FORMAX FlashCard XL Business Card Cutter Instruction Manual

FORMAX FlashCard XL Business Card Cutter

DESCRIPTION

FUNCTION

The FlashCard XL Business Card Cutter is designed to transform printed sheets into professional-quality cards, with crisp accurate cuts.

SPECIFICATIONS

x 40.5” H
Weight:| 45 lbs. (21kg)
Power:| 110V, 50/60Hz, .6 Amp
Certifications:| CE

SAFETY NOTES

To prevent operator injury and avoid machine damage:

• Be sure the FlashCard XL is plugged into an appropriate power supply.

• Keep long hair, clothing, jewelry, neckties, scarves and other items away from the cutting area.

• Do not touch the cutter with wet hands.

• When the FlashCard XL is not in use, shut off the power with the power switch.

• In case of a malfunction, shut off the power directly buy unplugging the power cord.

• Contact your Formax Dealer with any questions about safe cutter operation.

• Do not attempt to open or repair the machine. Consult the Troubleshooting Guide on page 15, or contact an authorized service provider.
  Pay special attention to the areas marked by the following warning labels:
  

• The top safety cover is designed to prevent tools, loose clothing, jewelry and long hair from being caught in the cutter.
  DO NOT operate the cutter with the cover open. The top safety cover has a magnet and toggle switch. Once the cover is opened, the cutter will stop moving immediately. To resume operation, close the cover.

• Locate the cutter in an area with adequate ventilation, with a minimum of 12” of working space in front and behind.

• Avoid placing the machine in areas with the following: direct sunshine, moisture, mist, water vapor, extreme heat/cold.

• Use a static-electricity preventing cover and/or a humidifier if static electricity is a regular issue.

UNPACKING & SET-UP

1. Remove the FlashCard XL, operator manual, 5” catch tray, card divider, catch tray extender, waste paper bin, and power cord from the box. Place the machine on a sturdy surface.
   

2. Optional Cabinet is available.
   

3. For tabletop use, insert the waste paper bin, with the handle facing outward.
   

4. Insert the catch tray on the outfeed side of the machine.
   Align the notches on each side of the tray with the ones on the machine (see photo, right). The catch tray can be installed in two different configurations, based on the dimensions of the job being cut.
   

Catch Tray Options

1. a. The FlashCard XL comes with two catch tray options. Use the standard catch tray for cut pieces up to 5” in length.
   Attach the magnetic stop to the feed tray. Place the magnetic divider in position for cut pieces under 3.25” in width.
   

2. For longer cut pieces up to 18”, use the tray extender. See for installation instructions.
   
   a. Remove the magnetic guides from the standard tray.
   
   b. Take the outfeed tray extender and flip it so that the lip of the tray is facing upwards. This will ensure proper installation of the tray.
   
   c. With the tray lip facing upwards, slide the tray extender into the catch tray, insert the lip under the mounting pins and lay into position.
   
   d. Finish by adding the magnetic stop at the end of the extender tray.
   Note : Set the magnetic stop so that the cut pieces coming out can fully exit the cutter and lay flat on the gray.
   Continue to step 4
   

3. Flip the infeed tray extension to the open position.
   

4. Insert the power cord into the inlet, and plug into an appropriate outlet.
   

Optional Cabinet

1. Carefully place the FlashCard XL onto the optional cabinet.
   Be sure to properly align the machine with the indents on top of the cabinet.
   

2. Be sure that the waste hole of the cutter aligns with the cabinet waste hole on top of the cabinet to ensure the scraps are caught properly.

3. Place the metal plate on the outfeed of the cutter, making sure to align the the screw holes properly. From here, screw the provided screws into the holes at the top of the metal panel.
   
   

CONTROL PANEL

The control panel has an LCD screen and six buttons for operation. Operators can select from 5 programmed cut settings or create up to 11 custom cuts. The four color buttons at the bottom perform different functions depending on mode.

