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Formax FD 260 Operator's Manual

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FD 260 Tabber
1/2011
Operator Manual
First Edition

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Summary of Contents for Formax FD 260

  • Page 1 FD 260 Tabber Operator Manual First Edition 1/2011...

  • Page 3: Table Of Contents

    4.5.1 Tab Ready ...................... 14 4.5.2 Clear Tab ....................... 15 4.5.3 On/Off ......................15 5. FEEDING DEVICES ..................16 5.1 Placing the FD 260 In-Line ................16 5.2 FD 260-10 Feeder ..................17 6. OPERATION ....................19 6.1 Threading Tabs ..................... 19 6.2 Feeding Mail Pieces..................
  • Page 4 7. MAINTENANCE ....................25 7.1 General Cleaning & Clearing ................ 25 7.1.1 Removing Tabs & Debris From Peel Point Area ..........25 7.2 Replacing A Fuse ..................26 7.2.1 Line Fuse......................26 7.2.2 Accessory Fuse ....................27 8. TROUBLESHOOTING ................... 29 8.1 Troubleshooting Chart ..................

  • Page 5: Introduction

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

  • Page 7: Items Included

    Take note of each as you unpack the box. FD 260 Tabber Power cord Operating Manual 1 roll of white tabs 1 roll of clear tabs WARNING THE FD 260 IS A HEAVY MACHINE. USE PROPER LIFTING TECHNIQUES TO SET IT ON A WORK SURFACE.

  • Page 8: Operating Manual Safety 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 260’s productivity.

  • Page 9: Safety Precautions

    Observe the following safety precautions and warnings when operating, cleaning or repairing the FD 260. Failure to do so may result in physical injury or damage to the FD 260. The manufacturer assumes no liability for your failure to comply with these requirements.

  • Page 10: Warranty

    Warranty NOTE Your FORMAX FD 260 is covered under warranty by the dealership from which you purchased it. Formax warrants your FD 260 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

    Maximum roll diameter: 8.25" Core Diameter: 3" Tab Position Accuracy ± " guaranteed when using Formax Tabs within their specified shelf life Mail Piece Fold Quality Folds in mail pieces must result in perfectly flush panels. A lip (one panel longer than another on the same mail piece) will result in torn mail pieces when tabbed.

  • Page 12: Power Connection

    THE POWER CORD BEFORE REMOVING COVERS FROM THE FD 260. Line Voltage The FD 260 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 260 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 260 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 260 to properly supply power to in-line equipment. WARNING UNPLUG THE POWER CORD BEFORE STARTING THIS PROCEDURE.

  • Page 16: Accessory Power Outlet

    FD 260. Typical in-line equipment includes feeders and labelers. Since the ACCESSORY POWER OUTLET gets its power from the FD 260, you can control power to in-line equipment using the FD 260’s POWER SWITCH. Additionally, the FD 260 features an automatic interrupt that disables the ACCESSORY POWER OUTLET in case of a jam.

  • Page 17: Controls

    The POWER SWITCH is located on the bottom of the operator side panel. (Refer to Figure 4.1) Turn the POWER SWITCH on to supply power to the FD 260. LCD Counter The LCD COUNTER is located on the top of the operator side panel.

  • Page 18: Gap Adjustment Lever

    Control Panel. Figure 4.2 Tab Size Selector Switch Control Panel Figure 4.3 - FD 260 Control Panel 4.5.1 Tab Ready The TAB READY light illuminates when a tab is detected at the peel point. Stray tabs at the peel point will also illuminate the TAB READY light.

  • Page 19: Clear Tab

    The TAB READY light also warns you of malfunctions during tabbing by flashing as the FD 260 shuts down. 4.5.2 Clear Tab The CLEAR TAB control tells the FD 260 whether to detect clear (and translucent) or opaque tabs. When CLEAR TAB is toggled on, the light illuminates and the sensor is tuned to detect clear tabs.

