TABLE OF CONTENTS

SUBJECT

PAGE

DESCRIPTION

SPECIFICATIONS

UNPACKING & SETUP

CONTROL PANEL

OPERATION

AUTOBATCH COUNTING MODE

CUSTOM FOLDS SETUP

MEASURING FOLD LENGTHS

RECALLING, EDITING & DELETING SAVED CUSTOM FOLDS SETUP

OPERATOR SETTINGS

REMOVING ROLLER COVER

REMOVING INFEED TIRES

DAILY MAINTENANCE / CLEANING PROCEDURES

ERROR SCREENS

TROUBLESHOOTING / CLEARING PAPER JAMS

DETERMINING FOLD TYPE

FINE TUNING FOLD TEST SHEET

DESCRIPTION

Self Centering Paper Side Guides

Infeed Tray Extension

Telescoping Outfeed Stacker

Infeed Tray Lever

The FD 2056 Pressure Sealer is designed to process a variety of form sizes and weights. The fold tables are automatically

adjusted for standard folds and custom folds. Documents that are 8 ½” x 11”/14” and 11” x 17” (A5, A4, A3, B4, B5 & B6)

are detected by sensors on the infeed tray. Batch counting, and self-centering side guides are added features. Three

standard folds are pre-programmed for 11”, 14” and 17” forms, uneven C and Z folds for 14” forms, and up to 36 custom

folds can be programmed. The sealer will stop automatically after the last document has been processed.

SPECIFICATIONS

Speed:

Up to 17,000 forms per hour – based on 11” (279mm) Z-Fold

Hopper Capacity:

Up to 500 forms 20# (75gsm)

Pre-Set Folds:

Pre-programmed for C, V, Z in 11 - 17” forms, uneven C, Z in 14” forms

Pre-Set Paper Sizes:

FD Model: 11”, 14”, 17” FE Model: A5, A4, A3, B6, B5, B4

Custom Folds:

Stores up to 36 custom folds into memory

Paper Size:

Min: 3.5” W x 5” L (88.9 W x 127 L mm) Max: 12.25” W x 17” L (311 W x 432 L mm)

Dimensions:

Closed: 43” L x 21.28” W x 16” H (109 L x 54 W x 41 H cm) Fully Extended: 55” L x 21.28” W x 16” H (140 L x 54 W x 41 H cm)

Weight:

Power:

Safety Certifications: UL & CE applied for

UNPACKING & SETUP

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

Remove the machine and packed components from the box. The fold tables, telescoping stacker, and power cord are wrapped separately in the box.

NOTE: Two people must lift the machine from the box.

Place the folder on a solid stand.

Install upper and lower fold tables, telescoping conveyor and power cord

Upper Fold Table Pins

Be sure the tables are set firmly on the locating pins (Fig 1a & 1b). Slide each fold table in until it meets the first locating pin then push down to set in place.

Lower Fold Table Pins

Lock the fold table into position (Fig. 2)

Repeat the same steps for the lower fold table.

4. Plug the fold table cables into the receptacles on the side frame (Fig. 3 & 4).

Upper Fold Table Receptacle Location

Lower Fold Table Receptacle Location

5. Insert the telescoping extension tray into the end of the outfeed conveyor (Fig. 5).
6. Make sure the power switch is in the “OFF” position. Plug the power cord into the power inlet and the wall outlet.

CONTROL PANEL - Home Screen Interface

FUNCTION

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

Resets the counter to “0”

Press to decrease the processing speed

Press to increase the speed

Press to advance to fold selection screen

Shows the size of the paper in the pressure sealer

1X Fold Test Icon

Press to test the fold selected

Start / Stop Icon

Press to enter AutoBatch mode

1. Invoice Press to select or edit previously saved custom folds
2. Flyer Press to enter to the operator settings screen Brochure Press to 3. start the pressure sealer. Press to stop the pressure sealer.

Any icon with a blue frame around it (i.e. #2 above) can be adjusted by pressing the icon.

Icons without a blue frame (i.e. #4 above) provide status, and cannot be pressed.

In any other screens, use the

icon after choosing a setting or entering information.

