Secap SI5400 Manual

Operator Guide
US/Canada English Version
Document Inserting System
SI5200, SI5400
TM

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 inter-
ference, in which case the user will be required to correct the interference at his own expense.
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.
SV61611 Rev. B ©2006 SECAP™
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 SECAP™. 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 misap-
plication 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. DP800i, DP1000, SwiftStart, SureTrac, IntelliLink
and E-Z Seal are trademarks or registered trademarks of Pitney Bowes. Tyvek is a registered trademark of
Dupont.
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.

iSV61611 Rev. B
Table of Contents
Contact Information List
USA Contacts .................................................................................v
Canada Contacts............................................................................v
1 • Introduction
A Note to the Operator................................................................ 1-2
Viewing this Guide as a PDF File ............................................... 1-2
About Your System ..................................................................... 1-3
Standard Systems ................................................................ 1-4
System Options* ................................................................... 1-5
Safety Information....................................................................... 1-6
Warning Labels........................................................................... 1-7
Book Contents ............................................................................ 1-8
2 • Meet the Inserting System
System Components .................................................................. 2-2
Feeder Tower.............................................................................. 2-4
Feeder Trays............................................................................... 2-5
Sheet Trays........................................................................... 2-5
Insert Trays ........................................................................... 2-6
Manual Feeder............................................................................ 2-7
Transport Deck ........................................................................... 2-8
Mail Piece Path..................................................................... 2-8
Pre-fold Accumulator ............................................................ 2-8
Folder.................................................................................... 2-9
Post-fold Accumulator .......................................................... 2-9
Insertion Area........................................................................ 2-9
Folder Bypass Path .............................................................. 2-9
Moistener, Closer, Sealer...................................................... 2-9
About the Control Panel............................................................ 2-10
Screen Option Keys............................................................ 2-10
Fixed Function Keys ........................................................... 2-11
Machine Action Keys .......................................................... 2-13
Screen Navigation Keys ..................................................... 2-13
Display Screen.......................................................................... 2-14
Header Area........................................................................ 2-14
Status Area ......................................................................... 2-15
Access Rights ........................................................................... 2-20

ii SV61611 Rev. B
Table of Contents
Logging In ........................................................................... 2-21
Logging Out ........................................................................ 2-21
About System Covers............................................................... 2-22
Opening the Covers............................................................ 2-23
Closing the Covers ............................................................. 2-23
About the Paper Release Knobs/Levers................................... 2-24
About Add-On Modules............................................................. 2-24
3 • Basic Operation
Connecting to Power .................................................................. 3-2
Powering Up ............................................................................... 3-2
Home Screen.............................................................................. 3-3
Job Overview .............................................................................. 3-4
Selecting the Job ........................................................................ 3-5
Setting Up Feeders and Loading Materials ................................ 3-6
Attaching Trays to the Feeder Tower .................................... 3-6
Removing Trays from the Feeder Tower............................... 3-7
Loading Material into the Trays............................................. 3-8
Loading the SI5400 High Capacity Envelope Feeder
(HCEF)................................................................................ 3-13
Making Pre-Run Adjustments .................................................. 3-18
Adjusting the Envelope Openers ........................................ 3-18
Running a Trial Piece................................................................ 3-22
Reviewing the Job Settings ................................................ 3-24
Starting the Job......................................................................... 3-25
SwiftStart™ Jobs ........................................................................ 3-25
Using SwiftStart™............................................................... 3-26
Creating a Job .......................................................................... 3-26
Job Options............................................................................... 3-30
Envelope Options ............................................................... 3-30
Fold Options ....................................................................... 3-32
Sheet Options ..................................................................... 3-33
Insert Options ..................................................................... 3-36
Editing a Job............................................................................. 3-39
Modifying Job Settings........................................................ 3-40
Editing an Item.................................................................... 3-40
Adding an Item.................................................................... 3-41
Moving an Item ................................................................... 3-43
Deleting an Item.................................................................. 3-44

