Pitney Bowes OfficeRight DF500 Manual

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PB Form SV40124 First Edition, July 2003 © 2003 Pitney Bowes
Inc. All rights reserved. This book may not be reproduced in
whole or in part in any fashion or stored in a retrieval system of
any type or transmitted by any means, electronically or mechani-
cally, without the express written permission of Pitney Bowes Inc.
We have made every reasonable effort to assure the accuracy and
usefulness of this manual, however, we cannot assume responsi-
bility for errors or omissions or liability for the misuse or misap-
plication of our products.
OfficeRight is a registered trademark and PB Supply Line is a
service mark of Pitney Bowes Inc.
FCC Compliance
This equipment had been tested and found to comply with the
limits for a Class A digital device, pursuant to Part 15 of the FCC
rules. These limits are designed to provide reasonable protection
against interference when the equipment is operated in a com-
mercial environment. This equipment generates, uses, and can
radiate radio frequency energy, and if not installed and used in
accordance with the users manuals, may cause harmful interfer-
ence 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
own expense.
Shielded cables must be used with this unit to insure compliance
with Class A limits.
Canadian DOC Compliance
This digital apparatus does not exceed in the Class A limits for
radio noise emissions from digital apparatus set out in the Inter-
ference-causing Equipment Regulations (Standard ICES-003) of
the Canadian Department of Communications.
NOTE: This equipment has been tested and found to comply
with the U.S. Standard for Safety UL60950, Third Edition, Safety
of Information Technology Equipment including Electrical Busi-
ness Equipment and Canadian Standards C22.2 No 950-95,
Safety of Information Technology Equipment including Electri-
cal Business Equipment.
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DF500 Folder Operator Guide
1SV40214 Rev. A
Table of Contents
Section Page
Safety................................................................................................. 2
Description ..................................................................................... 2
Moving the DF500 ....................................................................... 8
Machine and Job Setup .............................................................. 9
utomatic Fold Setup................................................................12
Operating The Folder................................................................ 13
Folder Mechanics For Understanding Fold Problems .... 15
Total and Batch Count..............................................................20
Running a Job ..............................................................................23
Saving, Retrieving, or Deleting Jobs.....................................24
Manual Fold Setup......................................................................28
Manual Feed ................................................................................30
Operating Hints ..........................................................................32
Troubleshooting..........................................................................36
Maintenance................................................................................ 40
Supplies......................................................................................... 40
Form Handling.............................................................................41
Equipment/Form Specifications............................................43
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DF500 Folder Operator Guide
2 SV40214 Rev. A
SAFETY
series of messages may be used throughout this manual to
alert you to potentially hazardous con di tions. These messages
are ex plained below:
lways use safe operating procedures when running your folder.
Ob serve the following practices:
• Keep loose clothing, jewelry and long hair away from all mov-
ing parts.
• void touching moving parts or materials while the machine
is in use. Before clearing a jam, unplug the machine. Be sure
machine mechanisms have come to a stop.
• To protect against electric shock, the machine should only
be plugged into a properly grounded wall outlet.
• The power cord wall plug is the primary means of discon-
necting the folder from the C supply.
• The wall outlet should be near the machine and easily acces-
sible.
• DO NOT use an adapter plug on the line cord or wall outlet.
• DO NOT remove the ground pin from the line cord.
• void using wall outlets that are controlled by wall switches.
• DO NOT route the power cord over sharp edges or trapped
be tween furniture.
WARNING - indicates the presence of a hazard that
can cause severe personal injury or loss of life,
or substantial property damage if the warning is
ignored.
NOTE - calls attention to practices that could ad-
versely affect e uipment operation if instructions
are not followed exactly.
CAUTION - indicates the presence of a hazard that
will or can cause minor personal injury or property
damage if the warning is ignored.
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DF500 Folder Operator Guide
3SV40214 Rev. A
• Ensure there is no strain on the power cord where it be-
comes jammed between the equipment, walls or furniture.
• Be certain the area in front of the wall receptacle into which
the machine is plugged is free from obstruction.
