Loading special forms

Before doing this procedure, ensure that the center front and center top covers of the printer are open so that you can access the forms input area and the transfer station.

If forms are loaded in Printer 1, you must remove them from the printer before doing this procedure. See Removing forms for instructions.

This procedure describes how to load special forms using the Auto Load sequence when the printer is in Dual Simplex mode. The printers are designed so that special-purpose forms can be loaded semiautomatically by the operator. Paper paths illustrates the paper paths to use when loading special forms.

Do this procedure when you need to add or change special-purpose forms, you are prompted by a step in a forms jam recovery procedure, or when you see the 078 END OF FORMS message.

Note:
If you are using preprocessing or postprocessing devices with the printer, some steps involving the source and final destination of the forms may change. The provider of the preprocessing or postprocessing devices supplies specific instructions for the initial loading and exiting of forms from the printer output area.

Because you will be working inside the printer covers, we recommend that you use the printer operator panel of the affected printer whenever possible, especially while working on Printer 1.

You will do the following steps to load special forms:

Positioning boxed fan-fold forms in the forms input area

Do this procedure to load fan-fold forms from the forms input area to the transfer station.

Procedure:

  1. Open a box of forms.
  2. Put the forms on the floor of the forms input area. The print surface of the forms must be toward your right (as you face the printer) as you lift forms from the stack.
    Note:
    If you plan to leave the forms in the box, do the following:
    • Ensure that the box does not interfere with form movement.
    • Ensure that the box does not block any sensors in the forms input area. If you see the red light of the sensor reflecting on the box, take the forms out of the box, or cut down the sides of the box so that it is no longer blocking the sensors.
    Generally, it is best to take the forms out of the box near the printer, and then slide them into position in the forms input area. Leaving forms in the box can also cause excess tension on the forms. This can cause tractor jams.
    open box of forms
  3. Position the form stack so that the forms do not twist or tear when they travel around the input guide and the splicing table.
    position form stack in forms input area
  4. Move the form stack forward until the front edge lines up with the lip on the forms tray.
    Note:
    Message 161 STACKER JAM appears if you do not do the following three steps correctly. Loading forms with the wrong first fold direction causes the forms to fold opposite their natural fold direction in the stacker.
    first fold direction for different paper weights

Adjust the tractorless feeding unit. See Adjusting the tractorless feeding unit.

Adjusting the tractorless feeding unit

Do this procedure to adjust the tractorless feeding unit when loading tractorless forms.

Procedure:

  1. Open the lower tractor covers.
  2. Release the Transfer Station Control Lever and tilt the transfer station away from the photoconductive drum
    tilt transfer station away from drum
  3. Ensure that the transfer station is open completely.
    Note:
    The photoconductive drum is easily damaged, and it is very expensive to replace. When the transfer station is open, be extremely careful not to let anything touch the photoconductive drum.
  4. Open the upper tractor covers.
    open upper tractor covers
  5. Bring the forms up from the input area, over the forms guide(s), under the static brush, and across the splicing table.
  6. If you are loading a form with a different width, use the Tractor Control Knob to adjust the tractors close to the correct width. Use the scale just to the left of the tractor covers.
  7. Without putting the forms on the tractor pins if you are using tractored forms, carefully thread the forms:
    1. Over the transfer station lower tractors
    2. Around the retractors
    3. Under the small, plastic paper guides to the right of the upper tractors
    4. Over the upper tractors
  8. If necessary, use the Tractor Control Knob to adjust the distance between the front and rear tractors:

    When the tractors are adjusted correctly, a sheet of forms should drop easily onto the tractor pins and lay flat if you are using tractored forms. The pins should be centered in the tractor holes, without binding.

  9. Place the forms to the right of the transfer station jam sensor.
    Note:
    Do not cover the jam sensor with the forms.

    The first tractor hole on the front edge of the tractored form should be on the upper tractor pin directly across from the pin holding the first tractor hole on the rear edge of the form.

