Formax CT-10 User manual

CT-10
Envelope Feeder for ColorMaxT4 / ColorMaxT5
INSTALLATION MANUAL
10/2016

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The CT-10 Envelope Feeder is designed to operate with the ColorMaxT4 / ColorMaxT5 printers. This guide
will show the proper way to prepare the printer for the envelope feeder and installation and operation
of the feeder.
PREPARING THE LASER PRINTER FOR THE ENVELOPE FEEDER
1. To prepare the printer for the CT-10 Feeder, you must first remove the door from the manual feed
tray. First, open the manual feed tray door on the right side of the printer.
2. Press inward on the right side hinge of the door to release it from the slot
3. Press inward on the pivot point of the door on the right side to remove it from the printer housing

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4. Remove the left side of the door in the same fashion and remove the door from the printer.
5. Open the right side cover on the printer by pulling on the latch shown here:
6. With the right side door fully open, lift the feed roller assembly to gain access to the feed roller and sheet
separator area.
7. Pinch the two upper corners of the sheet separator assembly (rubber pad) and remove the assembly from the
printer
Remove the separator assembly

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NOTE: The envelope feeder is equipped with a paper sensor that will be positioned just to the left of the printer’s
manual feed tray feed roller. It is possible for the sensor to detect the white plastic housing just to the left of the
feed roller, which can cause erratic feeding. It is very important to place a piece of black tape or Velcro
(included with feeder) on this ledge so the sensor does not detect it.
Note: This tape will not affect the printer and can be left in place, even when not using envelope feeder!
ADJUSTABLE HEIGHT STAND ASSEMBLY INSTRUCTIONS
Your new dͲϭϬŶǀĞůŽƉĞ&ĞĞĚĞƌ is packaged with the adjustable height floor stand removed and partially
disassembled. With a single 1/8” allen wrench, (included with the feeder) the stand can be re-assembled and the
feeder can be attached to the stand.
Step 1.
Carefully remove the feeder and the stand components from the box and set them on the floor or a large table.
Step 2.
Remove the locking levers and flat washers from the two leg assemblies
Place black tape on this
area.
Upper stand assembly
2 Leg assemblies (with casters)
Feeder

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Step 3.
Stand the upper stand assembly on the floor with the slotted bars facing upward as shown below. Then position
one of the stand legs on the outside of one of the slotted bars with the bolts extending through the slot as shown.
Step 4.
Raise the leg all the way until the top bolt is at the highest point in the slot. Place a washer on the exposed bolt
ends and then thread the locking levers onto the bolts.
Tighten the locking levers to hold leg in this position.
Step 5.
Repeat this procedure for the other leg. Be sure to set both legs at the same height
and then lock the levers securely.
Place leg on outside of slotted
bar with bolts extending through slot
Put flat washer on bolt threads first
before locking levers.
Note: The leg assemblies are
identical. There is no left or right

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Step 6.
Flip the stand over so it is resting on the casters. Ensure that the locking levers are secure so the stand legs do not
slip while installing the feeder!
SETTING THE HEIGHT OF THE STAND TO MATCH YOUR PRINTER
Since printers of this type come with a variety of stand heights and additional paper tray options, the LF Pro
comes with an adjustable height stand.
The feeder is shipped detached from the stand. Assemble the stand as per the
stand assembly instructions included and set the height of the stand BEFORE
attaching the feeder.
After assembling the stand, but BEFORE attaching the feeder, move the stand into position alongside the printer
near the manual feed tray.
Step 1. Position the stand so that the top plate of the stand is close to the vents on the printer that cover the
cooling fan. (to the right of the manual feed tray)
As shown below, set the height of the stand so the top plate is approximately 7/8” below the bottom ledge of
the cooling vents.
Step 2.
Move the stand away from the printer for feeder attachment.
Locking levers on inside of stand

