Pitney dowes W360 Manual

Operator Guide

US English Version

W360 Multifunction Tabber System

SV62476 Rev. A

First Edition, June, 2010.

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 can not assume responsibility for errors or omissions or liability for the misuse or

misapplication of our products.

NOTICE

The use of this information by the recipient or others for purposes other than the repair,

adjustment or operation of Pitney Bowes equipment may constitute an infringement of patent

and/or other intellectual property rights of Pitney Bowes or others. Pitney Bowes assumes no

responsibility for any such use of the information.

Except as provided in writing, duly signed by an officer of Pitney Bowes, no license, either

express or implied, under any Pitney Bowes or any third party’s patent, copyright, or other

intellectual property rights is granted by providing this information.

Important Safety Notes

Follow the normal safety precautions for all office equipment.

• Use only Pitney Bowes approved supplies, in particular aerosol dusters. 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 Pitney Bowes supplies, please contact our Supply Line™ to place orders.

Material Safety Data Sheets can be obtained on the web or from our Supply Line™.

• Use the power cord supplied with the system and plug it into a properly grounded wall

outlet located near the system and easily accessible. Failure to properly ground the

system can result in severe personal injury and/or fire.

• Avoid touching moving parts or materials while the machine is in use. Keep hands, loose

clothing, jewelry and long hair away from all moving parts.

• Do not remove covers or defeat safety interlock switches. Covers enclose hazardous

parts that should only be accessed by properly trained service personnel. Immediately

report to Pitney Bowes Service any damaged or non-functioning components that renders

the unit unsafe.

• Place the unit in an accessible location to allow for proper venting of the equipment and

to facilitate servicing.

• The power cord wall plug is the primary means of disconnecting the machine from the 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.

• Before clearing a stoppage, be sure machine mechanisms have come to a stop.

• When clearing a stoppage, avoid using too much force to protect against minor personal

injury and damaging equipment.

• To prevent overheating, do not cover the vent openings.

• Operation of this equipment without periodic maintenance will inhibit optimum operating

performance and could cause the equipment to malfunction. Contact your Pitney Bowes

Customer Service Representative for required service schedule.

• Read all instructions before attempting to operate the equipment.

• Use this equipment only for its intended purpose.

NOTE: Always follow the specif c occupational safety and health standards for your workplace.

Compliance Information

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 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 ex-

pense.

CAUTION: Changes or modif cations to this equipment not expressly approved by

the party responsible for compliance could void the user’s authority to operate the

equipment.

WARNING: This is a Class A product. In a domestic environment this product may

cause radio interference in which case the user may be required to take adequate

measures.

Canada

This Class A digital apparatus complies with Canadian ICES-003.

Cet appareil numérique de la classe A est conforme à la norme NMB-003 du Canada.

Specifications

Model: W360

Product: Tabber

Electrical rating: 115VAC, 60Hz, 2.5A

Contact Information

Product Name - W360

• 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 supplies and accessories, call the Supply Line™ at: 1.800.243.7824 or 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 - 8:00 PM ET.

W360 Operator Guide TABLE OF CONTENTS

iSV62476 Rev. A

TABLE OF CONTENTS

SECTION 1 – Getting Acquainted

FrontView

ExitEndView

Tabber Electrical Connections

Feeder and Connections

Tabber Control Panel

1

2

3

4

5

SECTION 2 – Assembly and Installation

Assembly

Installing Reel Supports

Installing Optional Feeder

Connecting

7

8

SECTION 3 – Operating the Tabber

Tabber Mechanical Setup

Narrow Media Setup

Running Tri-Fold Long Edge

Applying Stamps to # 10 Envelopes

Applying Three Tabs to a Narrow Piece

Media Thickness Adjustment

Adjusting the Feeder

Setting Media Length

Loading Tabs (Head 1 or Head 2)

