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: J (June 14, 2022).

Xerox Customized Envelope Feeder – Problem Solving Guide iii
Contents
Section 1 Introduction................................................................................................... 1-1
Overview................................................................................................................................................1‐1
Section 2 Status Indicator RAPs ................................................................................ 2-1
2.1InitialRepairAnalysisProcedure.....................................................................................................2‐1
Section 3 Support ............................................................................................................ 3-1
Section 4 Repairs and Adjustments .......................................................................... 4-1
REP4.1CleaningFeedBelts,DischargeBeltsandO‐Rings...................................................................4‐1
REP4.2CleaningSensorLenses............................................................................................................4‐1
REP4.3CheckingforSeparatorAssemblyWear..................................................................................4‐1
REP4.4SeparatorO‐RingAdvancement..............................................................................................4‐2
REP4.5SeparatorO‐RingReplacement................................................................................................4‐4
REP4.6CarriageBelts...........................................................................................................................4‐5
REP4.7FeederDischargeHeightAdjustment......................................................................................4‐8
REP4.8SeparatorAdjustmentProcedure............................................................................................4‐9
REP4.9FeederHeightAdjustmentProcedure...................................................................................4‐10
REP5.0SeparatorO‐RingAdjustmentsforDifferentMedia..............................................................4‐11
Section 5 Parts List.......................................................................................................... 5-1
Section 6 General Procedures ..................................................................................... 6-1
GP6.1CleaningFeedBelts,DischargeBeltsandO‐Rings.....................................................................6‐1
Section 7 Wiring Data.................................................................................................... 7-1
Section 8 Installation..................................................................................................... 8-1
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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
Reset Button
(may not
be present)
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.
Reset Button
Resets the Feeder from a fault condition. The Reset Button is only present
on Feeders with “XPF125Axxx” and “XPF125Bxxx” serial numbers.
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 2-1
Section 2 Status Indicator RAPs
SAFETY – READ THIS FIRST
WARNING – For all of the RAPs, it is essential that the following safety procedures are
adopted, if not strictly observed there is a severe risk of injury or loss of life
Read this manual thoroughly before proceeding.
If there is any doubt at any stage, do not proceed but seek clarification.
This Safety information must be read together with, and does not take the place of, the
customer’s local procedures and Health and Safety Policies. Reference must be made to local
procedures for safe working practices, particularly the dangers of working with electricity.
Site regulations such as permission/permit to work rules must be followed.
“Isolated” means that the equipment is disconnected either by a plug being separated from the
socket, or switched off with an approved isolator where the disconnection is a minimum of 3mm.
Precautions must be taken to prevent plugs being put back into, either:
lock it off with a personal padlock or lock and tag.
instruct a person to prevent the equipment being reconnected.
if the plug and socket are in visual sight, attach a notice/sign to the isolation point warning
that the connection is not to be remade and keep a visual check to prevent any person
approaching the isolation point.
After disconnecting equipment, an electrical test must be made to ensure that the equipment is
disconnected from the electrical supply.
If it is necessary to run the equipment with a cover removed, suitable precautions must be made
to prevent any person approaching the equipment and being exposed to danger.
Never leave equipment unattended with covers removed or in an unsafe condition.
Handheld devices for making electrical tests, which rely on the human body to complete a test
circuit (such as neon-type screwdrivers) are not to be used; devices with insulated test probes are
particularly recommended.
Before installing, maintaining, cleaning, servicing, repairing or removing any covers from the
equipment, switch off and disconnect all of the equipment in the system by disconnecting the plug
from the socket.
Only competent persons trained on the equipment may service, maintain, repair or adjust the
equipment, or for any other reason, remove any covers or part of the equipment with a tool.
If left unattended for any time during servicing and/or repair, the equuipemnt must be switched off
and isolated.
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2-2 Xerox Customized Envelope Feeder – Problem Solving Guide
SAFETY – CONTINUED…
The equipment must not be used outdoors or in any situation where it is likely to be splashed or
exposed to excessive damp.
When moving the equipment, ensure that suitable facilities, or help, is available to lift or move the
equipment; particularly into or from awkward locations where overreaching may occur.
Do not block any of the ventilation holes on the equipment, either to the sides or on the top.
Before any work begins, people in the vicinity, or likely to approach the equipment must be
warned that the equipment is about to be serviced and/or repaired.
Every time the equipment is serviced, the following minimum safety checks must be made as a
matter of routine:
Correct wiring of the main cord/power cable.
Physical inspection of the main cord/power cable for damage.
Physical check of the cord grips at both ends of the main cord/power cable.
Physical check of cables inside and outside the equipment for discoloration/other signs of
overheating or damage.
Any sharp edges in accessible areas must be removed.
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Xerox Customized Envelope Feeder – Problem Solving Guide 2-3
2.1 Initial Repair Analysis Procedure
Is there a Versant Error Message associated with your problem?
Y N
Are the envelopes reaching the Tray Feed Head?
(use pictures shown to the right)
N Y
Is the Feeder feeding incorrectly?
YN
Is the Feeder making unusual noises?
YN
Is the problem related to power?
YN
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F (Go to page 2-10)
E (Go to page 2-9)
D (Go to page 2-8)
C (Go to page 2-7)
B (Go to page 2-5)
A (Go to page 2-4)

