are
installed mirrored.
2.1 Setting up for operation with the DI800 Inserter (Cont’d)
B
C
D
E

9
Operation
9. Loosen the two knobs (F) on the
inserter and move the deflector to its
top position.
1. Place one envelope on the belt.
2. Loosen the front and rear end side
guide knobs (A) of the side guide with
the sensor bracket only.
Make sure the side guide rests on
the belt!
3. Adjust the side guide to give a clearance of about 3mm (1/8”) and retighten
the front and rear end side guide knobs.
Make sure the side guides are parallel!
4. Read the safety information on page
2, then connect the Conveyor Stacker
to the mains supply and turn ON.
5. Set the belt speed to maximum.
F
2.2 Operation with the DI800 Inserter
3mm clearance
A

10
Operation
6. Start the DI800 system.
7. Adjust the envelope overlap by moving the Start sensor. When the sensor is
moved away from the inlet the distance between the envelopes will be
larger, and vice versa.
Keep the step as small as possible without envelopes building up too
much. That way you can optimise the belt capacity!
8. Reduce the belt speed until the
motor runs continuously.
2.2 Operation with the DI800 Inserter (Continued)
Sensor adjustment knob
Short Step
Long Step

11
Operation
1. The docking plate should be in the
outer position for in-line operation. Lift
the inserter slightly to be able to
position the plate.
2. Remove the deflector from the Inserter
by loosening the two knobs (A).
3. Position the Stacker as illustrated. The
upper outer corner of the left Side
Guide should be aligned with the lower
left output corner of the Inserter.
2.3 Setting up for DI800 and optional In-Line Kit
A
Align guide with output

12
Operation
Basic setting of side guides for DL size
envelopes.
Basic setting of side guides for C5 size
envelopes. Only the right hand side guide
needs to be moved when changing format.
Adjust the wheel position; place an
envelope with the trailing edge underneath
the black shaft, slide the wheels so that
they align with the leading edge of the
envelope.
See Section 2.2 for overlap and speed settings.
2.4 Operation with DI800 and optional In-Line Kit
Black shaft
Idler wheel

13
Operation
1. Install Entry Guide Kit, Sensor Bracket
1 and Sensor as shown in the picture.
For right hand orientation, install the
parts mirrored.
2. Check the correct height of the Stacker.
Place the Stacker close to the Inserter
and check whether the docking studs
on the side of the Stacker fit into the
cut-out on the inserter.
If not, loosen the height adjustment
knobs (A) and readjust.
3. Position the Stacker as close to the
inserter as possible and lock all four
castors.
2.5 Setting up for operation with the DI875
Entry Guide Kit
Sensor bracket 1
Sensor
Cut- out
Docking studs
A

14
Operation
4. Make sure the Exit roller shaft is
installed on the inserter.
5. Loosen the front- and rear end knobs
and move the side guide as close as
possible to the inserter
2.5 Setting up for operation with the DI875 (Continued)
Exit rollers
(rear end knob not visible)
Front end adjustment knob
Side guide

15
Operation
1. Place one envelope on the belt.
2. Loosen the front and rear end side
guide knobs (A) of the side guide with
the sensor bracket only.
Make sure the side guide rests on
the belt!
3. Adjust the side guide to give a
clearance of about 3mm (1/8”) and
retighten the front and rear end side
guide knobs.
Make sure the side guides are parallel!
4 Loosen the Brush adjustment knobs (B)
and set the brush position on the Entry
guide. The brushes should just about
touch the envelope. Retighten the
adjustment knobs.
The setting depends on envelope size,
thickness, inserter speed and belt
speed.
If the brushes are set too tight the
envelopes will not get in position.
If the brushes are set to loose the envelopes could bounce back and cause
jams.
5. Read the safety information on page
2, then connect the Conveyor Stacker
to the mains supply and turn ON.
6. Set the belt speed to maximum.
2.6 Operation with the DI875
A
3mm clearance
B
Brushes just touch envelope

16
Operation
7. Start the DI875 system.
8. Adjust the envelope overlap by moving the Start sensor. When the sensor is
moved away from the inlet the distance between the envelopes will be
larger, and vice versa.
Keep the step as small as possible without envelopes building up too
much. That way you can optimise the belt capacity!
9. Reduce the belt speed until the
motor runs continuously.
2.6 Operation with the DI875 (Continued)
Sensor adjustment knob
Short Step
Long Step

17
Operation
1. Install Sensor Bracket 2, Start sensor
and Idler roller assembly as illustrated.
2. Adjust the Stacker height so that the
docking studs can enter the cut-out in
the DI875 output end.
3. Place the Stacker as close to the
inserter as possible and lock all four
castors.
2.7 Setting up for the DI875 and optional In-Line Kit
Idler roller assembly
Sensor bracket 2
Start sensor
Cut- out
Docking studs

18
Operation
1. Place one envelope on the belt.
2. Centre the side guides around the middle, approx. 6mm (1/4”) wider than the
envelope. Use the front and rear scales to simplify the centring.
3. Adjust the idler wheel position; place
an envelope with the trailing edge under
the black shaft, slide the idler wheels
so that they align with the leading edge
of the envelope.
4. See Section 2.6 for overlap and speed settings.
2.8 Operation with the DI875 and optional In-Line Kit
Black shaft
Idler wheel

19
Reference
Symptom Possible cause Remedy
Material gets stuck in the
inlet area
Entry guide brushes set too tight/
low (DI875 only)
Belt speed too low, material builds
up and gets stuck
Step length too small
Side guides set too narrow
The incoming envelope catches
on the previous envelope’s
window
Material slips in underneath side
guide and gets stuck
Readjust brushes upwards
Increase belt speed
Increase step length
Adjust side guides
Increase belt speed and step
length, so that the incoming
envelope won’t hit the previous
envelope window
Loosen side guide knobs, press
side guide down and tighten knobs
Material doesn’t transport
all the way to the stacker
end stacking tray
Side guides too narrow or
funneled
Step too big, material slips on belt
because of insufficient weight
Check side guides are parallel and
have correct clearance
Reduce step length
Material topples over on the
belt, even with low numbers
of items
Step length too big
Side guides not parallel or too
tight
Reduce step, reduce belt speed
Check side guides are parallel and
have correct clearance
Pitney Bowes provides service throughout the world. Should you have questions
about your F625 Conveyor Stacker, or require service or assistance with your
particular application, please call Pitney Bowes or the dealer serving your area.
The phone number will be on a sticker on your F625, and/or on the back cover
of this guide.
A service maintenance contract is available to keep your F625 (as well as your
entire Inserting system) in top condition at nominal cost. Contact Pitney Bowes
or your dealer for details.
3. REFERENCE
3.1 Troubleshooting
3.2 Service