Pitney Bowes Epic v3.1 Manual

Shipping & Mailing
Inserting
Epic™ v3.1(ZVE0)
Inserting System
Auto Adjust Chassis
Operator Guide
US English Edition
SV63233 RevG
May 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
lHPI Pinless Cutter (Y484/Y485) Operator Guide (OG-AF-INPU-102006)
lHPI Accumulator (Y470 ) Operator Guide (OG-ADFS-INPU-031005)
lHPI RAT/FIM (Y47EWP) Operator Guide (SV63088)
lPrint+ Messenger Digital Inkjet System Operator Guide (OG_APF_PRINT_020111)
lHunkeler UW6 Unwinding Module Operator Guide (OG-Hunk-Unwinder)
lAuto Buckle Chute (Y488, Y20R, Y20S) Operator Guide (OG-APF-INPU-011513)
lY254 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 2
Power 3
Operation 4
Maintenance 5
Warning Labels and Cautions 6
Safety Features 10
2 - Product Overview
Epic v3.1 (ZVE0) Inserting System 14
Component Overview - Epic v3.1 (ZVE0) 15
Indicator Lights 17
About the Remote Control 18
3 - Power the System On and Off
Powering Up the System 20
Powering Down the System 22
4 - Using Direct Connect
Direct Connect Software Overview 26
DC Main Screen 27
Changing the UI Display Language 30
Powering Down the DC Computer 31
Viewing DC Software Details 32
Logging In and Logging Out of DC 33
Loading a Mode 35
Setting the Mail Date 37
Checking Status with Job Manager 38
Accessing Reports in DC 39
Starting and Stopping the Inserter Using DC 40
Assigning an MRDF File (File Based Jobs) 41
Disabling (and Enabling) the Inserter 42
Clear Deck Function 43
About the Speed Indicators in DC 46
About the DC Alarm Message Box 47
5 - Operator Adjustments
Operator Adjustments 51
Adjusting the Envelope Feeder Separator Gap 52
Adjusting the Envelope Fence 55
Adjusting the Suction Cups in the Engine 56
Adjusting the Engine Tongue Position 60
Adjusting the Engine Tongue Height 63
About Engine Horns 65
Changing Engine Horns 66
Envelope Settings 71
Setting Up the RAT (Right Angle Transfer) 78
Adjusting 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 82
Moving the Flat Stacker 84
About the On Edge Stacker (OES) 88
Setting Up the Entrance to the On Edge
Stacker 90
Centering Mail on the On Edge Stacker
Conveyor Belt 94
Adjusting the Belt Speed and Stack Pressure
on the On Edge Stacker 96
Adjusting On Edge Stacker Fingers 100
Adjusting Chassis Material Center Deck
Control Strap 102
Adjusting Chassis Side Guide Control Straps 104
Setting the Chassis Collation Length 105
Setting the Chassis Speed 107
Friction Feeder Mechanical Adjustments 109
Adjusting the Friction Feeder Separator 110
Adjusting the Friction Feeder Side Guides 113
Adjusting the Feeder Pack Control Ramp 116
Rotary Feeder Mechanical Adjustments 118
Using Rotary Feeder Suction Cups 119
Adjusting the Rotary Feeder Side Guide and
Backstop 122
Adjusting the Rotary Feeder Deck Position 124
Setting the Rotary Feeder Feed Deck Angle 126
Adjusting the Rotary Feeder Separator Pins 128
Using the Wedge Accessory on the Rotary
Feeder 131
Using the Jog Function on the Rotary Feeder 133
