Pitney Bowes OfficeRight DI350 Manual

Inserting System
DI350 OfficeRight
TM
Operator Guide
SV40190-OG Rev. A

Contents
ii
First Edition, September 2002
©2002 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 assure 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.
NOTE: This equipment has been tested and found to
comply with the limits for a Class A 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 fre-
quency 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, at their own expense, will be required to
correct the interference.
Trademark Notice
OfficeRight™ and EZ Seal® are trademarks of Pitney Bowes Inc.

Contents
iii
ABOUT THIS GUIDE
This guide explains how to setup and use the DI350
OfficeRight™ Inserting System . Please spend a few
moments reading through it. Understanding what the inserter
does, and how it does it, will keep problems to a minimum
and help you get the best performance possible.
This Guide is organized into seven sections:
1. INTRODUCTION
To the Operator 1-5
Three-Station Model .................................................... 1-5
Two-Station Model ...................................................... 1-6
One-Station Model ...................................................... 1-6
Safety ................................................................................ 1-7
Machine Identification ....................................................... 1-8
Control Panel .................................................................. 1-10
Control Panel Buttons ............................................... 1-10
Display Symbols ........................................................ 1-12
2. OPERATION
Connecting Power ............................................................. 2-1
Selecting and Running a Job ............................................ 2-1
Select the Job.............................................................. 2-1
Run a Trial Piece ......................................................... 2-2
Start Machine Operation ............................................. 2-3
Setting the Sheet Feeders ................................................ 2-3
Setting the Envelope Feeder............................................. 2-4
Setting the Insert Feeder................................................... 2-5
Filling the Sealer ............................................................... 2-6
Programming Options By Model ....................................... 2-7

Contents
iv
3. CREATE A NEW NON-OMR JOB
Create New Non-OMR Job ............................................... 3-1
Entering the Setup Mode............................................. 3-1
Choosing the New Job Number .................................. 3-2
Selecting Non-OMR Option ......................................... 3-2
Flowchart for Non-OMR Job........................................ 3-3
Setting the Accumulation Function .............................. 3-5
Fold Type .................................................................... 3-6
Setting Sheet Feeder 1 ............................................... 3-7
Setting Sheet Feeder 2 ............................................... 3-8
Setting Insert Feeder ................................................... 3-9
Mode ........................................................................... 3-9
Sealer ........................................................................ 3-10
Paper Length ............................................................. 3-10
Fold A ........................................................................ 3-11
Fold B ........................................................................ 3-11
Envelope Depth ......................................................... 3-12
Envelope Stop ........................................................... 3-12
Batch Mode ............................................................... 3-13
Confirming the Job Setup .......................................... 3-13
Testing the Job .......................................................... 3-14
Changing an Existing Job ............................................... 3-15
Deleting a Job ................................................................. 3-15

Contents
v
4. WHAT IS OMR (OPTICAL MARK
RECOGNITION)?
What is OMR? ................................................................... 4-1
What Do OMR Marks Look Like on Paper? ...................... 4-2
How are OMR Marks Read on the DI350? ....................... 4-3
How are OMR Marks Generated?..................................... 4-4
What OMR Marks are Used on the DI350? ...................... 4-5
OMR Group Combinations ................................................ 4-9
Details of Basic Level OMR ............................................ 4-10
Group 1 Marks (“OMR”) ............................................. 4-10
Details of Enhanced Level OMR ..................................... 4-14
Group 2 Marks (“Select Feed”) ................................... 4-14
Group 3 Marks (“Sequence”) ...................................... 4-17
Considerations When Implementing OMR ...................... 4-20

