Xerox Versant 4100 Press User manual

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Xerox Customized Envelope Feeder
Problem Solving Guide

ii Xerox Customized Envelope Feeder – Problem Solving Guide
©2022 Xerox Corporation. All rights reserved. Xerox and the sphere of connectivity
design and all product names mentioned in this publication are trademarks of Xerox
Corporation in the United States and/or other counties.
Copyright protection claimed includes all forms and matters of copyrightable material
and information now allowed by statutory judicial law or hereinafter granted,
including without limitation, material generated from the software programs
displayed on the screen such as icons, screen displays, or looks.
Other company trademarks are also acknowledged.
Changes are periodically made to this document. Changes, technical inaccuracies, and
typographic errors will be corrected in subsequent editions.
Document Revision: K (August 22, 2022).

Xerox Customized Envelope Feeder – Problem Solving Guide iii
Contents
Section 1 Introduction................................................................................................... 1-1
Overview ...................................................................................................................................................................................1-1
Section 2 Initial Entry RAP........................................................................................... 2-1
Section 3 Troubleshooting ........................................................................................... 3-1
Section 4 Repairs and Adjustments .......................................................................... 4-1
REP 4.1 Cleaning Feed Belts, Discharge Belts and O-Rings ...............................................................................4-3
REP 4.2 Cleaning Sensor Lenses ....................................................................................................................................4-3
REP 4.3 Checking for Separator Assembly Wear....................................................................................................4-3
REP 4.4 Separator O-Ring Advancement...................................................................................................................4-4
REP 4.5 Separator O-Ring Replacement ....................................................................................................................4-6
REP 4.6 Carriage Belts........................................................................................................................................................4-8
REP 4.7 Versant Error Messages.................................................................................................................................4-11
REP 4.8 Separator Adjustment Procedure..............................................................................................................4-13
REP 4.9 Not Used.............................................................................................................................................................. 4-15
REP 5.0 Separator O-Ring Adjustments for Different Media.........................................................................4-16
Section 5 General Procedures ..................................................................................... 5-1
GP 5.1 Cleaning Feed Belts, Discharge Belts and O-Rings .................................................................................5-1
Section 6 Mechanincal/Electrical Components .................................................... 6-1
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iv Xerox Customized Envelope Feeder – Problem Solving Guide
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Xerox Customized Envelope Feeder – Problem Solving Guide 1-1
Section 1 Introduction
Overview
The names and locations of the Feeder components are shown below.
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Hopper Side Guides
Wedge
Jog Button
Ready/Suspend
Switch
Mounting
Arm
Locator
Block
Discharge Height
Adjustment Knob
Separator Adjustment Knob
Hopper Adjustment Knob
Hold Down
Sizing
Pocket
Adjustment
Knob
Sizing Pocket
Discharge
Assembly Floating
Discharge
Block

1-2 Xerox Customized Envelope Feeder – Problem Solving Guide
Overview, continued.
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Feature Description
Hopper Side Guides
The stack of product to be fed is loaded between the Hopper Side Guides to
help keep it aligned for entry through the separator assembly area.
Wedge
The wedge provides the support necessary to transfer the center of gravity
of the product stack in the hopper up off the deck plate onto the feed belts
and against the separator assembly.
Stand (not shown)
The stand supports the Feeder including casters to provide easy mobility.
Feed Belts (not shown)
The feed belts provide the friction and motion necessary to pull individual
product from the bottom of the stack and through the separator assembly
area. The feed belts must be cleaned with isopropyl alcohol to ensure
proper functionality.
Discharge Belt (not shown)
The long discharge belt provides the friction and increased speed necessary
to pull the piece of product away from the separator assembly, resulting in
a gap between each piece of product as it leaves the separator assembly
area. The discharge belts must be cleaned with isopropyl alcohol to ensure
proper functionality.
Hold Down
The Hold Down assembly forces the product onto the discharge belt so it
can be singled out after it exits the separator assembly. The Hold Down
Rollers must be in contact with the clear discharge belt but not so low that
the black bar is resting on the belt. This would result in jams.
Separator
The separator assembly is adjustable so the gap between the separator
assembly and the feed belts allows only a single piece of product at a time
to pass under the separator. Allows quick adjustment from paper thickness
to envelope thickness.
Jog Button
Advances the Feeder at a fixed speed. This function is useful during Feeder
setup and may be used to clear jams.
Ready/Suspend Switch
Toggles between ready mode and suspend mode.
Stand Mount Interface
Designed to easily fit over the top of the stand. Once installed onto the
stand, fasten with provided thumb screws.
Locator Blocks
Designed to help align the Feeder within the Versant Paper Tray while
positioning the Feeder during installation, or when clearing a jam.
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Xerox Customized Envelope Feeder – Problem Solving Guide 1-3
Installation Configurations
Side MSI (Bypass) Configuration
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OHCF MSI (Bypass) Configuration