2-4 Xerox Customized Envelope Feeder – Problem Solving Guide
A Versant Error Messages
Does the Versant User Interface display a fault showing “The original size could
not be detected…”?
N Y
Adjust the Versant Paper Tray Guides to meet or “hug” the Envelope Feeder Side Guides.
Does the Versant User Interface display a fault showing “Paper Size/Orientation
inTray5isDifferent…”?
N Y
Adjust the length value and width value on the Versant Paper Tray Attributes screen (on
the Versant User Interface) to match the actual media loaded in the Hopper.
NOTE: If the envelope size is measured in hundredths-of-an-inch (for example, 4.75), you may
be required to try a slightly larger size (4.8) on the Versant User Interface (since the Versant
User Interface only accepts sizes measured in tenths-of-an-inch).
Does the Versant User Interface display a fault showing “Tray5isOutofPaper…”?
N Y
Are some envelopes (more than one) feeding and printing before the message appears?
N Y
Clean the Feeder Belts (REP 4.1).
The feeder may not be properly registered against the OHCF or Side MSI Tray.
Remove the Feeder from the OHCF or Side MSI Tray.
For OHCF configurations, reinstall the Feeder and verify the OHCF back guides are adjacent to
the Feeder.
For Side MSI Tray configurations, reinstall the Feeder and verify the Side Guide Blocks are
adjacent to the Feeder.
OHCF Configuration MSI Tray Configuration
Call CAS at 585-427-5414 for assistance.

Xerox Customized Envelope Feeder – Problem Solving Guide 2-5
B Feeder Jamming
Use the images below as a guide:
Are the envelopes stopping before reaching the MSI/Bypass Feed Roller?
N Y
Confirm the side guides on the Feeder
are approximately 0.1” wider than the
envelope itself. Adjust if needed.
Are the corners on larger envelopes
drooping or stubbing on the Bypass Tray
front registration wall?
N Y
Raise the Feeder Discharge height (REP 4.7). Only
raise the Feeder Discharge height in small increments.
Are envelopes feeding over the tabs on the Versant Bypass Tray Guides?
N Y
Lower the Feeder Discharge height (REP 4.7).
If only large envelopes (wider than 9 inches) are being
used, the envelope corners may be drooping and hitting
the registration wall (see image at right).
Go to next page.

2-6 Xerox Customized Envelope Feeder – Problem Solving Guide
Insert the Feed Ramps into the tray to eliminate jamming.
Are the envelope jams occurring at the Separator?
N Y
Set the wedge position to match the media size. Also make sure the Separator setting is
optimized for the media being fed.
Are envelopes jamming at the Separator
Gate, before reaching the Discharge?
N Y
Confirm the O-Ring Separator is located in between the belts - not over the belts.
Clear any jams and press the Jog button in short increments to confirm the envelopes are not getting
caught on the guides at the top of the discharge.
Are envelopes being fed out of the Hopper?
Y N
Increase the pressure on the Separator.
NOTE: If A2 envelopes are not reaching the feed head on the Versant, perform the following steps:
Be sure the side guides are not too tight and are “choking” the envelopes, preventing them
from reaching the Versant feed head.
Lower the height of the feeder discharge by turning the knob with the orange sticker on it at
the back (inboard) side of the feeder one half of a turn COUNTERCLOCKWISE, as noted
in the Adjustment procedure.

