FD 150
Document Signer
OPERATOR MANUAL
FIRST EDITION
Thank you for purchasing the
Formax FD 150 Document Signer
The FD 150 has been tested and found to comply with the limits for a Class A
digital device pursuant to Part 15 of FCC Rules. These limits are designed to
provide reasonable protection against harmful interference when this equipment
is operated in a commercial environment. This equipment generates, uses, and
can radiate radio frequency energy and, if not installed and used in accordance
with this manual, may cause harmful interference in which case the user will be
required to correct the interference at his/her own expense.
The FD 150 is UL listed.
1/97 02-092501
Operating Manual
TABLE OF CONTENTS
1. INTRODUCTION ................................................................................................
1.1 FD 150 DESCRIPTION .......................................................................................1
1.2 ITEMS INCLUDED................................................................................................1
1.3 OPERATING MANUAL SAFETY TERMS ..................................................................2
1.4 SAFETY PRECAUTIONS....................................................................................... 3
1.5 FREQUENTLY-USED TERMS................................................................................ 3
1.6 LOG BOOK ........................................................................................................4
1.7 SERVICE ........................................................................................................... 4
EPACKING INSTRUCTIONS ................................................................................ 5
1.8 R
2. SPECIFICATIONS............................................................................................ 6
2.1 S
PECIFICATIONS................................................................................................6
PERATING REQUIREMENTS...............................................................................6
2.2 O
3. ASSEMBLY......................................................................................................7
3.1 K
EY POSITIONS .................................................................................................7
3.2 INK ROLL INSTALLATION .....................................................................................8
3.3 RECEIVING TRAY, TEMPORARY INSTALLATION...................................................... 9
3.4 RECEIVING TRAY, PERMANENT INSTALLATION.................................................... 10
3.5 OPTIONAL FEED TRAY EXTENSION .................................................................... 11
4. POWER CONNECTION ................................................................................. 12
4.1 SAFETY .......................................................................................................... 12
4.2 LINE VOLTAGE ................................................................................................ 13
4.3 LINE FUSES .................................................................................................... 14
4.4 POWER CORD .................................................................................................15
5. CONTROLS & INDICATORS......................................................................... 16
OUNTER, NON-RESETTABLE .......................................................................... 16
5.1 C
5.2 COUNTER, RESETTABLE .................................................................................. 17
5.3 EXECUTIVE KEY .............................................................................................. 17
5.3.1 Unlocked ...........................................................................................................................17
5.3.2 Locked...............................................................................................................................17
5.4 FEED ADJUST KNOB ........................................................................................17
MPRINT INDICATOR ......................................................................................... 18
5.5 I
5.6 IMPRINT KEY ...................................................................................................18
5.7 INK ADJUSTMENT KNOB ................................................................................... 18
5.8 I
MPRINT POSITIONING ......................................................................................19
5.8.1 Light ON / OFF..................................................................................................................19
5.8.2 UP / DOWN .......................................................................................................................20
5.9 MEDIA FEED ................................................................................................... 20
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Operating Manual
5.10 MEMORY IMPRINT POSITIONS .........................................................................21
5.10.1 Positions 1 - 4 .................................................................................................................21
5.10.2 Store Position..................................................................................................................21
5.11 PAPER WEIGHT .............................................................................................21
5.12 POWER SWITCH ............................................................................................22
5.13 READY INDICATOR .........................................................................................22
5.14 SEPARATORS ................................................................................................22
6. OPERATION...................................................................................................23
6.1 LOADING SADDLES ..........................................................................................23
6.2 LOADING DOCUMENTS .....................................................................................25
6.3 FEEDING DOCUMENTS .....................................................................................27
6.4 SETTING IMPRINT POSITION UP / DOWN.......................................................... 28
6.4.1 Imprint Position Example ..................................................................................................30
6.5 STORING AN IMPRINT POSITION........................................................................ 31
6.5.1 Sample Stored Imprint Positions.......................................................................................31
6.6 SETTING IMPRINT POSITION LEFT / RIGHT ......................................................32
6.7 IMPRINTING DOCUMENTS ................................................................................. 34
6.8 FEEDING VARIOUS SIZED DOCUMENTS.............................................................. 35
7. MAINTENANCE .............................................................................................36
7.1 PRESSURE TIRE SHAFT REMOVAL & INSTALLATION ............................................36
7.2 CLEANING....................................................................................................... 37
7.3 REPLACING A FUSE......................................................................................... 38
8. TROUBLESHOOTING ...................................................................................40
8.1 IMPROPER IMPRINTING ..................................................................................... 40
8.1.1 Double Feeding.................................................................................................................40
8.1.2 Executive Key Turned Too Quickly...................................................................................40
8.1.3 Imprint Is Too Light ...........................................................................................................41
8.1.4 Document Jam ..................................................................................................................42
8.2 TROUBLESHOOTING CHART .............................................................................. 42
ii 1/97
1. INTRODUCTION
1.1 FD150
Description
Operating Manual
This manual shows you how to use the FD 150. It presents
information about the FD 150’s specifications, physical
features and operation.
The FD 150 is a document imprinter used for signing,
endorsing and validating cut-sheet documents. Documents
to be imprinted are stacked in the feed tray. Two paper
guides hold the stack in position as the documents are fed
through the FD 150.
