Pitney Bowes OFFICERIGHT DI200 Manual

Operator Guide
OfficeRight
™
Inserting System
DI200

SV40189-OG Revision C February 2005 ©2005 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.
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.
Due to our continuing program of product improvement, equipment and material
specifications as well as performance features are subject to change without
notice.
OfficeRight is a trademark and E-Z Seal is a registered trademark of Pitney
Bowes.
Statement of FCC Compliance
This equipment has been tested and found to comply with the limits for a Class
A digital device, pursuant to part 15 of the FCC rules. These limits are designed
to provide reasonable protection against interference when the equipment is
operated in a commercial environment. This equipment generates, uses, and
can radiate radio frequency energy and, if not installed and used in accordance
with the instruction manual, may cause interference to radio communications.
Operation of this equipment in a residential area is likely to cause interference,
in which case the user will be required to correct the interference at his own
expense.
Canada
This class A digital apparatus complies with Canadian ICES-003.
Cet appareil numérique de la classe A est conforme á la norme NMB-003 du
Canada.
CAUTION: Changes or modifications to this equipment not expressly approved
by the party responsible for compliance (Pitney Bowes) could void the user’s
authority to operate the equipment.

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OfficeRight™ DI200 Operator Guide (SV41289-OG Rev. C)
Contents
1. Introduction
Important Safety Information.......................................................4
About Your Machine .................................................................... 5
Machine Configurations ..............................................................5
Machine Controls, Indicators and Features ................................6
The Controls ...............................................................................8
2. Preparing and Loading
Connecting Power and Turning On ...........................................10
Filling the Moistener..................................................................11
Loading the Sheet Feeders (Feeders A1 and A2) ....................12
Loading the Envelope Feeder (Feeder B) .................................13
Loading the Insert Feeder (Feeder C).......................................14
3. Running Jobs
Job Listing.................................................................................15
Job 1: One Folded Sheet into an Envelope ..............................17
Job 2: One Folded Sheet, No Envelope (Fold Only) .................18
Job 3: One Folded Sheet + One Insert into an Envelope .........19
Job 4: One Insert into an Envelope........................................... 21
Job 5: Two Folded Sheets into an Envelope .............................22
Job 6: Two Collated, Folded Sheets into an Envelope..............23
Job 7: Two Folded Sheets, No Envelope (Fold Only)................24
Job 8: Two Collated, Folded Sheets, No Envelope
(Fold Only)..............................................................................25
Job 9: Two Folded Sheets and an Insert into an Envelope....... 26
Job 10: Two Collated, Folded Sheets and an Insert into an
Envelope ................................................................................28
The Manual Feeder M...............................................................30
4. Advanced Menu Options
Reset Counter...........................................................................31
Change Paper Size ...................................................................32
Move the Address in the Window..............................................32
Sheet Double Detect On/Off ..................................................... 33
Insert Double Detect On/Off......................................................34
Safe Seal On/Off.......................................................................34
5. Reference
Error Messages.........................................................................35
General Troubleshooting ...........................................................39
Clearing Material Jams .............................................................40
Getting Help .............................................................................41
Ordering Supplies .....................................................................42
Material Specifications .............................................................. 43
Machine Specifications .............................................................44
Index .....................................................................................45
Page

4
OfficeRight™ DI200 Operator Guide (SV41289-OG Rev. C)
Safety
• Please read all the instructions in this manual before you attempt
to operate your OfficeRight™ DI200. Save all instructions.
WARNING! Always use the power cord sup-
plied with your machine and plug it into a
prop-
erly grounded wall outlet that’s located near the
machine and easily accessible. Failure to properly
ground the machine can result in severe personal
injury and/or fire.
• DO NOT use a wall outlet controlled by a wall switch or one that
is shared with other equipment.
• Do not use an adapter plug on the line cord or wall outlet.
• Do not remove the ground pin from the line cord.
• Make sure the area in front of the wall outlet into which the ma-
chine is plugged is free from obstruction.
• DO NOT route the power cord over sharp edges or trap it be-
tween pieces of furniture. Make sure there is no strain on the
power cord.
• To reduce the risk of fire or electrical shock, DO NOT attempt to
remove covers or disassemble the inserter. The cabinet encloses
hazardous parts. Refer servicing to qualified personnel.
• Keep fingers, long hair, jewelry and loose clothing away from
moving parts at all times.
• Never reach into the machine while it is running. Avoid touching
moving parts or materials while the machine is in use. Before
clearing a jam, be sure all machine mechanisms come to a com-
plete stop.
• Know your equipment, especially how to stop it in the event of an
emergency.
• When removing jammed material, avoid using too much force to
protect against minor personal injury and damage to the equip-
ment.
• Use the equipment only for its intended purpose.
• Always follow the specific occupational safety and health stan-
dards prescribed for your workplace.
CAUTION! If you relocate an OfficeRight™ DI200
that has the optional Second Sheet Feeder A2
installed, remove it from the Second Sheet Feeder
first—that is, as you lift it clear, make sure it fully
disengages from the Second Sheet Feeder. Obtain
help if necessary.
Important Safety Information
1. INTRODUCTION

