FD 260 Tabber
|
Operator Manual |
1/2011 |
First Edition |
TABLE OF CONTENTS
1. INTRODUCTION .............................................................................................. |
1 |
|
1.1 |
Organization of this Operating Manual ........................................................... |
1 |
1.2 |
FD 260 Description ......................................................................................... |
1 |
1.3 |
Items Included ................................................................................................ |
3 |
1.4 |
Operating Manual Safety Terms ..................................................................... |
4 |
1.5 |
Safety Precautions.......................................................................................... |
5 |
1.6 |
Operating Manual Terms ................................................................................ |
5 |
1.7 |
Warranty ......................................................................................................... |
6 |
1.8 |
Ordering Additional Equipment ....................................................................... |
6 |
2. SPECIFICATIONS & REQUIREMENTS .......................................................... |
7 |
|
2.1 |
Specifications.................................................................................................. |
7 |
2.2 |
Operating Requirements................................................................................. |
7 |
3. POWER CONNECTION ................................................................................... |
8 |
|
3.1 |
Safety.............................................................................................................. |
8 |
3.2 |
Line Voltage.................................................................................................... |
8 |
3.3 |
Line Fuses .................................................................................................... |
10 |
3.4 |
Accessory Fuses........................................................................................... |
11 |
3.5 |
Accessory Power Outlet................................................................................ |
12 |
3.6 |
Power Cord ................................................................................................... |
12 |
4. CONTROLS.................................................................................................... |
13 |
|
4.1 |
Power Switch ................................................................................................ |
13 |
4.2 |
LCD Counter................................................................................................. |
13 |
4.3 |
Gap Adjustment Lever .................................................................................. |
14 |
4.4 |
Tab Size Switch……………………………………...………………………...…14 |
|
4.5 |
Control Panel ................................................................................................ |
14 |
|
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...................................................................................... |
22 |
6.3 |
Tabbing Mail Pieces ..................................................................................... |
22 |
6.4 |
Removing Waste Backing Paper .................................................................. |
24 |
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 |
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7.2.2 Accessory Fuse .............................................................................................. |
27 |
8. TROUBLESHOOTING ................................................................................... |
29 |
|
8.1 |
Troubleshooting Chart .................................................................................. |
29 |
9. CORRECTING TABBING PROBLEMS ......................................................... |
32 |
|
9.1 |
No Tabs Applied To Mail Pieces................................................................... |
23 |
|
9.1.1 Sensor Could Not Detect Tab......................................................................... |
32 |
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9.1.2 Sensor Is Not Tuned For Clear Tabs .............................................................. |
33 |
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9.1.3 Mail Piece Jam ............................................................................................... |
34 |
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9.1.4 Torn Backing Paper........................................................................................ |
36 |
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9.1.5 Incorrect Threading ........................................................................................ |
37 |
9.2 |
Poor Tab Placement or Appearance…………………………...……………….38 |
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9.2.1 Tab Placement Is Inconsistent........................................................................ |
38 |
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9.2.2 Tab Fold Is Uneven ........................................................................................ |
38 |
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9.2.3 Tab Fold Is Off Mail Piece -- Tab Is Tenting ................................................... |
40 |
|
9.2.4 More Than One Clear Tab On Mail Piece....................................................... |
41 |
10. SERVICE ...................................................................................................... |
42 |
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10.1 Service........................................................................................................ |
42 |
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10.2 Repacking Instructions................................................................................ |
42 |
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1. INTRODUCTION
1.1Organization Of This Operating Manual
This manual starts with a description of your FD 260, then describes its set up, operation and maintenance. Finally, information is offered to help you determine what can go wrong and what to do about it. There are many helpful tips along the way, and it is strongly suggested that you become familiar with this entire manual prior to operating the FD 260.
1.2FD 260 Description
The FD 260 is an automatic tabbing machine used to seal open mail pieces. Tabs are peeled from rolls of backing paper and applied to mail pieces such as self-mailers, brochures, newsletters and double postcards.
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 FD 260 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 260 with mail pieces. Please read your feeding device operating manual before using it in-line with the
FD 260.
NOTE
Some feeding devices require a stand in order to operate in-line with the FD 260. Check with your FORMAX dealer.
The FD 260 uses a tabbing head to advance rolls of pressure-sensitive tabs past a peel bar. Partially peeled tabs hang from the backing paper, ready to be peeled at the peel bar before they contact the mail piece. Tabs are pressed onto mail pieces between a sweep and rolls. The tabbed mail pieces exit the FD 260 and can be collected in an optional FORMAX
1
FD 260-20 Conveyor.
