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Envelope Feeder for use with HD-CX Series Printers

HD-CXENVL-FDR v2

User Guide

NOTE: If your feeder looks different than shown above, please refer to the guide for the original feeder version (HD-CXENVL-FDR v1).

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Table of Contents PREPARING THE HD-CX1600/1700/1750 (C9xx) PRINTER ................................................................... 3 FEEDER STAND ASSEMBLY AND STAND HEIGHT ADJUSTMENT ................................................ 5

Feeder Stand Assembly .............................................................................................................................. 5 Setting the height of the stand to match your printer ................................................................................. 7 Attaching the feeder to the stand ................................................................................................................ 8 Aligning the feeder with the printer and final stand height adjustment ..................................................... 9

HD-CXENVL-FDR FEEDER OVERVIEW ............................................................................................... 13 Component Identification ......................................................................................................................... 13 Features and function................................................................................................................................ 14 Time-out (out of paper) Feature ............................................................................................................... 14

SETTING UP THE FEEDER ...................................................................................................................... 15 Setting the Hopper Paper Guides ............................................................................................................. 15 Setting the Sheet Separator(s) .................................................................................................................. 17 Setting up the envelope support wedge (back wedge) ............................................................................. 19 Setting the Envelope Support Wedge for Other Envelope Types ............................................................ 22 Setting the delivery table paper guides .................................................................................................... 23 Testing the feeder ..................................................................................................................................... 25 Setting the speed of the feeder ................................................................................................................. 27

RUNNING A JOB WITH THE FEEDER AND PRINTER........................................................................ 28 DETACHING THE FEEDER FROM THE PRINTER ............................................................................... 33 IMPORTANT OPERATING TIPS/NOTES ................................................................................................ 34

Suggested Feeder Speed Settings ............................................................................................................. 34 Feeder Ready Lever Function .................................................................................................................. 34 How to Pause/Resume Print ..................................................................................................................... 34 Automatic “Feeder Ready Lever” Reset .................................................................................................. 35 Avoiding false “Paper Jam” conditions ................................................................................................... 35

TROUBLESHOOTING ............................................................................................................................... 36 SPECIFICATIONS ...................................................................................................................................... 38 OPERATOR MAINTENANCE ................................................................................................................... 38 OPTIONAL HARDWARE .......................................................................................................................... 39 The HD-CXENVL-FDR feeder is designed to operate with the Quadient HD-CX Digital Color LED printers. This guide will show the proper way to prepare the printer for the envelope feeder along with setup and operation of the feeder.

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PREPARING THE HD-CX1600/1700/1750 (C9xx) PRINTER Use the following instructions to prepare your HD-CX1600/1700/1750 printer for use with your envelope feeder. 1. To prepare the printer, for the feeder, you must first remove the door from the manual feed tray. First, open the manual feed tray door on the right side of the printer. 2. Press inward on the right side hinge of the door to release it from the slot 3. Press inward on the pivot point of the door on the right side to remove it from the printer housing 4. Remove the left side of the door in the same fashion and remove the door from the printer.

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5. Open the right side cover on the printer by pulling on the latch shown here: 6. With the right side door fully open, lift the feed roller assembly to gain access to the feed roller and sheet separator area. 7. Pinch the two upper corners of the sheet separator assembly (rubber pad) and remove the assembly from the printer NOTE: The envelope feeder is equipped with a paper sensor that will be positioned just to the left of the printer’s manual feed tray feed roller. It is possible for the sensor to detect the white plastic housing just to the left of the feed roller, which can cause erratic feeding. It is very important to place a piece of black tape or Velcro (included with feeder) on this ledge so the sensor does not detect it. Note: This tape will not affect the printer and can be left in place, even when not using envelope feeder! THE HD-CXENVL-FDR INCLUDES AN ADJUSTABLE HEIGHT STAND. IT IS VERY IMPORTANT TO SET THE STAND HEIGHT PROPERLY. REFER TO THE SECTION TITLED “FEEDER STAND ASSEMBLY AND STAND HEIGHT ADJUSTMENT” FOR MORE INFORMATION.

Remove the separator assembly

Place black tape on this area. (black Velcro included with feeder accessories)

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FEEDER STAND ASSEMBLY AND STAND HEIGHT ADJUSTMENT Your new envelope feeder is packaged with the adjustable height floor stand removed and partially disassembled. With a single 1/8” allen wrench, (included with the feeder) the stand can be re-assembled and the feeder can be attached to the stand.

Feeder Stand Assembly When assembled; the stand should look like this: Step 1. Carefully remove the feeder and the stand components from the box and set them on the floor or a large table. Step 2. Remove the locking levers and flat washers from the two leg assemblies

Upper stand assembly

2 Leg assemblies (with casters)

Top Plate (note orientation)

Locking casters

Top Plate (note orientation)

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Step 3. Stand the upper stand assembly on the floor with the slotted bars facing upward as shown below. Then position one of the stand legs on the outside of one of the slotted bars with the bolts extending through the slot as shown. The short end of the base bar should be on the same side as the cross bar (shown below) Step 4. Raise the leg all the way until the top bolt is at the highest point in the slot. Place a washer on the exposed bolt ends and then thread the locking levers onto the bolts. Tighten the locking levers to hold leg in this position. Step 5. Repeat this procedure for the other leg. Be sure to set both legs at the same height and then lock the levers securely.