The stack is separated into single pieces by separators and
rolls which feed each document into the FD 150. A
photosensor (an electric eye) in the base of the FD 150,
senses the document and transmits this information to the
microprocessor which controls the FD 150. The microprocessor directs a motor to rotate the saddle holder and
imprint the document at the position set on the imprint
position control. The imprinted documents then exit the FD
150 and stack on the receiving tray.
1.2 Items Included
The following items are shipped together in one box. Take
note of each as you unpack the box.
• FD 150
• receiving tray
• accessories carton
• FD 150 Operating Manual
• cloth bag (2 tray screws, 2 sets of keys and 2 knobs)
• feed tray extension
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Operating Manual
1.3 Operating
Manual
Safety Terms
The accessories carton includes the following items:
• ink roll (with rubber gloves)
• power cord
• document stops (wrapped in foam)
• log book
• allen wrench
• warranty cards
The following highlighted blocks are used throughout this
manual to emphasize important information. Pay very
careful attention to this information.
WARNING
USED TO ALERT YOU TO ACTIONS OR
CONDITIONS WHICH MAY PRESENT HAZARDS
OR CAUSE INJURY TO PERSONNEL.
CAUTION
USED TO ALERT YOU TO ACTIONS WHICH MAY
DAMAGE DOCUMENTS OR EQUIPMENT.
NOTE
Used to identify unusual or unexpected
conditions or to point out the need for alternate
procedures. A NOTE may also be used for
emphasis when a WARNING or CAUTION are not
required.
2 1/97
1.4 Safety
Precautions
Operating Manual
Please observe the following safety precautions and
warnings at all times while operating, cleaning or repairing
the FD 150. Failure to so may result in physical injury or
damage to the FD 150. Neither Formax nor the
manufacturer assumes any liability for your failure to
comply with these requirements.
WARNING
NEVER CLEAN, CLEAR OR DISASSEMBLE THE
FD 150 WITHOUT FIRST UNPLUGGING THE
POWER CORD.
WARNING
KEEP LOOSE CLOTHING, TIES, SCARVES AND
HAIR AWAY FROM ALL MOVING PARTS.
1.5 FrequentlyUsed Terms
WARNING
DO NOT PLACE FINGERS BETWEEN OR NEAR
MOVING PARTS.
leading edge The edge of the document that
enters and exits the FD 150 first.
trailing edge The edge of the document that
enters and exits the FD 150 last.
imprint position The point at which the document
is imprinted.
imprint saddle Contains a plastic relief of the
imprint; 2 imprint saddles are in
the rounded imprint saddle
holder - as one is imprinting, the
other is being inked.
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Operating Manual
1.6 Log Book
operator side The side of the FD 150 where
most of the controls are located.
input end The end of the FD 150 where the
document enters the FD 150.
output end The end of the FD 150 where the
document exits the FD 150.
When used properly, the Log Book provides a written
record of the number of documents imprinted. Keep the
Log Book with the FD 150 whenever the machine is
operating. Before imprinting new documents, record the
number of imprints displayed on the non-resettable counter.
After imprinting, record the new number displayed on the
non-resettable counter.
1.7 Service
If any problems occur with the FD 150 or if you need
assistance installing or operating your FD 150, contact your
Formax dealer.
4 1/97
1.8 Repacking
Instructions
Operating Manual
If it is necessary to return the FD 150 to your Formax
dealer, pack it in the original shipping container and
material. If the original container is not available, the FD
150 and its accessories should be carefully packed so that
they will not be damaged in transit.
NOTE
The Shipping Carrier is liable for any damages
that may occur during shipping.
Use the following instructions to pack the FD 150 with
commercially available materials.
1. Double wrap the machine in plastic.
2. Use a heavy duty, double-walled container of 350pound test material.
3. Surround the FD 150 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.
4. Seal the top and bottom of the shipping container with
strong tape or banding.
5. Clearly and legibly mark the shipping container
FRAGILE.
6. Ship the FD 150 prepaid and insured.
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Operating Manual
2. SPECIFICATIONS
This section contains specifications of the FD 150.
2.1 Specifications
Size
Weight
Power
Speed
19½" (49.53 cm) W x 10" (25.43 cm) H x
19" (48.26 cm) D
The receiving tray is not measured.
Machine alone: 50 pounds (22.68 kg )
Shipping weight: 57 pounds (25.85 kg)
Possible line voltages are 240V, 220V, 120V
and 100V at 50-60 Hz
19" (45.72 cm) per second
2.2 Operating
Requirements
Document Size
Maximum length: 14" (35.56 cm)
Minimum length: 31/8" (10.92 cm)
Maximum width: 14" (35.56 cm)
7
Minimum width: 2
/8" (7.3 cm)
Weight: 20# - 125# stock
Range of Imprint Placement
Approximately 9" (22.86 cm) from the leading edge
toward the trailing edge.
Approximately 6½" (16.51 cm) left or right from the
center of the document.
Range of Accuracy
1
±
/8"
6 1/97
3. ASSEMBLY
3.1 Key Positions
Operating Manual
This section shows you how to assemble the FD 150.
WARNING
DO NOT PLUG THE FD 150 POWER CORD INTO
AN ELECTRICAL OUTLET UNTIL ASSEMBLY IS
COMPLETE AND YOU HAVE READ SECTION 4,
POWER CONNECTION.
Use the following instructions to open the FD 150 COVER.
(Refer to Figure 3.1.)
Figure 3.1 -- Key Positions
1. Unlock the COVER by turning the brass EXECUTIVE
KEY to the UNLOCKED position.