Head 1 Adjustment - General

Head 1 Adjustment – Side Tabbing

Head 1 Adjustment – End Tabbing

Head 1 Adjustment – Applying Stamps

Head 2 Adjusting for Side Tabbing

Operating the Tabber

Understanding the Start-up Screen

Exceeding Tabbing Rate

Select and Run a Pre-Programmed Job

Stacker Interface

Fine Tuning Adjustments

Side Tab Positioning

Head 1 Side Tab Adjustment

Head 1 Tabbing at the Lead Edge of a Piece

Head 2 Side Tab Adjustment

11

14

15

16

17

18

19

20

22

25

27

29

30

31

33

34

35

W360 Operator Guide

ii SV62476 Rev. A

SECTION 4 – Programming the Tabber

Notes before Programming

Advanced Soft Key

Job #

Manual Tab/Stamp Positioning Features

Head #2

Head #1

Pitch

Automatic Tab Positioning Features

Tab Sensor (V-Tab) Adjustment

Manual V-Tab Adjustment

Programming Jobs

Programming: Tabs with Automatic Setup

Programming: Stamps with Manual Setup

Placing Multiple Stamps

Programming: Tabs on Opposite Sides

Programming Tabs on Perpendicular Sides

37

38

39

40

41

42

43

46

48

49

50

55

59

60

66

SECTION 5 – Maintenance

Cleaning

Rollers and Transport Belts

Cleaning the Sensors

Media Sensor Test

Tab Sensor Test

Cleaning Tab Wrap Guides

Lubrication

73

74

75

76

SECTION 6 – Troubleshooting

Jams

Tab Placement

Stamp Placement

Tabber Operation Problems

77

78

81

82

APPENDIX

Appendix A – Specifications Tabber

Appendix B – Identifying the Tab Types

83

84

INDEX 85

W360 Operator Guide GETTING ACQUAINTED

1SV62476 Rev. A

SECTION 1 – Getting Acquainted

Front View

1 Control Panel – The machine is controlled and programmed from this panel.

2 Head 1 Fine Tuning Adjustment – This Knob permits fine positioning of the Tabs on

Head 1.

3 Head 2 Fine Tuning Adjustment – This Knob permits fine positioning of the Tabs on

Head 2.

4 Head 1 – This head can apply stamps or tabs on either the edge or end of the media.

5 Head 2 – This head can only apply tabs on the edge of the media.

6 Take-up Reels – The tab web is wound up here after the tab is applied.

7 Left Media Guide Assembly – Transports the media to the tabbing area. This guide is

not adjustable.

8 Main Power Switch & Receptacle-Tabber – The power cord is plugged here and the

switch turns the Tabber On and Off.

9 Center Support Plate – Used to support media 6.5” wide or larger. This plate also

contains the slot used when tabbing at the lead edge of a piece.

10 Right Media Guide Assembly – This guide transports the media to the tabbing area

and is adjustable for the width of the media.

11. Media Thickness Adjustment Knob – Adjusts the Heads and Pressure Rollers to the

thickness of the media.

12. Media Width Fine Adjustment – knob fine tunes the media guide for width of media.

W360 Operator Guide

GETTING ACQUAINTED

2SV62476 Rev. A

Exit End View

1 Head 2 Fine Tuning Adjustment – This Knob permits fine positioning of the Tabs on

Head 2.

2 Head 1 Securing Knob – This Knob locks in the position of Head 1.

3 Right Media Guide Securing Knob – This knob locks right media guide in position.

4 Head 1 Transport Belt and Guide – This guide is adjustable for media width.

5 Center Plate – The Center Plate supports media wider than 6.5” and the slot in the

middle is used when tabbing on the end of a piece.

6 Exit Foot – This device holds the media down aw it travels under the exit rollers. It is

adjusted with Head 1.

7 Tab Wrap Guide – Head 1 – When side tabbing, this guide wraps the tab around the

media.