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OfficeRight™ DI200 Operator Guide (SV41289-OG Rev. C)
Your new OfficeRight™ DI200 is a compact folding and inserting
machine designed to speed the process of mail creation.
It has a minimal number of user adjustments and an intuitive, easy-
to-use control panel. This greatly simplifies machine operation and
will enhance the productivity of your mailing operation.
There are two configurations of the OfficeRight™ DI200 available.
The basic model is supplied with an insert feeder and one sheet
feeder. The second configuration is supplied with an insert feeder
and two sheet feeders.
Introduction
Machine Configurations
About Your Machine
Configuration 1
Basic machine with insert
feeder and one sheet feeder
insert feeder
Configuration 2
Machine with insert feeder
and a 2nd sheet feeder added
2nd sheet
feeder
insert feeder

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OfficeRight™ DI200 Operator Guide (SV41289-OG Rev. C)
1 2
3
4
5
6
7
12
11
10
9
8
1. Insert Cover E Release Button (Blue Button Marked E)
Press this button to release the insert cover if a jam occurs in
this area of the machine. The display prompts you if you need to
open this cover to remove jammed material.
2. Insert Feeder (Not on All Models)
Use this feeder to add additional inserts to your envelope.
Material fed from this feeder cannot be folded by the inserter.
However, this feeder is especially suited to feeding pre-folded or
thicker inserts.
3. Operating Guide Slot
Store this Operating Guide in the slot provided so that it doesn’t
get lost and is readily available when you need it.
4. Control Panel
This is where you enter commands and where the machine in-
forms you of its status. See pages 8 and 9 for a full explanation
of what each button does.
Machine Controls, Indicators and Features
Introduction

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OfficeRight™ DI200 Operator Guide (SV41289-OG Rev. C)
5. Moistener Tank
This tank contains E-Z Seal®solution or water to moisten and
seal envelope flaps. It slides out to the right for refilling and has
an oval level indicator window at the front so you can easily
check fluid level.
6. Lifting Handles (One Each Side)
Always lift the OfficeRight™ DI200 using the side handles. DO
NOT lift the machine by any of the feeders or the stacker.
7. Second Sheet Feeder A2 (Optional)
You can add this feeder to the machine to enable folding and
inserting of a second sheet into the envelope. It functions in
exactly the same way as the standard sheet feeder, A1.
IMPORTANT: When you use both sheet feeders
A1 and A2 together, always load the address bear-
ing sheet into sheet feeder A2. If you fail to do this,
the address won’t show in the envelope window.
Always load sheets into feeder A2
face down and
bottom edge first, that is, with the bottom edge of
the sheet furthest into the machine.
8. Standard Sheet Feeder A1
This feeder enables folding and inserting of a sheet into the
envelope. Always load sheets into this feeder face down and
bottom edge first.
9. Manual Feeder M
Use this feeder to manually feed stapled sets of up to three
sheets each. The machine waits for you to feed each set by
hand into this feeder before it folds and inserts the set automati-
cally. Always feed sheets into this feeder face down and bottom
edge first, that is, with the bottom edge of the sheet furthest into
the machine.
10. Stacker
The machine delivers finished pieces to this area.
11. Front Cover D Release Button (Blue Button Marked D)
Press this button to release the front cover if a jam occurs in
this area of the machine. The display prompts you if you need to
open this cover to remove jammed material.
12. Envelope Feeder B
This feeder feeds envelopes into the inserting area where they
are filled with sheets or inserts from other feeders.
Introduction

