TABLE OF CONTENTS

SUBJECT

PAGE

DESCRIPTION

SPECIFICATIONS

UNPACKING & SETUP

CONTROL PANEL

OPERATION

CUSTOM FOLDS SETUP

MEASURING FOLD LENGTHS

RECALLING, EDITING & DELETING SAVED CUSTOM FOLDS SETUP

OPERATOR SETTINGS

DAILY MAINTENANCE / CLEANING PROCEDURES

ERROR SCREENS

TROUBLESHOOTING / CLEARING PAPER JAMS

DETERMINING FOLD TYPE

FOLD FINE-TUNING SAMPLE PAGE

DESCRIPTION

The FD 1606 AutoSeal ® Pressure Sealer is designed to process a variety of form sizes and weights. The fold tables

adjust automatically for standard folds and custom folds in 8.5” x 11”, 8.5” x 14”, and A4 (metric mode) forms. Three

standard folds are pre-programmed for 11” forms, and 5 standard folds for 14” forms including uneven C and Z folds. Up

to 3 custom folds can be programmed into memory. The sealer will stop automatically after the last document has been

SPECIFICATIONS

Speed:

Up to 100 forms per minute– based on 11” (279mm) Z-Fold

Hopper Capacity:

Up to 200 forms 20# (75gsm)

Pre-Set Folds:

Pre-programmed for C, V, Z in 11” and 14” forms, plus uneven C & Z in 14” forms

Pre-Set Paper Sizes:

FD Model: 11”, 14” FE Model: A4

Custom Folds:

Stores up to 3 custom folds into memory

Form Size:

Up to 8.5’’ W x 14” L

Dimensions:

30” L x 18” W x 13.5” H (76 L x 45 W x 34 H cm)

Weight:

Power:

Safety Certifications: UL & CE

UNPACKING & SETUP

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

Carefully lift the machine out of the box and place it on a solid surface. CAUTION: Two people are required to lift the machine out of the box.

Install fold tables (refer to page 3 for proper installation).

Plug cord into machine and into wall outlet.

Contents

Outfeed Form Knock Down Strap

Install Upper Fold Table

Remove the top cover, lift the cover up and pull out (Fig. 1a).

Locate mounting notches on the fold table (Fig. 1b) and the fold mounting pins on the unit (circled in red, Fig. 1c).

Slide the fold table into position guiding it under the cover support pins (circled in green, Fig 1c). When the fold table meets the pins press down firmly on the fold table to lock it into position.

Upper Fold Table Receptacle Location

Insert the fold table plug into the receptacle on the unit (Fig. 1d). Then replace the top cover to complete installation.

Install Lower Fold Table

Lift Feed Tray Extension

Lift the feed tray extension and lock into position under the alignment pins (Fig. 2a).

Locate mounting notches on the fold table (Fig. 2b) and the fold mounting pins on the unit (circled in Fig. 2c).

Slide the fold plate into position. When the fold table meets the pins press down firmly on the fold table to lock it into position.

Lower Fold Table Receptacle Location

Insert the fold table plug into the receptacle on the unit (Fig. 2d). Then replace the top cover to complete installation.

Install Form Knock Down Strap

To improve the stacking of folded forms attach the magnetic form knock down strap to the support bar below the upper fold table (Fig. 3). The strap can be adjusted up or down or left to right for best results.

CONTROL PANEL - Home Screen Interface

FUNCTION

1. size of the forms loaded in the pressure sealer Shows the

Displays 2. the number of forms processed, can be reset between each job

3. counter to “0” Resets the

Press to advance to fold selection screen

Press to select or edit previously saved custom folds

Press to enter to the operator settings screen

Start / Stop Icon

Press to start the pressure sealer. Press to stop the pressure sealer.

Any icon with a blue frame around it (i.e. #4 above) can be adjusted by pressing the icon.

1. Invoice Icons without a blue frame (i.e. #1 above) provide status, and cannot be pressed.
2. Flyer

In any other screen, use the

Brochure icon 3. after choosing a setting or entering information.

To return to the home screen from any other screen, press the

OPERATION

Press power switch to the ON / “I” position. The power switch is located under the lower fold table (Fig. 4a).

Set the side guides for the width of the forms. Slide each guide inward or outward to allow the forms to slide freely. (Fig. 4b)

Select the type of fold desired by pressing the fold

(Fig. 5a). Note: If the fold selection

icon shows the desired fold press the “Start/Stop” icon

to begin processing forms.

