unpacking your RENA L-300 Labeler

unpacking your RENA L-300 Labeler WARNING THE L-300 IS A HEAVY MACHINE. USE PROPER LIFTING TECHNIQUES TO SET IT ON A WORK SURFACE. NEVER LIFT OR MOVE THE L-300 BY ITS HEAD. ONLY LIFT OR MOVE THE XL BY ITS BASE. Each L-300 is assembled and tested by the manufacturer. Once tested, the L-300 is disassembled and packed in two boxes for shipping. 1. Before unpacking the contents of these boxes, inspect each box for any sign of shipping damage. NOTE Shipping damage is the carrier s responsibility and must be reported to the same immediately. 2. Unpack the contents, noting how everything is packed. Remove and save all packing materials (plastic, foam and cardboard) until you have successfully operated your L-300. 3. Inspect the contents for damaged or missing parts. The smaller box contains the head. The larger box contains the base, and the four accessories illustrated below (which are packed and nested in foam): (1) TAKE-UP SPOOL with CLIP (2) FEED WEDGE (3) POWER CORD (4) PRESS ROLL 4. Report any damaged or missing parts to the carrier and your RENA dealer. If you need additional assistance, contact RENA Systems at 888-444-7362. 5. Read all assembly, power and operating instructions in the before using your L-300. 03/2003 3200-UP

RENA SYSTEMS, INC. L-300 Stand Alone Labeler YOUR IS COVERED UNDER WARRANTY BY THE DEALERSHIP FROM WHICH YOU PURCHASED IT. IF YOU HAVE ANY QUESTIONS ABOUT YOUR TABBER OR ITS WARRANTY, CALL YOUR LOCAL RENA DEALER. 03/2003 Part #: 3200

TABLE OF CONTENTS 1. INTRODUCTION...1 1.1 Organization of this...1 1.2 FCC Statement...1 1.3 L-300 Description...1 1.4 Items Included...2 1.5 Safety Terms...4 1.6 Safety Precautions...5 1.7 Terms...6 1.8 Warranty...7 1.9 Copyrights & Trademarks...7 1.10 Ordering Additional Equipment...8 2. SPECIFICATIONS & REQUIREMENTS...9 2.1 Specifications...9 2.2 Operating Requirements...9 3. POWER CONNECTION...10 3.1 Safety...10 3.2 Line Voltage...10 3.3 Line Fuses...12 3.4 Power Cord...13 4. ASSEMBLY...14 5. CONTROLS...17 5.1 Feed...17 5.2 Speed...17 5.3 Label...17 5.4 Label Position 1 & 2...18 5.5 Label Ready...18 5.6 LCD...18 5.7 Missing Label...18 5.8 Move Label Lead / Trail...19 5.9 Piece Ready...20 5.10 Reset Counter...20 5.11 Run/Thread Knob...20 5.12 Tray Height Adjustment Knob...20 6. HIDDEN CONTROLS...21 6.1 Metric Units...21 6.2 English Units...21 6.3 About L-300...22 03/2003 i

7. OPERATION...23 7.1 Threading Labels...23 7.2 Programming Label Position...25 7.3 Feeding Mail Pieces...25 7.4 Applying Labels...28 7.5 Stop Labeling...28 7.6 Resume Labeling...29 7.7 Splicing Labels...29 7.8 ZIP Code Sorting...30 8. LCD MESSAGES...31 8.1 Label Is Missing...31 8.2 Position Label On Mail Piece...31 8.3 Label Take-Up Spool Is Full...31 8.4 Feeder Jam...32 8.5 Transport Jam...32 9. MAINTENANCE...34 9.1 Cleaning...34 10. TROUBLESHOOTING...38 10.1 Troubleshooting Chart...38 11. SERVICE...41 11.1 Service...41 11.2 Repacking Instructions...41 ii 03/2003

1. INTRODUCTION 1.1 Organization of this Operating Manual This manual starts with a description of your L-300, then describes its set up, operation and maintenance. Finally, information is offered to help you determine what can go wrong and what to do about it. There are many helpful tips along the way, and it is strongly suggested that you become familiar with this entire manual prior to operating the L- 300. 1.2 FCC Statement This equipment has been tested and found to comply with the limits for Class A digital device pursuant to Part 15 of FCC Rules. These limits are designed to provide reasonable protection against harmful interference when this 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 instructions in this manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his/her own expense. 1.3 L-300 Description The L-300 is an automatic labeling machine that applies 1-up pressure-sensitive labels to mail pieces. Unlabeled mail pieces are stacked in the feed tray. Two paper guides hold this stack in position as the mail pieces are fed through the L-300. A feed wedge improves the feeding of certain types of mail pieces. 03/2003 1

