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Formax FD 280, Operator'S Manual

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Formax FD 280 Operator'S Manual Download Page 23

 

 

19 

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.  Splices can be made 
between tab sizes.  

When changing tab sizes, make sure that the 

backing paper width of the tabs being run is less 

than the tab width specification. 

 
 
To splice tabs: 
 
1.  Stop tabbing with at least 12 inches of tab material 

between the peel bar and the end of the strip. 

  

2.  Trim the last tab so that the end of the strip is 

square. 

 

3.  Trim the end of the new tab strip square and 

attach a tab to the underside of the strip so that it 
is half on, half off the strip. 

 

4.  Remove the first few tabs from the new strip and 

the last few from the old. 

 

5.  Attach the new strip to the old strip so that the end 

on the old strip is on top of the new strip and in the 
place of the first tab that was peeled off the new 
strip.  Use the tab on the new strip to stick the two 
strips together. 

 

Summary of Contents for FD 280

Page 1: ...Formax FD 280 Double Head Edge Tabber Instruction Manual ...

Page 2: ...FD 280 Double Head Edge Tabbing System Operator Manual 10 2011 First Edition ...

Page 3: ...NNECTION 9 3 1 Safety 9 3 2 Line Voltage 9 3 3 Line Fuses 11 3 4 Accessory Fuses 12 3 5 Accessory Power Outlet 13 3 6 Power Cord 13 4 CONTROLS 14 4 1 Power Switch 14 4 2 LCD Counter 14 4 3 Control Panel 4 3 1 Power Indicator 15 4 3 2 Stop 15 4 3 3 Start 15 4 3 4 Tab Ready 15 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 ...

Page 4: ...leaning Clearing 28 7 2 Replacing a Fuse 29 7 2 1 Line Fuse 30 7 2 2 Accessory Fuse 31 8 TROUBLESHOOTING 32 8 1 Troubleshooting Chart 32 9 CORRECTING TABBING PROBLEMS 35 9 1 No Tabs Applied To Mail Pieces 9 1 1 Tab Ready Light Off 35 9 1 2 Mail Piece Jam 35 9 1 3 Torn Backing Paper 36 9 2 Incorrect Threading 37 9 3 Poor Tab Placement or Appearance 38 9 3 1 Tab Placement Is Inconsistent 38 9 4 Unev...

Page 5: ...x FD 260 10 Feeder a feeder or labeler from another manufacturer If the FD 280 is to work correctly mail pieces must be fed into it correctly with a gap of about one inch between mail pieces This manual does not cover the operation of the various feeding devices that may be used to supply the FD 280 with mail pieces Please read your feeding device operating manual before using it in line with the ...

Page 6: ...s and the encoder are fed to the microprocessor which monitors the length of pieces fed and calculates the average length of the piece Without correct measuring the FD 280 will not tab The FD 280 s sensors work like all other electric eyes When an object breaks the beam of light the SENSOR BEAM between them an electrical signal is generated It is imperative that this SENSOR BEAM PATH be maintained...

Page 7: ...luded The following items are shipped together in one box Take note of each as you unpack the box FD 280 Tabber with input shafts Power cord Catch Tray 2 Magnetic Tab Guides Operating Manual WARNING THE FD 280 IS A HEAVY MACHINE USE PROPER LIFTING TECHNIQUES TO SET IT ON A WORK SURFACE ...

Page 8: ...attention to this information WARNING ALERTS YOU TO ACTIONS OR CONDITIONS THAT MAY PRESENT HAZARDS OR CAUSE 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 TIP A suggestion to enhance the FD 280 s productivity ...

Page 9: ...ER CLEAN CLEAR OR DISASSEMBLE THE FD 280 WITHOUT FIRST UNPLUGGING THE POWER CORD WARNING KEEP LOOSE CLOTHING TIES SCARVES AND HAIR AWAY FROM ALL MOVING PARTS WARNING DO NOT PLACE FINGERS OR TOOLS BETWEEN OR NEAR MOVING PARTS OBSERVE ALL POSTED WARNING DECALS 1 6 Operating Manual Terms The following terms are used throughout this manual input end where mail pieces enter output end where mail pieces...

Page 10: ...hould warranty repairs become necessary the service provider at his her option will repair or replace such parts required to restore the FD 280 to serviceable condition This warranty does not cover consumable parts such as belts rollers and sweeps used to contact and transport mail pieces and tabs This warranty does not extend to incidental or consequential damages arising out of a warranty claim ...

Page 11: ...tabs Maximum 200 Tab Specs Tab width 1 and 1 5 fan fold or roll Tab length 1 1 5 Backing paper width between 1 125 1 tab and 1 625 1 5 Tabs Maximum roll diameter 10 00 Core Diameter 3 Fan Fold Case Based Clear or translucent tabs require blacked out tab areas Tab Position Accuracy 1 8 guaranteed when using Formax Tabs within their specified shelf life Mail Piece Fold Quality Folds in mail pieces s...