1.| | Press to scroll through jobs
Press to select an option in the operator settings mode
Press to set the desired parameter in the operator settings mode
---|---|---
2.| | Press to start cutting. Press again to stop the cutter.
3.| | Press to increase the number of pieces cut. NOTE: AUTO feeds until the infeed is empty. Press to increase the values in the operator settings mode
Press to move cutting blades up in manual mode
4.| | Press to decrease the number of pieces cut
Press to decrease the value in the operator settings mode Press to move cutting blades down in manual mode
5.| | Press to toggle between Mark and Edge (printed registration mark or leading edge of sheet) Press to advance to the next setting in the operator settings mode
Press to reverse paper in manual mode
6.| | Press to toggle between Blade size and counter displayed on screen Press to go back to the previous setting in the operator settings mode Press to advance paper in manual mode

STANDARD OPERATION

NOTE:

• Do not place more than the recommended number of sheets of card stock on the infeed at one time.
• Do not use different thicknesses of card stock in a single stack, as this will affect the accuracy of the automatic friction feeder.
• Do not attempt to feed sheets more than the recommended 350gsm weight. Sheets that are too thick for the machine to handle may damage the cutting and slitting blades.

CAUTION:

• Keep fingers, jewelry, long hair, and loose clothing away from the infeed and cutting mechanisms to avoid injury.

1. Switch the power on. When the power is turned on, the cutter starts initializing and goes into standby mode.

2. Place the stack of sheets to be cut on the infeed tray with the printed side facing up and leading. If using a registration mark, make sure the mark is on the leading edge.

3. Loosen the thumbscrews and slide the paper side guides in or out to accommodate the width of the card stock. There should be about 1mm between each edge and the side guides.
   NOTE : The side guides move independently of each other and can be moved left or right to accommodate print variances.
   

4. Tighten the thumbscrews to lock them in position.

5. Push down on the side guides to lower the spring loaded infeed tray, and slide the paper stack under the feed tires. Release the guides.

6. Select the Job # that corresponds to the cut needed .
   
   Using the control panel buttons, select the number of pieces/cards to be cut, and the number of sheets. Press the Start button. The cutter will automatically stop when the selected number of pieces is cut or the feeder is empty, then return to standby mode.
   To cut another stack, load more sheets and press the Start button.

7. After completing cutting jobs, switch off the power.
   

REGISTRATION MARK DETECTION MODE

A registration mark can be used to compensate for any variance in the printing process. The Cutter will detect the mark and begin cutting ensuring consistent cuts between print runs.
When Mark Detection mode is engaged, the cutter will use an optical sensor to find the registration mark on the printed page. The screen will indicate “MARK.” The mark should be printed on the leading edge of the sheet.
To turn off Mark Detection, press the yellow right arrow button. The screen will indicate “EDGE.” With Mark Detection off, the cutter will use the leading edge of the sheet to determine where to make cuts.

Mark Specifications

The Mark should be 50mm x 3mm and be placed in the top center of the sheet. For pre-programmed jobs, the top of the mark should be positioned 5mm above the first cut. The position can be adjusted for custom jobs.

PRE-PROGRAMMED JOBS

Pre-programmed jobs are listed numerically, with each representing a product that can be cut from a sheet of card stock.
The machine has six (6) pre-programmed jobs. The Job #s and item details are listed below.
In addition, users can program and save up to 10 custom jobs, the details of which can be written in the list for reference:

Job| Template Mode| # of Pieces/ Cards| Blade Cassette| Product (Inches)| Sheet Size| Finished Size (Inches)
---|---|---|---|---|---|---
1| Job 1 – 2” x 3.5”| 24| 3.5” Blade| 3.5” x 2” Business Cards| 12” x 18”| 3.5” x 2”
2| Job 2 – 2” x 3.5”| 24| 3.5” Blade| 3.5” x 2” Full Bleed Business Cards| 12” x 18”| 3.5” x 2”
3| Job 3 – 8.5” x 11”| 2| 11” Blade| 8.5” x 11” Brochure| 12” x 18”| 8.5” x 11”
4| Job 4 – 5” x 7”| 4| 5” Blade| 5” x 7” PostCard| 12” x 18”| 5” x 7”
5| Job 5 – 11” x “17| 1| 11” Blade| 11” x 17” Brochure| 12” x 18”| 11” x “17
6| Job 6 – 3.5” x 5”| 9| 3.5” Blade| 3.5” x 5” Postcard| 12” x 18”| 3.5” x 5”
7| Custom Job|  |  |  |  |
8| Custom Job|  |  |  |  |
9| Custom Job|  |  |  |  |
10| Custom Job|  |  |  |  |
11| Custom Job|  |  |  |  |
12| Custom Job|  |  |  |  |
13| Custom Job|  |  |  |  |
14| Custom Job|  |  |  |  |
15| Custom Job|  |  |  |  |
16| Custom Job|  |  |  |  |

