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Pitney Bowes DI380 Series User Manual

Pitney Bowes DI380 Series
122 pages
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DI380/DI425 Series
Document Inserting Systems
(Includes Secap models SI3300/SI3500)
Service Manual
FORM SDT333A (4-06)

Table of Contents

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Pitney Bowes DI380 Series Specifications

General IconGeneral
Double Document DetectionYes
Weight385 lbs
Envelope Capacity325 envelopes
Fold TypesC-fold, Z-fold, half-fold
Optical Mark Recognition (OMR)Optional
Barcode RecognitionOptional
Output Stacker Capacity500
ConnectivityEthernet, USB
Document Size5" x 7" to 14" x 9"
Document Sizes5" x 7" to 14" x 9"

Summary

SECTION 1 Introduction

1.1 Purpose

Manual supports installation and site repair of the DI380/DI425/SI3300/SI3500 Inserter.

1.2 Equipment Covered

Manual applies to sheet feeder, accessories, and interface kits for tabletop system operation.

1.5 Safety Summary

Explains warning, caution, and important messages for safe operation and potential hazards.

1.6 Equipment Safety

Guidelines to protect sensitive equipment from static damage and general safety precautions.

SECTION 2 Specifications

2.1 Material Specifications

Details sheet feeder, insert feeder, paper weights, fold configurations, and thickness limits.

2.2 Machine Specifications

Provides physical dimensions, noise level, electrical requirements, and maximum speed for models.

SECTION 3 Theory of Operation

3.1 Introduction to System Theory

Explains the low volume, easy-to-use nature of the Folding/Inserting machines.

3.2 Single Sheet Feeder Mode & Linked Feeder Mode

Describes the process of feeding a single sheet with an envelope and collation.

3.3 Insert Feeder Mode

Details the process of feeding a single insert with an envelope and collation.

3.9 Double Detect Sensors

Explains the function and positions of double detection sensors.

SECTION 4 Removal & Replacement

4.1 Removing Covers and P.C.B

Steps for removing machine covers and the logic board.

4.3 Removing Sheetfeeder Separator Roller & Pad

Steps to remove the sheet feeder separator roller and pad assembly.

4.8 Dismantling Insert Feeder (DI380) Only

Detailed steps for dismantling the DI380 insert feeder.

4.12 Removing Envelope Feeder (DI425/SI3500 Only)

Instructions for removing the envelope feeder for DI425/SI3500.

4.21 Removal of the Power Supply Unit and AC Motor

Steps to remove the power supply unit and AC motor.

SECTION 5 Adjustments

5.1 Envelope feed tray guides (DI380/SI3300 Only)

Adjusts side guides to the middle of the tray for proper feed.

5.2 Envelope Feeder Offset Adjustment (DI425/SI3500 Only)

Enables envelope to feed biased left or right for better insertion.

5.6 Insertion Flipper Actuation Height/ Hold Down Solenoid Adjustment

Adjusts flipper height and hold down solenoid for proper operation.

5.10 Fold Plates 1 and 2 Offset

Sets offset values for fold plates to match job setup dimensions.

5.12 Q Station Adjustments

Covers alignment, calibration, and height adjustments for the Q station.

SECTION 6 OMR

6.1 A Brief Overview of OMR on this system

Explains OMR sensor placement, adjustability, and paper size support.

6.2 OMR Specifications

Details mark requirements, paper weight, width, and clear zone specifications.

'Standard' OMR Positions

Illustrates standard OMR mark placement for different fold types.

6.3 OMR Mark Grouping

Explains OMR code structure, groups, and data marks for different folds.

6.16 Enabling the OMR Features

Steps to enable Basic OMR and Enhanced OMR options.

SECTION 7 Service Menu & Troubleshooting

7.1 Entering the Service Menu

Steps to access the service menu and navigate its options.

7.2 Parameters Menu

Allows engineers to change NVM settings, including machine configuration.

7.3 Service Diagnostics

Guides for testing components using the control panel.

7.5 Fault Finding Charts

Detailed charts correlating error codes with operator checks and diagnostics.

SECTION 8 Preventive Maintenance

8.1 General Information

Overview of service intervals and items to check, clean, or replace.

8.2 The 100K service

Checklist for 100,000 cycle preventive maintenance.

8.3 The 200K service

Checklist for 200,000 cycle preventive maintenance.

SECTION 9 Installation

9.1 UNPACK AND CHECK

Steps for unpacking the machine, checking for damage, and initial setup.

9.2 OPERATOR TRAINING

Guide for training operators on machine layout, functions, and operation.

SECTION 10 Diagrams

10.1 FLOW DIAGRAMS

Visual representation of machine operation for DI380/SI3300 and DI425/SI3500.

10.2 COMPONENT LOCATIONS

Diagrams showing the location of various components on the PCBs.

10.3 SWITCHES, SENSORS, MOTORS, SOLENOIDS TEST LEVELS

Tables detailing test levels for mechanical switches, barrier switches, and sensors.

10.6 SCHEMATIC - INSERTION/MOISTENER/EXIT AREAS

Schematic showing wiring for insertion, moistener, and exit areas.

10.13 SCHEMATIC - DISPLAY/PSU

Schematic for the display and power supply unit connections.

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