Formax FD 260 User manual

FD 260 Tabber
Operator Manual
1/2011 First Edition

TABLE OF CONTENTS
1. INTRODUCTION ..............................................................................................1
1.1 Organization of this Operating Manual ...........................................................1
1.2 FD 260 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
1.8 Ordering Additional Equipment.......................................................................6
2. SPECIFICATIONS & REQUIREMENTS ..........................................................7
2.1 Specifications..................................................................................................7
2.2 Operating Requirements.................................................................................7
3. POWER CONNECTION ...................................................................................8
3.1 Safety..............................................................................................................8
3.2 Line Voltage....................................................................................................8
3.3 Line Fuses....................................................................................................10
3.4 Accessory Fuses...........................................................................................11
3.5 Accessory Power Outlet................................................................................12
3.6 Power Cord...................................................................................................12
4. CONTROLS....................................................................................................13
4.1 Power Switch................................................................................................13
4.2 LCD Counter.................................................................................................13
4.3 Gap Adjustment Lever..................................................................................14
4.4 Tab Size Switch……………………………………...………………………...…14
4.5 Control Panel................................................................................................14
4.5.1 Tab Ready......................................................................................................14
4.5.2 Clear Tab .......................................................................................................15
4.5.3 On/Off ............................................................................................................15
5. FEEDING DEVICES.......................................................................................16
5.1 Placing the FD 260 In-Line ...........................................................................16
5.2 FD 260-10 Feeder ........................................................................................17
6. OPERATION...................................................................................................19
6.1 Threading Tabs.............................................................................................19
6.2 Feeding Mail Pieces......................................................................................22
6.3 Tabbing Mail Pieces .....................................................................................22
6.4 Removing Waste Backing Paper..................................................................24

7. MAINTENANCE..............................................................................................25
7.1 General Cleaning & Clearing ........................................................................25
7.1.1 Removing Tabs & Debris From Peel Point Area.............................................25
7.2 Replacing A Fuse .........................................................................................26
7.2.1 Line Fuse........................................................................................................26
7.2.2 Accessory Fuse..............................................................................................27
8. TROUBLESHOOTING ...................................................................................29
8.1 Troubleshooting Chart ..................................................................................29
9. CORRECTING TABBING PROBLEMS .........................................................32
9.1 No Tabs Applied To Mail Pieces...................................................................23
9.1.1 Sensor Could Not Detect Tab.........................................................................32
9.1.2 Sensor Is Not Tuned For Clear Tabs..............................................................33
9.1.3 Mail Piece Jam...............................................................................................34
9.1.4 Torn Backing Paper........................................................................................36
9.1.5 Incorrect Threading ........................................................................................37
9.2 Poor Tab Placement or Appearance…………………………...……………….38
9.2.1 Tab Placement Is Inconsistent........................................................................38
9.2.2 Tab Fold Is Uneven........................................................................................38
9.2.3 Tab Fold Is Off Mail Piece -- Tab Is Tenting...................................................40
9.2.4 More Than One Clear Tab On Mail Piece.......................................................41
10. SERVICE......................................................................................................42
10.1 Service........................................................................................................42
10.2 Repacking Instructions................................................................................42

1
1. INTRODUCTION
1.1 Organization Of
This Operating
Manual This manual starts with a description of your FD 260,
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 260.
1.2 FD 260
Description The FD 260 is an automatic tabbing machine used to
seal open mail pieces. Tabs are peeled from rolls of
backing paper and applied to mail pieces such as
self-mailers, brochures, newsletters and double
postcards.
Mail pieces are fed into the FD 260 using a feeding
device such as the FORMAX FD 260-10 Feeder, or a
feeder or labeler from another manufacturer. If the
FD 260 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 260 with mail pieces. Please
read your feeding device operating manual before
using it in-line with the
FD 260.
NOTE
Some feeding devices require a stand in order
to operate in-line with the FD 260.
Check with your FORMAX dealer.
The FD 260 uses a tabbing head to advance rolls of
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 onto mail pieces between a
sweep and rolls. The tabbed mail pieces exit the FD
260 and can be collected in an optional FORMAX

2
FD 260-20 Conveyor.
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, and are the only tabs that say
FORMAX on the box. Imitation tabs can be run on
FORMAX Tabbers, but are not guaranteed to run
problem-free.
The FD 260 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 260
needs a few seconds to get itself ready to run. When
you turn the power on, the FD 260 takes 5 seconds to
boot up. During this time, all lights flash and the
control panel is inoperative.
Signals from sensors are fed to the microprocessor
which monitors the condition of the tabbing head and
lets you know the condition through lights on the
control panel. Without correct sensing, the FD 260
will behave improperly. The FD 260’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. The emitter half of the sensor is located under
the transport tray beneath the peel bar. It can be
seen by looking into the FD 260, along the paper path
below the peel bar. The detector half is shrouded
under the steel covers at the input end of the FD 260
in front of the peel bar.
Debris and stray tabs can become caught in the
paper path and sensor beam. Rough, careless
handling of the FD 260 can cause the sensors to
become mis-aligned. Both of these conditions must
be prevented. The FD 260 requires periodic cleaning
and reasonable handling. Paper dust build-up or
abuse will bring the successful operation of the FD
260 to an end. Take care of your FD 260 by following
the set up, operation and maintenance instructions in
this manual.

3
1.3 Items Included
The following items are shipped together in one box.
Take note of each as you unpack the box.
FD 260 Tabber
Power cord
Operating Manual
1 roll of white tabs
1 roll of clear tabs
WARNING
THE FD 260 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 260’s
productivity.

5
1.5 Safety
Precautions Observe the following safety precautions and
warnings when operating, cleaning or repairing the
FD 260. Failure to do so may result in physical injury
or damage to the FD 260. The manufacturer
assumes no liability for your failure to comply with
these requirements.
WARNING
NEVER CLEAN, CLEAR OR DISASSEMBLE THE
FD 260 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 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 260 is covered under warranty
by the dealership from which you purchased it.
Formax warrants your FD 260 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 260 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.
1.8 Ordering
Additional
Equipment To order, or find out about, additional Formax
equipment or supplies, contact an authorized Formax
dealer.