The stack is separated into single pieces by separators and feed rolls which feed the mail pieces into the L-300. A photosensor (electric eye) in the base sees each mail piece and transmits information to the microprocessor which controls the L-300. When the photosensor sees a mail piece, the microprocessor waits for the programmed delay, then directs the label feed motor to advance the labels. A second photosensor sees the end of the label and signals the microprocessor to stop advancing labels. As the label strip exits between the label door and the label chute, the peel bar peels the label from the backing paper. At this point, the mail piece contacts the label and the press roll presses the label onto the mail piece. The labeled mail piece exits the L-300, usually onto an material catch tray or TB-356 conveyor. 1.4 Items Included The following items are shipped separately in two boxes. Take note of each as you unpack both boxes. (Refer to Figure 1.1.) smaller box RENA L-300 Head larger box RENA L-300 Base Feed Wedge Press Roll Take-Up Spool with Clip Power Cord L-300 2 03/2003

Figure 1.1 -- The RENA L-300, Exploded View WARNING THE L-300 IS A HEAVY MACHINE. USE CORRECT LIFTING TECHNIQUES TO SET IT ON A WORK SURFACE. CAUTION DO NOT LIFT OR MOVE THE L-300 BY ITS HEAD. ONLY LIFT OR MOVE THE L-300 BY ITS BASE. 03/2003 3

1.5 Operating Manual Safety Terms The following highlighted blocks are used throughout this manual to emphasize important information. Pay careful attention to this information. WARNING ALERTS YOU TO ACTIONS OR CONDITIONS WHICH MAY PRESENT HAZARDS OR CAUSE INJURY TO PERSONNEL. CAUTION ALERTS YOU TO ACTIONS WHICH MAY CAUSE LOSS OF MATERIALS (MAIL PIECES AND LABELS) OR DAMAGE TO EQUIPMENT. NOTE Draws your attention to an important statement or action. TIP A suggestion to enhance the L-300 s productivity. 4 03/2003

1.6 Safety Precautions Observe the following safety precautions and warnings when operating, cleaning or repairing the L-300. Failure to do so may result in physical injury or damage to the L-300. The manufacturer assumes no liability for your failure to comply with these requirements. WARNING NEVER CLEAN, CLEAR OR DISASSEMBLE THE L- 300 WITHOUT FIRST UNPLUGGING THE POWER CORD. WARNING KEEP LOOSE CLOTHING, TIES, SCARVES AND HAIR AWAY FROM ALL MOVING PARTS. WARNING DO NOT PLACE FINGERS OR TOOLS BETWEEN OR NEAR MOVING PARTS. 03/2003 5

1.7 Operating Manual Terms The following terms are used throughout this manual: operator side non-operator side rear front leading edge trailing edge backing paper leader side of L-300 where the controls are located opposite the operator side input end output end edge of mail pieces that enters and exits the L-300 first edge of mail pieces that enters and exits the L-300 last paper holding the labels on the label strip leading portion of the label strip with the labels removed application point point where the label is applied to the mail piece 6 03/2003

1.8 Warranty NOTE Your RENA L-300 is covered under warranty by the dealership from which you purchased it. If you have any questions about the L-300, its warranty, or your authorized RENA Systems dealer, simply call 888-444-7362. RENA Systems, Inc. warrants your RENA L-300 against defects in materials and workmanship for a period of ninety (90) days from the original ship date when used in accordance with the operating instructions in this manual. This warranty covers the cost of parts when the machine is presented by its original purchaser to an authorized RENA Service Center. Should warranty repairs become necessary, the service provider, at his/her option, will repair or replace such parts required to restore the L-300 to serviceable condition. This warranty does not cover consumable parts such as belts, rollers and sweeps used to contact and transport mail pieces and tabs. This warranty does not extend to incidental or consequential damages arising out of a warranty claim, or to costs associated with maintenance of the equipment. This warranty does not cover damages resulting from shipping, accident, misuse, abuse, neglect, mishandling, alteration or modification. Contact your local RENA dealer should difficulties arise with any warranty claim. 1.9 Copyrights & Trademarks Copyright 2003 by RENA Systems, Inc. All rights reserved. This publication is protected by U.S. copyright law. No part of this publication may be copied, transferred or distributed without the express written permission of RENA Systems, Inc. 03/2003 7

1.10 Ordering Additional Equipment To order, or find out about, additional RENA Systems equipment, contact an authorized RENA dealer. To locate an authorized dealer in your area, call RENA Systems at 888-444-7362. RENA L-300 LABELER RENA TB-356 CONVEYOR RENA T-L SLIDE STAND RENA T-600 IN-LINE TABBER. Figure 1.2 -- In-line labeling, tabbing & sorting with RENA Systems Equipment. 8 03/2003

