Neopost HD-CXENVL-FDR V2 Installation instructions

1
HD-CXENVL-FDR V2
Envelope Feeder, Version 2
Assembly and Operations Guide
Rev: 2-1-18
NOTE: If you feeder looks different than shown above; please refer to the guide for the
original feeder version (HD-CXENVL-FDR V1).
Neopost Digital Print Group
3100 Horizon Drive, Suite 100
King of Prussia, PA 19406-2660
Phone: [phone]
www.neopost.com
www.haslerinc.com
www.renausa.com

2
Table of Contents
PREPARING THE HD-CX1600/1700/1750 (C9xx) PRINTER...................................................................3
FEEDER STAND ASSEMBLY AND STAND HEIGHT ADJUSTMENT.................................................5
Feeder Stand Assembly..............................................................................................................................5
Setting the height of the stand to match your printer.................................................................................7
Attaching the feeder to the stand................................................................................................................8
Aligning the feeder with the printer and final stand height adjustment.....................................................9
HD-CXENVL-FDR FEEDER OVERVIEW...............................................................................................13
Component Identification.........................................................................................................................13
Features and function...............................................................................................................................14
Time-out (out of paper) Feature...............................................................................................................14
SETTING UP THE FEEDER......................................................................................................................15
Setting the Hopper Paper Guides.............................................................................................................15
Setting the Sheet Separator(s)..................................................................................................................17
Setting up the envelope support wedge (back wedge).............................................................................19
Setting the Envelope Support Wedge for Other Envelope Types............................................................22
Setting the delivery table paper guides ....................................................................................................23
Testing the feeder.....................................................................................................................................25
Setting the speed of the feeder .................................................................................................................27
RUNNING A JOB WITH THE FEEDER AND PRINTER........................................................................28
DETACHING THE FEEDER FROM THE PRINTER...............................................................................33
IMPORTANT OPERATING TIPS/NOTES................................................................................................34
Suggested Feeder Speed Settings.............................................................................................................34
Feeder Ready Lever Function..................................................................................................................34
How to Pause/Resume Print.....................................................................................................................34
Automatic “Feeder Ready Lever” Reset..................................................................................................35
Avoiding false “Paper Jam” conditions ...................................................................................................35
TROUBLESHOOTING...............................................................................................................................36
SPECIFICATIONS......................................................................................................................................38
OPERATOR MAINTENANCE ..................................................................................................................38
OPTIONAL HARDWARE..........................................................................................................................39
The HD-CXENVL-FDR feeder is designed to operate with the Neopost HD-CX Digital Color LED printers.
This guide will show the proper way to prepare the printer for the envelope feeder along with setup and
operation of the feeder.

3
PREPARING THE HD-CX1600/1700/1750 (C9xx) PRINTER
Use the following instructions to prepare your HD-CX1600/1700/1750 printer for use with your envelope feeder.
1. To prepare the printer,for the 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
4. Remove the left side of the door in the same fashion and remove the door from the printer.

4
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
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!
THE HD-CXENVL-FDR INCLUDES AN ADJUSTABLE HEIGHT STAND. IT IS VERY IMPORTANT TO SET THE
STAND HEIGHT PROPERLY. REFER TO THE SECTION TITLED “FEEDER STAND ASSEMBLY AND STAND
HEIGHT ADJUSTMENT” FOR MORE INFORMATION.
Remove the separator assembly
Place black tape on this
area. (black Velcro
included with feeder
accessories)

5
FEEDER STAND ASSEMBLY AND STAND HEIGHT ADJUSTMENT
Your new envelope feeder 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.
Feeder Stand Assembly
When assembled; the stand should look like this:
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
Upper stand assembly
2 Leg assemblies (with casters)
Top Plate (note orientation)
Locking casters
Top Plate (note orientation)

6
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.
The short end of the base bar should be on the same side as the cross bar (shown below)
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 shorter end of the base
bars (with locking casters) should be
on the same side as the stand cross
bar.
Cross Bar

7
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
It is very important to set the stand height properly so the feeder is positioned properly relative to the
printer. You can make a preliminary adjustment to the stand height easily before the feeder is bolted to
the stand. Final height adjustment may be necessary after the feeder is installed.
Place one side of the stand alongside the printer adjacent the manual feed tray. Adjust the stand height
so the top plate is about 1/8” below the horizontal ledge at the entrance of the manual feed tray.
Before attaching the feeder to the
stand, set the stand height so the top
plate of the stand is 1/8” below this
ledge. After adjusting one side,
rotate the stand and adjust the other.