INDIVIDUAL PRE-SET JOB PROGRAM ADJUSTMENTS

The Pre-set programs can be adjusted to compensate for printing variances. Adjustments can be made to the First Cut, Mark Position, Card Length, and Groove/Gutter Width.

To Adjust a pre-set job, select the job to be adjusted and press and hold the “Mode/Set” button for five seconds to enter the operator setting mode. Use the Blue or Yellow arrow buttons to select CARD OPTION from the settings menu.
Press the “Mode/Set” button to access settings.
NOTE : To exit the operator settings mode, press and hold the “Mode/Set” button for three seconds from the operator settings main screen.

First Cutting Compensation: Adjusts the position of where the first cut is made.

1. Use the Blue or Yellow arrow buttons to advance to First Cutting Compensation screen.
2. Adjust the value using the Green [+] or Red [-] arrow buttons (Select from -5.0 to +5.0mm)
3. Press the Blue or Yellow arrow buttons to advance or press the “Mode/Set” button to return to the main operator settings screen.

Mark Position Compensation: Adjusts where the cut is made after the mark

1. Use the Blue or Yellow arrow buttons to advance to Mark Position Compensation screen.
2. Adjust the value using the Green [+] or Red [-] arrow buttons (Select from -3.0 to +3.0mm)
3. Press the Blue or Yellow arrow buttons to advance or press the “Mode/Set” button to return to the main operator settings screen.

Card Length Compensation: Adjusts the length of the card

1. Use the Blue or Yellow arrow buttons to advance to Card Length Compensation screen.
2. Adjust the value using the Green [+] or Red [-] arrow buttons (Select from -3.0 to +3.0mm)
3. Press the Blue or Yellow arrow buttons to advance or press the “Mode/Set” button to return to the main operator settings screen.

Groove (Gutter) Width Compensation: Adjusts the cut width between cards

1. Use the Blue or Yellow arrow buttons to advance to Groove (Gutter) Compensation screen.
2. Adjust the value using the Green [+] or Red [-] arrow buttons (Select from -3.0 to +3.0mm)
3. Press the Blue or Yellow arrow buttons to advance or press the “Mode/Set” button to return to the main operator settings screen.

GLOBAL JOB PROGRAM ADJUSTMENTS AND USER OPTIONS

Global program adjustments can be made to apply to every job. By accessing the System Option menu, compensations can be made to the System Accuracy, First Cut, Mark Position, Groove/Gutter Width, Last Card, Second From Last Card, and Third From Last Card. In addition, users can access the Resettable Counter, Life Counter, System Restore to Factory Settings, and Firmware Version.

To make a global program adjustment, press and hold the “Mode/Set” button for five seconds to enter the operator setting mode. Use the Blue or Yellow arrow buttons to select SYSTEM OPTION from the settings menu. Press the “Mode/Set” button to access settings.
NOTE : To exit the operator settings mode press and hold the “Mode/Set” button for three seconds from the operator settings main screen.

System Accuracy Compensation: Adjusts the position for all cuts, shifting them up or down together based on the value entered.

1. Use the Blue or Yellow arrow buttons to advance to the System Accuracy Compensation screen.
2. Adjust the value using the Green [+] or Red [-] arrow buttons (Select from -5.0 to +5.0mm)
3. Press the Blue or Yellow arrow buttons to advance or press the “Mode/Set” button to return to the main operator settings screen.

