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DF500 Folder Operator Guide - Pitney Bowes Canada

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PB Form SV40124 First Edition, July 2003 © 2003 <strong>Pitney</strong> <strong>Bowes</strong><br />

Inc. All rights reserved. This book may not be reproduced in<br />

whole or in part in any fashion or stored in a retrieval system of<br />

any type or transmitted by any means, electronically or mechanically,<br />

without the express written permission of <strong>Pitney</strong> <strong>Bowes</strong> Inc.<br />

We have made every reasonable effort to assure the accuracy and<br />

usefulness of this manual, however, we cannot assume responsibility<br />

for errors or omissions or liability for the misuse or misapplication<br />

of our products.<br />

OfficeRight is a registered trademark and PB Supply Line is a<br />

service mark of <strong>Pitney</strong> <strong>Bowes</strong> Inc.<br />

FCC Compliance<br />

This equipment had been tested and found to comply with the<br />

limits for a Class A digital device, pursuant to Part 15 of the FCC<br />

rules. These limits are designed to provide reasonable protection<br />

against interference when the equipment is operated in a commercial<br />

environment. This equipment generates, uses, and can<br />

radiate radio frequency energy, and if not installed and used in<br />

accordance with the users manuals, may cause harmful interference<br />

to radio communications. Operation of this equipment in a<br />

residential area is likely to cause harmful interference in which<br />

case the user will be required to correct the interference at his<br />

own expense.<br />

Shielded cables must be used with this unit to insure compliance<br />

with Class A limits.<br />

Canadian DOC Compliance<br />

This digital apparatus does not exceed in the Class A limits for<br />

radio noise emissions from digital apparatus set out in the Interference-causing<br />

Equipment Regulations (Standard ICES-003) of<br />

the Canadian Department of Communications.<br />

NOTE: This equipment has been tested and found to comply<br />

with the U.S. Standard for Safety UL60950, Third Edition, Safety<br />

of Information Technology Equipment including Electrical Business<br />

Equipment and Canadian Standards C22.2 No 950-95,<br />

Safety of Information Technology Equipment including Electrical<br />

Business Equipment.


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

Table of Contents<br />

Section Page<br />

Safety.................................................................................................2<br />

Description .....................................................................................2<br />

Moving the <strong>DF500</strong> .......................................................................8<br />

Machine and Job Setup ..............................................................9<br />

Automatic Fold Setup................................................................12<br />

Operating The <strong>Folder</strong>................................................................ 13<br />

<strong>Folder</strong> Mechanics For Understanding Fold Problems .... 15<br />

Total and Batch Count..............................................................20<br />

Running a Job ..............................................................................23<br />

Saving, Retrieving, or Deleting Jobs.....................................24<br />

Manual Fold Setup......................................................................28<br />

Manual Feed ................................................................................30<br />

Operating Hints ..........................................................................32<br />

Troubleshooting..........................................................................36<br />

Maintenance................................................................................ 40<br />

Supplies......................................................................................... 40<br />

Form Handling.............................................................................41<br />

Equipment/Form Specifications............................................43<br />

SV40214 Rev. A<br />

1


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

SAFETY<br />

A series of messages may be used throughout this manual to<br />

alert you to potentially hazardous con di tions. These messages<br />

are ex plained below:<br />

WARNING - indicates the presence of a hazard that<br />

can cause severe personal injury or loss of life,<br />

or substantial property damage if the warning is<br />

ignored.<br />

CAUTION - indicates the presence of a hazard that<br />

will or can cause minor personal injury or property<br />

damage if the warning is ignored.<br />

NOTE - calls attention to practices that could adversely<br />

affect equipment operation if instructions<br />

are not followed exactly.<br />

Always use safe operating procedures when running your folder.<br />

Ob serve the following practices:<br />

• Keep loose clothing, jewelry and long hair away from all moving<br />

parts.<br />

• Avoid touching moving parts or materials while the machine<br />

is in use. Before clearing a jam, unplug the machine. Be sure<br />

machine mechanisms have come to a stop.<br />

• To protect against electric shock, the machine should only<br />

be plugged into a properly grounded wall outlet.<br />

• The power cord wall plug is the primary means of disconnecting<br />

the folder from the AC supply.<br />

• The wall outlet should be near the machine and easily accessible.<br />

• DO NOT use an adapter plug on the line cord or wall outlet.<br />

• DO NOT remove the ground pin from the line cord.<br />

• Avoid using wall outlets that are controlled by wall switches.<br />

• DO NOT route the power cord over sharp edges or trapped<br />

be tween furniture.<br />

2 SV40214 Rev. A


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

• Ensure there is no strain on the power cord where it becomes<br />

jammed between the equipment, walls or furniture.<br />

• Be certain the area in front of the wall receptacle into which<br />

the machine is plugged is free from obstruction.<br />

• DO NOT remove covers. This machine cabinet serves to enclose<br />

hazardous parts. If the machine has been dropped or<br />

has oth er wise been stressed in any way, report it to your <strong>Pitney</strong><br />

<strong>Bowes</strong> Cus tom er Service Representative.<br />

• To reduce the risk of fire and/or electrical shock, do not attempt<br />

to disassemble this machine. If service is required,<br />

contact your <strong>Pitney</strong> <strong>Bowes</strong> Customer Service Representative.<br />

• To prevent overheating, do not cover the vent openings.<br />

• All areas of the machine requiring disassembly or removal of<br />

covers should be accessed only by your <strong>Pitney</strong> <strong>Bowes</strong> Customer<br />

Service Representative.<br />

• Read all instructions before attempting to operate the equipment.<br />

• Use this equipment only for its intended purpose.<br />

In addition, follow any specific occupational safety and health<br />

stan dards for your workplace or area.<br />

SV40214 Rev. A<br />

3


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

DESCRIPTION<br />

The Model <strong>DF500</strong> <strong>Folder</strong> is a stand-alone tabletop folder capable<br />

of processing up to 40,000 doc u ments per month. The machine<br />

folds single and multi-part cut-sheet forms and then feeds<br />

them folded onto the stacker. It is equipped with two fold plates<br />

which allow it to produce single or double folds.<br />

Two covers (one on top, one on the right side) can be opened to<br />

allow access to the fold rollers and fold plates for maintenance<br />

and clear ing of jams. When a cover is opened, the machine stops<br />

automatically and cannot be started accidentally.<br />

A control panel with an LCD display informs you of the status<br />

of the machine and of the jobs your are running. Up to ten jobs<br />

may be setup and saved for easy retrieval. In addition, system<br />

di ag nos tics are available con ve nient ly from the control panel.<br />

One feature of the <strong>DF500</strong> is the Auto-Set mode for producing<br />

com mon folds (see below). This mode allows the au to mat ic setting<br />

of dif fer ent pro grammed folds and the adjustment of the<br />

paper thick ness. The following standard folds can be called up<br />

via the Auto-Set mode:<br />

Single Fold Double Parallel Fold Letter Fold<br />

Gate Fold Z-Fold Z-Fold with Margin<br />

In addition, other types of folds can be produced by entering the<br />

mea sure ments manually as described later in this guide.<br />

NOTE: The <strong>DF500</strong> is built for folding paper and is unsuitable for<br />