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OfficeRight™ DI200 Operator Guide (SV41289-OG Rev. C)
Feeder A1
Menu / Enter
no yes
Feeder A2
2nd Page
Seal
No Seal
Trial Piece Stop
Start
Envelope Fdr B
Insert Fdr C
Fold Only
1. Display
Shows the current status of your OfficeRight™ DI200 and dis-
plays prompts or error messages which help you in operating
the machine.
2. Menu/Enter
Press this button to enter the menu options. Options available
are:
• Reset Counter
• Change Paper Size. Choose 11” (letter size) or 14” (legal
size)
• Move Address in Window
• Turn Sheet Double Detection On/Off
• Turn Insert Double Detection On/Off
• Turn Safe Seal On/Off
3. yes and no buttons
Once you’ve entered the menu using Menu/Enter, press these
buttons to answer yes or no to prompts.You also use them to
change (increase or decrease) settings offered by menu op-
tions.
1
2
3
4
57
6
The Controls
Introduction

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OfficeRight™ DI200 Operator Guide (SV41289-OG Rev. C)
4. Selection Buttons and Indicator Lights
Press these buttons to step through the feeders and options
that are available on your machine.
Depending on your model configuration, some indicator lights
and associated feeders may be inoperable. If your model
doesn’t have a second sheet feeder, for example, the indicators
associated with this feeder will not light. This is normal.
A
green indicator shows that a feeder or function is selected for
use.
A red indicator shows that you selected an invalid (impossible)
combination of functions. Simply correct the error in selection and
the indicator(s) will change back to green.
An
unlit indicator means that the feeder or function is turned OFF.
5. Trial Piece
After you’ve set up a job using the control panel, you
must run
a trial piece. If you press Start before running a trial piece, the
machine display will prompt you to run a trial piece first.
Press this button to run one fully collated piece as programmed
via the control panel. The envelope will not seal regardless of
whether the system has been told to seal or not. This allows
you to inspect the processed job to make sure that everything is
inserted correctly and that the address appears in the window.
The trial piece also allows the system to calibrate itself and set
its double detect feature, if selected.
IMPORTANT: Running the trial piece is an
es-
sential function for the machine to perform. You
must do it before a start every time you use a
new batch of material. This allows the system to
re-calibrate in case different batches of material
vary slightly.
6. Start
Press to begin automatic operation.
7. Stop
Press to stop automatic operation at the end of the next cycle.
About the Sleep Mode
After 10 minutes of inactivity, the system enters a power-saving
“sleep mode” and displays Powersave On. Pressing any button
will wake the machine up. The machine remembers the last job
setup.
Introduction

10
OfficeRight™ DI200 Operator Guide (SV41289-OG Rev. C)
This chapter explains how to connect and load the machine.
Once you understand the subjects covered in this chapter, you can
quickly set up and use the machine for a variety of jobs as explained
later in Chapter 3,
Running Jobs .
IMPORTANT: Before running a job, make sure your material meets
our published specifications (see Specifications on page 43). This
helps assure reliable operation and greatest productivity.
WARNING! Read all the safety information on page 4 before con-
necting the machine.
Connect the power cord to the socket on the back of the machine.
Plug the power cord into a suitable power outlet. Make sure the
power outlet is near the machine and is easily accessible.
Turn the power switch ON. After a few seconds, the display shows
Ready.
When turned ON, the machine remembers the last job setup, but
resets the item counter back to zero automatically.
Loading
2. PREPARING AND LOADING
Connecting Power and Turning On
IMPORTANT: When the machine is first turned ON, the message
“Check Moistener’” appears on the display until any other button is
pressed. This is only a reminder. As an additional reminder, this mes-
sage appears every 1,000 cycles at the end of a batch or when the
Stop button is pressed.

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OfficeRight™ DI200 Operator Guide (SV41289-OG Rev. C)
Refill the moistener when the fluid gets low. Check fluid level through
the oval viewing window (figure, below right).
Slide the moistener out to the
right.
IMPORTANT: Never open the
moistener while the machine is
processing material.
Carefully fill the moistener with E-Z
Seal®solution or water up to the
“Max” mark in the filler funnel.
We recommend E-Z Seal®to
minimize algae growth and scale
buildup.
Slide the moistener back into the machine.
From the dry state, the moistener will take about five minutes to be-
come fully wet and ready for use.
Loading
Filling the Moistener

