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PB Form SV40124 First Edition, July 2003 © 2003 Pitney Bowes
Inc. All rights reserved. This book may not be reproduced in
whole or in part in any fashion or stored in a retrieval system of
any type or transmitted by any means, electronically or 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.
Page 3
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
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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
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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.
8
9
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DF500 Folder Operator Guide
More DF500 Controls and Features
3
2
8
1
4
5
7
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
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DF500 Folder Operator Guide
DF500 Control Panel Features
1
2
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 "–".
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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)
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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)
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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.
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DF500 Folder Operator Guide
Stop ping the DF500
1. To in ter rupt the folding process at any time, press the Stop
key. This will stop the machine in a controlled manner.
2. The sheets already in process will be folded and delivered be-
fore the machine stops. The stacker belts will move all folded
sheets to the end of the stacker table for easy removal.
CAUTION: Unless there is an emergency
situation, do not stop the ma chine by turning
power off by the main switch or wall socket.
Doing this while the DF500 is folding will
result in a paper jam inside the machine.
FOLDER MECHANICS FOR UNDERSTANDING FOLD
PROBLEMS
There can be many reasons for a fold to be slightly off–the paper
composition, paper weight, size and direction of grain. Also, folding speed and ambient conditions like temperature and humidity
can have an effect. Consequently, an understanding of what is
hap pen ing in the folder can be helpful when correcting a fold
problem.
A. The top sheet of paper is fed into the folder and is driven by
rollers (1) and (2) into fold plate 1.
6
4
5
2
3
1
Stop
Fold plate 1
(continued on next page)
Stop
Fold plate 2
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DF500 Folder Operator Guide
Folder Mechanics (continued)
B. The paper con tin ues into the fold plate until it hits the stop.
Since the two rollers are still driving the paper, a buckle will
form at the en trance to the fold plate and will, eventually, be
caught be tween fold rollers (2) and (3). This is how the first
fold is made.
C. The folded edge will be guided by the deflector into the grip
of rollers (3) and (4). Here the same thing happens as in the
first fold plate and a second fold is made.
NOTE: If a single fold is selected, the second fold plate is au-
to mat i cal ly closed off and the folded sheet is routed past it.
4
2
3
1
6
4
5
3
2
1
D. The folded sheet is now guided by the second deflector into the
grip of rollers (5) and (6) where it is fed out onto the stacker.
It is obvious that the position of each fold plate stop determines
the length of the fold resulting from it. Keeping this in mind, it
is easy to make corrections to each fold by simply moving the
relevant stop in or out. You only need to know which end of the
sheet entered the machine first to recognize which was the first
fold and which was the second.
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DF500 Folder Operator Guide
Fine Tuning the Folder
Fold corrections can be made with the machine stopped or running.
Correcting a fold with the machine stopped…
1. Select which fold you want to correct by pressing the Fold 1
or Fold 2 key. (If a single fold is set, the Fold 2 key will not
respond). The display shows, for example:
T1 FOLD1 = 148.Ø
CHG:
DONE: Enter
2. Change the value by pressing the " or ! key, then press
Enter to confirm the new setting. The fold is now set and the
display shows:
TEMP JOB: 1 READY
ШШШШШШ
3. If you try to start the machine without pressing Enter, the
display will prompt:
USE NEW SETTING?
YES: Enter No:
The machine will not start until you press either Enter or ! key.
!
Correcting a fold with the machine running…
1. Select which fold you want to correct by pressing the Fold 1
or Fold 2 key. (If a single fold is set, the Fold 2 key will not
respond). The display shows, for example:
or
FOLD 1 = 148.Ø
ШШШШШ1
FOLD 2 = 74.Ø
ШШШШШ1
2. Change the value by pressing the " or ! key. You can judge
the result instantly by taking a folded sample from the stacker.
NOTE: This procedure should only be used to correct small
errors; oth er wise you will produce many reject sheets before you get the fold right.
3. The correction display will remain until you either press
Enter, Speed, or you stop the machine.
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DF500 Folder Operator Guide
Correcting a Skewed Fold
A skewed fold will result if the paper has not been fed exactly at
right angles with respect to the fold rollers. To correct a skew, the
entire feed table can be moved left or right by turning the skew
ad just ment knob. A pointer in the slot above the knob will show
which way the deck is moving
when turn ing the knob. As a general rule, the pointer should be
in the center of the slot.
NOTE: Before attempting to
correct the skew, make sure the
feeder side guides are adjusted
as close to the paper as possible without binding.
The steps below de scribe in detail how to correct a skewed fold.
