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Pitney Bowes OfficeRight DF800, Operator'S Manual

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Pitney Bowes OfficeRight DF800 Operator'S Manual Download Page 1

Offi ceRight™ Folding Machine 

DF800/DF900

Operator Guide

English Version

Summary of Contents for OfficeRight DF800

Page 1: ...OfficeRight Folding Machine DF800 DF900 Operator Guide English Version ...

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Page 3: ...tion Icons 1 10 Chapter 2 Operation About this Chapter 2 1 Connecting Power 2 1 Language 2 1 Select a Job 2 2 Feed Tray Setup for a Folding Job 2 3 Setting up the Tray Stacker 2 5 Setting up the Conveyor Stacker 2 6 Run a Trial Piece 2 7 Running the Job 2 7 Manual Feed 2 8 Crossfold optional extra for DF900 only 2 10 Chapter 3 Job Functions Introduction 3 1 Supervisor Access Code 3 1 Create a Job ...

Page 4: ...ps 4 1 General Troubleshooting 4 2 Adjusting Double Detect Position 4 5 Clearing Material Stalls 4 7 Removal and Replacement 4 8 Chapter 5 Reference Machine Specifications 5 1 Material Specifications 5 2 Compliance 5 4 Service 5 6 Operator Supervisor Training Check List 5 7 ...

Page 5: ...lick on My Account To view material safety data sheets call the Pitney Bowes Supply Line at 1 800 243 7824 or go to www pb com and click on Customer Support For direct questions call 1 800 522 0020 Customer Service Representatives are available Monday through Friday 8 00 AM 8 00 PM ET Canada Contacts Product Name DF800 DF900 For frequently asked questions or to order supplies go to www pitneybowes...

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Page 7: ...e and plug it into a properly grounded wall outlet located near the machine and easily accessible Failure to properly ground the machine can result in severe personal injury and or fire Avoid touching moving parts or materials while the machine is in use Keep hands loose clothing jewellery and long hair away from all moving parts Do not remove covers or defeat safety interlock switches Covers encl...

Page 8: ...ng a stoppage be sure machine mechanisms come to a stop When removing stalled material avoid using too much force to protect against minor personal injury and damaging equipment To prevent overheating do not cover any vent openings Operation of this equipment without periodic maintenance will inhibit optimum operating performance and could cause the equipment to malfunction Contact your machine su...

Page 9: ...to cross fold sheets see page 2 10 for more cross fold information The folder has a pre programmable feature allowing up to 20 job definitions to be stored for automatic setting and running of the machine Standard Features The OfficeRight DF800 DF900 offers an impressive array of standard features Among them Fully automatic material seperation on sheet feeder Fold adjustment capabilities Fully aut...

Page 10: ...CS88 Conveyor Stacker CS88 Can be added as an additional feature to the DF800 High Capacity Extension Can be added as an additional feature to either DF800 or DF900 with a Conveyor Stacker CS88 already attached Cross fold Kit An optional extra feature on the DF900 Only IMPORTANT Model and features availability varies by country Contact your machine supplier for more information Inclusion within th...

Page 11: ...cker OfficeRight DF900 or DF800 with Conveyor Stacker CS88 Optional Extra on DF800 The High Capacity Extension can be added to both the OfficeRight Folder DF800 or DF900 if it is already equiped with a Conveyor Stacker OfficeRight DF800 or DF900 with High Capacity Extension ...

Page 12: ... manually turn the machine mechanisms to assist in clearing a material stoppage Sheet Feeder The Sheet Feeder automatically feeds material that requires folding It can automatically detect if more than one sheet feeds Double Detect In addition the sheet feeder can be set to Manual Feed see item 6 This allows manual feed of stapled or unstapled sets of up to 5 sheets of 80g m2 20lb paper 1 2 1 5 3 ...

Page 13: ... Position this lever to the left to adjust the tension of the Feed Plate when using A3 sheets larger sheets Fold Plate 2 P2 This Fold Plate is used to create the desired fold in material fed from the Sheet Feeder The Fold Plates are automatically set from the Control Panel Control Panel This is where you enter commands and where the machine informs you of its status with the use of symbols and ico...

Page 14: ... it ready for automatic operation Start Starts automatic operation Stop Stops automatic operation at the end of the next cycle A double press of the Stop key will stop the machine immediately Back This key returns the machine to the previous screen where appropriate Screen Keys These are the four oval keys located directly to the right of the display These keys correspond to the changeable options...