Page 12: ...EAN INTERIOR PARTS OF THE FD 280 REMAIN AT A HAZARDOUS VOLTAGE ALWAYS UNPLUG THE POWER CORD BEFORE REMOVING COVERS FROM THE FD 280 3 2 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 The manufacturer configures the FD 280 to operate with the voltage requested by the customer CAUTION ...

Page 13: ...DRAWER LOCKING TAB 3 Pull the FUSE DRAWER out of the POWER ENTRY CASING 4 Pull the VOLTAGE SELECTOR out of the FUSE DRAWER 5 Rotate the VOLTAGE SELECTOR until the correct voltage is on the same side as the 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 Connect...

Page 14: ...screwdriver or similar tool to push up on and release the FUSE DRAWER LOCKING TAB 3 Pull the FUSE DRAWER out of the POWER ENTRY CASING The LINE FUSES are inside 4 Determine the proper fuse value as well as the condition of the LINE FUSE The fuse value is shown on the metal tip of the LINE FUSE The chart below lists the selected voltage in the left column followed by the proper fuse value in the ri...

Page 15: ...USES installed have the proper fuse value or to replace a blown fuse 1 Unplug the POWER CORD 2 Use a small screwdriver or similar tool to press in and rotate the FUSEHOLDER CAP counterclockwise to release this cap 3 Pull the FUSEHOLDER CAP with the ACCESSORY FUSE inside out of the FUSEHOLDER 4 Verify the fuse value Inspect fuses replace if blown Selected Voltage Line Fuse Value 100V 6 3A 250V time...

Page 16: ...H Additionally the FD 280 features an automatic interrupt that disables the ACCESSORY POWER OUTLET in case of a jam The ACCESSORY POWER OUTLET is limited to a 6 3A maximum for 100V and 120V and 3 15A maximum for 220V and 240V 3 6 Power Cord The FD 280 comes with a three wire POWER CORD The POWER CORD grounds the FD 280 when connected to an approved three contact electrical outlet 1 Plug the POWER ...

Page 17: ...to supply power to the FD 280 4 2 LCD Counter 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 Figure 4 2 Tab Pressure Controls ...

Page 18: ...ed up into the run position Lifting the button will not start the machine Press the STOP switch to change tab mode settings 4 3 3 Start The Start button is a momentary switch that causes the resumption of movement after the Stop Switch has been pressed 4 3 4 Tab Ready Then green Tab Ready light illuminates when enough usually 3 4 pieces have been fed regularly through the machine to allow precise ...

Page 19: ...ability to select the number location and type of the tabs as well as to change location of tabs 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 There are three buttons per Tab Head ...

Page 20: ...r feeding device place the output end of the feeding device next to the input end of the FD 280 Leave about an 1 8 gap between the machines Align machines to place tabs where desired on the mail pieces The gap between the feeding device and the FD 280 may need adjusting if the mail pieces are curled or rigid If the mail pieces leading edge curls up the gap should be larger than 1 8 to allow the cu...

Page 21: ...imple accessory that greatly improves the operation of the machine with fan fold tabs Boxes are placed on the stand one on each side The boxes are tilted at the correct angle to allow for smooth tab removal from the box Tab columns are spliced lead to tail to run continuously See Fig 1 1 5 2 2 FD 280 30 Stand The FD 280 30 Adjustable Height Stand holds the FD 280 and a Fan Fold Tab Stand It featur...

Page 22: ... 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 One per head is needed ...

Page 23: ...abs being run is less than the tab width specification To splice tabs 1 Stop tabbing with at least 12 inches of tab material between the peel bar and the end of the strip 2 Trim the last tab so that the end of the strip is square 3 Trim the end of the new tab strip square and attach a tab to the underside of the strip so that it is half on half off the strip 4 Remove the first few tabs from the ne...

Page 24: ...de of the box to the other removing stack separators as stacks are consumed 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 Threading tabs is a more involved process The tab peeling mechanism must be removed and replaced Before threading tak...

Page 25: ...teel knob 5 Run the backing paper up and over the black rubber roll from behind the roller To allow space between the black roller and the red rollers press the threading release lever 6 Bring the backing paper up over the front of the red roller taking the slack out of the strip and squaring it under the various rollers in the paper path Take care that the edge of the strip is not caught in the p...

Page 26: ...he vertical tab indicator plates on the exit side of the tab heads Run the transport and rotate the Head Position control to bring the heads close to within a sixteenth of an inch to both edges of the piece Some pieces are not folded square Use the widest part of the piece to set the distance between the heads 5 Stop the transport and slide a feeder up into position Start the transport and send sa...

Page 27: ...uide and the operator side head set to apply either 1 or 2 tabs to the piece 1 Press the Stop Button and select SET UP on the Tab Size Switch Tab Ready Light will be off 2 Set the feeder to the width of the narrow piece to be run 3 Set the Input Guides about 1 inch wider than their narrowest setting 4 Adjust the space between the heads to about 1 inch This will put the Operator side head wider tha...

Page 28: ...es Thin material may require a single bar to be offset thick material may require both to be offset Run the material under one of the set of rollers only See Figure 6 5 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...