Place leg on outside of slotted bar with bolts extending through slot

Put flat washer on bolt threads first before locking levers.

Note: The shorter end of the base bars (with locking casters) should be on the same side as the stand cross bar. Cross Bar

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Step 6. Flip the stand over so it is resting on the casters. Ensure that the locking levers are secure so the stand legs do not slip while installing the feeder!

Setting the height of the stand to match your printer

It is very important to set the stand height properly so the feeder is positioned properly relative to the printer. You can make a preliminary adjustment to the stand height easily before the feeder is bolted to

the stand. Final height adjustment may be necessary after the feeder is installed.

Place one side of the stand alongside the printer adjacent the manual feed tray. Adjust the stand height so the top plate is about 1/8” below the horizontal ledge at the entrance of the manual feed tray.

Before attaching the feeder to the stand, set the stand height so the top plate of the stand is 1/8” below this ledge. After adjusting one side, rotate the stand and adjust the other.

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Attaching the feeder to the stand Step 1. Now you will attach the feeder to the stand using four button head screws and the included 1/8” allen wrench. The bolts have been attached to the uprights of the stand for shipping. Remove these bolts from the stand. Step 2. (It is helpful to have an assistant hold the stand steady while attaching the feeder) Carefully lift the feeder up by grasping the bridge as shown below and place the feeder over the top of the stand with the stand legs near the middle of the feeder side plates The stand should be oriented so the back plate of the feeder is on the same side as the back plate of the stand!

The feeder will be attached to the stand using these threaded holes

Back plate of feeder

Cross bar on stand

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Step 3. Carefully line up the two holes in the side plate with the two threaded holes in the top of the stand legs and install the 5/8” long button head screws securing the feeder to the stand. DO NOT LET GO OF THE FEEDER UNTIL THE SCREWS ARE IN! Step 4. Tighten the screws on one side of the feeder first, and then tighten the opposite side.

Aligning the feeder with the printer and final stand height adjustment Step 1. After the feeder has been attached to the stand, carefully move the feeder into position near the manual feed tray on the printer.

Step 2. Move the manual feed tray paper guides outward as far as they can go to allow room for the feeder transport table.

Line up these two holes with the threaded holes on the stand legs

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Step 3. Lift the end of the feeder’s delivery table up so that it can be moved into position in the manual feed tray as shown here: Step 4. While holding the delivery table up, carefully push the feeder in towards the printer, ensuring that the delivery table slides in between the printer paper guides. Step 5. Slowly push the feeder in toward the printer. The exit end of the delivery table should go into the manual feed tray just above the tray bottom and below the overhanging tabs on the manual feed tray side guides. When the end of the delivery table is near the overhanging tabs on the manual tray guides, let the delivery table rest on the manual feed tray. NOTE: As you carefully push the feeder in towards the printer, ensure that the delivery table drops below the overhanging tabs on the manual tray paper guides.

Overhanging “tab” on manual feed tray guides. The end of the table should go in just under these.

Delivery table

Lift delivery table to slide over ledge on printer

Delivery table

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Step 6. Push the feeder in towards the printer until the ends of the feeder side plate begin to enter the manual feed tray opening. At this point, you may need to fine tune the stand height adjustment to enable the feeder to move all the way into position. Step 7. Set the stand height on each side of the feeder so the top of the feeder side plate enters just underneath the gray metal plate on the printer as shown here: THE STAND HEIGHT MUST BE SET PROPERLY FOR THE FEEDER TO MOVE ALL THE WAY INTO POSITION.

The top of the feeder side plate should go in just underneath the gray metal plate in the printer

This edge must go in just over the lip in the manual feed tray

Lip

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Step 8. When the stand height is adjusted properly, push the feeder all the way in until it stops. AS YOU PUSH THE FEEDER INTO POSITION, A LATCHING MECHANISM UNDERNEATH THE DELIVERY TABLE SECURES THE FEEDER TO THE PRINTER. YOU WILL HEAR THIS MECHANISM SNAP INTO PLACE AS YOU MOVE THE FEEDER IN. Step 9. After the stand height has been properly set so the feeder latches into position, tighten the locking levers on both legs of the stand securely. You may now detach the feeder from the printer to set up your envelopes THE FEEDER IS EQUIPPED WITH A RELEASE LEVER ON THE NON-OPERATOR SIDE THAT ALLOWS IT TO BE EASILY DETACHED FROM THE PRINTER. Step 10. To detach the feeder from the printer, pull the release lever back towards the feeder and carefully pull the feeder away from the printer. MOVE THE FEEDER AWAY SLOWLY AND SUPPORT THE DELIVERY TABLE OF THE FEEDER SO IT DOES NOT DROP ABRUPTLY WHEN IT EXITS THE MANUAL FEED TRAY!

Side plates should be against the printer here.

Support the table here so that it does not drop abruptly!