  • Page 20: Feeding Devices

    To operate the FD 260 in-line with your feeding device, place the output end of the feeding device next to the input end of the FD 260. Leave about an " gap between the machines. Align machines to place tabs where desired on the mail pieces.
  • Page 21 FD 260. Figure 5.1 illustrates the FD 260-10 in-line with the FD 260. Figure 5.1 - The Formax FD 260-10 Feeder in-line with the FD 260 Tabber.

  • Page 22: Operation

    6. 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 Threading Tabs To thread tabs: 1. Remove 12 tabs from the leading edge of the tab strip.
  • Page 23 3. Insert one or both TAB ROLL ADAPTERS into the core of the TAB ROLL. The TAB ROLL width may allow only one TAB ROLL ADAPTER to fit in the TAB ROLL. 4. Pull the SHELF down. Place the TAB ROLL ADAPTER (rim away from you) with the TAB ROLL attached on the TAB SPINDLE.
  • Page 24 5. Center the TAB ROLL between the two GUIDES on the SHELF. Slide these GUIDES against the TAB ROLL. Place the RUBBER RING (removed in step 2) on the TAB SPINDLE. Press both RUBBER RINGS against the TAB SPOOL ADAPTER. 6.

  • Page 25: Feeding Mail Pieces

    2. Turn FD 260’s POWER SWITCH on. NOTE Turn the FD 260’s POWER SWITCH on before turning on the feeding device. If the FD 260 is not turned on first, it will not accept the mail pieces. 3. Toggle ON/OFF so light does not illuminate.
  • Page 26 Figure 6.3 – FD 260 Controls 5. Make sure the GAP ADJUSTMENT LEVER is set properly. 6. Begin feeding mail pieces into the FD 260. The TAB READY light will illuminate every time a tab reaches the application point. 7. Make sure each mail piece is tabbed. Re-align the machines if the tabs are not being placed in the desired position on the mail pieces.

  • Page 27: Removing Waste Backing Paper

    6.4 Removing Waste Backing Paper Figure 6.4 - Removing Waste Backing Paper 1. Tear the waste backing paper, leaving enough to reach and wrap around the TAKE-UP SPINDLE. 2. Pull the waste backing paper off the TAKE-UP SPINDLE. 3. Remove the CLIP from the center of the waste backing paper.

  • Page 28: Maintenance

    Your FD 260 will need regular cleaning. How often you’ll need to clean the FD 260 depends on the amount of paper dust your mail pieces generate. Wipe surface dust or debris from the FD 260 with a damp cloth as necessary. 7.1.1 Removing Tabs &...

  • Page 29: Replacing A Fuse

    7.2 Replacing a Fuse 7.2.1 Line Fuse When one or both LINE FUSES are blown, the FD 260 will appear to have no power and the LINE FUSE must be replaced. WARNING UNPLUG THE POWER CORD BEFORE OPENING THE FUSE DRAWER. To replace a LINE FUSE: 1.

  • Page 30: Accessory Fuse

    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. 4. Pull the blown FUSE from its slot. WARNING REPLACE ONLY WITH SAME TYPE AND RATING OF FUSE.
  • Page 31 WARNING REPLACE ONLY WITH SAME TYPE AND RATING OF FUSE. (REFER TO CHART BELOW.) Selected Voltage Line Fuse Value 100V…………………… 6.3A (250V time delay) 120V…………………… 6.3A (250V time delay) 220V…………………… 3.15A (250V time delay) 240V (or 230V)……….. 3.15A (250V time delay) 4.

