Formax FD 280 User manual

Formax FD 280 Double-
Head Edge Tabber
Instruction Manual

FD 280
Double-Head Edge Tabbing System
Operator Manual
10/2011 First Edition

TABLE OF CONTENTS
1. INTRODUCTION ..............................................................................................1
1.1 Organization of this Operating Manual ...........................................................1
1.2 FD 280 Description.........................................................................................1
1.3 Items Included ................................................................................................3
1.4 Operating Manual Safety Terms.....................................................................4
1.5 Safety Precautions..........................................................................................5
1.6 Operating Manual Terms................................................................................5
1.7 Warranty.........................................................................................................6
2. SPECIFICATIONS & REQUIREMENTS ..........................................................8
2.1 Specifications..................................................................................................8
2.2 Operating Requirements.................................................................................8
3. POWER CONNECTION ...................................................................................9
3.1 Safety..............................................................................................................9
3.2 Line Voltage....................................................................................................9
3.3 Line Fuses....................................................................................................11
3.4 Accessory Fuses...........................................................................................12
3.5 Accessory Power Outlet................................................................................13
3.6 Power Cord...................................................................................................13
4. CONTROLS....................................................................................................14
4.1 Power Switch................................................................................................14
4.2 LCD Counter.................................................................................................14
4.3 Control Panel
4.3.1 Power Indicator ..............................................................................................15
4.3.2 Stop................................................................................................................15
4.3.3 Start ..............................................................................................................15
4.3.4 Tab Ready……………… ……………………………………………………… 15
4.4 Head Position Knob......................................................................................16
4.5 Tab Mode Switch..........................................................................................16
5. FEEDING DEVICES.......................................................................................17
5.1 Placing the FD 280 In-Line ...........................................................................17
5.2 ACCESSORY ITEMS ...................................................................................18
5.2.1 Fan Fold Tab Stand………………………………………………………………...18
5.2.2 FD 280 Short Cart ..........................................................................................19
5.2.3 FD 280 Long Cart………………………………………………………….………..19
5.2.4 FD 280-20 Label Delivery Module ………….…………………………………….19

6. OPERATION...................................................................................................20
6.1 Splicing Tabs................................................................................................20
6.2 Threading Tabs……………………………………………………………………21
6.3 Feeding Portrait Mail Pieces.........................................................................22
6.4 Feeding Landscape Pieces ..........................................................................24
6.5 Tabbing Mail Pieces .....................................................................................25
6.6 Adjusting Tab Position …………………………………………………………..26
6.7 Remove Waste Backing Paper…………………………………………………27
6.8 Restore Default Tab Settings……………………………………………………27
6.9 Change Piece Size………………………………………………………………27
7. MAINTENANCE..............................................................................................28
7.1 General Cleaning & Clearing........................................................................28
7.2 Replacing a Fuse..........................................................................................29
7.2.1 Line Fuse........................................................................................................30
7.2.2 Accessory Fuse..............................................................................................31
8. TROUBLESHOOTING ...................................................................................32
8.1 Troubleshooting Chart ..................................................................................32
9. CORRECTING TABBING PROBLEMS .........................................................35
9.1 No Tabs Applied To Mail Pieces
9.1.1 Tab Ready Light Off........................................................................................35
9.1.2 Mail Piece Jam........................................................................................ 35
9.1.3 Torn Backing Paper ........................................................................................36
9.2 Incorrect Threading.....................................................................................37
9.3 Poor Tab Placement or Appearance…………………………………………...38
9.3.1 Tab Placement Is Inconsistent ..................................................................38
9.4 Uneven tab Folds……………………………………………………..…………..38
9.5 Restoring factory settings ………………………………………………………..39
10. SERVICE......................................................................................................40
10.1 Service........................................................................................................40
10.2 Repacking Instructions................................................................................40

1
1. INTRODUCTION
1.1 Organization Of
This Operating
Manual This manual starts with a description of your FD 280,
then describes its set up, operation and maintenance.
Finally, information is offered to help you determine
what can go wrong and what to do about it. 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.
1.2 ET Description The FD 280 is an automatic tabbing machine used to
seal open mail pieces. Tabs are peeled from rolls or
fan folds of backing paper and applied to mail pieces
such as self-mailers, booklets, brochures, newsletters
and double postcards.
Mail pieces are fed into the FD 280 using a feeding
device such as the Formax FD 260-10 Feeder, a
feeder or labeler from another manufacturer. If the
FD 280 is to work correctly, mail pieces must be fed
into it correctly -- with a gap of about one inch
between mail pieces. This manual does not cover the
operation of the various feeding devices that may be
used to supply the FD 280 with mail pieces. Please
read your feeding device operating manual before
using it in-line with the FD 280.
NOTE
Some feeding devices require a stand
in order to operate in-line with the FD 280.
Check with your Formax dealer.
The FD 280 uses two tabbing heads to advance
pressure-sensitive tabs past a peel bar. Partially
peeled tabs hang from the backing paper, ready to be
peeled at the peel bar before they contact the mail
piece. Tabs are pressed and folded onto mail pieces
between a set of belts and rollers. The tabbed mail
pieces exit the FD 280 and can be collected in an
optional Catch Tray or stacked by a Formax
FD 260-20 Conveyor.

