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Formax FD 280 Operator's Manual

Double-head edge tabbing system
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Formax FD 280 Double-
Head Edge Tabber
Instruction Manual

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Summary of Contents for Formax FD 280

  • Page 1 Formax FD 280 Double- Head Edge Tabber Instruction Manual...
  • Page 2 FD 280 Double-Head Edge Tabbing System Operator Manual First Edition 10/2011...

  • Page 3: Table Of Contents

    4.4 Head Position Knob ..................16 4.5 Tab Mode Switch ..................16 5. FEEDING DEVICES ..................17 5.1 Placing the FD 280 In-Line ................17 5.2 ACCESSORY ITEMS ................... 18 5.2.1 Fan Fold Tab Stand………………………………………………………………...18 5.2.2 FD 280 Short Cart ..................19 5.2.3 FD 280 Long Cart………………………………………………………….………..19...

  • Page 4: Fd 280 Description

    6. OPERATION ....................20 6.1 Splicing Tabs ....................20 6.2 Threading Tabs……………………………………………………………………21 6.3 Feeding Portrait Mail Pieces ................. 22 6.4 Feeding Landscape Pieces ................24 6.5 Tabbing Mail Pieces ..................25 6.6 Adjusting Tab Position …………………………………………………………..26 6.7 Remove Waste Backing Paper…………………………………………………27 6.8 Restore Default Tab Settings……………………………………………………27 6.9 Change Piece Size………………………………………………………………27 7.

  • Page 5: Introduction

    Mail pieces are fed into the FD 280 using a feeding device such as the Formax FD 260-10 Feeder, a feeder or labeler from another manufacturer. If the...
  • Page 6 FD 280 needs a few seconds to get itself ready to run. When you turn the power on, the FD 280 takes 5 seconds to boot up. During this time the tab ready light flashes and the control panel is inoperative.

  • Page 7: Items Included

    Figure 1.1 – Formax FD 280 with FD 280-10 High Volume Feeder and stand. Items Included The following items are shipped together in one box. Take note of each as you unpack the box. FD 280 Tabber with input shafts...

  • Page 8: Operating Manual Terms

    INJURY TO PERSONNEL. CAUTION ALERTS YOU TO ACTIONS THAT MAY CAUSE LOSS OF MATERIALS (MAIL PIECES AND TABS) OR DAMAGE TO EQUIPMENT. NOTE Draws your attention to an important statement or action. A suggestion to enhance the FD 280’s productivity.

  • Page 9: Safety Precautions

    Observe the following safety precautions and warnings when operating, cleaning or repairing the FD 280. Failure to do so may result in physical injury or damage to the FD 280. The manufacturer assumes no liability for your failure to comply with these requirements.

  • Page 10: Warranty

    Warranty NOTE Your FORMAX FD 280 is covered under warranty by the dealership from which you purchased it. Formax warrants your FD 280 against defects in materials and workmanship for a period of six months from the original ship date when used in accordance with the operating instructions in this manual.

  • Page 11: Specifications & Requirements

    Clear or translucent tabs require blacked out tab areas. Tab Position Accuracy ® ± " guaranteed when using Formax Tabs within their specified shelf life Mail Piece Fold Quality Folds in mail pieces should result in flush panels. Mail piece squareness is important when meeting USPS tab tenting specifications.

  • Page 12: Power Connection

    THE POWER CORD BEFORE REMOVING COVERS FROM THE FD 280. Line Voltage The FD 280 is rated for continuous operation using a variety of supply voltages. Possible line voltages are 240V, 230V, 220V, 120V and 100V at 50 or 60 Hz.
  • Page 13 VOLTAGE SELECTOR WINDOW. 6. Place the VOLTAGE SELECTOR in the FUSE DRAWER and verify the correct voltage selection. 7. Place the FUSE DRAWER in the POWER ENTRY CASING. Figure 3.1 – FD 280 Power Connection...

  • Page 14: Line Fuses

    The FUSE DRAWER located on the non-operator side contains two LINE FUSES. (Refer to Figure 3.1.) The neutral and hot lines of power are fused. Both LINE FUSES must be intact for the FD 280 to operate properly. CAUTION VERIFY THAT THE LINE FUSE VALUE IS CORRECT FOR THE VOLTAGE SETTING.

  • Page 15: Accessory Fuses

    ACCESSORY POWER OUTLET. As with the LINE FUSES mentioned previously, both the neutral and hot lines are fused. Both ACCESSORY FUSES must be intact for the FD 280 to properly supply power to in-line equipment. WARNING UNPLUG THE POWER CORD BEFORE STARTING THIS PROCEDURE.