  • Page 32: Troubleshooting

    TAB READY light is Toggle ON/OFF until pieces. off. Peel point is free light illuminates. of tabs and debris. 4. FD 260 shuts Sensor could not find Tune sensor. Refer to down. TAB tab during the pre-set Section 9.1.2. time.
  • Page 33 Trouble Cause Solution 7. FD 260 stops. Power entry fuse is Replace blown line blown. fuse. Refer to Section 3.3. FD 260 keeps blowing Contact authorized fuses after you replace Formax dealer. them. Mail piece has jammed Clear the jam. Refer in machine.
  • Page 34 16. Mail pieces jam Sweep position Contact authorized upon entering requires adjustment. Formax dealer. FD 260. Sweep is reversed. Slide plastic ruler along feed tray to reverse sweep. 17. Tab does not Feeding device is too Reduce speed of fold, one tab is fast.

  • Page 35: Correcting Tabbing Problems

    At start-up, when the ON/OFF light is illuminated, the tab strip advances until the sensor detects a tab at the peel point. If no tab is detected, toggle ON/OFF until the TAB READY light illuminates. Figure 9.1 – FD 260 Control Panel...

  • Page 36: Sensor Is Not Tuned For Clear Tabs

    9.1.2 Sensor Is Not Tuned for Clear Tabs If the sensor is not tuned for clear tabs, one of the following problems may occur: TAB READY light remains on, but there is more than one tab at the peel point. TAB READY light flashes and the tab strip stops advancing after peeling several clear tabs at the peel point.

  • Page 37: Mail Piece Jam

    TRAY. Mail pieces can jam if the SWEEP is too high. Mail pieces can be blocked if the SWEEP is not bent on the FEED TRAY. If jamming is caused by the SWEEP, contact an authorized Formax dealer for service. Figure 9.2 – Clearing Jammed Mail Pieces...
  • Page 38 CAUTION PULLING MAIL PIECES IN THE OPPOSITE DIRECTION THAT THEY MOVE THROUGH THE FD 260 MAY DAMAGE THE SWEEP OR MOVE IT OUT OF POSITION. 3. If you cannot reach the jammed mail pieces, continue through the following instructions. 4. Set the GAP ADJUSTMENT LEVER to thick, if it is set for thin.

  • Page 39: Torn Backing Paper

    DO NOT PLACE FINGERS OR TOOLS BETWEEN OR NEAR MOVING PARTS. 1. Turn the POWER SWITCH off. 2. Thread the FD 260 from the point where the backing paper tore. (Refer to Section 6.1.) NOTE When backing paper is pulled, tabs will peel at the PEEL PLATE until pulling is stopped.

  • Page 40: Incorrect Threading

    PEEL PLATE assembly will block any mail pieces entering the FD 260. Backing paper is threaded under the DRIVE ROLL. The backing paper will pull backward and no tabs will peel.

  • Page 41: Poor Tab Placement Or Appearance

    9.2 Poor Tab Placement Or Appearance 9.2.1 Tab Placement Is Inconsistent If tab placement on mail pieces varies during the same run, check to see if mail pieces are feeding straight. Make sure the paper guides on your feeding device are set against the sides of the stack of mail pieces.
  • Page 42 6. Replace the PEEL PLATE ASSEMBLY. 7. Turn the POWER SWITCH on. 8. Feed a few mail pieces through the FD 260 and observe the tab placement. Repeat until the tab has equal portions on the top and bottom of the...

  • Page 43: Tab Fold Is Off Mail Piece - Tab Is Tenting

    9.2.3 Tab Fold Is Off Mail Piece – Tab Is Tenting If tabs fold too early so the tab fold is not on the mail piece, the SWEEP needs adjusting. If the fold resembles Figure 9.5, the SWEEP position is too high.

  • Page 44: More Than One Clear Tab On Mail Piece

    One Clear Tab On Mail Piece The FD 260 may place more than one clear tab on a mail piece if the sensor is not tuned for clear tabs. To correct this, tune the sensor for clear tabs. Refer to...

  • Page 45: Service

    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 260 on ALL sides with at least 4 to 5 inches of shock absorbing packaging material. This will provide firm cushioning and prevent movement inside the container.

This manual is also suitable for:

Fd 260-10

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