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HD-CXENVL-FDR FEEDER OVERVIEW

Component Identification The components described above, and their usage are explained in detail within this manual

Envelope support wedge

Paper guide

Bridge

Feed belt (6)

Paper guide adjustment knob

Separator

Delivery table paper guide

Delivery table

Start sensor Stop sensor

Exit shaft Adjustable height stand

Envelope ready lever

Exit belt

Envelope hold down strap

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Photo sensors

Paper guides

Features and function The HD-CXENVL-FDR envelope feeder is a top load, bottom feed machine designed to feed a wide variety of envelope types and sizes into a digital printer. The HD-CXENVL-FDR makes digital printers more productive by continually feeding envelopes, one at a time, from a stack in the feed hopper, and delivering each envelope to the printer’s manual feed tray pickup roller. The delivery table on the HD-CXENVL-FDR centers and aligns the envelopes and positions them properly in the manual feed tray by means of an envelope stop sensor. As each envelope is pulled away by the printer’s pickup roller, the feeder advances another envelope into the printer for the next cycle. With a top-load design, the operator can continually add envelopes on top of the stack for uninterrupted production. The HD-CXENVL-FDR consists of two main sections: The feed hopper and the delivery table. The envelopes are stacked in the feed hopper and are transported, one at a time to the printer via the delivery table. The delivery table is equipped with self centering paper guides and a set of photo sensors. The photo sensors are used to control (stop/start) the flow of media. When the envelope(s) being fed cover both sensors at the same time, the feeder will stop feeding; presenting the envelope under the printer's feed roller for media take-away. As the printer removes the presented envelope from the delivery table, the feeder will resume feeding when either sensor becomes uncovered during the media take-away process.

Time-out (out of paper) Feature The time-out feature is automatic with the timer starting as soon as the power to the feeder is turned on. If, after 4 seconds, an envelope does not advance far enough to cover the photo sensors, the feeder will stop running. IMPORTANT! The time-out feature is not dependent on the speed of the feeder, therefore it is possible, when running the motor at very slow speeds, the envelope may not advance to cover both sensors before the timer expires which would stop the feeder. If this is the case, turn the speed control up to at least 50% speed and reset the timer as described above. Time-out Reset: To reset the timer and start the feeder running again, momentarily press the “Reset / Hold to Jog” button on the back plate. Other time-out reset methods:

- Switching the power off and then back on will also reset the timer and start the feeder.

- If the machine is moved away from the printer, you can also reset the timer by momentarily blocking, and then unblocking both photo sensors on the delivery table with two fingertips or a piece of media.

Jog Feature: Pressing and holding the “Reset / Hold to Jog” button will make the feeder run continuously and override the timeout feature. This is helpful for setup and maintenance.

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SETTING UP THE FEEDER IT IS ADVISABLE TO MOVE THE FEEDER AWAY FROM THE PRINTER TO SET IT FOR YOUR ENVELOPES.

Note: The feeder can be setup for your envelopes away from the printer, and then easily placed in line with the printer after setup is complete. While familiarizing yourself with the feeder; it is recommended that you setup and test the feeder before integrating it with the printer.

Setting the feeder for your envelopes consists of the following basic steps: 1. Setting up the hopper paper guides 2. Setting up the sheet separator(s) 3. Setting the envelope support wedge (back wedge) 4. Setting the delivery table paper guides 5. Testing the feeder 6. Setting the speed 7. Putting feeder in line with printer

Setting the Hopper Paper Guides Step 1: Ensure that the main power switch on the feeder’s control panel is in the OFF position and plug the 24 vdc power supply included with the feeder in the power jack on the control panel. Step 2: Loosen the paper guide locking knobs on the front of each paper guide to allow repositioning of the paper guides

24 vdc power input

Locking knob (2)

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Step 3: With power to the feeder OFF, rotate the paper guide adjustment knob to move the paper guides outward towards the side plates of the feeder. Move the guides outward enough to accommodate your envelopes NOTE: The HD-CXENVL-FDR features self-centering paper guides. When the paper guide adjustment knob is turned, both paper guides will move. Step 4: Position one of your envelopes between the paper guides above the feed belts Step 5: While holding the envelope in position, rotate the paper guide adjusting knob to move the paper guides in toward the edges of the envelope Step 6: Position the paper guides alongside the edges of the envelope leaving them loose enough to allow free movement of the envelopes. (do not pinch the envelope)

Paper guide adjustment knob

Position paper guides to hold envelopes straight

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Step 7: (Optional) Tighten the paper guide locking knobs to secure the paper guides in position. (NOTE: These knobs must be loosened to move the paper guides)

Setting the Sheet Separator(s)

The HD-CXENVL-FDR utilizes a patented “Buckle Separation” technique for separating the bottom envelope from the stack. Most envelopes will run well with a single separator positioned in the middle of the feeder. A second separator assembly is included with the feeder and can be added if needed. (more on this later) Note that the separator device on the HD-CXENVL-FDR is positioned between two feed belts. When set properly, the separator tip will push down on the envelope as it is advanced by the feed belts from the bottom of the stack. This forms a downward “buckle” in the envelope for easy separation from the stack. This method is simple, effective and easy to set up, and does not require a lot of fine tuning. The downward buckle breaks the friction “bond” between the bottom envelope and the stack, making it easier to pull the bottom envelope away. This method of separation also reduces jams because with the separators pushing down on the envelope between, rather than on top of, the feed belts, there is not a “pinch point” created. The green “Flex Belt” positioned in the middle directly beneath the separator serves to help advance the envelopes while allowing the envelope to buckle downward, resulting in positive envelope advance and enhancing consistency.

