Pitney Bowes F65A Manual

Feeder/Loader
F65A/B
Operator Guide
English Version

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Introduction
This manual contains instructions on the operation and maintenance of this machine. To
get the maximum versatility from this machine all operators should carefully read and fol-
low the instructions in this manual. Keep this manual in a handy place near the machine.
Please read the Safety Information before using this machine. It contains information re-
lated to USER SAFETY and PREVENTING EQUIPMENT PROBLEMS.
How to read this manual
Notation conventions
Whenever necessary, the following points for attention are indicated in this manual.
WARNING:
Indicates a potentially hazardous situation which, if instructions are not followed, could
result in death or serious injury.
CAUTION:
Indicates a potentiality hazardous situation which, if instructions are not followed, may
result in minor or moderate injury or damage to machine or property.
Note
This sign refers to:
• Remarks for making the operation much easier. You get practical hints or knowledge to
assist you in the machine operation such as:
• Preparations required before operating
• How to prevent papers from being misfed or damaged
• Precautions required or actions to take after misoperation
• Limitations like numerical limits, functions that cannot be used together or conditions,
under which a particular function cannot be used or obtained.
• Information.
[ ]
Keys that appear on the machine’s display panel.
It is certied that the system complies with all applicable Directives of the
European Union.
For a formal Declaration of Conformity please contact Compliance Engineering. Contact
information is given in the front of this guide or on a separate document supplied with your
system.
Note
The domestic environment is an environment where the use of broadcast radio and televi-
sion receivers may be expected within a distance of 10 m of the apparatus concerned.
WARNING:
• Electromagnetic compliance:
• This is a Class A product. In a domestic environment this product may cause radio
interference in which case the user may be required to take adequate measures.
• The product (System) which is connected to this machine will be class A.

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Safety
Follow the normal safety precautions for all o󰀩ce equipment:
• Use only Pitney Bowes approved supplies, in particular aerosol dusters. Improper stor-
age and use of aerosol dusters or ammable aerosol dusters can cause an explosive-
like condition that could result in personal injury and/or property damage. Never use
aerosol dusters labeled ammable and always read instructions and safety precautions
on the duster label.
• To obtain supplies, please contact our Supply Line™ to place orders. Material Safety
Data Sheets can be obtained on the web or from our Supply Line™. Refer to the Con-
tact Information List for more information.
• Use the power cord supplied with the machine and plug it into a properly grounded wall
outlet located near the machine and easily accessible. Failure to properly ground the
machine can result in severe personal injury and/or re.
• Avoid touching moving parts or materials while the machine is in use. Keep hands,
loose clothing, jewellery and long hair away from all moving parts.
• Do not remove covers or defeat safety interlock switches. Covers enclose hazardous
parts that should only be accessed by properly trained service personnel. Immediately
report to service any damaged or non-functioning components that renders the unit
unsafe.
• Place the unit in an accessible location to allow for proper venting of the equipment and
to facilitate servicing.
• The power cord wall plug is the primary means of disconnecting the machine from the
AC supply.
• Do not use an adapter plug on the line cord or wall outlet.
• Do not remove the ground pin from the line cord.
• Avoid using wall outlets that are controlled by wall switches, or shared with other equip-
ment.
• Do not route the power cord over sharp edges or trap between furniture.
• Ensure there is no strain on the power cord and that it does not become jammed be-
tween the equipment, walls or furniture.
• Be certain the area in front of the wall receptacle into which the machine is plugged is
free from obstruction.

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• Before clearing a stoppage, be sure machine mechanisms come to a stop.
• When removing stalled material, avoid using too much force to protect against minor
personal injury and damaging equipment.
• To prevent overheating, do not cover any vent openings.
• Operation of this equipment without periodic maintenance will inhibit optimum operat-
ing performance and could cause the equipment to malfunction. Contact your machine
supplier for required service schedule.
• Read all instructions before attempting to operate the equipment.
• Use this equipment only for its intended purpose.
• Always follow the specic occupational safety and health standards for your workplace.

