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.