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Step 3.
Now you will attach the feeder to the stand using four button head screws and the included 1/8” allen wrench.
The bolts have been attached to the uprights of the stand for shipping.
Step 4. (It is helpful to have an assistant hold the stand steady while attaching the feeder)
Carefully lift the feeder up and place over the top of the stand with the stand legs near the middle of the feeder
side plates
The stand should be oriented so the back plate of the feeder is on the same side as the back plate of the stand!
Step 5.
Carefully line up the two holes in the side plate with the two threaded holes in the top of the stand legs. DO NOT
LET GO OF THE FEEDER UNTIL THE SCREWS ARE IN!
The feeder will be attached to the
stand using these threaded holes
These two holes (on each side) will be
used to bolt the feeder to the stand with
the button head screws
Line up these two holes with the
threaded holes on the stand legs
Back plate of feeder
Back plate of stand

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Step 6.
Insert one of the button head screws into one of the holes in the side plate and use the 1/8” allen wrench to
tighten the screw. Ensure that the screw is threaded into the threaded hole in the stand
Step 7.
Add the other screw to the other hole and repeat for the other side of the machine
Ensure that all four screws are tight.
Aligning the feeder with the printer and final stand height adjustment
1. After the feeder has been attached to the stand, carefully move the feeder into position near the manual feed
tray on the printer.
2. Move the manual feed tray paper guides all the way to their widest position.

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3. Lift the acceleration table up as far as it will go with one hand while you push the feeder in towards the printer
with the other hand.
4. As you slowly push the feeder in toward the printer, the exit end of the acceleration table should go into the
manual feed tray just above the bottom shelf and below the overhanging tabs on the manual feed tray side
guides.
NOTE: If the end of the feeder does not slide into the area described above, you may need to adjust the stand
height a bit.
5. Once the feeder has been pushed in far enough to get the end in past the overhanging tabs lower the
acceleration table so that it rests on the bottom of the manual feed tray.
Overhanging “tab” on manual
feed tray guides. The end of the
table should go in just under
these.
Acceleration table
Acceleration table

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6. Continue to push the feeder in toward the printer, ensuring that the feeder side plate extension fingers enter
inside the left and right walls of the manual feed tray opening.
7. Ensure that the feeder can be pushed in far enough for the side plates to be up against the printer body as
shown here:
If you cannot push the feeder in this far, you may need to lower the stand a bit. The extension fingers should
enter the manual tray opening just below the gray steel plate
After the feeder has been moved into position and the height adjusted properly, you are now ready to feed
envelopes.
IT IS ADVISABLE TO MOVE THE FEEDER AWAY FROM THE PRINTER TO SET IT FOR YOUR
ENVELOPES.
The dͲϭϬ envelope feeder can feed a variety of envelope sizes and types into the printer via the printer’s
manual feed tray. The following instructions illustrate the proper setup of the feeder.
Note: The feeder can be setup for your envelopes away from the printer, and then easily placed in line with the
printer after setup is complete.
While familiarizing yourself with the feeder it is recommended that you setup and test the feeder before
integrating it with the printer.
When the stand is set at the
proper height, the top ledge of
the extension “finger” should be
approximately ¼” below the
bottom of the gray metal plate on
the printer.

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SETTING UP THE FEEDER FOR ENVELOPES
Setting the feeder for your envelopes consists of the following basic steps:
1. Setting up the hopper paper guides
2. Setting up the sheet separator(s)
3. Setting the back wedge (envelope stack support)
4. Setting the delivery table paper guides
5. Testing the feeder
6. Setting the speed
7. Putting feeder in line with printer
SETTING THE HOPPER PAPER GUIDES
Step 1:
Ensure that the main power switch on the feeder’s control panel is in the OFF position and plug the 24 vdc power
supply included with the feeder in the power jack on the control panel.
Step 2:
With power to the feeder OFF, loosen the locking knobs for both paper guides on the bridge which will allow
repositioning of the paper guides
Step 3:
Rotate the paper guide adjusting knob on the bridge to position the paper guides outwards toward the side plates
of your feeder.
24 vdc power input
Loosen paper guide locking knobs
Paper guide adjusting knob