Additional holes for alternate separator positioning

Standard separator position (centered)

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Step 1. Turn the separator height adjustment knob clockwise several turns to raise the separator Step 2. Place the lead edge of your envelope underneath the separator as shown below Step 3. Slowly turn the separator height adjustment knob counter-clockwise to lower the separator tip onto the envelope. Step 4. Continue to slowly lower the separator tip until the envelope is buckled downward between the belts slightly (approximately 1/16” to 1/8”) NOTE: Thin envelopes may require a more pronounced buckle for consistent separation

Separator height adjustment knob

Lower the separator tip to “buckle” the envelope down between belts

Turn knob counter-clockwise to lower separator tip

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Step 6. (optional) If you run envelopes that require more than one separator, install the second separator in one of the alternate positions on the bridge using the included attaching bolt. Set the second separator like the center one. NOTES The separators do not need a lot of fine tuning, as a small buckle is all that is required. Some experimentation is recommended to get the best results with your materials. There is no specific configuration that you must use, and this design offers tremendous flexibility. If one configuration doesn’t work, try moving the separators to different positions across the feeder bridge.

Setting up the envelope support wedge (back wedge)

The HD-CXENVL-FDR features a unique one-piece envelope support wedge that promotes consistent separation and feeding of a variety of envelopes. It is very important to set the envelope support wedge position properly for the best results. The envelope support wedge is attached to the top plate of the feeder. When the feed motor is running, the top plate and envelope support wedge move up and down to “jostle” the envelope stack. This unique feature improves feed consistency by helping the envelope stack to descend in the hopper more consistently. Additionally, the “jostling” feature aids in aligning the envelopes properly for straighter feeding. The envelope support wedge performs several important functions: 1. Supports the weight of the stack so that the weight is not all on the belts 2. Tilts the back end of the media stack up so the lead edge presses against the belts 3. (most important) While the bottom envelope is getting pulled away from the stack by the feed belts, the support wedge holds the other envelopes off the belts, so they don’t advance too closely after the first one. NOTE: Consistent envelope separation and feeding requires proper setup of the separator (shown earlier) and the position of the envelope support wedge. As with the separators, some experimentation with wedge positions is recommended.

Envelope support wedge

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Step 1. After setting the separator as shown in the previous steps, leave the one envelope in the feeder that you used for the separator setup Step 2. Carefully shingle out a small stack of envelopes so that the bottom one will be the foremost envelope in the stack as shown here. Step 3. Place the stack in the hopper on top of the envelope left on the belts from the separator setup. Try to “nudge” the envelopes a bit from the back to help the stack conform to the curvature of the paper guides at the bottom.

Work a small stack of envelopes into a shingle with the bottom envelopes foremost

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Step 4. With one hand, raise the back end of the envelope stack up. With the other hand, loosen the wedge locking knob and slide the wedge into position underneath the back end of the stack. As shown in the pictures above and below, the support wedge should be in just far enough to hold the back edge of the envelope stack up off the belts. Step 5. When the wedge is in position, tighten the locking knob. As noted earlier, the envelope support wedge is an important component for proper feeding. Some adjustment may be required for the best results.

Locking knob

Proper position for standard envelopes

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Setting the Envelope Support Wedge for Other Envelope Types The following examples illustrate suggested wedge positions for several different envelope sizes. When running standard envelopes, i.e., #10, 6 x 9, greeting card envelopes, the wedge should be positioned as shown in steps 4 and 5 above. Larger envelopes require a different approach with the wedge. These envelopes, i.e., 9” x 12” or 10” x 13” tend to “sag” downward in the middle when supported in the front by the feed belts and the back by the wedge. This “sagging” can result in miss-feeds and inconsistent production. This can be remedied by positioning the wedge underneath the stack of envelopes rather than at the back edge as with standard envelopes. This is illustrated below: As with the separators, some experimentation would be helpful to obtain the best results

3.75” x 6.5” 6” x 9” Standard #9 and #10

Long envelope “sag”

Wedge can be positioned to support stack and eliminate” sag”.

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Setting the delivery table paper guides

The patented “floating” or tilting delivery table on the HD-CXENVL-FDR is designed to advance the envelopes that the feed belts deliver, one at a time, into the printer’s manual feed tray feed roller. The delivery table is equipped with self-centering paper guides, an envelope drive belt, and a stop photo sensor at the end, which is used to stop each envelope in position underneath the printer’s feed roller, for take-away by the printer. An additional envelope sensor is positioned a few inches back from the stop sensor. This is the start sensor. When the first envelope is pulled away by the printer, the trail edge of that envelope uncovers the start sensor, which starts the feeder motor. Using the dual sensors allows the HD-CXENVL-FDR to run larger envelopes and keep pace with the printer. Step 1. After the feeder portion has been setup properly and a small stack of envelopes is loaded into the hopper, turn the speed control knob completely counter-clockwise to set the feeder speed on zero. Step 2. Grasp the delivery table paper guides near the bridge and move them outward toward the sides of the machine. CAUTION: Do not push paper guides at the ends as it may bend the guides.

Speed control knob

Move guides outward. As you move one guide, the other will also move.