han dling other materials such as foils, plastics and textiles.<br />

4 SV40214 Rev. A


4<br />

5<br />

6<br />

SV40214 Rev. A<br />

3<br />

<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

<strong>DF500</strong> Controls and Features<br />

2 1<br />

7 8<br />

1. Stacker Deck – holds the folded documents.<br />

2. Top Cover – allows access inside of folder for removing<br />

jams.<br />

3. Material Feed Deck – where paper is fed into the folder.<br />

4. Skew Adjustment Control – used to offset skewing when<br />

feeding ma te ri al.<br />

5. Fuses – disconnects power to the folder when there is an<br />

over load of power con sumed by the machine.<br />

6. AC Input for Power Cord – connects to AC line cord.<br />

7. Power Switch – turns on and off machine.<br />

8. <strong>Operator</strong> Side of Machine<br />

9. Right Hand Cover (on side) – allows access to fold plate.<br />

9<br />

5


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

4<br />

5<br />

6<br />

More <strong>DF500</strong> Controls and Features<br />

8<br />

3 2<br />

1. Stacker Extension – allows more space for collected doc u -<br />

ments after folding.<br />

2. Stacker Rollers – helps guide material on to stacker belts.<br />

3. Stacker Belts – moves folded documents away from exit<br />

area.<br />

4. Input Feed Deck Extension <strong>Guide</strong>s – allows long sheets of<br />

material to be supported. Flip up to activate.<br />

5. Pre-feed Adjustment Knob – allows you to change the<br />

amount of feed pressure for feeding various types of material.<br />

6. Operating <strong>Guide</strong> Holder – holds this <strong>DF500</strong> Operating<br />

<strong>Guide</strong>.<br />

7. Control Panel – allows user to setup and operate the folder.<br />

8. Hand Wheel Knob (under cover) – allows for manual turning<br />

of fold rollers to aid in clearing jams.<br />

6 SV40214 Rev. A<br />

7<br />

1


1<br />

SV40214 Rev. A<br />

<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

<strong>DF500</strong> Control Panel Features<br />

2 3 4<br />

5 6<br />

1. Paper Size Indicators – shows the paper size in use.<br />

2. Standard Fold Type Indicators – shows the type of fold<br />

se lect ed.<br />

3. LCD Display – displays machine and job status to operator.<br />

4. Dual Function Buttons – used for setting paper thickness<br />

or manual feeding. Also used for scroll ing in certain setup<br />

menus.<br />

5. Setup Buttons – sets up the folder functions.<br />

6. Main Control Buttons – used to control main folder oper<br />

a tion.<br />

7


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

MOVING THE <strong>DF500</strong><br />

1. If moving the <strong>DF500</strong>, make sure that it is unplugged and that<br />

it is placed on an ap pro pri ate work surface. There has to be<br />

a min i mum clear ance of 36" (914mm) on three sides of the<br />

machine for op er a tor access. Rec om mend ed table height is<br />

30" (762mm).<br />

2. Lift the <strong>DF500</strong> from under each end. Do not lift the unit using<br />

the paper support guides, control panel, or fold plate door.<br />

AC Input for<br />

Power Cord<br />

WARNING: To avoid personal injury or damage<br />

to the machine, two people should be used to<br />

lift the <strong>DF500</strong>.<br />

WARNING: To avoid personal injury or damage to<br />

the machine, make sure you lift the folder by the<br />

bottom of the chassis. Do not use the fold plate<br />

compartment door on the side as a handle, as it<br />

will open up and cause you to drop the machine.<br />

3. Install the line cord into the AC input on the side of the<br />

<strong>DF500</strong> (see below) and then plug it in to a grounded 115<br />

VAC outlet.<br />

Power Switch<br />

4. Turn the machine on and verify that the control panel displays<br />

the power-up screen (see below).<br />

JOB: 1 READY<br />

ØØØØØØ<br />

8 SV40214 Rev. A


MACHINE AND JOB SETUP<br />

SV40214 Rev. A<br />

<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

Feeder Setup<br />

Setting the Paper Thickness<br />

1. Turn the power switch to ON. The display will read:<br />

JOB: 1 READY<br />

ØØØØØØ<br />

2. Press the Paper Thickness key on the control panel. The<br />

display changes to:<br />

SET THICKNESS?<br />

YES: Enter NO: <br />

3. Press Enter. The sheet separator in the feeder will open and<br />

the display will prompt:<br />

INSERT ONE SHEET<br />

DONE - Enter<br />

4. Insert a sample sheet of the paper<br />

you want to fold into the feeder.<br />

Push in the pressure roll er and<br />

insert the pa per into the feeder<br />

(see be low) about 2" (50mm).<br />

5. Press the Enter key. The <strong>DF500</strong> will now automatically adjust<br />

itself to the thickness of the paper.<br />

6. If your fold is already setup, you may now press the Trial<br />

Piece key to fold this sample sheet. If you have not yet setup<br />

your fold, withdraw the sheet. You will feel a slight resistance.<br />

7. The display will again show:<br />

JOB: 1 READY<br />

ØØØØØ1<br />

9


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

Setting the Paper <strong>Guide</strong>s<br />

1. Squeeze the blue lever against the right hand paper guide,<br />

and, using two hands,<br />

move the guides to the<br />

width of the paper.<br />

2. Allow about 1/32"<br />

(1mm) clear ance so that<br />

the paper is not held<br />

too tightly (see below).<br />

Do not allow too much<br />

clear ance as this will affect<br />

fold accuracy.<br />

Loading Paper<br />

When paper is loaded into the <strong>DF500</strong>, the top sheet of the paper<br />

stack is fed first. This means that the paper stack must be<br />

“fanned out” so that the top sheet is closest to the feed roller.<br />

1. Place a stack of paper onto the feed table. Firmly grasp the<br />

upper end of the stack with your left hand and bend the entire<br />

stack up and forward as shown.<br />

2. While still holding the stack with your left hand, press down<br />

on the lower end of the stack<br />

with your right hand. Now<br />

release the upper end of the<br />

stack and let it fall onto the<br />

feed table. The stack should<br />

appear slightly fanned out.<br />

3. Repeat this process several<br />

times and the stack will be<br />

fanned out properly. Allow<br />

the fanned stack to slide<br />

down into the mouth of the<br />

feeder as far as it will go<br />

without forcing it.<br />

10 SV40214 Rev. A


SV40214 Rev. A<br />

<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

Using the Table Extension<br />

1. Lift the table extension up to sup port longer paper like legal<br />

size.<br />

Setting the Pressure Roller<br />

The pressure roller knob allows you to set the pressure applied to<br />

the first set of feed rollers.<br />

• For 20 lb. bond paper,<br />

set the knob halfway<br />

between "+" and "–".<br />

• For heavier paper, or if<br />

you see the feed rollers<br />

slipping, move the knob<br />

towards "+".<br />

• For lighter paper, or<br />

if the paper tends to<br />

bunch up under the<br />

feed rollers, set the knob<br />

towards "–".<br />

11


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

AUTOMATIC FOLD SETUP<br />

Selecting Paper Size<br />

1. Press the Paper key to select the desired paper size length.<br />

Each press of the key will step through the three standard<br />

paper sizes and “other” and will light the appropriate paper<br />

size indicator on the control panel.<br />

2. At the same time, the display will show the selected paper<br />

length in millimeters. For example:<br />

T1 PAPER = 297.Ø<br />

CHG: DONE: Enter<br />

3. If your paper isn’t a standard size, press the or key, to<br />

change the size. Each key press will change the paper size by<br />

about 1/64" (0.5mm). Holding the key down for more than<br />

one second will increase the step size, allowing large changes<br />

to be made rapidly.<br />

4. When the correct paper size is shown, proceed with “Selecting<br />

Fold Type” below. NOTE: The <strong>DF500</strong>’s electronic control<br />

system will not allow you to deviate too far from the standard<br />

settings. This will prevent jams caused by “impossible” folds.<br />

Selecting Fold Type<br />

Before selecting a fold, make sure you have already set the<br />

<strong>DF500</strong> to the correct paper size length. This will prevent the machine<br />

