Formax AutoSeal FK Series User manual

AutoSeal®
FD 1506 Plus / FE 1506 Plus
FK / FL SERIES
OPERATOR MANUAL
FIRST EDITION
06/2018

TABLE OF CONTENTS
DESCRIPTION 1
UNPACKING AND SET-UP 2
CONTROL PANEL 3
OPERATION 3
FOLD PLATE ADJUSTMENT 4
SETTING CUSTOM FOLDS 5
DETERMINING FOLD TYPE 6
TEST SHEET 6
INSTALLING OPTIONAL FLOW STRAPS 7
DAILY MAINTENANCE 7
TROUBLESHOOTING 8

1
DESCRIPTION
Lower Fold Plate
Touchscreen
Control Panel
Top Cover
Upper Fold Plate
In-feed Table
Paper Side Guides
Stacking Rollers
Integrated Conveyor
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. Place the jam clearing handle into the the holder
which is mounted to the machine. This is the jam
clearing tool’s proper location (see picture, right).
4. Install upper fold plate (refer to pages 4 and 5
for proper installation).
UNPACKING & SET-UP
Jam clearing tool
FUNCTION:
The 1506Plus Pressure Sealer folds and seals many different congurations, including “C”, “Z”, “V” and
custom folds. It also accommodates several different sizes of forms. For congurations and/or paper
sizes specications below.
Paper size: Up to 8.5” W x 14” L
Fold styles: C, Z, V uneven Z, uneven C, custom folds
Fixed speed: Up to 6,250 sheets per hour
Hopper capacity: Up to 200 sheets 20#
Weight: 90 lbs.
Dimensions: 37” L x 17” W x 13” H
Power supply: 120V, 50/60 Hz
Certications: UL Approved

2
UNPACKING AND SET UP, continued
5. To attach the conveyor to the out-feed, align the tab on the right side of the conveyor with the slot
on the machine (Figure 1a). Rest the support braces on the two alignment studs (see arrows), and
tighten the four thumbscrews provided (Figure 1b).
Figure 1bFigure 1a
Tab and slot
3. Install outfeed wheels (Fig. 1c) by inserting the right side (spring loaded) into the right side of the
body, just above the conveyor (Fig 1d), then insert the left end of the outfeed wheel crossbar into the
left side.
4. Plug cord into machine and into wall outlet.
Figure 1dFigure 1c
Spring-loaded end

3
OPERATION
1. Adjust fold plates to desired fold for length of paper (see fold plate adjustment on page 4). To do this,
loosen the two thumbscrews (Figure 4a & b) on each fold plate. Align center bar (Figure 4a & b) so the
marks on each side match up. For “V” folds, remove the lower fold plate, turn around 180º and reinstall.
2. Make sure fold plates and cover are reinstalled properly.
3. Plug in cord and turn power on (Figure 2).
4. To make sure folds are in the correct location, push the paper feed lever (Figure 3) down and place
one form onto the in-feed table and press the start button. Adjust fold plates if necessary (see fold plate
adjustment on page 4).
5. Push the paper feed lever down and load paper neatly stacked and squared onto 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. Be sure the ready light is green and press the start button to begin operation.
Figure 2 Figure 3
Power Switch
Paper Feed Lever
CONTROL PANEL
1 Start Starts machine operation
2 Stop Stops machine operation
3 Counter Displays number of forms processed
4 Counter Reset Resets Counter
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2
4

FOLD PLATE ADJUSTMENT
1. To adjust the rst fold remove the top cover to access the top fold plate. If the rst 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” , Uneven “C” 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 4a & 4b).
4
Thumbscrews
Upper Fold Plate Lower Fold Plate
Center
Bar
Throat
Throat
Deector (for Half Folds)
Figure 4a Figure 4b, correctly installed
Fold Plate Pins

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, gure 5b) until it rests on the two silver bars (gure 5a) and locks into place (gure
5c).
5
Bars
Figure 5a Figure 5b Figure 5c

