Formax FD 38X User manual

Instruction Manual
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Formax FD 38x &
FD 382 Document
Folder

FD 38X / FD 382
Document Folder
OPERATOR MANUAL
FIRST EDITION
6/2010

SUBJECT PAGE
DESCRIPTION 1
SPECIFICATION 1
UNPACKING & SETUP 2
CONTROL PANEL 4
OPERATION 5
INTERFACE MENU 7
BATCH COUNTING 8
FD 382 CUSTOM FOLD SETUP 10
FD 38X CUSTOM FOLD SETUP 11
OPERATOR SETTINGS 14 - 17
Language 14
Standard Fold override 15
Stacker Override ( FD 38X only ) 16
Test Sheet Setting 17
Default Settings 17
MULTI-SHEET FEEDING 18
CROSS FOLDING 19
FD 382 STACKER WHEEL POSITIONING CHART 19
THICK PAPER / HIGH SPEED MODE 20
REMOVING INFEED TIRES 20
OPERATOR MAINTENANCE 21
TROUBLE SHOOTING 22
TABLE OF CONTENTS

DESCRIPTION
The FD 38X / FD 382 Folder is designed to perform a wide variety of folds using a variety of paper weights. The fold
tables are automatically adjusted for standard folds and custom folds. Documents that are 8 ½” x 11”/14” and 11” x 17”
(A5, A4, A3, B4, B5 & B6) 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 35 custom folds
available. The folder will automatically stop after the last document has been folded.
SPECIFICATIONS
Speed: Standard Mode: Up to 16,450/hour, depending on fold type
Thick Stock Mode: Up to 20,100/hour, depending on fold type
Hopper Capacity: Up to 500 sheets of 20# paper (75gsm)
Paper size: Min: 3.5” X 5” (88.9 W x 127 L mm)
Max: 12.25” X 18” (311 W x 457 L mm)
Pre programmed fold types: Letter , Zig-Zag , Single , Gate , Fold Out ,
Double Parallel
Pre-Set Paper Sizes: 11”, 14”, 17”, A5, A4, A3, B6, B5, B4
Languages: English, Spanish, French, German, Italian & Dutch
Dimensions 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: 74 lbs (34 kg)
Power: 120V - 240V AC, 50/60 Hz, 2.5 amps.
Safety Certications: UL & CE Applied For
1
Upper Fold Table
Telescoping
Outfeed Stacker
Self Centering Paper
Side Guides
Infeed Tray
Infeed Tray
Extension
Infeed Tray
Lever
Lower Fold Table
Non Operator Side
Operator Side
Multi-Sheet Feeder
(Option for FD 382)
Stacker Wheels
Top Cover
Control Panel

Fig. 1b Locating Pins
2
Lower Fold Table Pins
Fig. 1a Locating Pins
Upper Fold Table Pins
UNPACKING & SETUP
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 tables, telescoping stacker, Multi Sheet
Feeder (standard feature FD 38X, option for FD 382), 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 folder on a solid stand.
Install upper and lower fold tables, telescoping conveyor
multi-sheet feeder and power cord
1. Be sure the plates are set rmly on the locating pins
(Fig 1a & 1b). Slide each fold table in until it meets the
rst locating pin then push down to set in place.
2. Lock the fold table into position (FD38X Only) (Fig. 2)
3. Repeat the same steps for the lower fold table.
Fold Table Lock
Fig. 2

Upper Fold Table Receptacle Location
Lower Fold Table Receptacle Location
Plug in Receptacle
Plug in Receptacle
Fig. 3b
Fig. 3a
4. Plug the fold table cables in to the receptacles on the
side frame (Fig. 3a & 3b).
5. Insert the telescoping extension tray into the end of the
outfeed conveyor (Fig. 4).
6. Insert the Multi-Sheet Feeder into the four slots located
on the top cover (Fig 5).
7. Make sure the power switch is in the “OFF” position.
Plug the power cord into the power inlet and the wall
outlet.
Fig. 4
Fig. 5
4 Slots
3
Telescoping extension tray

CONTROL PANEL
4
No.NAME FUNCTION
1 Standard Fold Button Select the desired pre-programmed fold.
2 LED Interface Displays current settings and used for setup and programming.
3 Start Button Press to start the folder.
4 Stop Button Press to stop the folder.
5 Clear/Reset Button Clears operation and returns to main screen. NOTE: this button can be pressed at any
time to return to the main screen. Resets the counter and clears fault indications.
6 Test Button “1x” Test fold documents.
7 Enter Arrow Used to save settings or advance to the next screen.
8 Up and Down Arrows Used to scroll up and down through settings or change settings.
9 Speed Control Buttons Increase or decrease speed
10 Custom Fold Buttons Select and program a custom fold (see page 5).
10
987 56
34
12