8 Exit Pressure Rollers – These rollers provide the pressure to transport the media and

seal the tabs.

9 Tab Wrap Guide – Head 2 – When tabbing on this head the guide wraps the tab

around the media.

10 Exit Foot Knob – This knob is used to position and secure the exit foot (6).

11 Exit Roller Assembly Securing Latches – These latches are used to lock down the exit

roller assembly.

W360 Operator Guide GETTING ACQUAINTED

3SV62476 Rev. A

Tabber Electrical Connections

1 Emergency Stop Input – This connector when wired into an existing safety circuit

permits an emergency stop on from the existing circuit to stop the Tabber. The jumper

plug is required when this feature is not used.

2 Emergency Stop Output –This connector permits the Tabber to control the emergency

stopping of another machine.

3 Conveyor Interface – The W985 Stacker is connected here to control the Tabber

Operation.

4 Tabber/Feeder Connection – The feeder is connected here to permit automatic

operation of the feeder when used with the Tabber.

5 Main Power Switch-Tabber – This switch turns the Tabber On and Off.

6 Fuse – The main power fuse (2.5A / 250V) for the Tabber is located here

Caution!

Disconnect the power before replacing the fuse.

7 Power Inlet Tabber – The power cord is plugged in here.

W360 Operator Guide

GETTING ACQUAINTED

4SV62476 Rev. A

Feeder and Connections

1 Tabber/Feeder Control Cable – This connection permits the tabber to control the

feeder when the mode switch is in the Automatic Position.

2 Power Inlet-Feeder – The power cord is plugged in here.

3 Fuse – The feeder fuse is located here.

4 Main Power Switch-Feeder – This switch will turn the feeder On and Off.

5 Mode Switch – The mode switch permits selection of either the Automatic Mode (the

tabber controls the Feeder) or Manual Mode (the feeder speed is controlled manually by

the Feeder Speed Control).

6 Feeder Speed Control – When the feeder mode switch is in the manual position, this

knob controls the speed of the feeder.

7 Media Thickness Adjustment-Feeder – Loosening the knob and repositioning the

lever is used for adjusting the exit rollers of the feeder for thicker media.

W360 Operator Guide GETTING ACQUAINTED

5SV62476 Rev. A

Tabber Control Panel

1. Transport Power Switch – Turns the Tabber transport power ON.

NOTE: The Transport Power will not activate unless all of the safety and

emergency switches are closed.

2. Speed Control – Adjusts the speed of the Tabber.

NOTE: The maximum speed of the Tabber tabber is controlled by the software.

The speed of the tabber for applying single tabs to one side of a piece is 25,000

pieces per hour, for applying double tabs to one side of a piece it is 15,000 pieces

per hour and for applying triple tabs to one side of a piece is 10, 000 pieces per

hour. Exceeding these speeds will cause the tabber to stop. The Tab placed on the

end of the piece is not counted in the above.

3. LED Display – Keeps the operator informed of the status of the Tabber.

4. Key Pad – Used to enter the data to program the Tabber

5. Emergency Stop – When the Tabber is properly connected to the feeder and/or other

pieces of equipment activating this button will stop the machines.

6. Soft Keys – The soft keys are used to step through the various menu options to program

the Tabber.

7. Stop Key – Pressing this key will stop the Tabber and hold it in a ready state to resume

operation.

8. Run Key – Pressing this key to start the Tabber when running a job.

9. Info Key – Pressing this key will change the display to the information mode.

10. Save Key – This key is used to save the entries into the memory.

11. Clear Key – This key will clear any incorrect entry before it is saved in the memory.

12. Measuring Scale – Use the scale to determine where to place the tabs.

W360 Operator Guide

GETTING ACQUAINTED

6SV62476 Rev. A

Notes

_____________________________________________________________________________________________

W360 Operator Guide ASSEMBLY AND INSTALLATION

7SV62476 Rev. A

SECTION 2 - Assembly and Installation

The Tabber is shipped in a single carton.