2. SPECIFICATIONS & REQUIREMENTS 2.1 Specifications Size 20" l x 16" h x 21" w Weight 69 lb. assembled Power Possible line voltages are 240V, 230V, 220V, 120V, and 100V at 50-60 Hz 2.2 Operating Requirements Mail Piece Size Length: 3" minimum, 14" maximum Width: 4 1 / 2 " minimum, 16" maximum Mail Piece Thickness Minimum: single sheet of 20 lb. bond paper tri-folded Maximum: 1 / 4 " Label Size Length: 15 / 16 " minimum, 4" maximum Width: 2 3 / 8 " minimum, 6" maximum Space: There must be some space between labels on the backing paper) Label Position Accuracy ± 1 / 16 " guaranteed when using non-expired labels designed for machine application Production up to 15,000 mail pieces per hour (based on #10 envelope) 03/2003 9

3. POWER CONNECTION WARNING BEFORE PLUGGING THE L-300 INTO AN OUTLET, CAREFULLY READ THE FOLLOWING INFORMATION ABOUT VOLTAGES, FUSES AND THE POWER CORD. 3.1 Safety The L-300 can connect to any power distribution system, including the European IT Power System. Because the European IT Power System does not have a grounded neutral leg, the L-300 uses protective fusing in both the neutral and hot supply lines of power. WARNING A BLOWN FUSE IN THE NEUTRAL LEG COULD MEAN INTERIOR PARTS OF THE L-300 REMAIN AT A HAZARDOUS VOLTAGE. ALWAYS UNPLUG THE POWER CORD BEFORE SERVICING THE L- 300. 3.2 Line Voltage The L-300 is rated for continuous operation using a variety of supply voltages. Possible line voltages are 240V, 220V, 120V and 100V at 50 or 60 Hz. The manufacturer configures the L-300 to operate with the voltage requested by the customer. CAUTION VERIFY THE CORRECT VOLTAGE SETTING BEFORE PLUGGING THE L-300 INTO AN OUTLET. Read the current voltage setting through the VOLTAGE SELECTOR WINDOW on the non-operator side of the L- 300. (Refer to Figure 3.1.) Use the following instructions to change the voltage setting: 10 03/2003

NOTE The detachable POWER CORD may have to be changed to match the particular power-source output. 1. Unplug the POWER CORD. 2. Use a small screwdriver or similar tool to push up on and release the FUSE DRAWER LOCKING TAB. 3. Pull the FUSE DRAWER out of the POWER ENTRY CASING. 4. Pull the VOLTAGE SELECTOR out of the FUSE DRAWER. 5. Rotate the VOLTAGE SELECTOR until the correct voltage is on the same side as the VOLTAGE SELECTOR WINDOW. 6. Place the VOLTAGE SELECTOR in the FUSE DRAWER and verify the correct voltage selection. 7. Place the FUSE DRAWER in the POWER ENTRY CASING. Figure 3.1 -- Power Connection 03/2003 11

3.3 Line Fuses The FUSE DRAWER located on the non-operator side contains two LINE FUSES. (Refer to Figure 3.1.) The neutral and hot lines of power are fused. Both LINE FUSES must be intact for the L-300 to operate properly. CAUTION VERIFY THAT THE LINE FUSE VALUE IS CORRECT FOR THE VOLTAGE SETTING. UNPLUG THE L-300 BEFORE STARTING THIS PROCEDURE. Use the following instructions to verify that the LINE FUSES installed have the proper fuse value or to replace a blown fuse: 1. Unplug the POWER CORD. 2. Use a small screwdriver or similar tool to push up on and release the FUSE DRAWER LOCKING TAB. 3. Pull the FUSE DRAWER out of the POWER ENTRY CASING. The LINE FUSES are inside. 4. Determine the proper fuse value as well as the condition of the LINE FUSE. The fuse value is shown on the metal tip of the LINE FUSE. The chart below lists the selected voltage in the left column followed by the proper fuse value in the right column. Selected Voltage Fuse Value 100V... 2.0A (250V time delay) 120V... 2.0A (250V time delay) 220V... 1.0A (250V time delay) 240V (or 230V)... 1.0A (250V time delay) 5. Replace the LINE FUSE if necessary. Both LINE FUSES must be intact for the L-300 to operate properly. 6. Install the FUSE DRAWER in the POWER ENTRY CASING. 12 03/2003

3.4 Power Cord The L-300 comes with a three-wire POWER CORD. The POWER CORD grounds the L-300 when connected to an approved three-contact electrical outlet. 1. Plug the POWER CORD into the APPLIANCE INLET on the non-operator side. (Refer to Figure 3.4.) 2. Plug the POWER CORD into a grounded outlet. WARNING TO PREVENT ELECTRICAL SHOCK, ONLY PLUG THE POWER CORD INTO A GROUNDED OUTLET. 03/2003 13