2. Open the COVER.
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Operating Manual
3.2 Ink Roll
Installation
Use the following instructions to install the INK ROLL.
(Refer to Figure 3.2.)
Figure 3.2 -- Ink Roll Installation
NOTE
The FD 150 comes with one black INK ROLL.
Formax offers a tri-color INK ROLL. To order INK
ROLLS, call your Formax dealer.
NOTE
Use care when handling the ink roll. The ink is
indelible and will not wash out of clothing.
1. Turn the EXECUTIVE KEY to the UNLOCKED
position and open the COVER.
2. Pull out the COTTER PIN.
3. Pull out the AXLE.
4. Put on the gloves shipped with the INK ROLL.
8 1/97
3.3 Receiving Tray,
Temporary
Installation
Operating Manual
5. Hold the INK ROLL between the sides of the INK
ROLL CARRIAGE.
6. Insert the AXLE, pointed end first, through the holes in
the INK ROLL CARRIAGE and the INK ROLL.
7. Insert the straight side of the COTTER PIN into the
hole in the pointed end of the AXLE.
8. Push the COTTER PIN until the AXLE is secured
between the two loops on the COTTER PIN.
9. Close the COVER.
Use the following instructions to temporarily install the
receiving tray. (Refer to Figure 3.3.)
Figure 3.3 -- FD 150 Receiving Tray Installation
1. Place the FD 150 on a table or work surface about 2"
from the straight edge.
2. Slide the NOTCHES in the tray up under the
MOUNTING STUDS on the output end of the FD 150.
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Operating Manual
3.4 Receiving Tray,
Permanent
Installation
3. Re-position the FD 150 so the L-shaped cutout on each
side of the RECEIVING TRAY fits the straight edge of
the table or work surface. The RECEIVING TRAY will
hang off the edge of the table or work surface.
1
1. Remove the MOUNTING STUDS with a
/8" allen
wrench.
2. Place the FD 150 on a table or work surface about 2"
from the straight edge.
3. Place the NOTCHES in the RECEIVING TRAY
against the machine so they surround the holes left after
the MOUNTING STUDS were removed.
4. Re-position the FD 150 so the L-shaped cutout on each
side of the RECEIVING TRAY fits the straight edge of
the table or work surface. The RECEIVING TRAY will
hang off the edge of the table or work surface.
5. Screw the screws (included in the cloth bag) tightly into
these holes.
6. Place the two straight DOCUMENT STOPS in-line
with the PAPER GUIDES. (Refer to Figure 3.4.)
7. Position the curved DOCUMENT STOP so it stops and
stacks exiting documents.
8. To extend the RECEIVING TRAY, pull the tray to the
desired position or length.
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Operating Manual
3.5 Optional Feed
Tray Extension
Figure 3.4 -- Paper Path & Document Stops
The FEED TRAY EXTENSION which comes with the
FD 150 is used to help feed documents longer than 9”.
Keep it in a place you’ll remember, as you may need it in
the future. Refer to Section 6.2 for installation details.
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Operating Manual
4. POWER CONNECTION
This section shows you how to connect power to the
FD 150.
BEFORE PLUGGING THE FD 150 INTO AN
ELECTRICAL OUTLET, CAREFULLY READ THE
FOLLOWING INFORMATION ABOUT VOLTAGES,
FUSES AND THE POWER CORD.
4.1 Safety
The FD 150 can connect to any power distribution system,
including the European IT Power System. Because the
European IT Power System does not have a grounded
neutral leg, the FD 150 uses protective fusing in both the
neutral and hot supply lines of power. Both LINE FUSES
must be in place for the FD 150 to operate properly.
WARNING
WARNING
A BLOWN FUSE IN THE NEUTRAL LEG COULD
MEAN INTERIOR PARTS OF THE FD 150 REMAIN
AT A HAZARDOUS VOLTAGE. ALWAYS UNPLUG
THE POWER CORD BEFORE SERVICING THE
FD 150.
12 1/97
4.2 Line Voltage
Operating Manual
The FD 150 is rated for continuous operation using a
variety of supply voltages. Possible line voltages are 240V,
220V, 120V and 100V at 50 to 60 Hz. The manufacturer
configures the FD 150 to operate with the voltage requested
by the customer.
CAUTION
VERIFY THE CORRECT VOLTAGE SETTING
BEFORE PLUGGING THE FD 150 INTO AN
OUTLET.
Read the selected voltage through the VOLTAGE
SELECTOR WINDOW at the input end of the FD 150.
(Refer to Figure 4.1.) To select a different voltage, use the
following instructions:
NOTE
The detachable POWER CORD may have to be
changed to match the particular power-source
output.
1. Unplug the POWER CORD.
2. Use a small 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.
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.
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Operating Manual
Figure 4.1 -- FD 150 Power Connection
4.3 Line Fuses
The FUSE DRAWER, located on the input end, contains
two LINE FUSES. (Refer to Figure 4.1.) The neutral and
hot lines of power are fused. Both LINE FUSES must be in
place for the FD 150 to operate properly.
CAUTION
VERIFY THAT THE LINE FUSE VALUE IS
CORRECT FOR THE VOLTAGE SETTING.
UNPLUG THE FD 150 BEFORE STARTING THIS
PROCEDURE.
Use the following instructions to verify that the installed
LINE FUSES have the proper fuse value:
1. Unplug the POWER CORD.
2. Use a small 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 attached LINE FUSES are inside.
14 1/97
Operating Manual
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 right column.