Assembly

Choose a Location

Place the Tabber with its feeder on a sturdy worktable or cabinet at least 12 inches from any

walls. Allow enough room to place the Feeder on the same work surface. Protect the Tabber

from excessive heat, dust, and moisture – avoid placing it in direct sunlight.

CAUTION

THE UNIT IS HEAVY.

IT IS STRONGLY RECOMMENDED THAT TWO TECHNICIANS REMOVE THE

Tabber FROM THE CARTON AND PLACE IT ON THE WORKING SURFACE.

Install Reel Supports

The two Reel Supports have to be installed. Remove the upper mounting screw and loosen the

lower mounting screw. Slide the Reel Supports over the frame until they bottom on the lower

mounting screw. Then install and tighten the upper screw and lower screw.

W360 Operator Guide

ASSEMBLY AND INSTALLATION

8SV62476 Rev. A

Install the Optional Feeder

1. The pin [A] on the feeder should mate

with the hole [B] on the Tabber body.

2. When the feeder is properly aligned with

the tabber body it will appear as in this

picture.

Connecting

Plugging in the Feeder and Tabber

Make sure that the emergency stop switch of the Tabber is in the OFF position and the main

power switch above the power cord receptacle is in the OFF position. Make sure that the power

switch on the feeder is in the OFF position also.

1. Connect one end of the Tabber power cord [1] to the rear of the Tabber in the

corresponding receptacle.

2. Connect one end of the Feeder power cord [2] to the rear of the Feeder in the

corresponding receptacle.

3. Plug the other end each cord into a 115 Volt AC (220VAC International), 50/60 Hz.

Grounded outlet.

W360 Operator Guide ASSEMBLY AND INSTALLATION

9SV62476 Rev. A

CAUTION

DO NOT USE ADAPTER PLUGS OR EXTENSION CORDS TO CONNECT THE

Tabber OR THE FEEDER TO THE WALL RECEPTACLE.

DO NOT USE OUTLETS CONTROLLED BY WALL SWITCHES.

DO NOT USE AN OUTLET THAT SHARES THE SAME CIRCUIT WITH LARGE

ELECTRICAL MACHINES OR APPLIANCES.

4. Connect the Feeder Interface cable [3] to the Feeder and to the lower connector on the

Tabber.

5. If the installation includes a Stacker, the Stacker Interface cable (4) is connected here.

W360 Operator Guide

ASSEMBLY AND INSTALLATION

10 SV62476 Rev. A

Notes

_____________________________________________________________________________________________

W360 Operator Guide OPERATING THE Tabber

11 SV62476 Rev. A

SECTION 3- Operating the Tabber

The Tabber is capable of applying up to three tabs or stamps on each of two sides of the media in

one pass. The steps required to set-up the Tabber for applying tabs or stamps are:

Determine the type of tabbing and the number of tabs.

Determine the orientation that the media must feed to accommodate the application.

Set-up the Tabber and feeder feed the media.

Load the tabs or stamps in the proper head.

Adjust the head positions (side tab or end tab) for the application.

Program the Job

Run the Job

Tabber Mechanical Setup

Once you have determined the tab location and number of tabs you are ready to setup the Tabber

for handling the media and placing the tabs.

IMPORTANT

TO PERMIT PROPER FEEDING THROUGH THE Tabber; THE MEDIA YOU PLAN

TO TAB/STAMP MUST HAVE SQUARE, TIGHT FOLDS, AND BE NEARLY

UNIFORMLY THICK. IF THE MEDIA DOES NOT FEED PROPERLY, IT WILL NOT

BE TAB/STAMPED PROPERLY.

Turn OFF the Tabber and the Feeder using the main power switches.

1. Loosen, the Exit Foot Knob,

located on top of the eixt roller

assembly, and ;move it toward the

back of the tabber (toward Head

2), as showm.