If the fold required is not available in the standard fold

settings, a custom fold set up is needed. See page 8.

Select the standard fold type (Fig. 5b) needed and

press the “Enter” icon

to set the fold stop

Standard folds selection icons 1.

When the fold stops are set, the control panel will return

to the home screen. The selected fold icon will be

Paper size selection icons

Invoice Custom fold setup icon

Push down on the infeed tray lever to lower the infeed tray (Fig. 6).

Place one form onto the feeder and press the “Start/

to process one test form.

If the fold is skewed, remove forms and turn the skew adjustment knob under the infeed tray left or right slightly to make corrections (Fig. 7). Test another form and make additional corrections as needed.

Adjust the outfeed catch tray to accommodate the form size being processed. Slide it in or out until to align the mark matching the form size (Fig. 8).

When satisfied with the test fold, load a stack of

forms and press the “Start/Stop” icon

processing forms. Press the same icon to stop. Note: The forms should be neatly stacked and squared for best results.

CUSTOM FOLDS SETUP

Three (3) custom fold settings can be stored into memory for recurring jobs with fold settings that vary from the standard fold settings. To create a custom fold, from the Home Screen press the fold selection icon to access the fold selection screen (Fig. 9). From the fold selection screen press the Custom Fold icon (Fig. 10). See page 10 to help determine the new fold measurements.

1. Select 1. the upper fold table icon

(Fig. 11) to set the fold stop position for the first fold (the icon will flash dark 2. gray when selected). Using the touch pad, key in the 3. measurement for the first fold stop position. (Note: the minimum position is 1.75” and the max. position is 11”).

Press the enter key to enter the measurement . The white box under the icon will show the measurement entered (Fig. 12).

lower fold plate icon

2. Select 2. the Flyer

(Fig. 12) to set the fold stop

3. position Brochure for the second fold (the icon will flash dark gray when selected). Using the touch pad, key in the measurement for the second fold stop position.

(Note: the minimum position is 1.49” and the max. position is 8.40”).

Press the enter key to enter the measurement . The white box under the icon will show the measurement entered.

For a Half Fold, leave the lower fold stop position at Zero.

CUSTOM FOLDS SETUP, cont.

3. With one form loaded in the feeder press the “Start/Stop”

icon (Fig. 13) to check that the fold settings are correct. To adjust the settings repeat steps 1 - 3.

When the folds and stacker wheels are set correctly, 3. press the save icon and to name and save the custom fold.

4. Select the job number the fold will be saved as by

toughing the screen (Fig. 14). Press the letter icon to bring up the keypad to name the custom fold.

5. Key in the name of the job (Fig. 15) and press the save

Job name Brochure

in the bottom right corner.

6. Select the custom job and press the blue enter icon

to confirm the fold stops (Fig. 16).

When the fold stops are set, the folder will return to the Home Screen with the custom job selected.

Press the start icon

Measuring Fold Lengths

Use the examples below to help determine the fold lengths for custom fold settings.

Example 1: “Z” Fold

Measure the length of panel “A”, enter this number as the upper fold table measurement.

Measure the length of panel “B”, enter this number as the lower fold table measurement.

Panel A

Panel B

Example 2: “C” Fold

Measure the length of panel “A” + “B”, enter this number as the upper fold table measurement.

Measure the length of panel “B”, enter this number as the lower fold table measurement.

Panel A

Panel B

RECALLING, EDITING & DELETING SAVED CUSTOM FOLDS SETUP

To recall, edit, or delete a saved custom fold from the home screen press the saved job icon (Fig. 17).

From the saved custom job screen you can recall a job, edit, rename, or delete a stored custom fold.

To recall, select the job from the list and press the blue enter button (Fig. 18). The fold tables will be set and the control panel will return to the home screen to start processing the job.

2.

1. Brochure 3.

2.

To rename a job, select the job from the list and press the letter icon (Fig. 18). Use the keypad to change the name and press the save icon in the lower right corner (Fig. 19).

Brochure Flyer

To delete a job, select the job from the list and press the delete icon (Fig. 20). On the confirmation screen press the green box with the check to confirm the deletion or press the red box with the X to cancel the deletion (Fig. 20).

