Formax FD 280-20 User manual

FD 280-20
High Volume Tab Delivery Module
Operator Manual
8/2011 First Edition

TABLE OF CONTENTS
1. INTRODUCTION ..............................................................................................1
1.1 Organization of this Operator Manual.............................................................1
1.2 FD 280-20 Description....................................................................................1
1.3 Items Included ................................................................................................2
1.4 Operator Manual Safety Terms ......................................................................2
1.5 Safety Precautions..........................................................................................3
1.6 Warranty.........................................................................................................3
1.7 Ordering Additional Equipment.......................................................................4
2. SPECIFICATIONS & REQUIREMENTS ..........................................................5
2.1 Specifications..................................................................................................5
2.2 Operating Requirements.................................................................................5
3. POWER CONNECTION...................................................................................5
3.1 Safety..............................................................................................................5
3.2 Line Voltage....................................................................................................6
3.3 Line Fuses......................................................................................................6
3.4 Accessory Fuses.............................................................................................6
3.5 Accessory Power Outlet..................................................................................7
3.6 Power Cord.....................................................................................................8
4. CONTROLS AND INDICATORS......................................................................9
4.1 Power Switch..................................................................................................9
4.2 Momentary Advance (Jog) Switch ..................................................................9
4.3 Indicators......................................................................................................10
4.4 Emergency Stop ...........................................................................................10
5. OPERATION...................................................................................................11
5.1 Placing the FD 280-20 In-Line......................................................................11
5.2 Threading tabs (labels).................................................................................11
5.3 Replacing Empty Spools...............................................................................12
5.4 Using Flat Rolls.............................................................................................13
5.5 Splicing Tabs…………………………………………...………………………….14
6. MAINTENANCE…………………………………………………………………….15
6.1 General Cleaning & Clearing........................................................................15
6.2 Replacing A Fuse .........................................................................................15
6.2.1 Line Fuse........................................................................................................15
6.2.2 Accessory Fuse..............................................................................................16
7. TROUBLESHOOTING AND SERVICE..........................................................17
7.1 Troubleshooting Chart ..................................................................................17
7.2 Service..........................................................................................................19
7.3 Repacking Instructions..................................................................................19

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1. INTRODUCTION
1.1 Organization Of
This Operating
Manual This manual includes a description of your
FD 280-20, set up, operation, maintenance and
troubleshooting. 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 280-20.
1.2 FD 280-20
Description The Formax FD 280-20 may be used as an accessory
label feeder for many labeling machines or printers.
In this manual the FD 280-20 is described as a part of
a system featuring the Formax FD 280 tabbing
machine.
The FD 280-20 is equipped with a dolly using locking
casters. Place it in position and lock the casters.
Rolls of tabs are placed between spool end plates
(included) and mounted on the FD 280-20. The web
of tabs is then threaded through the FD 280-20 and
up to the FD 280. One strip of tabs may be spliced to
another.
As the tabber uses tabs, the FD 280-20 automatically
unrolls more tabs as needed. At the end of the spool,
the FD 280-20 goes into an error state and shuts
down the FD 280’s feeder.
The FD 280-20 has a unique feature that facilitates its
use as a part of a tabbing or labeling system. The
Accessory Power Outlet is switched and controlled by
the operation of the FD 280-20. Typically, the FD
280-20 receives its power from the FD 280. It then
supplies all upstream equipment based on the FD
280’s transport. When the FD 280 is capable of
running material through it, the FD 280-20 and the
feeder will run in turn. Stop the FD 280’s transport
with the E-Stop switch and all upstream modules stop
as well.

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1.3 Items Included
The following items are shipped together in one box.
Take note of each as you unpack the box.
Formax FD 280-20 Tab Delivery Module
Power cord
Operating Manual
Tab Roll End Plates
Dolly
WARNING
THE FD 280-20 IS A HEAVY MACHINE.
USE PROPER LIFTING TECHNIQUES TO
SET IT ON A WORK SURFACE.
1.4 Operating
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.

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TIP
A suggestion to enhance the FD 280-20’s
productivity.
1.5 Safety
Precautions Observe the following safety precautions and
warnings when operating, cleaning or repairing the
FD 280-20. Failure to do so may result in physical
injury or damage to the FD 280-20. The
manufacturer assumes no liability for your failure to
comply with these requirements.
WARNING
NEVER CLEAN, CLEAR OR DISASSEMBLE THE
FD 280-20 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.
1.6 Warranty NOTE
Your FORMAX FD 280-20 is covered under
warranty by the dealership from which you
purchased it.
If you have any questions about the FD 280-20,
contact your authorized FORMAX dealer.
Formax warrants your FD 280-20 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

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warranty covers the cost of parts when the machine is
presented by its original purchaser to an authorized
Formax Dealer. Should warranty repairs become
necessary, the service provider, at his/her option, will
repair or replace such parts required to restore the FD
280-20 to serviceable condition.
This warranty does not cover consumable parts such
as belts, rollers and sweeps used to contact and
transport labels and/or 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.
1.7 Additional
Equipment To order or find out about additional Formax
equipment, parts or supplies, contact an authorized
Formax dealer. To locate an authorized dealer in
your area, call Formax 800-232-5535.