SV61611 Rev. B iii
Table of Contents
4 • Advanced Operation
Overview..................................................................................... 4-2
Using the Alphanumeric Matrix ................................................... 4-2
Saving a Job .............................................................................. 4-3
Deleting a Job............................................................................. 4-4
Assigning User IDs and Passwords............................................ 4-5
Enabling and Disabling the High Capacity Sheet Feeder
(HCSF)........................................................................................ 4-5
5 • Troubleshooting and Maintenance
Adjusting Screen Brightness and Contrast................................. 5-2
Setting the Time and/or Date...................................................... 5-3
Changing the Language ............................................................. 5-4
Refilling the Sealing Solution...................................................... 5-5
Handling Material Stoppages...................................................... 5-5
Clearing a Stoppage ............................................................. 5-5
Resuming the Job................................................................. 5-6
Handling Outsorted Material ................................................. 5-6
Troubleshooting Tables............................................................... 5-7
Routine Maintenance................................................................ 5-16
Daily Tasks.......................................................................... 5-16
Replacing the Moistener Wick ............................................ 5-16
Replacing the Moistener Brushes....................................... 5-18
6 • Reference
Overview..................................................................................... 6-2
System Specifications................................................................. 6-2
Component Specifications .......................................................... 6-4
Feeder Tower and Base Material Specifications......................... 6-7
General Information .............................................................. 6-7
Outer Envelopes ................................................................... 6-7
Inserts ................................................................................. 6-10
Sheets................................................................................. 6-11
High Capacity Sheet Feeder (HCSF) Material Specifications .. 6-12
General Information ............................................................ 6-12
Sheets................................................................................. 6-12
Materials Not Certied for Use............................................ 6-13

iv SV61611 Rev. B
Table of Contents
7 • Add-On Modules
About the Add-On Modules......................................................... 7-2
High Capacity Sheet Feeder (HCSF) ......................................... 7-2
Loading the HCSF ................................................................ 7-3
Adjusting the HCSF Guides.................................................. 7-5
Flats Sealer................................................................................. 7-7
Replacing the Envelope Edge Marker Roller........................ 7-8
Attached Printer .......................................................................... 7-9
Loading the Attached Printer .............................................. 7-10
Adjusting the Printer Interface Guides ................................ 7-11
Printing a Cover Sheet to the Top of the Attached Printer .. 7-13
SureTrac™Process Verification System ................................... 7-13
Exit Options .............................................................................. 7-15
Mailing System Interface
(DP800i or DP1000 only).................................................... 7-15
Envelope Stacker ............................................................... 7-18
Belt Stacker ........................................................................ 7-18
Exit Transport...................................................................... 7-18
8 • Scanning
Scanning Overview..................................................................... 8-2
OMR ..................................................................................... 8-2
BCR ...................................................................................... 8-2
Scanning Features................................................................ 8-4
Setting Up a New Scan Configuration ........................................ 8-6
Setting Up an OMR Scan Conguration ............................... 8-6
Setting Up a BCR Scan Conguration.................................. 8-9
Editing a Scan Configuration .................................................... 8-13
Editing an OMR Scan Conguration................................... 8-13
Editing a BCR Scan Conguration...................................... 8-14
Copying a Scan Configuration.................................................. 8-15
Deleting a Scan Configuration.................................................. 8-15
Reviewing a Scan Configuration............................................... 8-16
Viewing the Job List.................................................................. 8-16
Assigning a Scan Configuration to an Existing Job ................. 8-17
Adjusting the Scan Heads ........................................................ 8-19
Adjusting the Scan Heads for Ladder Orientation Marks.... 8-19
Adjusting the Scan Heads for Picket Orientation Marks ..... 8-22
OMR Specifications .................................................................. 8-24
Barcode Specifications ............................................................ 8-26
Setting the OMR Scanning Area............................................... 8-29

