Formax FD 380 User manual

FD 380
Document Folder
OPERATOR MANUAL
THIRD EDITION
2/08

TABLE OF CONTENTS
SUBJECT
PAGE
DESCRIPTION
1
SPECIFICATIONS
1
UNPACKING
1
SETUP
2
CONTROL PANEL
3
OPERATION
4
SETTING CUSTOM FOLDS
5
BATCH COUNTING
6
MULTI-SHEET FEEDER
7
CROSS FOLDING
8
STACKER WHEEL POSITIONING CHART
8
STACKER WHEEL SETUP FOR THICK PAPER
9
OPERATOR MAINTENANCE
10
TROUBLE SHOOTING
11

Paper size:
3.5” x 5” to 11” x 17” (88.9 W x 127 L to 311W x 432 L mm)
Fold types:
Letter , Zig-Zag , Single , Gate , Fold Out ,
Double Parallel and Custom Folds
Feed table capacity:
Up to 500 sheets of 20# paper
Processing speed:
Up to 12,000/hour, depending on fold type.
Power requirements:
FD Model: 120 volts A.C., 50/60 Hz, 2.5 amps.
FE Model: 240 volts A.C., 50/60 Hz, 2 amps
Dimensions during use:
Closed: 33” L x 20” W x 19” H (84 L x 51 W x 48 H cm)
Fully Extended: 60”L x 20” W x 19” H (152 L x 51 W x 48 H cm)
Weight:
67 lbs (30.39 kg)
DESCRIPTION
FUNCTION
The FD 380 Folder is designed to perform a wide variety of folds using a variety of paper weights. The fold
plates are automatically adjusted for standard and custom folds. Documents that are 11”, 14”, and 17” long are
detected by sensors on the in-feed tray. Batch counting, self-centering side guides, and the capability to cross-
fold are added features. There are six pre-programmed standard folds and up to nine custom folds available.
The folder will automatically stop after the last document has been folded.
1. Check package for shipping damage. If there is shipping damage, do not discard the box.
2. Remove the machine and packed components from the box. The fold plates, telescoping stacker, power
cord and cross-fold guide are wrapped separately in the box.
NOTE:
Two people must lift the machine from the box.
3. Place the machine on a solid stand.
4. Attach telescoping outfeed stacker.
UNPACKING
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
1
Upper Fold Plate
Telescoping
Outfeed Stacker
Self Centering Paper
Side Guides
Infeed Tray
Infeed Tray
Extension
Infeed Tray
Lever
Lower Fold Plate
Non Operator Side
Operator Side
SPECIFICATIONS
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Letter , Zig-Zag , Single , Gate , Fold Out ,
Double Parallel and Custom Folds
Double Parallel and Custom Folds
Double Parallel and Custom Folds
Double Parallel and Custom Folds
Double Parallel and Custom Folds

SETUP
1. Install upper and lower fold plates in position. Be sure
the plates are set fi rmly on the locating pins (Fig 1a &
1b).
Slide the fold plate in until it meets the fi rst locating
pin then push down to lock it in position (Fig. 2).
2. Plug the fold plate cables into the receptacles on the
side frame (Fig. 3a & 3b).
3. Make sure the power switch is in the “OFF” position.
4. Plug the power cord into the power inlet and the wall
outlet.
Fig. 1b
Locating Pins
Locating Pins
Locating Pins
Locating Pins
2
Lower Fold Plate Pins
Upper Fold Plate Receptacle Location
Lower Fold Plate Receptacle Location
Plug in Receptacle
Plug in Receptacle
Fig. 3b
Fig. 3a
Fig. 1a
Locating Pins
Fig. 2
Upper Fold Plate Pins

CONTROL PANEL
3
No
.
NAME
FUNCTION
1
Standard Folds Menu
Select the desired pre programmed fold.
2
Start/Stop Button
Press to start or stop the machine.
3
Speed Control Lever
Select the speed to run the machine.
4
Test Button
Test folds one document.
5
Counter Reset Button
Resets the counter and clears fault indications.
6
Batch Count Button
Select the batch counting function.
7
“-“ and “+” buttons
Select the number of documents to be folded.
8
Display Screen
Shows the number of documents processed and the type of fold being used.
9
Custom Folds Menu
Select and program a custom fold (see page 5).
9
8
7
6
4
5
2
3
1

OPERATION
1. Place power switch in the “ON” position.
2. Extend the catch tray as required.
3. Move the stacker wheels to the proper position for
the paper size (Fig. 4) ( Refer to chart on page 8).
4. Raise the in-feed tray lever.
5. Set the paper side guides for the paper you’re using
and lock in position.
6. Neatly stack paper on the in-feed tray.
7. Lower the in-feed tray lever.
8. Select the type of fold desired (Fig 5).
9. Press the “Test” button on the control panel to check
the folds. Fine adjustments can be made with the
adjustment knob at the end of the plate (Fig 6).
NOTE:
When the “Test” or “Start” button is pressed, the
fold plate stops go to the “home” position then reposition
to the programmed setting.
10. If the fold is skewed, lower the paper table extension
and turn the skew adjustment knob left or right to make
corrections (Fig 7).
11. Once you’re satisfi ed with the test folds, press the
“Start” button to operate the machine.
12. Adjust machine speed to desired level.
Fig. 5
Fig. 7
Fig. 4
Fig. 6
Stacker Wheels
Stacker Wheel Positions A, B & C
Stacker Wheel Positions A, B & C
Skew Adjuster
Skew Adjuster
Fold selection button
4