from setting up a fold for the wrong paper length, which<br />

could result in a paper jam.<br />

1. Press the Fold Type key to select one of the six pre-programmed<br />

fold types. Each key press will turn on the indicator<br />

associated with each fold type.<br />

2. When you have made your selection, press the Enter key. The<br />

display will show:<br />

TEMP JOB: 1 READY<br />

ØØØØØØ<br />

3. While the machine is setting up the fold, all keys on the control<br />

panel are disabled and will not respond if pressed.<br />

(continued on next page)<br />

12 SV40214 Rev. A


SV40214 Rev. A<br />

<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

Selecting Fold Type (continued)<br />

4. When the setup is complete, the display will change back to<br />

the “Ready” state.<br />

TEMP JOB: 1 READY<br />

ØØØØØØ<br />

NOTE: “TEMP JOB” or “T” in the display means that the job<br />

just setup is considered a temporary job because it has not<br />

yet been saved in memory.<br />

OPERATING THE FOLDER<br />

Setting the Speed<br />

Set the proper speed before attempting to run the folder. The<br />

speed setting depends on the weight and size of the paper used.<br />

Light weight and large size papers (lighter than 20 lb. bond and<br />

larger than 8-1/2" by 11") must be run slower than heavy paper<br />

and smaller sheets. A good value to start with is 35.<br />

1. Press the Speed key. The display will typically show:<br />

T1 SPEED = 40<br />

CHG: DONE: Enter<br />

2. To change the speed, press the or key, then press Enter.<br />

3. If you forgot to press Enter and try to start the folder, the<br />

display will show:<br />

USE NEW SETTING?<br />

YES: Enter No: <br />

This message will also appear if you have entered any other<br />

new parameter such as paper size, fold type, batch or fold<br />

plate setting.<br />

4. Press Enter now to activate your setting or the key to stay<br />

with your previous setting.<br />

(continued on next page)<br />

13


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

Setting the Speed (continued)<br />

The speed can also be changed while the machine is running.<br />

1. Press the Speed key. The display will change to:<br />

SPEED 35<br />

ØØØØØØ<br />

2. Use the or keys to run slower or faster.<br />

3. The speed will change instantly. You need not press the Enter<br />

key to activate the new setting.<br />

Running a Trial Piece<br />

Always run a trial piece before starting a run. It is also a good<br />

idea to run a trial piece each time a new stack of paper has been<br />

loaded onto the feed table. This will prevent a jam if the stack<br />

has been loaded incorrectly.<br />

1. Press the Trial Piece key. A single sheet will be folded and<br />

de liv ered to the stacker for you to check.<br />

Startup<br />

1. If you are happy with the trial piece, press the Start key to<br />

begin the au to mat ic feeding and folding. The folded sheets<br />

will be delivered neatly shingled on the stacker table.<br />

2. Remove the folded sheets as soon as they start piling up in<br />

front of the stacker extension.<br />

3. When the entire paper stack has been fed the machine will<br />

stop and the display will show:<br />

– FAIL TO FEED –<br />

DONE - Enter<br />

4. Reload the feed table with a new stack of paper and press the<br />

Enter key to clear the message on the display.<br />

TEMP JOB: 1 READY<br />

ØØØØØØ<br />

5. When the display shows ‘Ready’, press the Start key to resume<br />

folding.<br />

14 SV40214 Rev. A


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

Stop ping the <strong>DF500</strong><br />

1. To in ter rupt the folding process at any time, press the Stop<br />

key. This will stop the machine in a controlled manner.<br />

2. The sheets already in process will be folded and delivered before<br />

the machine stops. The stacker belts will move all folded<br />

sheets to the end of the stacker table for easy removal.<br />

SV40214 Rev. A<br />

CAUTION: Unless there is an emergency<br />

situation, do not stop the ma chine by turning<br />

power off by the main switch or wall socket.<br />

Doing this while the <strong>DF500</strong> is folding will<br />

result in a paper jam inside the machine.<br />

FOLDER MECHANICS FOR UNDERSTANDING FOLD<br />

PROBLEMS<br />

There can be many reasons for a fold to be slightly off–the paper<br />

composition, paper weight, size and direction of grain. Also, folding<br />

speed and ambient conditions like temperature and humidity<br />

can have an effect. Consequently, an understanding of what is<br />

hap pen ing in the folder can be helpful when correcting a fold<br />

problem.<br />

A. The top sheet of paper is fed into the folder and is driven by<br />

rollers (1) and (2) into fold plate 1.<br />

2 3<br />

1<br />

Stop<br />

Fold plate 1<br />

6<br />

4 5<br />

(continued on next page)<br />

Stop<br />

Fold plate 2<br />

15


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

<strong>Folder</strong> Mechanics (continued)<br />

B. The paper con tin ues into the fold plate until it hits the stop.<br />

Since the two rollers are still driving the paper, a buckle will<br />

form at the en trance to the fold plate and will, eventually, be<br />

caught be tween fold rollers (2) and (3). This is how the first<br />

fold is made.<br />

4<br />

2 3<br />

1<br />

C. The folded edge will be guided by the deflector into the grip<br />

of rollers (3) and (4). Here the same thing happens as in the<br />

first fold plate and a second fold is made.<br />

NOTE: If a single fold is selected, the second fold plate is auto<br />

mat i cal ly closed off and the folded sheet is routed past it.<br />

2 3<br />

1<br />

6<br />

4 5<br />

D. The folded sheet is now guided by the second deflector into the<br />

grip of rollers (5) and (6) where it is fed out onto the stacker.<br />

It is obvious that the position of each fold plate stop determines<br />

the length of the fold resulting from it. Keeping this in mind, it<br />

is easy to make corrections to each fold by simply moving the<br />

relevant stop in or out. You only need to know which end of the<br />

sheet entered the machine first to recognize which was the first<br />

fold and which was the second.<br />

16 SV40214 Rev. A


SV40214 Rev. A<br />

<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

Fine Tuning the <strong>Folder</strong><br />

Fold corrections can be made with the machine stopped or running.<br />

Correcting a fold with the machine stopped…<br />

1. Select which fold you want to correct by pressing the Fold 1<br />

or Fold 2 key. (If a single fold is set, the Fold 2 key will not<br />

respond). The display shows, for example:<br />

T1 FOLD1 = 148.Ø<br />

CHG: DONE: Enter<br />

2. Change the value by pressing the or key, then press<br />

Enter to confirm the new setting. The fold is now set and the<br />

display shows:<br />

3. If you try to start the machine without pressing Enter, the<br />

display will prompt:<br />

The machine will not start until you press either Enter or key.<br />

Correcting a fold with the machine running…<br />

1. Select which fold you want to correct by pressing the Fold 1<br />

or Fold 2 key. (If a single fold is set, the Fold 2 key will not<br />

respond). The display shows, for example:<br />

FOLD 1 = 148.Ø<br />

ØØØØØ1<br />

TEMP JOB: 1 READY<br />

ØØØØØØ<br />

USE NEW SETTING?<br />

YES: Enter No: <br />

2. Change the value by pressing the or key. You can judge<br />

the result instantly by taking a folded sample from the stacker.<br />

NOTE: This procedure should only be used to correct small<br />

errors; oth er wise you will produce many reject sheets before<br />

you get the fold right.<br />

3. The correction display will remain until you either press<br />

Enter, Speed, or you stop the machine.<br />

or<br />

FOLD 2 = 74.Ø<br />

ØØØØØ1<br />

17


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

Correcting a Skewed Fold<br />

A skewed fold will result if the paper has not been fed exactly at<br />