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Step 3. Place one of your envelopes between the delivery table guides near the exit and move the guides inward with your free hand until they are alongside the envelope. (push guides near the bridge) NOTE: Do not push the guides tightly against the envelope as this will keep the envelopes from advancing down the delivery table! Set the guides close to the envelope but do not pinch it. Step 4. With the speed control all the way down so the motor will not start, switch the power button ON. NOTE: When you turn the power on, the motor will not run, but the timeout timer will start. This is okay, as you will use the RESET/JOG button to advance your envelopes slowly.

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Testing the feeder Step 1. Turn the speed control knob up a little bit and then press the JOG/RESET button to start the motor at slow speed. Watch the first envelope advance from the feed area towards the delivery table. Step 2. While holding the RESET/JOG button, watch the first envelope advance into the delivery table. The envelope should enter the delivery table between the paper guides. Continue to hold the button to advance the envelope(s) down the delivery table. If your envelopes appear to advance down the delivery table unrestricted, you can release the RESET/JOG button to stop the motor. (Note: The motor will continue to run until the 4 second timer elapses, OR the envelope reaches the stop sensor at the end of the delivery table) Step 3. With a small stack of envelopes in the hopper, turn the speed control knob up to approximately 50% of maximum speed (12:00 position on dial indicator), then press the RESET/JOG button to start the motor. (do not hold)

Turn speed control up a little and then press and hold the RESET/JOG button to start advancing an envelope

Envelope should advance into the delivery table paper guides without catching or dragging.

With the speed set on 50% press the RESET button

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The feeder will now begin advancing envelopes UNLESS THE STOP AND START SENSORS ARE BOTH BLOCKED. The envelopes should advance from the feeder one at a time, and then travel down the delivery table. As they travel down the delivery table, they should be accelerated slightly, creating a small gap between the envelopes as shown here: Note: If the envelopes do not advance smoothly down the delivery table, or if they tend to “bunch up” you may need to open the delivery table guides up a little bit to allow free movement of the envelopes. As your envelopes advance down the delivery table, the two envelope sensors will become blocked. When both sensors are blocked by one or more envelopes, the motor will stop. It is strongly recommended at this point to test the feeding and consistency of the envelope delivery before moving the feeder into position with the printer. Step 4. Pull the first envelope away from the end of the delivery table so the machine will advance a second envelope to the stop sensor. Repeat this to test the consistency of the feeder. Adjust if necessary to obtain the best results. While you are testing the feeder, make note of the gaps between the envelopes as they travel down the delivery table. A small gap of ¼” to 1.5” is satisfactory although the gap can vary a bit. *

Pull the envelope straight away from the exit end of the delivery table.

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*If there is no gap at all, you may need to move your envelope support wedge in underneath the envelope stack a little farther, or lower the separator tip a bit to create a more pronounced buckle for better envelope separation. *If the envelopes do not feed consistently, or the gap between envelopes on the delivery table exceeds 3 or 4 inches, you may need to move the back wedge back a little to let the envelopes contact the feed belts more.

If you have consistent feeding with consistent gaps between envelopes, you are now ready to move the feeder into position with the printer. Turn power to the feeder OFF and remove the envelope from the end of the delivery table.

Setting the speed of the feeder As a general rule, the feeder should be set to run small envelopes (#9, #10, 6x9, etc.) at approximately 70% of maximum (2:00 on the dial) For larger envelopes, (9x12, 10x13, etc.) set the speed at 100% As a rule, larger envelopes will require a higher speed setting. NOTES ON SPEED SETTINGS:

2:00 to 3:00 position for standard envelopes

Set speed at 100% for large envelopes (over 6” long in the running direction)

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The printer will run at varying speeds, based on media settings. It is not necessary to try to “coordinate” or match the feeder speed with the printer speeds. The feeder operates in what is known as “Presentation Mode”, that is, the feeder presents an envelope to the printer and the printer pulls the envelope away. The feeder “presents” another envelope and the process is repeated. So long as the feeder is running fast enough to have an envelope in position for each cycle of the printer, the process will continue. On the HD-CXENVL-FDR, speed settings below 50% are not fast enough for printing, but the slower settings are good for testing and diagnostics. When you are ready to run with the printer, ensure your speed is set on at least 70% of maximum. If your feeder is not running fast enough to stay ahead of the printer, it will result in the printer’s manual feed tray pickup roller trying to pull an envelope in before the feeder has advanced it into position. This will result in the printer stopping and displaying a “Paper Jam” condition. This is not actually a jam, but the printer will need to be reset before continuing. After turning the speed of the feeder up somewhat, simply open and close the door on the top left side of the printer to continue.

RUNNING A JOB WITH THE FEEDER AND PRINTER

After you have successfully set up and tested the feeder and performed the steps outlined earlier for preparing the printer, you can now feed and print your envelopes. Prepare the printer for the feeder as shown in the beginning of this manual! 1. With power to the feeder off, remove the lead envelope from the exit end of the delivery table. 2. Position the feeder in front of the printer’s manual feed tray

Open and close this door to reset the printer.

