Pitney Bowes DI425 FastPac Manual

FastPac™ Document Inserting System
DI425
Operator Guide
US/Canada English Version

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 oper-
ated 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. Opera-
tion 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.
SV61789 Rev. A ©2006 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 use-
fulness 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 no-
tice. OfficeRight and E-Z Seal are trademarks or registered trademarks of Pitney
Bowes.
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.

iSV61789 Rev. A
Table of Contents
If You Need Assistance
Contact Information for the USA and Canada ......................iii
Chapter 1 Introduction
Safety ................................................................................1-1
To The Operator ................................................................1-3
Machine Configurations.....................................................1-3
Machine Identification........................................................1-5
Control Panel.....................................................................1-8
Display Symbols ................................................................1-9
Chapter 2 Operation
About this Chapter.............................................................2-1
Connecting Power .............................................................2-1
Select a Job.......................................................................2-2
Run a Trial Piece ...............................................................2-3
Start Machine Operation....................................................2-3
Setting the Sheet Feeders.................................................2-4
Setting the Envelope Feeder .............................................2-6
Setting the Insert Feeder ...................................................2-8
Filling the Sealer..............................................................2-10
Adjusting the Stacker.......................................................2-10
Programming Jobs .......................................................... 2-11
Creating a New Job ......................................................... 2-11
Confirming the Job Setup ................................................2-22
Testing the Job ................................................................2-23
Changing an Existing Job................................................2-24
Deleting a Job..................................................................2-24

Table of Contents
ii SV61789 Rev. A
Chapter 3 Optical Mark Recognition (OMR)
OMR Availability ................................................................3-1
What is OMR? ...................................................................3-1
A Brief Overview of OMR on your Machine .......................3-1
Levels of OMR on the System...........................................3-2
OMR Mark Positions..........................................................3-2
OMR Specifications ...........................................................3-3
OMR Marks Available ........................................................3-6
OMR Mark Grouping .........................................................3-8
Programming an OMR Job..............................................3-10
Adjustment of OMR Scanner...........................................3-16
OMR Troubleshooting......................................................3-18
Chapter 4 Reference
Changing the Display Language .......................................4-1
Clearing Material ...............................................................4-1
Changing the Sealer Unit Felts..........................................4-5
General Troubleshooting ...................................................4-7
Error Messages ...............................................................4-12
Material Specifications.....................................................4-15
Machine Specifications....................................................4-19
Jobs
Customer Job Programming Record .................................5-1
Appendix A
Glossary of Terms............................................................. A-1
Index
Index to the Operator Guide .......................................Index-1

Table of Contents
iiiSV61789 Rev. A
If You Need Assistance
USA Contacts
▪Product Name - FastPac™ Document Inserting System
▪Model - DI425
▪For frequently asked questions, go to:
www.pb.com and click on Customer Support.
▪To place requests for service or training, go to:
www.pb.com and click on My Account.
▪To order PB supplies and accessories, go to:
www.pb.com and click on Online Store.
▪To view and pay invoices online, go to:
www.pb.com and click on My Account.
▪To view inventory, go to:
www.pb.com and click on My Account.
▪For direct questions, call: 1.800.522.0020. Customer Service
Representatives are available Monday through Friday, 8:00 AM
to 8:00 PM ET.
Canada Contacts
▪Product Name - FastPac™ Document Inserting System
▪Model - DI425
▪For frequently asked questions or to order supplies, go to:
www.pitneybowes.ca
▪For direct questions, call: 1.800.672.6937. Customer Service
Representatives are available Monday through Friday, 8:30 AM
to 4:00 PM ET.
Pitney Bowes Contact List