right angles with respect to the fold rollers. To correct a skew, the<br />

entire feed table can be moved left or right by turning the skew<br />

ad just ment knob. A pointer in the slot above the knob will show<br />

which way the deck is moving<br />

when turn ing the knob. As a general<br />

rule, the pointer should be<br />

in the center of the slot.<br />

NOTE: Before attempting to<br />

correct the skew, make sure the<br />

feeder side guides are adjusted<br />

as close to the paper as possible<br />

without binding.<br />

The steps below de scribe in detail how to correct a skewed fold.<br />

1. Remove the paper from the feed table.<br />

2. Turn the skew adjustment knob to center the pointer in its<br />

slot.<br />

3. Reload the paper making sure there isn’t too much clear ance<br />

between the stack and the side guides.<br />

4. Set the machine for a half (single) fold. This makes it easier<br />

to determine which way to turn the skew ad just ing knob.<br />

5. Run a trial piece.<br />

6. If the fold is skewed, compare your sample with the drawings<br />

below.<br />

If the sample looks like "A", turn the skew<br />

ad just ment knob counter-clockwise slightly.<br />

If the sample looks like "B", turn the skew<br />

ad just ment knob clock wise slightly.<br />

7. Remove and reload the paper stack. This is<br />

im por tant – if you do not reload the stack<br />

the adjustment you just made may not take ef fect immediately.<br />

8. Run another trial piece and readjust if necessary.<br />

18 SV40214 Rev. A


SV40214 Rev. A<br />

<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

Fine Tuning the Feeder for "Problem" Paper<br />

The fine tuning feature allows you to adjust the feeder gap (the<br />

opening through which the paper must pass) in small steps while<br />

the machine is running. This is helpful with some “problem”<br />

papers, such as lightweight recycling papers and heavy stock because<br />

the stan dard feeder settings tend to mark the coated surface<br />

of the paper.<br />

Observe the paper feed while folding. If the feeding is erratic<br />

(paper seems to hesitate before entering the folder) or if you get<br />

“FAIL TO FEED” messages, check first whether the pressure roller<br />

is exerting enough pressure on the paper (see page 11 for details).<br />

If more pressure does not help, you must open the feeder<br />

gap a little. If you tend to get double sheets being fed, you must<br />

close the gap slightly.<br />

The steps below de scribe in detail how to fine tune paper feeding.<br />

1. With the machine running, press the or key. The display<br />

will change to:<br />

TUNE THICKNESS<br />

ØØØØØ1<br />

2. Press the key to open the gap, or the key to close the<br />

gap. Typically, the display will show:<br />

:+ ENTER<br />

ØØØØØ1<br />

NOTE: A "+" symbol on the display shows you are opening<br />

the gap a little. A "–" symbol on the display shows you are<br />

closing the gap a little.<br />

3. By using the or keys, you can open or close the gap in<br />

steps shown on the display by up to five "+" or five "–" symbols.<br />

Consequently, a typical display might be something like:<br />

:+++++ ENTER<br />

:----- ENTER<br />

or<br />

ØØØØØ1<br />

ØØØØØ1<br />

If no symbols show on the display, you are back to the standard<br />

feeder setting.<br />

(continued on next page)<br />

19


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

Fine Tuning the Feeder (continued)<br />

4. To leave the fine tuning mode, press Enter. The display will<br />

switch back to normal running mode.<br />

If you don’t press Enter, the machine will stay in fine tuning<br />

mode until power is turned off. When the machine is turned<br />

back on again, the display will be back in normal running mode.<br />

NOTE: The paper thickness setting will not automatically<br />

change when switching jobs. You must set paper thickness<br />

first when starting a new job (see page 9). It is good practice<br />

to set paper thickness even when the same weight of paper is<br />

used with the new job.<br />

TOTAL AND BATCH COUNT<br />

Clearing Total Count<br />

The total count feature is always active and cannot be turned off.<br />

The counter must therefore be reset for each individual job that<br />

requires counting.<br />

1. To reset the count, press the Reset Counter key. The display<br />

shows:<br />

RESET ØØØØ29<br />

YES: Enter No: <br />

2. Press the Enter key to reset the counter, or the key, if you<br />

have changed your mind. The counter digits at the bottom<br />

right of the display will revert to zero:<br />

TEMP JOB: 1 READY<br />

ØØØØØØ<br />

20 SV40214 Rev. A


SV40214 Rev. A<br />

<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

Setting a Batch Count<br />

The batch count feature will make the machine fold a pre-selected<br />

number of sheets (a batch) and then stop. The remaining<br />

folded sheets on the stacker will be carried to the end of the<br />

stacker table to aid removal. Follow the steps below to set a batch<br />

count function.<br />

1. Press the Batch key. The indicator next to the key will light<br />

and the display will show:<br />

T1 BATCH = ØØ5<br />

CHG: DONE: Enter<br />

2. Change the batch count number (which must be from 5 to<br />

999) by using the or keys, then press Enter to confirm.<br />

3. The indicator will remain lit and the display will change to:<br />

TEMP JOB: 1 READY<br />

BATCH: Ø5Ø ØØØØØØ<br />

4. Folding of the next batch is resumed by pressing the Start key.<br />

Turning off the batch count<br />

The batch count function will operate as long as the batch indicator<br />

is on, even if the paper size and/or fold type is changed.<br />

1. Press the Batch key.<br />

2. The indicator will go off and the display will briefly show:<br />

BATCH MODE OFF<br />

then go back to the normal running mode display:<br />

TEMP JOB: 1 READY<br />

ØØØØØØ<br />

21


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

Restoring a Batch Count<br />

If you have set a batch of 50, for instance, and have taken a trial<br />

piece or have run several pieces you cannot use, you may want to<br />

restore the batch count to 50 before starting a folding run. Follow<br />

the steps below to restore a batch count.<br />

1. Press the Batch key (to turn batch off).<br />

2. Press the Batch key a second time (batch setting mode on).<br />

3. Press Enter. The batch count will be restored and the machine<br />

is ready to run a full batch.<br />

22 SV40214 Rev. A


RUNNING A JOB<br />

SV40214 Rev. A<br />

<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

Normal Job<br />

The Normal Job is a commonly used setup which can be recalled<br />

very quickly when required. From the factory, this job is set to<br />

give a letter (C) fold on 8-1/2" by 11" paper. However, it can be<br />

set to a dif fer ent fold and paper com bi na tion, if required, by a<br />

<strong>Pitney</strong> <strong>Bowes</strong> service engineer. Follow the steps below to select a<br />

normal job.<br />

1. Simply press the Normal Job key. The display will prompt:<br />

SET NORMAL JOB?<br />

YES: Enter No: <br />

2. Press Enter to activate the Normal Job settings or press if<br />

you have changed your mind.<br />

3. During activation of the Normal Job, the display will show:<br />

SETTING<br />

4. When the Normal Job is set, the display will only show:<br />

READY<br />

ØØØØØØ<br />

Temporary Job<br />

A Temporary Job is any folding job setup without it having been<br />

stored in the machine’s memory. The settings are not retained by<br />

the machine and cannot be recalled at a future date. A Temporary<br />

Job will be shown in the display by the word “TEMP” or the<br />

letter “T”:<br />

TEMP JOB: 1 READY<br />

ØØØØØØ<br />

T1 PAPER = 297.Ø<br />

CHG: DONE: Enter<br />

If you recall a programmed job and change any of its settings,<br />

it will be regarded as a Temporary Job by the <strong>DF500</strong> until it is<br />