  10. Close the upper tractor covers.
  11. Gently push the transfer station toward the photoconductive drum until it locks securely into position.
  12. Remove any slack from the forms and place the forms on the lower tractor pins, if using tractored paper.
  13. Remove any slack from the forms and place the forms on the lower tractor pins, if using tractored paper.
  14. Close the lower tractor covers.
  15. Adjust the rear paper-edge guide as follows:
    Note:
    This step applies to InfoPrint Models MS1, HS2, HS3, MD1/2, HD3/4, and HD5/6 when the Dual Toner Mark/Side Verify Sensor feature (FC 4570) is installed.
    1. Loosen the thumbscrew (2).
    2. Slide the rear paper-edge guide (1) to the correct location for the current paper width. The paper should be positioned against the vertical surface of the guide (3) so that the sensor on the bottom side of the sensor mounting plate can read side verify marks and registration marks, which are printed on the outside edge of the paper. The edge guide is also used to guide the paper in tractorless mode.
      rear paper-edge guide
    3. Tighten the thumbscrew (2).
      Note:
      The thumbscrew (4) adjusts the position of the Dual Toner Mark/Side Verify Sensor on the bottom side of the sensor mounting plate. It must be turned fully counterclockwise to position the sensor to read the side verify or registration marks at the outside edge of the paper (this is the default position). If you change the location of the marks (Forms -> Special Marks), you must adjust the position of the sensor. See Adjusting the rear paper-edge guide and Dual Toner Mark/Side Verify Sensor for more information.

For tractored forms, check that the forms are aligned correctly on the tractor holes. See Checking alignment of tractored forms. For tractorless forms, start the printer. See Starting the printer.

Changing forms settings on Printer 1

Do this procedure to select and load the correct Snapshot when you are changing to a different size form on Printer 1.

Note:
Do this step when loading forms in Dual Simplex mode or loading Printer 1 in Duplex mode.

Procedure:

  1. Select Forms -> Form Settings to display the Form Settings panel.
  2. If the name listed in the Form Name field contains the form definition you want to load, select Cancel.
  3. If the name listed in the Form Name field does not contain the form definition you want to load, do the following:
    1. Ensure that the length and width values are correct.
    2. Select Frequent Tasks -> Snapshots. You see a list of the currently defined Snapshots.
    3. If you are loading a Snapshot that has been previously defined, select the Snapshot you want to load from the Saved Snapshots area, and select Load.
    Note:
    If the Snapshot is not defined, see Working with Snapshots for more information about defining Snapshots.

If you are using the Auto Load sequence to load the forms, you must set the forms length at the stacker control panel. See Setting the forms length for Auto Load. If you are loading the forms manually, see Loading forms using the Forms Feed button.

Loading forms using the Forms Feed button

Hold the tension arm so that it stays aligned with the blue mark on the guide notch while you do the following steps. Otherwise, the 079A CHECK TENSION ARM 079A message appears when you turn on the forms path vacuum, and you must do the Check Tension Arm procedure.

Do this procedure to manually load the forms using the Forms Feed button on the printer control panel.

Procedure:

  1. Open all paper guides, tractor units, and feeding units to their widest position in both Printer 1 and Printer 2:
    adjust tractor units
    adjust tractorless feeding unit
  2. Swing the roller (3) into the open position by pressing down on (1) and (2).
    open roller, open gate, and engage tractorless pressure roller
  3. Open the gate by pushing in (4) and pulling up and out on (5).
  4. Engage the tractorless pressure roller (6) by moving it into the down position.
  5. Turn off the forms path vacuum by pressing the Vacuum Push Button in the forms input area. The Vacuum-Off warning indicator flashes and then stays lit.
  6. Use the Forms Feed keys on the printer control panel to feed the forms over the tension arm and into the preheat platen area, guiding them with your other hand. Keep feeding the forms until the scuff rollers grab them and feeds them into the forms exit area. Continue feeding the forms until there is enough length to allow you to splice the forms before feeding them into the post processor, or until there is enough length to reach the post processor.
  7. Ensure that the tension arm is aligned correctly. The mark on the tension arm (1) should be visible in the notch in the transfer station frame.
    tension arm alignment
  8. Turn on the forms path vacuum by pressing the Vacuum Push Button. The Vacuum-Off warning indicator flashes and then stays off.
  9. Raise the tension arm until you see the alignment mark in the guide notch.