2
Tab quality is as important as mail piece quality. Poor
quality tabs and mail pieces take longer to run, jam
often and produce poor results. Only genuine
Formax brand tabs are 100% guaranteed to run on
Formax Tabbers. Imitation tabs can be run on Formax
Tabbers, but are not guaranteed to run problem-free.
The FD 280 depends on a smooth flow of both tabs
and mail pieces. This flow is monitored by a set of
sensors and a microprocessor. As with most
microprocessor-controlled machines, the FD 280
needs a few seconds to get itself ready to run. When
you turn the power on, the FD 280 takes 5 seconds to
boot up. During this time the tab ready light flashes
and the control panel is inoperative.
Signals from sensors and the encoder are fed to the
microprocessor which monitors the length of pieces
fed and calculates the average length of the piece.
Without correct measuring, the FD 280 will not tab.
The FD 280’s sensors work like all other electric eyes.
When an object breaks the beam of light (the
SENSOR BEAM) between them, an electrical signal
is generated. It is imperative that this SENSOR
BEAM PATH be maintained in its proper condition
and alignment at all times.
Debris and stray tabs can become caught in the
paper path and sensor beam. Rough, careless
handling of the FD 280 can cause the sensors to
become mis-aligned. Both of these conditions must
be prevented. The FD 280 requires periodic cleaning
and reasonable handling. Paper dust build-up or
abuse will bring the successful operation of the FD
280 to an end. Take care of your FD 280 by following
the set up, operation and maintenance instructions in
this manual.

3
Figure 1.1 –Formax FD 280 with FD 280-10 High Volume Feeder and stand.
1.3 Items Included
The following items are shipped together in one box.
Take note of each as you unpack the box.
FD 280 Tabber with input shafts
Power cord
Catch Tray
2 Magnetic Tab Guides
Operating Manual
WARNING
THE FD 280 IS A HEAVY MACHINE.
USE PROPER LIFTING TECHNIQUES
TO SET IT ON A WORK SURFACE.

4
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.
TIP
A suggestion to enhance the
FD 280’s productivity.

5
1.5 Safety
Precautions Observe the following safety precautions and
warnings when operating, cleaning or repairing the
FD 280. Failure to do so may result in physical injury
or damage to the FD 280. The manufacturer
assumes no liability for your failure to comply with
these requirements.
WARNING
NEVER CLEAN, CLEAR OR DISASSEMBLE THE
FD 280 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.
OBSERVE ALL POSTED WARNING DECALS
1.6 Operating
Manual Terms
The following terms are used throughout this manual:
input end where mail pieces enter
output end where mail pieces exit
operator side side where the controls are
located
non-operator side opposite the operator side

6
1.7 Warranty NOTE
Your FORMAX FD 280 is covered under warranty
by the dealership from which you purchased it.
Formax warrants your FD 280 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
warranty covers the cost of parts when the machine is
presented by its original purchaser to an authorized
FORMAX Service Center. Should warranty repairs
become necessary, the service provider, at his/her
option, will repair or replace such parts required to
restore the FD 280 to serviceable condition.
This warranty does not cover consumable parts such
as belts, rollers and sweeps used to contact and
transport mail pieces and 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.