saved again to memory. See page 24 for details of saving a job in<br />

memory or updating a job already in memory.<br />

23


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

SAVING, RETRIEVING, OR DELETING JOBS<br />

After setting up and running a job, you might want to save it for<br />

later use. This is especially useful for jobs which occur frequently<br />

or for difficult jobs that run well only at a certain speed and fold<br />

plate setting. The following parameters are saved with a job:<br />

• The paper size (standard or not)<br />

• The type of fold (including any manual fold plate corrections)<br />

• The speed<br />

• The batch count (if any)<br />

You can save up to nine different jobs on the <strong>DF500</strong>.<br />

Saving A New Or Replacement Job<br />

1. Press the Store Job key. The display will prompt:<br />

MAKE NEW JOB: 2?<br />

YES: Enter No: <br />

2. If you don’t want to save the job, press the key. The display<br />

will go back to running mode and the job will not be saved.<br />

3. To save the job, press the Enter key. If the memory space is<br />

available, the display will show for a few seconds…<br />

STORED AS: JOB2<br />

… then return to running mode with the job saved.<br />

JOB: 2 READY<br />

ØØØØØØ<br />

If the memory space is already occupied by another job, the<br />

display will show:<br />

REPLACE JOB2?<br />

YES: Enter No: <br />

(continued on next page)<br />

24 SV40214 Rev. A


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

Saving a New or Replacement Job (continued)<br />

4. If you press Enter, the job previously saved under “JOB 2”<br />

(for this example) will be replaced by the new job under the<br />

same job number:<br />

SV40214 Rev. A<br />

STORED AS: JOB2<br />

5. If you don’t want to erase the job already in memory, press<br />

the key. The display will increment the job number up by<br />

one and will prompt:<br />

MAKE NEW JOB3?<br />

YES: Enter No:<br />

6. The new job number offered (in this example 3), is always<br />

the lowest available job number. In this case jobs 1 and 2<br />

are already occupied, while job numbers 3 to 9 are available.<br />

Available job numbers are always offered in ascending order.<br />

It is not pos si ble to “jump” one number.<br />

7. Press Enter to save your new job under the new job number.<br />

STORED AS: JOB3<br />

8. If all 9 memory spaces are full and you choose not to replace<br />

an existing job, the display will show:<br />

–PROGRAMS FULL–<br />

CLEAR JOB FIRST<br />

9. To store any more jobs you must first delete existing job(s) as<br />

described in "Deleting a Job from Memory" on page 27.<br />

25


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

Retrieving A Job From Memory<br />

1. To retrieve a job from memory and set it up, press the Select<br />

Job key repeatedly until the job you want is displayed:<br />

2. If you press Enter, the job shown will be set up and the display<br />

will show in succession:<br />

JOB: 2<br />

SETTING<br />

SELECT JOB: 2?<br />

YES: Enter No: <br />

3. If you press key, the display will return to the normal running<br />

mode without a job being selected.<br />

Identifying A Job In Memory<br />

1. Use the Select Job key to step through the available jobs<br />

stored in memory. The appropriate indicators for paper size<br />

and fold type will light up for each job. This way you can tell<br />

what kind of job is stored under each job number.<br />

SELECT JOB: 2?<br />

YES: Enter No: <br />

2. If you want to know exactly what dimensions are stored for<br />

each fold plate, press the Fold 1 or Fold 2 keys. The display<br />

will briefly show the fold plate dimension set for the job:<br />

SELECT JOB: 2?<br />

FOLD 1 = Ø9Ø.Ø<br />

JOB: 2 READY<br />

ØØØØØØ<br />

3. If the job has a single fold, pressing Fold 2 will not display<br />

a di men sion as fold plate 2 is closed for single fold applications.<br />

26 SV40214 Rev. A


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

Deleting A Job From Memory<br />

1. Select the job number you want to delete by pressing Select<br />

Job until the correct job number is displayed.<br />

2. Press the Reset Counter key. The display will prompt:<br />

SV40214 Rev. A<br />

DELETE JOB: 3?<br />

YES: Enter No: <br />

3. Press Enter to delete the job:<br />

JOB DELETED<br />

4. The memory location is now clear and another job may be<br />

stored under that number. This job number will be automatically<br />

offered when you want to store a new job without erasing<br />

any others.<br />

27


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

MANUAL FOLD SETUP<br />

Setting A Standard Fold With Non-standard Size Paper<br />

1. Press the Fold Type key to select the desired type of standard<br />

fold.<br />

2. Press the Paper key until the “Other” indicator lights. The<br />

display will show:<br />

TØ PAPER = 297.Ø<br />

CHG: DONE: Enter<br />

3. Use the or keys to change the dimension shown to the<br />

length of your paper in millimeters.<br />

4. Press Enter and the fold will be setup automatically. The display<br />

will first show…<br />

TEMP JOB: Ø<br />

SETTING<br />

… then return to the normal running mode display.<br />

TEMP JOB: Ø READY<br />

ØØØØØØ<br />

5. Run a trial piece to check the fold. If necessary, make cor rec -<br />

tions as described on page 14.<br />

NOTE: The <strong>DF500</strong>’s electronic control system will not allow<br />