Checking alignment of tractored forms

Do this procedure to check that the forms are aligned correctly on the tractor holes.

Procedure:

  1. Check the tractor holes on the forms between the transfer station and the fuser entry area. If the holes show signs of tearing, adjust the Tractor Control Knob as needed.
    checking forms alignment on the tractor holes
  2. Ensure that the forms-path vacuum is on (the Vacuum-Off warning indicator is off).

If you need to align the front and back sides of duplex forms, such as when you are printing on preprinted form, you must set print registration. See Setting print registration. Otherwise, you can start the printer. See Starting the printer.

Setting print registration

Things To Keep In Mind When You Adjust the Print Position:

Print jobs with data too close to the edges of the forms do not have the full adjustment range. If you attempt to adjust the print position off the page, Print Error Markers (PEMs) result, which are marks turned on by the host system. If PEMs are turned off, missing data can occur.

If the Adjustment Required Is Out of Range:

If more than 20 mm adjustment (from 0) is required, refer the application owner to the Planning and Configuration Guide.

Note:
  1. Once you have determined the adjustments for a particular form, you can save it in a Snapshot or make a note of the adjustment values on the Forms Identification Work Sheet (from the Planning and Configuration Guide).
  2. Be aware that occasionally some maintenance procedures can affect the print position. If this happens, adjust the print position as needed.

Do this procedure to align the front and back sides of duplex forms or whenever you print on preprinted forms. Setting print registration allows you to adjust the position of the image on the paper.

Note:
A print job must be queued so that print data is available to print test pages during this procedure. Visual verification of the results of moving the print data and print test portions of this procedure cannot be completed without available queued print data.

In printing, the term registration refers to the relative print positions of images that are printed at different times. For example, when you process preprinted forms, the registration is good if the new image printed by the system printer aligns correctly with the preprinted image (as shown in Figure 46.)

Note:
Print registration settings do not apply to print samples.

Figure 46. Example of good print registration
example of good registration

Print that extends beyond box edges and text that overlaps other text are examples of poor registration (as shown in Figure 47).

Figure 47. Example of poor print registration
Example of poor print registration

Print registration values are stored as part of a Snapshot. The adjustment remains in effect (even when the printer is powered off) until it is changed later by another Print Registration procedure or another Snapshot is loaded.

Procedure:

  1. Select Stop.
  2. Select Forms -> Print Registration to display the Print Registration panel.
  3. Select the arrows or type in numbers to change the print position. Values can be entered in PELs, inches, or millimeters.
    Note:
    1. Remember that you are not moving the physical forms. You are moving the image on the paper.
    2. Be aware that the printed output can be rotated when it is printed.
    3. The values vary depending on the printhead resolution (PEL) selected for the printer. This value is set in the PDL - IPDS panel (Printer Definition -> Printer -> PDL -> IPDS).
  4. To print a few pages of the current job with the current registration values, do the following from the touch panel:
    Note:
    This step and the remainder of the procedure can only be accomplished if a queued print job is available.
    1. Enter a value for X in Print X Pages, where X specifies the number of pages you want to print.
    2. Select Print. The printer uses the print registration values currently displayed on the Print Registration panel.
      Note:
      You must wait while the printer receives the job from the host.
    3. Look at the pages just printed (located above the transfer station) to determine how much to adjust the print position, if at all.
  5. Select OK to return to the Main touch panel.
  6. Select Start on the printer operator panel or on the Main touch panel to begin printing.
    caution 85
    Note:
    1. After the printer has run for a few seconds, select Stop. Then look at the output to ensure that the print position is still correct. Sometimes the print position changes slightly when forms are moving at full speed.
    2. Most applications generate a few sample pages at the beginning of each job so that you can adjust the forms without losing any output. If you need more sample pages to test, ask the host system console operator to restart the job.