1-4 Xerox Customized Envelope Feeder – Problem Solving Guide
Installation Video
An installation video is accessible by clicking the link below.
https://xerox.sharepoint.com/teams/USACAS/SitePages/Xerox%20Customized%20Envelope%20Feeder.aspx
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Xerox Customized Envelope Feeder – Problem Solving Guide 2-1
Section2InitialEntryRAP
UsethestepsonthefollowingpagetodiagnoseproblemswiththeEnvelopeFeeder
NOTEIftheenvelopefeederissetupproperly,asingleenvelopeshouldreachthefeedheadonthe
printerapproximatelyhalfwayoverthefeedrolleratthebottomoftheMSItray.
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Correctenvelopefeedposition
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2-2 Xerox Customized Envelope Feeder – Problem Solving Guide
Envelopesarenotreachingthecorrectfeedrollerposition(seebelowfordetails).
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YN
Multipleenvelopesarereachingthefeedrolleratonce(multifeeds).
YN
Envelopesarejammingatthetopofthedischarge,wrappingaroundtheseparator.
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NY
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Gotopage3‐3.
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CallXeroxforassistance.
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Gotopage3‐4.
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Gotopage3‐8.

Xerox Customized Envelope Feeder – Problem Solving Guide 3-1
Section3Troubleshooting
Envelopesarejammingatthetopofthedischarge,wrappingaroundtheseparator.
Therearetypicallyonlytworeasonswhyenvelopesjamdirectlyundertheseparator.Insuchscenarios,
severalenvelopesendupgettingwrappedaround/underneaththeseparator,asshownbelow.
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ThemostcommonrootcauseforthisproblemisthattheO‐ringassembliesareoverthebeltsANDthey
aretooclosetothebelts.Todetermineifthisistherootcause,followtheprocedureinSectionBand
RAISEtheO‐ringsintheseparatorassembly(turnthe“DONOTADJUST”knobinthecenterCLOCKWISE,
insteadofCOUNTER‐CLOCKWISEasnotedinSectionB.
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Asecond,lessfrequentrootcauseforjammingrightbelowtheseparator,iswhenenvelopeflapsget
caughtatthetopofthesideguidesinthedischarge.Thisrarelyoccursandonlywithodd‐shaped
envelopeflaps.Insuchascenario,pleasecontactCAS([email protected],
585-427-5414), astheguides
mayneedcustommodification.
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3-2 Xerox Customized Envelope Feeder – Problem Solving Guide
Multipleenvelopesarereachingthefeedrolleratonce
If the envelope feeder is feeding more than one envelope at a time, the printer will usually separate
the envelopes and feed one at a time into the printer. However, if the feeder is set up properly, the
feeder should be feeding only one envelope will be fed at a time.
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CORRECTIVEACTION:Whentheenvelopefeederisfeedingmorethanoneenvelopeatatime,it
typicallymeansthattheseparatorneedsadjustment.
Theseparatorisaremovablefrictionretardassemblyinthecenterofthefeederthatenablesthe
feederto“peeloff”anenvelopefromthebottomofthestackwhenthebeltsmove(seebelow).
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Multifeed
O‐rings

Xerox Customized Envelope Feeder – Problem Solving Guide 3-3
Toreducethelikelihoodofmorethanoneenvelopedischargingatonce,increasethefrictiononthe
separatorbyturningthe“DONOTADJUST”knobinthecenterofthefeedercounterclockwise.Thiswill
lowertheO‐ringsonthebottomoftheseparatorassembly.
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Loweringtheseparator(increasefrictionforbetterseparation)
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Ifyoudoturnpastthestop,besuretodouble
checkthattheseparatorassemblydidnotjump
outoftheJ‐channelsinthefeede
r
(seebelow).
NOTE:Ifthethreadedstud(bluearrow)no
longerturnsduetothestop(redarrow),youcan
liftthe“donotadjustknob”overthestopand
continueturningtheknob(seebelow).
A, B, AND C Models Only