8
Attaching the feeder to the stand
Step 1.
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. Remove these bolts from the stand.
Step 2. (It is helpful to have an assistant hold the stand steady while attaching the feeder)
Carefully lift the feeder up by grasping the bridge as shown below and place the feeder 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!
The feeder will be attached to the
stand using these threaded holes
Back plate of feeder
Cross bar on stand

9
Step 3.
Carefully line up the two holes in the side plate with the two threaded holes in the top of the stand legs and install
the 5/8” long button head screws securing the feeder to the stand. DO NOT LET GO OF THE FEEDER UNTIL THE
SCREWS ARE IN!
Step 4.
Tighten the screws on one side of the feeder first, and then tighten the opposite side.
Aligning the feeder with the printer and final stand height adjustment
Step 1. After the feeder has been attached to the stand, carefully move the feeder into position near the
manual feed tray on the printer.
Step 2. Move the manual feed tray paper guides outward as far as they can go to allow room for the feeder
transport table.
Line up these two holes with the
threaded holes on the stand legs

10
Step 3. Lift the end of the feeder’s delivery table up so that it can be moved into position in the manual feed
tray as shown here:
Step 4. While holding the delivery table up, carefully push the feeder in towards the printer, ensuring that the
delivery table slides in between the printer paper guides.
Step 5. Slowly push the feeder in toward the printer. The exit end of the delivery table should go into the
manual feed tray just above the tray bottom and below the overhanging tabs on the manual feed tray side guides.
When the end of the delivery table is near the overhanging tabs on the manual tray guides, let the delivery table
rest on the manual feed tray.
NOTE: As you carefully push the feeder in towards the printer, ensure that the delivery table drops below the
overhanging tabs on the manual tray paper guides.
Overhanging “tab” on manual
feed tray guides. The end of the
table should go in just under
these.
Delivery table
Lift delivery table to slide over
ledge on printer
Delivery table

11
Step 6. Push the feeder in towards the printer until the ends of the feeder side plate begin to enter the manual
feed tray opening.
At this point, you may need to fine tune the stand height adjustment to enable the feeder to move all
the way into position.
Step 7. Set the stand height on each side of the feeder so the top of the feeder side plate enters just
underneath the gray metal plate on the printer as shown here:
THE STAND HEIGHT MUST BE SET PROPERLY FOR THE FEEDER TO MOVE ALL THE WAY INTO POSITION.
The top of the feeder side plate
should go in just underneath the
gray metal plate in the printer
This edge must go in just over
the lip in the manual feed tray
Lip

12
Step 8. When the stand height is adjusted properly, push the feeder all the way in until it stops.
AS YOU PUSH THE FEEDER INTO POSITION, A LATCHING MECHANISM UNDERNEATH THE DELIVERY TABLE
SECURES THE FEEDER TO THE PRINTER. YOU WILL HEAR THIS MECHANISM SNAP INTO PLACE AS YOU MOVE
THE FEEDER IN.
Step 9. After the stand height has been properly set so the feeder latches into position, tighten the locking
levers on both legs of the stand securely. You may now detach the feeder from the printer to set up your
envelopes
THE FEEDER IS EQUIPPED WITH A RELEASE LEVER ON THE NON-OPERATOR SIDE THAT ALLOWS IT TO BE EASILY
DETACHED FROM THE PRINTER.
Step 10. To detach the feeder from the printer, pull the release lever back towards the feeder and carefully
pull the feeder away from the printer. MOVE THE FEEDER AWAY SLOWLY AND SUPPORT THE DELIVERY TABLE
OF THE FEEDER SO IT DOES NOT DROP ABRUPTLY WHEN IT EXITS THE MANUAL FEED TRAY!
Side plates should be against the
printer here.
Support the table here so that it
does not drop abruptly!

13
HD-CXENVL-FDR FEEDER OVERVIEW
Component Identification
The components described above, and their usage are explained in detail within this manual
Envelope support wedge
Paper guide
Bridge
Feed belt (6)
Paper guide
adjustment knob
Separator
Delivery table paper guide
Delivery table
Start sensor
Stop sensor
Exit shaft
Adjustable height stand
Envelope ready lever
Exit belt
Envelope hold down strap

14
Photo sensors
Paper guides
Features and function
The HD-CXENVL-FDR envelope feeder is a top load, bottom feed machine designed to feed a wide
variety of envelope types and sizes into a digital printer. The HD-CXENVL-FDR makes digital printers
more productive by continually feeding envelopes, one at a time, from a stack in the feed hopper, and
delivering each envelope to the printer’s manual feed tray pickup roller. The delivery table on the HD-
CXENVL-FDR centers and aligns the envelopes and positions them properly in the manual feed tray by
means of an envelope stop sensor. As each envelope is pulled away by the printer’s pickup roller, the
feeder advances another envelope into the printer for the next cycle. With a top-load design, the
operator can continually add envelopes on top of the stack for uninterrupted production.
The HD-CXENVL-FDR consists of two main sections: The feed hopper and the delivery table.
The envelopes are stacked in the feed hopper and are transported, one at a time to the printer via the
delivery table.
The delivery table is equipped with self
centering paper guides and a set of photo
sensors. The photo sensors are used to control
(stop/start) the flow of media. When the
envelope(s) being fed cover both sensors at the
same time, the feeder will stop feeding;
presenting the envelope under the printer's feed
roller for media take-away.
As the printer removes the presented envelope
from the delivery table, the feeder will resume
feeding when either sensor becomes uncovered
during the media take-away process.
Time-out (out of paper) Feature
The time-out feature is automatic with the timer starting as soon as the power to the feeder is turned on. If, after
4 seconds, an envelope does not advance far enough to cover the photo sensors, the feeder will stop running.
IMPORTANT! The time-out feature is not dependent on the speed of the feeder, therefore it is possible, when
running the motor at very slow speeds, the envelope may not advance to cover both sensors before the timer
expires which would stop the feeder. If this is the case, turn the speed control up to at least 50% speed and reset
the timer as described above.
Time-out Reset: To reset the timer and start the feeder running again,
momentarily press the “Reset / Hold to Jog” button on the back plate.
Other time-out reset methods:
-Switching the power off and then back on will also reset the
timer and start the feeder.
-If the machine is moved away from the printer, you can also reset
the timer by momentarily blocking, and then unblocking both
photo sensors on the delivery table with two fingertips or a piece
of media.
Jog Feature: Pressing and holding the “Reset / Hold to Jog” button will make the feeder run continuously and
override the timeout feature. This is helpful for setup and maintenance.

