Formax AutoSeal FD 2052 Bedienungsanleitung

FD 2052

AutoSeal®

OPERATOR MANUAL

FOURTH EDITION

12/2007

TABLE OF CONTENTS

DESCRIPTION 1

SPECIFICATIONS 1

UNPACKING AND SET-UP 1 - 2

CONTROLS 2

OPERATION 3

CUSTOM FOLDS 3 - 4

Measuring Fold Lengths 3

Custom Fold programming 4

BATCH COUNTING 4 - 5

DAILY MAINTENANCE 5

TROUBLESHOOTING 6 - 7

DETERMINING FOLD TYPE 8

TEST SHEET 9

OPTIONAL CONVEYOR INSTALLATION 10

SPECIFICATIONS

DESCRIPTION

FUNCTION

The 2052 folds and seals pressure sensitive forms with pre-applied glue lines into mail-ready pieces. Numerous

folds using several different paper sizes can be processed to meet your needs. For conﬁgurations and paper

sizes, see speciﬁcations.

Maximum foldable paper size 17” length x 8.5” width

Fold styles “C”, “Z”, “V” and custom folds

Paper loading capacity Up to 350 sheets of 24 # pre-glued forms

Weight 90 lbs.

Power supply FD Model: 120 volts, 60 Hz, 3.5 amps.

FE Model: 240 volts, 50 Hz, 3.5 amps.

UNPACKING AND SETUP

1. Check package for shipping damage. If there is shipping damage, do not discard the box.

2. CAUTION: Two people must lift the machine out of the box.

3. Remove the accessory bag which is between the machine and the catch tray.

4. Place the jam clearing handle into the holder which is mounted to the machine. This is the jam clearing

handle’s proper location (ﬁgure 1).

Paper Side Guides

Lower Fold Plate

Side Cover

Optional 18” Conveyor

Upper Fold PlateTop Cover

Feed Table

Jam clearing handle location

Figure 1

LOWER FOLD TABLE UPPER FOLD TABLE

5. Install the lower fold table and plug the cord (ﬁgure 2a) into the fold plate receptacle.

6. Install the upper fold table and plug the cord (ﬁgure 2b) into the fold plate receptacle.

7. Plug machine into wall outlet.

CAUTION: Do not operate the machine without the fold tables plugged in.

NOTE: The display screen should read (COUNT: 0000) and a fold setting (i.e. Letter, ZigZag, Single or

custom #) when the machine is plugged in and the power is turned on.

Start/Stop...................Starts and stops the machine

Test.............................Allows one form to be folded

Counter Reset............Resets counter and resets faults

Display Screen...........Displays all current functions

Standard Folds Menu:

The Standard Folds Menu consists of three folds; Letter (C-fold), Zig-Zag (Z-fold), and Single (Half fold). By

pressing the green button in the Standard Folds Menu, you can toggle between the fold settings. An indicator

will light up on the fold type selected. These fold types are standard for 11” and 14” forms. The 2052 will

identify the form length 11” or 14” via a sensor.

Custom Folds Menu:

To use a custom fold setting press one of the custom fold buttons (1, 2, 3-9). Press the 3-9 button multiple

times to toggle through the 3rd and the 9th custom folds.

CONTROLS

Figure 2b

Figure 2a

OPERATION

1. Plug in cord and turn power on.

2. Lift load handle.

3. Load neatly stacked and squared paper into the hopper.

4. Adjust the side guides until they make light contact with the squared paper edges.

5. Make sure covers are closed properly.

6. Select the fold-type and press the test button to verify fold.

7. Press the start button to begin operation.

8. Set speed to desired setting.

SETTING CUSTOM FOLDS

Example 1: Uneven “Z”

a. Measure the length of panel “A” + “B”

b. Measure the length of panel “B”

c. Enter these measurements according to the

instructions on next page

Example 2: Uneven “C”

a. Measure the length of panel “A”.

b. Measure the length of panel “B”

c. Enter these measurements according to the

instructions on next page.