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)
5. Replace the LINE FUSE if necessary. Both LINE
FUSES must be in place for the FD 150 to operate
properly.
6. Install the FUSE DRAWER in the POWER ENTRY
CASING.
4.4 Power Cord
The FD 150 comes with a three-wire POWER CORD. The
POWER CORD grounds the FD 150 when connected to an
approved three-contact electrical outlet.
1. Plug the POWER CORD into the APPLIANCE INLET
on the non-operator side. (Refer to Figure 4.1.)
2. Plug the POWER CORD into a grounded outlet.
WARNING
TO PREVENT ELECTRICAL SHOCK, ONLY PLUG
THE POWER CORD INTO A GROUNDED OUTLET.
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Operating Manual
5. CONTROLS & INDICATORS
This section lists the FD 150 controls and indicators in
alphabetical order. Refer to Figure 5.1 throughout this
section.
5.1 Counter,
Non-Resettable
Figure 5.1 -- FD 150 Controls
The NON-RESETTABLE COUNTER counts and displays
the total number of imprinted documents for the life of the
FD 150.
NOTE
The red button on the NON-RESETTABLE
COUNTER has been permanently disabled.
16 1/97
5.2 Counter,
Resettable
5.3 Executive Key
5.3.1 UNLOCKED
5.3.2 LOCKED
Operating Manual
The RESETTABLE COUNTER counts and displays the
total number of imprinted documents for each run. Reset
this counter at the beginning of each run by pressing the
red button.
Two brass EXECUTIVE KEYS come with the FD 150. The
EXECUTIVE KEY can be set in two positions: LOCKED
and UNLOCKED.
Turning the EXECUTIVE KEY to the UNLOCKED
position allows you to open the COVER (which disables
imprinting) and access the IMPRINT SADDLES.
5.4 Feed Adjust
Knob
Turning the EXECUTIVE KEY to the LOCKED position:
• locks the COVER which enables imprinting
• indexes the SADDLE HOLDER which inks the
IMPRINT SADDLE
• allows you to activate the IMPRINT KEY and imprint a
document.
NOTE
Turn the EXECUTIVE KEY slowly. If the SADDLE
HOLDER does not index, turn the key slower.
The FEED ADJUST KNOB, located behind the PAPER
WEIGHT, secures the SEPARATOR. Loosen the FEED
ADJUST KNOB to raise or lower the SEPARATOR in
order to adjust the size of the gap between the
1/97 17
Operating Manual
5.5 Imprint
Indicator
5.6 Imprint Key
SEPARATOR and FEED ROLL. This gap must be
adjusted to allow only one document to feed at a time.
Once the SEPARATOR is in the correct position, tighten
the FEED ADJUST KNOB.
The IMPRINT INDICATOR is a red light that turns on
while a document is being imprinted, then turns off until
the next document is imprinted. When the IMPRINT
INDICATOR turns ON, the NON-RESETTABLE and
RESETTABLE COUNTERS both increment.
Two silver IMPRINT KEYS are shipped with the FD 150.
The IMPRINT KEY has two positions: ON and OFF.
(Refer to Figure 5.2.)
Turn the IMPRINT KEY to the ON position to start
imprinting prior to feeding documents. Turn the IMPRINT
KEY to the OFF position to stop imprinting.
5.7 Ink Adjustment
Knob
Turn the INK ADJUSTMENT KNOB clockwise to make
the imprint darker, counterclockwise to make the imprint
lighter.
NOTE
If you turn the INK ADJUSTMENT KNOB clockwise
as far as it allows and the imprint is still too light
or the COVER starts knocking, the INK ROLL
must be replaced. For best results, the INK ROLL
should just lightly touch the IMPRINT SADDLE.
This will also extend the life of the INK ROLL.
18 1/97
5.8 Imprint
Positioning
Operating Manual
The IMPRINT POSITIONING controls, located on the
CONTROL PANEL include: LIGHT, ↑UP and ↓DOWN.
To activate one of these functions, press to the lower left of
the LED. Use these controls to set imprint positions. (Refer
to Figure 5.2.)
Figure 5.2 -- Control Panel
5.8.1 LIGHT ON / OFF
Toggle the IMPRINT POSITIONING LIGHT ON and
OFF by pressing on the CONTROL PANEL to the lower
left of the IMPRINT POSITIONING LED (directly on
1
/16"). When the light is ON, the imprint position moves 1"
each time ↑UP or ↓DOWN arrow is pressed. When the
light is OFF, the imprint position moves 1/16" each time
↑UP or ↓DOWN arrow is pressed.
NOTE
Do not feed documents while adjusting the
imprint position.
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Operating Manual
5.8.2 ↑UP / ↓DOWN
Press ↑UP to move the imprint position toward the trailing
edge of the document.
Press ↓DOWN to move the imprint position toward the
leading edge of the document.
The ↑UP and ↓DOWN lights illuminate with each
selection. This means that the imprint position moved the
selected amount.
NOTE
In order to adjust the imprint position higher
or lower, you must use the LIGHT ON / OFF
together with the ↑UP / ↓DOWN controls.
5.9 Media Feed
To start feeding documents, press the MEDIA FEED
button so its light turns ON. This light illuminates while
documents are being fed.
NOTE
The EXECUTIVE KEY must be in the LOCKED
position in order to activate the MEDIA FEED
button.