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TABLE OF CONTENTS
What You Can Do With This Machine ............................................................................................ 9
Guide To Components .................................................................................................................. 11
F65A/B Feeder/Loader ............................................................................................................... 11
High Capacity Loader ................................................................................................................. 12
User Interface ............................................................................................................................. 12
1. Operation
Operation........................................................................................................................................ 13
F65A/B setup .............................................................................................................................. 13
Power Up..............................................................................................................................................13
Program selection...............................................................................................................................14
Loading orientation.............................................................................................................................14
Feeder side guides adjustment..........................................................................................................15
Loading the Feeder .............................................................................................................................15
Set the scanning head ........................................................................................................................16
Side to side adjustment of OMR scanners .......................................................................................16
Side to side adjustment of BCR scanners........................................................................................17
Setting material guide ngers............................................................................................................17
Feeder head adjustment.....................................................................................................................18
Transport material to accumulator ....................................................................................................19
Setting the accumulator side guides.................................................................................................19
Accumulator ramp adjustment ..........................................................................................................20
Start the Job ........................................................................................................................................20
High capacity loader setup ......................................................................................................... 21
Transport material to feeder...............................................................................................................21
Setting the loader side guides ...........................................................................................................22
2. Main menu
Job Handling.................................................................................................................................. 23
New non scanning job ................................................................................................................ 23
Program name .....................................................................................................................................23
Choice of material ...............................................................................................................................24
Number of sheets in one batch..........................................................................................................24
New scanning job ....................................................................................................................... 25
OMR job example ................................................................................................................................25
Program name .................................................................................................................................25
Choice of material ............................................................................................................................25
Version (scan method example OMR Plockmatic)...........................................................................25
OMR location (scanner postion).......................................................................................................26
Scan line increment..........................................................................................................................26
Scan line increment..........................................................................................................................26
Bypass advanced settings ...............................................................................................................27
Step by step example.......................................................................................................................27
BCR job example.................................................................................................................................29
Program name .................................................................................................................................29
Choice of material ............................................................................................................................29
Version (scan method example BCR-1D Plockmatic)......................................................................29
BCR location (scanner position).......................................................................................................29
Set integrity ......................................................................................................................................30
Select feed .......................................................................................................................................30
Optional functions ............................................................................................................................30
Bypass advanced settings ...............................................................................................................30
Version (scan method example BCR-2D Plockmatic)......................................................................30
BCR location (scanner position).......................................................................................................31
Job id................................................................................................................................................31
Set integrity ......................................................................................................................................31
Select feed .......................................................................................................................................31

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Optional functions ............................................................................................................................31
Bypass advanced settings ...............................................................................................................31
Modify job ................................................................................................................................... 32
Delete job.................................................................................................................................... 32
3. Settings
OMR ................................................................................................................................................ 33
Safety functions .......................................................................................................................... 33
IGNore (IGN).........................................................................................................................................33
PARity Even (PARe) ............................................................................................................................33
PARity Odd (PARo)..............................................................................................................................33
Wrap Around Sequence (WAS) ..........................................................................................................33
ALWays 0 (ALW0) ................................................................................................................................34
ALWays 1 (ALW1) ................................................................................................................................34
Set Integrity (SI)...................................................................................................................................34
Set SeQuence (SSQ) ...........................................................................................................................34
Machine control functions ........................................................................................................... 35
Beginning Of Collation (BOC)............................................................................................................35
End Of Collation (EOC).......................................................................................................................35
Selective Feed 1 to 7 (SF1 to 7)..........................................................................................................35
Hand Feed Last (HFl) ..........................................................................................................................35
Hand Feed First (HFf)..........................................................................................................................35
DiVert Finished (DVF)..........................................................................................................................36
DiVert to Deck (DVD)...........................................................................................................................36
STop (ST)..............................................................................................................................................36
4. Trouble shooting
Clearing paper jam ..................................................................................................................... 37
Paper feeding ............................................................................................................................. 38
Stream feed..........................................................................................................................................38
Double feed..........................................................................................................................................38
Low performance ................................................................................................................................38
5. General Remarks
Do’s And Don’ts............................................................................................................................. 39
6. Specications
Machine Specications................................................................................................................. 41
F65A/B Feeder incl. High capacity loader .................................................................................. 41
OMR............................................................................................................................................ 42
Application functionality ....................................................................................................................42
Physical specication.........................................................................................................................42
OMR reading area................................................................................................................................43
Top reading ......................................................................................................................................43
Bottom reading.................................................................................................................................44
Custom top and bottom with a camera like scanner ........................................................................45
Barcode ...................................................................................................................................... 46
Application functionality ....................................................................................................................46
2D application functionality ...............................................................................................................46
Barcode reading area..........................................................................................................................47
Top and bottom loading....................................................................................................................47