Job name Sales Brochure

1. Invoice

RECALLING, EDITING & DELETING SAVED CUSTOM FOLDS SETUP

To edit a previously saved job, select the job from the list and press the edit icon (Fig. 18). From the fold setup screen use the same process as setting a custom fold (page 9) to edit the job settings (Fig. 21). See page 10 for measuring guidelines.

OPERATOR SETTINGS

A number of operator settings can be adjusted to personalize the FD 1606. This includes changing between standard and

metric settings, Standard Fold Override, and restoring to Default Settings.

This section will review each setting and how to adjust them. If needed, there is a Default Settings option that will restore

to factory settings. To advance to the Operator Settings Screen press the Tool icon

on the Home screen (Fig. 22).

Standard / Metric Settings

2.

From the Operator Settings screen (Fig. 23) press the measurement setting icon (Fig. 24) to change between settings. The icon highlighted in blue is the selected setting. By changing this setting the paper sizes will change from standard to metric or vice versa.

Press the Invoice

home icon 1. Screen.

2. Flyer

to return to the Home

Ve rsions : CP :06.01.XX MCB :C00XX

Standard Fold Override: Adjust standard fold mm inch and stacker settings Anulación de plegado estándar: ajuste la configuración estándar de plegado y apilador

Standard Fold Override: Passen Sie die Standardeinstellungen für Falz und Stapler an

Standard / Metric Icon

Standard Fold Override: Adjust standard fold settings Anulación de plegado estándar: ajuste la configuración Ve rsions : de plegado estándar

C Standard P : 0 6 . 0 Fold 1 . X X Override: Passen Sie die M Standard C B : C 0 0 Fold-Einstellungen an

Standard Fold Override: Adjust standard fold and stacker settings Anulación de plegado estándar: ajuste la configuración estándar de plegado y apilador

Standard Fold Override: Passen Sie die

Default settings

Restabl pliegues

Standar Werksei

Standard Fold Override Icon

Standard Fold Override

It may be necessary to adjust the factory set standard fold settings for a particular fold type and paper size. This can be done in the Standard Fold Override Mode. From the Operator Settings menu select the Standard Fold Override icon (Fig. 25) and press the enter icon to select.

Ve rsions : CP :06.01.XX MCB :C00XX

“Standard Fold Override” warning will be displayed (Fig. 26). Press the green box with the check to continue or the red box with the X to exit and return to the operator screen.

Standard Fold Override: Adjust standard fold and stacker settings Anulación de plegado estándar: ajuste la configuración estándar de plegado y apilador

Standard Fold Override: Passen Sie die Standardeinstellungen für Falz und Stapler an

Ve rsions : CP :06.01.XX MCB :C00XX

From the Standard Fold Override Screen select the paper size and fold type that you would like to override (Fig. 27). Then press the enter icon.

Standard Fold Override: Adjust standard fold settings Fold Override: Adjust standard fold Standard and stacker de settings Anulación plegado estándar: ajuste la configuración plegado estándar ajuste la Anulación de de plegado estándar: configuración estándar de plegado apilador Standard Fold Override: Passen Sie y die Standard Fold-Einstellungen an Sie die Standard Fold Override: Passen Standardeinstellungen für Falz und Stapler an

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Follow the same procedures as the custom fold settings to adjust the folds (Fig. 28). Load one form and press the “Start/Stop” icon to confirm the change is correct. If the settings are good press the Save Icon to save the new settings. A save confirmation screen will be displayed.

Press the green box with the check to continue or the red box with the X to return to the fold setup screen (Fig. 29).

Standard Fold Override: Adjust standard fold settings Anulación de plegado estándar: ajuste la configuración de plegado estándar

Def sett

Standard Fold Override: Passen Sie die Standard Fold-Einstellungen an

Sta Wer

Res plie

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Default Settings C P - : Return 0 6 . 0 1 . X X to Factory Settings

MCB :C00XX

From the Operator Settings screen press the Default Settings icon (Fig. 30). Standard Fold Override: Adjust standard fold A confirmation come up (Fig. 31). Press the and screen stacker will settings green box with the check to confirm or the red box la with the Anulación de plegado estándar: ajuste X to cancel configuración the setting. estándar de plegado y apilador

Standard Fold Override: Passen Sie die Standardeinstellungen für Falz und Stapler an

Standard Fold Override: Adjust standard fold settings Anulación de plegado estándar: ajuste la configuración de plegado estándar

Standard Fold Override: Passen Sie die Standard Fold-Einstellungen an

Default Reset: Resets standard folds to factory settings

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Standard Fold Override: Adjust standard fold Fig.

and stacker Default settings setting confirmation screen Anulación de plegado estándar: ajuste la configuración estándar de plegado y apilador

Standard Fold Override: Passen Sie die Standardeinstellungen für Falz und Stapler an

Software Information

Press the Software Information Icon (Fig. 32a) to verify the current software revision. The software version information will be displayed (Fig. 32b). To return to the previous screen, press the icon.