• DO NOT remove covers. This machine cabinet serves to en-
close hazardous parts. If the machine has been dropped or
has oth er wise been stressed in any way, report it to your Pit-
ney Bowes Cus tom er Service Representative.
• To reduce the risk of fire and/or electrical shock, do not at-
tempt to disassemble this machine. If service is required,
contact your Pitney Bowes Customer Service Representative.
• To prevent overheating, do not cover the vent openings.
• ll areas of the machine requiring disassembly or removal of
covers should be accessed only by your Pitney Bowes Cus-
tomer Service Representative.
• Read all instructions before attempting to operate the equip-
ment.
• Use this equipment only for its intended purpose.
In addition, follow any specific occupational safety and health
stan dards for your workplace or area.
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DF500 Folder Operator Guide
4 SV40214 Rev. A
DESCRIPTION
The Model DF500 Folder is a stand-alone tabletop folder capa-
ble of processing up to 40,000 doc u ments per month. The ma-
chine folds single and multi-part cut-sheet forms and then feeds
them folded onto the stacker. It is equipped with two fold plates
which allow it to produce single or double folds.
Two covers (one on top, one on the right side) can be opened to
allow access to the fold rollers and fold plates for maintenance
and clear ing of jams. When a cover is opened, the machine stops
automatically and cannot be started accidentally.
control panel with an LCD display informs you of the status
of the machine and of the jobs your are running. Up to ten jobs
may be setup and saved for easy retrieval. In addition, system
di ag nos tics are available con ve nient ly from the control panel.
One feature of the DF500 is the uto-Set mode for producing
com mon folds (see below). This mode allows the au to mat ic set-
ting of dif fer ent pro grammed folds and the adjustment of the
paper thick ness. The following standard folds can be called up
via the uto-Set mode:
In addition, other types of folds can be produced by entering the
mea sure ments manually as described later in this guide.
NOTE: The DF500 is built for folding paper and is unsuitable for
han dling other materials such as foils, plastics and textiles.
Single Fold Double Parallel Fold Letter Fold
Gate Fold Z-Fold Z-Fold with Margin
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DF500 Folder Operator Guide
5SV40214 Rev. A
DF500 Controls and Features
1. Stacker Deck – holds the folded documents.
2. Top Cover – allows access inside of folder for removing
jams.
3. Material Feed Deck – where paper is fed into the folder.
4. Skew djustment Control – used to offset skewing when
feeding ma te ri al.
5. Fuses – disconnects power to the folder when there is an
over load of power con sumed by the machine.
6. C Input for Power Cord – connects to C line cord.
7. Power Switch – turns on and off machine.
8. Operator Side of Machine
9. Right Hand Cover (on side) – allows access to fold plate.
3
21
5
6
78
9
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DF500 Folder Operator Guide
6 SV40214 Rev. A
More DF500 Controls and Features
1. Stacker Extension – allows more space for collected doc u -
ments after folding.
2. Stacker Rollers – helps guide material on to stacker belts.
3. Stacker Belts – moves folded documents away from exit
area.
4. Input Feed Deck Extension Guides – allows long sheets of
material to be supported. Flip up to activate.
5. Pre-feed djustment Knob – allows you to change the
amount of feed pressure for feeding various types of material.
6. Operating Guide Holder – holds this DF500 Operating
Guide.
7. Control Panel – allows user to setup and operate the folder.
8. Hand Wheel Knob (under cover) – allows for manual turn-
ing of fold rollers to aid in clearing jams.
32
1
5
6
7
8
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DF500 Folder Operator Guide
7SV40214 Rev. A
1. Paper Size Indicators – shows the paper size in use.
2. Standard Fold Type Indicators – shows the type of fold
se lect ed.
3. LCD Display – displays machine and job status to opera-
tor.
4. Dual Function Buttons – used for setting paper thickness
or manual feeding. lso used for scroll ing in certain setup
menus.
5. Setup Buttons – sets up the folder functions.
6. Main Control Buttons – used to control main folder op-
er a tion.
123
56
DF500 Control Panel Features
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DF500 Folder Operator Guide
8 SV40214 Rev. A
4. Turn the machine on and verify that the control panel dis-
plays the power-up screen (see below).