Xerox Customized Envelope Feeder – Problem Solving Guide 2-7
C Feeding Stops (Feeder Models A and B Only)
Did you press the RESET button prior to submitting the job?
N Y
Check the alignment of the Interlock Sensors. Adjust the Interlock Sensors so they are aligned.
The sensors must be touching for the Feeder to operate properly. (For XPF125Axxx and
XPF125Bxxx models only.)
Poorly Aligned Sensors (BAD) Properly Aligned Sensors (GOOD)
Press the RESET button and restart the job.
Does the Feeder stop feeding after just one envelope is fed?
N Y
Check the alignment of the Interlock Sensors. Adjust the Interlock Sensors so they are aligned.
The sensors must be touching for the Feeder to operate properly. (For XPF125Axxx and
XPF125Bxxx models only.)
Poorly Aligned Sensors (BAD) Properly Aligned Sensors (GOOD)
Normal Operation.

2-8 Xerox Customized Envelope Feeder – Problem Solving Guide
D Unusual Noises
Is the Versant Press making a Gear Grinding noise?
N Y
The Feeder Discharge height may not be set correctly.
Use the Feeder Discharge height adjustment (REP 4.7) to
raise the Feeder Discharge.
Normal operation.

Xerox Customized Envelope Feeder – Problem Solving Guide 2-9
E Power Problems
Is the Feeder powered on?
Y N
Move the Feeder Power Switch to the ON position.
The Feeder Power Switch is located on the inboard side of the Feeder.
Is the Feeder Mode Switch set to READY?
The Feeder Mode Switch is located on the outboard side of the Feeder.
Y N
Move the Feeder Mode Switch to the READY position.
Press the RESET Button (the RESET Button is only present on XPF125Axxx and XPFB125xxx models).
Does the problem still exist?
Y N
Problem resolved.
Check and secure the power cord at the AC power outlet (power source) and at the AC power inlet on
the rear of the Feeder. Replace the power cord if it is damaged.

2-10 Xerox Customized Envelope Feeder – Problem Solving Guide
F Multifeed Problems
Are the envelopes 9” x 12”?
N Y
• Be sure to feed with the flap at the back of the envelopes stacked in the hopper AND be
sure the flap is open.
• Change the length of the envelope to 13.1, to accommodate the open flap.
• Set the wedge at the following position:
Move the Separator O-Rings so they are positioned either partially over or completely over the belts
using REP 5.0 (Separator O-Ring Adjustment for Different Media).
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Xerox Customized Envelope Feeder – Problem Solving Guide 3-1
Section 3 Support
Contacting StreamFeeder:
Telephone [phone]
Fax [phone]
Email [email protected]
Web www.streamfeeder.com
Online Parts Ordering:
http://www.barrywehmlller.com/Login/Loginfailed.asp?reason=denied_empty&scr lpt_name=/storefront/partsearch.asp
Telephone Parts Ordering and Inside Service Support (8am-5pm, Monday through Friday, CST)
Main: 1-612-782-1220- Extension 810-3221-Lynn Diskerud
Toll free U.S.A. and Canada: 1- 800-932-3647- Extension 810-3221-Lynn Dlskerud
[email protected]
Technical Assistance:
1-800-932-3647
1-612-782-1220
[email protected]
Obtaining Replacement Parts
Should you determine that a Xerox supplied part is suspect, obtain required spare parts through the
normal Xerox spares part process.
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Xerox Customized Envelope Feeder – Problem Solving Guide 4-1
Section 4 Repairs and Adjustments
REP 4.1 Cleaning Feed Belts, Discharge Belts and O-Rings
1. Turn the power switch to O (off) and remove the power cord from the power source.
2. Apply a small amount of isopropyl alcohol to a soft cloth.
3. For belts, use moderate pressure to wipe across one belt at a time while manually rotating
it. Repeat for several rotations of each belt.
4. For O-rings, remove the gate assembly from the gate plate first and then wipe in each direction.
REP 4.2 Cleaning Sensor Lenses
1. Turn the power knob to O (off) and remove the power cord from the power source.
2. Use a soft, dry cloth to wipe gently across the face of each lens.
REP 4.3 Checking for Separator Assembly Wear
1. Check for visual signs of wear:
2. Flat areas along the O-rings.

4-2 Xerox Customized Envelope Feeder – Problem Solving Guide
REP 4.4 Separator O-Ring Advancement
Advance the separator assembly O-rings when they show wear. Follow the steps below to access the
O-rings on the Separator:
1. Turn the power switch to the Off position and remove the Feederpower 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. Repeat when re-
installing.
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