1. Measuring Fold Lengths

Panel A

Panel B

Panel A

Panel B

The Custom Folds Menu allows you to program custom folds into memory. The 2052 can store up to nine

custom folds. To store a custom fold into memory, follow these steps:

1. Select the custom fold number you want to program.

2. Press the green button next to the Table A and Table B lights.

Note: The display will read “Tbls A: #.## B: #.## CUSTOM #”.

Table A adjusts the upper fold plate.

Table B adjusts the lower fold plate.

The “-“ and “+” buttons decrease and increase the fold numbers.

3. Press the “-” and/or “+” button to enter the length of the fold. Fine adjustments can be made with the

adjustment screw at the end of the plate.

4. Press the “Test” button to insure the proper folds have been entered.

5. Once the folds are correct, press and hold the “Custom Fold” green arrow button until the machine sounds

a tone. The fold has been memorized.

Note: The display screen will read “count # and custom #”. To run your custom fold without saving it, simply

press the “Start” button after step 4 above.

1. To enter the manual batch counting mode press the

“Batch Count” button and select “MANUBATCH” by

pressing the “+” button (Fig 3a) .

2. Select the number of sheets to be folded by pressing

the “+” or “-” buttons (Fig. 3c) , then press the “Start/

stop” button to start.

MANUBATCH:

The “Manubatch” or “manual batch” feature allows you to program the number of sheets you would like to

process in a set. When the set is complete, the folder will stop and automatically reset the batch count to the

previously set number of sheets. It will then fold the next set when the “Start/Stop” button is pressed.

AUTOBATCHTM:

“Autobatch” or “automatic batch” allows you to batch count with automated features. In the Autobatch mode

you can program the number of sheets you would like to process in a set, the number of sets you would like

and the delay between each set. For example: you can program 10 sheets to be pulled to create a set, then

program 100 sets to be processed with a 3 second time delay between each set.

Batch Counting

Figure 3a

Figure 3c

1. To enter the Autobatch mode press the “Batch

Count” button and select “AUTOBATCH” by pressing

the “-” button (Fig 3a).

2. Once you have entered the Autobatch mode press

the “+” or “-” button and “Sheets” (Fig. 3c) will blink.

Press the “+” or “-” buttons to increase or decrease the

number of sheets to be pulled.

3. When the sheet number is set wait 5 seconds and

“Sets” (Fig. 3c) will blink. Press the “+” or “-” buttons

to increase or decrease the number of sets to be

pulled.

4. When the number of sets has been selected wait 5

seconds and “Delay” (Fig. 3c) will blink. Press the “+”

or “-” buttons to increase or decrease the time delay

between the sets.

5.When the settings are correct press the “Start/Stop”

to start.

NOTE: The system will cycle through the settings until

the “Start/Stop” button is pressed.

NOTE: If a fault occurs during a set, the set will be

completed when the fault is reset.

NOTE: The batch counting program selected will

remain on after the job is processed. You must press

the Batch Counting button to turn off the light and

cancel the batch count setting.

“Sheets” = Number of sheets of paper in a set

“Sets” = Number of sets to be processed

“Delay” = Time between each set

“C” = Total number of sheets processed

Figure 3b

DAILY MAINTENANCE

1. It is recommended to let forms cool for one-half hour, from the laser printer, before folding and sealing. This

allows toner to set on the forms, and static electricity to discharge. A 400 Series Jogger is recommended for

best results. The Jogger squares the forms and dissipates heat and static electricity created by laser printers.

2. If toner builds up on the metal sealer rollers, clean the rollers with a lint-free cloth dampened sparingly with a

mild household cleaner.

3. Clean in-feed wheels and fold rollers with Formax recommended roller cleaner & rejuvenator to remove

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.

TROUBLESHOOTING

1. If paper folds left or right adjust the skew adjuster. To adjust the skew, turn it left or right until the paper is

feeding correctly and folds squarely (ﬁ gure 6)

B. Paper Pulls Left or Right During Feeding:

WARNING: Turn off machine and unplug cord from its receptacle.