20 1/97
5.10 Memory Imprint
Positions
5.10.1 POSITIONS 1 - 4
5.10.2 STORE POSITION
Operating Manual
Set and store up to four imprint positions using the
MEMORY IMPRINT POSITIONS controls. (Refer to
Figure 5.2.)
Press the MEMORY IMPRINT POSITIONS 1 - 4 to recall
a stored imprint position (which is measured from the
leading edge of the document). An imprint position can be
set up to 9" (22.86 cm) from the leading edge of the
document.
Press STORE to save a selected imprint position. Up to
four imprint positions can be saved by pressing STORE
while at the same time pressing 1 of the 4 MEMORY
IMPRINT POSITIONS.
5.11 Paper Weight
The PAPER WEIGHT presses down on a stack of loaded
documents to aid feeding. If documents don’t require extra
weight for proper feeding, the PAPER WEIGHT can be
lifted up and locked out of the way.
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Operating Manual
5.12 Power Switch
5.13 Ready Indicator
5.14 Separators
The POWER SWITCH is located on the input end next
to the POWER ENTRY CASING. Turn the POWER
SWITCH ON to supply power to the FD 150.
The READY INDICATOR is a red light that turns on when
the POWER SWITCH is ON and the EXECUTIVE KEY is
in the LOCKED position. It flashes each time the
FD 150 detects a document.
SEPARATORS prevent more than one document from
feeding at a time. SEPARATORS can be lifted up and
lowered to create the perfect sized gap for documents of
different thicknesses.
22 1/97
6. OPERATION
Operating Manual
This section shows you how to operate the FD 150. Follow
the step-by-step instructions in the order they are presented.
Before operating the FD 150, please review Section 4,
Power Connection.
WARNING
KEEP LOOSE CLOTHING, TIES, SCARVES,
JEWELRY AND HAIR AWAY FROM ALL MOVING
PARTS.
WARNING
DO NOT PLACE FINGERS BETWEEN OR NEAR
MOVING PARTS.
6.1 Loading
Saddles
1. Turn the EXECUTIVE KEY to the UNLOCKED
position and open the COVER.
2. Hold down the SADDLE HOLDER LATCH. The short
tip will lift.
3. Place the notch in the IMPRINT SADDLE around the
PIN on the SADDLE HOLDER. (Refer to Figure 6.1.)
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Operating Manual
Figure 6.1 -- Loading Imprint Saddles
4. Rest the IMPRINT SADDLE on the SADDLE
HOLDER.
5. Release the SADDLE HOLDER LATCH. It will fit
into the BEVEL in the IMPRINT SADDLE.
6. Close the COVER. Turn the EXECUTIVE KEY slowly
to index the SADDLE HOLDER which inks the
IMPRINT SADDLE.
7. To load the second saddle, repeat steps 1-6.
To order SADDLES, contact your Formax dealer.
Always order SADDLES in pairs.
NOTE
Two SADDLES are always necessary for proper
imprinting.
24 1/97
6.2 Loading
Documents
Operating Manual
Use the following instructions to align and load documents
for imprinting. (Refer to Figure 6.2.)
Figure 6.2 --
Paper Path & Marks for Frequently Used Settings
√
Tip: Draw marks in-line with the PAPER GUIDES for frequently
used document sizes.
1. Press the MEDIA FEED button so its light turns OFF.
2. Lift up and lock the PAPER WEIGHT.
3. With the FD 150 turned ON, center the document in the
FEED TRAY.
4. Lift up the PAPER GUIDE CAMLOCKS and slide the
PAPER GUIDES to fit the document. The fit should
not be binding or sloppy.
5. Push down the PAPER GUIDE CAMLOCKS to lock
the PAPER GUIDES in place.
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Operating Manual
6. Align the two straight RECEIVING TRAY
MAGNETIC DOCUMENT STOPS with the PAPER
GUIDES. Center the curved RECEIVING TRAY
MAGNETIC DOCUMENT STOP so it stops and
stacks the exiting documents.
7. Loosen the FEED ADJUST KNOB and lift up the
SEPARATOR.
8. Place one document, face up in the PAPER GUIDES,
atop the FEED ROLLS.
Documents LONGER than 9”
Use the following instructions to imprint documents
longer than approximately 9" (22.86 cm):
• If necessary, install the FEED TRAY
EXTENSION by attaching it to the input end of
the FD 150 FEED TRAY with the knobs
provided.
• Feed the top of the document first.
• Install the REVERSE IMPRINT SADDLES.
Refer to Section 6.1 and follow the instructions
given for IMPRINT SADDLES. Call your
Formax dealer to order these saddles.
9. Lower the SEPARATOR against the document and
tighten the FEED ADJUST KNOB.
10. Now place a stack of documents up to 1½" high, face
up in the PAPER GUIDES.
11. Lower the PAPER WEIGHT to rest on the stack.
26 1/97
6.3 Feeding
Documents
Operating Manual
Use the following instructions to feed documents through
the FD 150. (Refer to Figure 6.3.)
NOTE
Smooth feeding is necessary for accurate
imprinting.
Figure 6.3 -- FD 150 Components
1. Turn the POWER SWITCH ON.
2. Turn the IMPRINT KEY OFF.
3. Press the MEDIA FEED button so its light turns ON
and watch that documents feed straight and regularly.
1/97 27
Operating Manual
NOTE
In order to imprint and count properly, documents
must feed through the FD 150 accurately. If your
FD 150 does not feed documents straight and with
a steady rhythm, call your Formax dealer for
service. FD 150 feeding components wear with use
and need periodic replacement.