4. ASSEMBLY WARNING BEFORE PLUGGING THE L-300 INTO AN OUTLET, CAREFULLY READ SECTION 3 ON POWER CONNECTION. 1. Unscrew and save the four SHIPPING KNOBS fastened underneath the BASE. (Refer to Figure 4.1.) A colored tab is placed on each SHIPPING KNOB. These knobs prevent FEED TRAY movement during shipping. If you need to ship your L-300, lower the FEED TRAY as far it allows, and screw in the SHIPPING KNOBS. NOTE The L-300 will not operate until the SHIPPING KNOBS are removed. Figure 4.1 -- Attaching Head to Base 14 03/2003

Figure 4.2 -- L-300 Components 2. Attach the HEAD to the BASE by sliding the two lower hooks on the rear of the HEAD into the two SLOTS on the BASE. (Refer to Figures 4.1 & 4.2.) This will align the male and female halves of the CONNECTOR. The CONNECTOR electronically links the HEAD and the BASE. 3. The two plastic guides on the bottom of the HEAD allow the HEAD to slide from side to side on the BASE. 4. Place the FEED WEDGE on the FEED TRAY. (Refer to Figure 4.2.) CAUTION DO NOT PLACE THE FEED WEDGE VERY CLOSE TO FEED ROLLS OR THE PADDLE WHEEL. 03/2003 15

5. Place the TAKE-UP SPOOL in the HEAD. (Refer to Figure 4.3.) Place the gear end of the TAKE-UP SPOOL in the hole above the gear in one HEAD side frame. Slide the other end of the TAKE-UP SPOOL into the slot in the opposite HEAD side frame. 6. Attach the CLIP to the TAKE-UP SPOOL. 7. Lift the PRESS ROLL LATCHES and place the PRESS ROLL in the two slots under the PRESS ROLL LATCHES. (Refer to Figure 4.3.) NOTE All components must be in place for the L-300 to operate properly. Figure 4.3 -- L-300 Head Components 16 03/2003

5. CONTROLS This section lists L-300 controls alphabetically and explains the function of each. (Refer to Figure 5.1.) Figure 5.1 -- L-300 Control Panel 5.1 Feed Turn the Feeder ON and OFF by pressing FEED. The FEED light illuminates when Feeder is ON. To begin feeding, slide the SPEED CONTROL to a desired speed from 1 to 10. 5.2 Speed Slide the SPEED CONTROL to STOP to stop feeding. Slide it to the right to feed at increasing speeds from 1 (slow) to 10 (fast). 5.3 Label Toggle LABEL ON and OFF to start and stop labeling. The LABEL light illuminates when LABEL is ON. 03/2003 17

5.4 Label Position 1 & 2 Frequently used label settings can be saved in one of the two LABEL POSITION controls. When a label position is programmed into memory, the L-300 will remember that setting until it is changed. When preparing to label, press either LABEL POSITION 1 or LABEL POSITION 2 for the L-300 to adjust the labels to the programmed position. To save a LABEL POSITION: 1. Press either MOVE LABEL LEAD or MOVE LABEL TRAIL until labels are in the desired position. 2. Hold down PROGRAM and press LABEL POSITION 1 or LABEL POSITION 2. 3. The LCD will verify the action. 5.5 Label Ready The LABEL READY light will illuminate each time a label is at the application point. 5.6 LCD When the POWER SWITCH is ON, the LCD displays the current number of labeled mail pieces and the current label position. Saved settings and error messages are also displayed on the LCD when appropriate. 5.7 Missing Label Toggle MISSING LABEL ON and OFF to enable or disable the MISSING LABEL detect feature. The MISSING LABEL light illuminates when the MISSING LABEL is enabled. The MISSING LABEL control is used for sorting by ZIP Code. When MISSING LABEL is ON, labeling and 18 03/2003

feeding stop when a missing label is detected. When this happens, the LCD displays the message LABEL IS MISSING. To resume labeling, toggle LABEL and FEED ON. NOTE The TRANSPORT DRIVE does not stop when the FEED and the LABEL controls are turned off, so mail pieces already fed will exit unlabeled. When the MISSING LABEL feature is OFF and a label is missing, the L-300 will apply the next available label as if no label were missing. This allows for nonstop labeling even if unwanted labels were intentionally removed. The L-300 will automatically stop labeling and feeding if another label isn t sensed after approximately 4". The error message LABEL IS MISSING is shown on the LCD. 5.8 Move Label Lead / Trail The label position displayed on the LCD is based on the label s distance from the leading edge. For example, if the LCD displays POSITION 04.0 IN, the label is 4" from the leading edge. Press MOVE LABEL LEAD or MOVE LABEL TRAIL to move the current label position in the direction of the arrows on the CONTROL PANEL in.1" increments (0.2 cm increments). NOTE When the label is placed beyond the trailing edge of the mail piece and its position is changed while labeling, adjust the LABEL POSITION slowly to avoid a jam. When the label position is changed from either LABEL POSITION 1 or LABEL POSITION 2, the label position will return to the last used position before the LABEL POSITION 1 or 2 was selected. 03/2003 19