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2. SPECIFICATIONS & REQUIREMENTS
2.1 Specifications
Size & Weight
12.5" l x 17.5" h x 16" weight -- 45 lb.
Power
USA household voltage 120V, 60 Hz
2.2 Operating
Requirements
Tab Specs
Tab width: between 11/2" and 1"
Tab length: 1" –1.5”
Backing paper width: 1”-2”
Maximum roll diameter: 12" (50,000 1.5" tabs/roll)
Core Diameter: 3"
Production
60,000 inches/hr.
WARNING
BEFORE PLUGGING THE FD 280-20 INTO AN
OUTLET, CAREFULLY READ THE FOLLOWING
INFORMATION ABOUT VOLTAGES, FUSES AND
THE POWER CORD.
3. POWER CONNECTION
3.1 Safety
The FD 280-20 connects to a grounded 120 VAC
power distribution system. The FD 280-20 uses
protective fusing in both the neutral and hot supply
lines of power.

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WARNING
A BLOWN FUSE IN THE NEUTRAL LEG COULD
MEAN INTERIOR PARTS OF THE FD 280-20
REMAIN AT A HAZARDOUS VOLTAGE. ALWAYS
UNPLUG THE POWER CORD BEFORE REMOVING
COVERS FROM THE FD 280-20.
3.2 Line Voltage
The FD 280-20 is rated for continuous operation
using a 120VAC/60 Hz grounded supply
3.3 Line Fuses
The FUSE DRAWER located on the Power Entry
Module 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 280-20
to operate properly.
Always replace blown fuses with like type and rating
fuses.
3.4 Accessory
Fuses Two FUSEHOLDERS are located on the Power Entry
panel between the APPLIANCE INLET and the
ACCESSORY POWER OUTLET. (Refer to Figure
3.1.) The FUSEHOLDERS hold two ACCESSORY
FUSES which protect the ACCESSORY POWER
OUTLET. As with the LINE FUSES mentioned
previously, both the neutral and hot lines are fused.
Both ACCESSORY FUSES must be intact for the FD
280-20 to properly supply power to in-line equipment.

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WARNING
UNPLUG THE POWER CORD BEFORE STARTING
THIS PROCEDURE.
Use the following instructions to verify that the
ACCESSORY 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 press in
and rotate the FUSEHOLDER CAP
counterclockwise to release this cap.
3. Pull the FUSEHOLDER CAP (with the
ACCESSORY FUSE inside) out of the
FUSEHOLDER.
4. Verify the fuse value. Inspect fuses, replace if
blown.
Selected Voltage Line Fuse Value
120V…………………… 6.3A (250V time delay)
5. Install the ACCESSORY FUSE and the
FUSEHOLDER CAP in the FUSEHOLDER. Both
ACCESSORY FUSES must be intact for the FD
280-20 to properly supply power to in-line
equipment.
6. Using the screwdriver, press in and turn the
FUSEHOLDER CAP clockwise to lock it.
3.5 Accessory
Power Outlet The ACCESSORY POWER OUTLET is located next
to the FUSEHOLDER and Power Inlet. This outlet
supplies power to equipment running upstream from
the FD 280-20. The Accessory Power Outlet is
switched by the FD 280-20. Should a fault occur on
the FD 280-20 all machines attached to it through the
Accessory Outlet will stop as well.
The ACCESSORY POWER OUTLET is limited to a
6.3A maximum at 120 volts. The total amperage of
all machines upstream of the FD 280-20’s Accessory
Power outlet must not exceed the maximum rated
amperage.

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3.6 Power Cord The FD 280-20 comes with a three-wire POWER
CORD. The POWER CORD grounds the FD 280-20
when connected to an approved three-contact
electrical outlet.
1. Plug the POWER CORD into the APPLIANCE
INLET.. (Refer to Figure 3.1.)
2. Plug the POWER CORD into a grounded outlet.
WARNING
TO PREVENT ELECTRICAL SHOCK, ONLY PLUG
THE POWER CORD INTO A GROUNDED OUTLET.
Figure 3.1 Power Entry Panel

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4. CONTROLS AND INDICATORS
Figure 4.1 - FD 280-20 Controls
4.1 Power Switch The POWER SWITCH is located on the upper front
of the FD 280-20. It is on a bracket accompanied by
the orange power indicator
4.2 Momentary
Advance (Jog)
Switch The Jog Switch is located on the opposite side of the
machine from the Power Switch. It is accompanied
by a red and a green LED on its mounting bracket.
Jog Button
Red and Green
Status Indicators