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Step 4:
Place one of your envelopes in the feeder between the paper guides and then rotate the paper guide adjusting
knob to move the paper guides in toward the edges of the envelope
Step 5:
Position the paper guides alongside the edges of the envelope leaving them loose enough to allow free movement
of the envelopes. (do not pinch the envelope)
Step 6:
Tighten the paper guide locking knobs to secure the paper guides in position (optional)
Place envelope in hopper to
adjust paper guides
Position paper guides to hold
envelopes straight

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SETTING THE SHEET SEPARATOR(S)
The dͲϭϬutilizes patented “Buckle Separation” technique for separating the bottom envelope from the
stack.
You will notice in the following instructions that the separator(s) are positioned between feed belts, not over
them.
When in this position, the separators push down on the envelope as it is advanced from the bottom of the stack,
forming a downward “buckle” in the envelope between feed belts.
This method is simple, effective and easy to set up, and does not require a lot of fine tuning. The downward
buckle breaks the friction “bond” between the bottom envelope and the stack, making it easier to pull the bottom
envelope away.
This method of separation also reduces jams because with the separators pushing down on the envelope
between, rather than on top of, the feed belts, there is not a “pinch point” created.
The dͲϭϬ comes with two separator assemblies. Most jobs only require the use of one separator so we
recommend trying a single one in the middle first as shown here:
If you are not getting consistent results after some time and adjustments, you may wish to try two separators
as shown here
Note that in both examples above, the separators are positioned between belts.
Two separators, each
positioned between two
feed belts
Single separator
(positioned between belts)
Separator locking knob
(loosen to reposition separator(s)

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Setting the sheet separator(s) (continued)
Step 1.
Loosen the locking knob on the front of the separator and slide the separator into the middle of the feeder
between the feed belts. (You may need to raise the separator to allow it to slide over the feed belts. Turn the
separator height adjustment knob clockwise to raise the separator)
Step 2.
Turn the separator height adjustment knob clockwise several turns to raise the separator tip up above the level of
the feed belts
Step 3.
Place the lead edge of your envelope underneath the separator as shown below
Step 4.
Slowly turn the separator height adjustment knob counter-clockwise to lower the separator tip onto the
envelope.
Separator locking knob
Separator height adjustment
knob
Separator height
adjustment knob
Separator tip

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Step 5.
Continue to slowly lower the separator tip until the envelope is buckled downward between the belts slightly
(approx 1/16” to 1/8”)
NOTE: Ensure that the separator tip is between feed belts so it does not “pinch” the envelope.
Step 6. (optional)
If you are using two separators, repeat the above steps for both.
NOTES
The separators do not need a lot of fine tuning, as a small buckle is all that is required. Some experimentation is
recommended to get the best results with your materials.
One or both separators can be used as desired, but be sure to position the separators between belts and buckle
the envelopes down slightly.
There is no specific configuration that you must use, and this design offers tremendous flexibility. If one setup
doesn’t work, try moving the separators to different positions across the feeder bridge.
Setting up the back wedge
The back wedge, attached to the rear plate of the feed hopper is a very important tool that must be set properly
to obtain the best results
The back wedge performs several important functions:
1. Supports the weight of the stack so that the weight is not all on the belts
2. Tilts the back end of the media stack up so the lead edge presses against the belts
3. (most important) While the bottom envelope is getting pulled away from the stack by
the feed belts, the back wedge holds the other envelopes off the belts so they don’t
advance too closely after the first one.
The back wedge
Lower the separator tip to “buckle”
the envelope down between belts

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Step 1.
After setting the separator as shown in the previous steps, leave the one envelope in the feeder that you used for
the separator setup
Step 2.
Carefully shingle out a small stack of envelopes so that the bottom one will be the foremost envelope in the stack
as shown here.
Step 3.
Place the stack in the hopper on top of the envelope left on the belts from the separator setup. Try to “nudge”
the envelopes a bit from the back to help the stack conform to the curvature of the paper guides at the bottom.
Step 4.
With one hand, raise the back end of the envelope stack up and then slide the back wedge into position
underneath the back end of the stack. Lock the wedge in place with the locking knobs.