MO ING THE DF500
1. If moving the DF500, make sure that it is unplugged and that
it is placed on an ap pro pri ate work surface. There has to be
a min i mum clear ance of 36" (914mm) on three sides of the
machine for op er a tor access. Rec om mend ed table height is
30" (762mm).
2. Lift the DF500 from under each end. Do not lift the unit using
the paper support guides, control panel, or fold plate door.
AC Input for
Power Cord
Power Switch
JOB: 1 READY
ØØØØØØ
WARNING: To avoid personal injury or damage
to the machine, two people should be used to
lift the DF500.
3. Install the line cord into the C input on the side of the
DF500 (see below) and then plug it in to a grounded 115
V C outlet.
WARNING: To avoid personal injury or damage to
the machine, make sure you lift the folder by the
bottom of the chassis. Do not use the fold plate
compartment door on the side as a handle, as it
will open up and cause you to drop the machine.
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DF500 Folder Operator Guide
9SV40214 Rev. A
MACHINE AND JOB SETUP
Feeder Setup
Setting the Paper Thickness
1. Turn the power switch to ON. The display will read:
2. Press the Paper Thickness key on the control panel. The
display changes to:
3. Press Enter. The sheet separator in the feeder will open and
the display will prompt:
4. Insert a sample sheet of the paper
you want to fold into the feeder.
Push in the pressure roll er and
insert the pa per into the feeder
(see be low) about 2" (50mm).
5. Press the Enter key. The DF500 will now automatically adjust
itself to the thickness of the paper.
6. If your fold is already setup, you may now press the Trial
Piece key to fold this sample sheet. If you have not yet setup
your fold, withdraw the sheet. You will feel a slight resistance.
7. The display will again show:
JOB: 1 READY
ØØØØØØ
SET THICKNESS?
YES: Enter NO: !
INSERT ONE SHEET
DONE - Enter
JOB: 1 READY
ØØØØØ1
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DF500 Folder Operator Guide
10 SV40214 Rev. A
Setting the Paper Guides
1. Squeeze the blue lever against the right hand paper guide,
and, using two hands,
move the guides to the
width of the paper.
2. llow about 1/32"
(1mm) clear ance so that
the paper is not held
too tightly (see below).
Do not allow too much
clear ance as this will af-
fect fold accuracy.
Loading Paper
When paper is loaded into the DF500, the top sheet of the pa-
per stack is fed first. This means that the paper stack must be
“fanned out” so that the top sheet is closest to the feed roller.
1. Place a stack of paper onto the feed table. Firmly grasp the
upper end of the stack with your left hand and bend the en-
tire stack up and forward as shown.
2. While still holding the stack with your left hand, press down
on the lower end of the stack
with your right hand. Now
release the upper end of the
stack and let it fall onto the
feed table. The stack should
appear slightly fanned out.
3. Repeat this process several
times and the stack will be
fanned out properly. llow
the fanned stack to slide
down into the mouth of the
feeder as far as it will go
without forcing it.
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DF500 Folder Operator Guide
11SV40214 Rev. A
Using the Table Extension
1. Lift the table extension up to sup port longer paper like legal
size.
Setting the Pressure Roller
The pressure roller knob allows you to set the pressure applied to
the first set of feed rollers.
• For 20 lb. bond paper,
set the knob halfway
between "+" and "–".
• For heavier paper, or if
you see the feed rollers
slipping, move the knob
towards "+".
• For lighter paper, or
if the paper tends to
bunch up under the
feed rollers, set the knob
towards "–".
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DF500 Folder Operator Guide
12 SV40214 Rev. A
AUTOMATIC FOLD SETUP
Sele ting Paper Size
1. Press the Paper key to select the desired paper size length.
Each press of the key will step through the three standard
paper sizes and “other” and will light the appropriate paper
size indicator on the control panel.
2. t the same time, the display will show the selected paper
length in millimeters. For example:
3. If your paper isn’t a standard size, press the " or ! key, to
change the size. Each key press will change the paper size by
about 1/64" (0.5mm). Holding the key down for more than
one second will increase the step size, allowing large changes
to be made rapidly.