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

OPERATION

Place power switch in the ON / “I” position.

Extend the catch tray as required.

Set the self-centring paper side guides for the width of the forms and lock in position using thumbscrews. (Fig. 6)

Self centering side guides

Adjust infeed tray tension lever (Fig. 7) for different paper weights. Move the lever up towards the “-” symbol for lighter paper and down toward the “+” symbol for heavier paper. The middle position is for standard paper weights.

Raise the infeed tray lever to lower the infeed tray. (Fig. 8)

Neatly stack forms on the infeed tray.

Lower the infeed tray lever to raise the infeed tray.

Select the type of fold desired by pressing the fold

(Fig. 9). Note: If the fold selection

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

to begin processing forms.

Standard folds selection icons

10. Select the standard fold type (Fig. 10) needed and

press the “Enter” icon

to set the fold stop

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

to the home screen. The selected fold icon should now

Press the “Start/Stop” icon

Press the test icon

to check the fold.

Custom fold setup icon

11. If the fold is skewed, remove forms, lower the infeed tray extension and turn the skew adjustment knob left or right to make corrections (Fig. 11).
12. When satisfied with the test fold, press the “Start/Stop”

icon to begin processing forms. Press the same icon to stop.

13. Press the “-” or “+” icons to adjust machine speed to desired level.

AUTOBATCH COUNTING MODE

The AutoBatch feature can be set to count down the number of sets in a batch, the number of sheets in each set, and the delay between each set. To enter the AutoBatch Mode press the icon on the main screen (Fig. 12a).

To enter the number of sets press the icon (fig. 12b). Enter the number of sets on the keypad that appears. Next press the icon to select the number of sheets, and then press the icon to enter the delay between sets. Press the to exit the keypad (Fig. 12c).

Press the icon to begin folding. The folder will stop when the number of sets counts down to zero (0).

To exit the AutoBatch Mode press the

Invoices “Start/Stop” icon

Number of Sets 1.

Number of Sheets per Set

Note: Press the icon on the keypad to exit back to the Auto Batch screen. Press the icon to edit the number entered. Press the icon on the keypad to reset the entered number to zero (0).

Fig. 1. 12b Invoice

2. Flyer Return to Home Screen
3. Brochure

Delay between sets (seconds)

FD 2056 CUSTOM FOLDS SETUP

The FD 2056 has 36 custom fold settings that 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 . See page 11 to help determine the new fold measurements.

1. Select 1. the top fold plate icon

(Fig. 15) to set the fold stop position for the first fold (the icon will flash 2. dark gray when selected). Using the touch pad key, in 3. the measurement for the first fold stop position, (Note: the minimum position is 1.62” and the max. position is 12.59”.).

Press the enter key to enter the measurement . The white box under the icon will show the measurement entered (Fig. 16).

lower fold plate icon

2. Select 2. the Flyer

(Fig. 16) to set the fold stop Brochure for the second fold (the icon will flash

3. position 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.

Leave the fold stop position at Zero for Half Fold.

FD 2056 CUSTOM FOLDS SETUP, cont.

5. Next set the automatic outfeed stackers. There are 10

stacker positions available. Select the one that best matches the size of the folded document. Using the touch pad key in the stacker position (Fig. 17), key in 0 - 9 based on the chart below. Press the enter key to enter the position. The white box under the icon will show the position entered. (Fig. 18). Stacker Wheel Positions:

Folded size to: 3.75”

Folded size to: 4.00”

Folded size to: 4.43”

Folded size to: 4.87”

Folded size to: 5.30”

Folded size to: 5.73”

Folded size to: 6.16”

Folded size to: 6.60”

Folded size to: 7.03”

Folded size to: 7.46” and greater

4. With forms loaded in the feeder press the test icon

(Fig. 18) 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 press the save icon to name and save the custom fold.

5. Select the job number the fold will be saved as (Fig. 19).

Press the letter icon the custom fold.

to bring up the keypad to name

FD 2056 CUSTOM FOLDS SETUP, cont.

5. Key in the name of the job (Fig. 20) and press the save

icon in the bottom right corner.

