Pitney Bowes Horizontal Belt Stacker Manual

Shipping & Mailing
Inserter
Operator Guide
International English Edition
SV40231 Rev. C
October 1, 2015
Horizontal Belt Stacker
for Relay Systems
TM

SV40231 Rev. C October 1, 2015
©2005, 2015 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 sub-
ject to change without notice. Your machine may not have some of
the features described in this book.
E-Z Seal a registered trademark of Pitney Bowes Inc. ENERGY
STAR is a registered trademark of the United States Environmental
Protection Agency.
NOTE: 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 commer-
cial 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 com-
munications. 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.
CAUTION! Changes or modifications to this equipment not express-
ly approved by the party responsible for compliance could void the
user’s authority to operate the equipment.
It is certified that this system complies with all applicable
Directives of the European Union.

SV40231 Rev. C iii
Safety ...................................................................................iii
Chapter 1: Product Overview
Horizontal Belt Stacker ......................................................1-3
Your Model ................................................................. 1-4
Main Components .............................................................1-5
Control Panel.....................................................................1-6
Change Position of the Control Panel........................ 1-6
How the Belt Stacker Works..............................................1-6
Chapter 2: Stacker Setup and Operation
Belt Stacker Setup.............................................................2-3
Right-Angled Configuration Setup ............................. 2-3
Run the Stacker in Right-Angle Mode........................ 2-6
In-Line Configuration Setup -
Letter Sized Envelopes ......................................... 2-8
Run in In-Line Mode - Letter Sized Envelopes ........ 2-10
In-Line Configuration Setup -
Flat Sized Envelopes ...........................................2-11
Run in In-Line Mode - Flat Sized Envelopes............ 2-13
Tandem Belt Stacker .......................................................2-14
Use the Belt Stacker with Other Equipment ....................2-14
Chapter 3: Troubleshooting
Troubleshooting.................................................................3-3
Envelopes Stuck in Inlet Area
or Poor Feed into Stacker ..................................... 3-3
Envelopes Hit Sensor Bracket ................................... 3-4
Material Doesn’t Transport Fully
to Stacker End Stacker Tray ................................. 3-4
Material Topples Over on the Left,
Low Number of Items Too ..................................... 3-4
Chapter 4: Specifications
Material Specifications.......................................................4-3
Equipment Specifications ..................................................4-3

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SV40231 Rev. C v
Safety
Follow these precautions when using your belt stacker:
• 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 machine is
plugged is free from obstruction.
• DO NOT route the power cord over sharp edges or trap it between
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.
• If the unit becomes damaged, unplug it from the wall, contact your
system supplier.
• 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.
• Do not place lighted candles, cigarettes, cigars, etc., on the system.
• To prevent overheating, do not cover vent openings.

SV40231 Rev. C
vi
• Use only approved supplies, in particular aerosol duster. Improper
storage and use of aerosol dusters or flammable aerosol 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.
• 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.
Before running the horizontal belt stacker you should be thoroughly
familiar with its controls, setup procedures, and how it interacts with the
components in the inserting system.

1 ● Product Overview
Contents
Horizontal Belt Stacker......................................1-3
Your Model ..................................................1-4
Main Components .............................................1-5
Control Panel.....................................................1-6
Change Position of the Control Panel.........1-6
How the Belt Stacker Works..............................1-6

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Product Overview • 1
1-3SV40231 Rev. C
Horizontal Belt Stacker
The stacker is an output device for a range of inserting systems and a
general output device for other machines such as address printers.
Belt Stacker Configurations
The belt stacker can operate at right angles (to the left or right) and also
in-line with the machine outputting to it, depending on machine and/or
material being used.
The control panel can be positioned on either side of the stacker to
accommodate the different configurations possible. It incorporates a
variable speed control, run-out button, power switch and power supply.
In most cases, the belt stacker is mounted on height adjustable legs.
However, versions without legs are available that can be placed on an
existing table of the correct height. In these cases, no adjustment of the
belt stacker height is possible.
Inserter
Belt
Stacker
Belt Stacker positioned
at right angles to the
right
Inserter
Belt
Stacker
Belt Stacker positioned
at right angles to the
left
Inserter Belt Stacker Belt Stacker
positioned ‘in line’

1 • Product Overview
1-4 SV40231 Rev. C
The Relay™ 5000/6000/7000/8000 Inserters output small (‘letter’)
envelopes at a different height to large (‘flat’) envelopes. Tandem belt
stacker configurations are available to allow automatic stacking of both
envelope sizes simultaneously.
Your Model
The belt stacker is tailored to work with the particular machine outputting
to it, and the configuration used, by the addition of kits. Your stacker will
be supplied with only the correct kit(s) for your particular installation.
This guide explains setup and operator adjustments for each machine
combination, but assumes that the stacker has been previously installed
by a service representative and that all necessary kits of adapters and
parts are available.
In most cases, it is NOT possible to change the belt stacker configuration
or link the stacker to a different Inserter without some modifications being
necessary. If you wish to do this, contact your machine supplier.

Product Overview • 1
1-5SV40231 Rev. C
Main Components
The horizontal belt stacker is made up of these main components:
7
8
1 6
9
5
4
3
2
5
Item Description
1 Side guides
2 Control panel box
3 Leg assembly
4 Lockable castors
5 Height adjustment knobs (two on each leg)
6 Stacking tray
7 Entry guide (varies with machine configuration)
8 Front end side guide adjustment knobs
9 Rear end side guide adjustment knobs
(underneath, not visible)
NOTE: Certain models do not have a stand (items 3, 4 and 5)
if they are being used on a table of the correct height.