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3. Carefully lift the delivery table up high enough to clear the lower edge of the manual tray opening and move the feeder in toward the printer. Ensure that the delivery table enters the manual feed tray opening without resistance. 4. As you carefully push the feeder in towards the printer, guide the end of the delivery table in between the manual feed tray paper guides. (manual tray guides MUST be positioned all the way out) 5. As the end of the delivery table approaches the overhanging tabs on the manual feed tray paper guides, allow the table to drop down onto the manual tray. 6. Slowly push the feeder in towards the printer. If the side plates of the feeder do not enter the manual feed tray opening, you may need to adjust the stand height. (Refer to the beginning of the manual for this procedure) 7. Continue to push the feeder in towards the printer until the lower portion of the side plates contact the printer body as shown here:

Allow table to drop below the overhanging tabs here before pushing feeder in further

Feeder side plate must fit in opening just below the gray metal plate on the printer.

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The HD-CXENVL-FDR is equipped with a latching mechanism underneath the delivery table that secures the feeder to the printer for consistent envelope registration. These spring-loaded latches connect to the lower lip on the opening of the manual feed tray as you push the feeder in. You will hear a snapping sound as the latches engage the printer. 8. After the feeder has been pushed all the way in and the latches have secured the feeder in place, set the speed control of the feeder on at least 70% of maximum speed. 9. Turn the power switch ON to start the feeder. The first envelope in the delivery table should now advance to the stop sensor at the end of the delivery table and the motor will stop.

Feeder should touch the printer here.

Delivery table lifted to show latching mechanism

Spring-loaded latches attach to lower “lip” on printer when feeder is pushed in

Lip

Envelopes will advance into the printer. The gap between envelopes will likely close at this point. This is normal when starting.

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10. Push the “FEEDER READY” lever on the operator side of the delivery table forward toward the printer. This will trigger the manual feed tray paper present sensor so the printer knows you have envelopes in place. At this point, you are now ready to send data to the printer. Once data has been sent, the manual feed tray will rise, lifting the patented floating delivery table up to the printer’s feed roller. IMPORTANT NOTES The printer will only recognize that the feeder is ready (paper present) if the “Feeder Ready” lever has been pushed forward. You also need to insure that the envelopes have been advanced down the delivery table, to the stop photo sensor, before you begin printing. If you want to pause printing, simply move the “Feeder Ready” Lever back (right) and the printer will consider this an envelope out condition. The printer display will indicate that you need to “install paper” in the manual (bypass) feed tray. When you are ready to resume printing, simply move the “Feeder Ready” lever back to the left (forward) and the printer will resume operation. When you lift the delivery table up to remove the feeder from the printer, or to move the feeder into position with the printer, the Feeder Ready lever will automatically be moved to the right. This gives the operator ample opportunity to advance envelopes properly into the printer before moving the lever forward, indicating a ready state to the printer.

FEEDER READY LEVER Push this lever forward to begin printing after advancing envelopes.

Feeder Ready lever Left to run, right to stop

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Paper jam or feeder out condition: If the envelope feeder runs out of envelopes, jams, or is delayed in getting envelopes to the printer in time, the printer will recognize this as a “PAPER JAM” and will indicate this on the display. Since this circumstance may not actually be a paper jam, (i.e., feeder runs out), the printer can easily be reset with minimal effort. The following steps should be taken to reset the printer: 1. If the feeder was simply late in delivering the envelopes to the printer, but envelopes are still in position on the delivery table, simply open the top left door on the exit end of the printer and then close the door to reset the printer. 2. If the feeder runs out of envelopes, the 4 second timer will elapse and stop the feeder. Move the “feeder ready” lever to the right or “not ready” position. Load more envelopes into the feeder and press the RESET button to start the motor and advance the first envelope down the delivery table to the stop sensor. Then move the “feeder ready” lever back to the left (forward) to indicate to the printer that the feeder is ready. You will then need to open and close the top left door on the printer’s exit end to reset the printer. 3. If the feeder jams, turn power to the feeder off, and then clear the envelope jam. Moving the feeder away from the printer may be necessary to do this. After clearing the jam, reload the feeder, and advance envelopes down the delivery table to the stop sensor. Then open and close the top left door on the printer’s exit side to reset the printer. REMEMBER: IF THE “FEEDER READY” LEVER IS NOT IN THE FORWARD POSITION, THE PRINTER WILL NOT RUN YOUR ENVELOPES. To help insure proper feeder performance; the belts and sensors should be cleaned routinely. See the section titled “Operator Maintenance” for details.

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DETACHING THE FEEDER FROM THE PRINTER

As described earlier in this manual, the HD-CXENVL-FDR features a spring-loaded latching system that secures the feeder to the printer during operation. When changing jobs, servicing the feeder, or in the event you want to use the manual feed tray without the envelope feeder, you may wish to detach the feeder from the printer. A convenient release lever is positioned on the non-operator side, close to the printer for this purpose. To detach the feeder, pull the release lever back towards the feeder and move the feeder away from the printer. Once the feeder has been moved back ½” or more, you can release the lever. While moving the feeder away from the printer, support the delivery table so that it does not fall abruptly as it exits the manual feed tray!

Release lever

Move feeder back a little, and then release the lever.