Table of Contents
iv SV61789 Rev. A

Introduction • 1
1-1SV61789 Rev. A
Safety Notes
Follow these precautions whenever you use your inserting system:
• Read all instructions before you attempt to operate the system.
Keep the Operator Guide accessible for quick reference.
• Use this equipment only for its intended purpose.
• Place the system close to an easily accessible wall outlet.
• Place the system in an accessible location to allow for proper
venting of the equipment and to facilitate servicing.
• Use the power cord supplied with the machine and plug it into a
properly grounded wall outlet that is located near the machine
and easily accessible. Failure to properly ground the machine
can result in severe personal injury and/or fire.
• The power cord wall plug is the primary means of disconnecting
the
machine from the AC supply.
• 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 control panel or its base.
The cabinet encloses hazardous parts. If you should damage
the unit, contact Your system supplier. Refer to the Contact
Information List at the front of this guide for more information.
• If the unit becomes damaged, unplug it from the wall, then con-
tact Your system supplier. Refer to the Contact Information List at
the front of this guide for more information.
• Keep fingers, long hair, jewelry and loose clothing away from
moving parts at all times.
• Avoid touching moving parts or materials while the machine is in
use. Before clearing a jam, be sure machine mechanisms come
to a complete stop.
• Remove jammed material gently and carefully.

1 • Introduction
1-2 SV61789 Rev. A
• Do not place lighted candles, cigarettes, cigars, etc., on the sys-
tem.
• To prevent overheating, do not cover vent openings.
• Use only approved supplies, in particular aerosol duster.
Improper storage and use of aerosol dusters or flammable aero-
sol dusters, can cause an explosive-like condition that could
result in a personal injury and/or property damage. Never use
aerosol dusters labeled flammable and always read instructions
and safety precautions on the duster container label.
• To obtain supplies and/or Material Safety Data Sheets, contact
your system supplier. Refer to the Contact Information List at the
front of this guide for more information.
• Operation of this equipment without periodic maintenance will
inhibit optimum operating performance and could cause the
equipment to malfunction. Contact your system supplier for the
required service schedule.
• Always follow specific occupational safety and health standards
for your workplace.
• To reduce the risk of fire or electrical shock, DO NOT attempt
to remove covers or disassemble the control panel or its base.
The cabinet encloses hazardous parts. If you should damage
the unit, contact your system supplier. Refer to the Contact
Information List at the front of this guide for more information.
If your stacker has an AC adapter to power the stacker:
• Use only the AC adapter designed specifically for the stacker.
Third-party AC adapters may damage the stacker.
• To protect against electrical shock, plug the AC adapter power
cord into a properly grounded wall outlet.
• Do not route the AC adapter cable over sharp edges or trap it
between furniture.
Safety Notes (Continued)

Introduction • 1
1-3SV61789 Rev. A
To the Operator
Your new Folding/Inserting Machine has an easy-to-follow user in-
terface which makes it simple to set up, yet offers the following ad-
vanced features:
• Envelope seal/no seal option
• Fully automatic material separation on sheet feeders
• Fully automatic setting of fold plates
• Fully automatic envelope separation
• Fully automatic double document detection (when selected)
• Fold-only option (fold without insertion)
• Manually fed, semi-automatic insertion of single and multiple
sheet collations
• Option of single fold, letter (C) fold, accordion (Z) fold or
double fold
• Job recall facility.
• Linked feeding (three-station machines only)
• Optical Mark Recognition (OMR) scanning (some models)
Machine Configurations
The following machine configurations are available:
• 1 Station – One sheet feeder only
• 2 Station – One sheet feeder and an insert feeder
• 3 Station – Two sheet feeders and an insert feeder
IMPORTANT: This guide covers all models, features and equip-
ment variations. Some of the features and machine options
mentioned in this book may not be available on your machine.

1 • Introduction
1-4 SV61789 Rev. A
Bottom Sheet
Feeder Scanner
Top Sheet
Feeder Scanner
Processing speed will vary, depending on machine configuration.
See Specifications in Chapter 4 for further details.
Your system may be equipped with OMR (Optical Mark Recognition)
scanning, depending on the model you purchased.
An OMR mark is normally a dark solid line on a sheet of light colored
paper that is perpendicular to the direction of paper travel. This line
must be thick and dense enough to trigger the system’s OMR scan-
ner.
The scanner, together with the system software, checks for one or
more different OMR marks on a document as it feeds through the
system. Tracking of these marks enhances mail piece integrity by
assuring that documents that belong together (a set) stay together
throughout the inserting process.
OMR-equipped models have scanning heads located on each of the
sheet feeders.
Instructions for using OMR functions appear in Chapter 3 of this
guide.