Page 15: ... a zig zag of equal lengths C Fold Also known as Letter fold Sheet folded twice into the centre so that the sides overlap and all sides are of almost equal length Gate Fold Sheet folded twice into the centre so that the edges join in the centre without overlapping Double Fold Sheet folded once and then the folded sheet is folded a second time creating a double fold Offset C Fold Sheet folded twice...

Page 16: ... feed tray and output stacker for each type of fold The symbol indicates the front panel address panel depending on your job of the material being folded This helps to detemine the required orientation of material as it is fed into the machine Single fold Gate fold C Fold Offset C Fold Z fold Offset Z Fold Double fold ...

Page 17: ...onnecting the machine Connect the power cord to the socket on the left side of the machine Plug the power cord into a suitable power outlet Make sure the power outlet is near the machine and is easily accessible Turn the power switch ON Image of power sw tch Image of power sw tch Language Your machine will start set to the the default language The default language is set by the engineer at the tim...

Page 18: ...reen Key A list of Job Definitions that have been created and stored appears on the screen Then If you are certain which job you want press the Screen Keys to select the job that you require and then press the OK Screen Key to confirm If you need confirmation of the job details press the Screen Keys to select a job and then press the Job Summary Screen Key to view the job details You may access lo...

Page 19: ...rmation To process a Crossfold job available as an option on the DF900 only refer to the Crossfold Setup procedure on page 2 10 You can view information about the feed requirements for your job 1 Press the Loading Details and then Load Tray Screen Keys 2 Adjust the Side Guides to the width of the sheets being fed using the Side Guide Adjustment Knob then back off a 1 4 of a turn This will set the ...

Page 20: ...eck and slide the stack fully under the feed roller 7 The DF900 is capable of feeding large sheets The marker on the Side Guide will indicate the correct position for the Paper Adjustment Lever Match the position of the Paper Adjustment Lever to the setting shown on the Feed Tray Position 1 is the normal position for standard sized sheets Position 2 increases the tension on the lift plate for larg...

Page 21: ...utwards to match the size of the material being processed Before attaching or removing the stacker pull the collection tray to its full extension so that the tray does not catch under the machine when unhooking The stacker is fitted to the machine with two hooks which slide into the apertures at the base of the machine Note Opening the Exit Path Cover before proceeding can assist in attaching or r...

Page 22: ...t the Stacker Roller and place both ends in the corresponding number slot Note Ensure that both ends are in the correct number slot or this could result in material skew on exit of the machine When stacker setup is complete continue with running a Trial Piece as described on the next page High Capacity Extension The High Capacity Extension is an optional extension to the Conveyor Stacker The High ...

Page 23: ...e changes Select Yes or No screen keys as required All jobs except the Operator Job require Supervisor access to save changes Running the Job After confirming the Trial Piece is OK You are taken back to the Home screen which indicates Ready to Run Press the Start key to commence automatic operation The machine operates until material runs out the Stop key is pressed the batch count is reached if b...

Page 24: ...creen Adjustments for Manual Feed Jobs Move the Manual Feed Lever to the right which opens the Separator Assembly for Manual Feed operation Adjust the Side Guide to the width of the sheets being fed using the Side Guide Adjustment Knob then back off a 1 4 of a turn This will set the correct clearance between the guides and the material Note When using manual feed the material weight should not exc...

Page 25: ...sing Manual Feed jobs See image above You can accept the Trial Piece or adjust the job and re run the job as described on page 2 7 When ready press the Start key and feed material one set at a time If the machine times out or is stopped by pressing the Stop key it may be restarted by pressing the Start key again When you have completed feeding the sets you require the machine can be left to time o...

Page 26: ...he instructions in Create a Job on page 3 2 of this guide or by selecting an exisiting single fold job as described in Select a Job on page 2 2 You are now working with folded material and need to setup a crossfold job for your second fold Prior to this follow the instructions below to physically set the folder to process the pre folded material Setting Machine for Crossfold Job 1 Adjust the Side ...

Page 27: ...e Manual Feed Lever to prevent damage to the separator roller and separator pad 3 Open the top cover 4 Lift the Crossfold paper path 6 Lock the blue lever 7 Remove the Feed Tray 5 Unlock the Upper Blue Lever and slide the Feed Roller Housing to the Front Side Guide aligning the marker on the housing to the marking on the Side Guide Crossfold Paper Path ...

Page 28: ...ign with the separator roller and relock in position 14 Lower the weighted roller back into position over the creased folded edge of the material 9 Refit the Feed Tray 10 Close the top cover 11 Set the Manual Feed Lever back to Auto 12 Lift the weighted roller 13 Load material with the crease folded edge under the weighted roller NOTE The Maximum number of sheets in the tray in Auto mode is 20 Wei...