Job name Brochure

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

to set the fold stops (Fig. 21).

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. 22).

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. 23). The fold will be set and then 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. 23). Use the keypad to change the name and press the save icon in the lower right corner (Fig. 24).

To delete a job, select the job from the list and press the delete icon (Fig. 23). 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. 25).

Job name Sales Brochure

1. Invoice Brochure

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. 23). From the fold setup screen use the same process as setting a custom fold to edit the job settings (Fig. 26). See page 11 for measuring guidelines.

OPERATOR SETTINGS

A number of operator settings can be adjusted to personalize the FD 386 / FD 38Xi. This includes changing between

standard and metric settings, number of test sheets, Fold and Stacker Override, and Standard Fold Override.

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

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

on the Home screen.

Standard

2. / Metric Settings

From the Operator Settings screen (Fig. 28) press the measurement setting icon (Fig. 29) to change between settings. The icon highlights in blue is the selected setting. By changing this setting the paper sizes will change from standard to metric or vice versa.

Press home icon Invoice

1. the

Screen. Flyer

to return to the Home

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

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

Standard / Metric Icon

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

Default settings

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

Standar Werksei

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

Restabl pliegues

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. 30) and press the enter icon to select.

“Standard folds will be modified from factory settings” warning will be displayed (Fig. 31). 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

From the Standard Fold Override Screen select the paper size and fold type that you would like to override (Fig. 32). Then press the enter icon.

mm mm

inch inch

Follow the same procedures as the custom fold settings to adjust the folds (Fig. 33). Press the Test icon to confirm the change is correct. If the settings are good press the Save Icon to save the new settings. A save confirmation will be displayed.

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

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

Standard Fold Override: Adjust standard Press the green box with the check to continue or the fold Standard Fold Override: Adjust standard fold and stacker settings stacker to settings red box with the X and to return the fold setup screen (Fig. Anulación de plegado estándar: ajuste la Anulación de plegado estándar: ajuste la 34). configuración estándar de plegado y apilador

configuración estándar de plegado y apilador Standard Fold Override: Passen Sie die Standard Fold Override: Passen Sie die Standardeinstellungen für Falz und Stapler an Standardeinstellungen für Falz und Stapler an

Standard Fold Override: Adjust standard 15 fold Standard Fold Override: Adjust standard fold settings settings Anulación de plegado estándar: ajuste la

Default Reset: Resets standard folds to factory Default Reset: Resets standard folds to factory settings settings Restablecimiento predeterminado: restablece los Restablecimiento predeterminado: restablece los

Defau setting

Restab pliegu

Stand Werks

Defaul settings

Restab pliegue

Standa Werkse

Test Sheet Setting

The number of test sheets can be changed between 1, 2 or 3.

From the Operator Settings Menu press the Test Icon to access Test Sheet Setting (Fig. 35).

The number of test sheets can be changed to 1, 2, or 3. Press the corresponding test button and then press the enter icon to save the selection. The chosen icon will be highlighted in black (Fig. 36).

Press the Home button Settings screen.

to return to the Operator

Default Settings - Return to Factory Settings

From the Operator Settings screen press the Default Settings icon (Fig. 37). A confirmation screen will come up. Press the green box with the check to con- Standard Fold Override: Adjust standard fold firm or the red box with the X to cancel the setting (Fig. and stacker settings 38). 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 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

Standard Fold Override: Adjust standard fold settings Anulación de plegado estándar: ajuste la Fig. Default setting Icon configuración de plegado estándar

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

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

Default Reset: Resets standard folds to factory settings

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

Standard Reset: Setzt den Standard-Falz auf die Werkseinstellungen zurück

Restablecimiento predeterminado: restablece los pliegues estándar a la configuración de fábrica

Standard Fold Override: Adjust standard fold and stacker settings Fig. Anulación de plegado estándar: ajuste screen la Default setting confirmation configuración estándar de plegado y apilador

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

Default R settings

Restablec pliegues e

Standard Werkseins

REMOVING ROLLER COVER

The roller cover can be removed to access the sealing rollers. To remove, unscrew thumbscrews that hold the cover in place. (Fig. 39)

REMOVING INFEED TIRES

The infeed tires can easily be removed for cleaning and replacement. Remove the Allen screw located on the left side of the feed tire shaft (Fig. 40). Slide the shaft to the right to release from the side frame and remove (Fig. 41).

