Pitney bowes OFFICERIGHT DF500 User Manual
PB Form SV40124 First Edition, July 2003 © 2003 Pitney Bowes
Inc. All rights reserved. This book may not be reproduced in
whole or in part in any fashion or stored in a retrieval system of
any type or transmitted by any means, electronically or mechanically, without the express written permission of Pitney Bowes Inc.
We have made every reasonable effort to assure the accuracy and
usefulness of this manual, however, we cannot assume responsibility for errors or omissions or liability for the misuse or misapplication of our products.
OfficeRight is a registered trademark and PB Supply Line is a
service mark of Pitney Bowes Inc.
FCC Compliance
This equipment had been tested and found to comply with the
limits for a Class A digital device, pursuant to Part 15 of the FCC
rules. These limits are designed to provide reasonable protection
against interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can
radiate radio frequency energy, and if not installed and used in
accordance with the users manuals, may cause harmful interference to radio communications. Operation of this equipment in a
residential area is likely to cause harmful interference in which
case the user will be required to correct the interference at his
own expense.
Shielded cables must be used with this unit to insure compliance
with Class A limits.
Canadian DOC Compliance
This digital apparatus does not exceed in the Class A limits for
radio noise emissions from digital apparatus set out in the Interference-causing Equipment Regulations (Standard ICES-003) of
the Canadian Department of Communications.
NOTE: This equipment has been tested and found to comply
with the U.S. Standard for Safety UL60950, Third Edition, Safety
of Information Technology Equipment including Electrical Business Equipment and Canadian Standards C22.2 No 950-95,
Safety of Information Technology Equipment including Electrical Business Equipment.
DF500 Folder Operator Guide
Table of Contents
Section Page
Safety.................................................................................................2
Description ..................................................................................... 2
Moving the DF500 .......................................................................8
Machine and Job Setup ..............................................................9
Automatic Fold Setup................................................................12
Operating The Folder................................................................ 13
Folder Mechanics For Understanding Fold Problems .... 15
Total and Batch Count ..............................................................20
Running a Job ..............................................................................23
Saving, Retrieving, or Deleting Jobs.....................................24
Manual Fold Setup......................................................................28
Manual Feed ................................................................................30
Operating Hints ..........................................................................32
Troubleshooting ..........................................................................36
Maintenance................................................................................ 40
Supplies......................................................................................... 40
Form Handling.............................................................................41
Equipment/Form Specifications............................................43
1SV40214 Rev. A
DF500 Folder Operator Guide
SAFETY
A series of messages may be used throughout this manual to
alert you to potentially hazardous con di tions. These messages
are ex plained below:
WARNING - indicates the presence of a hazard that
can cause severe personal injury or loss of life,
or substantial property damage if the warning is
ignored.
CAUTION - indicates the presence of a hazard that
will or can cause minor personal injury or property
damage if the warning is ignored.
NOTE - calls attention to practices that could adversely affect equipment operation if instructions
are not followed exactly.
Always use safe operating procedures when running your folder.
Ob serve the following practices:
• Keep loose clothing, jewelry and long hair away from all moving parts.
• Avoid touching moving parts or materials while the machine
is in use. Before clearing a jam, unplug the machine. Be sure
machine mechanisms have come to a stop.
• To protect against electric shock, the machine should only
be plugged into a properly grounded wall outlet.
• The power cord wall plug is the primary means of disconnecting the folder from the AC supply.
• The wall outlet should be near the machine and easily accessible.
• DO NOT use an adapter plug on the line cord or wall outlet.
• DO NOT remove the ground pin from the line cord.
• Avoid using wall outlets that are controlled by wall switches.
• DO NOT route the power cord over sharp edges or trapped
be tween furniture.
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DF500 Folder Operator Guide
• Ensure there is no strain on the power cord where it be-
comes jammed between the equipment, walls or furniture.
• Be certain the area in front of the wall receptacle into which
the machine is plugged is free from obstruction.
• DO NOT remove covers. This machine cabinet serves to en-
close hazardous parts. If the machine has been dropped or
has oth er wise been stressed in any way, report it to your Pitney Bowes Cus tom er Service Representative.
• To reduce the risk of fire and/or electrical shock, do not at-
tempt to disassemble this machine. If service is required,
contact your Pitney Bowes Customer Service Representative.
• To prevent overheating, do not cover the vent openings.
• All areas of the machine requiring disassembly or removal of
covers should be accessed only by your Pitney Bowes Customer Service Representative.
• Read all instructions before attempting to operate the equip-
ment.
• Use this equipment only for its intended purpose.
In addition, follow any specific occupational safety and health
stan dards for your workplace or area.
3SV40214 Rev. A
DF500 Folder Operator Guide
DESCRIPTION
The Model DF500 Folder is a stand-alone tabletop folder capable of processing up to 40,000 doc u ments per month. The machine folds single and multi-part cut-sheet forms and then feeds
them folded onto the stacker. It is equipped with two fold plates
which allow it to produce single or double folds.