1. Remove the paper from the feed table.
2. Turn the skew adjustment knob to center the pointer in its
slot.
3. Reload the paper making sure there isn’t too much clear ance
between the stack and the side guides.
4. Set the machine for a half (single) fold. This makes it easier
to determine which way to turn the skew ad just ing knob.
5. Run a trial piece.
6. If the fold is skewed, compare your sample with the drawings
below.
If the sample looks like "A", turn the skew
ad just ment knob counter-clockwise slightly.
If the sample looks like "B", turn the skew
ad just ment knob clock wise slightly.
7. Remove and reload the paper stack. This is
im por tant – if you do not reload the stack
the adjustment you just made may not take ef fect immediately.
8. Run another trial piece and readjust if necessary.
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DF500 Folder Operator Guide
Fine Tuning the Feeder for "Problem" Paper
The fine tuning feature allows you to adjust the feeder gap (the
opening through which the paper must pass) in small steps while
the machine is running. This is helpful with some “problem”
papers, such as lightweight recycling papers and heavy stock because the stan dard feeder settings tend to mark the coated surface of the paper.
Observe the paper feed while folding. If the feeding is erratic
(paper seems to hesitate before entering the folder) or if you get
“FAIL TO FEED” messages, check first whether the pressure roller
is exerting enough pressure on the paper (see page 11 for details). If more pressure does not help, you must open the feeder
gap a little. If you tend to get double sheets being fed, you must
close the gap slightly.
The steps below de scribe in detail how to fine tune paper feeding.
1. With the machine running, press the " or ! key. The display
will change to:
TUNE THICKNESS
ШШШШШ1
2. Press the " key to open the gap, or the ! key to close the
gap. Typically, the display will show:
:+ ENTER
ШШШШШ1
NOTE: A "+" symbol on the display shows you are opening
the gap a little. A "–" symbol on the display shows you are
closing the gap a little.
3. By using the " or ! keys, you can open or close the gap in
steps shown on the display by up to five "+" or five "–" sym bols. Consequently, a typical display might be something like:
or
:+++++ ENTER
ШШШШШ1
:----- ENTER
ШШШШШ1
If no symbols show on the display, you are back to the stan-
dard feeder setting.
(continued on next page)
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DF500 Folder Operator Guide
Fine Tuning the Feeder (continued)
4. To leave the fine tuning mode, press Enter. The display will
switch back to normal running mode.
If you don’t press Enter, the machine will stay in fine tuning
mode until power is turned off. When the machine is turned
back on again, the display will be back in normal running mode.
NOTE: The paper thickness setting will not automatically
change when switching jobs. You must set paper thickness
first when starting a new job (see page 9). It is good practice
to set paper thickness even when the same weight of paper is
used with the new job.
TOTAL AND BATCH COUNT
Clearing Total Count
The total count feature is always active and cannot be turned off.
The counter must therefore be reset for each individual job that
requires counting.
1. To reset the count, press the Reset Counter key. The display
shows:
RESET ØØØØ29
YES: Enter No:
!
2. Press the Enter key to reset the counter, or the ! key, if you
have changed your mind. The counter digits at the bottom
right of the display will revert to zero:
TEMP JOB: 1 READY
ШШШШШШ
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DF500 Folder Operator Guide
Setting a Batch Count
The batch count feature will make the machine fold a pre-selected number of sheets (a batch) and then stop. The remaining
folded sheets on the stacker will be carried to the end of the
stacker table to aid removal. Follow the steps below to set a batch
count function.
1. Press the Batch key. The indicator next to the key will light
and the display will show:
T1 BATCH = ØØ5
CHG:
DONE: Enter
2. Change the batch count number (which must be from 5 to
999) by using the " or ! keys, then press Enter to confirm.
3. The indicator will remain lit and the display will change to:
TEMP JOB: 1 READY
BATCH: Ш5Ш ШШШШШШ
4. Folding of the next batch is resumed by pressing the Start key.
Turning off the batch count
The batch count function will operate as long as the batch indicator is on, even if the paper size and/or fold type is changed.
1. Press the Batch key.
2. The indicator will go off and the display will briefly show:
BATCH MODE OFF
then go back to the normal running mode display:
TEMP JOB: 1 READY
ШШШШШШ
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DF500 Folder Operator Guide
Restoring a Batch Count
If you have set a batch of 50, for instance, and have taken a trial
piece or have run several pieces you cannot use, you may want to
restore the batch count to 50 before starting a folding run. Follow the steps below to restore a batch count.