Page 29: ...be overwritten when a new operator job is created Supervisor Access Code Many of the following functions will require you to enter a Supervisor Access Code during the process This prevents unauthorised access to functions mainly relating to administration of jobs Your installing engineer will tell you the Supervisor Access Code If you wish you can write it in the box on this page as a reminder How...

Page 30: ...kes you through several easy steps to set up your job Note If you select Create Job and the maximum number of saved jobs has been reached the machine informs you If you wish to save the new job into the job library you must cancel and proceed with deleting another job before creating a new one Alternatively you can proceed by overwriting the operator job The following sections give background info...

Page 31: ...s until the length of your paper in millimetres is displayed When the paper length is correct press OK Fold Types Seven fold types are available See Fold Options on Page 1 9 of this guide The fold type dictates how the sheet will be folded before it exits the machine Once a fold type is selected and the new job is created the display indicates the correct orientation of the paper for loading into ...

Page 32: ...played The highlighted flashing icon on the screen shows the fold panel you are adjusting Note The fold panel marked with a diamond should be adjusted first as this will minimise interaction on adjustment of the other panels The machine will automatically limit your choices to what is physically possible within the machine specifications For example as you change the length of a fold panel you wil...

Page 33: ... that a further fold can be made at right angles to the first fold a cross fold See Crossfold Setup on page 2 10 of this guide If your system does not have a crossfold option this screen will not display during your create job procedure Double Detect The double detector stops the machine if more than one sheet simultaneously feeds from the feeder The Double Detect function can be run on single she...

Page 34: ...t the machine times out or you press the Stop key Set Speed The speed that the folder can run with it s maximum throughput is dependant on the job type and material being fed This is not always the maximum speed that the machine can operate at The Set Speed screen allows you to increase or decrease the machine s running speed when you press the Start key The speed can also be adjusted as required ...

Page 35: ...ial Piece Run a Trial Piece to confirm settings See Page 2 7 of this guide for how to run a Trial Piece Job settings are retained by the machine even with power disconnected and may be recalled as required Logging Out of Supervisor Mode If you are logged in as a Supervisor you must log out by pressing the Stop key whilst the Menu screen is displayed If you do not the machine will remain logged on ...

Page 36: ...u wish to permanently delete the job Edit Job The Edit Job function is used to change a Job Definition and so always overwrites the original Job Definition in the machine s memory even if the Job Name has been edited If you wish to create a NEW Job Definition which is similar to an existing job and leave the existing Job Definition untouched use the Create From function described on page 3 7 Press...

Page 37: ...ich with the troubleshooting sources above should resolve most problems If problems related to material handling persist make sure your material conforms to the material specifications given in Chapter 5 Reference of this guide If you still cannot resolve the problem call your machine supplier for help Contact details can be found On the back cover of this guide In the System Information option in...

Page 38: ...etting At the Home Screen select Menu Then select Display Preferences Performance Machine runs slowly The machine speed can be dependant on the job being run Check the machine s speed setting using the Edit function or whilst the job is running to ensure it is set to a suitable level 3 6 Language The wrong language is displayed on the screen Turn the machine off and then after a few seconds on aga...

Page 39: ...y Ensure the Paper Adjustment Lever is set to the correct paper size especially if feeding larger material DF900 only 2 4 Sheets skewing as they feed through the machine Use the Skew Adjustment Knob to correct See Skew Adjust in Poor Folding and check side guides adjustment DF900 Fail to Feed with photocopied sheets Remove some of the material stack from the feeder Large quantities of photocopied ...

Page 40: ... Tip It may be beneficial to set up a single fold job to run when adjusting skew to make the adjustment results more apparent 2 3 Sheets creasing as they exit the machine DF900 Only Reduce the running speed Lighter material and larger sheets can sometimes crease when folding Slowing the machine down will allow the material to be folded crease free 3 6 Conveyor Stacker CS88 The material entering th...

Page 41: ... batch of material is loaded to recalibrate Double Detect The new batch might be of slightly different thickness 2 7 Material is too densely printed on the leading edge of the material Change the double detect position to read material in a less densely printed position See Adjusting Double Detect Position below Adjusting Double Detect Position If you continually get doubles detected when no doubl...