If multiple documents feed through the FD 150, re-adjust
the gap between the SEPARATOR and the FEED ROLL
by applying slight downward pressure to the SEPARATOR
while tightening the FEED ADJUST KNOB.
If the FD 150 feeds with difficulty, re-adjust the gap
between the SEPARATOR and the FEED ROLL by
tightening the SEPARATOR using the thickness of two
documents instead of one. If feeding does not improve,
refer back to section 6.2, Loading Documents.
6.4 Setting
Imprint Position
UP / DOWN
Use the following instructions to change the imprint
position toward or away from the leading edge of the
document. (Refer to Figure 6.3.)
NOTE
Always imprint several void or test documents
until the imprint position is exactly where you
want it.
1. Turn POWER SWITCH ON.
2. Turn the EXECUTIVE KEY to the LOCKED position
and the IMPRINT KEY ON. (Refer to Figure 6.1.)
NOTE
Turn the EXECUTIVE KEY slowly. If the SADDLE
HOLDER does not index, turn the key slower.
28 1/97
Operating Manual
3. Press the MEDIA FEED button so its light turns ON.
4. Feed one test document to determine the imprint
position.
5. If the imprint position is not in the desired position,
re-adjust it using the IMPRINT POSITIONING
controls.
6. Toggle the IMPRINT POSITIONING LIGHT ON to
move the imprint position approximately 1 inch or
toggle the IMPRINT POSITIONING LIGHT OFF to
move the imprint position approximately 1/16 inch.
7. Press IMPRINT POSITIONING ↑UP to move the
imprinting position toward the trailing edge of the
document. The amount the imprint position moves is
determined by the IMPRINT POSITIONING LIGHT
selection.
8. Press ↓DOWN to move the imprinting position toward
the leading edge of the document. The amount the
imprint position moves is determined by the IMPRINT
POSITIONING LIGHT selection.
NOTE
Match the IMPRINT POSITION setting to the length
of the document. A high setting may position the
imprint beyond the trailing edge of a short
document. This results in a non-imprinted
document. If this occurs, the counter will not
count that document.
1/97 29
Operating Manual
6.4.1 Imprint Position
Example
Use this example as a guide to understanding the functions
of the IMPRINT POSITIONING controls.
1. Feed a test document through the FD 150 to determine
where the current imprint position is.
2. Measure the distance from the current imprint position
to the desired imprint position. Ex. The distance from
the current imprint position to the desired imprint
position equals 23/16" inches.
3. Toggle the IMPRINT POSITIONING LIGHT ON.
4. Press the ↑UP LED twice to move the imprint
approximately 2 inches from its current position.
5. Toggle the IMPRINT POSITIONING LIGHT OFF.
6. Press the ↑UP LED three times to move the imprint an
additional 3/16 of an inch (i.e., three 1/16" increments).
7. Press the MEDIA FEED button so its light turns on.
8. Feed a test document through the FD 150 to verify and
fine tune the imprint position.
30 1/97
6.5 Storing An
Imprint Position
6.5.1 Sample Stored
Imprint Positions
Operating Manual
Use the following procedure to STORE an imprint
position.
1. Using the IMPRINT POSITIONING controls, set the
imprint to the desired position.
2. Select a MEMORY IMPRINT POSITION (1-4) in
which to store the current imprint position.
3. Press and hold STORE (LED on) while pressing the
desired MEMORY IMPRINT POSITION (1-4) LED.
NOTE
The STORE and MEMORY IMPRINT POSITION
LEDs must be illuminated in order for the position
to be saved.
The MEMORY IMPRINT POSITIONS can be used
commonly used jobs. Ex:
MEMORY IMPRINT POSITION 1 Payroll
MEMORY IMPRINT POSITION 2 Accounts Payable
MEMORY IMPRINT POSITION 3 Endorsing
MEMORY IMPRINT POSITION 4 Form Letter
1/97 31
Operating Manual
6.6 Setting
Imprint Position
LEFT / RIGHT
Use the following instructions to move the imprint position
left and right on the document. (Refer to Figure 6.4.)
Figure 6.4 -- Setting Imprint Position Left / Right
1. Turn the POWER SWITCH OFF.
2. Turn the EXECUTIVE KEY to the UNLOCKED
position and open the COVER.
3. Locate the SADDLE HOLDER SCREW midway
between the two IMPRINT SADDLES. (Refer to
Figure 6.4.)
4. If you cannot see the SADDLE HOLDER, turn the
POWER SWITCH ON. Close the COVER and slowly
turn the EXECUTIVE KEY to the LOCKED position
indexing the SADDLE HOLDER.
5. Open the COVER.
32 1/97
Operating Manual
NOTE
When using ENDORSING SADDLES, remove the
saddle to find the SADDLE HOLDER SCREW.
6. Using the supplied allen wrench, loosen the SADDLE
HOLDER SCREW.
NOTE
Only loosen this screw 1-2 turns, or until the
SADDLE HOLDER will slide. The SADDLE
HOLDER SCREW must stay in the IMPRINT
SHAFT GROOVE.
7. Slide the SADDLE HOLDER to the desired position.
8. Tighten the SADDLE HOLDER SCREW.
9. Slide the INK ROLL CARRIAGE to align it with the
SADDLE HOLDER.