5.9 Piece Ready The PIECE READY light illuminates when a mail piece approaches the application point. 5.10 Reset Counter Pressing RESET COUNTER clears the current count of labeled mail pieces. 5.11 Run/Thread Knob This knob is located on the HEAD. Turn knob toward THREAD when threading labels. This allows the leader to pass between the FLOAT ROLL and the GRIT ROLL inside the HEAD. Turn knob toward RUN to label. NOTE Always make sure to turn the RUN/THREAD KNOB to RUN before labeling. 5.12 Tray Height Adjustment Knob This knob is located on the input end of the L-300. Moving the tray height adjusts the gap between the SEPARATORS and FEED ROLLS. This gap must be adjusted to feed one mail piece at a time. To enlarge the gap, turn knob counterclockwise toward THICK. To reduce the gap, turn knob clockwise toward THIN. You may need to turn this knob several times to reach the desired gap. 20 03/2003

6. HIDDEN CONTROLS NOTE To access hidden feature, several L-300 controls must be pressed. Therefore, always clear the LCD display after using or setting a hidden feature. 6.1 Metric Units NOTE Make sure FEED is OFF before programming the L-300 for Metric units. To program the L-300 for Metric units: 1. Hold down the PROGRAM and ABOUT controls simultaneously. 2. While holding down the controls listed above, press LABEL. 3. The LCD will verify the action, then return to its normal display. The following information is loaded into memory for Metric default positions: Label Position... 5 cm Label Position 1... 5 cm Label Position 2... 15 cm 6.2 English Units NOTE Make sure FEED is OFF before programming the L-300 for English units. To program the L-300 for English units: 1. Hold down the PROGRAM and ABOUT controls simultaneously. 03/2003 21

2. While holding down the controls listed above, press FEED. 3. The LCD will verify the action, then return to its normal display. The following information is loaded into memory for English default positions: Label Position... 2 in. Label Position 1... 2 in. Label Position 2... 6 in. 6.3 About L-300 To view the firmware version (revision status) of your L- 300: 1. Hold down the PROGRAM and ABOUT controls simultaneously. 2. While holding down the controls listed above, press MISSING LABEL. 3. The LCD will display the version number for approximately 2 seconds, then return to its normal display. NOTE The LCD may display the missing label size after displaying the firmware version. Press MOVE LABEL TRAIL to exit the missing label size display. 22 03/2003

7. OPERATION 7.1 Threading Labels WARNING UNPLUG THE POWER BEFORE THREADING THE L-300. 1. Place a stack of labels face up in the LABEL TRAY. Pull out the LABEL TRAY EXTENSION if necessary. (Refer to Figure 7.1.) 2. Turn the RUN/THREAD KNOB to THREAD. 3. Lift the PRESS ROLL LATCHES and pull the PRESS ROLL out of the slots. 4. Peel blank labels from approximately the first 2 feet (60 cm) of the label strip. Remove any paper curl from the leader. Figure 7.1 -- The L-300 Head Exploded View 03/2003 23

5. Thread the leader under the LABEL GUIDE BAR. (Refer to Figure 7.1.) 6. Loosen and slide the LABEL GUIDES as far apart as possible. 7. Pull up the bottom of the LABEL CHUTE until it is in a horizontal position. 8. Pull the white LABEL CHUTE PROP out to support the LABEL CHUTE. This prop is located behind the LABEL CHUTE and rests against the HEAD. 9. Slide the leader between the LABEL CHUTE and the LABEL DOOR, keeping the leader straight. 10. Thread the leader over the LABEL DRIVE ROLL and under the IDLER ROLL inside the HEAD. (Refer to Figure 7.2.) 11. Make sure the leader is threaded between the THREADING GUIDES. The leader will appear at the rear of the HEAD near the TAKE-UP SPOOL. NOTE If the edge of the leader has any curl, it may thread above the THREADING GUIDES and appear behind the IDLER ROLL. Figure 7.2 -- The L-300 Head, Inside View 12. Pull the leader approximately 2" past the TAKE-UP SPOOL. 13. Lift the LABEL CHUTE slightly and push the LABEL CHUTE PROP back against the HEAD. 24 03/2003

14. Push the LABEL CHUTE back against the HEAD until it locks into position. NOTE The L-300 will not operate properly if the LABEL CHUTE is not locked into position. 15. Pull the leader straight until there is no slack in the backing paper. 16. Close both LABEL GUIDES against the LABEL STRIP and tighten. 17. Remove the CLIP and wrap the leader around the bottom of the TAKE-UP SPOOL. Snap the CLIP onto the TAKE-UP SPOOL to secure the leader. 18. Lift the PRESS ROLL LATCHES and place the PRESS ROLL in its slots. 19. Turn the RUN/THREAD KNOB to RUN. 7.2 Programming Label Position To program label position: 1. Press either MOVE LABEL LEAD or MOVE LABEL TRAIL to reach the desired label position. 2. Hold down PROGRAM. 3. While holding down PROGRAM, press either LABEL MEMORY 1 or LABEL POSITION 2. 4. The LCD will verify the action. 7.3 Feeding Mail Pieces CAUTION DO NOT BEGIN FEEDING WHILE THE SEPARATORS ARE TOUCHING THE FEED ROLLS. SUCH ROLLING CONTACT WILL DAMAGE THE FEED ROLLS. 03/2003 25