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4.3 Indicators
1. Orange –Power ON. Lights when the FD 280-20
is powered on.
2. Green –Ready. Lights when all systems are
operating correctly.
3. Red –Fault. Lights when something goes wrong,
and the FD 280-20 stops. Accompanied by an
audible alarm. All machines plugged into the FD
280-20 Auxiliary Outlet stop on a fault as well.
4.4 Emergency
Stop
The front door is equipped with an interlock that acts
as an Emergency Stop. Open the door and the FD
280-20 stops as do all machines attached to it.
Figure 4.2 Threaded FD 280-20

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5. OPERATION
5.1 Placing The
FD 280-20
In-Line To operate the FD 280-20 in-line with your tabbing
device, place the FD 280-20 near the label head that
is to be fed by an FD 280-20. Keep the label web
from twisting as much as possible while allowing the
tabber to pull tabs from the FD 280-20.
NOTE
Turn on the FD 280-20 before turning on any
feeding device.
Typically the system’s feeder is plugged into the
FD 280-20’s Auxilliary Power Outlet.
5.2 Threading Tabs To thread tabs:
1. Place the tab roll atop the FD 280-20 with about a
foot of tabs coming over the top of the roll toward
the operator
2. Turn Power ON and open the front door.
3. Place the lead edge of the tabs between the brush
and the red tab feed roll.
4. Advance the tabs by pressing the momentary jog
switch.
5. The tab web will be fed into the FD 280-20 and a
loop will form coming back to the operator. Stop
pressing the jog button.
6. Insert the lead edge of the tab web into the slot in
the door and while closing the door, catch the tab
web under the door handle to direct the web up
and away from the FD 280-20.
The FD 280-20 will now unwind tabs on demand. To
gain slack, merely pull tabs from the FD 280-20.
When you stop pulling, the FD 280-20 will stop
advancing tabs.

12 6/10
5.3 Replacing
Empty Spools
When the spool is nearly empty, watch to be sure that
the last strip of tabs does not catch on the spool. Stop
tabbing, remove the empty spool and splice on a new
strip of tabs from the new spool. Be sure to secure
the spool ends on the new spool. Splice by placing
the lead edge of the new strip under the existing strip
and securing the bottom of the tab strips. (See fig.
5.3)
Tabs
Label Yoke
Label Drive Roll
Front Door
Label Well

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5.4 Using Flat Rolls
The maximum diameter of the roll to be fed is 12”.
1. Arrange the flat roll (s) on a common shaft.
2. Lock the rolls in place using the collars provided.
3. Slip the end plates on the shaft.
4. Place the assembly on the FD 280-20.
Using this method, it is possible to have a variety of
tabs stored in flat rolls on the FD 280-20 until needed.
Figure 5.2 Flat Roll Set Up

14 6/10
5.5 Splicing Tabs
In order to maintain continuous operation, tabs should
be spliced using the following technique.
Figure 5.3 Splicing Details

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6. MAINTENANCE
6.1 General
Cleaning Your FD 280-20 will need regular cleaning. How
often depends on the amount of use. Wipe surface
dust or debris from the FD 280-20 with a damp cloth
as necessary.
Watch for wear on the spool ends. If they become
worn and flattened, replace them.
WARNING
DO NOT PLACE FINGERS OR TOOLS BETWEEN
OR NEAR MOVING PARTS.
6.2 Replacing a
Fuse
6.2.1 Line Fuse When one or both LINE FUSES are blown, the
FD 280-20 will appear to have no power and the
LINE FUSE must be replaced.
WARNING
UNPLUG THE POWER CORD BEFORE OPENING
THE FUSE DRAWER.
To replace a LINE FUSE:
1. Use a small screwdriver or similar tool to push up
on the FUSE DRAWER LOCKING TAB to release
this locking tab. (Refer to Figure 7.1.)

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2. Pull the FUSE DRAWER out of the POWER
ENTRY CASING. (Refer to Figure 7.1.)
Figure 7.1 –Replacing a Line Fuse
3. Inspect the FUSES; look for blackened glass,
melted wire or a disconnected wire between the
ends of the tube. If you find any of these
problems in either FUSE, that FUSE is blown and
must be replaced.
4. Pull the blown FUSE from its slot.
WARNING
REPLACE ONLY WITH SAME TYPE AND RATING
OF FUSE. (REFER TO CHART BELOW.)
Selected Voltage Line Fuse Value
120V………………….....1.0A (250V time delay)
5. Place the new FUSE into the same slot.
6. Install the FUSE DRAWER. (Refer to Figure 7.1.)