Introduction • 1
1-5SV61789 Rev. A
Machine Identification
Sheet Feeder 1 — This feeder is intended for feeding material
that requires folding.
In addition, you can set sheet feeder 1 to Manual Feed. In this
mode, you can run stapled sets of up to five sheets. The ma-
chine waits for you to feed each set by hand into sheet feeder
1 before folding and inserting the set automatically. See the
Specifications section of this guide for full details of the sets
possible.
Sheet Feeder 2 — For feeding material that requires folding.
Its functions are similar to those of sheet feeder 1, but the
manual feed option is NOT available from this feeder.
1
2
1
5
3
6
4
7
2
8
9
10
11
12

1 • Introduction
1-6 SV61789 Rev. A
5
3
6
4
7
8
9
10
11
12
Insert Feeder-— Use this feeder to add additional inserts to
your envelope. The inserter cannot fold material fed from this
feeder. However, this feeder is especially suited to feeding
pre-folded or thicker inserts.
Fold Plates 1 and 2 — These units create the desired fold in
material fed from the sheet feeder(s). The fold plates are auto-
matically set from the control panel.
Display/Control Panel — This is where you enter commands
and where the machine informs you of its status through sym-
bols and icons. Each button is explained on page 1-8.
3
4
5
6
Machine Identification (Continued)

Introduction • 1
1-7SV61789 Rev. A
Drop Stacker or Output Device (not illustrated)
A fold-down stacker is located at the machine exit to collect fin-
ished mail pieces. You can latch this unit against the machine
when it is not in use. Alternatively, a range of power stackers
are available which offer greater capacity than the standard
drop stacker.
A mailing machine interface can be installed in place of a
stacker. This option automatically transports mail pieces to a
Pitney Bowes mailing machine for postage imprinting.
Manual Advance Knob — This is located inside an opening
cover at the lower center of the machine. Use it to turn the
machine by hand to help clear material stoppages.
Envelope Feeder — This feeder feeds envelopes into the
inserting area where they are filled with the material requested
from the other feeder(s).
Sealer Bottle — The sealer bottle is located inside an opening
cover at the front right side of the machine. It provides sealing
solution to the envelope sealer.
Measuring Scale The scale is located on the left side of the
machine near the sheet feeders. Use it to measure sheets,
insert material and envelopes.
Envelope Inverter This unit causes the envelope to exit into
the stacker face up.
7
8
9
10
11
12
Machine Identification (Continued)

1 • Introduction
1-8 SV61789 Rev. A
Control Panel
Control Panel Buttons
Default — Press to return the machine to its default or standard
settings. These settings come pre-configured from the factory but a
Pitney Bowes Service Representative can change them to suit your
needs.
Job — Press to step through the jobs you’ve programmed into the
machine’s memory. You can program the machine with up to 20 jobs.
See page 2-11 for instructions.
Reset Counter — Press to reset the item or batch counter.
Clear Deck — Press to jog material through and out of the inserter.
Also use it to clear the machine and make it ready for automatic
operation after a stoppage has occurred.
Trial Piece — Press to run a single test piece to check machine
setup. You must run a trial piece before you begin automatic
operation using the Start button. If you’re using double detection, the
machine sets itself automatically as it runs the trial piece. The trial
piece envelope will be unsealed and counted as one item.
Start — Press to start automatic operation.
Stop — Press to stop automatic operation at the end of the next
cycle.
Delete — Press while in setup mode to delete a programmed job
from memory.
Setup — Press to enter the setup mode. This mode allows you to
program jobs into memory for instant recall using the Job button.
Change + – In setup mode, press to select options or set values
of machine settings.
Prev. ◄ ► Next — In setup mode, press to step backward or for-
ward through the various job settings.