NOTE
Use care when handling the INK ROLL. The ink is
indelible and will not wash out of clothing.
10. Close the COVER.
1/97 33
Operating Manual
6.7 Imprinting
Documents
Use the following instructions to imprint documents.
1. Turn POWER SWITCH ON.
2. Turn the EXECUTIVE KEY slowly to the LOCKED
position. (Refer to Figure 6.1.)
NOTE
If the SADDLE HOLDER does not index, turn the
key slower.
3. Check the FEED TRAY to be sure that documents are
loaded properly. Refer to Section 6.2.
4. Check the RECEIVING TRAY to be sure that
MAGNETIC PAPER GUIDES are set properly. Refer
to Section 6.2
5. Press the MEDIA FEED button so its light turns ON.
6. If documents feed straight and regularly, press the
MEDIA FEED button OFF and turn the IMPRINT
KEY to ON.
7. Press the MEDIA FEED button quickly ON and OFF
to feed a single test document.
8. Adjust the imprint position if necessary. Refer to
Sections 6.4 and 6.6.
9. Make Log Book entries and re-set counter.
10. Press the MEDIA FEED button and imprint the rest of
the documents.
NOTE
If you encounter a problem, (i.e. - jammed
documents, wrong imprint position, erratic
feeding, etc.) STOP feeding immediately by
pressing the MEDIA FEED button so its light turns
OFF.
34 1/97
6.8 Feeding
Various Sized
Documents
Operating Manual
Use the following procedures to imprint various sized
documents at one time.
1. Place the documents between the PAPER GUIDES.
Justify the documents to the right with the leading edge
as shown in Figure 6.5.
Figure 6.5 -- Right Justified Documents
1/97 35
Operating Manual
7. MAINTENANCE
7.1 Pressure Tire
Shaft Removal &
Installation
Clean and inspect your FD 150 regularly.
WARNING
ALWAYS UNPLUG THE POWER CORD BEFORE
CLEANING OR SERVICING THE FD 150.
In case of jams or when cleaning, you’ll need the following
instructions to remove and install the PRESSURE TIRE
SHAFT. (Refer to Figure 7.1.)
Figure 7.1 -- Pressure Tire Shaft Assembly
36 1/97
7.2 Cleaning
Operating Manual
1. Turn the EXECUTIVE KEY to the UNLOCKED
position and open the COVER.
2. Grasp the pressure tires and push the spring-loaded end
of the PRESSURE TIRE SHAFT into the hole opposite
the operator’s side.
3. Pull the d-hole end of the shaft up and out of the
FD 150, removing the shaft.
4. To install, push the spring-loaded end of the
PRESSURE TIRE SHAFT into its hole.
5. Mate the other end of the PRESSURE TIRE SHAFT
into the d-hole on the operator’s side and release.
6. Close the COVER.
Use the following instructions to clean the exterior and
paper path of the FD 150. Refer to Figure 7.2 throughout
this procedure.
Figure 7.2 -- Under Cover View of the FD 150 with the
Tire Pressure Shaft Removed
1/97 37
Operating Manual
1. Clean the FD 150 exterior surfaces periodically with a
mild soap cleaner and a cloth. This will help maintain
the appearance and operation of the machine.
NOTE
If you cannot remove ink from the FD 150 with a
mild soap cleaner, use lemon extract.
√
Tip: Clean ink off your hands with rubbing alcohol or pumice soap.
2. Using compressed air, blow away any dust or debris
from the outside of the FD 150.
3. Open the COVER.
4. Using compressed air, blow away any dust or debris
from the inside of the FD 150. Aim at the photosensors.
NOTE
Do not hold the compressed air can close enough
to the PHOTOSENSORS to freeze them.
5. Clean the FEED ROLL, TRANSPORT ROLLS,
BUMPER WHEEL (which is on the FEED TRAY),
SADDLE HOLDER, IMPRINT SADDLES and the
BACKUP PLATEN with isopropyl alcohol and a cloth.
7.3 Replacing A
Fuse
NOTE
Clean the PRESSURE TIRES with a dry cloth or
dry coarse brush ONLY. Do not clean these rolls
with alcohol or any other liquid cleaner.
6. Close the COVER.
When one or both FUSES are blown, the FD 150 will
appear to have no power. If the FD 150 has blown a FUSE,
replace the fuse. The FUSE DRAWER is located on the
input end of the machine. Use the following instructions to
replace one or both FUSES. (Refer to Figure 7.3.)
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Operating Manual
WARNING
A BLOWN FUSE IN THE NEUTRAL LEG COULD
MEAN THAT INTERIOR PARTS OF THE FD 150
REMAIN AT A HAZARDOUS VOLTAGE. ALWAYS
UNPLUG THE POWER CORD BEFORE SERVICING
THE FD 150.
Figure 7.3 -- Replacing A Fuse
1. Unplug the POWER CORD.
2. Use a small 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.
4. 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 needs to be replaced.
5. Pull the blown FUSE from its slot.
6. Place a new FUSE into the same slot. Both fuses must
be in place for the FD 150 to operate properly.
7. Install the FUSE DRAWER in the POWER ENTRY
CASING.
1/97 39
Operating Manual
8. TROUBLESHOOTING
This section helps you identify and correct machine and
operator errors.
8.1 Improper
Imprinting
This section lists the different circumstances that prevent or
interrupt proper imprinting and explains the solution to
each problem. Each circumstance is on the far left with an
explanation on the right.