SV61611 Rev. B v
Table of Contents
Defining the First Mark Position and Code Length ................... 8-29
Defining the Clear Zone............................................................ 8-30
Additional Information ............................................................... 8-31
BCR and OMR Mark Levels ..................................................... 8-31
Basic Level ......................................................................... 8-32
Enhanced Integrity Level .................................................... 8-34
Selective Operations Level ................................................. 8-35
Appendix A • Glossary
Basic Terms ...............................................................................A-2
Material References..............................................................A-2
Machine Functions................................................................A-3
Icon Glossary..............................................................................A-4
Envelope Icons .....................................................................A-4
Fold Icons .............................................................................A-5
Sheet Icons...........................................................................A-5
Insert Icons ...........................................................................A-6
Feeder Assignment Icons .....................................................A-7
Other Icons ...........................................................................A-7
Index
Index............................................................................................ I-1

vi SV61611 Rev. B
Table of Contents
This page is intentionally blank.

v
SV61611 Rev. B
USA Contacts
Product Name - SI5200 or SI5400
For direct questions, or to order SECAP™approved supplies and accessories,
contact your local dealer.
Other Country Contacts
Contact information is given in a separate publication supplied with the prod-
uct.
Contact Information List

vi SV61611 Rev. B
Contact Information List
This page is intentionally blank.

1-1SV61611 Rev. B
1 • Introduction
A Note to the Operator.................................................................1-2
Viewing this Guide as a PDF File................................................1-2
About Your System......................................................................1-3
Standard Systems ................................................................. 1-4
System Options ..................................................................... 1-5
Safety Information .......................................................................1-6
Warning Labels............................................................................1-7
Book Contents.............................................................................1-8

1-2 SV61611 Rev. B
1 • Introduction
Viewing this
Guide as a PDF
File
There are several built-in features you can use to navigate through this
guide when viewing it as a pdf file:
• Topics highlighted by a blue rectangle are hyperlinks.
Using the Hand tool ( ), you can click anywhere within a hyperlink to
jump to the topic's location in the Help guide.
• Entries in the main Table of Contents and the table of contents at the
beginning of every chapter are hyperlinks, although they are not high-
lighted.
Move the Hand tool over a table of contents entry until it points, then
click to jump to the location of the entry in the Help guide.
• Page numbers in the Index are hyperlinks, although they are not high-
lighted.
Move the Hand tool over the page number until it points, then click on
the page number to jump to that page of the Help guide.
Highlighted Hyperlink
Table of Contents Hyperlink
Index Hyperlink
It is important to be familiar with this guide as it will enable you to utilize the
system to its full potential, while keeping problems to a minimum.
NOTE: This guide applies to systems running software version 1.10.04. The soft-
ware version is displayed on the control panel screen at power up.
A Note to the
Operator

SV61611 Rev. B 1-3
Introduction • 1
SI5200/SI5400 are high throughput, mail creation systems designed to han-
dle a broad range of applications with minimum operator setup adjustments.
These systems have the ability to feed, fold, and insert mail piece compo-
nents into an outer envelope. The systems generate Letters or Flats as the
final mail piece. The systems also accept a variety of options that provide a
wide range of capacities and operating speeds.
About Your
System
The systems can be configured with four flexible Feeder Trays. There are
two types of Feeder Trays:
• Sheet Trays, which are capable of feeding sheets; and
• Insert Trays, which are capable of feeding slip/insert materials, pre-fold-
ed inserts, thin booklets, and envelopes.
In addition, the SI5400 system is equipped with a dedicated High Capacity
Envelope Feeder (HCEF) that allows for greater speed and throughput. The
systems also accept material from optional upstream input devices, such as
High Capacity Sheet Feeders, Attached Printer, and other devices.
Basic system features are summarized in this chapter. Refer to Chapter 6
for detailed equipment and material specifications.
The systems are configured with two major components:
• Feeder Tower, and
• Transport Deck.
The Feeder Tower sends material from the Feeder Trays to the Transport
Deck. Depending on the job parameters, the material may or may not need
to pass through the Folder in the Transport Deck. If it does, the system of-
fers numerous types of folds and the ability to insert the folded material into
the appropriate position in the mail piece collation. The system can also seal
the envelope (Letter only) before sending the final mail piece to a stacking
unit.
Figure 1.1: The SI5200 System