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What You Can Do With This Machine
The System Overview shows the Loader, Feeder and User Interface as it is designed for
the DI880 System.
The F65A/B is capable of loading about 200 sheets of 80g paper. The High Capacity
Loader expands the capacity with up to 4000 sheets. They are easy to handle and allow
the User to load paper at any time without interruption of the production ow. The handling
of the system is interactive and guided by the HMI Console. Program selection and status
signaling as well as start, stop and other actions are accessible. The necessary adjust-
ments are the side guides close to the separation and the ones in the accumulator.
OMR - Optical Mark Recognition or Optical Mark Reading (optional) is available as is BCR
and 2D. The interpreting facility in the DI880 system is completely exible and program-
mable to match any code and ensures individual handling of each set and guarantees the
integrity of each sheet fed.
The F65A/B Sheet Feeder/Loader, F651 Inserter, F657 Folder and F653 Mailfeeder, form
a direct mail inserting system. The F651 is the inserting and sealing unit of the system.
F657 is a multi function folder that can do half-, C-, Z-, and double fold of 1 - 10 sheets.
F653 is the feeding unit of the system and can feed from up to eight individual sources.
The (single or rightmost) F653 Mailfeeder is equipped with at least one of the following
separately delivered modules: The F654 Tower Feeder, the F655 Booklet Feeder and
the F652 Accumulator. The F652 Accumulator module receives material from an external
feed source and merges it with the material from the Tower and Booklet Feeder. The F652
makes it possible to run the system with a upstream device such as a secondary F653
Mail Feeder or a printer/copier. Contact your sales representative for currently available
congurations.
The mail inserting system has a capacity to handle booklets with a thickness up to 8 mm
(⅓”) and envelopes lled to a thickness up to 12 mm (½”).
Intuitive touch screen user interface (optional) that graphically visualizes and facilitates set
up and adjustments is available.
User Interface
High Capacity Loader Feeder

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Guide To Components
F65A/B Feeder/Loader
The separation adjustment is very important for smooth workow. If it is too wide, double
feed errors will occur and if it is too narrow the system will slow down and the material
edge could be a󰀨ected.
In case of a jam, the feeder head lock can be released and material removed.
Separation
Adjustment
User Interface
Feeder Belt
Ramp Dump Motor
Feeder Head
Locking
Ramp Material
Sensor
Dump Exit
Sensor
O-ring Motor
Accumulator Side
Guide Adjustment
Double Feed
Sensor
Eject Motor
Retard Roller
Motor
Material Height
Sensor
Side Guides
Adjustment
Accumulator Side
Guides

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High Capacity Loader
There are only two adjustments necessary: the side guides for size and the distance be-
tween ramp and the feeder.
User Interface
To interact with the system a User Interface is present. Usually just a Job is selected and
then started or a CONFIRMATION of an error is required (e.g. no material). Jobs are also
programmed with this device and all the required settings have to be dened for an initial
setup of the system.
Start Exit Job Interrupt Job or Clear Deck
(depending on the mode displayed function
Display 2 x 20 Character
Ramp Motor
Transport Motor
Transport Belt Side Guides
Side Guides Adjustment
Ramp Belt
or
Select (scroll)

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1. Operation
Operation
To run the F65A/B correctly, some adjustments are necessary. There is the mechanical
setup, the scanner setup and the job (i.e. program) selection.
F65A/B setup
The most e󰀩cient method is to go through the pre-run adjustments. If you are starting a
di󰀨erent job than was running before, you will be guided through these adjustments. In this
chapter we show the basic settings to run an already programmed job.
First of all the power switch has to be in the “ON” position.
Power Up
Make sure all covers are closed. Turn the main Power Switch ON. The User Interface will
momentarily display the current software version number and then proceed to a listing of
available programs. The Exit (blue) indicator will be lit.
The User Interface momentarily displays the Firmware Version.
*** PITNEY BOWES F65AB
***
*** Version 825.001.10 ***
030> EXAMPLEJOB Paper/ DF BCR <PROG
Then the default Menu shows the last job run.
1. Operation