1. Press the Batch key (to turn batch off).
2. Press the Batch key a second time (batch setting mode on).
3. Press Enter. The batch count will be restored and the machine is ready to run a full batch.
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DF500 Folder Operator Guide
RUNNING A JOB
Normal Job
The Normal Job is a commonly used setup which can be recalled
very quickly when required. From the factory, this job is set to
give a letter (C) fold on 8-1/2" by 11" paper. However, it can be
set to a dif fer ent fold and paper com bi na tion, if required, by a
Pitney Bowes service engineer. Follow the steps below to select a
normal job.
1. Simply press the Normal Job key. The display will prompt:
SET NORMAL JOB?
YES: Enter No:
2. Press Enter to activate the Normal Job settings or press ! if
you have changed your mind.
3. During activation of the Normal Job, the display will show:
SETTING
4. When the Normal Job is set, the display will only show:
!
READY
ШШШШШШ
Temporary Job
A Temporary Job is any folding job setup without it having been
stored in the machine’s memory. The settings are not retained by
the machine and cannot be recalled at a future date. A Temporary Job will be shown in the display by the word “TEMP” or the
letter “T”:
TEMP JOB: 1 READY
ШШШШШШ
T1 PAPER = 297.Ø
CHG:
DONE: Enter
If you recall a programmed job and change any of its settings,
it will be regarded as a Temporary Job by the DF500 until it is
saved again to memory. See page 24 for details of saving a job in
memory or updating a job already in memory.
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DF500 Folder Operator Guide
SAVING, RETRIEVING, OR DELETING JOBS
After setting up and running a job, you might want to save it for
later use. This is especially useful for jobs which occur frequently
or for difficult jobs that run well only at a certain speed and fold
plate setting. The following parameters are saved with a job:
• The paper size (standard or not)
• The type of fold (including any manual fold plate corrections)
• The speed
• The batch count (if any)
You can save up to nine different jobs on the DF500.
Saving A New Or Replacement Job
1. Press the Store Job key. The display will prompt:
MAKE NEW JOB: 2?
YES: Enter No:
!
2. If you don’t want to save the job, press the ! key. The display
will go back to running mode and the job will not be saved.
3. To save the job, press the Enter key. If the memory space is
available, the display will show for a few seconds…
STORED AS: JOB2
… then return to running mode with the job saved.
JOB: 2 READY
ШШШШШШ
If the memory space is already occupied by another job, the
display will show:
REPLACE JOB2?
YES: Enter No:
(continued on next page)
24 SV40214 Rev. A
!
Page 27
DF500 Folder Operator Guide
Saving a New or Replacement Job (continued)
4. If you press Enter, the job previously saved under “JOB 2”
(for this example) will be replaced by the new job under the
same job number:
STORED AS: JOB2
5. If you don’t want to erase the job already in memory, press
the ! key. The display will increment the job number up by
one and will prompt:
MAKE NEW JOB3?
YES: Enter No:
6. The new job number offered (in this example 3), is always
the lowest available job number. In this case jobs 1 and 2
are already occupied, while job numbers 3 to 9 are available.
Available job numbers are always offered in ascending order.
It is not pos si ble to “jump” one number.
!
7. Press Enter to save your new job under the new job number.
STORED AS: JOB3
8. If all 9 memory spaces are full and you choose not to replace
an existing job, the display will show:
–PROGRAMS FULL–
CLEAR JOB FIRST
9. To store any more jobs you must first delete existing job(s) as
described in "Deleting a Job from Memory" on page 27.
25SV40214 Rev. A
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DF500 Folder Operator Guide
Retrieving A Job From Memory
1. To retrieve a job from memory and set it up, press the Select
Job key repeatedly until the job you want is displayed:
SELECT JOB: 2?
YES: Enter No:
2. If you press Enter, the job shown will be set up and the dis-
play will show in succession:
!
JOB: 2
SETTING
JOB: 2 READY
ШШШШШШ
3. If you press ! key, the display will return to the normal running mode without a job being selected.
Identifying A Job In Memory
1. Use the Select Job key to step through the available jobs
stored in memory. The appropriate indicators for paper size
and fold type will light up for each job. This way you can tell
what kind of job is stored under each job number.
SELECT JOB: 2?
YES: Enter No:
!
2. If you want to know exactly what dimensions are stored for
each fold plate, press the Fold 1 or Fold 2 keys. The display
will briefly show the fold plate dimension set for the job:
SELECT JOB: 2?
FOLD 1 = Ø9Ø.Ø
3. If the job has a single fold, pressing Fold 2 will not display
a di men sion as fold plate 2 is closed for single fold applications.
26 SV40214 Rev. A
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DF500 Folder Operator Guide
Deleting A Job From Memory
1. Select the job number you want to delete by pressing Select
Job until the correct job number is displayed.