Two covers (one on top, one on the right side) can be opened to
allow access to the fold rollers and fold plates for maintenance
and clear ing of jams. When a cover is opened, the machine stops
automatically and cannot be started accidentally.
A control panel with an LCD display informs you of the status
of the machine and of the jobs your are running. Up to ten jobs
may be setup and saved for easy retrieval. In addition, system
di ag nos tics are available con ve nient ly from the control panel.
One feature of the DF500 is the Auto-Set mode for producing
com mon folds (see below). This mode allows the au to mat ic setting of dif fer ent pro grammed folds and the adjustment of the
paper thick ness. The following standard folds can be called up
via the Auto-Set mode:
Single Fold Double Parallel Fold Letter Fold
Gate Fold Z-Fold Z-Fold with Margin
In addition, other types of folds can be produced by entering the
mea sure ments manually as described later in this guide.
NOTE: The DF500 is built for folding paper and is unsuitable for
han dling other materials such as foils, plastics and textiles.
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DF500 Folder Operator Guide
DF500 Controls and Features
2
1
3
4
5
6
7
1. Stacker Deck – holds the folded documents.
2. Top Cover – allows access inside of folder for removing
jams.
3. Material Feed Deck – where paper is fed into the folder.
4. Skew Adjustment Control – used to offset skewing when
feeding ma te ri al.
5. Fuses – disconnects power to the folder when there is an
over load of power con sumed by the machine.
6. AC Input for Power Cord – connects to AC line cord.
7. Power Switch – turns on and off machine.
8. Operator Side of Machine
9. Right Hand Cover (on side) – allows access to fold plate.
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DF500 Folder Operator Guide
More DF500 Controls and Features
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5
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6
1. Stacker Extension – allows more space for collected doc u ments after folding.
2. Stacker Rollers – helps guide material on to stacker belts.
3. Stacker Belts – moves folded documents away from exit
area.
4. Input Feed Deck Extension Guides – allows long sheets of
material to be supported. Flip up to activate.
5. Pre-feed Adjustment Knob – allows you to change the
amount of feed pressure for feeding various types of material.
6. Operating Guide Holder – holds this DF500 Operating
Guide.
7. Control Panel – allows user to setup and operate the folder.
8. Hand Wheel Knob (under cover) – allows for manual turning of fold rollers to aid in clearing jams.
6 SV40214 Rev. A
DF500 Folder Operator Guide
DF500 Control Panel Features
1
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3
5
1. Paper Size Indicators – shows the paper size in use.
2. Standard Fold Type Indicators – shows the type of fold
se lect ed.
3. LCD Display – displays machine and job status to operator.
4. Dual Function Buttons – used for setting paper thickness
or manual feeding. Also used for scroll ing in certain setup
menus.
5. Setup Buttons – sets up the folder functions.
6. Main Control Buttons – used to control main folder op er a tion.
4
6
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DF500 Folder Operator Guide
MOVING THE DF500
WARNING: To avoid personal injury or damage
to the machine, two people should be used to
lift the DF500.
1. If moving the DF500, make sure that it is unplugged and that
it is placed on an ap pro pri ate work surface. There has to be
a min i mum clear ance of 36" (914mm) on three sides of the
machine for op er a tor access. Rec om mend ed table height is
30" (762mm).
2. Lift the DF500 from under each end. Do not lift the unit using
the paper support guides, control panel, or fold plate door.
WARNING: To avoid personal injury or damage to
the machine, make sure you lift the folder by the
bottom of the chassis. Do not use the fold plate
compartment door on the side as a handle, as it
will open up and cause you to drop the machine.
3. Install the line cord into the AC input on the side of the
DF500 (see below) and then plug it in to a grounded 115
VAC outlet.
AC Input for
Power Cord
Power Switch
4. Turn the machine on and verify that the control panel displays the power-up screen (see below).
JOB: 1 READY
ШШШШШШ
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DF500 Folder Operator Guide
MACHINE AND JOB SETUP
Feeder Setup
Setting the Paper Thickness
1. Turn the power switch to ON. The display will read:
JOB: 1 READY
ШШШШШШ
2. Press the Paper Thickness key on the control panel. The
display changes to:
SET THICKNESS?
YES: Enter NO:
3. Press Enter. The sheet separator in the feeder will open and
the display will prompt:
!
INSERT ONE SHEET
DONE - Enter
4. Insert a sample sheet of the paper
you want to fold into the feeder.
Push in the pressure roll er and
insert the pa per into the feeder
(see be low) about 2" (50mm).
5. Press the Enter key. The DF500 will now automatically adjust
itself to the thickness of the paper.
6. If your fold is already setup, you may now press the Trial
Piece key to fold this sample sheet. If you have not yet setup
your fold, withdraw the sheet. You will feel a slight resistance.
7. The display will again show:
JOB: 1 READY
ШШШШШ1
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DF500 Folder Operator Guide
Setting the Paper Guides
1. Squeeze the blue lever against the right hand paper guide,
and, using two hands,
move the guides to the
width of the paper.
2. Allow about 1/32"
(1mm) clear ance so that
the paper is not held
too tightly (see below).
Do not allow too much
clear ance as this will affect fold accuracy.