15
SETTING UP THE FEEDER
IT IS ADVISABLE TO MOVE THE FEEDER AWAY FROM THE PRINTER TO SET IT FOR YOUR ENVELOPES.
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.
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 envelope support wedge (back wedge)
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:
Loosen the paper guide locking knobs on the front of each paper guide to allow repositioning of the paper guides
24 vdc power input
Locking knob (2)

16
Step 3:
With power to the feeder OFF, rotate the paper guide adjustment knob to move the paper guides outward
towards the side plates of the feeder. Move the guides outward enough to accommodate your envelopes
NOTE: The HD-CXENVL-FDR features self-centering paper guides. When the paper guide adjustment
knob is turned, both paper guides will move.
Step 4:
Position one of your envelopes between the paper guides above the feed belts
Step 5:
While holding the envelope in position, rotate the paper guide adjusting knob to move the paper guides in toward
the edges of the envelope
Step 6:
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)
Paper guide adjustment knob
Position paper guides to hold
envelopes straight

17
Step 7: (Optional) Tighten the paper guide locking knobs to secure the paper guides in position.
(NOTE: These knobs must be loosened to move the paper guides)
Setting the Sheet Separator(s)
The HD-CXENVL-FDR utilizes a patented “Buckle Separation” technique for separating the bottom envelope from
the stack.
Most envelopes will run well with a single separator positioned in the middle of the feeder. A second separator
assembly is included with the feeder and can be added if needed. (more on this later)
Note that the separator device on the HD-CXENVL-FDR is positioned between two feed belts. When set
properly, the separator tip will push down on the envelope as it is advanced by the feed belts from the bottom
of the stack. This forms a downward “buckle” in the envelope for easy separation from the stack.
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 green “Flex Belt” positioned in the middle directly beneath the separator serves to help advance the
envelopes while allowing the envelope to buckle downward, resulting in positive envelope advance and
enhancing consistency.
Additional holes for alternate
separator positioning
Standard separator position
(centered)

18
Step 1.
Turn the separator height adjustment knob clockwise several turns to raise the separator
Step 2.
Place the lead edge of your envelope underneath the separator as shown below
Step 3.
Slowly turn the separator height adjustment knob counter-clockwise to lower the separator tip onto the
envelope.
Step 4.
Continue to slowly lower the separator tip until the envelope is buckled downward between the belts slightly
(approximately 1/16” to 1/8”)
NOTE: Thin envelopes may require a more pronounced buckle for consistent separation
Separator height adjustment knob
Lower the separator tip to “buckle”
the envelope down between belts
Turn knob counter-clockwise to
lower separator tip

19
Step 6. (optional)
If you run envelopes that require more than one separator, install the second separator in one of the alternate
positions on the bridge using the included attaching bolt. Set the second separator like the center one.
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.
There is no specific configuration that you must use, and this design offers tremendous flexibility. If one
configuration doesn’t work, try moving the separators to different positions across the feeder bridge.
Setting up the envelope support wedge (back wedge)
The HD-CXENVL-FDR features a unique one-piece envelope support wedge that promotes consistent
separation and feeding of a variety of envelopes. It is very important to set the envelope support wedge
position properly for the best results.
The envelope support wedge is attached to the top plate of the feeder. When the feed motor is
running, the top plate and envelope support wedge move up and down to “jostle” the envelope stack.
This unique feature improves feed consistency by helping the envelope stack to descend in the hopper
more consistently. Additionally, the “jostling” feature aids in aligning the envelopes properly for
straighter feeding.
The envelope support 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 support wedge holds the other envelopes off the belts, so they don’t
advance too closely after the first one.
NOTE: Consistent envelope separation and feeding requires proper setup of the separator (shown
earlier) and the position of the envelope support wedge. As with the separators, some experimentation
with wedge positions is recommended.
Envelope support wedge

20
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.
Work a small stack of envelopes
into a shingle with the bottom
envelopes foremost