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As shown in the pictures above and below, the back wedge should be in just far enough to hold the back edge
of the envelope stack up off the belts.
Step 5.
The angle of the back wedge can be adjusted to assist with different kinds of envelopes. To adjust the angle,
loosen the locking lever on the side of the back wedge. Generally, for smaller envelopes the back wedge upright
should be positioned as shown below
Step 6.
The height of the back wedge ramp can also be adjusted by loosening the round locking knob on the back of the
upright as shown here. For smaller envelopes, the top of the ramp should be close to the top of the upright.
SETTING THE BACK WEDGE FOR LARGE ENVELOPES
In addition to setting the paper guides properly for large envelopes, the back wedge will need to be adjusted.
For larger (longer) envelopes, you will need to move the back farther away from the bridge. The top plate of the
feeder features multiple threaded holes for securing the back wedge in different positions
Back wedge upright
(Angle as shown here for
small envelopes)
Top plate
Back wedge locking knobs

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Larger (longer) envelopes have a tendency to “sag” downward in the middle, which can cause double feeding or
inconsistent gaps between envelopes. This “sagging” can be remedied by lowering the angle of the back wedge
and moving it a bit underneath the stack of envelopes as shown below.
As with the separators, some experimentation would be helpful to obtain the best results
Setting the acceleration table paper guides
The patented “floating” or tilting delivery table on the dͲϭϬ is designed to advance the envelopes that the
feed belts deliver, one at a time, into the printers manual feed tray feed roller.
The acceleration table is equipped with self centering paper guides, an envelope drive belt, and a stop photo
sensor at the end, which is used to stop each envelope in position underneath the printer’s feed roller, for take-
away by the printer. An additional photo envelope sensor is positioned a few inches back from the stop sensor.
This is the restart sensor. When the first envelope is pulled away by the printer, the trail edge of that envelope
uncovers the start sensor, which starts the feeder motor. Using the dual sensors allows the dͲϭϬ to run
larger envelopes at higher speeds.
Step 1.
After the feeder portion has been setup properly and a small stack of envelopes is loaded into the hopper, turn
the speed control knob completely counter-clockwise to set the feeder speed on zero.
Speed control knob
The back wedge ramp can be used to lift
the middle of the envelopes off the belts

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Step 2.
Place the power switch in the ON position.
Step 3.
Grasp one of the acceleration table paper guide adjusting blocks and move the paper guide outward to make
room for your envelope. (locking knobs MUST be loose)
Step 4.
SLOWLY rotate the speed control knob clockwise until the feeder starts to advance the bottom envelope toward
the acceleration table.
STOP the feeder as soon as the lead edge of the envelope is near the acceleration table paper guides as shown
here:
Step 5.
Move the acceleration table paper guides inward alongside your envelope edges.
Grab block to move paper guide
outward. Opposite paper guide
will move outward also.
Stop the feeder when
envelope is in this position.
Line up paper guides with envelope edge.
Do not set so tightly as to “pinch” the envelope

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Step 7.
Using the speed control knob, SLOWLY advance the envelope to the end of the delivery table and check the paper
guides to see if they are close enough to the envelope edges.
When the envelope lead edge blocks the stop photo, the feeder motor will stop.
MAKE SURE THE GUIDES ARE NOT SO TIGHT AS TO RESTRICT THE ENVELOPE’S MOVEMENT
Step 8.
After setting the acceleration table paper guides so that they guide properly without “pinching” the envelopes,
tighten the locking knobs to secure the paper guides
Testing the feeder
Step 1.
Set the speed control to approximately 20% and then pull the lead envelope out of the end of the delivery table.
The feeder should advance a second envelope to the stop photo.
Repeat this to test the consistency of the feeder. Adjust if necessary to obtain the best results.
Envelope stop photo
Paper guide