1-4 SV61611 Rev. B
1 • Introduction
SI5200-2h
SI5200-4
SI5400-2h
SI5400-4
Letter and Flats Drop Stacker
(standard on all systems)
Standard
Systems

SV61611 Rev. B 1-5
Introduction • 1
Fold Expansion Kit
(Document Inverter)
High Capacity Sheet
Feeder (HCSF)
Envelope Stacker
Exit Transport
Belt StackerTandem Belt Stacker
Mailing System DP800i,
DP1000
System Options*
*Furniture, designed
specifically for the
system, is also
available.
DI900/DI950 Document Printing Options - Beta
DI950 with integrated monochrome document printer
Black and white printing option:
x 50 pages per minute simplex (3,000 pieces per hour for
1 printed page)
x Duplex printing at 20 sheets per minute
x 2,000 sheet capacity with one 500 sheet and one 1,500
sheet tray
Color printing option:
x Color or monochrome printing at 28 pages per minute
simplex (1,700 pieces per hour for 1 printed page)
x Duplex printing at 15 sheets per minute
x 1,000 sheet capacity with two 500 sheet trays
x For Launch, High Capacity option adds two 500 sheet
trays
Prints and inserts in one step, typically into window
envelopes
Printer paper path is covered to help ensure privacy
A4 or letter size paper only for printing with inserting (not
Legal, no odd sizes)
Printed sheets can be C or Single folded and inserted or
inserted into flats without folding (no Top Address Z fold for
integrated printing)
Printing option adds approx. 4 feet (1.22 m) to the length of
the system
System as shown is approx. 110” long on table
Printer can also be used for normal printing applications
Inserter can also be used for standalone inserting
applications.
For launch, full support for printer tray switching
For launch, no marks required on documents when running
jobs with a fixed number of pages per document
Print and insert from most Microsoft Windows applications
Supports all DI900/DI950 scanning functions except for BOC
control
Fully integrated with PB FIRST PD and DF
Jobs can run open loop (without Process Verification)
x Reprinting works just like standalone printer and inserter.
Fully integrated with Process Verification software to provide
maximum integrity, automated reprinting, and job reports.
General capabilities
Operates with other DI900/DI950 options, including stackers,
postage printing and one high capacity sheet feeder
Adjustable height furniture available
Works with new flats sealer/edge marker option
Can be added in the field to existing DI900/DI950 installations
Comparison to DocuMatch
Color printing option available
Monochrome operates over 3 times faster than DocuMatch, color
more than 2 times faster
Uses OMR or barcode on document to control insertion and
ensure maximum integrity
Folds up to 8 sheets vs. 4 for DocuMatch
Inserts up to 25 sheets into flats
Add up to 6 pre-printed sheets or 2 sheets plus 4 inserts vs. 2
sheets and 1 insert for DocuMatch
Can produce #11, 6x9½, and flat envelopes in addition to #10
Full DI900/DI950 inserter capabilities for off-line printed jobs
Window envelopes only, no matching for Beta
Supports mailing machine interface for one-step mail production
Works with 240V, A4 paper size for applications outside the US.
System controlled and monitored by attached PC.
Pitney Bowes Confidential Wave 2 v2
Attached Printer
Flats Sealer

1-6 SV61611 Rev. B
1 • Introduction
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 accessi-
ble. 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 piec-
es 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 enclos-
es 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 contact 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 com-
plete 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.
• Use only approved supplies, in particular aerosol duster. Improper stor-
age 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.
Safety
Information