2. Press the Reset Counter key. The display will prompt:
DELETE JOB: 3?
YES: Enter No:
3. Press Enter to delete the job:
JOB DELETED
4. The memory location is now clear and another job may be
stored under that number. This job number will be automatically offered when you want to store a new job without erasing any others.
!
27SV40214 Rev. A
Page 30
DF500 Folder Operator Guide
MANUAL FOLD SETUP
Setting A Standard Fold With Non-standard Size Paper
1. Press the Fold Type key to select the desired type of standard
fold.
2. Press the Paper key until the “Other” indicator lights. The
display will show:
TØ PAPER = 297.Ø
CHG: DONE: Enter
3. Use the " or ! keys to change the dimension shown to the
length of your paper in millimeters.
4. Press Enter and the fold will be setup automatically. The display will first show…
TEMP JOB: Ø
SETTING
… then return to the normal running mode display.
TEMP JOB: Ш READY
ШШШШШШ
5. Run a trial piece to check the fold. If necessary, make cor rec tions as described on page 14.
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.
28 SV40214 Rev. A
Page 31
DF500 Folder Operator Guide
Setting A Non-standard Fold With Any Size Paper
1. Press the Paper key to select any of the 3 standard paper
sizes, or select “Other” and set the paper size as described
above.
2. Press the Fold Type key to select a fold which comes closest
to the type of fold you want.
3. Press the Fold 1 key to set fold plate 1. Measure the length of
the first fold on your sample and transfer the measurement
using the " or ! keys.
4. Press Fold 2 and transfer the measurement of the second
fold. If your special fold is a single fold, you do not need to
set fold plate 2.
5. Press Enter, the machine will set itself automatically.
TEMP JOB: Ø
SETTING
TEMP JOB: Ш READY
ШШШШШШ
6. Run a trial piece to check the fold. If necessary make correc-
tions as described on page 14.
29SV40214 Rev. A
Page 32
DF500 Folder Operator Guide
MANUAL FEED
The manual feed mode allows you to hand-feed sets of two or
more sheets, loose, glued or stapled. The limit is five sheets of 20
lb. (80g/m
In manual feed mode the fold rollers will be turning, but the
feeder is disabled. Automatic feeding is not possible because the
paper is fed by hand, one set at a time.
Setting The Feeder For Manual Feed
1. Press the Manual Feed key. The display will show:
2)
bond, folded into a single, letter (C) or Z fold.
CAUTION: Do not attempt to fold sets into
any other type of fold. This could result in
serious damage to the machine.
MANUAL FEED MODE
YES: Enter No:
!
2. Press Enter. You will hear a small motor opening the feeder
gap, which will enable you to feed more than one sheet at a
time. After the motor stops, the display will show:
MAN. FEED READY
ШШШШШШ
3. Press Start and start feeding your collated sets one by one.
In order to get cleanly folded sets, make sure to insert the
sets straight down the paper guides on the feed table.
MAN. FEED RUN
ШШШШШ1
NOTE: If the pressure rollers interfere with hand feeding,
turn the pressure roller setting knob fully to "-".
4. Press Stop to halt feed motors when finished.
30 SV40214 Rev. A
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DF500 Folder Operator Guide
Returning To Automatic Feed
1. To get out of the manual feed mode, press the Manual Feed
key again. The display will prompt:
MANUAL FEED EXIT?
YES: Enter No:
2. Press the Enter key. The display will show:
INSERT ONE SHEET
DONE - Enter
3. Insert a sheet of paper to be fed automatically and press Enter.
The machine will set the feed gap to the thickness of the
sample sheet and the display will return to normal running
mode.
4. Remove the sample sheet or press Trial Piece to feed the
sheet through the machine.
!
31SV40214 Rev. A
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DF500 Folder Operator Guide
OPERATING HINTS
Clearing A Jam
Jams can occur for a number of reasons, including:
• Double sheets being fed
• Running a certain type of fold with the wrong size paper
• Running very light paper too fast
• Running heavy stock too slow
Whenever there is a jam in the machine, errors such as these may
display:
–JAM IN FOLDER–
OPEN TOP COVER
–JAM IN STACKER–
DONE - Enter
Follow the steps below to clear a jam.
1. Open the top cover and look for any paper stuck inside. With
the cover open, either turn the fold rollers by hand or use
the handwheel knob to remove any stalled paper.
2. To use the handwheel
knob (see figure on
right), press in on the
end of the knob and
then release. This will
cause it to pop out to its
operating position. For
safety rea sons, the knob
is still disengaged in
this po si tion.