Booklet Feeder Mechanical Adjustments 137
Changing Out the Booklet Feeder Separator
Assemblies 138
Adjusting the Booklet Feeder Separator Gap 145
Adjusting the Booklet Feeder Side Guides 148
Adjusting the Booklet Feeder Pack Control
Ramp 151
Adjusting the Booklet Feeder Double Detect
Feature 155
Adjusting the Bulk Loader Hopper Deck 158
Adjusting the Bulk Loader Hopper Side
Guides 161
Insert Feeder Software Adjustments 163
Enabling and Disabling Feeders 164
Document Information 165
Setting Feeder Feed Modes 169
Setting Backup Feeders (Backup Feed
Mode) 171
Transport Envelope Setup (Xport Setup) 174
Setting Separator Options for Friction
Feeders 175
Recalibrating the Double Detect Feature 177
Adjusting Buffer Upper O-ring Belt Height 178
6 - Job Changeover Guidelines
Job Changeover Guidelines 182
Auto Adjustments - Engine and Chassis 185
Manually Adjusting Engine and Chassis Auto
Settings 187
7 - Running the System
Loading the Envelope Feeder 194
Reloading the Envelope Feeder 196
Loading the Insert Feeders 199
Loading the Booklet Feeder 200
Reloading Insert Feeders (with the system is
running) 201
Removing Finished Mail from the On Edge
Stacker 202
Removing 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 210
Alarms in Direct Connect 211
Removing Material Jams in the Buffer 215
Removing Material Jams Under the Nip
Rollers 217
Removing Material Jams in the Dump Station
Exit 218
Removing Material Jams on Chassis Deck 219
Removing Material Jams in the Friction
Feeder 221
Removing Material Jams in the Rotary
Feeder 224
Removing Material Jams in the Booklet
Feeder 227
Removing Material Jams in the Engine 231
Removing Material Jams in the Envelope
Feeder 237
Removing Material Jams in the Sealer or
Vertical Stacker #1 240
Removing Material Jams in the Turnover 241
Removing Material Jams in the Vertical
Stackers 242
Removing Material Jams in the On Edge
Stacker 243
Removing Material Jams in the Flat Conveyor 244
9 - Troubleshooting
Troubleshooting 248
Engine Troubleshooting 249
Chassis Troubleshooting 252
Buffer Troubleshooting 258
10 - Maintenance
Operator Maintenance 260
Replacing Suction Cups in the Engine 262
Buffer Maintenance 266
Rotary Feeder Maintenance 267
Friction Feeder Maintenance 268
Vertical Stacker Maintenance 269
On Edge Stacker Maintenance 270
11 - Specifications
Epic V3 Description and Features 272
Epic Material Specifications 274
Epic v3.1 Engine (ZVE0) 276
Envelope Specifications 281
MPS/Epic Friction Feeder (Y554) 296
Epic Rotary Feeder (Y558) 300
Epic Universal Friction Feeder (ZVF1) 305
Epic P2L Buffer with TNT (ZVB2) 309
Epic Turnover (Y370) 312
Epic V-Bin (Y31E, Y31F, Y31G, Y31H ) 314
Epic On-Edge Stacker (Y396) 317
Epic Shingling Stacker (Y32S) 320
Epic Edge Markers (Y367, Y368, Y369 ) 321
Environmental Operating Conditions 323
Network and Power Requirements 324
Air Requirements 326
Expected Lifetime 327
Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page vii of 7