Page 42: ...lead edge to the start of the Double Detect window This allows you to move the window down the sheet to a less densely printed area The machine will limit this adjustment relative to the size of the material If the print density on your material does not allow you to allocate a 27mm 1 Double Detect window which can sense accurately you will be required to turn Double Detect off for this job DENSE ...

Page 43: ...if necessary Top Cover Lift Top Cover to access Manual Advance Knob and stalled material See page 1 6 1 7 The Manual Advance Knob A Having located the material you may need to use the Manual Advance Knob to manually feed material out of the rollers etc Folder Access Cover B Lift the blue lever to raise the Rear Access Cover This will allow access to any stalled material and rollers at the exit rig...

Page 44: ...te straight outwards from the machine If removing Fold Plate 2 lift the plate slightly before pulling out from the machine To replace Place the Fold Plate into its location guides in the frame Pull the two blue levers gently outwards on either side of the Fold Plate Push the Fold Plate gently into the machine The plate will automatically drop into its correct location and the levers can be release...

Page 45: ...re that the Manual Feed Lever is set to Automatic Feed before removing or replacing the Feed Tray This is because if the Manual Feed mechanism is lowered when the Feed Tray is removed or replaced it could cause damage to your machine To replace Remove all material from the tray Place the tray into its location guides in the side frame Lift the rear of the tray slightly and push it into the machine...

Page 46: ...4 Troubleshooting 4 10 SDC820A ...

Page 47: ...terial and running speed DF900 Approx 74dBA 80gsm C Fold Speed 4 65dBA 88dBA dependant on material and running speed Please note that when running at sound levels over 80dBA First Action Level operator hearing protection must be provided For sound levels over 85dBA Second Action Level the use of hearing protection is mandatory Electrical 100 240VAC 50 60Hz 5A Maximum Speed Actual folder throughput...

Page 48: ...F900 Minimum 55g m2 15 lbs Maximum 200g m2 53 lbs Double detect Minimum 55g m2 16 lbs Maximum 120g m2 32 lbs Cross fold Pre folded material Minimum 55g m2 15 lbs Maximum 100g m2 27 lbs Fold configurations Fold Panel Min Max Dimensions Fold Panel 1 Minimum DF800 DF900 80mm 3 15 Maximum DF800 235mm 9 25 Maximum DF900 320 mm 12 6 Fold Panel 2 Minimum DF800 DF900 75 mm 3 Maximum DF800 235mm 9 25 Maxim...

Page 49: ...tapled sets are used no staples can be in an area of 35mm 1 4 both sides of the centre line of the material being fed NOTE The machine speed when running a Manual Feed or Crossfold job is limited to Setting 1 4 100 per hour Material Requirements For best performance use only materials approved by your machine supplier Materials should be good quality and properly stored Rotate your material stock ...

Page 50: ...t in a residential area is likely to cause interference in which case the user will be required to correct the interference at his own expense CAUTION Changes or modifications to this equipment not expressly approved by the party responsible for compliance could void the user s authority to operate the equipment It is certified that the system complies with all applicable Directives of the Europea...

Page 51: ...5 Class A subparts as applicable Canada ICES 003 EU EMC Directive 2004 108 EEC referencing EN55022 and EN61000 3 Australia and New Zealand AS NZS 3548 Equivalent to EN55022 Safety US CTUVUS Canada CSA Approval Standard C22 2 as applicable EU EN60950 TUVGS x CB CERTIFIED ...

Page 52: ...e or assistance with your particular application please call your machine supplier Your machine supplier will also offer a service maintenance contract to keep your machine in top condition at nominal cost Contact details can be found On the separate leaflet supplied with your system In the System Information option in the menus At the Home Screen select Menu Then select System Information ...

Page 53: ...l Feeding Access Areas and Fold Plates Manual Advance Knob Measuring Scale Crossfold Options if applicable DF900 only Control Panel Screen Keys Hard Keys Relevant Stacker High Capacity Extension if applicable Power Switch Screens for operator s Select Job select and run a sample job Trial Piece Running a Job Manual Feed Menu Language Display adjustments System Information ...

Page 54: ...eate Job Edit Job Create From Delete Job Stoppage Recovery Maintenance Cleaning The following operators have been trained on this equipment Name Level Date Operator Supervisor Operator Supervisor Operator Supervisor Operator Supervisor Operator Supervisor Operator Supervisor ...

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Page 56: ...A 11 08 Pitney Bowes Limited 2008 We have made every reasonable effort to assure the accuracy and usefulness of this guide however we cannot assume responsibility for errors or omissions or liability for the misuse or misapplication of our products Printed in the UK Printed on recyclable paper SDC820A ...

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