1. Slide a mail piece in and out of the gap between the SEPARATORS and the FEED ROLLS so that there is moderate resistance on the mail piece. (Refer to Figure 7.3.) Figure 7.3 -- L-300 Input End 2. To increase the resistance, turn the TRAY HEIGHT ADJUSTMENT KNOB clockwise toward THIN. To decrease the resistance, turn this knob counterclockwise toward THICK. 3. Center the leading edge of the mail piece against the PAPER STOP. Rest the mail piece in the FEED TRAY. (Refer to Figure 7.3.) 4. Loosen the PAPER GUIDE ADJUSTMENT KNOBS and slide the PAPER GUIDES against the mail piece. Make sure they are straight and do not bind the mail piece. Tighten the PAPER GUIDE ADJUSTMENT KNOBS. 26 03/2003

5. Place a stack of mail pieces between the PAPER GUIDES. a. Remove as much paper curl as possible from the mail pieces. b. The leading edge of the stack should be straight or shingle slightly into the SEPARATORS and FEED ROLLS. c. The sides of the stack should have straight, even edges and slide easily between the PAPER GUIDES. Figure 7.4 -- Cross Section of Feed Tray CAUTION IMPROPER STACKING WILL CAUSE JAMS. 6. Slide the FEED WEDGE against the stack to help support the back of the stack. (Refer to Figure 7.4.) 7. Turn the POWER SWITCH ON. 8. Slide SPEED CONTROL to STOP. 9. Toggle FEED ON. 10. Slide SPEED CONTROL to any speed (1-10) on the SPEED scale. 11. Watch the feeding mail pieces. If they are not feeding smoothly or one at a time, adjust the TRAY HEIGHT ADJUSTMENT KNOB and/or the SPEED until they feed smoothly. 03/2003 27

7.4 Applying Labels Before labeling, select a label position. The L-300 uses the English or Metric system of measurement. Refer to Section 3.2 to change the present system of measurement. 1. Slide the HEAD to align the label strip with the desired position between the sides of the mail piece. 2. Press either MOVE LABEL LEAD or MOVE LABEL TRAIL to desired label position. 3. Turn the RUN/THREAD KNOB to RUN. 4. Toggle LABEL ON to advance the first label to the application point. The LABEL light will illuminate when the label reaches the application point. NOTE Toggle LABEL more than once if the label strip has at least 4 of empty backing paper before the application point. 5. Toggle FEED ON. 6. Press any speed on the SPEED scale to begin labeling mail pieces. 7. Note the position of the labels. Slide the HEAD to adjust the left-right position of the labels if necessary. 7.5 Stop Labeling Choose one of several ways to stop labeling: Toggle LABEL OFF. Labeling stops; feeding continues. Toggle FEED OFF. Labeling and feeding stop; power remains on. Slide SPEED CONTROL to STOP. Labeling and feeding stop; power remains on. Turn POWER SWITCH OFF. 28 03/2003

7.6 Resume Labeling To resume labeling, find the control you turned off listed in the left column and follow the instructions given at the right. LABEL FEED SPEED POWER Toggle LABEL ON. Press FEED ON. The L-300 will remember the last SPEED selected. Slide SPEED CONTROL to any speed on the SPEED scale. Press POWER, LABEL, FEED and set SPEED to any point on the SPEED scale. 7.7 Splicing Labels NOTE The technique of splicing labels eliminates the bother of re-threading them in the middle of a run. Figure 7.5 -- Splicing Labels 03/2003 29

To splice labels: 1. Peel the first two labels from the leading edge of the new label strip. 2. Attach the two removed labels underneath the leading edge of the new LABEL STRIP. (Refer to Figure 7.5.) 3. Place the old label strip on top of the new label strip and align them (using pin-feed holes) so they are parallel. 4. Apply the labels (perpendicular) to the old label strip so the two label strips are spliced together. 7.8 ZIP Code Sorting To sort mail by ZIP Code while labeling: 1. When printing labels, assign a label break (or endorsement line) at the beginning of each presorted ZIP Code group. 2. Peel the assigned labels from the LABEL STRIP. 3. Toggle MISSING LABEL ON. 4. Toggle LABEL ON and FEED ON. 5. Begin labeling mail pieces. When each missing label area reaches the application point, the L-300 will stop feeding and labeling. The LCD will display LABEL IS MISSING. 6. Put any unlabeled mail pieces that exited the L-300 back in the FEED TRAY. 7. Gather and set aside the labeled mail pieces in that ZIP Code group. Note the count of the labeled mail pieces. 8. Toggle LABEL ON and FEED ON to begin labeling the next presorted group of mail pieces. 30 03/2003