SETTING CUSTOM FOLDS
Example 1: Uneven “Z”
a.
Measure the length of panel “A” & “B”
b. Measure the length of panel “B”
c. Enter these measurements according to the
instructions below.
Example 2: Uneven “C”
5
a. Measure the length of panel “A”.
b. Measure the length of panel “B”
c. Enter these measurements according to the
instructions below.
1. Measuring Fold Lengths
2. Programming a custom fold:
a. Select the custom fold number you want to program.
b. Press the green button next to the Table A and Table B lights.
Note:
The display will read “Tbls A: #.## B: #.## CUSTOM #”.
Table A adjusts the upper fold plate.
Table B adjusts the lower fold plate.
The “-“ and “+” buttons decrease and increase the fold numbers.
c. Press the “-“ and/or “+” button to enter the length of the fold. Fine adjustments can be made with the
adjustment knob at the end of the plate (Fig. 6).
d. Press the “Test” button to insure the proper folds have been entered.
e. Once the folds are correct, press and hold the “Custom Fold” green arrow until the machine sounds a
tone. The fold has been memorized.
Note:
The display screen will read “count # and custom #”.
To run your custom fold without saving it, simply press the “Start” button
after step “d” above.
Panel A
Panel B
Panel A
Panel B

BATCH
COUNTING
1. To enter the manual batch counting mode press the
“Batch Count” button and select “MANUBATCH” by
pressing the “+” button (Fig 8) .
2. Select the number of sheets to be folded by pressing
the “+” or “-” buttons (Fig. 9a) , then press the “Start/
stop” button to start.
6
MANUBATCH:
The “Manubatch” or “manual batch” feature allows you to program the number of sheets you would like to
process in a set. When the set is complete the folder will stop and automatically reset the batch count to the
previously set number of sheets, it will then fold the next set when the “Start/Stop” button is pressed.
Fig. 8
Fig. 9b
AUTOBATCH:
“Autobatch” or “automatic batch” allows you to batch count with automated features. In the Autobatch mode
you can program the number of sheets you would like to process in a set, the number of sets you would like
and the delay between each set. For example: you can program 10 sheets to be pulled to create a set, then
program 100 sets to be processed with a 3 second time delay between each set.
1. To enter the Autobatch mode press the “Batch
Count” button and select “AUTOBATCH” by pressing
the “-” button (Fig 8).
2. Once you have entered the Autobatch mode press
the “+” or “-” button and “Sheets”(Fig. 9b) will blink.
Press the “+” or “-” buttons to increase or decrease the
number of sheets to be pulled.
3. When the sheet number is set wait 5 seconds and
“Sets” (Fig. 9b) will blink. Press the “+” or “-” buttons to
increase or decrease the number of sets to be pulled.
4. When the number of sets has been selected wait 5
seconds and “Delay” (Fig. 9b) will blink. Press the “+”
or “-” buttons to increase or decrease the time delay
between the sets.
5.When the settings are correct press the “Start/Stop”
to start.
NOTE:
The system will cycle through the settings until
the “Start/Stop” button is pressed.
NOTE:
If a fault occurs during a set the set will be
completed when the fault is reset.
NOTE
: The batch counting program selected will
remain on after the job is processed. You
must
press
must press must
the Batch Counting button to turn off the light and
cancel the batch count setting.
“Sheets” = Number of sheets of paper in a set
“Sets” = Number of sets to be processed
“Delay” = Time between each set
“C” = Total number of sheets processed
Fig. 9a

MULTI-SHEET FEEDING
The multi-sheet feeder is designed to fold pre-collated stapled or unstapled sets of up to three 20 # sheets of
paper.
1. Adjust the side guides on the feeder for the proper
paper size. Loosen the brass thumb screw. Open or
close the guides to fi t the paper width and re-tighten
the thumbscrew (Fig 10a).
2. Slide the pre-collated paper set into the multi-sheet
feeder. When feeding stapled sets the documents
should be placed with the staple on the operator’s
side and leading (Fig 11).
3. The sheets of paper will be automatically pulled into
the folder (there is a one second delay after the paper
is placed in the feeder).
4. If the fold is skewed, turn the skew adjustment knob
located on the back of the feeder left or right to make
corrections (Fig 10b).
5. To remove the multi-sheet feeder depress the
release levers located on either side of the lower back
side of the feeder (Fig. 12), tilt the feeder forward and
lift. To reinstall depress the levers and reinsert.
Staple
Fig. 11
Fig. 10a
Fig 10b
Brass thumbscrew
Skew Adjuster
Release Levers
Fig. 12
7