1 • Product Overview
1-6 SV40231 Rev. C
Control Panel
The stacker is controlled by the control panel. It can be positioned on
either side of the stacker, depending on system configuration.
Change Position of the Control Panel
To change the position of the control panel:
1. Pull the panel firmly towards you to remove it.
2. Refit the control panel to the opening on the opposite side of the belt
stacker.
Power switch
Switches main power
on/off.
Speed selector
Sets belt speed.
Run-out button
Runs the belt at
full speed - when
you want to gather
the material on the
stacking tray.
2
4
0
6
8
10
How the Belt Stacker Works
The belt starts as soon as the start sensor is covered. When the material
has moved out of the sensor area, the belt stops again.
• The Start sensor position is adjustable, allowing the material overlap
to be adjusted.
• The speed of the belt can be adjusted to optimize the stacking
function for various materials.
• The Run-out button is used to gather the material after a job is
finished. The belt moves at the highest speed, independent of the
Speed selector setting.

2-1
Contents
Belt Stacker Setup.............................................2-3
Right-Angled Configuration Setup ..............2-3
Run the Stacker in Right-Angle Mode.........2-6
In-Line Configuration Setup -
Letter Sized Envelopes ..........................2-8
Run in In-Line Mode -
Letter Sized Envelopes ........................2-10
In-Line Configuration Setup -
Flat Sized Envelopes ...........................2-11
Run in In-Line Mode -
Flat Sized Envelopes ...........................2-13
Tandem Belt Stacker .......................................2-14
Use the Belt Stacker with Other Equipment ....2-14
2 ● Stacker Setup
and Operation

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Stacker Setup and Operation • 2
2-3SV40231 Rev. C
Belt Stacker Setup
The belt stacker can be used in either right-angle or in-line configuration
with the Relay 5000/6000/7000/8000 Inserters.
In-line configuration has two setups:
• Letter-sized envelopes (#10, DL/C5)
• Flat-sized envelopes (#9, C4); in-line configuration is essential for
running flat material
Both right-angle and in-line setup and operation are described here.
Right-Angled Configuration Setup
This image shows the belt stacker correctly docked to the Relay inserter
in a right-angled configuration.

2 • Stacker Setup and Operation
2-4 SV40231 Rev. C
To set the stacker up in a right-angled configuration correctly:
1. The exit roller bridge (A) should
already be installed to the
inserter output.
Make sure the bridge assembly
is correctly located on its
mounting studs.
A
2. Loosen the front and rear end
knobs (B) of the side guide
closest to the inserter output
and move the side guide as
far open (in the direction of the
arrow) as it will go.
3. Retighten the front and rear
end knobs.
B
4. Check the stacker alignment.
The top of the side guide
should fit into the cut-out on the
exit roller bridge assembly.
Top of guide fits into
cut-out with minimal gap

Stacker Setup and Operation • 2
2-5SV40231 Rev. C
5. If necessary, loosen the height
adjustment knobs (C) on each
leg in turn and readjust the
stacker height.
Alternatively, if the Inserter is
on a height adjustable table,
the table can be adjusted to
achieve the correct height
setting.
C
6. Position the stacker against the
Inserter, making sure the side
guide fits FULLY into the exit
roller bridge cut-out.
7. When positioned correctly, lock
all four castors.
8. For right hand operation, the
sensor and sensor bracket (D)
should be installed as shown
in the picture. Make sure there
is a spacer (E) between the
bracket and stacker side guide
at each knob position.
For left hand operation the
parts are installed mirrored.
D
E

2 • Stacker Setup and Operation
2-6 SV40231 Rev. C
Run the Stacker in Right-Angle Mode
To run the stacker in right-angle mode:
1. Place one envelope on the
belt.
2. Loosen the front and rear end
side guide knobs (A) of the
side guide with the sensor
bracket only.
Make sure the side guide rests
on the belt.
3. Adjust the side guide to give a
clearance of about 1/8” (3mm)
and retighten the front and rear
end side guide knobs.
Make sure the side guides are
parallel.
4. Connect the belt stacker to
the power supply and turn
ON. (Refer to the safety
information.)
A
1/8” (3mm)
clearance
5. Set the belt speed to
maximum.
2
4
0
6
8
10
6. Start the inserter.

Stacker Setup and Operation • 2
2-7SV40231 Rev. C
7. Adjust the envelope overlap by
moving the start sensor. When
the sensor is moved away from
the inlet the distance between
the envelopes will be larger,
and vice versa.
Keep the step as small as
possible without envelopes
building up too much; this
optimizes belt capacity.
Short Step
Long Step
8. Reduce the belt speed until the
motor runs continuously.
2
4
0
6
8
10

2 • Stacker Setup and Operation
2-8 SV40231 Rev. C
In-Line Configuration Setup - Letter Sized Envelopes
This image shows the belt stacker correctly docked to the Relay inserter in
the in-line orientation running letters.
In this mode the stacker enables
the Relay “flats” stacker to remain
in use. Flats stacker
To set the stacker up in an in-line configuration correctly for letter-sized
envelopes:
1. Check that the in-line sensor
bracket (A) is installed as
shown, using the two knobs
(B) with a spacer between the
bracket and stacker side guide
at each knob position.
Initially, position the sensor at
the end of its slot and pivot the
bracket fully counter-clockwise,
as shown by the arrow.
AB