1 - Safety
In this section
Safety Information 2
Power 3
Operation 4
Maintenance 5
Warning Labels and Cautions 6
Safety 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 Guidelines
Ear 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.
l85dBA 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)
l90dBA 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

Power
System Power
The inserter receives its power from a customer provided, single drop, external connection.
General Power Safety
lUse 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.
lThe power cord wall plug is the primary means of disconnecting the machine from the AC power
supply for Lock Out/Tag Out (LOTO).
lDo not use an adapter plug on the line cord or wall outlet.
lDo not route the power cord over sharp edges or trap it between furniture.
lEnsure there is no strain on the power cord where it becomes jammed between the equipment,
walls or furniture.
lBe certain the area in front of the wall receptacle into which the machine is plugged is free from
obstruction.
lFor 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
Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 3 of 328

Operation
lOnly trained personnel are permitted to operate this equipment. Training must include instruction
in operation under normal conditions and emergency situations.
lRead all instructions before attempting to operate the equipment.
lUse this equipment only for its intended purpose.
lPersonnel working on or near this equipment must be instructed about the location and operation
of emergency stop buttons (ESTOPs).
lBefore starting the machine, check that:
oAll persons are clear of the machine
oNo maintenance work is being performed on the machine
oAll covers and guards are in place
oThe machine is free of scraps, jams, and foreign objects
lNever run the machine when any of the covers or guards are missing.
lKeep 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.
lWhen lifting covers, wait for all parts to stop moving before placing hands near paper path.
lAvoid touching moving parts or materials while the machine is in use. Before clearing a jam, be
sure machine mechanisms come to a stop.
lWhen removing jammed material, avoid using too much force to prevent personal injury and
damaging equipment.
lThe 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.
lIt is essential that personnel employ safe working practices and observe all related regulations and
legal requirements for safety when operating this product.
Safety
Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 4 of 328

Maintenance
lOperators must understand and adhere to safety precautions when working with the equipment.
lOnly qualified service personnel should service this equipment per local national requirements.
lService that requires removal of protective covering is performed by qualified service personnel.
lOnly setup maintenance, as described in the information provided, is to be performed by
operators.
lA setup tool is supplied for adjustments to accommodate different size paper on the inserter.
lUse only Pitney Bowes approved printer ink and cleaners.
lTo prevent overheating, do not cover the vent openings.
lDo not store flammable fluids inside this machine.
lDo not place any container with liquid on this machine, (i.e. coffee cups, soda, etc.)
lDo not use flammable cleaners in this machine.
lDo 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.
lDo not spray liquid onto or into any part of the machine. Use a cloth to apply cleaning solution.
Safety
Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 5 of 328

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 Shaft
Pinch hazard; rotating shaft. Keep hands clear during operation.
Caution: Pinch Point Rollers
Pinch hazard; moving belts and rollers in this area. Do not operate with cover open.
Caution: Hand Entanglement
Moving belts; use caution. Keep hands clear during operation.
Caution: Rotating Roller Hazard
Moving rollers; use caution. Keep hands clear of this area during operation.
Safety
Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 6 of 328

Caution: Hand Crush from Left
Crush hazard; force from the left. Use caution; keep hands clear during operation.
Caution: Hand Crush from Above
Crush hazard; force from above. Use caution; keep hands clear during operation.
Caution: Hand Crush
Crush hazard; use caution when working in this area.
Caution: Hot Surface
Burn hazard; hot surface inside. Allow to cool before servicing.
Caution: Motor Capacitor Discharge
Allow six minutes for motor capacitors to discharge before servicing motor driver
module.
Safety
Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 7 of 328

Warning! Severe Shock Hazard
Only authorized personnel should service this equipment. Turn power OFF before entry.
Caution: Hand Abrasion
Caution, moving belts. Keep hands clear during operation to avoid hand abrasion.
Caution: Hair Entanglement
Caution, rotating parts. Keep hair, jewelry, and loose clothing away during operation to
prevent potential injury.
Caution: Cut Hazard
Caution, sharp blades. Keep hands clear during operation.
Caution: Sharp Point
Caution, sharp points. Use care when working in this area; keep hands clear during
operation.
Safety
Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 8 of 328

Caution: Tip Over Hazard
When moving unit, push or pull in direction shown by arrow. Tipping over may cause
injury or damage to equipment.
Caution: Refer to Operator Guide
Read 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 Belts
Feeder 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 Gripper
To prevent potential injury do not put your hands near the infeed envelope conveyor
gripper area.
Safety
Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 9 of 328

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
Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 10 of 328

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:
lCovers that require a tool for access are to be opened by trained Service personnel only.
lIf 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
Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 11 of 328

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
Pitney Bowes Epic v3.1 (ZVE0) Operator Guide May, 2018 Page 12 of 328

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