1. If a jam occurs in a fold table, unplug and remove the fold table and remove paper. Reinstall and plug in fold

table and then press the counter reset button on the control panel to clear the fault signal.

2. If a jam occurs in between the metal sealing rollers, remove any remaining forms from the hopper. Open

the top cover and remove the upper fold table. Remove the jam-clearing tool (located under the top fold table),

apply the tool to the upper metal roller (ﬁ gure 4) and turn clockwise until the paper jam is clear. (Caution: Do

not apply excessive force or rollers may be damaged.) (Caution: Do not turn counter-clockwise and force the

form(s) to exit the machine or the rollers may be damaged.) Remove the jammed form, return tool to holder

and reinstall the upper fold table. Reinstall cover and press the reset button.

Note: Press the black button (ﬁ gure 5) near the power cord inlet to reset the breaker if necessary.

A. Clearing Paper Jams and Fault Signals on the Display Panel:

1. Adjust the side guides to the edge of the forms.

2. Clean the three infeed wheels with a cloth dampened with a mild household cleaner.

C. Skewed Forms

2. Side guides should be adjusted so that the forms do not have free play between the guides.

Figure 4 Figure 5

Figure 6

D. Machine Plugged in, no Power:

1. Turn machine on.

2. Check wall outlet.

3. Press the circuit breaker (ﬁgure 5).

4. If the display screen on the control board is not on, then check the green power light on the power board.

To view the green power light, open the operator side cover and look though the air slots in view of the

power board. If that light is on there’s a loose wire or connector not connected.

E. Power on, Machine does not Work:

1. If the green power light is not on at the power board check the circuit breaker (ﬁgure 5), then troubleshoot

back to where you have power.

2. If the display screen reads “COVER OPEN,” ensure that the operator and top covers are closed properly.

3. If the display screen reads “PAPER OUT,” load paper into hopper.

4. If the display screen reads “FAULT,” then the photo eye has detected the presence of paper for

more than half a second. Remove the jammed paper, then press the counter reset button to reset

the fault. If there is no paper jam, check for proper operation of the photo eye.

F. Photo Eye Adjustment:

There is a single photo eye, just upstream from the pressure rollers, used for both counting and fault detection

(doubles). There is another photo eye, at the end of the paper tray extension. This is used for detecting 11”

paper or 14” paper. There are 2 sets of lights that will allow you to adjust the sensitivity of the photo eyes.

The ﬁrst set of lights on the left is used to adjust the photo eye sensitivity, for the fault detection. There are

three lights to help you do this. The ﬁrst is a red light (low signal). The second is a green light (good signal).

The last is a red light (excess signal). These lights can be viewed by opening the operator side cover.

The second set of lights on the right is used to adjust the photo eye sensitivity, for the paper detection. There

are three lights to help you do this. The ﬁrst is a red light (low signal). The second is a green light (good signal).

The last is a red light (excess signal). These lights can be viewed by opening the operator side cover.

The photo eyes can be adjusted using the two small blue square boxes on the control board. They have screw

slots in them for delicate adjustment. The ﬁrst one on the left is for the fault detection and the second one to

the right is used for the 14” paper detection. To adjust, place a form on top of the photo eye and change the

setting on the small blue box until the red light (excess signal) just turns to the green light (good signal).

G. Misfeeding of Forms:

1. Clean the feeder wheels.

2. Adjust the skew adjust.

3. Turn forms upside down and rotate 180 degrees and place in hopper (Z” fold forms only).

H. Double Feeding:

If double feeding occurs, try the following steps:

1. Jog the forms to reduce static build up and to make sure the forms are not stuck together.

2. Clean the infeed wheels with a cloth dampened with a mild household cleaner.

3. Ask the technician to adjust the gate tip.

DETERMINING FOLD TYPE

Two Standard Folds 11” “Z” & 11” “C”

Refer to Operator Manual for custom fold setup.

11” “Z” Fold

11” “C” Fold

Leading glue edge

11” “Z” Fold

11” “C” Fold

Glue

Glue Glue

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