8. LCD MESSAGES 8.1 Label Is Missing condition: response: At least 4" of empty space on the label strip. Toggle LABEL ON until LABEL READY light illuminates. condition: response: A missing label has reached the application point while the MISSING LABEL is ON. Toggle LABEL ON and FEED ON to resume labeling. 8.2 Position Label on Mail Piece condition: response: The label position is programmed beyond the trailing edge of the mail piece. Move the label position closer to the leading edge of the mail piece. 8.3 Label Take-Up Spool is Full condition: response: The TAKE-UP SPOOL is full of waste backing paper. Remove the waste backing paper. 1. Remove the TAKE-UP SPOOL from the HEAD. 2. Unroll some of the backing paper. 3. Tear or cut the backing paper 2-3" from the HEAD. 4. Remove the waste backing paper from the TAKE-UP SPOOL. 03/2003 31

NOTE Do not lose the CLIP while removing the waste backing paper from the TAKE-UP SPOOL. 5. Replace the TAKE-UP SPOOL in the HEAD. 6. Wrap the remaining backing paper around the bottom of the spool and attach it with the CLIP. 7. Toggle LABEL ON and FEED ON to resume labeling. TIP Have a few extra CLIPS on hand as they are easy to lose. 8.4 Feeder Jam condition: rolls. response: One or more mail pieces are jammed between the separators and feed Clear the feeder jam. 1. Turn the POWER SWITCH OFF. 2. Turn the TRAY HEIGHT ADJUSTMENT KNOB counterclockwise to enlarge the gap. 3. Pull the jammed mail pieces out of the FEEDER. 4. Repeat steps 2 and 3 until jammed mail pieces are removed. 8.5 Transport Jam condition: response: One or more pieces are jammed in the transport area. Clear the transport jam. 32 03/2003

Figure 8.1 -- Clearing A Transport Jam 1. Turn the POWER SWITCH OFF. 2. Remove the HEAD. 3. Remove any mail pieces jammed in the TRANSPORT AREA. 4. Remove both TRANSPORT SHAFTS. (Refer to Figure 8.1.) Push the shaft toward its spring-loaded end and pull out the other end. 5. Replace both TRANSPORT SHAFTS. Push the springloaded end into the hole opposite the non-operator side and place the other end into the d-hole on the operator side. 03/2003 33

9. MAINTENANCE 9.1 Cleaning WARNING UNPLUG THE POWER CORD BEFORE REMOVING, ADJUSTING OR REPAIRING ANY PARTS IN THE L-300. You do not need to lubricate any L-300 parts. However, clean the machine regularly to maintain proper operation, preferably after every 100 hours of use, or more frequently if necessary. To clean the L-300: 1. Lift the PRESS ROLL LATCHES and remove the PRESS ROLL. 2. Open the LABEL CHUTE using the LABEL CHUTE PROP for support. (Refer to Figure 9.1.) 3. Turn the RUN/THREAD KNOB to THREAD. 4. Using a cloth with isopropyl alcohol, remove any debris from the IDLER ROLL while rotating it with your fingers. 5. Remove the LABEL DOOR by unscrewing the knobs holding it to the PHOTOSENSOR SUPPORT. 6. Using compressed air, blow any dust or debris off the UPPER LABEL SENSOR and the LOWER LABEL SENSOR. 7. Remove any debris from the LOWER LABEL SUPPORT using a cloth and isopropyl alcohol. 8. Using a cloth and isopropyl alcohol, remove any debris from the LABEL TRAY, LABEL CHUTE, LABEL DOOR and the PHOTOSENSOR SUPPORT surfaces. 34 03/2003

Figure 9.1 -- Cleaning the Head 9. Install the LABEL DOOR. 10. Place the LABEL CHUTE back against the HEAD. 11. Clean the PRESS ROLL using a cloth and isopropyl alcohol. 12. Lift the PRESS ROLL LATCHES and insert the PRESS ROLL into its slots. 13. Turn the TRAY HEIGHT ADJUSTMENT KNOB counterclockwise as far as it will turn to open the gap between the SEPARATORS and FEED ROLLS. (Refer to Figure 9.2.) 14. Clean the PADDLE WHEEL, one side at a time using a cloth and isopropyl alcohol. The PADDLE WHEEL does not rotate easily so push one side down to clean the next side. 15. Using a cloth and isopropyl alcohol, clean both FEED ROLLS while rotating each with your finger. 16. Clean both SEPARATORS using a cloth and isopropyl alcohol. Neither SEPARATOR rotates. 03/2003 35