Contents
vi
5. CREATE A NEW OMR JOB
Creating a New OMR job .................................................. 5-1
What Is OMR? ............................................................. 5-1
Entering the Setup Mode............................................. 5-1
Choosing the New Job Number .................................. 5-2
Selecting OMR Option................................................. 5-3
Flowchart for OMR Job ............................................... 5-4
Fold Type .................................................................... 5-6
Setting Main (Scanning) Sheet Feeder ....................... 5-7
Setting Other Sheet Feeder ........................................ 5-7
Setting Insert Feeder ................................................... 5-9
Sealer ........................................................................ 5-10
Paper Length ............................................................. 5-10
Fold A ........................................................................ 5-11
Fold B ........................................................................ 5-11
Envelope Depth ......................................................... 5-12
Envelope Stop ........................................................... 5-12
Batch Mode ............................................................... 5-13
Confirming the Job Setup .......................................... 5-13
Adjustment of OMR Scanner..................................... 5-14
Loading the Material .................................................. 5-17
Testing the Job .......................................................... 5-18
Changing an Existing Job ............................................... 5-19
Deleting a job .................................................................. 5-19

Contents
vii
6. REFERENCE
Changing the Display Language ....................................... 6-1
Clearing Material ............................................................... 6-1
Hand Crank ................................................................. 6-1
Removal & Replacement of Sheet Feeder and
Envelope Trays ........................................................ 6-2
Removal & Replacement of the Fold Plates................ 6-2
Removal & Replacement of the Insert Tray ................ 6-3
Access to Carriage Assembly ..................................... 6-3
Access to Envelope Feeder Area ................................ 6-3
Access to the Envelope Exit Area ............................... 6-4
Access to the Envelope Inserting Area ....................... 6-4
Access to the Sheet Feed Area................................... 6-4
Troubleshooting ................................................................ 6-5
Error Messages ............................................................... 6-11
Paper Handling.......................................................... 6-11
OMR Errors ............................................................... 6-15
Material Specifications .................................................... 6-17
Sheet Feeders ........................................................... 6-17
Insert Feeder ............................................................. 6-17
Sealer ........................................................................ 6-18
Stacker ...................................................................... 6-18
Envelope Feeder ....................................................... 6-18
Material Requirements .............................................. 6-19
OMR Specifications (General) ........................................ 6-19
Machine Specifications ................................................... 6-20
Physical Dimensions: ................................................ 6-20
Noise Level................................................................ 6-20
Electrical/BTU Rating ................................................ 6-20
Speed ........................................................................ 6-20
Fold Modes................................................................ 6-20
Compliance ............................................................... 6-20
Usage ........................................................................ 6-21
Machine Life .............................................................. 6-21
Service ............................................................................ 6-21

Contents
viii
APPENDIX A – TRAINING CHECKLIST
Operator Training Checklist ..............................................A-1
Introduction..................................................................A-1
Operation.....................................................................A-1
Create (Program) Non-OMR Job ................................A-1
What Is OMR? .............................................................A-2
Create (Program) OMR Job ........................................A-2
Reference ....................................................................A-2
INDEX

1-1
Introduction
1. INTRODUCTION
To the Operator
Your Pitney Bowes DI350 Inserting System is a compact,
desk top unit, which is simple to set up and run while offering
the following features:
•Envelope seal/no seal option
•Semi-automatic single insert operation (not on single station model)
•Fully automatic material separation on sheet feeder(s)
•Fully automatic settings on fold plates
•Fully automatic envelope separation
•Fully automatic double document detection when selected
•Fold only option (fold without insertion)
•Semi-automatic insertion of single and multiple sheet Inserts
•Option of single fold, letter (C) fold, accordion (Z) fold or double fold
•Job recall, operator programmable (up to 20, depending on model)
•Switchable feeding
•Optical Mark Recognition (OMR) scanning for greater collation
integrity and additional feeding flexibility (3-station model only)
This guide covers all three models of the DI350 inserter system.
Three-Station Model
This model incorporates two sheet feeders and an insert feeder.
It is the only model that has OMR and has the most setup
options. For this reason, all illustrations in this guide show this
model.
Sheet
Feeder 1 Insert Feeder
Sheet
Feeder 2

1-2
Introduction
Two-Station Model
This model incorporates a single sheet feeder and an insert
feeder.
One-Station Model
This model incorporates a single sheet feeder.
All models are set up and operated in a very similar way.
Procedures in this guide cover all models. If a function is
model dependent, the accompanying text will explain this.
Sheet Feeder 1
Insert Feeder
Sheet Feeder 1