Page 29: ... 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 TIP When finishing a tabbing job leave tabs threaded in the machine and press the Stop Button before turning off the Power 6 6 Adjusting Tab Position 1 Press the STOP button 2 Determine which tab or pair...

Page 30: ...ng paper leaving enough to reach and wrap around the TAKE UP SPINDLE 2 Pull the waste backing paper off the TAKE UP SPINDLE 3 Place backing paper under the TAKE UP SPINDLE from the input end 4 Secure the backing paper to the underside of the 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 ...

Page 31: ...to achieve smooth operation 5 Press Stop and switch to the tab size and location 6 Lift Stop and feed three pieces The TAB READY light will come if the three pieces have fed regularly and have been measured correctly by the machine 7 0 MAINTENANCE 7 1 General Cleaning 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 gener...

Page 32: ...ve the tabs from the roller using a roller cleaning solvent 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 WARNING UNPLUG THE POWER CORD BEFORE OPENING THE FUSE DRAWER 7 2 1 To replace a LINE FUSE 1 Use a small screwdriver or similar tool to push up...

Page 33: ...ted 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 REFER TO CHART BELOW Selected Voltage Line Fuse Value 100V 1 0A 250V time delay 120V 1 0A 250V time delay 220V 0 5A 250V time delay 240V or 230V 0 5A 250V time delay ...

Page 34: ...Refer to Figure 7 1 2 Inspect the FUSE look for blackened glass melted wire or a disconnected wire between the ends of the tube If you find any of these problems in the FUSE it is blown and must be replaced If the first FUSE is fine repeat steps 1 and 2 for the second FUSE 3 Pull the blown FUSE from its slot WARNING REPLACE ONLY WITH SAME TYPE AND RATING OF FUSE REFER TO CHART BELOW Selected Volta...

Page 35: ...ADY light is on but no tabs at peel point Tabs not threaded correctly Tab motor failure Microprocessor Failure Out of tabs or tab sensor blocked Check and re thread Toggle Power Off and on waiting 5 10 seconds to reset processor Remove tabs from the sensor if present and re thread 3 Not Tabbing Tab Ready Light is OFF Transport Failure Tab Mode Switch Inconsistent tab length counts due to slippage ...

Page 36: ...thout resetting tab placement locations Insert and latch peel plate assembly Thoroughly clean tab fold and seal rollers and belts Remove all tab debris Move lead tab closer to lead edge Reset tab placements see sec 6 9 8 Multiple tabs on mail piece Incorrect TAB MODE selection Make Mode selection for tabs and forms being run Section 9 1 2 9 Tab placement is inconsistent Mail pieces are feeding cro...

Page 37: ...il pieces are too thin Spread the heads apart slightly If tenting is too great move heads closer together slightly 12 Mail pieces jam upon entering FD 280 Input Guides are too close together Spread guides Input device and tabber are misaligned Correct alignment is critical Carefully position the input device for correct feeding and transport Feeding device is too fast Reduce speed of feeding devic...

Page 38: ...ns 9 1 2 Mail Piece Jam Mail pieces usually jam during set up The cause of a set up jam is usually obvious Any of the piece width adjustments is not made correctly Carefully set up the machine and check the width of the heads and input guides Make sure that the feed device is lined up correctly and precisely before feeding pieces A feeder must deliver the piece as square and as straight as possibl...

Page 39: ...se spring pressure and slide the entire roll assembly out of the machine by compressing the spring on the shaft and lifting the shaft out once one end is free from its mounting hole Note one mounting hole is shaped like s D to prevent the shaft from turning Make sure to replace the shaft as you have removed it WARNING DO NOT PLACE FINGERS OR TOOLS BETWEEN OR NEAR MOVING PARTS 9 1 3 Torn Backing Pa...

Page 40: ...To continue tabbing accurately WARNING DO NOT PLACE FINGERS OR TOOLS BETWEEN OR NEAR MOVING PARTS 1 Turn the POWER SWITCH off 2 Secure the backing paper around the TAKE UP SPINDLE with the CLIP You may need to pull the backing paper a little to reach the TAKE UP SPINDLE 9 2 Incorrect Threading Threading a tab strip incorrectly can prevent tabbing Three examples are listed below See Sec 6 1 PEEL PL...

Page 41: ...ays between the paper guides they will not feed straight To check your tab placement 1 Hold a stack of tabbed mail pieces Make sure all edges are straight and even and all tabs are on the same side 2 Look at the tabbed side of the stack If the tabs do not form a straight line down the stack the mail pieces are moving sideways as they enter the FD 280 3 Set paper guides correctly and securely on th...

Page 42: ...d differently than foil tabs Colored tabs may fold differently than white tabs because ink adds moisture and density Genuine Formax tabs are tested with machines and will work in the most consistent manner 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 posi...

Page 43: ... with this equipment or if you need assistance installing or operating your FD 280 contact an authorized 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...

Page 44: ...erial 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 This will provide firm cushioning and prevent movement inside the container 4 Seal the top and bottom of the shipping container with strong tape or banding material 5 Clearly and legibly mark the shipping container FRAGILE...

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