4. When the correct paper size is shown, proceed with “Select-
ing Fold Type” below. NOTE: The DF500’s electronic control
system will not allow you to deviate too far from the standard
settings. This will prevent jams caused by “impossible” folds.
Sele ting Fold Type
Before selecting a fold, make sure you have already set the
DF500 to the correct paper size length. This will prevent the ma-
chine from setting up a fold for the wrong paper length, which
could result in a paper jam.
1. Press the Fold Type key to select one of the six pre-pro-
grammed fold types. Each key press will turn on the indicator
associated with each fold type.
2. When you have made your selection, press the Enter key. The
display will show:
3. While the machine is setting up the fold, all keys on the con-
trol panel are disabled and will not respond if pressed.
(continued on next page)
T1 PAPER = 297.Ø
CH : DONE: Enter
TEMP JOB: 1 READY
ØØØØØØ
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DF500 Folder Operator Guide
13SV40214 Rev. A
Sele ting Fold Type ( ontinued)
4. When the setup is complete, the display will change back to
the “Ready” state.
NOTE: “TEMP JOB” or “T” in the display means that the job
just setup is considered a temporary job because it has not
yet been saved in memory.
TEMP JOB: 1 READY
ØØØØØØ
OPERATING THE FOLDER
Setting the Speed
Set the proper speed before attempting to run the folder. The
speed setting depends on the weight and size of the paper used.
Light weight and large size papers (lighter than 20 lb. bond and
larger than 8-1/2" by 11") must be run slower than heavy paper
and smaller sheets. good value to start with is 35.
1. Press the Speed key. The display will typically show:
2. To change the speed, press the " or ! key, then press Enter.
3. If you forgot to press Enter and try to start the folder, the
display will show:
This message will also appear if you have entered any other
new parameter such as paper size, fold type, batch or fold
plate setting.
4. Press Enter now to activate your setting or the ! key to stay
with your previous setting.
(continued on next page)
T1 SPEED = 40
CH : DONE: Enter
USE NEW SETTIN ?
YES: Enter No: !
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DF500 Folder Operator Guide
14 SV40214 Rev. A
Setting the Speed ( ontinued)
The speed can also be changed while the machine is running.
1. Press the Speed key. The display will change to:
2. Use the " or ! keys to run slower or faster.
3. The speed will change instantly. You need not press the Enter
key to activate the new setting.
Running a Trial Pie e
lways run a trial piece before starting a run. It is also a good
idea to run a trial piece each time a new stack of paper has been
loaded onto the feed table. This will prevent a jam if the stack
has been loaded incorrectly.
1. Press the Trial Piece key. single sheet will be folded and
de liv ered to the stacker for you to check.
Startup
1. If you are happy with the trial piece, press the Start key to
begin the au to mat ic feeding and folding. The folded sheets
will be delivered neatly shingled on the stacker table.
2. Remove the folded sheets as soon as they start piling up in
front of the stacker extension.
3. When the entire paper stack has been fed the machine will
stop and the display will show:
4. Reload the feed table with a new stack of paper and press the
Enter key to clear the message on the display.
5. When the display shows ‘Ready’, press the Start key to re-
sume folding.
SPEED 35
ØØØØØØ
– FAIL TO FEED –
DONE - Enter
TEMP JOB: 1 READY
ØØØØØØ
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DF500 Folder Operator Guide
15SV40214 Rev. A
Stop ping the DF500
1. To in ter rupt the folding process at any time, press the Stop
key. This will stop the machine in a controlled manner.
2. The sheets already in process will be folded and delivered be-
fore the machine stops. The stacker belts will move all folded
sheets to the end of the stacker table for easy removal.
Fold plate 1
Stop
Fold plate 2
Stop
1
23
5
6
(continued on next page)
FOLDER MECHANICS FOR UNDERSTANDING FOLD
PROBLEMS
There can be many reasons for a fold to be slightly off–the paper
composition, paper weight, size and direction of grain. lso, fold-
ing speed and ambient conditions like temperature and humidity
can have an effect. Consequently, an understanding of what is
hap pen ing in the folder can be helpful when correcting a fold
problem.