First Cutting Compensation: Adjusts the position of where the first cut is made.

1. Use the Blue or Yellow arrow buttons to advance to First Cutting Compensation screen.
2. Adjust the value using the Green [+] or Red [-] arrow buttons (Select from -5.0 to +5.0mm)
3. Press the Blue or Yellow arrow buttons to advance or press the “Mode/Set” button to return to the main operator settings screen.

Mark Position Compensation: Adjusts where the cut is made after the mark

1. Use the Blue or Yellow arrow buttons to advance to Mark Position Compensation screen.
2. Adjust the value using the Green [+] or Red [-] arrow buttons (Select from -3.0 to +3.0mm)
3. Press the Blue or Yellow arrow buttons to advance or press the “Mode/Set” button to return to the main operator settings screen.

Groove (Gutter) Width Compensation: Adjusts the cut length between cards

1. Use the Blue or Yellow arrow buttons to advance to Groove (Gutter) Width Compensation screen.
2. Adjust the value using the Green [+] or Red [-] arrow buttons (Select from -3.0 to +3.0mm)
3. Press the Blue or Yellow arrow buttons to advance or press the “Mode/Set” button to return to the main operator settings screen.

Last Card Compensation: Adjusts the cut length of the last card individually

1. Use the Blue or Yellow arrow buttons to advance to the Last Card Compensation screen.
2. Adjust the value using the Green [+] or Red [-] arrow buttons (Select from -3.0 to +3.0mm)
3. Press the Blue or Yellow arrow buttons to advance or press the “Mode/Set” button to return to the main operator settings screen.

Penultimate Card Compensation: Adjusts the cut length of the second to last card individually

1. Use the Blue or Yellow arrow buttons to advance to the Penultimate Card Compensation screen.
2. Adjust the value using the Green [+] or Red [-] arrow buttons (Select from -3.0 to +3.0mm)
3. Press the Blue or Yellow arrow buttons to advance or press the “Mode/Set” button to return to the main operator settings screen.

Third From Last Card Compensation: Adjusts the cut length of the third to last card individually

1. Use the Blue or Yellow arrow buttons to advance to the Third To Last Card Compensation screen.
2. Adjust the value using the Green [+] or Red [-] arrow buttons (Select from -3.0 to +3.0mm)
3. Press the Blue or Yellow arrow buttons to advance or press the “Mode/Set” button to return to the main operator settings screen.

Subtotal Clear: Resettable count of pieces cut

1. Use the Blue or Yellow arrow buttons to advance to the Subtotal screen.
2. Press the red “-” arrow to reset to “0”
3. Press the Blue or Yellow arrow buttons to advance or press the “Mode/Set” button to return to the main operator settings screen.

Total: Life count of pieces cut, non-resettable

1. Use the Blue or Yellow arrow buttons to advance to the Total screen to view the life count.
2. Press the Blue or Yellow arrow buttons to advance or press the “Mode/Set” button to return to the main operator settings screen.

Restore Factory Setting: Restores the System Options to the factory settings

1. Use the Blue or Yellow arrow buttons to advance to the Restore Factory Setting screen.
2. Press the red “-” arrow to restore to factory settings
3. Press the Blue or Yellow arrow buttons to advance or press the “Mode/Set” button to return to the main operator settings screen.

Firmware: Displays the firmware revision of the cutter

1. Use the Blue or Yellow arrow buttons to advance to the Firmware screen to view the revision.
2. Press the Blue or Yellow arrow buttons to advance or Press the “Mode/Set” button to return to the main operator settings screen.

PROGRAMMING A CUSTOM JOB

Eleven custom jobs can be programmed into the Flashcard. The Jobs can be written in the spreadsheet on for quick reference. Follow the steps below to program a custom Job.

To program a custom job, select a custom job, numbers 6-16. With the job selected press and hold the “Mode/Set” button for five seconds to enter the operator setting mode. Use the Blue or Yellow arrow buttons to select CARD OPTION from the settings menu. Press the “Mode/Set” button to access settings.
NOTE : To exit the operator settings mode press and hold the “Mode/Set” button for three seconds from the operator settings main screen.