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OfficeRight™ DI200 Operator Guide (SV41289-OG Rev. C)
Sheet Feeder A1 is common to all models and is located immediately
below the Manual Feeder M. Sheet Feeder A2 is an option on all
models. It allows the machine to insert a second folded sheet into an
envelope.
Both feeders are used for sheets that require folding before inserting.
Load both feeders in exactly the same way.
Always fan (aerate) sheets before
you load them. This prevents them
from sticking together.
Then tap the stack of sheets onto
a firm surface to align the edges.
Place the sheets into Sheet
Feeder A1 or A2 as required.
IMPORTANT:
Always load sheets
into these feeders
face down and bot-
tom edge first. The
bottom edge of the
sheet is furthest
into the machine.
If you’re using both Sheet Feeders
A1
and A2 at the same time, you
must load the document printed
with the address into Sheet Feed-
er A2. If you load the address-
bearing document into Sheet
Feeder A1,
the address won’t be
visible in the envelope window.
Slide the back stop in until it just
touches the paper stack.
Loading
Loading the Sheet Feeders (Feeders A1 and A2)

13
OfficeRight™ DI200 Operator Guide (SV41289-OG Rev. C)
Always fan (aerate) envelopes
before you load them. This
prevents them from sticking
together.
Then tap the stack of envelopes
onto a firm surface to align the
edges.
IMPORTANT:
Load envelopes right way up and
facing you. This means that the
envelope flap is on the back of
the envelope and at the top. Any
other orientation will prevent the
machine from inserting properly.
Place the envelope stack into
Feeder B with the back envelope
flat against the feed belts. There’s
no need to “shingle” or stagger
the envelope stack.
Slide the two side guides up to
the envelope stack then slightly
back them off. Use the blue
handles at the rear of the guides
when moving them.
The correct setting is achieved
when the guides control the
envelopes but in no way restrict
their feed into the machine or
cause them to feed at an angle
(skew).
IMPORTANT: If the guides are too tight, envelopes may not feed
reliably; if the guides are too loose, envelopes may skew as they feed
into the machine.
Loading
Loading the Envelope Feeder (Feeder B)

14
OfficeRight™ DI200 Operator Guide (SV41289-OG Rev. C)
Insert Feeder C is only available on certain machine configurations.
Use this feeder to add additional inserts to your envelope that do
not
require folding by the machine. Feeder C is especially suited
to feeding pre-folded or thicker inserts such as business reply
envelopes (BREs), response cards and similar materials.
Always fan (aerate) inserts before
you load them. This prevents them
from sticking together.
Then tap the stack of inserts onto a
firm surface to align the edges.
Place the insert stack into Feeder C.
IMPORTANT: The orientation of
the insert stack depends on the
nature of the material being run.
For pre-folded inserts, it’s normally
best to load with the “closed” edge
feeding first. You can usually load
business reply envelopes right way
up and facing you. However, if the
flaps are pulled open when feeding,
try loading the envelopes with the
flaps down and facing you.
Slide the two side guides up to
the insert stack then slightly back
them off. Use the blue handles
at the rear of the guides when
moving them.
IMPORTANT: The setting is
correct when the guides control
the inserts but in no way restrict
their feed into the machine or
cause them to feed at an angle
(skew). If the guides are too tight,
inserts may not feed reliably; if
they are too loose, inserts may
skew as they feed into the machine.
Loading
Loading the Insert Feeder (Feeder C)

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OfficeRight™ DI200 Operator Guide (SV41289-OG Rev. C)
Chapter 1 explained the main features of the machine and how to use
the control panel. Chapter 2 described how to turn the machine ON
and load the feeders and moistener unit.
This chapter assumes you understand the content of the previous
chapters. It includes illustrations that identify the various jobs you can
run on your OfficeRight™ DI200, and then gives a table of quick steps
to set up and run each job.
Once you’re familiar with the machine, use this chapter as a quick
reference when you have to change a job setup.
The Manual Feeder M is used to feed stapled sets of up to three sheets
by hand. See page 30 for an explanation of how to set up and use this
feeder.
envelope
1 folded sheet
JOB 1 Page 17
1 folded sheet
no envelope (fold only)
JOB 2 Page 18
JOB 3 Page 19 JOB 4 Page 21
envelope
1 insert
1 folded sheet
envelope
1 insert
Running
ALL MODELS
MODELS with an INSERT FEEDER C
3. RUNNING JOBS
Job Listing