DETERMINING FOLD TYPE
Two Standard Folds 11” “Z” & 11” “C”
Refer to page 5 for custom fold setup.
11” “Z” Fold
11” “C” Fold
Leading glue edge
Leading glue edge
11” “Z” Fold
11” “C” Fold
Glue
Glue
Glue Glue
8
6

h
Leading Edge
Make copies of this page on copy paper for ne tuning folds
Instruction For Lining Up Folds
Fig. 17 “C” Fold Form
Fold “A” Fold “B” Leading Edge
Fig. 16 “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. 16 for a “Z” fold and Fig. 17 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

ERROR SCREENS
Paper Out / Paper Mis-Feed / Paper Jam
1. The feeder is empty. Load paper paper into the
feeder and press the “ “ icon to resume opera-
tion.
2. A mis-feed has occurred. Reset the stack of paper
in the in-feed and press the “ “ icon to resume
operation.
3. A Paper jam has occurred in one of the areas
indicated. Turn the folder to the off position and un-
plug. Check the area indicated for paper and remove.
Replace the fold plates and plug the folder in and the
power on.
The top cover is open. Close the top cover and press
the “ “ icon to resume operation.
FD 342 Touch Screen -Error Screens
Error screen will appear with arrow pointing to empty
infeed tray. Press return arrow to go back to the home
screen.
* Paper Out screen will come on if start is pressed and
the is no paper in the feed tray.
Error screen will apear with arrow pointing to open
cover with indicator to close cover. Press return arrow
to go back to the main screen.
Paper Jam
Error screen appears with arrows pointing to possible areas
to check. Press the return arrow to go back to home screen
at any time. If the jam is not cleared the error screen will
appear again after pressing start or 1x.
Paper misfeed
Error screen will appear with arrow pointing to infeed.
Press return arrow to go back to the home screen.
Cover Open
Paper Out
FD 342 Touch Screen -Error Screens
Error screen will appear with arrow pointing to empty
infeed tray. Press return arrow to go back to the home
screen.
* Paper Out screen will come on if start is pressed and
the is no paper in the feed tray.
Error screen will apear with arrow pointing to open
cover with indicator to close cover. Press return arrow
to go back to the main screen.
Paper Jam
Error screen appears with arrows pointing to possible areas
to check. Press the return arrow to go back to home screen
at any time. If the jam is not cleared the error screen will
appear again after pressing start or 1x.
Paper misfeed
Error screen will appear with arrow pointing to infeed.
Press return arrow to go back to the home screen.
Cover Open
Paper Out
Cover Open
FD 342 Touch Screen -Error Screens
Error screen will appear with arrow pointing to empty
infeed tray. Press return arrow to go back to the home
screen.
* Paper Out screen will come on if start is pressed and
the is no paper in the feed tray.
Error screen will apear with arrow pointing to open
cover with indicator to close cover. Press return arrow
to go back to the main screen.
Paper Jam
Error screen appears with arrows pointing to possible areas
to check. Press the return arrow to go back to home screen
at any time. If the jam is not cleared the error screen will
appear again after pressing start or 1x.
Paper misfeed
Error screen will appear with arrow pointing to infeed.
Press return arrow to go back to the home screen.
Cover Open
Paper Out
8

INSTALLING OPTIONAL FLOW STRAPS
Figure 11
Figure 13
3. With strap in place, press clip down over strap. (Figure 13)
4. Figure 14 shows strap and clip in place.
NOTE: Clip must be removed before moving strap to a different location.
Figure 14
Figure 15
5. Repeat process on other side. Figure 15 shows two straps in place.
Flow
Strap
1. Optional Flow Straps can be used when processing thicker paper stock. To install, fold over 1/2 inch of
strap. (Figure 11)
2. Place strap over static brush in appropriate location. (Figure 12)
NOTE: Straps should not be placed where they will interfere with the conveyor belts or the weighted out-
feed tires, (see Figure 15).
Figure 12
Flow
Strap
9

