Formax FD 1500 AutoSeal User manual

FD 1500
AutoSeal®
OPERATOR MANUAL
THIRD EDITION
12/07

TABLE OF CONTENTS
TOPIC PAGE
DESCRIPTION, UNPACKING, SET-UP, CONTROLS 1
OPERATION 2
FOLD PLATE INSTALLATION, ADJUSTMENT 3
SETTING CUSTOM FOLDS 4
DAILY MAINTENANCE, TROUBLESHOOTING 5
TROUBLESHOOTING 6
TEST SHEET 7
FD 1500 shown with optional cabinet

Paper side guides
1
SPECIFICATIONS
Maximum foldable paper size: 14” L x 8.5” W
Fold styles: C, Z, V and custom folds
Paper loading capacity: Up to 150 sheets
Speed: Up to 85 sheets per minute
Machine weight 82 lbs.
Power supply 120V, 50/60 Hz, 3.5 amps
FUNCTION:
The 1500 Folder/Sealer folds and seals many different configurations including C, V, Z and custom
folds. It may also use several different sizes of forms. For configuration and/or paper sizes, see listing
below.
1. Check package for shipping damage. If there is shipping damage, do not discard the box.
2. CAUTION: Two people are required to lift the machine out of the box.
3. Remove the paper tray and insert into rails on bottom pan.
4. Plug cord into machine and into wall outlet.
UNPACKING & SET-UP
In-feed table
Lower Fold Plate
Upper Fold Plate
Control Panel
with Counter
Top Cover
CONTROL PANEL
Start: Starts machine operation
Stop: Stops machine operation
Ready Light: Steady green when power is on
Blinks red when cover is open or
fault is detected
Counter Reset: Resets counter
Counter: Shows forms count

2
OPERATION
1. Adjust fold plates to desired fold for length of paper (see fold plate adjustment on page 3). To do
this, loosen the two thumbscrews (figure 3a & b) on each fold plate. Align center bar (figure 3a & b)
so the marks on each side match up. For “V” folds remove the lower fold plate, turn around 180° and
reinstall.
2. Make sure fold plates and cover are reinstalled properly (see page 3).
3. Plug in cord and turn power on (figure 1).
4. Test fold settings. Push the paper feed lever (figure 2) down, place one form onto the in-feed table
and press the start button. Examine document and adjust fold plates if necessary (see fold plate ad-
justment on page 3).
5. Load forms. Push the paper feed lever down and load paper neatly stacked and squared on to the
in-feed table. Paper can be stacked up to 150 sheets. Note: Standard “Z” fold forms can be loaded
face up or down with the glue edge leading. All “C” fold forms must be loaded face up with glue edge
leading.
6. Check to that the ready light is green and press the start button to begin operation.
Figure 1 Figure 2
Power Switch
Paper Feed Lever

FOLD PLATE ADJUSTMENT
Thumbscrews
Upper Fold Plate Lower Fold Plate
Bar
Throat
Throat
1. To adjust the first fold remove the top cover. If the first fold is too long loosen the two thumbscrews
on the upper fold plate and slide the bar down. If the fold is too short loosen the thumbscrews and
slide the bar up.
NOTE: The bar should be on the same marks on each side.
2. To adjust the second fold remove the lower fold plate. If the second fold is too long loosen the two
thumbscrews and slide the bar up. If the fold is too short loosen the thumbscrews and slide the bar
down.
NOTE: The bar should be on the same marks on each side.
3. For quick setup of “C”, “Z” and “V” folds refer to the blue lines on the fold plate.
4. To reinstall the upper fold plate, slide the plate (with thumbscrews facing up and the throat toward
the inside of the machine) until the grooves on the underside line up with the four pins on the machine
(figure 4 & 4b).
Figure 4a Figure 4b, correctly installed
Figure 3a Figure 3b
3
Fold Plate Pins