7
2. SPECIFICATIONS & OPERATING REQUIREMENTS
2.0 Specifications
Size & Weight
20" L x 18" H x 24" W
67 lb. assembled
Power
Possible line voltages are 240V, 230V, 220V,
120V, and 100V at 50-60 Hz
2.1 Operating
Requirements
Mail Piece Size
Height: 31/2" minimum, 9" maximum
Width: 5.5" minimum, 12" maximum
Mail Piece Thickness
Minimum: single sheet of 20 lb. bond paper
tri-folded –2 tabs.
Maximum: .200”
Tab Specs
Tab width: 1" and 1.5" fan fold or roll
Tab length: 1", 1.5”
Backing paper width: between 1.125" (1" tab) and
1.625 " (1.5" Tabs)
Maximum roll diameter: 10.00" Core Diameter: 3"
Fan Fold: Case Based
Clear or translucent tabs require blacked out tab
areas.
Tab Position Accuracy
±1/8" guaranteed when using Formax®Tabs within
their specified shelf life
Mail Piece Fold Quality
Folds in mail pieces should result in flush panels.
Mail piece squareness is important when meeting
USPS tab tenting specifications.
Production
Over 15,000 mail pieces (8.4" long) per hour

8
3. POWER CONNECTION
WARNING
BEFORE PLUGGING THE FD 280 INTO AN
OUTLET, CAREFULLY READ THE FOLLOWING
INFORMATION ABOUT VOLTAGES, FUSES AND
THE POWER CORD.
3.1 Safety The FD 280 can connect to any power distribution
system, including the European IT Power System.
Because the European IT Power System does not
have a grounded neutral leg, the FD 280 uses
protective fusing in both the neutral and hot supply
lines of power.
WARNING
A BLOWN FUSE IN THE NEUTRAL LEG COULD
MEAN INTERIOR PARTS OF THE FD 280 REMAIN
AT A HAZARDOUS VOLTAGE. ALWAYS UNPLUG
THE POWER CORD BEFORE REMOVING COVERS
FROM THE FD 280.
3.2 Line Voltage The FD 280 is rated for continuous operation using a
variety of supply voltages. Possible line voltages are
240V, 230V, 220V, 120V and 100V at 50 or 60 Hz.
The manufacturer configures the FD 280 to operate
with the voltage requested by the customer.
CAUTION
VERIFY THE CORRECT VOLTAGE
SETTING BEFORE PLUGGING THE FD 280
INTO AN OUTLET.
Read the current voltage setting through the
VOLTAGE SELECTOR WINDOW on the non-
operator side of the FD 280. (Refer to Figure 3.1.)
Use the following instructions to change the voltage
setting:

9
NOTE
The detachable POWER CORD may need to be
changed to match the particular power-source
output.
1. Unplug the POWER CORD.
2. Use a small screwdriver or similar tool to push up
on and release the FUSE DRAWER LOCKING
TAB.
3. Pull the FUSE DRAWER out of the POWER
ENTRY CASING.
4. Pull the VOLTAGE SELECTOR out of the FUSE
DRAWER.
5. Rotate the VOLTAGE SELECTOR until the correct
voltage is on the same side as the VOLTAGE
SELECTOR WINDOW.
6. Place the VOLTAGE SELECTOR in the FUSE
DRAWER and verify the correct voltage selection.
7. Place the FUSE DRAWER in the POWER ENTRY
CASING.
Figure 3.1 –FD 280 Power Connection

10
3.3 Line Fuses
The FUSE DRAWER located on the non-operator
side 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 to operate
properly.
CAUTION
VERIFY THAT THE LINE FUSE VALUE IS
CORRECT FOR THE VOLTAGE SETTING.
UNPLUG THE FD 280 BEFORE STARTING THIS
PROCEDURE.
Use the following instructions to verify that the LINE
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 push up
on and release the FUSE DRAWER LOCKING
TAB.
3. Pull the FUSE DRAWER out of the POWER
ENTRY CASING. The LINE FUSES are inside.
4. Determine the proper fuse value as well as the
condition of the LINE FUSE. The fuse value is
shown on the metal tip of the LINE FUSE. The
chart below lists the selected voltage in the left
column followed by the proper fuse value in the
right column.
Selected Voltage Line Fuse Value
100V…………………….1.0A (250V time delay)
120V………………….....1.0A (250V time delay)
220V……………………..0.5A (250V time delay)
240V (or 230V)…………0.5A (250V time delay)
5. Replace the LINE FUSE if necessary. Both LINE
FUSES must be intact for the FD 280 to operate
properly.
6. Install the FUSE DRAWER in the POWER
ENTRY CASING.

11
3.4 Accessory
Fuses Two FUSEHOLDERS are located on the non-
operator side 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 to properly supply power to
in-line equipment.
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
100V…………………… 6.3A (250V time delay)
120V…………………… 6.3A (250V time delay)
220V…………………… 3.15A (250V time delay)
240V (or 230V)……….. 3.15A (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 to properly supply power to in-line equipment.
6. Using the screwdriver, press in and turn the
FUSEHOLDER CAP clockwise to lock it.