Standard Fold Override: Adjust standard fold mm inch settings Anulación de plegado estándar: ajuste la configuración de plegado estándar

Defau setting

Standard Fold Override: Passen Sie die Standard Fold-Einstellungen Software an Information Icon

Stand Werks

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DAILY MAINTENANCE

1. I t is recommended to let forms cool for one-half hour after being removed from the laser printer, before processing.

This allows toner to set on the forms and static electricity to discharge. The FD 402 Jogger is recommended for best results. The Jogger squares the forms and dissipates heat and static electricity created by laser printers.

2. Clean infeed tires and fold rollers with Formax recommended roller cleaner & rejuvenator to remove paper dust and toner. A Formax Cleaner Kit is available from your dealer. A damp cloth with water is the best alternative.

CAUTION: Do not use any chemicals other than the roller cleaner & rejuvenator or water.

CLEANING PROCEDURES:

1. Make sure machine is turned off and unplugged. All folder/sealers have three infeed tires, four rubber fold rollers and two metal seal rollers (Fig. 33).
2. Remove the top cover and remove the upper and lower fold tables.
3. Using Formax roller cleaner, spray a new cotton cloth until the cloth is saturated. Wipe the wet cloth in a back and forth motion making sure to clean the entire surface of the infeed tires, fold and seal rollers. Next, use a dry cloth to wipe off excess toner. The cloth should be covered with black toner surplus from cleaning the rollers.
4. Run 10-15 sheets of blank copy paper to ensure all cleaner has been removed from the tires, fold and seal rollers. Running blank sheets will remove any excess residue of cleaner on the rollers.

NOTE: If the fold rollers are very dirty, you may use a green scrubbing sponge, i.e. Scotch Brite, with the roller cleaning solution.

DO NOT use a scrubbing sponge on the metal seal rollers. It will damage the surface. Use ONLY a new cotton cloth and roller cleaning solution on the seal rollers (Fig. 33).

ERROR SCREENS

FD 1606 / FD 1606 Plus -Error Screens

FD Jam 1606 / FD Out 1606 Plus -Error Screens Paper / Paper FD 1606

Paper Out / Paper Misfeed / Paper Jam

Paper Jam / Paper Out FD 1606

Paper Jam / Paper Out FD 1606 Plus

1. The feeder Paper is misfeed empty. Load paper into the feeder and press Paper Jam icon / Paper Out FD 1606 Plus the to resume operation.

to possible areas k to home screen ror screen will

Error screen will appear with arrow pointing to infeed.

return arrow to go has back to the occurred. home screen.

2. A Press misfeed Reset the stack of paper in the infeed and press the icon to resume operation.

g to empty o the home

Error screen will appear with arrow pointing to infeed.

return arrow to go back to the home

3. A paper jam Press has occurred in screen. one of the areas indicated. Switch off the power and unplug the power cable.

Check the area indicated for paper and remove. You may need to Cover Open remove the fold tables. Replace and plug in the fold tables, plug in the power cable and swtich on the power.

ears with arrows pointing to possible areas Cover Open he return arrow to go back to home screen e jam is not cleared the error screen will er pressing start or 1x.

Error screen will apear with arrow pointing to open cover with indicator to close cover. Press return arrow to go back to the main screen.

Cover Open

Cover Open

ppear with arrow pointing to empty return arrow to go back to the home

Error screen will apear with arrow pointing to open cover with indicator to close cover. Press return arrow to go back to the main screen.

Cover Open

n will come on if start is pressed and the feed tray.

o possible areas to home screen or screen will

The top cover is open. Close the top cover and press the icon to resume operation.

Error screen will appear with arrow pointing to infeed. Press return arrow to go back to the home screen.

TROUBLESHOOTING

TROUBLE

POSSIBLE CAUSE

REMEDY

Control panel is not illuminated.

Power switch turned off.

Turn on power switch.

No power at the wall outlet.

No power to the machine inlet.

Check power cord for frayed/broken wires.

No power to the control panel.