3. Pull the knob out as far as it will go to engage the gears inside. Turn the knob while keeping it pulled out. Turning it
clockwise will feed the paper towards the stacker.
(continued on next page)
32 SV40214 Rev. A
Page 35
DF500 Folder Operator Guide
Clearing a Jam (continued)
4. If the paper is bunched up inside, making it hard to turn the
knob or the fold roller directly,
remove the two de flec tor bars.
Using the screw as a handle,
push the bar towards the control panel, then lift it out. Any
paper inside should now be visible and is easily removed.
5. Refit the deflector bars by inserting the round end with the
spring into its hole in the operator side frame. Guide the
other end of the bar into the square hole on the opposite
side frame.
6. When you have finished using the manual turnover knob,
press it back in so that it latches into position.
7. While the top cover is open, the display will show:
TOP–COVER OPEN
Close the cover and the display will return to normal running
mode, showing whatever fold job, etc.. had been there before
the jam.
8. If the display still shows “JAM IN FOLDER”, press Enter and
the display should return to running mode.
9. If the error message does not go away, this means that there
is paper stuck in the fold plate. Turn off the main power
switch and refer to the following section “Removing the fold
plates”.
33SV40214 Rev. A
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DF500 Folder Operator Guide
Removing The Fold Plates
You will need to remove the fold plate assembly if paper is stalled
in this area and you have been unable to clear a jam as described
in the previous “Clearing a Jam” section.
CAUTION: Before opening the fold plate
door, always turn off the power first. This
will prevent any possibility of dam age to
the machine’s electronic control system.
Follow the steps below to remove the fold plates.
1. Turn power OFF.
Fold Plate Door
2. Open the fold
plate door by
pulling it away
from the ma chine. NOTE:
Some force may
be needed to
open the door.
The door will
stay in its up per most po si tion.
Silver Handle
Fold Plate Assembly
Blue Lock Levers
3. Press and release the two blue lock levers on either side of
fold plate assembly. This will cause the fold plate assembly to
drop slightly.
4. Grab the silver handle and lift the fold plate assembly up and
out.
(continued on next page)
34 SV40214 Rev. A
Page 37
DF500 Folder Operator Guide
Removing Fold Plates (continued)
5. Check for any paper in the fold plates or between the fold
rollers in the machine. Turn the rollers by hand or use the
hand wheel knob to make sure that all paper has been removed.
6. Reinstall fold plates by sliding fold plate assembly back into
folder until it is supported by the latch mechanism.
7. Push up from bottom of fold plate assembly until you feel
and hear the latches fully engage.
8. Close fold plate compartment door.
CAUTION: If door does not close, the fold plate
assembly has not been installed correctly.
Redo Steps 6 and 7 above until you can close
the door properly.
9. Turn power on. The display will return to running mode and
folding may be resumed.
35SV40214 Rev. A
Page 38
DF500 Folder Operator Guide
TROUBLESHOOTING
Feeding and folding problems are usually due to im prop er ad just ment of the machine or to improperly setting up a job. Refer
to the Symptom/Probable Cause section below and the Error
Mes sag es Dis played on the Control Panel table (starting on the
next page) to help you resolve prob lems when operating the
DF500.
Symptom Probable Cause–Solution
Folder will not run
Forms folded improperly
Forms skew to one side
Improper stacking
Rollers do not rotate while
motor is running
No display
Line plug loose or pulled
out–attach.
Power switch is off–Turn ON.
Safety cover not completely
closed–close.
Circuit breaker needs to be
reset–reset.
Need to redo setup proce-
dures–page 17.
Infeed guides not set prop-
erly–adjust.
Form stop bracket not po-
sitioned properly–check job
setup.
Form guides not positioned
properly –adjust.
Internal problems –contact
Service personnel.
Internal problems–contact
Service personnel.
36 SV40214 Rev. A
Page 39
DF500 Folder Operator Guide
Error Messages Displayed on the Control Panel
Error Message What It Means Operator Action
Fail To Feed
Done Enter
Fold Is
Not Available
Fold Plate Error
The paper was fed
either too late or
not at all.
You have tried to set
up an “impossible”
fold.
The fold plate stop
is prevented from
travelling along its
guide screw by an
obstruction like an
accumulation of
dirt and paper dust.
• Remove the paper stack from the feed
table, fan it out and place it back on
the feeder. Slide the stack down into
the grip of the pressure roller.
• Adjust side guides (see page 10) to
loosen the side guides.
• Adjust the roller pressure setting (see
page 11).
• Adjust the feeder gap (see page 19).