TROUBLESHOOTING
A. Clearing paper jams:
WARNING: Turn machine off and unplug cord from its receptacle.
1. If a jam occurs in 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 8) and turn clockwise
(Caution: Do not apply excessive 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 9) near the power cord inlet to reset the breaker if necessary.
DAILY MAINTENANCE
1. It is recommended to let forms cool for one-half hour, from the laser printer, before folding and seal-
ing. This allows toner to set on the forms, and static electricity to discharge. The FD400 Jogger is
recommended for best results. The Jogger squares the forms and dissipates heat and static created
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 re-
move 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.
2. If a jam occurs in the fold plates, remove fold plate and remove paper. Reinstall fold plate.
Figure 8 Figure 9
10

Figure 10
C. Paper is not folding square (Skewing):
TROUBLESHOOTING
D. Machine plugged in, no power
1. Turn machine ON.
2. Make sure top cover is installed properly.
3. Press the circuit breaker (Figure 9).
4. Check wall outlet.
5. Remove operator cover check the fuse located on control board next to transformer.
6. Check all electrical connections.
E. Double feeding / Mis-feeding
1. Clean feed wheel, using soap and water.
a. Check center in-feed roller and singulator pad for wear. Replace pad if it is cupped.
b. Check to see if center in-feed roller is centered on the gate tip.
2. Run a stack of plain paper. This is done to check on proper feeding. If double-feeding does
not occur on the paper:
a. Check to be sure pressure seal forms are not sticking together. Jogging or hand
separating may be necessary to determine this.
b. Hand separate about 50 forms, align and test-run the forms. If no double feeding
occurs, proper forms handling is necessary.
1. If paper pulls left or right adjust the skew. Turn
the skew adjuster, located under the infeed tray,
(Fig. 10) left or right until the paper is feeding
correctly.
11

Figure 10
C. Paper is not folding square (Skewing):
TROUBLESHOOTING
D. Machine plugged in, no power
1. Turn machine ON.
2. Make sure top cover is installed properly.
3. Press the circuit breaker (Figure 9).
4. Check wall outlet.
5. Remove operator cover check the fuse located on control board next to transformer.
6. Check all electrical connections.
E. Double feeding / Mis-feeding
1. Clean feed wheel, using soap and water.
a. Check center in-feed roller and singulator pad for wear. Replace pad if it is cupped.
b. Check to see if center in-feed roller is centered on the gate tip.
2. Run a stack of plain paper. This is done to check on proper feeding. If double-feeding does
not occur on the paper:
a. Check to be sure pressure seal forms are not sticking together. Jogging or hand
separating may be necessary to determine this.
b. Hand separate about 50 forms, align and test-run the forms. If no double feeding
occurs, proper forms handling is necessary.
3. If double-feeding continues to occur, the next step is to check the gate tip pressure.
12
1. If paper pulls left or right adjust the skew. Turn
the skew adjuster, located under the infeed tray,
(Fig. 10) left or right until the paper is feeding
correctly.

4. With the in-feed tray pushed down and free of forms, spin the center in-feed roller. You are
looking for a minimal drag.
5. Make sure singulator mount is sitting straight on bracket. If crooked, loosen the two screws
and adjust until straight.
6. To evaluate operation of the singulator/gate tip assembly:
a. Turn OFF machine and unplug.
b. Remove lower fold plate.
c. Reach hand up underneath paper feed tray. You will feel the gate tip adjusting screw;
back off the screw about 3 turns.
d. Press down on the gate tip and remove your nger. The gate tip should go down and
spring up again. If it doesn’t work smoothly, determine where it’s binding and correct the
problem.
NOTE: Increase the spring tension on the singulator assembly by moving the springs up one
more notch.
7. After you have determined that the singulator assembly is operating smoothly, readjust the
gate-tip adjusting screw. Back off pressure on the gate tip until it moves freely up and down.
With paper in-feed tray in lowered position, turn screw to tighten until the gate tip no longer
moves up and down.
8. Reinstall the lower fold plate. Place a stack of unprinted forms on the feed tray and test run.
You are looking for consistent feeding with no hesitation and no double feeding.
9. If needed, ne tune adjustments can be made by turning the gate tip adjusting screw in small
increments until you get the desired results.
TROUBLESHOOTING
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