Press the button on the circuit breaker, located on the rear, near the power cord inlet.

Internal electrical failure Fold table is not plugged in.

Call for service. Plug in fold table.

Electrical or mechanical failure

“Cover Open” image is displayed.

Close FD 342 Touch cover. Screen -Error Screens

Magnetic switch is broken.

Call for service. FD 342 Touch Screen -Error Screens

“Paper out” image is displayed. “Paper Jam / Misfeed” image is displayed.

Infeed tray is empty.

Place documents on the infeed tray.

Reload paper and press the

Fold table stop not moving when “Test”/ “Start” is pressed.

Black marks on the folded paper.

Paper jammed at exit of folder Infeed tires, separator, and/or fold rollers are dirty.

Infeed tray is out of alignment.

Documents are wrinkled or Fold tables are not inserted crunched. correctly.

Remove paper and press the

Error screen appears with arrows pointing to possible areas to check. Press the return arrow to go back to home screen at any time. If the jam is not cleared the error screen will appear again after pressing start or 1x.

Error screen appears with arrows pointing to possible areas to check. Press the return arrow to go back to home screen at any time. If the jam is not cleared the error screen will appear again after pressing start or 1x. Paper Out

Error screen will appear with arrow pointing to infeed. Press return arrow to go back to the home screen.

Error screen will appear with arrow pointing to infeed. Press return arrow to go back to the home screen.

Clean the parts with approved roller cleaner and rejuvenator.

Turn skew adjuster knob to remove the skew.

Remove and reinstall fold tables. Be sure they’re properly positioned.

Error screen will appear with arrow pointing to empty infeed tray. Press return arrow to go back to the home screen.

Error screen will apear with arrow pointing to open cover with indicator to close cover. Press return arrow to go back to the main screen.

Piece of paper or other material Power off, unplug and remove fold table. is stuck in the fold table. Remove jammed material. Reinstall table.

• Paper Out screen will come on if start is pressed and the is Error no paper the appear feed tray. screen in will with arrow pointing to empty infeed tray. Press return arrow to go back to the home screen.

Error screen will apear with arrow pointing to open cover with indicator to close cover. Press return arrow to go back to the main screen.

Infeed tray lever does not work

Jog forms to remove static electricity.

More tension is needed

Adjust the infeed tension lever

Feed tire or separator worn Feed tires are dirty

Call for service Clean feed tires

Feed tires or separator worn Circuit Breaker tripped

Call for Service Press black reset button next to power inlet.

Under adverse conditions, power input level may drop below acceptable limits

When power is restored, turn off machine, then turn on again to restore normal operations.

• Paper Out screen will come on if start is pressed and the is no paper in the feed tray.

TROUBLESHOOTING

Clearing Paper Jams

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

If a jam occurs between the metal seal rollers, open the top cover, unplug and remove the upper fold table.

Remove the jam clearing tool (located under the upper fold table), insert the tool into the cutout on the upper metal roller, and turn clockwise until the paper jam is clear (Fig. 34a). Refer to the label inside the machine for the correct turning direction (Fig. 34b)

NOTE: Do not turn counter-clockwise and force the forms to exit machine as rollers may be damaged. Remove the jammed form, return tool to holder and reinstall upper fold table. Reinstall cover and press reset button.

Using the Jam Clearing Tool

DETERMINING FOLD TYPE

Two Standard Folds 11” “Z” & 11” “C” Refer to page 8 for custom fold setup.

Leading Edge

Make copies of this page on copy paper for fine tuning folds

Instruction For Lining Up Folds

1. Place a stack of these sheets into the feeder and fold one (1) or two (2) sheets.
2. Take a folded sheet from the catch tray and lay it on top of a pressure seal form lining up the leading edge of this sheet with leading edge of the pressure seal form.
3. If the folds on this test sheet do not line up with the perforated folds on the form, the fold plates need to be adjusted up or down to make the folds line up. Refer to Fig. 35 for a “Z” fold and Fig. 36 for a “C” fold.

• If fold “A” on the test form is to the right of the perforation on the pressure seal form move the top fold plate stop position up. If fold ”A” is to the left move the top fold plate stop position down.
• If fold “B” on the test form is to the right of the perforation on the pressure seal form move the bottom fold plate stop position down. If fold ”B” is to the left move the bottom fold plate stop position up.

Fig. 35 “Z” fold Form

Fig. 36 “C” Fold Form