Although this is set automatically
using the Paper Thickness control,
certain papers may need manual
adjustment.
Do not go beyond the setup parameters
of the machine. For example, you may
have tried to set a “Z” fold for a paper
length of 4” (100mm). Such a folded
piece would become too small to
transport through the machine and so
the internal electronic control system
rejects the request.
• Press Enter. The fault may be cleared
automatically and the display will
revert to the normal running mode.
• If this does not help, turn power off
and remove the fold plate assembly as
described on page 33. Place the fold
plate assembly on its side. Working
through the openings in each fold
plate, try to turn the long guide screw
on which the fold plate stop travels.
Turn the screw several turns each way
to clean out any paper dust which may
have accumulated in the brass nut
of the paper stop. If you fi nd that the
paper stop has travelled to the very
end of its travel at either end, turn
the screw so that the stop is at least
3/4” (20mm) away from the extreme
position. Refi t the fold plate assembly
as described on page 33 and turn
power back on. The fold plate stops
will move to their proper positions and
the display will return to the running
mode. If the “FOLD PLATE ERROR”
message appears again, try the above
procedure once or twice more. If the
fault persists, call Pitney Bowes for
assistance.
37SV40214 Rev. A
Page 40
DF500 Folder Operator Guide
Error Messages Displayed on the Control Panel (continued)
Error Message What It Means Operator Action
Jam In Folder
Open Top Cover
Jam In Stacker
Done Enter
Limit Switch F.P.1
Or
Limit Switch F.P.2
Motor Stopped
Open Top Cover
Programs Full
Clear Job First
A paper jam has occurred
within the machine.
A folded sheet has not
been ejected properly
onto the stacker table. It
is usually caused by paper
piling up when the stacker
table is full or by a double
sheet. In rare cases, with
certain types of paper,
it can also happen when
a folded sheet catches
the topmost panel of the
preceding sheet. The
sheet causing the jam will
probably look like this: Z
or like this: Z
The stop in either fold
plate 1 (F.P.1) or fold plate
2 (F.P.2) has moved to
the very end of its travel
and has operated the
emergency limit switches
at those positions.
A large paper jam caused
the motor to stall. The
internal electronic control
in the DF500 will shut
down the motor and
display this message.
You have attempted to
save a new job but all nine
memory locations are
already full.
Refer to “Clearing a jam”
on page 32 and “Removing
the fold plates” on page
33.
• Remove all paper from
the stacker table,
then press Enter. The
stacker wheels will
return to their operating
position and the display
will show operating
mode again.
• Open the top cover
and remove any paper
inside. Close the top
cover and press Enter
to clear the display
message.
• If possible, adjust the
fold to look more even
like this: Z
Follow the procedure for
“FOLD PLATE ERROR”
above to clear this
condition.
Refer to “Clearing a jam”
on page 32 and “Removing
the fold plates” on page
33.
Delete some jobs to make
room (see page 27).
38 SV40214 Rev. A
Page 41
DF500 Folder Operator Guide
Error Messages Displayed on the Control Panel (continued)
Error Message What It Means Operator Action
Stacker Error
Use New Setting ?
Yes: Enter No:!
There is a problem
with the stacker
rollers.
This message
appears when you
have changed a
setting but have
not confi rmed it by
pressing Enter.
• Press Enter and the problem may
clear itself automatically.
• If this does not help, turn power off
and remove the fold plate assembly
as described on page 33. This
gives access to the stacker drive
mechanisms on the underside of
the stacker table. Locate the stacker
motor and turn the small drive gear
on the motor shaft. This will move the
stacker rollers. Turn the gear in the
direction that will move the stacker
rollers away from the extreme end
of their travel. Keep turning until the
stacker rollers have moved about 3/4”
(20mm) away from the end of their
guide slots in the stacker table. Refi t
the fold plate assembly as described
on page 33 and turn power back
on. The stacker rollers will move to
their proper position and the display
will return to the running mode. If
the rollers return to their extreme
position and the “STACKER ERROR”
message appears again, try the above
procedure once or twice more. If the
fault persists, call Pitney Bowes for
assistance.
Press Enter to activate your setting or
! to stay with your previous setting.
39SV40214 Rev. A
Page 42
DF500 Folder Operator Guide
MAINTENANCE
Regular and proper cleaning contributes to a long life of the ma chine and a consistent quality. It is important, therefore, to clean
the machine at regular intervals. The interval between machine
main te nance depends on the workload, but once a week is a
good starting point. Maintenance of the DF500 includes:
• Removing accumulated paper dust
• Removing any built-up debris on the fold rollers. This should
be done with a stiff brush only-not with liquids
as soap and water, alcohol, roller cleaner, ink re mov er, etc.
would dam age the rollers' anti-static surface and cause folding prob lems.
