Pitney Bowes Epic User manual

Shipping & Mailing
Inserting
Epic™ Select
Inserting System


Operator Guide
USEnglishEdition
SV63276-RevA
December10,2017

©2017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SelectInsertingSystem.ThisguidecoversEpicSelect
InsertersystemcomponentsfromtheBufferthroughtheOnEdgeStacker.Systeminputcontentcanbe
foundinrelatedoperatorguides.
Version History
DocumentPartNumber ReleaseDate Comments
SV63276RevA December10,2017 Initialrelease
  
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About this Book
Pitney Bowes Epic Select Operator Guide December,2017 Page iii of 6

1-Safety
SafetyInformation 2
Power 3
Operation 4
Maintenance 5
WarningLabelsandCautions 6
SafetyFeatures 10
2-ProductOverview
EpicSelectInsertingSystem 14
ComponentOverview 17
IndicatorLights 19
AbouttheRemoteControl 20
3-PowertheSystemOnandOff
PowerUptheSystem 22
PowerDowntheSystem 24
4-UsingDirectConnect
DirectConnectSoftwareOverview 28
DCMainScreen 29
ChangingtheUIDisplayLanguage 32
PoweringDowntheDCComputer 33
ViewingDCSoftwareDetails 34
LoggingInandLoggingOutofDC 35
LoadingaMode 37
SettingtheMailDate 39
CheckingStatuswithJobManager 40
AccessingReportsinDC 41
StartingandStoppingtheInserterUsingDC 42
AssigninganMRDFFile(FileBasedJobs) 43
Disabling(andEnabling)theInserter 44
ClearDeckFunction 45
AbouttheSpeedIndicatorsinDC 47
AbouttheDCAlarmMessageBox 48
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ThroatHeight 63
AboutEngineHorns 65
ChangingEngineHorns 66
ChangingEnvelopeSettings 71
SettingUptheRAT(RightAngleTransfer) 78
AdjustingAmountofSealerFluidApplied 80
SettingUptheVerticalStacker 82
AbouttheOnEdgeStacker(OES) 84
Table of Contents
Pitney Bowes Epic Select Operator Guide December,2017 Page iv of 6

SettingUptheEntrancetotheOnEdge
Stacker 86
CenteringMailontheOnEdgeStacker
ConveyorBelt 90
AdjustingtheBeltSpeedandStackPressure
ontheOnEdgeStacker 92
AdjustingOnEdgeStackerFingers 96
AdjustingtheEngineObservationSideGuides 98
AdjustingtheChassisSideGuides 101
AdjustingtheBufferChassisSideGuides 105
AdjustingtheChassisEntranceBrushHeight 107
AdjustingChassisMaterialCenterDeck
ControlStraps 108
SettingtheChassisCollationLength 111
SettingtheChassisSpeed 112
FrictionFeederMechanicalAdjustments 114
AdjustingtheFrictionFeederSeparator 115
AdjustingtheFrictionFeederSideGuides 118
AdjustingtheFeederPackControlRamp 121
RotaryFeederMechanicalAdjustments 123
UsingRotaryFeederSuctionCups 124
AdjustingtheRotaryFeederSideGuideand
Backstop 127
AdjustingtheRotaryFeederDeckPosition 129
SettingtheRotaryFeederFeedDeckAngle 131
AdjustingtheRotaryFeederSeparatorPins 133
UsingtheWedgeAccessoryontheRotary
Feeder 136
UsingtheJogFunctionontheRotaryFeeder 138
InsertFeederSoftwareAdjustments 142
EnablingandDisablingFeeders 143
DocumentInformation 144
SettingFeederFeedModes 148
SettingBackupFeeders(BackupFeed
Mode) 150
TransportEnvelopeSetup(XportSetup) 153
SettingSeparatorOptionsforFriction
Feeders 154
RecalibratingtheDoubleDetectFeature 156
6-JobChangeoverGuidelines
JobChangeoverGuidelines 158
AutoAdjustments 161
TransferInterfaceModule(TIM)Setup 164
7-RunningtheSystem
LoadingtheEnvelopeFeeder 174
ReloadingtheEnvelopeFeeder 176
LoadingtheInsertFeeders 179
ReloadingInsertFeeders(withthesystemis
running) 180
RemovingFinishedMailfromtheOnEdge
Stacker 181
RemovingMailfromtheFlatConveyor 184
AddingSealerFluid 185
8-ErrorRecovery
ErrorRecovery 190
AlarmsinDirectConnect 191
RemovingMaterialJamsintheBuffer 195
RemovingMaterialJamsintheFriction
Feeder 197
RemovingMaterialJamsintheRotary
Feeder 200
RemovingMaterialJamsintheEngine 202
RemovingMaterialJamsintheEnvelope
Feeder 207
Pitney Bowes Epic Select Operator Guide December,2017 Page v of 6

RemovingMaterialJamsintheSealeror
VerticalStacker#1 210
RemovingMaterialJamsintheTurnover 211
SettingUptheVerticalStacker 212
RemovingMaterialJamsintheOnEdge
Stacker 214
RemovingMaterialJamsintheFlatConveyor 215
9-Troubleshooting
Troubleshooting 220
EngineTroubleshooting 221
ChassisTroubleshooting 224
BufferTroubleshooting 229
10-Maintenance
OperatorMaintenance 232
ReplacingSuctionCupsintheEngine 234
BufferMaintenance 239
RotaryFeederMaintenance 240
FrictionFeederMaintenance 241
VerticalStackerMaintenance 242
OnEdgeStackerMaintenance 243
11-Specifications
EpicSelectEngine(ZVE2) 246
EnvelopeSpecifications 251
MPS/EpicFrictionFeeder(Y554) 263
EpicRotaryFeeder(Y558) 267
EpicBufferwithTNT(Y574) 272
EpicTurnover(Y371) 275
EpicV-Bin(Y31E,Y31F,Y31G,Y31H) 277
EpicOnEdgeStacker(Y396) 279
EpicShinglingStacker(Y32S) 281
EpicEdgeMarkers(Y367,Y368,Y369) 282
EnvironmentalOperatingConditions 284
NetworkandPowerRequirements 285
AirRequirements 287
Pitney Bowes Epic Select Operator Guide December,2017 Page vi of 6

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 Select Operator Guide December,2017 Page 2 of 288

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 Select Operator Guide December,2017 Page 3 of 288

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 Select Operator Guide December,2017 Page 4 of 288

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
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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
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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
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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
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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 Select Operator Guide December,2017 Page 9 of 288

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
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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
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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 Select Operator Guide December,2017 Page 12 of 288

2 - Product Overview
Inthissection
EpicSelectInsertingSystem 14
ComponentOverview 17
IndicatorLights 19
AbouttheRemoteControl 20

Epic Select Inserting System
TheEpicSelectInsertingSystemiscapableofprocessingupto21,000transactionalmailpiecesper
hour,dependingontheapplicationandconfigurationsoftheinserter.Thesystemprocesstri-fold/C-fold
andhalffoldsmaterialandiscontrolledbyDirectConnect(DC)software.

EpicSelectInsertingSystem
Product Overview
Pitney Bowes Epic Select Operator Guide December,2017 Page 14 of 288