12
3.5 Accessory
Power Outlet The ACCESSORY POWER OUTLET is located next
to the FUSEHOLDER on the non-operator side.
(Refer to Figure 3.1.) This outlet supplies power to
equipment running in-line with the FD 280.
Typical in-line equipment includes feeders and
labelers. Since the ACCESSORY POWER OUTLET
gets its power from the FD 280, you can control
power to in-line equipment using the FD 280’s
POWER SWITCH. Additionally, the FD 280 features
an automatic interrupt that disables the ACCESSORY
POWER OUTLET in case of a jam. The
ACCESSORY POWER OUTLET is limited to a 6.3A
maximum for 100V and 120V, and 3.15A maximum
for 220V and 240V.
3.6 Power Cord The FD 280 comes with a three-wire POWER CORD.
The POWER CORD grounds the FD 280 when
connected to an approved three-contact electrical
outlet.
1. Plug the POWER CORD into the APPLIANCE
INLET on the non-operator side. (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.

13
4. CONTROLS
4.1 Power Switch The POWER SWITCH is located on the bottom of the
operator side panel. Turn the POWER SWITCH on
to supply power to the FD 280.
4.2 LCD Counter
The LCD COUNTER is located on the right of the
operator side panel. The LCD COUNTER displays
the current number of tabbed mail pieces fed through
the FD 280. Reset the LCD COUNTER by pressing
its reset button.
Figure 4.1 - FD 280 Operator Panel Controls
Figure 4.2 Tab Pressure Controls

14
4.3 Control Panel
Figure 4.3 - FD 280 Control Panel
4.3.1 Power Indicator The orange Power Indicator light illuminates when the
power switch is turned on.
4.3.2 Stop The STOP (red pushbutton mushroom) Switch
interrupts the movement of all moving parts and
resets the microprocessor. Once the STOP button
has been pressed, it must be lifted up into the run
position. Lifting the button will not start the machine.
Press the STOP switch to change tab mode settings.
4.3.3 Start The Start button is a momentary switch that causes
the resumption of movement after the Stop Switch
has been pressed.
4.3.4 Tab Ready Then green Tab Ready light illuminates when enough
(usually 3-4) pieces have been fed regularly through
the machine to allow precise and regular tabbing. If
the Tab Ready light stays unlit, there is a problem
with the feed mechanism as pieces are not being
counted well.

15
4.4 Head Position
Knob Turning the Head Position Knob moves the tabbing
heads closer together or farther apart. The decal
indicates the direction. Move heads only while
machine is running.
4.5 Tab Size SwitchThis three position switch indicates 1.0 inch tabs (up,
used for self mailers), 1.5 inch tabs (down used for
booklets) and Set Up (Center –no tabs).
4.6 Tab Mode Touch
Pad The Tab Mode Touch Pad offers the ability to select
the number, location and type of the tabs as well as
to change location of tabs. Changing mode settings
can only be done with the STOP button pressed.
Figure 4.4 FD 280 Tab Mode Touch Pad
Once the Tab Size Switch has been moved off Set
Up to a tab size, pressing the key pad selects the
tabs to be run as well as their general location on the
piece. There are three buttons per Tab Head - one
for the lead edge, the center and the trail edge.
A typical booklet setting will call for two tabs to be
selected on one head (lead and trail) and one on the
opposite (trail). To do a Booklet, use 1.5 inch tabs.

16
To adjust the position of the tabs, press the Stop
Button and hold down the key pad for the tab to be
moved. After a second or two, the tab select light on
that pad will begin to flash. Use the Lead /Trail
arrows on the right of the touch pad to move the tab
toward the lead edge or trail edge. Ten touches of a
position arrow will result in about half an inch in
movement in the direction selected. If corresponding
tabs on the opposite head are selected, both will
move as one. Starting the transport will save your
changes.
5. FEEDING DEVICES
5.1 Placing The
FD 280 In-Line To operate the FD 280 in-line with your feeding
device, place the output end of the feeding device
next to the input end of the FD 280. Leave about an
1/8" gap between the machines. Align machines to
place tabs where desired on the mail pieces.
The gap between the feeding device and the FD 280
may need adjusting if the mail pieces are curled or
rigid. If the mail pieces’ leading edge curls up, the
gap should be larger than 1/8" to allow the curled edge
to come down before entering the FD 280. If the
leading edge curls down, the gap should be as small
as possible, so the mail pieces will not fall between
the two machines. A rigid mail piece may require a
larger gap if it hits the bracket above the FD 280
PAPER PATH.
NOTE
Turn on the FD 280 before turning on any feeding
device. If the FD 280 is not turned on first, it will
not accept the fed mail pieces.