  • Page 16: Accessory Power Outlet

    FD 280. Typical in-line equipment includes feeders and labelers. Since the ACCESSORY POWER OUTLET gets its power from the FD 280, you can control power to in-line equipment using the FD 280’s POWER SWITCH. Additionally, the FD 280 features an automatic interrupt that disables the ACCESSORY POWER OUTLET in case of a jam.

  • Page 17: Controls

    The LCD COUNTER is located on the right of the operator side panel. The LCD COUNTER displays the current number of tabbed mail pieces fed through the FD 280. Reset the LCD COUNTER by pressing its reset button. Figure 4.1 - FD 280 Operator Panel Controls...

  • Page 18: Control Panel

    Control Panel Figure 4.3 - FD 280 Control Panel 4.3.1 Power Indicator The orange Power Indicator light illuminates when the power switch is turned on. 4.3.2 Stop The STOP (red pushbutton mushroom) Switch interrupts the movement of all moving parts and resets the microprocessor.

  • Page 19: Head Position Knob

    Changing mode settings can only be done with the STOP button pressed. Figure 4.4 FD 280 Tab Mode Touch Pad Once the Tab Size Switch has been moved off Set Up to a tab size, pressing the key pad selects the tabs to be run as well as their general location on the piece.

  • Page 20: Feeding Devices

    To operate the FD 280 in-line with your feeding device, place the output end of the feeding device next to the input end of the FD 280. Leave about an " gap between the machines. Align machines to place tabs where desired on the mail pieces.

  • Page 21: Accessory Items

    NOTE Some equipment, when run in-line with the FD 280, requires a stand to raise it to the level of the FD 280. When ordering additional equipment, specify which machine you plan to operate in-line with the FD 280. Accessory items 5.2.1 FD 280-50 Fan...

  • Page 22: Fd 280 Short Cart

    5.2.3 FD 280-40 Stand The FD 280-40 Adjustable Height Stand holds the FD 280-20 High Volume Tab Delivery Module Stand. 5.2.4 FD 280-20 High Volume Tab Delivery Module The FD 280-20 automatically delivers tabs from high volume spools to the FD 280.

  • Page 23: Operation

    6.0 OPERATION WARNING KEEP LOOSE CLOTHING, TIES, SCARVES AND HAIR AWAY FROM ALL MOVING PARTS. DO NOT PLACE FINGERS OR TOOLS BETWEEN OR NEAR MOVING PARTS. 6.1 Splicing Tabs It is highly recommended that splicing one tab strip to another be the way to add or change strips of tabs. Splicing is much quicker than threading and the machine is delivered threaded.

  • Page 24: Threading Tabs

    Second, set the box at an angle so that the tabs will always tend to fall away from the tabber. A Formax FD 280-50 tab stand is a simple means of accomplishing this. Figure 6.1 – Splicing Tabs 6.2 Threading Tabs...
  • Page 25 7. Take the strip back over the top plastic guide roller and attach it to the take up spool. Check for squareness. Figure 6.2 Threaded Formax FD 280...

  • Page 26: Feeding Portrait Mail Pieces

    Figure 6.3 Setting up Input Guides on the FD 280 4. Take the same sample piece and set it between the vertical tab indicator plates on the exit side of the tab heads.

  • Page 27: Feeding Landscape Pieces

    Figure 6.4 Setting the heads to match a piece on the FD 280 6.4 Feeding Landscape Mail Pieces The FD 280 is capable of accepting pieces in either Portrait or Landscape orientation. Booklets are typically edge tabbed in Portrait direction while self mailers are often top tabbed in landscape.

  • Page 28: Tabbing Mail Pieces

    Figure 6.5 Roller Offset for stiff self mailers. 6.5 Tabbing Mail Pieces 1. Make sure tabs are threaded correctly and peel point area is clear. 2. Turn the POWER SWITCH on. CAUTION TO AVOID A JAM, TURN THE FD 280 ON BEFORE TURNING ON THE FEEDING DEVICE.

  • Page 29: Adjusting Tab Position

    7. Lift the Stop Button and press Start. 8. Feed pieces through the machine until the tab ready light comes on (usually three). 9. The FD 280 begins tabbing in the mode selected. Tabs are placed and folded per the USPS regulations.