• Cleaning the outside
a damp ened cloth and a water-based mild liquid or spray
clean er.
WARNING: Before cleaning or doing any
maintenance on the ma chine, always
unplug the AC cord from the wall.
surface of the DF500 as needed with
. Liquids such
Do not attempt to service the Model DF500 your self, as re mov ing
covers may expose you to dangerous voltage and moving parts.
Refer all servicing to a trained Pitney Bowes Cus tom er Service
Rep re sen ta tive.
SUPPLIES
To order the following item, just call the PB Supply Line at 1-800-243782 4 .
Multipurpose Cleaning Kit, Item code F902-0
40 SV40214 Rev. A
Page 43
DF500 Folder Operator Guide
FORM HANDLING
Material Handling Notes
Material handling problems with paper handling equipment are
often due to distortion (warping, curl, sticking, etc.). This can be
a result of poor packaging, improper handling or environmental
ex tremes during manufacture, transit, or storage. This is particularly true of material which contains glue that is extremely sensitive to tem per a ture and humidity.
Fortunately, there are a number of easy and effective measures
you can take to minimize problems, improve production and get
the most out of your Pitney Bowes equipment.
Be Sure Material Meets Our Forms Specifications
The DF500 is designed to handle a certain range of material.
Ma te ri al which falls outside this range may run poorly or not at
all. Many operating problems are actually due to out-of-spec i fi ca tion material.
Store and Handle Material with Care
• Do not "crash" skids, loaded with the material, onto loading
docks, in trans port vans, or in the final storage area.
• Block loaded skids in transport vans.
• Do not expose cartons to the elements; prolonged exposure to
intense sunlight, high humidity and so on can damage material.
• Store materials in a controlled environment. We recommend
a nominal temperature of 75°F at 50% relative humidity. Glue
formulas do vary, however, so temperature and humidity limits
above and below these may be better for certain materials.
• Store cartons on skids or shelves to prevent absorption of
moisture, never directly on floors or against cement walls.
Very dry material may accumulate static and be difficult to handle, whereas damp material will almost certainly stick together.
• Do not stack cartons too high; this can deform the cartons
on the bottom and damage the material. Try to stack cartons
so that material lies flat.
41SV40214 Rev. A
Page 44
DF500 Folder Operator Guide
FORM HANDLING (continued)
Rotate Stock; Give Material Time to Stabilize
• Rotate stock; use oldest stock first (first in, first out).
• Transfer cartons from the storage area to the work area no
more than several hours before use.
• Do not remove boxes from their cartons until they are needed.
• Allow about one hour of stabilization time for each degree of
temperature change from the storage to the processing area.
42 SV40214 Rev. A
Page 45
DF500 Folder Operator Guide
EQUIPMENT/FORM SPECIFICATIONS
Equipment
Dimensions
Weight
Electrical
Operating Speed
Nominal Usage
Sound Level:
Environment Amb.
Temperature
Operation
Fold Types
Fold Plate Range
Width: 25" (640mm)
Length: 34" (860mm)
Height: 17" (430mm)
95 lbs. (43 kg) shipping weight
120 VAC, 60 Hz, 3A (also 230 VAC, 50 Hz, 2A)
Up to 20,000 sheets per hour, depending
on fold (actual speed will depend on the
paper size, paper quality, system setup,
operator experience, and environmental
conditions)
2,000 pieces/day; 40,000 pieces/month
Maximum peak operation is 40,000 piec-
es per day, no more than once a month.
75 dBA, based on folding 20 lb. bond
2
(80 g/m
) paper into a letter (C) fold at
a speed of 10,000 sheets per hour (Aweighted sound level at op er a tor position).
55 - 95°F (13 - 35 °C)
Max. Wet Bulb: 80 °F (27 °C)
Relative humidity: 20 - 80% (noncondense)
• Single (half fold)
• Z-fold (accordion)
• Letter (C) fold
• Double Parallel fold
• Z+ fold with margin
Fold plate 1: min. 1-9/16" (40 mm),
max. 12-3/4" (324 mm)
Fold plate 2: min. 1-9/16" (40 mm),
max. 8-1/2" (216 mm)
43SV40214 Rev. A
Page 46
DF500 Folder Operator Guide
Skew Allowance -based on 20 lb. 8.5" x 11" (80 g/m2 A4 bond paper)
• 68% of samples will deviate from the ideal fold center line
within ±.02" (±0.5mm)
• 28% of samples will deviate from the ideal fold center line
within ±.02-.04" (±0.5-1.0mm)
• 4% of samples will deviate from the ideal fold center line
within ±.04-.06" (±1.0-1.5mm)
Multi-Skew Allowance:
Collated sets of up to five sheets may deviate from the ideal fold
life by a maximum of ±1/12" (±2mm) either side.