SV61611 Rev. B 1-7
Introduction • 1
• 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 mal-
function. 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 enclos-
es 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
Information
(continued)
Warning Labels The following warning labels are attached to modules on the system to alert
you to potential injury that could occur with careless operating procedures.
These same labels will be shown throughout the manual as they apply to
the various modules that are discussed in that section.
NOTICE CAUTION
Moving mechanism can result
in personal injury.
Keep hands, long hair, ties,
jewelry and loose clothing
away from moving parts.
CAUTION
Moving mechanism can result in
personal injury.
Keep hands, long hair, ties,
jewelry and loose clothing away
from moving parts.

1-8 SV61611 Rev. B
1 • Introduction
This remaining chapters in this book contain setup, operation, troubleshoot-
ing and reference information about your document inserting system.
• Chapter 2, Meet the Inserting System - orients you to system software
and hardware components.
• Chapter 3, Basic Operation - explains basic steps for running a job.
• Chapter 4, Advanced Operation - describes advanced procedures.
• Chapter 5, Troubleshooting - explains screen adjustment procedures,
lists errors and their corrective actions, and describes routine mainte-
nance procedures.
• Chapter 6, Reference - lists system specifications.
• Chapter 7, Add-On Modules - provides a brief description of each add-
on module.
• Chapter 8, Scanning - explains scanning options.
• Appendix A, Glossary - contains definitions for commonly used terms,
and explanations of the icons you'll see on the display screen.
NOTE: Machine Keys will appear in all capital letters. Option Keys will appear in
Initial Caps in quotes ("). Variables within options will appear in quotes (") and in
the same case as shown on the screen.
Book Contents

2-1
SV61611 Rev. B
System Components ...................................................................2-2
Feeder Tower...............................................................................2-4
Feeder Trays ...............................................................................2-5
Sheet Trays ........................................................................... 2-5
Insert Trays............................................................................ 2-6
Manual Feeder ............................................................................2-7
Transport Deck ............................................................................2-8
Mail Piece Path...................................................................... 2-8
Pre-fold Accumulator ............................................................. 2-8
Folder .................................................................................... 2-9
Post-fold Accumulator ........................................................... 2-9
Insertion Area ........................................................................ 2-9
Folder Bypass Path ............................................................... 2-9
Moistener, Closer, Sealer ...................................................... 2-9
About the Control Panel ............................................................2-10
Screen Option Keys............................................................. 2-10
Fixed Function Keys .............................................................2-11
Machine Action Keys ........................................................... 2-13
Screen Navigation Keys ...................................................... 2-13
Display Screen ..........................................................................2-14
Header Area ........................................................................ 2-14
Status Area .......................................................................... 2-15
Access Rights............................................................................2-20
Logging In............................................................................ 2-21
Logging Out ......................................................................... 2-21
About System Covers................................................................2-22
Opening the Covers............................................................. 2-23
Closing the Covers .............................................................. 2-23
About the Paper Release Knobs/Levers ...................................2-24
About Add-On Modules .............................................................2-24
2 • Meet the Inserting
System

2-2 SV61611 Rev. B
2 • Meet the Inserting System
The base system configuration includes a Feeder Tower, Transport Deck,
and Envelope Sealer; the SI5400 features an additional integrated High Ca-
pacity Envelope Feeder. Additional modules can be added to utilize the full
potential of the system.
System
Components
1Feeder Tower Trays - feed sheets or inserts to the Feeder Tower.
NOTE: If enabled, the lower left Tray is assigned with the letter "A" on
the Mail Piece Icon Tree. When a High Capacity Envelope Feeder is not
part of the system conguration, this Tray is the primary Tray for feeding
envelopes designated for a given job.
2Feeder Tower - is a two-sided Tray holder/material feeder.
SI5400 only
Figure 2.1: The SI5200 System
2
34567
8
9
10
1
11