8.1.1 Double Feeding
If the gap between the SEPARATOR and the FEED ROLL
is too large, more than one document may be fed at a time.
If there is no separation between documents, the leading
document will be imprinted but the overlapping document
will not. Re-adjust the FEED ADJUST KNOB. Refer to
Section 6.3.
8.1.2 Executive Key Turned
Too Quickly
If the SADDLE HOLDER does not index when you turn
the EXECUTIVE KEY to the LOCKED position, you
have turned the EXECUTIVE KEY too quickly. The first
few imprints may not appear in the desired position.
To index the SADDLE HOLDER, turn the EXECUTIVE
KEY to the UNLOCKED position, then slowly turn it back
to the LOCKED position.
40 1/97
8.1.3 Imprint Is Too Light
Operating Manual
Replace the INK ROLL if the imprint does not improve
after turning the INK ADJUSTMENT KNOB. The INK
ROLL also needs to be replaced if you hear the COVER
knocking. Refer to Figure 8.1 throughout this procedure.
Figure 8.1 -- Ink Roll Installation
NOTE
Before replacing the used INK ROLL, put on the
gloves provided with the new INK ROLL.
1. Open the COVER.
2. Pull out the COTTER PIN.
3. Hold the INK ROLL currently installed in the FD 150.
4. Pull out the AXLE.
5. Discard the used INK ROLL.
6. Hold the new INK ROLL between the sides of the INK
ROLL CARRIAGE.
7. Insert the AXLE, pointed end first, through the holes in
the INK ROLL CARRIAGE.
8. Insert the straight side of the COTTER PIN into the
hole in the pointed end of the AXLE.
1/97 41
Operating Manual
8.1.4 Document Jam
9. Push the COTTER PIN until the AXLE is secured
between the two CLIPS on the COTTER PIN.
If the FD 150 stops feeding, there may be one or more
documents jammed inside the machine. To clear a jam,
follow this procedure:
1. Unplug the POWER CORD.
2. Turn the EXECUTIVE KEY to the UNLOCKED
position.
3. Open the COVER.
4. Remove the PRESSURE TIRE SHAFT by pushing the
spring-loaded end of the PRESSURE TIRE SHAFT
toward the hole opposite the operator’s side. Pull the
other end toward you and out of the machine.
5. Pull any jammed documents out of the FD 150.
6. Push the spring loaded end of the PRESSURE TIRE
SHAFT into hole opposite the operator side.
8.2 Troubleshooting
Chart
7. Mate the other end of the PRESSURE TIRE SHAFT
into the d-hole on the operator’s side and release.
The following Troubleshooting Chart helps you identify
and correct malfunctions. To use the Troubleshooting
Chart:
1. Locate the malfunctions in the trouble column.
2. Read across to the cause column.
3. Follow the instructions given in the remedy column.
42 1/97
WARNING
DISCONNECT THE POWER CORD BEFORE
CLEANING, CLEARING OR REPAIRING THE
FD 150.
Troubleshooting Chart
trouble cause remedy
Operating Manual
1. Nothing works.
2. Does not feed.
POWER SWITCH is
turned OFF.
POWER CORD is
damaged
or not plugged into proper
voltage receptacle.
Receptacle does not have
power present.
Power entry FUSE is
blown.
4330S keeps blowing
FUSES.
MEDIA FEED button is
turned OFF.
Gap between the
SEPARATOR and FEED
ROLL is too small to feed
documents.
Turn POWER SWITCH
ON.
Inspect the POWER
CORD and plug into the
proper receptacle, or
replace the POWER
CORD if necessary.
Check the circuit source
for a blown FUSE or
circuit breaker, or other
problems.
Follow the procedure for
replacing a FUSE. Refer
to Section 7.2.
Contact your Formax
Dealer.
Press the MEDIA FEED
button so its light turns
ON.
Turn the FEED ADJUST
KNOB to enlarge the gap.
3. Feeds but does
not imprint.
IMPRINT KEY is not in the
ON position.
Imprint position is set
beyond trailing edge of
document.
Turn the IMPRINT KEY to
the ON position.
Select a different
MEMORY IMPRINT
POSITION or re-adjust
the imprint position.
Refer to Sections 6.4 &
6.6.
1/97 43
Operating Manual
trouble cause remedy
4. Misplaced
imprint.
5. Partial ink on
document.
6. Light imprint.
Imprint position is not set
correctly.
SADDLE HOLDER and
INK ROLL CARRIAGE are
not located correctly.
EXECUTIVE KEY was
turned too quickly to index
SADDLE HOLDER.
INK ROLL is not
positioned over the
IMPRINT SADDLE
correctly.
IMPRINT SADDLES are
not being inked.
Select a different
MEMORY IMPRINT
POSITION or re-adjust
the imprint position.
Refer to Sections 6.4 &
6.6.
Re-adjust imprint
position. Refer to
Section 6.6.
Turn the EXECUTIVE
KEY to the UNLOCKED
position, then slowly turn
it to the LOCKED
position.
Open the COVER and
align the INK ROLL
CARRIAGE directly
above the SADDLE
HOLDER.
Turn the INK
ADJUSTMENT KNOB
clockwise to darken
imprint.
INK ROLL is out of ink. Install a new INK ROLL.
To order a new INK
ROLL, call your
Formax Dealer.
IMPRINT SADDLES are
worn.
Install new IMPRINT
SADDLES. To order a
new pair, call your
Formax Dealer.
44 1/97
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