4
SETTING CUSTOM FOLDS
Eccentric “Z”
1. Measure the length of panel “A”.
2. Adjust the upper fold plate so that the bar lines up with the measurements of
panel “A”, for example: if panel “A” is 5 1/4” long move the bar up or down so
that it lines up with the 5 1/4” mark on the fold plate.
3. Measure the length of panel “B”.
4. Adjust the lower fold plate so that the bar lines up with the measurements of
panel “B”.
5. Load forms and press start (refer to OPERATION on page 2).
Uneven “C” / Return Mailer
1. Measure the length of panel “A” & “B”.
2. Adjust the upper fold plate so that the bar lines up with the measurements of
panel “A” & “B”, for example: if panel “A” + “B” is 10 1/2” long move the bar up
or down so that it lines up with the 10 1/2” mark on the fold plate.
3. Measure the length of panel “B”.
4. Adjust the lower fold plate so that the bar lines up with the measurements of
panel “B”.
5. Load forms and press start (refer to OPERATION on page 2).
Panel A
Panel B
Panel A
Panel B
5. To reinstall the lower fold plate, slide the plate (with the thumbscrews facing up and throat toward
inside of machine, figure 5b) until it rests on the two silver bars (figure 5a) and locks into place (figure
5c).
Bars
Figure 5a Figure 5b Figure 5b

5
DAILY MAINTENANCE
1. It is recommended to let forms cool for one-half hour, from the laser printer, before folding and
sealing. This allows toner to set on the forms, and static electricity to discharge. A 400 Series Jogger
is recommended for best results. The Jogger squares the forms and dissipates heat and static cre-
ated by laser printers.
2. If toner builds up on the metal sealer rollers, clean the rollers with a lint-free cloth dampened spar-
ingly with a mild household cleaner.
3. Clean in-feed wheels and fold rollers with Formax-recommended roller cleaner & rejuvenator to
remove paper dust and toner. A damp cloth with water is the best alternative. CAUTION: Do not use
any chemicals other than the roller cleaner & rejuvenator or water.
TROUBLESHOOTING
A. Clearing Paper Jams:
WARNING: Turn machine off and unplug cord from its receptacle.
1. If a jam occurs between the metal sealing rollers remove any remaining forms from the hopper.
Remove the top cover and the upper fold plate. Remove the jam clearing tool (located under top fold
plate), apply the tool to the upper metal roller (figure 6) and turn clockwise (Caution: do not apply ex-
cessive force or rollers may be damaged) until the paper jam is clear. Remove the jammed form and
return tool in holder and reinstall the upper fold plate. Reinstall cover and press the start button.
Note: Press the black button (figure 7) near the power cord inlet to reset the breaker if necessary.
2. If a jam occurs in the fold plates remove fold plate and remove paper. Reinstall fold plate.
Figure 6
Figure 7 Breaker reset

6
TROUBLESHOOTING
B. Fold Quality Needs Improving:
1. Make sure paper is squared and installed correctly. Side guides should be evenly balanced and
snug against the paper.
2. If folds are still incorrect adjust fold plates (see fold plate adjustment on page 3).
C. Paper is not Folding Square (Skewing):
1. If paper pulls left or right adjust the skew adjuster. To adjust the skew, turn the skew adjuster
(figure 8) left or right until the paper is feeding correctly.
D. Ready light is not illuminated and power is on:
1. Press the black button (figure 7) near the power cord inlet to reset the breaker.
E. Ready light is blinking red:
1. Check to see that the top cover is installed properly.
2. Check that the photo-eye, before the metal sealer rollers, is clear of forms and/or paper dust.
Figure 8


Leading Edge
Make copies of this page on copy paper for fine tuning folds
Instruction For Lining Up Folds
Fig. 2 “C” Fold Form
Fold “A” Fold “B” Leading Edge
Fig. 1 “Z” fold Form
Leading Edge
Fold “A” Fold “B”
1. Place a stack of these sheets into the feeder and fold
one (1) or two (2) sheets.
2. Take a folded sheet from the catch tray and lay it on
top of a pressure seal form lining the leading edge of
this sheet up with leading edge of the pressure seal
form.
3.
-
-
If the folds on this test sheet do not line up with the
perforated folds on the form, the fold plates need to
be adjusted up or down to make the folds line up.
Refer to Fig. 1 for a “Z” fold and Fig. 2 for a “C” fold.
If fold “A” on the test form is right of the perforation on
the pressure seal form move the top fold plate
stop up. If fold ”A” is below move the top fold plate
stop fold stop down.
If fold “B” on the test form is right of the perforation
on the pressure seal form move the bottom fold plate
stop down. If fold ”B” is to the left move the bottom
fold plate stop up.
7