1-3
Introduction
Safety Precautions:
When using this machine, follow the normal safety precautions for all
office equipment:
Keep loose clothing, jewelry and long hair away from all moving parts.
Avoid touching moving parts or materials while the machine is in use.
Before clearing a jam, be sure machine mechanisms come to a stop.
When removing jammed material, avoid using too much force to
protect against minor personal injury and damaging equipment.
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 properlyground the machine can resultin severe
personal injury and/or fire.
The power cord wall plug is the primary means of disconnecting the
machine from 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 equipment.
DO NOT route the power cord over sharp edges or trapped between
furniture.
Insure there is no strain on the power cord where it becomes jammed
between 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.
Do not remove covers. Covers enclose hazardous parts that should
only be accessed by Pitney Bowes Customer Service. Report any
damageofcovers toaPitney BowesCustomerService Representative.
To prevent overheating, do not cover the vent openings.
Read all instructions before attempting to operate the equipment.
Use this equipment only for its intended purpose.
In addition, follow any specific occupational safety and health
standards for your workplace or area.
Safety

1-4
Introduction
2
Machine Identification
1 6 11 3410
987
5
1Sheet Feeder 1
This feeder is intended for feeding material that requires
folding. If you are running addressed documents for
insertion into window envelopes, feed them from this
feeder.
In addition, sheet feeder 1 can be set to ‘manual feed’. In
this mode, stapled sets of up to 5 sheets may be run. The
machine waits for each set to be manually fed into sheet
feeder 1 before folding and inserting the set automatic-
ally. See the specifications section of Chapter 6
(Reference) for full details of the sets possible.
2Sheet Feeder 2
(three-station machine only)
For feeding material that requires folding. Its functions
are similar to sheet feeder 1 but ‘manual feed’is NOT
available from this feeder.
12
13

1-5
Introduction
3Insert Feeder (two and three-station machines only)
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.
4Fold Plate 2
5Fold Plate 1
These units are used to create the desired fold in
material fed from the sheet feeder(s). The fold plates are
automatically set from the control panel.
6Display/Control Panel
This is where you enter commands and where the
machine informs you of its status with the use of symbols
and icons. Full details of each button function are given
on the following page.
7Stacker and Measuring Scale
Located at the right end, is the fold-down stacker. This
unit can be latched against the right side of the machine
when not in use to save space.
A scale is located along the front edge of the stacker to
aid measurement of material and envelopes.
8Hand Crank
The hand crank is located behind a drop down cover at
the left front. It can be used to manually turn the machine
mechanisms to free a material stoppage.
9Envelope Feeder
This feeder feeds envelopes into the inserting area
where they are filled with the sheets requested from the
other feeders.
10 Envelope Inverter Unit
This unit exits the envelope into the stacker face up.11

1-6
Introduction
11 Sealer Water Bottle
The sealer water bottle is located behind a drop down
cover at the right rear of the machine. It provides water or
EZ Seal®solution to the envelope sealer unit.
12 Upper OMR Scanner (three-station machine only)
Scanner used to read OMR marks on sheet feeder 1 from
above the sheet.
13 Lower OMR Scanner
(three-station machine only)
Scanner used to read OMR marks on sheet feeder 2 from
under sheet.
Control Panel
Control Panel Buttons
Default Press this button to return the system to its
‘standard’settings. These settings come pre-
configured from the factory but can be modified to
suit your needs by a Pitney Bowes Customer Service
Representative.
Job Press to step through the jobs you have programmed
into the machine’s memory. Up to twenty (20) jobs can
be held, depending on model (see page 2-9). See
Chapters 3 or 5 for details on programming jobs.