Support the delivery tray so it does not fall abruptly

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Feeder Ready Lever Left to run (ready) Right to stop (not ready)

IMPORTANT OPERATING TIPS/NOTES The printer will only recognize that media is present if the “Feeder Ready Lever” has been pushed forward. Note on HD-CX printers: Setting up the HD-CXENVL-FDR properly, to achieve consistent envelope delivery to the printer, is imperative; as the printer does not feature a “retry” in the manual feed tray. This means that if the printer’s feed roller cycles once and does not feed an envelope into the printer, the printer immediately considers it a jam and stops. For this reason, it is important to run the HD-CXENVL-FDR at 70% speed or more on most envelopes. It is also important that the feeder is maintained properly to deliver consistent envelope feeding with small gaps between envelopes on the delivery table. We strongly recommend setting the feeder up away from the printer to ensure consistent feeding before trying to print envelopes. If inconsistent feeding develops, the printer will stop more frequently. These stoppages result in user intervention as described on the previous page, but also results in the printer recalibrating temperatures more often, which slows printing down considerably.

Suggested Feeder Speed Settings Although there is no exact speed specification for every job, the feeder will work with a wide range of envelope sizes at a wide range of speeds. As a general rule, the feeder will work best with the speed control set at approximately 50% to 70% of maximum. As a general rule, larger envelopes will require a higher speed setting. Suggestions for speed settings on the envelope feeder:

• #10 envelopes, (landscape orientation) - 50% to 60 % speed • 6 x 9 envelopes (landscape) - 50% to 75% speed • 9 x 12 or 10 x 13 envelopes (either orientation) - 75% to 100% speed.

NOTE: The speed settings, above, are just recommendations. Some experimenting may be needed. Different envelope types/orientations, feeder setup and condition are all factors that can affect operation. Clean the white feed belts regularly, to ensure best results.

Feeder Ready Lever Function The “Feeder Ready Lever” mechanism is used to interrupt the printer’s “paper present” flag. When the Feeder Ready Lever is in the forward (to the left) position, the printer’s “paper present” flag is depressed by this mechanism and the printer detects this condition as “paper present”. When the “Feeder Ready Lever” is in the back (to the right) position, the printers “paper present” flag is released by this mechanism and the printer detects this condition as “out of paper” (MP Tray Empty).

How to Pause/Resume Print If you want to pause printing, simply move the “Feeder Ready Lever” back (right) and the printer will consider this an envelope out condition. The printer display will indicate that you need to “install paper” in the MP Tray. When you are ready to resume printing, simply move the “Feeder Ready Lever” back to the left (forward) and the printer will resume operation.

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Automatic “Feeder Ready Lever” Reset When you lift the delivery table up to remove the feeder from the printer, or to move the feeder into position with the printer, the Feeder Ready Lever will automatically be moved to the right (not ready position). This gives the operator ample opportunity to advance envelopes properly into the printer before moving the Feeder Ready Lever forward, indicating a ready state to the printer. REMEMBER: If the “Feeder Ready Lever” is NOT in the forward position, the printer will NOT recognize that there is media present in the MP Tray.

Avoiding false “Paper Jam” conditions Setting up the HD-CXENVL-FDR properly to achieve consistent envelope delivery to the printer is imperative as the printer does not feature a “retry” in the Multi-Purpose Tray (MP Tray). This means that if the feed roller cycles once and does not feed an envelope into the printer, the printer immediately considers it a jam and stops. For this reason, it is important to run the ENVELOPE FEEDER at 50% speed or more on most envelopes. It is also important that the feeder is maintained properly to deliver consistent envelope feeding with small gaps between envelopes on the delivery table. We strongly recommend setting the feeder up away from the printer to ensure consistent feeding before trying to print envelopes. If inconsistent feeding develops, the printer will stop more frequently. These stoppages result in user intervention as described on the previous page, but also results in the printer recalibrating temperatures more often, which slows printing down considerably. If the envelope feeder runs out of envelopes, jams, or is delayed in getting envelopes to the printer in time, the printer will recognize this as a “PAPER JAM” and will indicate this on the display. Since this circumstance may not actually be a paper jam (i.e., feeder out of paper); the printer can easily be reset with minimal effort. The following steps should be taken to reset the printer: 1. If the feeder was simply late in delivering the envelopes to the printer, but envelopes are still in position over both photo sensors on the delivery table. Simply open the top left door on the exit end of the printer and then close the door to reset the “Paper Jam” condition on the printer. Tip: Check that the feeder speed is set appropriately (normally 50% or higher). 2. If the feeder ran out of envelopes. Move the “Feeder Ready Lever” to the right or “not ready” position. Load more envelopes into the feeder. Momentarily press the “Reset / Hold to Jog” button to advance the first envelope down the delivery table to the exit sensor. Then move the “Feeder Ready Lever” back to the left (forward) to indicate to the printer that the feeder is ready. You will then need to open the top left door on the exit end of the printer and then close the door to reset the “Paper Jam” condition on the printer. 3. If the feeder jammed. Turn power to the feeder off and then clear the envelope jam. Moving the feeder away from the printer may be necessary to do this. After clearing the jam, reposition and reload the feeder. Momentarily press the “Reset / Hold to Jog” button to advance the first envelope down the delivery table to the exit sensor. Then move the “Feeder Ready Lever” back to the left (forward) to indicate to the printer that the feeder is ready. You will then need to open the top left door on the exit end of the printer and then close the door to reset the “Paper Jam” condition on the printer.

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TROUBLESHOOTING TROUBLESHOOTING Feeder will not feed (belts not turning)

Possible Causes/Solutions: 1. Causes: No Power. Not turned on. Speed Set to zero.