3-4 Xerox Customized Envelope Feeder – Problem Solving Guide
Occasionally, the envelope substrate/material is either too smooth or t0o rough, and multifeeds
still occur even at the lowest setting for the separator. In such instances, you may need to move the
O-ring assemblies in the Separator to a position where they are partially or completely over the belts
instead of the defualt position in the middle of the belts.
NOTE: Models A, B, and C have the default position of the O-ring assembly in between the belts. Model D
has the default position of the O-ring assemblies directly on top of the belts.
Follow the steps below to access the O-Rings on the Separator
1. Turn the power switch to the Off position and remove the Feeder power cord from the power source.
2. Move the Feeder away from the Versant Bypass Tray.
3. Engage the J-Hook to lock the Discharge Assembly of the Feeder in the UP position.
4. Remove the Separator Assembly from the Separator Bracket by pushing down on the Separator
Barrel while lifting up on the Separator Adjustment Knob (see below)
5. Move the O-Ring assemblies along the shaft to change the O-Ring orientation on the Nudger.
(See next page for sample settings of O-rings)
Asanalternative,youcanuseascrewdrivertoseparatetheO‐ringswithoutremovingtheSeparatorAssembly.
Insertaflat‐headscrewdriverinbetweenthetwoO‐ringassembliesandtwistthescrewdriver
**BESURETHEUNITISPOWEREDOFF/UNPLUGGEDWHEN
PERFORMINGTHISPROCEDURE**
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Xerox Customized Envelope Feeder – Problem Solving Guide 3-5
Here are some examples of recommended O-ring assembly locations when feeding non-standard
stock
Off-centered O-ring Assembly Location - Avoids Hitting Windows on Windowed Envelopes
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O‐ringAssembliesLocated
DirectlyovertheBelts:
DModelDefaultPosition
O‐ringAssemblieslocatedpartiallyover
theBelts:Idealwhenusingmany
differentenvelopetypes/substrates
NOTE:O‐ringseparatoradjustmentwillbesignificantlymoresensitiveintheconfigurationsshownabove.

3-6 Xerox Customized Envelope Feeder – Problem Solving Guide
Envelopesarenotreachingthecorrectfeedposition
Therearethreelikelyreasonstheenvelopeisnotreachingthecorrectfeedposition:
1. Thesideguidesonthefeederdischargearetooclosetogether,“Squeezing”theenvelopeand
preventingtheenvelopefromfeedingallthewaydowntheenvelopefeederdischarge(seebelow).
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Envelopestops
shortofcorrect
feedposition
Sideguidesaretoo
tight,“Squeezing”
envelope

Xerox Customized Envelope Feeder – Problem Solving Guide 3-7
CORRECTIVEACTION:Setsideguidestoapositionapproximately¼”widerthantheenvelope(seebelow)
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Leaveapproximately¼”gapwhensettingenvelopewidth
Note:thisadditional¼”MUSTbeaddedtoenvelopewidthwhenprogrammingthewidthonthe
printer/DFE
2. Thetopguidesonthedischargearepressingdownontheenvelopetoomuch,creatingtoo
muchdownwardpressureandpreventingtheenvelopefromfeedingallthewaydownthe
envelopefeederdischarge(seebelow).
Thelikelyrootcauseforthisproblemisthatthedischargeontheenvelopefeederisprobably
toohigh.
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¼”gap
…envelopestops
shortofcorrect
feedposition
Downward
pressurefrom
topguides…
DischargeFeedHeadis
higherthanMSI
RegistrationWallcausing
downwardpressure.
TopofFeed
Head
MSI
Registration
Wall

3-8 Xerox Customized Envelope Feeder – Problem Solving Guide
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CORRECTIVEACTION:Lowerthefeederdischargesuchthatthefeedheadisslightlylowerthanthe
MSIregwall.Thiscanbedonebyturningthefluorescent“DoNotAdjust”knobontheINBOARDside
ofthefeedercounterclockwise.Itisrecommendedthatyoumakethischangeinsmallincrements.
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Lowerin
g
thefeederdischar
g
ecorrectfeederheadsettin
g
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Xerox Customized Envelope Feeder – Problem Solving Guide 3-9
3. Similartothesideguidesonthefeederdischargeassembly,thesideguidesinthehoppermust
besetwithapproximately¼”ofadditionalspacetoensureenvelopesarenot“squeezed”inthe
hopper(seebelow).
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¼”gap

3-10 Xerox Customized Envelope Feeder – Problem Solving Guide
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