you to deviate too far from the standard settings. This will<br />

prevent jams caused by “impossible” folds.<br />

28 SV40214 Rev. A


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

Setting A Non-standard Fold With Any Size Paper<br />

1. Press the Paper key to select any of the 3 standard paper<br />

sizes, or select “Other” and set the paper size as described<br />

above.<br />

2. Press the Fold Type key to select a fold which comes closest<br />

to the type of fold you want.<br />

3. Press the Fold 1 key to set fold plate 1. Measure the length of<br />

the first fold on your sample and transfer the measurement<br />

using the or keys.<br />

4. Press Fold 2 and transfer the measurement of the second<br />

fold. If your special fold is a single fold, you do not need to<br />

set fold plate 2.<br />

5. Press Enter, the machine will set itself automatically.<br />

SV40214 Rev. A<br />

TEMP JOB: Ø<br />

SETTING<br />

TEMP JOB: Ø READY<br />

ØØØØØØ<br />

6. Run a trial piece to check the fold. If necessary make corrections<br />

as described on page 14.<br />

29


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

MANUAL FEED<br />

The manual feed mode allows you to hand-feed sets of two or<br />

more sheets, loose, glued or stapled. The limit is five sheets of 20<br />

lb. (80g/m 2) bond, folded into a single, letter (C) or Z fold.<br />

CAUTION: Do not attempt to fold sets into<br />

any other type of fold. This could result in<br />

serious damage to the machine.<br />

In manual feed mode the fold rollers will be turning, but the<br />

feeder is disabled. Automatic feeding is not possible because the<br />

paper is fed by hand, one set at a time.<br />

Setting The Feeder For Manual Feed<br />

1. Press the Manual Feed key. The display will show:<br />

MANUAL FEED MODE<br />

YES: Enter No: <br />

2. Press Enter. You will hear a small motor opening the feeder<br />

gap, which will enable you to feed more than one sheet at a<br />

time. After the motor stops, the display will show:<br />

MAN. FEED READY<br />

ØØØØØØ<br />

3. Press Start and start feeding your collated sets one by one.<br />

In order to get cleanly folded sets, make sure to insert the<br />

sets straight down the paper guides on the feed table.<br />

MAN. FEED RUN<br />

ØØØØØ1<br />

NOTE: If the pressure rollers interfere with hand feeding,<br />

turn the pressure roller setting knob fully to "-".<br />

4. Press Stop to halt feed motors when finished.<br />

30 SV40214 Rev. A


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

Returning To Automatic Feed<br />

1. To get out of the manual feed mode, press the Manual Feed<br />

key again. The display will prompt:<br />

SV40214 Rev. A<br />

MANUAL FEED EXIT?<br />

YES: Enter No: <br />

2. Press the Enter key. The display will show:<br />

INSERT ONE SHEET<br />

DONE - Enter<br />

3. Insert a sheet of paper to be fed automatically and press Enter.<br />

The machine will set the feed gap to the thickness of the<br />

sample sheet and the display will return to normal running<br />

mode.<br />

4. Remove the sample sheet or press Trial Piece to feed the<br />

sheet through the machine.<br />

31


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

OPERATING HINTS<br />

Clearing A Jam<br />

Jams can occur for a number of reasons, including:<br />

• Double sheets being fed<br />

• Running a certain type of fold with the wrong size paper<br />

• Running very light paper too fast<br />

• Running heavy stock too slow<br />

Whenever there is a jam in the machine, errors such as these may<br />

display:<br />

–JAM IN FOLDER–<br />

OPEN TOP COVER<br />

Follow the steps below to clear a jam.<br />

1. Open the top cover and look for any paper stuck inside. With<br />

the cover open, either turn the fold rollers by hand or use<br />

the handwheel knob to remove any stalled paper.<br />

2. To use the handwheel<br />

knob (see figure on<br />

right), press in on the<br />

end of the knob and<br />

then release. This will<br />

cause it to pop out to its<br />

operating position. For<br />

safety rea sons, the knob<br />

is still disengaged in<br />

this po si tion.<br />

3. Pull the knob out as far as it will go to engage the gears inside.<br />

Turn the knob while keeping it pulled out. Turning it<br />

clockwise will feed the paper towards the stacker.<br />

(continued on next page)<br />

–JAM IN STACKER–<br />

DONE - Enter<br />

32 SV40214 Rev. A


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

Clearing a Jam (continued)<br />

4. If the paper is bunched up inside, making it hard to turn the<br />

knob or the fold roller directly,<br />

remove the two de flec tor bars.<br />

Using the screw as a handle,<br />

push the bar towards the control<br />

panel, then lift it out. Any<br />

paper inside should now be visible<br />

and is easily removed.<br />

5. Refit the deflector bars by inserting the round end with the<br />

spring into its hole in the operator side frame. <strong>Guide</strong> the<br />