OPERATION
1. Place power switch in the ON / “O” position.
2. Extend the catch tray as required.
3. FD 382 ONLY: Move the stacker wheels to the proper
position for the paper size (Fig. 6) (Refer to chart on
page 8). Stacker wheels will automatically adjust on
the FD 38X.
4. Set the self-centring paper side guides for the width of
the paper and lock in position using thumbscrews.
5. Adjust in-feed tray tension lever (Fig 7) for different
paper weights. Move the lever up towards the “-”
symbol for lighter paper and down toward the “+”
symbol for heavier paper. The middle position is for
standard paper weights.
6. Raise the in-feed tray lever to lower the in-feed tray.
7. Neatly stack paper on the in-feed tray.
8. Lower the in-feed tray lever to raise the in-feed tray.
Fig. 6
5
Tension Lever
Fig.7
Self centering side guides
Fig.7
Stacker Wheels
Stacker Wheel Positions A, B & C

Fig. 10
Skew Adjuster
9. Select the type of fold desired by pressing the fold
selection button (Fig 8).
10. Press the “1x” button on the control panel to test and
check the folds. (Fig 9).
NOTE: When the “1x” or “ ” button is pressed, the
fold tables return to the “home” position then reposition
to the programmed setting.
11. If the fold is skewed, remove paper, lower the infeed
tray extension and turn the skew adjustment knob left
or right to make corrections (Fig 10).
12. When satised with the test folds, press the “ ” button
to start the folder. Press the “ ” button to stop.
13. Press the “-” or “+” buttons to adjust machine speed to
desired level.
Fig. 8 Fold selection button
6
Fig. 9 Test Button

INTERFACE MENU
Main Screen - Press the “ ” button to
advance to the Program Menu
Press the “ “ buttons to scroll
through the program settings. Press
the “ “ button to enter the selection
Choose between “ManuBatch” or
“AutoBatch” - see pages 8 and 9
Set up to 35 custom folds on the
FD 38X or up to 25 custom folds on
the FD 382 (page 10)
Adjustable Operator Settings - see
page 14
7

BATCH COUNTING
1. To enter ManuBatch mode, highlight “ManuBatch”
on the “Batch Counting” screen using the “ ”
buttons. Press the “ ” button to enter.
2. Select the number of sheets to be folded by pressing
the “ ” buttons. Press the “ ” button to start.
Press the “C” button to exit to the main screen.
8
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 “ ” button is pressed.
Two options are available for batch counting: ManuBatch for
standard batch counting, and AutoBatch for programmed
batch counting. Select “BatchCounting” and press the “ ”
button to enter batch counting modes.

9
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 total number of sets 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 AutoBatch mode, highlight “AutoBatch”
on the “Batch Counting” screen using the “ ”
buttons. Press the “ ” button to enter.
2. “Sheets” is highlighted. Press the “ ” buttons to
set the number of sheets for each set. Press the “ ”
button to enter your selection and advance to the next
screen.
3. “Sets” is highlighted. Press the “ ” buttons to
select the number of sets. Press the “ ” button to
enter your selection and advance to the next screen.
4. “Delay” is highlighted. Press the “ ” buttons to
set the time delay between each set. Press the
“ ” button to enter your selection and advance to the
next screen.
5. Press the “ ” button to begin folding. The “ ”
button can be pressed to edit the settings. Press the
“C” button to exit to the main screen.
NOTE: If a fault occurs during a set the set will be
completed when the fault is reset.

FD 382 CUSTOM FOLDS SETUP
10
1. Select the custom fold number you want to program
using the “ ” buttons. Press the “ ” button to
enter number and advance to the next screen.
2. The current settings for the custom fold will be displayed.
Press the “ ” button to edit the settings or the “ ” to
go back and select a different custom fold number.
Note: All custom folds are pre-set for a standard 11”
C-fold.
3. Adjust Fold Table screen will be displayed. Use the
“ ” buttons to change the upper fold table setting.
Press the “ ” button to enter and advance to the lower
fold table setting. Adjust the lower fold table and press
the “ ” button to enter and advance to the test screen.
4. Press the “1x” button to ensure the proper folds have
been entered. If the folds are correct press the “ ”
button to save. If the folds need to be adjusted press the
“ ” button to edit.
7.36
3.70
The FD 382 has 25 custom fold settings that can be stored into
memory for recurring jobs with fold settings that vary from the
standard fold settings. To create or edit custom folds select
“Custom Folds Setup” from the Program Menu screen and
press the “ ” button to enter. See page 13 to help determine
the new fold measurements.