W360 Operator Guide

OPERATING THE Tabber

12 SV62476 Rev. A

2. Measure the width of the piece using the scale on the Tabber. If the media width is less

than 6.5 inches, the Center

Support Plate must be removed

from the tabber. This is done to

allow the Right Media Guide to

be positioned closer to the Left

Media Guide. (See Narrow

Media Setup for more

information.)

To remove the Center Support

Plate, first remove the Hold-

down Guide, and then lift up on

the Center Support Plate to

remove it, as shown.

IMPORTANT

THE CENTER SUPPORT PLATE AND HOLD-DOWN GUIDE MUST BE

INSTALLED WHEN USING MEDIA THAT MEASURES 6.5 INCHES OR WIDER.

FOR MEDIA LESS THAN 6.5 INCHES GO TO NARROW MEDIA SETUP ON

PAGE 14.

3. Loosen the securing knob for the Right

Media Guide.

NOTE: The right media guide is

movable. The left media guide is fixed.

4. Turn ON the Tabber’s main power

switch. Verify that the Exit Roller

Assembly is closed and secured (lock

the latches). Verify that the Emergency

Stop Button has been released. Press

the green Transport Power Button.

5. Press the soft key

labeled:”Pass-Thru” to set

the tabber in the pass-thru

mode.

NOTE: When the tabber is in

the “Pass-Thru” mode it will

display “Press-Run for pass-

thru mode” and the soft key

will change to “Operate”.

W360 Operator Guide OPERATING THE Tabber

13 SV62476 Rev. A

WARNING

DO NOT MOVE THE RIGHT-HAND MEDIA GUIDE IF THE MACHINE IS NOT

RUNNING. TO DO SO WILL RESULT IN DAMAGE OR BREAKAGE TO THE

TRANSPORT BELT.

6. Press the RUN button and center the Speed Control Dial so the transport is running at a

medium speed.

7. With the tabber transport running,

adjust the position of the Right

Media Guide Assembly to match

the media’s measured width.

The scale; located at the entrance

end of the tabber, can be used to

accomplish this step.

IMPORTANT

IF THE MEDIA IS NOT FOLDED SQUARE MAKE THE INITIAL SETTING OF THE

GUIDE AT THE WIDEST POINT ON THE PIECE. ONCE THE INITIAL

ADJUSTMENT IS MADE, THE MEDIA WIDTH FINE ADJUSTMENT CAN BE USED

TO FINE TUNE THE RIGHT-HAND GUIDE.

8. Secure the Right Media Guide’s position using the locking knob.

9. Press the STOP button to stop the Tabber.

10. Slide the Exit Foot Knob towards the

operator side until it stops against the

Right Media Guide Assembly, then

back off a small amount (no more

than 1/8”). Tighten the Exit Foot

Knob to secure its position.

11. Turn the Tabber OFF using the main

power switch.

12. Proceed to Media Thickness

Adjustment.

W360 Operator Guide

OPERATING THE Tabber

14 SV62476 Rev. A

Narrow Media Setup

The Narrow Media Guide is designed to help you feed media that is less than 5-1/2” and place

two side tabs and one end tab on media 5-1/4” wide or more. The Guide will also permit tabbing

the long edge of a Tri-Fold and improve Stamp application.

The Narrow Media Guide has a side rail (1) held in place by two screws that is used for front

tabbing media that is between 5” and 6-1/2” and can be removed when running very narrow

media and stamps.

Running Tri-Fold Long Edge

1. Remove the side rail (1) in the photo above.

2. Remove the standard support plate.

3. Install the Narrow Media Guide in place of the Standard Support Plate.

4. Adjust the Narrow Media Guide to the width of the Tri-Fold media and then move the

Transport Belt against the Narrow Media Guide.

5. Set up the Tabber to side tab from Head 2.

6. Run the Job.

Pitney Dowes W360 Manual

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