Starting the printer

Do this procedure to start the printer from the touch panel or the printer control panel.

Procedure:

Press the Start key on the operator panel or select Start on the Main touch panel for the affected printer.

caution 85

Setting the forms length for Auto Load

Do this procedure to set the forms length at the stacker control panel. The forms length value is used when doing the Auto Load sequence.

Procedure:

  1. If you are loading forms that are the same as the forms that were last used on the printer, no action is required. Go to Starting the Auto Load sequence. Otherwise, continue to the next step.
  2. For the Auto Load sequence to execute properly, you must set the forms length on the stacker control panel to match the folding length of the forms you are loading.
    1. Set the FORMS LENGTH as follows:
      • For forms that are 7 inches or greater - set the forms length to the actual length of the form.
      • For forms that are 3-1/2 to 6-2/3 inches - set the forms length to two times the actual length of the form.
      • For forms that are 3 or 3-1/3 inches - set the forms length to three times the length of the actual form (at the perforation to perforation distance) as it is folded before printing.
    2. Press the FORMS LENGTH key to increase or decrease the form length (see About the stacker control panel).
      Note:
      The forms length value entered here is the form length as measured from fold perforation to fold perforation before printing. For example, if a form has page perforations that are 3-1/2 inches apart and fold perforations that are 7 inches apart, use 7 as the stacker form-length value. Refer to "Valid Forms Lengths in Inches" in the Planning and Configuration Guide for help in deciding the correct length to specify at the stacker control panel.

Starting the Auto Load sequence

Do this procedure to start the Auto Load sequence.

Note:
This procedure is for tractored forms. If you are loading tractorless forms and the damper kit is installed, Auto Load controls will not be available on the printer control panel. You must load the forms using the manual load procedure (see Loading forms using the Forms Feed button for instructions).

Procedure:

  1. Press the Auto Load - Load key on the printer control panel to start the automatic loading process.

    The automatic loading process does the following:

    Note:
    If a forms jam occurs during the Auto Load sequence, see Clearing forms jams.
  2. Ensure that the tension arm is aligned correctly. The mark on the tension arm (1) should be visible in the notch in the transfer station frame. See Checking the tension arm.
    tension arm
  3. At the transfer station, ensure that the perforation is aligned with the correct forms length (the forms length set at the stacker control panel). For example, forms that are 11 inches long should be aligned so that the perforation is at the 11-inch mark. The forms length must be set as follows:
    stacker length setting on Infoprint 4100
  4. If the perforation is not aligned correctly, do the following:
    Note:
    Hold the tension arm so that it stays aligned with the blue mark on the guide notch while you do the following steps. Otherwise, the 079A CHECK TENSION ARM 079A message appears when you turn on the forms path vacuum, and you must do the Check Tension Arm procedure (see Checking the tension arm.
    1. Press the vacuum push button. The Vacuum-Off warning indicator flashes and then stays lit.
    2. Use the Forms Feed Forward key on the printer control panel to adjust the position of the perforation. Only the Forward key works with the tension arm held down. Adjust the perforation forward as far as necessary.
    3. Press the vacuum push button. The Vacuum-Off warning indicator flashes and then stays off.
  5. Ensure that the Forms Set indicator on the printer control panel is set to match the fold direction of the fold on the transfer station lower tractors. If it is not, press the correct Forms Set key.
    Note:
    This step is required only if you are using fan-fold forms, and the forms are going to the stacker.