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1. Operation
029> OMREX Paper/ DF OMR <PROG
030> EXAMPLEJOB Paper/ DF BCR
1. Check loading Orientation
GREEN=CONFIRM BLUE=EXIT
Program selection
To select a program, scroll until it appears on the rst line of the display as indicated by the
arrow <PROG prompt. Press GREEN to select the program.
You are asked about running pre-run adjustments. If this is a new job, press Green and
carry out the adjustments as described. If pre-run adjustments have already been carried
out or if this is a current job, press Red. If you skip the pre run adjustment you go straight
to Start the Job below.
Loading orientation
The four possible loading orientations are shown upon program selection:
The rst check asks you to make sure the material orientation is correct.
The four possible loading orientations are:
1. Face up, bottom rst
2. Face up, top rst
3. Face down, bottom rst
4. Face down, top rst
When feeding individual pieces of material during setup or when loading material prior to a
job run, it is important to observe the correct loading orientation for the program selected.
Press GREEN to go to the next step.

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1. Operation
Feeder side guides adjustment
The display shows the second instruction:
Loading the Feeder
Load sheets to the approximate level as illustrated. Loading too many sheets might
cause excess friction between the sheets at the bottom of the stack and sheets might get
damaged.
2. Feeder side guide adjustment
GREEN=CONFIRM BLUE=EXIT
Rotate the feeder Side Guide adjustment wheel anticlockwise until the side guides give ap-
proximately 3mm of clearance between the material and the side guides.
Press GREEN to go to the next step. If you have a non scanning job, the next step will be
Feeder Head adjustment, otherwise for the scanning jobs you just continue.

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1. Operation
Set the scanning head
The OMR scanner has to be in the middle of the OMR Code ow. Make sure that the scan-
ner is as close as possible to the paper (reading quality is much better).
3. Adjust the OMR Scanner
GREEN=CONFIRM BLUE=EXIT
Place a test sheet of paper on the feeder and adjust the position.
Use the Material Guide Fingers (see below) to facilitate reading of OMR code on curled
paper.
OMR Light indicates e󰀨ective reading position
Side to side adjustment of OMR scanners
The OMR scanners can be mounted on either side of the separation head and also from
the bottom of the feeder for bottom up scanning.

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1. Operation
Side to side adjustment of BCR scanners
The BCR scanner is positioned in front of the separation head and can be positioned with-
out any tools. Be aware that the scanner needs a minimum distance to the code.
Setting material guide ngers
If the paper is curled, you can use the material guide ngers. Always use two guide ngers
and place them above the curled material.

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1. Operation
Feeder head adjustment
Ensure that the feeder separation head is at its base position. The black and red lever (A)
has to be in a horizontal position and stepped in with a click.
The following message is shown on the display:
3. Feeder head adjustment
GREEN=CONFIRM BLUE=EXIT
Lower the separator by adjusting knob (B) clockwise until only one piece of material ts
beneath it without leaving space for a second.
The single piece should t without any force under the separation. Close the gap until you
cannot move the paper easily, then turn 3 to 5 clicks backwards. The second piece should
still not be able to get under the separation, whereas the rst piece can be moved.
A
B

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1. Operation
Transport material to accumulator
Turn the Accumulator Side Guide adjustment wheel anticlockwise to open the accumulator
side guides as wide as needed. Load one piece of material and press Run /conrm (green)
until it is fed into the accumulator.
The display shows the message:
4. Transport material to Accumulator
GREEN=Transport BLUE=EXIT
Setting the accumulator side guides
With the paper in the accumulator you can adjust the side guides and leave gap of 2-3 mm
on each side. The display shows:
5. Accumulator side guide adjustment
GREEN=CONFIRM BLUE=EXIT
Rotate the Accumulator Side Guide adjustment wheel clockwise to set the Accumulator
Side Guides. The correct setting allows approximately 3mm overall clearance so that the
material is controlled but not restricted by the guides

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1. Operation
Start the Job
If you nished the pre run adjustments (or skipped them) you will have a short overview of
your job on the display:
OMREX Paper /DF OMR Overcount:*25
Count: 00 Total:00000 Speed:100%
Accumulator ramp adjustment
The ramp adjustment is achieved in the same step.
The yellow mark should be visible if a piece of material is in the accumulator.
By using the select button you can change the speed of the system down to 25% in 5%
steps. To start the system, press GREEN for more than 2 seconds (if you press it for less
time, just one piece will be fed)
If an error occurs, a conrmation is expected by pressing the GREEN button.
If you need to use the outermost position of the Accumulator Side Guides, you have to lift
the o-rings to clear the side guides while adjusting.