Introduction • 1
1-9SV61789 Rev. A
Used on sheet feeders to signify that the feeder is on
without double detection.
Used on sheet feeders to signify that the feeder is on
with double detection.
Used on insert feeder to signify that the feeder is on
without double detection.
Used on insert feeder to signify that the feeder is on
with double detection.
Used on sheet feeder 1 to signify that the feeder is set
for manual feed.
Used on envelope feeder to signify that the feeder is
on.
Indicates the setting (from 1 to 5) of the envelope
stop.
Indicates that the sealer bottle needs refilling.
Indicates the envelope depth.
Indicates that the sealer unit is off (envelopes not
sealed).
Display Symbols


1 • Introduction
1-10 SV61789 Rev. A
Display Symbols (Continued)
!"#
Indicates that the sealer unit is on (automatic enve-
lope sealing).
Indicates a C (letter) fold is selected.
Indicates a Z (accordion fold) is selected.
Indicates a double fold is selected.
Indicates a single fold is selected.
Indicates a no-fold insert operation.
Indicates a material stoppage. The position of this
symbol in the display indicates where the stoppage
has occurred.
Call Pitney Bowes for service.
Indicates the paper size, address orientation and
fold(s) set for sheet feeder.
Indicates a material stoppage in a downstream de-
vice, such as a power stacker or mailing machine
interface.

Operation • 2
2-1SV61789 Rev. A
About this Chapter
This chapter explains operation of the machine, assuming the job to
be run is already programmed into the system.
If you have not programmed the job, see to Programming Jobs on
page 2-11.
Connecting Power
Read the safety information on page 1-1 before
connecting 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 pow-
er outlet is near the machine and is easily accessible.
Turn the power switch ON as
shown at the right.

2 • Operation
2-2 SV61789 Rev. A
Select a Job
When the machine is turned ON,
the display shows the last job run
and Trial Piece Required.
Press the Job button until the
job you want displays, or press
Default if you want to run the
machine with your standard job
settings.
Note: Only a Pitney Bowes Service Representative can modify the
default job.
If you have material loaded, press
Trial Piece. The machine will set
itself and run a test piece for you
to check.
If you don’t have material loaded,
do this now, then return to this
section. You’ll find instructions for loading the machine on pages 2-4
to 2-9.
Note:
You may have selected a manual feed job where sheet feeder 1 is
set for manual feed of collated sets. If this is the case, DO NOT load
the sheet feeder. Instead, you’ll feed collated sets one at a time by
hand as required by the machine.
Before you run a manual feed
job, pull back the lever as shown
at the right. This opens the feed
mechanism for manual feed op-
eration.
Remember to return this lever to
its normal position when you use
the feeder for automatic opera-
tion.

Operation • 2
2-3SV61789 Rev. A
Run a Trial Piece
Once material is in place, press Trial Piece so that you can check
the setup is correct.
You can make minor changes to the job settings at this stage if the
trial piece needs fine tuning. Enter setup as described on page
2-11, then use the Prev (◄), Next (►) and Change (+/-) buttons as
required to modify job settings. When you’ve made the necessary
changes, press Setup again to return to run mode. Your inserter sys-
tem will save the job with the new settings.
Notes:
1. When you use linked feeding, load both sheet feeders before
you run a trial piece.
2. If you load material during a run which seems to have differ-
ent characteristics (weight, color shade, etc.), or if you have any
problems with double detection, run another trial piece. This
causes the machine to recalibrate the double detect function for
the new material which may vary slightly from the old.
Start Machine Operation
Press Start to begin automatic operation.
The machine operates until material runs out or you press the Stop
button.
Note: If the machine is set for linked feeding, the display shows:
1 > 2 > 1
This confirms that feeding will automatically switch between
sheet feeders. See page 2-15 for more information.

2 • Operation
2-4 SV61789 Rev. A
Setting the Sheet Feeders
1. Adjust the side guides to the
width of the material, then
back-off a quarter turn on
the side guide control. This
sets the correct clearance
between the guides and the
material.
2. Take the stack of paper and
aerate (fan) it to ensure that
individual sheets are not
stuck together.
3. Jog the stack back into align-
ment. The sheet feeders take
the paper stack aligned in a
manner similar to that used
for a photocopier paper cas-
sette.
4. The display indicates the correct orientation of the paper.
FACE UP
HEAD FIRST
ABC
FACE DOWN
FEET FIRST
ABC