8
CROSS FOLDING
Cross folding refers to folding a document in one pass and then running it through the folder a second time to
be folded again.
Common Application: Folding an 11” x 17” document in half and then letter folding it to fi t in a standard #10
envelope.
1. Load folded paper into the feed tray with the fold
crease facing the non-operator side of the folder (Fig
13).
Note: For best results fi rmly run your hand over the fold
crease to help fl atten the paper before loading.
2. Attach the cross fold paper guide onto the feed tray
paper guide (Fig. 14) and lower guide.
Note: Cross folding ability will vary based on the paper
weight and type. If the paper is too heavy it may not be
able to be cross folded.
Tab “B”
Tab “A”
Slot “B”
Slot “A”
Fig. 14
To install cross fold guide hook tab “A” into slot “A”
and then lower tab “B” into slot “B”
Fig. 13
Fold Crease
Cross Fold Guide
STACKER WHEEL POSITIONING GUIDE
Move the stacker wheels to the proper position indicated on the chart based on the fold and paper size. For
paper between 28# and 65#* refer to the “
Stacker Wheel Setup For Thick Paper” on page 9.
8.5" x 11" 8.5" x 14" 11" x 17"
Letter
Zig-Zag
Single
Gate
Fold Out
Double ll
A
A
B
A
B
A
A or B
A or B
B
B
C
A
B
B
C
C
C
A or B
Stacker Wheels

Thicker paper from 28 # up to 65 # may require special stacker wheel setup moving the stacker wheels closer
than the position “A” slot.
If stacking is inconsistent move the stacker wheels from the standard position #1 (Fig. 15) to the thick paper
weight position #2 (Fig. 16) as indicated in the pictures below. Position # 2 may also be good for small folded
documents.
Fig. 15 - Standard Stacker Wheel Position
Fig. 16 - Thick Paper Weight Position
Position 1
Position 2
9
STACKER
WHEEL SETUP FOR
THICK PAPER

OPERATOR MAINTENANCE
1. It is recommended to let forms cool for one-half hour, from the laser printer, before folding. This allows
toner to set on the forms and static electricity to discharge. A 400 Series Paper Jogger is recommended for
best results. The Jogger squares the forms and dissipates heat and static created by laser printers.
2. Clean in-feed tires and fold rollers with Formax recommended roller cleaner & rejuvenator to remove paper
dust and toner. A Formax Cleaner Kit is available from your dealer. A damp cloth with water is the best
alternative.
CAUTION:
Do not use any chemicals other than the roller cleaner & rejuvenator or water.
10
Fig. 17
Fold Rollers
1. Make sure machine is turned off and unplugged. All
folders have four (4) rubber rollers (Fig. 17).
2. Remove the upper and lower fold plates.
3. Using Formax roller cleaner, spray a new cotton cloth
until the cloth is saturated. Wipe the wet cloth in a back
and forth motion making sure to clean the entire surface
of the fold and seal rollers. Next, use a dry cloth to wipe
off excess toner. The cloth should be covered with black
toner surplus from cleaning the rollers.
4. Make sure to run 10-15 sheets of blank copy paper
to ensure all cleaner has been removed from the fold
rollers. Running blank sheets will remove any excess
residue of cleaner on the rollers.
CLEANING PROCEDURES:

TROUBLE-SHOOTING
TROUBLE
POSSIBLE CAUSE
REMEDY
Control panel lights are
not illuminated.
No power at the wall outlet.
No power to the machine inlet.
No power to the control panel.
Internal electrical failure.
Check wall outlet.
Check power cord for frayed/broken
wires.
Press the button on the circuit breaker.
Call for service.
Fold plate stop not
moving when “Test”/
“Start” is pressed.
Fold plate is not plugged in.
Electrical or mechanical failure
Plug fold plate in.
Call for service.
“Cover Open” is
displayed.
Cover open
Magnetic switch is broken.
Close cover.
Call for service.
“Paper out” is displayed.
In-feed tray is empty.
Place documents on the in-feed tray.
“Paper Jam” is displayed.
Paper misfeed
Paper jammed at exit of folder.
Reload paper and press “Counter Reset”
button.
Remove paper and press “Counter
Reset” button.
Black marks on the folded
paper.
In-feed tires, separator, and/or
fold rollers are dirty.
Clean the parts with approved roller
cleaner and rejuvenator.
Fold is skewed.
In-feed tray is out of
adjustment.
Turn skew adjuster knob to remove the
skew.
Stacker belts do not turn.
Broken drive belt, worn drive
gear.
Call for service.
Documents are wrinkled
or crunched.
Fold plates are not inserted
correctly.
Piece of paper or other material
is stuck in the fold plate.
Remove and reinstall fold plates. Be
sure they’re properly positioned.
Remove object from the fold plate.
In-feed tray lever does
not work.
Broken spring
Call for service
Double feeding forms
Documents stuck together
Feed tire or separator worn
Jog forms to remove static electricity.
Call for service
Not feeding documents
Feed tire dirty
Feed tire or separator worn
Clean feed tire
Call for Service
11