1-7
Introduction
Next
Reset Counter Press this button to reset the item counter.
Clear Deck Pressing this button will jog material through and out
of the machine. It can be used to clear the machine
ready for automatic operation after a stoppage has
occurred etc.
Trial Piece This button is used to run a single test piece so that
you can check machine setup. A trial piece must be
run before automatic operation can be commenced
using the Start button. If double detection is in use,
the machine sets itself automatically as it runs the
trial piece. This envelope will be unsealed and
counted as one item.
Start Starts automatic operation.
Stop Stops automatic operation at the end of the next
cycle.
Delete Used in setup mode to delete a programmed job
from memory.
Setup When pressed, the machine enters setup mode. This
mode allows you to program jobs into memory for
instant recall using the Job button.
Change + –In setup mode, used to select options or set values
of machine settings.
Prev. In setup mode, used to step backwards/forwards
through the various machine settings.

1-8
Introduction
Display Symbols
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
waterbottleneedsrefilling.
Indicates the envelope
depth.
Indicates that the sealer
unit is off (envelopes not
sealed).
Used on any feeder to
indicatefeederisnotinuse.
Indicates that the sealer
unit is on (automatic
envelope 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.
Indicatesa no-fold insert
operation.
Indicates a material
stoppage.Thepositionof
this symbol in the display
indicates where the
stoppage has occurred.
Call Pitney Bowes
Service.
Indicatesthe paper size,
address orientation and
fold(s) set for sheet
feeder.
. . 3 . .

Operation
2-1
2. OPERATION
This section explains operation of the DI350 inserter, assum-
ing the job to be run is already programmed into the machine.
If the job has not been programmed, refer to “Create Non-
OMR Job”on page 3-1 or “Create OMR Job”on page 5-1.
Connecting Power
Read the safety
information on
page 1-3 before
connecting the
machine.
Connect the power cord to
the socket on the left side 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 machine power switch ON.
!
Select the Job
When the machine is turned
ON, the display will show the
last job run and ‘Trial Piece
Required’.
Press the Job button until the
job you require is displayed,
or press Default if you want to run the machine with your
‘standard’settings.
Note: The default job can be altered only by a Pitney Bowes
Customer Service Representative.
Selecting and Running a Job

Operation
2-2
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. Loading feeders etc. is covered on the following
pages.
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, the sheet
feeder should not be loaded,
as the collated sets are fed
one at a time as required by
the machine. However, the
lever shown in the illustration should be pulled back to open
the feed mechanism to ready the manual feed operation.
Remember to return this lever to its normal position when
you use the feeder for automatic operation.
Run a Trial Piece
Once material is in place, press Trial Piece so you can
check that the setup is correct.
Note: In switchable mode both sheet feeders must be loaded. A
trial piece will be run for both feeders.
Minor changes to the job settings can be made at this stage
if the trial piece needs ‘fine tuning’. Press Setup, then use
the Prev ( ), Next ( ) and Change (+/-) buttons as
required to modify job settings. When you have made the
necessary changes, press Setup again to return to run
mode. The job will be saved with the new settings.

Operation
2-3
Start Machine Operation
Press Start to begin automatic operation. The machine will
operate until either material runs out or the Stop button is
pressed.
Note: If the three station machine is set for switchable
feeding, the display will show:
Ready: 1 > 2 > 1
This confirms that feeding will automatically switch between
sheet feeders. See page 3-8 or 5-7 for more details.
Setting the Sheet Feeders
1. Adjust the side guides to
the width of the material
being fed, then back-off a
quarter turn on the side
guide control. This will
set the correct clearance
between the guides and
the material.
2. Take the stack of paper
and aerate it to ensure
the individual sheets are
not stuck together.

Operation
2-4
3. Jog the stack back into
alignment. The sheet
feeders take the paper
stack aligned in a similar
way to a photocopier
paper cassette.
4. The three possible
choices for loading you documents with addresses are
listed below. NOTE: The display will indicate the correct
orientation of the paper in the first two cases only.
5. Place the paper stack onto
the feed deck. Allow the
deck to move down and
the top of the paper stack
to slide under the feed
roller.
Note: When using both
sheet feeders with
accordion fold, sheet
feeder 2 must be used for
the prime (address bearing)
document.
6. You can pull out the sliding supports from the end of the
deck to help support long material.
FACE UP
FEET FIRST
ABC
FACE DOWN
FEET FIRST
ABC
FACE UP
HEAD FIRST
ABC