FD 38X CUSTOM FOLDS SETUP
1. Select the custom fold number you want to program
using the “ ” buttons. Press the “ ” button to
enter number and advance to the next screen.
2. The current settings for the custom fold and stacker
position will be displayed. Press the “ ” button to edit
the settings or the “ ” to go back and select a different
custom fold number.
Note: All custom folds are pre-set for a standard 11”
C-fold.
3. Adjust Fold Table screen will be displayed. Use the
“ ” buttons to change the upper fold table setting.
Press the “ ” button to enter and advance to the lower
fold table setting. Adjust the lower fold table and press
the “ ” button to enter and advance to Stacker Position
screen.
The FD 38X has 35 custom fold settings that can be stored
into memory for recurring jobs with fold settings that vary from
the standard fold settings. To create or edit custom folds se-
lect “Custom Folds Setup” from the Program Menu screen and
press the “ ” button to enter. See page 13 to help determine
the new fold measurements.
11

5. There are 10 stacker positions available. Select the
one that best matches the size of the folded document.
Press “ ” buttons to select the correct position
# P0 - P9. Press the “ ” button to enter selection and
advance to the test screen.
Stacker Wheel Positions:
P0 Folded size to: 3.75”
P1 Folded size to: 4.00”
P2 Folded size to: 4.43”
P3 Folded size to: 4.87”
P4 Folded size to: 5.30”
P5 Folded size to: 5.73”
P6 Folded size to: 6.16”
P7 Folded size to: 6.60”
P8 Folded size to: 7.03”
P9 Folded size to: 7.46” and greater
4. Press the “1x” button to ensure the proper fold and
stacker positions have been entered. If the folds and
stacker position are correct press the “ ” button to
save. If the folds or stacker wheels need to be adjusted
press the “ ” button to edit.
FD 38X CUSTOM FOLDS SETUP, cont.
12

Example 1: “Z” Fold
1. Measure the length of panel “A” + “B”, enter this number as the
upper fold table measurement.
2. Measure the length of panel “B”, enter this number as the lower
fold table measurement.
Example 2: “C” Fold
1. Measure the length of panel “A”, enter this number as the upper
fold table measurement.
2. Measure the length of panel “B”, enter this number as the lower
fold table measurement.
Measuring Fold Lengths
Panel A
Panel B
Panel A
Panel B
Use the examples below to help determine the fold lengths for custom fold settings.
13

OPERATOR SETTINGS
Language
A number of operator settings can be adjusted to personal-
ize the FD 382 / FD 38X. The settings include Language,
Stacker Override, Standard Fold Override, and Test Sheet
Setting. This section will review each setting and how to
adjust them. If needed, there is a Default Settings option
that will reset to factory settings. To advance to each setting
press the “ “ buttons to highlight your selection and
press the “ ” to select setting.
Six languages are available. The factory default is “English
US”.
1. To change the language, select “Language” from the
Operator Settings screen and press the “ ” button to
select.
2. The language choices will be displayed. Press the
“” buttons to highlight your language. Press the
“ ” button to enter your selection.
14

Standard Fold Override
1. It may be necessary to adjust the factory set standard
fold settings for a particular fold type and paper size.
This can be done in the Standard Fold Override Mode.
From the Operator Settings menu select “Standard Fold
Override” and press the “ ” button to select.
2. “Standard folds will be modied from factory settings”
will be displayed. Press “ ” to continue or “C” to exit
and return to the main screen.
3. Use the “ ” buttons to select the fold type to be
modied. Press the “ ” button to enter.
4. Use the “ ” buttons to select the paper size.
Press the “ ” button to enter.
5. Adjust Fold Table screen will be displayed. Use the
“” buttons to change the upper fold table setting.
Press the “ ” button to enter and advance to the lower
fold table setting. Adjust the lower fold table and press
the “ ” button to enter and advance to the test screen.
6. Press the “1x” button to ensure the proper folds have
been entered. If the folds are correct press the “ ”
button to save and return to the main screen. If the folds
need to be adjusted press the “ ” button to edit.
15