Solutions: Check to be sure the external 24 VDC power supply is connected to a live AC outlet and to the feeder. Check to be sure feeders power switch is ON. Check speed setting (if at zero it will not feed).

2. Cause: Both photo sensors, in the delivery table, are covered (seeing media present). The feeder should stop when both photo sensors are covered; this is the “normal” function of the feeder. Solution: Uncovering (removing media) from either sensor should cause feeder to feed. If problem only occurs when feeder is positioned within MP Tray; check to be sure non-reflective tape/Velcro has been properly installed on printer. Refer to the section titled “Preparing the HD-CX1600/1700/1750 (C9xx) Printer”.

Feeder feeds inconsistently Possible Causes/Solutions: 1. Cause: Photo Sensor, located at exit end of feeder’s delivery table, is receiving false “covered” signal.

Solution: Ensure non-reflective black tape or black Velcro has been applied to printer above the envelope feeder’s photo sensor. Refer to the section titled “Preparing the HD-CX1600/1700/1750 (C9xx) Printer”.

2. Cause: Feeder not setup/adjusted properly. Solution: Move feed away from printer and readjust separator(s), back wedge and paper guides; so paper feeds consistently (without hesitation). Ensure that paper guides on feeder and delivery table are not set too tight (restricting envelope movement).

Feeder feeds for about 4 seconds then stops Possible Causes/Solutions: 1. Cause: “out of paper”.

Solution: Load more media and then press the “Reset / Hold to Jog” button to start the feeder. 2. Cause: Feeder not setup/adjusted properly.

Solution: Move feed away from printer and readjust separator(s), back wedge and paper guides; so paper feeds consistently (without hesitation). Ensure that paper guides on feeder and delivery table are not set too tight (restricting envelope movement). Ensure that speed is set to 50% or higher. Press the “Reset / Hold to Jog” button to start the feeder.

Printer displays “Install # x # inch in MP Tray” (# = width/length of media) Possible Causes/Solutions: 1. Cause: Feeder Ready Lever not in forward position.

Solution: Ensure that the “Feeder Ready Lever” is in the forward position. 2. Cause: Feeder not properly positioned. Paper present flag, in MP Tray, not being depressed by Feeder

Ready Lever mechanism. Solution: Ensure that the feeder is pushed all the way into the MP Tray and it is latched in place.

Troubleshooting continued on next page

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Printer displays “Paper Jam” and indicates to “Open Right Side Cover”. Possible Causes/Solutions: 1. Cause: Feeder not properly positioned.

Solution: Ensure that the feeder is pushed all the way into the MP Tray and it is latched in place. 2. Cause: Feeder not presenting media fast enough to catch each printer feed cycle.

Solution: Check the feeder setup and speed control setting. Try increasing feeder speed. Clean the feed belts to ensure consistent feeding. Loosen envelope separator (turn knob clockwise) to allow envelopes to feed closer together.

3. Cause: Feeder ran out of media (out of paper or hesitation in paper feed). Solution: Move the “Feeder Ready Lever” to the right or “not ready” position. Load more envelopes into the feeder and advance the first envelope down the delivery table to the exit sensor. Then move the “Feeder Ready Lever” back to the left (forward) to indicate to the printer that the feeder is ready. You will then need to open the top left door on the exit end of the printer and then close the door to reset the “Paper Jam” condition on the printer.

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SPECIFICATIONS Dimensions: 30” Length x 16” Width x 16” Height (excluding stand) Material Handling: - Width: Min 3.75” to Max 13” - Length: Min 4” to Max 15“ - Thickness: single sheets to 1/8” - Estimated maximum stack size: 400 #10 envelopes Speed: printer dependent/variable to 6,000 pph Boxed Weight: ~49 lbs (including stand) Electrical: 120/230 VAC, 5 Amp Fuse: 5 Amp (located in the fuse holder on the back plate)

OPERATOR MAINTENANCE CAUTION! Unplug power cord before cleaning.

• Clean dust from the feeder and delivery table; using a soft dry cloth, soft brush or vacuum. • Use a mild household cleaner to clean the feeder body. • Clean the photo sensors using a soft dry cloth or compressed air. • Use isopropyl alcohol to clean the white belts in the feeder. • Use a mild household cleaner to clean the green belt on the delivery table.

DO NOT USE ALCOHOL TO CLEAN THE GREEN BELT ON THE DELIVERY TABLE!

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OPTIONAL HARDWARE NOTICE: The wide range of options available for the HD-CX1600/1700/1750 printers allows them to be setup in a number of different configurations. However, only the configurations shown on this page are compatible with the height adjustment range of both the HD-CXENVL-FDR (feeder) and HD-CXENVL-CNV (conveyor).

HD-CXENVL-CNV (conveyor) with HD-CX1700 (printer) on HD-CX-3IN1 (3 paper trays with casters)

& HD-CXENVL-FDR (feeder) NOTE: The feeder and conveyor, shown above, can be purchased as a kit. Order Part # HD-CXENVL (Envelope Printing Kit); which includes the HD-CXENVL-FDR (feeder) & HD-CXENVL-CNV (conveyor).

HD-CX1600/1700/1750 (printer) on HD-CX-CSTR (printer cabinet with casters)

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© Quadient February 6, 2020