DAILY MAINTENANCE

1. I t is recommended to let forms cool for one-half hour, 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. 42a).
2. Lift top covers 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. ScotchBrite, with the roller cleaning solution.

DO NOT use a scrubbing sponge on the seal rollers. It will damage the surface. Use ONLY a new cotton cloth and roller cleaning solution on the seal rollers (Fig. 42b)

ERROR SCREENS

Paper Misfeed / Paper Jam

FD 386/38Xi Touch Screen -Error Screens

FD 386/38Xi Touch Screen -Error Screens Paper Jam

D 342 Touch Screen -Error Screens

A misfeed has occurred. Reset the stack of paper in the infeed and press the icon to resume operation. A Paper jam has occurred in one of the areas indicated. Error screen will appear with arrow pointing to infeed. Error screen appears with arrows pointing to possible areas arrow to go back to the home screen. to check. Press the return arrow to go back to home screen Turn the folder to the Press off return position and unplug. Check the at any time. If the jam is not cleared the error screen will appear again after pressing start or 1x. appears with arrows pointing to possible areas Error screen area indicated for paper and remove. Replace the areas fold Error screen appears with arrows pointing to possible to check. Press the return arrow to go back to home screen to check. to go to home plates and Press plug the the return folder arrow in and the back power on. screen at any time.

If the jam is not is cleared

the error screen will Open Paper Out at any time. If the jam Cover not cleared the error screen will appear appear again after start or 1x. or 1x. again pressing after pressing start

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

Press return arrow to go back to the home screen.

Paper Out

Paper Out Paper Out

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

Cover Open

Cover Open Cover Open

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.

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

FD 342 Touch Screen -Error Screens

Error screen will apear with arrow pointing to open

Error screen will appear with arrow pointing to empty

no appear paper in the infeed. Reload paper and infeed is tray. Press return arrow to go back the home

Error There

screen will with arrow pointing to to empty press the icon to resume operation. screen. infeed tray. Press return arrow to go back to the home screen.

Error screen will with arrow to open cover with indicator to close cover. Press return arrow The top cover is apear open. Close the pointing top cover and press to go back to the main screen. cover with indicator to close cover. Press return arrow the icon to resume operation. to go back to the main screen.

Error screen will appear will with arrow pointing on to infeed. screen appears with arrows pointing to possible areas

• Paper Out screen come if start Error is pressed and Press return arrow to go back to the home screen. 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 no paper the feed
• Paper the

Out is screen

will in come on tray. if start is pressed and appear again after pressing start or 1x.

arrows pointing to possible areas arrow to go back to home screen ot cleared the error screen will g start or 1x.

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

the is no paper in the feed tray.

h arrow pointing to empty

Error screen will apear with arrow pointing to open

Error screen will appear with arrow pointing to empty

Error screen will apear with arrow pointing to open

TROUBLE-SHOOTING

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.

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.

Magnetic switch is broken.

“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 “Counter Reset” button.

Paper jammed at exit of folder

Remove paper and press “Counter Reset” button. Clean the parts with approved roller cleaner and rejuvenator.

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

Black marks on the folded paper.

Infeed tires, separator, and/or fold rollers are dirty.

Infeed tray is out of adjustment. Turn skew adjuster knob to remove the skew.

Stacker belts do not turn.

Broken drive belt, worn drive gear.

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

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

Piece of paper or other material Remove object from the fold table. is stuck in the fold table.

Infeed tray lever does not work

Jog forms to remove static electricity.

More tension is needed

Adjust the infeed tension lever (page 5, Fig. 8)

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.

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), apply the tool to the upper metal roller (Fig. 43), and turn clockwise until the paper jam is clear.

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 Operator Manual 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 the leading edge of this sheet up 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. 44 for a “Z” fold and Fig. 45 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. 44 “Z” fold Form

Fig. 45 “C” Fold Form