other end of the bar into the square hole on the opposite<br />

side frame.<br />

6. When you have finished using the manual turnover knob,<br />

press it back in so that it latches into position.<br />

7. While the top cover is open, the display will show:<br />

SV40214 Rev. A<br />

TOP–COVER OPEN<br />

Close the cover and the display will return to normal running<br />

mode, showing whatever fold job, etc.. had been there before<br />

the jam.<br />

8. If the display still shows “JAM IN FOLDER”, press Enter and<br />

the display should return to running mode.<br />

9. If the error message does not go away, this means that there<br />

is paper stuck in the fold plate. Turn off the main power<br />

switch and refer to the following section “Removing the fold<br />

plates”.<br />

33


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

Removing The Fold Plates<br />

You will need to remove the fold plate assembly if paper is stalled<br />

in this area and you have been unable to clear a jam as described<br />

in the previous “Clearing a Jam” section.<br />

Follow the steps below to remove the fold plates.<br />

1. Turn power OFF.<br />

2. Open the fold<br />

plate door by<br />

pulling it away<br />

from the machine.<br />

NOTE:<br />

Some force may<br />

be needed to<br />

open the door.<br />

The door will<br />

stay in its up per -<br />

most po si tion.<br />

CAUTION: Before opening the fold plate<br />

door, always turn off the power first. This<br />

will prevent any possibility of dam age to<br />

the machine’s electronic control system.<br />

Silver Handle<br />

Fold Plate Assembly<br />

Blue Lock Levers<br />

Fold Plate Door<br />

3. Press and release the two blue lock levers on either side of<br />

fold plate assembly. This will cause the fold plate assembly to<br />

drop slightly.<br />

4. Grab the silver handle and lift the fold plate assembly up and<br />

out.<br />

(continued on next page)<br />

34 SV40214 Rev. A


Removing Fold Plates (continued)<br />

SV40214 Rev. A<br />

<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

5. Check for any paper in the fold plates or between the fold<br />

rollers in the machine. Turn the rollers by hand or use the<br />

hand wheel knob to make sure that all paper has been removed.<br />

6. Reinstall fold plates by sliding fold plate assembly back into<br />

folder until it is supported by the latch mechanism.<br />

7. Push up from bottom of fold plate assembly until you feel<br />

and hear the latches fully engage.<br />

8. Close fold plate compartment door.<br />

CAUTION: If door does not close, the fold plate<br />

assembly has not been installed correctly.<br />

Redo Steps 6 and 7 above until you can close<br />

the door properly.<br />

9. Turn power on. The display will return to running mode and<br />

folding may be resumed.<br />

35


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

TROUBLESHOOTING<br />

Feeding and folding problems are usually due to im prop er adjust<br />

ment of the machine or to improperly setting up a job. Refer<br />

to the Symptom/Probable Cause section below and the Error<br />

Mes sag es Dis played on the Control Panel table (starting on the<br />

next page) to help you resolve prob lems when operating the<br />

<strong>DF500</strong>.<br />

Symptom Probable Cause–Solution<br />

<strong>Folder</strong> will not run Line plug loose or pulled<br />

out–attach.<br />

Power switch is off–Turn ON.<br />

Safety cover not completely<br />

closed–close.<br />

Circuit breaker needs to be<br />

reset–reset.<br />

Forms folded improperly Need to redo setup procedures–page<br />

17.<br />

Forms skew to one side Infeed guides not set properly–adjust.<br />

Improper stacking Form stop bracket not positioned<br />

properly–check job<br />

setup.<br />

Form guides not positioned<br />

properly –adjust.<br />

Rollers do not rotate while Internal problems –contact<br />

motor is running<br />

Service personnel.<br />

No display Internal problems–contact<br />

Service personnel.<br />

36 SV40214 Rev. A


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

Error Messages Displayed on the Control Panel<br />

Error Message What It Means <strong>Operator</strong> Action<br />

Fail To Feed<br />

Done Enter<br />

Fold Is<br />

Not Available<br />

SV40214 Rev. A<br />

The paper was fed<br />

either too late or<br />

not at all.<br />

You have tried to set<br />

up an “impossible”<br />

fold.<br />

Fold Plate Error The fold plate stop<br />

is prevented from<br />

travelling along its<br />

guide screw by an<br />

obstruction like an<br />

accumulation of<br />

dirt and paper dust.<br />

• Remove the paper stack from the feed<br />

table, fan it out and place it back on<br />

the feeder. Slide the stack down into<br />

the grip of the pressure roller.<br />

• Adjust side guides (see page 10) to<br />

loosen the side guides.<br />

• Adjust the roller pressure setting (see<br />

page 11).<br />

• Adjust the feeder gap (see page 19).<br />

Although this is set automatically<br />

using the Paper Thickness control,<br />

certain papers may need manual<br />

adjustment.<br />

Do not go beyond the setup parameters<br />

of the machine. For example, you may<br />

have tried to set a “Z” fold for a paper<br />

length of 4” (100mm). Such a folded<br />

piece would become too small to<br />

transport through the machine and so<br />

the internal electronic control system<br />

rejects the request.<br />

• Press Enter. The fault may be cleared<br />

automatically and the display will<br />

revert to the normal running mode.<br />

• If this does not help, turn power off<br />

and remove the fold plate assembly as<br />

described on page 33. Place the fold<br />

plate assembly on its side. Working<br />

through the openings in each fold<br />

plate, try to turn the long guide screw<br />

on which the fold plate stop travels.<br />

Turn the screw several turns each way<br />

to clean out any paper dust which may<br />

have accumulated in the brass nut<br />

of the paper stop. If you fi nd that the<br />

paper stop has travelled to the very<br />

end of its travel at either end, turn<br />

the screw so that the stop is at least<br />

3/4” (20mm) away from the extreme<br />

position. Refi t the fold plate assembly<br />

as described on page 33 and turn<br />

power back on. The fold plate stops<br />

will move to their proper positions and<br />

the display will return to the running<br />

mode. If the “FOLD PLATE ERROR”<br />

message appears again, try the above<br />

procedure once or twice more. If the<br />

fault persists, call <strong>Pitney</strong> <strong>Bowes</strong> for<br />

assistance.<br />

37


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

Error Messages Displayed on the Control Panel (continued)<br />

Error Message What It Means <strong>Operator</strong> Action<br />

Jam In <strong>Folder</strong><br />

Open Top Cover<br />

Jam In Stacker<br />

Done Enter<br />

Limit Switch F.P.1<br />

Or<br />

Limit Switch F.P.2<br />

Motor Stopped<br />

Open Top Cover<br />

Programs Full<br />

Clear Job First<br />

A paper jam has occurred<br />

within the machine.<br />

A folded sheet has not<br />

been ejected properly<br />

onto the stacker table. It<br />

is usually caused by paper<br />

piling up when the stacker<br />

table is full or by a double<br />

sheet. In rare cases, with<br />

certain types of paper,<br />

it can also happen when<br />

a folded sheet catches<br />

the topmost panel of the<br />

preceding sheet. The<br />

sheet causing the jam will<br />

probably look like this: Z<br />

or like this: Z<br />

The stop in either fold<br />

plate 1 (F.P.1) or fold plate<br />

2 (F.P.2) has moved to<br />

the very end of its travel<br />

and has operated the<br />

emergency limit switches<br />

at those positions.<br />

A large paper jam caused<br />

the motor to stall. The<br />

internal electronic control<br />

in the <strong>DF500</strong> will shut<br />

down the motor and<br />

display this message.<br />

You have attempted to<br />

save a new job but all nine<br />

memory locations are<br />

already full.<br />

Refer to “Clearing a jam”<br />

on page 32 and “Removing<br />

the fold plates” on page<br />

33.<br />

• Remove all paper from<br />

the stacker table,<br />

then press Enter. The<br />

stacker wheels will<br />

return to their operating<br />

position and the display<br />

will show operating<br />

mode again.<br />

• Open the top cover<br />

and remove any paper<br />

inside. Close the top<br />

cover and press Enter<br />

to clear the display<br />

message.<br />

• If possible, adjust the<br />

fold to look more even<br />

like this: Z<br />

Follow the procedure for<br />

“FOLD PLATE ERROR”<br />

above to clear this<br />

condition.<br />

Refer to “Clearing a jam”<br />

on page 32 and “Removing<br />

the fold plates” on page<br />

33.<br />

Delete some jobs to make<br />

room (see page 27).<br />

38 SV40214 Rev. A


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

Error Messages Displayed on the Control Panel (continued)<br />

Error Message What It Means <strong>Operator</strong> Action<br />

Stacker Error There is a problem<br />

with the stacker<br />

rollers.<br />

Use New Setting ?<br />

Yes: Enter No:<br />

SV40214 Rev. A<br />

This message<br />

appears when you<br />

have changed a<br />

setting but have<br />

not confi rmed it by<br />

pressing Enter.<br />

• Press Enter and the problem may<br />

clear itself automatically.<br />

• If this does not help, turn power off<br />

and remove the fold plate assembly<br />

as described on page 33. This<br />

gives access to the stacker drive<br />

mechanisms on the underside of<br />

the stacker table. Locate the stacker<br />

motor and turn the small drive gear<br />

on the motor shaft. This will move the<br />

stacker rollers. Turn the gear in the<br />

direction that will move the stacker<br />

rollers away from the extreme end<br />

of their travel. Keep turning until the<br />

stacker rollers have moved about 3/4”<br />

(20mm) away from the end of their<br />

guide slots in the stacker table. Refi t<br />

the fold plate assembly as described<br />

on page 33 and turn power back<br />

on. The stacker rollers will move to<br />

their proper position and the display<br />

will return to the running mode. If<br />

the rollers return to their extreme<br />

position and the “STACKER ERROR”<br />

message appears again, try the above<br />

procedure once or twice more. If the<br />

fault persists, call <strong>Pitney</strong> <strong>Bowes</strong> for<br />

assistance.<br />

Press Enter to activate your setting or<br />

to stay with your previous setting.<br />

39


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

MAINTENANCE<br />

Regular and proper cleaning contributes to a long life of the machine<br />

and a consistent quality. It is important, therefore, to clean<br />

the machine at regular intervals. The interval between machine<br />

main te nance depends on the workload, but once a week is a<br />

good starting point. Maintenance of the <strong>DF500</strong> includes:<br />

• Removing accumulated paper dust<br />

• Removing any built-up debris on the fold rollers. This should<br />

be done with a stiff brush only-not with liquids. Liquids such<br />

as soap and water, alcohol, roller cleaner, ink re mov er, etc.<br />

would dam age the rollers' anti-static surface and cause folding<br />

prob lems.<br />

• Cleaning the outside surface of the <strong>DF500</strong> as needed with<br />

a damp ened cloth and a water-based mild liquid or spray<br />

clean er.<br />

SUPPLIES<br />

WARNING: Before cleaning or doing any<br />

maintenance on the ma chine, always<br />

unplug the AC cord from the wall.<br />

Do not attempt to service the Model <strong>DF500</strong> your self, as re mov ing<br />

covers may expose you to dangerous voltage and moving parts.<br />

Refer all servicing to a trained <strong>Pitney</strong> <strong>Bowes</strong> Cus tom er Service<br />

Rep re sen ta tive.<br />

To order the following item, just call the PB Supply Line at 1-800-243-<br />

7824.<br />

Multipurpose Cleaning Kit, Item code F902-0<br />

40 SV40214 Rev. A


FORM HANDLING<br />

SV40214 Rev. A<br />

<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

Material Handling Notes<br />

Material handling problems with paper handling equipment are<br />

often due to distortion (warping, curl, sticking, etc.). This can be<br />

a result of poor packaging, improper handling or environmental<br />

ex tremes during manufacture, transit, or storage. This is particularly<br />

true of material which contains glue that is extremely sensitive<br />

to tem per a ture and humidity.<br />

Fortunately, there are a number of easy and effective measures<br />

you can take to minimize problems, improve production and get<br />

the most out of your <strong>Pitney</strong> <strong>Bowes</strong> equipment.<br />

Be Sure Material Meets Our Forms Specifications<br />

The <strong>DF500</strong> is designed to handle a certain range of material.<br />

