If you go into the admin setting when using the web browser you can enter the email setting one of the options is binary, if you turn off or on depending on the setting it should stop this fault.
It sounds like a couple of things could happening that are possible causes of this:
First, your print controller has the Scanned File Separation selection set to 'Yes'. On the print server's web page check the Scan tab, then Scan Setting and look for the option. It will be a pull-down menu option. Set it to 'No'
Next, it's possible your Maximum Scan File Size and/or your default scan resolution create files that exceed the maximum file size limit of your mail server.
To check this, at the copier control panel get to the setup screen, then Network Setup -> Server Setup -> E-mail Setup and check the Maximum Scan File Size setting to make sure it doesn't exceed your IT's email size limits. In conjuction with that check the default scan resolution to make sure you're not creating scans that exceed the file size limit.
Hope this helps.
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Scan to emails are received as multiple email attachments with a .dat file extension.
Solution
CAUSE: The HDD is not set or has become corrupt and needs to be formatted.
SOLUTION: Set and format the HDD
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