  • Page 30: Remove Waste Backing Paper

    SPINDLE with tape. 6.8 Restore Default Tab Settings All FD 280’s are set at the factory to meet USPS recommended settings. Each “C” tab is set to the center of a piece. To quickly restore these settings. 1. Press Stop.

  • Page 31: Change Piece Size

    Your FD 280 will need regular cleaning. How often you’ll need to clean it depends on the amount of paper dust your mail pieces generate. Wipe surface dust or debris from the FD 280 with a damp cloth as necessary. TIP: It is easier to move heads apart and together when the rollers are turning.

  • Page 32: Replacing A Fuse

    7.2 Replacing Fuses When one or both LINE FUSES are blown, the FD 280 will appear to have no power and the LINE FUSE must be replaced. Press the STOP Button and turn Power OFF before replacing a fuse.

  • Page 33: Line Fuse

    2. Pull the FUSE DRAWER out of the POWER ENTRY CASING. (Refer to Figure 7.1.) Figure 7.1 Replacing FD 280 Fuses 3. Inspect the FUSES; look for blackened glass, melted wire or a disconnected wire between the ends of the tube. If you find any of these problems in either FUSE, that FUSE is blown and must be replaced.

  • Page 34: Accessory Fuse

    5. Place the new FUSE into the same slot. 6. Install the FUSE DRAWER. (Refer to Figure 7.1.) Accessory Fuse When one or both ACCESSORY FUSES are blown, the ACCESSORY POWER OUTLET and the machine plugged into this outlet lose power. WARNING UNPLUG THE POWER CORD BEFORE OPENING THE FUSE DRAWER.

  • Page 35: Troubleshooting

    8.0 TROUBLESHOOTING WARNING UNPLUG THE POWER CORD BEFORE REMOVING, ADJUSTING OR REPAIRING ANY PARTS IN THE FD 280. Trouble Cause Solution 1. Nothing works, Power switch is not Turn power switch on. no orange Power Indicator light Power cord is...
  • Page 36 9. Tab placement is Mail pieces are Make sure mail inconsistent. feeding crooked. pieces feed straight into FD 280. Refer to Section 9.2.1. Backing paper has Re-thread backing torn after the drive roll. paper from drive roll. Refer to Section 9.1.4.
  • Page 37 10. Tab fold is Head position needs Adjust head position. uneven. adjustment. Refer to Section With 1 inch tabs, the 9.2.2. tabs are not centered Make sure that the tab strip is between the hinged guides on the peel bar. Tab Size Wrong Power Off, select tab size...

  • Page 38: Correcting Tabbing Problems

    9.1.1 Tab Ready Light doesn’t come on Make sure that pieces are being fed through the FD 280 smoothly and consistently. The FD 280 measures the first three pieces through the machine after set up and if these three are not close in measurement, the ready light will not come on.

  • Page 39: Torn Backing Paper

    1. Press the STOP switch quickly 2. Leave the heads in place. 3. Reverse the piece through the FD 280 by turning the transport rolls by hand. Pull the jammed mail pieces out of the input area of the transport.

  • Page 40: Incorrect Threading

    TAB READY light illuminates. If the backing paper tears after the drive roll, the backing paper may fall away from the FD 280 and tabbing will continue. If the backing paper wraps around rolls in the threading path, tabbing may continue, but tab placement may not be accurate.

  • Page 41: Poor Tab Placement Or Appearance

    Also make sure that the tabs are freely moving from the tab supply into the FD 280. If tabs hang up, they will be misplaced. Do not feed the FD 280 from rolls that do not consistently run freely and/or are not advanced to keep slack between the roll and the FD 280.

  • Page 42: Restoring Factory Settings

    Contact an authorized Formax dealer for supplies. 9.5 Restoring Factory Settings The FD 280 affords the operator great flexibility in tab selection and placement. For example, a delayed center position tab may be set and selected instead of the opposite trailing edge tab when it is necessary to have the tab miss important text on the piece.

  • Page 43: Service

    Formax dealer. 10.1 Repacking Instructions If it is necessary to ship your FD 280 to your authorized Formax dealer for service, pack it in the original shipping container and packaging material. If the original container is not available, the FD 280 should be carefully packed so that it will not be damaged in transit.
  • Page 44 1. Double wrap the machine in heavy plastic. 2. Use a heavy duty, double-walled container of 350- pound test material. 3. Surround the FD 280 on ALL sides with at least 4 to 5 inches of heavy duty shock absorbing packaging material (peanuts or wadded up newspaper do not qualify as “heavy duty”.

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