Ma te ri al which falls outside this range may run poorly or not at<br />

all. Many operating problems are actually due to out-of-spec i -<br />

fi ca tion material.<br />

Store and Handle Material with Care<br />

• Do not "crash" skids, loaded with the material, onto loading<br />

docks, in trans port vans, or in the final storage area.<br />

• Block loaded skids in transport vans.<br />

• Do not expose cartons to the elements; prolonged exposure to<br />

intense sunlight, high humidity and so on can damage material.<br />

• Store materials in a controlled environment. We recommend<br />

a nominal temperature of 75°F at 50% relative humidity. Glue<br />

formulas do vary, however, so temperature and humidity limits<br />

above and below these may be better for certain materials.<br />

• Store cartons on skids or shelves to prevent absorption of<br />

moisture, never directly on floors or against cement walls.<br />

Very dry material may accumulate static and be difficult to handle,<br />

whereas damp material will almost certainly stick together.<br />

• Do not stack cartons too high; this can deform the cartons<br />

on the bottom and damage the material. Try to stack cartons<br />

so that material lies flat.<br />

41


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

FORM HANDLING (continued)<br />

Rotate Stock; Give Material Time to Stabilize<br />

• Rotate stock; use oldest stock first (first in, first out).<br />

• Transfer cartons from the storage area to the work area no<br />

more than several hours before use.<br />

• Do not remove boxes from their cartons until they are needed.<br />

• Allow about one hour of stabilization time for each degree of<br />

temperature change from the storage to the processing area.<br />

42 SV40214 Rev. A


Equipment<br />

SV40214 Rev. A<br />

<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

EQUIPMENT/FORM SPECIFICATIONS<br />

Dimensions Width: 25" (640mm)<br />

Length: 34" (860mm)<br />

Height: 17" (430mm)<br />

Weight 95 lbs. (43 kg) shipping weight<br />

Electrical 120 VAC, 60 Hz, 3A (also 230 VAC, 50 Hz, 2A)<br />

Operating Speed Up to 20,000 sheets per hour, depending<br />

on fold (actual speed will depend on the<br />

paper size, paper quality, system setup,<br />

operator experience, and environmental<br />

conditions)<br />

Nominal Usage 2,000 pieces/day; 40,000 pieces/month<br />

Maximum peak operation is 40,000 pieces<br />

per day, no more than once a month.<br />

Sound Level: 75 dBA, based on folding 20 lb. bond<br />

(80 g/m2 ) paper into a letter (C) fold at<br />

a speed of 10,000 sheets per hour (Aweighted<br />

sound level at op er a tor position).<br />

Environment Amb. 55 - 95°F (13 - 35 °C)<br />

Temperature<br />

Operation Max. Wet Bulb: 80 °F (27 °C)<br />

Relative humidity: 20 - 80% (noncondense)<br />

Fold Types • Single (half fold)<br />

• Z-fold (accordion)<br />

• Letter (C) fold<br />

• Double Parallel fold<br />

• Z+ fold with margin<br />

Fold Plate Range Fold plate 1: min. 1-9/16" (40 mm),<br />

max. 12-3/4" (324 mm)<br />

Fold plate 2: min. 1-9/16" (40 mm),<br />

max. 8-1/2" (216 mm)<br />

43


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

Skew Allowance -based on 20 lb. 8.5" x 11" (80 g/m2 A4 bond paper)<br />

• 68% of samples will deviate from the ideal fold center line<br />

within ±.02" (±0.5mm)<br />

• 28% of samples will deviate from the ideal fold center line<br />

within ±.02-.04" (±0.5-1.0mm)<br />

• 4% of samples will deviate from the ideal fold center line<br />

within ±.04-.06" (±1.0-1.5mm)<br />

Multi-Skew Allowance:<br />

Collated sets of up to five sheets may deviate from the ideal fold<br />

life by a maximum of ±1/12" (±2mm) either side.<br />

Ideal Fold Line<br />

+.02"<br />

-.02"<br />

Ideal Fold Line<br />

Fold Deviation: Based on 20 lb. 8.5" x 11" (80 g/m2 A4 bond paper)<br />

• 68% of samples will deviate from the ideal fold center line<br />

within ±.02" (±0.5mm)<br />

• 28% of samples will deviate from the ideal fold center line<br />

within ±.02-.04" (±0.5-1.0mm)<br />

• 4% of samples will deviate from the ideal fold center line<br />

within ±.04-.06" (±1.0-1.5mm)<br />

44 SV40214 Rev. A


Ideal Fold Line<br />

SV40214 Rev. A<br />

+.02"<br />

-.02"<br />

<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

Multi-Sheet Fold Allowance: Collated sets of up to five sheets<br />

may deviate from the ideal fold life by a max. of ±1/12" (±2mm)<br />

either side.<br />

Forms<br />

Size Width: min. 3-1/2" (90 mm), max. 12" (305 mm)<br />

Length: min. 4" (100 mm), max. 17" (432 mm)<br />

Form Weight Minimum: 14 lb. bond (53 g/m2 )<br />

Maximum: 65 lb. bond (180 g/m2 )<br />

Thickness The <strong>DF500</strong> can process, hand fed, stapled, or<br />

non-stapled collations of up to five sheets of<br />

8-1/2" by 11" 20 lb. (80 g/m2 ) material. Maximum<br />

thickness is 0.020"(0.5mm).<br />

Feeding The feed and stacking areas will ac com -<br />

Capacity mo date 250 sheets of 20 lb. (80 g/m2 ) material<br />

Paper Ratio The length of the paper must be at least two<br />

times the width of the paper.<br />

Length<br />

Width<br />

45


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

Index<br />

A<br />

Adjustments<br />

Feeder Gap 19<br />

Fold Type 17<br />

Paper <strong>Guide</strong>s 10<br />

Pressure Roller 11<br />

Skewed Fold 18<br />

Automatic Fold Setup 12<br />

Automatic Feed 31<br />

B<br />

Batch Count, Setting 21, 22<br />

C<br />

Clearing a Jam 32<br />

Controls/Features 5, 6, 7<br />

Control Panel, Description 7<br />

D<br />

Deleting a Job 27<br />

Description, Machine 4<br />

Double Parallel Fold<br />

Description 4<br />

Setup 12<br />

E<br />

Equipment Specifications 43<br />

Error Messages 37, 38, 39<br />

F<br />

Feed, Manual 30<br />

Feed, Automatic 31<br />

Feeder Gap, Adjusting 19<br />

Feeder, Setup 9, 10, 11<br />

<strong>Folder</strong> Mechanics 15<br />

Fold Plates, Removing 34<br />

Fold Types<br />

Description 4, 43<br />

Fine Tuning 17<br />

Setup, Automatic 12<br />

Setup, Manual 28, 29<br />

Form Handling 41<br />

Forms Specifications 45<br />

G<br />

Gap, Feeder, Adjusting 19<br />

Gate Fold<br />

Description 4<br />

Setup 12<br />

I<br />

Identifying a Job 26<br />

J<br />

Jam, Clearing 32<br />

Jobs<br />

Deleting Job 27<br />

Identifying Job 26<br />

Normal Job, Setup 23<br />

Retrieving Job 26<br />

Running Job 23<br />

Saving Job 24<br />

Temporary Job, Setup 23<br />

L<br />

Letter Fold<br />

Description 4<br />

Setup 12<br />

M<br />

Machine Setup 9<br />

Maintenance 40<br />

Manual Feed 30<br />

Manual Fold Setup 28, 29<br />

Moving the <strong>DF500</strong> 8<br />

46 SV40214 Rev. A


N<br />

Non-Standard Fold, Man.Setup 28<br />

Normal Job, Setup 23<br />

O<br />

Operating, <strong>Folder</strong> 13<br />

Operating Hints 32<br />

P<br />

Paper <strong>Guide</strong>s, Adjusting 10<br />

Paper, Loading 10<br />

Paper Size<br />

Setup for Automatic Fold 12<br />

Setup for Manual Fold 28<br />

Pressure Roller, Adjusting 11<br />

R<br />

Retrieving Job 26<br />

Running Job 23<br />

S<br />

Safety 2<br />

Saving Job 24<br />

Single Fold<br />

Description 4<br />

Setup 12<br />

Skewed Fold, Adjusting 18<br />

Specifications,<br />

Equipment 43, 44<br />

Forms 45<br />

Speed, Setting 13<br />

Standard Fold, Manual Setup 28<br />

Start/Stopping Machine 14, 15<br />

Supplies 40<br />

Symptoms , Troubleshooting 36<br />

SV40214 Rev. A<br />

<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

T<br />

Table Extension 11<br />

Temporary Job, Setup 23<br />

Theory, <strong>Folder</strong> Mechanics 15<br />

Total Count, Clearing 20<br />

Trial Piece, Running 14<br />

Troubleshooting 36, 37, 38, 39<br />

Z<br />

Z-Fold<br />

Description 4<br />

Setup 12<br />

Z-Fold with Margin<br />

Description 4<br />

Setup 12<br />

47


<strong>DF500</strong> <strong>Folder</strong> <strong>Operator</strong> <strong>Guide</strong><br />

48 SV40214 Rev. A

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