Loading Paper
When paper is loaded into the DF500, the top sheet of the paper stack is fed first. This means that the paper stack must be
“fanned out” so that the top sheet is closest to the feed roller.
1. Place a stack of paper onto the feed table. Firmly grasp the
upper end of the stack with your left hand and bend the entire stack up and forward as shown.
2. While still holding the stack with your left hand, press down
on the lower end of the stack
with your right hand. Now
release the upper end of the
stack and let it fall onto the
feed table. The stack should
appear slightly fanned out.
3. Repeat this process several
times and the stack will be
fanned out properly. Allow
the fanned stack to slide
down into the mouth of the
feeder as far as it will go
without forcing it.
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DF500 Folder Operator Guide
Using the Table Extension
1. Lift the table extension up to sup port longer paper like legal
size.
Setting the Pressure Roller
The pressure roller knob allows you to set the pressure applied to
the first set of feed rollers.
• For 20 lb. bond paper,
set the knob halfway
between "+" and "–".
• For heavier paper, or if
you see the feed rollers
slipping, move the knob
towards "+".
• For lighter paper, or
if the paper tends to
bunch up under the
feed rollers, set the knob
towards "–".
11SV40214 Rev. A
DF500 Folder Operator Guide
AUTOMATIC FOLD SETUP
Selecting Paper Size
1. Press the Paper key to select the desired paper size length.
Each press of the key will step through the three standard
paper sizes and “other” and will light the appropriate paper
size indicator on the control panel.
2. At the same time, the display will show the selected paper
length in millimeters. For example:
T1 PAPER = 297.Ø
CHG: DONE: Enter
3. If your paper isn’t a standard size, press the " or ! key, to
change the size. Each key press will change the paper size by
about 1/64" (0.5mm). Holding the key down for more than
one second will increase the step size, allowing large changes
to be made rapidly.
4. When the correct paper size is shown, proceed with “Selecting Fold Type” below. NOTE: The DF500’s electronic control
system will not allow you to deviate too far from the standard
settings. This will prevent jams caused by “impossible” folds.
Selecting Fold Type
Before selecting a fold, make sure you have already set the
DF500 to the correct paper size length. This will prevent the machine from setting up a fold for the wrong paper length, which
could result in a paper jam.
1. Press the Fold Type key to select one of the six pre-pro-
grammed fold types. Each key press will turn on the indicator
associated with each fold type.
2. When you have made your selection, press the Enter key. The
display will show:
TEMP JOB: 1 READY
ШШШШШШ
3. While the machine is setting up the fold, all keys on the control panel are disabled and will not respond if pressed.
(continued on next page)
12 SV40214 Rev. A
DF500 Folder Operator Guide
Selecting Fold Type (continued)
4. When the setup is complete, the display will change back to
the “Ready” state.
TEMP JOB: 1 READY
ШШШШШШ
NOTE: “TEMP JOB” or “T” in the display means that the job
just setup is considered a temporary job because it has not
yet been saved in memory.
OPERATING THE FOLDER
Setting the Speed
Set the proper speed before attempting to run the folder. The
speed setting depends on the weight and size of the paper used.
Light weight and large size papers (lighter than 20 lb. bond and
larger than 8-1/2" by 11") must be run slower than heavy paper
and smaller sheets. A good value to start with is 35.
1. Press the Speed key. The display will typically show:
T1 SPEED = 40
CHG: DONE: Enter
2. To change the speed, press the " or ! key, then press Enter.
3. If you forgot to press Enter and try to start the folder, the
display will show:
USE NEW SETTING?
YES: Enter No:
!
This message will also appear if you have entered any other
new parameter such as paper size, fold type, batch or fold
plate setting.
4. Press Enter now to activate your setting or the ! key to stay
with your previous setting.
(continued on next page)
13SV40214 Rev. A
DF500 Folder Operator Guide
Setting the Speed (continued)
The speed can also be changed while the machine is running.
1. Press the Speed key. The display will change to:
SPEED 35
ШШШШШШ
2. Use the " or ! keys to run slower or faster.
3. The speed will change instantly. You need not press the Enter
key to activate the new setting.
Running a Trial Piece
Always run a trial piece before starting a run. It is also a good
idea to run a trial piece each time a new stack of paper has been
loaded onto the feed table. This will prevent a jam if the stack
has been loaded incorrectly.
1. Press the Trial Piece key. A single sheet will be folded and
de liv ered to the stacker for you to check.
Startup
1. If you are happy with the trial piece, press the Start key to
begin the au to mat ic feeding and folding. The folded sheets
will be delivered neatly shingled on the stacker table.
2. Remove the folded sheets as soon as they start piling up in
front of the stacker extension.
3. When the entire paper stack has been fed the machine will
stop and the display will show:
– FAIL TO FEED –
DONE - Enter
4. Reload the feed table with a new stack of paper and press the
Enter key to clear the message on the display.
TEMP JOB: 1 READY
ШШШШШШ
5. When the display shows ‘Ready’, press the Start key to resume folding.
14 SV40214 Rev. A
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