Xerox OHCF Envelope Printing (Versant 180)

ReproElectroProspero

Well-known member
Xerox says that their production machines like the Versant 180 can run envelopes well. They even sold us an envelope feeder kit for our Xerox Oversize High Capacity Feeder. We've successfully ran some jobs, but it seems #9 and #10 envelopes just have an extremely difficult time running well. When we run 9x12s it's usually no problem. When we run regular size envelopes, we run into TONS of issues. Sometimes the OHCF doesn't recognize there is stock loaded, other times it jams with codes like 078-101 (Pre Registration Sensor Jam). We have to constantly fight the machine because if we load too many, or too little envelopes, the issues crop up. It's like we have to pray to the printing gods to get these things to feed. It's incredibly frustrating, and happens across a large variety of stocks.

We've tried using the plastic lift blocks that come with the envelope kit, running without them, feeding the envelopes rotated 180 degrees, fanning them constantly, replacing the rubber rollers, switching to another OHCF tray, and a myriad of other tricks.

While I search for a memjet-style solution, can anyone here recommend any tips or tricks to get a digital machine like a Versant 180 to run envelopes more consistently?
 

tngcas

Well-known member
We have the same problem. We also bought the envelope kit. It worked great the first run so I thought all our woes were solved but alas... nope. It's still time-consuming to do a large envelope run.

We usually run the envelopes out of our bypass try because the delay for an "error" is about 90 seconds and the delay for an "empty bypass tray" is only about 30 seconds so even being able to only put 25 envelopes into the bypass tray is faster than the 90 second delay if the printer doesn't recognize the envelopes are loaded and/or throws a jam that is just basically "open and close the tray and hope it works this time".

The bypass tray doesn't have the same trouble as the the OHCFs with running the envelopes.
 

A&BPat

Member
Xerox says that their production machines like the Versant 180 can run envelopes well. They even sold us an envelope feeder kit for our Xerox Oversize High Capacity Feeder. We've successfully ran some jobs, but it seems #9 and #10 envelopes just have an extremely difficult time running well. When we run 9x12s it's usually no problem. When we run regular size envelopes, we run into TONS of issues. Sometimes the OHCF doesn't recognize there is stock loaded, other times it jams with codes like 078-101 (Pre Registration Sensor Jam). We have to constantly fight the machine because if we load too many, or too little envelopes, the issues crop up. It's like we have to pray to the printing gods to get these things to feed. It's incredibly frustrating, and happens across a large variety of stocks.

We've tried using the plastic lift blocks that come with the envelope kit, running without them, feeding the envelopes rotated 180 degrees, fanning them constantly, replacing the rubber rollers, switching to another OHCF tray, and a myriad of other tricks.

While I search for a memjet-style solution, can anyone here recommend any tips or tricks to get a digital machine like a Versant 180 to run envelopes more consistently?
We run #10 envelopes very well on our Versant 180. You can only load about 150 at time in tray 6 with the envelope kit, but we have printed many boxes without a single jam. We print #10 window envelopes as well and they're not the laser safe ones. The window does get a little wavy but I've never had a client compliant.
 

pippip

Well-known member
I find the quality of the envelope is essential. A good envelope that comes flat out of the box can run 1000s without jams. Doesn't need to be an expensive or heavier envelope just some makes are better than others in how they're made and packed.
 

auscop123

Member
Personally I run them through the bypass tray. If you have them in short stacks before you start running and are very careful you can feed in envelopes under the stack while the machine is running. It is the same idea as Xerox's $15,000 high capacity envelope conveyor belt.
 

richsweeney

Active member
I bought the hi cap feeder, it is dummed down over priced Stream Feeder 71. #10 reg works best. I have had it less than a year, and every time I think I have it figured out, I don't.
When it runs it runs great. Don't bother with the conveyer belt, the machine does not need it. However it is way better then feeding from drawer 6 when it works. I paid about 10k for it.
 

Windward

Active member
We had reasonable success running envelopes on our Versant 180 without the envelope kit. We used the small sheet fence in tray 6. Sizes included #9, #10, A6, and A7. I agree with pippip that envelope quality does matter. Some types run just fine and others jam frequently. We loaded stacks of 150 to 200 envelopes at a time. This can be tedious for an order of 2500 but it was doable. Have you had a Xerox tech check your machine?
 

tngcas

Well-known member
Tech today told me that there is are two white slider in the OHCF that needs to be slide to the O side when doing envelopes. Will see how it helps but apparently it's supposed to allow for larger stacks to be input into the tray.
 

kdw75

Well-known member
On our semi-retired 2100, we always use the top bypass tray. We run primarily envelopes on that machine as it isn't under contract anymore. We run thousands between jams, but you definitely don't want envelopes that are too flimsy. We had some linen envelopes that were the wrong grain and it was a nightmare getting 500 through it.
 

ReproElectroProspero

Well-known member
On our semi-retired 2100, we always use the top bypass tray. We run primarily envelopes on that machine as it isn't under contract anymore. We run thousands between jams, but you definitely don't want envelopes that are too flimsy. We had some linen envelopes that were the wrong grain and it was a nightmare getting 500 through it.
You ran thousands through the bypass tray? Did you just have a staff member sit there and feed it every 50 envelopes? We dislike this method because of the 30-90 seconds the machine takes to 'reset' every time the bypass tray runs out, and since it's top-fed, we can't just keep adding to the stack. Do you have a trick to get around this?
 

tngcas

Well-known member
You ran thousands through the bypass tray? Did you just have a staff member sit there and feed it every 50 envelopes? We dislike this method because of the 30-90 seconds the machine takes to 'reset' every time the bypass tray runs out, and since it's top-fed, we can't just keep adding to the stack. Do you have a trick to get around this?
We've been doing this - running them out of the bypass tray and giving it 35 envelopes at a time. It's not a great method and slow and tedious and time-consuming to have an employee sit there and refill every 30 seconds.

A random printer tech was here last week and showed us how to move both white sliders. With those turned on we were able to fill the Tray 6 all the way to the max line with #10 envelopes and did 3500 envelopes in half the time it would have taken us with the bypass tray.

Ironically, it works better if you fill the tray all the way to the max line but then once it starts printing it'll print until the tray empties.
 

ReproElectroProspero

Well-known member
We've been doing this - running them out of the bypass tray and giving it 35 envelopes at a time. It's not a great method and slow and tedious and time-consuming to have an employee sit there and refill every 30 seconds.

A random printer tech was here last week and showed us how to move both white sliders. With those turned on we were able to fill the Tray 6 all the way to the max line with #10 envelopes and did 3500 envelopes in half the time it would have taken us with the bypass tray.

Ironically, it works better if you fill the tray all the way to the max line but then once it starts printing it'll print until the tray empties.
We've been trying to recreate this, but just can't recreate it reliably. Sometimes they run beautifully as you describe, other times it's a jam every 5 minutes. I've switched to side seam, which helps, but there's still a random element of "I just won't feed right" today. I'm seriously looking to invest in a dedicated envelope printer just to avoid this. Plus, the price per envelope would likely be better.
 

jwheeler

Well-known member
We've been trying to recreate this, but just can't recreate it reliably. Sometimes they run beautifully as you describe, other times it's a jam every 5 minutes. I've switched to side seam, which helps, but there's still a random element of "I just won't feed right" today. I'm seriously looking to invest in a dedicated envelope printer just to avoid this. Plus, the price per envelope would likely be better.
We have KM's so it may not relate, but we found that in addition to switching to side seam, we flipped the envelopes around 180 degrees (so flaps were towards the operator side) feeding became almost flawless. Might be worth trying on your Xerox if you haven't already.
 

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