. The top sheet of paper is fed into the folder and is driven by
rollers (1) and (2) into fold plate 1.
CAUTION: Unless there is an emergency
situation, do not stop the ma chine by turning
power off by the main switch or wall socket.
Doing this while the DF500 is folding will
result in a paper jam inside the machine.
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DF500 Folder Operator Guide
16 SV40214 Rev. A
Folder Me hani s ( ontinued)
B. The paper con tin ues into the fold plate until it hits the stop.
Since the two rollers are still driving the paper, a buckle will
form at the en trance to the fold plate and will, eventually, be
caught be tween fold rollers (2) and (3). This is how the first
fold is made.
C. The folded edge will be guided by the deflector into the grip
of rollers (3) and (4). Here the same thing happens as in the
first fold plate and a second fold is made.
NOTE: If a single fold is selected, the second fold plate is au-
to mat i cal ly closed off and the folded sheet is routed past it.
1
23
1
23
5
6
D. The folded sheet is now guided by the second deflector into the
grip of rollers (5) and (6) where it is fed out onto the stacker.
It is obvious that the position of each fold plate stop determines
the length of the fold resulting from it. Keeping this in mind, it
is easy to make corrections to each fold by simply moving the
relevant stop in or out. You only need to know which end of the
sheet entered the machine first to recognize which was the first
fold and which was the second.
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DF500 Folder Operator Guide
17SV40214 Rev. A
Fine Tuning the Folder
Fold corrections can be made with the machine stopped or running.
Correcting a fold with the machine stopped…
1. Select which fold you want to correct by pressing the Fold 1
or Fold 2 key. (If a single fold is set, the Fold 2 key will not
respond). The display shows, for example:
2. Change the value by pressing the " or ! key, then press
Enter to confirm the new setting. The fold is now set and the
display shows:
3. If you try to start the machine without pressing Enter, the
display will prompt:
The machine will not start until you press either Enter or ! key.
Correcting a fold with the machine running…
1. Select which fold you want to correct by pressing the Fold 1
or Fold 2 key. (If a single fold is set, the Fold 2 key will not
respond). The display shows, for example:
or
2. Change the value by pressing the " or ! key. You can judge
the result instantly by taking a folded sample from the stacker.
NOTE: This procedure should only be used to correct small
errors; oth er wise you will produce many reject sheets be-
fore you get the fold right.
3. The correction display will remain until you either press
Enter, Speed, or you stop the machine.
T1 FOLD1 = 148.Ø
CH : DONE: Enter
TEMP JOB: 1 READY
ØØØØØØ
USE NEW SETTIN ?
YES: Enter No: !
FOLD 1 = 148.Ø
ØØØØØ1
FOLD 2 = 74.Ø
ØØØØØ1
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DF500 Folder Operator Guide
18 SV40214 Rev. A
Corre ting a Skewed Fold
skewed fold will result if the paper has not been fed exactly at
right angles with respect to the fold rollers. To correct a skew, the
entire feed table can be moved left or right by turning the skew
ad just ment knob. pointer in the slot above the knob will show
which way the deck is moving
when turn ing the knob. s a gen-
eral rule, the pointer should be
in the center of the slot.
NOTE: Before attempting to
correct the skew, make sure the
feeder side guides are adjusted
as close to the paper as pos-
sible without binding.
The steps below de scribe in detail how to correct a skewed fold.
1. Remove the paper from the feed table.
2. Turn the skew adjustment knob to center the pointer in its
slot.
3. Reload the paper making sure there isn’t too much clear ance
between the stack and the side guides.
4. Set the machine for a half (single) fold. This makes it easier
to determine which way to turn the skew ad just ing knob.
5. Run a trial piece.
6. If the fold is skewed, compare your sample with the drawings
below.
If the sample looks like " ", turn the skew
ad just ment knob counter-clockwise slightly.
If the sample looks like "B", turn the skew
ad just ment knob clock wise slightly.
7. Remove and reload the paper stack. This is
im por tant – if you do not reload the stack
the adjustment you just made may not take ef fect immedi-
ately.
8. Run another trial piece and readjust if necessary.
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