Ideal Fold Line
+.02"
-.02"
Ideal Fold Line
Fold Deviation: Based on 20 lb. 8.5" x 11" (80 g/m2 A4 bond paper)
• 68% of samples will deviate from the ideal fold center line
within ±.02" (±0.5mm)
• 28% of samples will deviate from the ideal fold center line
within ±.02-.04" (±0.5-1.0mm)
• 4% of samples will deviate from the ideal fold center line
within ±.04-.06" (±1.0-1.5mm)
44 SV40214 Rev. A
Page 47
DF500 Folder Operator Guide
Multi-Sheet Fold Allowance: Collated sets of up to five sheets
may deviate from the ideal fold life by a max. of ±1/12" (±2mm)
either side.
+.02"
Ideal Fold Line
-.02"
Forms
Size
Form Weight
Thickness
Feeding
Capacity
Paper Ratio
Width: min. 3-1/2" (90 mm), max. 12" (305 mm)
Length: min. 4" (100 mm), max. 17" (432 mm)
2
Minimum: 14 lb. bond (53 g/m
Maximum: 65 lb. bond (180 g/m
)
2
)
The DF500 can process, hand fed, stapled, or
non-stapled collations of up to five sheets of
2
8-1/2" by 11" 20 lb. (80 g/m
) material. Maxi-
mum thickness is 0.020"(0.5mm).
The feed and stacking areas will ac com -
2
mo date 250 sheets of 20 lb. (80 g/m
) material
The length of the paper must be at least two
times the width of the paper.
Length
Width
45SV40214 Rev. A
Page 48
DF500 Folder Operator Guide
Index
A
Adjustments
Feeder Gap 19
Fold Type 17
Paper Guides 10
Pressure Roller 11
Skewed Fold 18
Automatic Fold Setup 12
Automatic Feed 31
B
Batch Count, Setting 21, 22
C
Clearing a Jam 32
Controls/Features 5, 6, 7
Control Panel, Description 7
D
Deleting a Job 27
Description, Machine 4
Double Parallel Fold
Description 4
Setup 12
E
Equipment Specifications 43
Error Messages 37, 38, 39
F
Feed, Manual 30
Feed, Automatic 31
Feeder Gap, Adjusting 19
Feeder, Setup 9, 10, 11
Folder Mechanics 15
Fold Plates, Removing 34
Fold Types
Description 4, 43
Fine Tuning 17
Setup, Automatic 12
Setup, Manual 28, 29
Form Handling 41
Forms Specifications 45
G
Gap, Feeder, Adjusting 19
Gate Fold
Description 4
Setup 12
I
Identifying a Job 26
J
Jam, Clearing 32
Jobs
Deleting Job 27
Identifying Job 26
Normal Job, Setup 23
Retrieving Job 26
Running Job 23
Saving Job 24
Temporary Job, Setup 23
L
Letter Fold
Description 4
Setup 12
M
Machine Setup 9
Maintenance 40
Manual Feed 30
Manual Fold Setup 28, 29
Moving the DF500 8
46 SV40214 Rev. A
Page 49
DF500 Folder Operator Guide
N
Non-Standard Fold, Man.Setup 28
Normal Job, Setup 23
O
Operating, Folder 13
Operating Hints 32
P
Paper Guides, Adjusting 10
Paper, Loading 10
Paper Size
Setup for Automatic Fold 12
Setup for Manual Fold 28
Pressure Roller, Adjusting 11
R
Retrieving Job 26
Running Job 23
S
Safety 2
Saving Job 24
Single Fold
Description 4
Setup 12
Skewed Fold, Adjusting 18
Specifications,
Equipment 43, 44
Forms 45
Speed, Setting 13
Standard Fold, Manual Setup 28
Start/Stopping Machine 14, 15
Supplies 40
Symptoms , Troubleshooting 36
T
Table Extension 11
Temporary Job, Setup 23
Theory, Folder Mechanics 15
Total Count, Clearing 20
Trial Piece, Running 14
Troubleshooting 36, 37, 38, 39
Z
Z-Fold
Description 4
Setup 12
Z-Fold with Margin
Description 4
Setup 12
47SV40214 Rev. A
Page 50
DF500 Folder Operator Guide
48 SV40214 Rev. A
Page 51
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