Tab quality is as important as mail piece quality. Poor quality tabs and mail pieces take longer to run, jam often and produce poor results. Only genuine FORMAX brand tabs are 100% guaranteed to run on FORMAX Tabbers, and are the only tabs that say FORMAX on the box. Imitation tabs can be run on FORMAX Tabbers, but are not guaranteed to run problem-free.
The FD 260 depends on a smooth flow of both tabs and mail pieces. This flow is monitored by a set of sensors and a microprocessor. As with most microprocessor-controlled machines, the 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.
Signals from sensors are fed to the microprocessor which monitors the condition of the tabbing head and lets you know the condition through lights on the control panel. Without correct sensing, the FD 260 will behave improperly. The FD 260’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 in its proper condition and alignment at all times. The emitter half of the sensor is located under the transport tray beneath the peel bar. It can be seen by looking into the FD 260, along the paper path below the peel bar. The detector half is shrouded under the steel covers at the input end of the FD 260 in front of the peel bar.
Debris and stray tabs can become caught in the paper path and sensor beam. Rough, careless handling of the FD 260 can cause the sensors to become mis-aligned. Both of these conditions must be prevented. The FD 260 requires periodic cleaning and reasonable handling. Paper dust build-up or abuse will bring the successful operation of the FD 260 to an end. Take care of your FD 260 by following the set up, operation and maintenance instructions in this manual.
2
1.3Items Included
The following items are shipped together in one box.
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.
3
1.4Operating Manual Safety Terms
The following highlighted blocks are used throughout this manual to emphasize important information. Pay careful 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 260’s productivity.
4
1.5Safety 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.
WARNING
NEVER CLEAN, CLEAR OR DISASSEMBLE THE
FD 260 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.
1.6Operating Manual Terms
The following terms are used throughout this manual:
input end |
where mail pieces enter |
output end |
where mail pieces exit |
operator side |
side where the controls are |
|
located |
non-operator side opposite the operator side
5
1.7Warranty
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. This warranty covers the cost of parts when the machine is presented by its original purchaser to an authorized FORMAX Service Center. Should warranty repairs become necessary, the service provider, at his/her option, will repair or replace such parts required to restore the FD 260 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, or to costs associated with maintenance of the equipment. This warranty does not cover damages resulting from shipping, accident, misuse, abuse, neglect, mishandling, alteration or modification. Your rights under this warranty may vary from state to state.
1.8Ordering Additional Equipment
To order, or find out about, additional Formax equipment or supplies, contact an authorized Formax dealer.
6
2. SPECIFICATIONS & REQUIREMENTS
2.1Specifications
Size & Weight
10" L x 17" H x 21" W -- 47 lb. assembled
Power
Possible line voltages are 240V, 230V, 220V,
120V, and 100V at 50-60 Hz
2.2Operating Requirements
Mail Piece Size
Height: 31/2" minimum, 9" maximum
Width: 5" minimum, 12" maximum
Mail Piece Thickness
Minimum: single sheet of 20 lb. bond paper tri-
folded
Maximum: 1/4"
Tab Specs
Tab width: between 1" and 1.5" Tab length: 1", 1.5”
Backing paper width: between 1.125" (1" tab) and
13/4" (1.5" TABS) Maximum roll diameter: 8.25"
Core Diameter: 3"
Tab Position Accuracy
±1/16" 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.
Production
Over 15,000 mail pieces (41/8" long) per hour
7
3. POWER CONNECTION
WARNING
BEFORE PLUGGING THE FD 260 INTO AN
OUTLET, CAREFULLY READ THE FOLLOWING
INFORMATION ABOUT VOLTAGES, FUSES AND
THE POWER CORD.
3.1Safety
The FD 260 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 260 uses protective fusing in both the neutral and hot supply lines of power.
WARNING
A BLOWN FUSE IN THE NEUTRAL LEG COULD
MEAN INTERIOR PARTS OF THE FD 260 REMAIN
AT A HAZARDOUS VOLTAGE. ALWAYS UNPLUG
THE POWER CORD BEFORE REMOVING COVERS
FROM THE FD 260.
3.2Line 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.
The manufacturer configures the FD 260 to operate with the voltage requested by the customer.
CAUTION
VERIFY THE CORRECT VOLTAGE
SETTING BEFORE PLUGGING THE FD 260
INTO AN OUTLET.
Read the current voltage setting through the VOLTAGE SELECTOR WINDOW on the nonoperator side of the FD 260. (Refer to Figure 3.1.) Use the following instructions to change the voltage setting:
8
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.
Figure 3.1 - FD 260 Power Connection
9
3.3Line 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.
UNPLUG THE FD 260 BEFORE STARTING THIS
PROCEDURE.
Use the following instructions to verify that the LINE FUSES 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 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 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 intact for the FD 260 to operate properly.
6.Install the FUSE DRAWER in the POWER ENTRY CASING.
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