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OfficeRight™ DI200 Operator Guide (SV41289-OG Rev. C)
MODELS with an OPTIONAL SECOND SHEET FEEDER A2
JOB 5 Page 22 JOB 6 Page 23
MODELS with an INSERT FEEDER C and SECOND SHEET
FEEDER A2
JOB 9 Page 26 JOB 10 Page 28
envelope
2 folded sheets
envelope
2 folded sheets
(collated)
JOB 7 Page 24 JOB 8 Page 25
2 folded sheets
no envelope (fold only)
2 folded sheets
(collated)
no envelope (fold only)
envelope
1 insert
2 folded sheets
envelope
1 insert
2 folded sheets
(collated)
*see note below
*see note below
NOTE: Jobs marked with an asterisk (*) use the second sheet feeder,
A2, in “2nd Page” mode to feed 2-sheet collated sets. You must load
sheets into the feeder in their collated sequence: first page, second
page, first page, second page, etc., just as they are printed by a
typical office laser printer.
Running
*see note below

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OfficeRight™ DI200 Operator Guide (SV41289-OG Rev. C)
Model Required: Any OfficeRight™DI200
Notes: If your machine has the optional 2nd
sheet feeder A2, you can use it instead of A1,
as long as you load and select it as described in
steps 1 and 3 below.
Step Action Tip More Details…
1 Make sure paper size Choose 11” or 14” Page 32
setting is correct
2 Load sheets Load face down Page 12
into Sheet Feeder and bottom edge first
A1
3 Load envelopes Load right way up Page 13
into Feeder B and facing you
4 Press button Make sure green Page 8, 9
to select Feeder A1 indicator lights
5 Press button to Make sure green Page 8, 9
select Envelope indicator lights
Fdr B
6 Press button to Make sure moistener has Page 8, 9
choose Seal or E-Z Seal®or water
No Seal
7 Press Trial Piece
Trial piece will not Page 8, 9
button and check seal—this is normal
trial piece
8 Press Start button Stop button will stop Page 8, 9
to run job machine at end of cycle
Problems? See
Error Messages, page 35, and Troubleshooting , page 39
Job 1
envelope
1 folded sheet
One Folded Sheet into an
Envelope

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OfficeRight™ DI200 Operator Guide (SV41289-OG Rev. C)
Job 2
One Folded Sheet, No Envelope
(Fold Only)
Model Required: Any OfficeRight™DI200
Notes: If your machine has the optional 2nd
sheet feeder A2, you can use it instead of
Feeder A1, as long as you load and select it as
described in steps 1 and 3 below.
Step Action Tips More Details…
1 Make sure paper size Choose 11” or 14” Page 32
setting is correct
2 Load sheets Load face down and Page 12
into Sheet Feeder bottom edge first
A1
3 Press button Make sure green Page 8, 9
to select Feeder A1 indicator lights
4 Press button to Make sure green Page 8, 9
select Fold Only indicator lights
5 Press Trial Piece Check trial piece Page 8, 9
button and look for a good fold
6 Press
Start button Stop button will stop Page 8, 9
to run job machine at end of cycle
Problems? See Error Messages, page 35, and Troubleshooting , page 39
1 folded sheet
no envelope (fold only)

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OfficeRight™ DI200 Operator Guide (SV41289-OG Rev. C)
Model Required: OfficeRight™DI200 must have
an Insert Feeder C
Notes: Inserts are pre-folded sheets or unfolded
items such as business reply envelopes,
response cards and similar items. If your machine
has the optional 2nd sheet feeder A2, you can
use it instead of Feeder A1, as long as you load
and select it as described in steps 1 and 4 below.
Step Action Tips More Details…
1 Make sure paper size Choose 11” or 14” Page 32
setting is correct
2 Load sheets Load face down Page 12
into Sheet Feeder and bottom edge first
A1
3 Load envelopes Load right way up Page 13
into Feeder B and facing you
4 Load inserts Loading orientation Page 14
into Insert Feeder C depends on item
5 Press button Make sure green Page 8, 9
to select Feeder A1 indicator lights
6 Press button Make sure BOTH Page 8, 9
to select Envelope
green indicators
Fdr B and Insert are lit
Fdr C
7 Press button to Make sure moistener Page 8, 9
choose Seal or has E-Z Seal®or water
No Seal
Job 3
envelope
1 insert
1 folded sheet
Continues on next page...
One Folded Sheet + One Insert
into an Envelope

20
OfficeRight™ DI200 Operator Guide (SV41289-OG Rev. C)
Job 3
Step Action Tips More Details…
8 Press Trial Piece Trial piece will not Page 8, 9
button and check seal—this is normal
trial piece
9 Press Start button Stop button will stop Page 8, 9
to run job machine at end of cycle
Problems? See
Error Messages, page 35, and Troubleshooting , page 39
One Folded Sheet + One Insert
into an Envelope (continued)