Figure 9.2 -- Cleaning the Base 17. Remove the HEAD to access the OUTPUT ROLL and TRANSPORT BELTS. (Refer to Figure 9.3.) 18. Using a cloth and isopropyl alcohol, clean the OUTPUT ROLL and TRANSPORT BELTS while rotating each one with your fingers. 19. Using compressed air, blow any dust or debris out of the LOWER PRODUCT SENSOR and the UPPER PRODUCT SENSOR. 20. Remove any labels remaining on or near the UPPER and LOWER PRODUCT SENSORS. 21. Remove the 3 screws in the ACCESS PANEL and remove any labels or debris caught under the TRANSPORT TRAY. 22. Mount the HEAD on the BASE. 36 03/2003

Figure 9.3 -- Cleaning the Base 03/2003 37

10. TROUBLESHOOTING WARNING UNPLUG THE POWER CORD BEFORE REMOVING, ADJUSTING OR REPAIRING ANY PARTS IN THE L-300. 10.1 Troubleshooting Chart TROUBLE CAUSE SOLUTION 1. Nothing works. POWER SWITCH is OFF. 2. Labels are being applied erratically. 3. Multiple labels on a single mail piece. POWER CORD is damaged or not plugged in. Receptacle does not have power present. POWER ENTRY FUSE is blown. RUN/THREAD KNOB is turned to THREAD. LABEL CHUTE is not locked in position. PRESS ROLL is not in its slots. FEED TRAY height is too low for PRESS ROLL to contact mail pieces. Turn POWER SWITCH ON. Replace POWER CORD if damaged or plug into proper receptacle. Check circuit source for a blown fuse or circuit breaker. Replace blown FUSE. (Refer to Section 3.3.) Turn RUN/THREAD KNOB to RUN. Toggle LABEL OFF, lock LABEL CHUTE into position and toggle LABEL ON. Lift PRESS ROLL LATCHES and place PRESS ROLL in its slots. Turn TRAY HEIGHT ADJUSTMENT KNOB clockwise to raise feed tray. 38 03/2003

TROUBLE CAUSE SOLUTION Multiple labels on a single mail piece. --continued-- 4. Labels not being applied to each mail piece. 5. Labels skewing on mail piece. PHOTOSENSOR that detects labels is blocked by debris. PHOTOSENSORS are damaged or not aligned. There is no space between mail pieces, so PHOTOSENSOR only detects one mail piece. LABEL GUIDES are not tight against LABEL STRIP. PAPER GUIDES are not close against mail piece. Debris inside L-300 has put more resistance on mail piece. Mail pieces not centered when feeding. SEPARATORS are not parallel to FEED ROLLS. Clean PHOTOSENSOR located on bottom of PHOTOSENSOR SUPPORT on LABEL CHUTE. Contact your local RENA Systems dealer. Turn TRAY HEIGHT ADJUSTMENT KNOB clockwise to reduce gap and add space between mail pieces. Move LABEL GUIDES tighter against LABEL STRIP. Set PAPER GUIDES close enough to keep mail piece straight while feeding. Remove HEAD from BASE and remove debris (envelope flap, part of label, etc.) Center mail piece in FEED TRAY. Contact your local RENA Systems dealer. 03/2003 39

TROUBLE CAUSE SOLUTION Labels skewing on mail piece. --continued-- 6. Machine will not label. 7. Program light remains lit. Backing paper is crooked. Label position is set beyond the trailing edge of mail piece. PHOTOSENSORS that detect mail are blocked by debris. Photosensors that detect mail are damaged or not aligned. 8. Grating noise. LABEL CHUTE is not locked in position. 9. Heavy rumbling noise. PRESS ROLL is pushing down on OUTPUT ROLL. Check threaded labels. Re-thread if necessary. (Refer to Section 7.1.) If skewing continues, contact your local RENA Systems dealer. Press MOVE LABEL LEAD until label position is set on mail piece. (Section 7.2.) Clean photosensors. Contact your local RENA Systems dealer. Toggle LABEL OFF, lock LABEL CHUTE in position and toggle LABEL ON. Turn TRAY HEIGHT ADJUSTMENT KNOB counterclockwise to lower feed tray height. Make sure PRESS ROLL still touches OUTPUT ROLL. 40 03/2003

11. SERVICE 11.1 Service If any problems occur with this equipment or if you need assistance installing or operating your L-300, contact an authorized RENA dealer. To locate an authorized dealer in your area, call RENA Systems at 888-444-7362. When calling for service, have your L-300 s serial number handy. 11.2 Repacking Instructions If it is necessary to ship your L-300 to your authorized RENA SYSTEMS dealer for service, pack it in the original shipping container and packaging material. If the original container is not available, contact your dealer to obtain replacement materials. Non-authorized packaging will be refused. NOTE If the L-300 is packed correctly, your Shipping Carrier is liable for any damages that occur during shipping. 03/2003 41