Card Width: The width is based on the cutting cassette. If a 7” cassette is being used, the width should be entered as 7.00”. This is a fixed setting based on the cassette. Note: The width and length are displayed on the Job screen for reference.

1. Use the Blue or Yellow arrow buttons to advance to the card width screen.
2. Enter the width based on the blade cassette size using the Green [+] or Red [-] arrow buttons
3. Press the Blue or Yellow arrow buttons to advance or press the “Mode/Set” button to return to the main operator settings screen.

Card length: adjust the length of the desired card size. The minimum cut size is 1.58”(40mm)

1. Use the Blue or Yellow arrow buttons to advance to the card length screen.
2. Enter the length of the card using the Green [+] or Red [-] arrow buttons.
3. Press the Blue or Yellow arrow buttons to advance or press the “Mode/Set” button to return to the main operator settings screen.

Card Rows: Enter the number of rows based on the sheet size and cut length.

1. Use the Blue or Yellow arrow buttons to advance to Card Rows screen.
2. Enter the number of rows using the Green [+] or Red [-] arrow buttons
3. Press the Blue or Yellow arrow buttons to advance or press the “Mode/Set” button to return to the main operator settings screen.

Card Columns: The columns are based on the blade cassette. The 3.50” cassette creates two columns and the 7” and 8” cassettes create 1 column. This entry is used to calculate the number of pieces from one sheet.

1. Use the Blue or Yellow arrow buttons to advance Card Columns screen.
2. Adjust the column value using the Green [+] or Red [-] arrow buttons
3. Press the Blue or Yellow arrow buttons to advance or press the “Mode/Set” button to return to the main operator settings screen.

First Cutting Length: This setting determines where the first cut will be made on the leading edge of the sheet.

1. Use the Blue or Yellow arrow buttons to advance First Cutting Length screen.
2. Adjust the length value using the Green [+] or Red [-] arrow buttons
3. Press the Blue or Yellow arrow buttons to advance or Press the “Mode/Set” button to return to the main operator settings screen.

Mark Position Length: This setting determines where the first cut will be made from the top edge of the mark. If “Mark” is selected on the job screen it will override the “First Cutting Length” value.

1. Use the Blue or Yellow arrow buttons to advance to Mark Position Length screen.
2. Adjust the mark position length value using the Green [+] or Red [-] arrow buttons
3. Press the Blue or Yellow arrow buttons to advance or press the “Mode/Set” button to return to the main operator settings screen.

Groove (Gutter) Width: This sets the cut length between each card, generally used for full bleed applications.

1. Use the Blue or Yellow arrow buttons to advance to Groove (Gutter) Width screen.
2. Adjust the Groove (Gutter) Width value using the Green [+] or Red [-] arrow buttons (Select from -3.0 to +3.0mm)
3. Press the Blue or Yellow arrow buttons to advance or press the “Mode/Set” button to return to the main operator settings screen.

NOTE : Compensation adjustments are available after the Grove Width value is entered. As with the Pre-programmed jobs, compensation adjustments can be made to the First Cut, Mark Position, Card Length, and Groove/Gutter Width.
These adjustments should be made after performing the cutting job to verify if any compensations are needed based on the print.

CHANGING BLADE CASSETTES

Follow these steps to change a blade cassette.
CAUTION : To avoid injury, do not touch the cutting blades.

NOTE : Be sure the machine is switched off, and that the power cord is unplugged.

1. Lift safety cover.

2. Remove the thumb screws holding the blade cassette in position.

3. Take the cassette out through the outfeed side of the machine.

Blade cassette notch on left side of the cassette.

4. Install the new cassette in through the same side. First, align the notch on the left side of the cassette with the mounting pin and then set the notch on the right side onto the mounting pin.
   Guide the cassette into position, making sure the blade cassette gears are completely aligned with the gears on the machine.

5. Reinsert and tighten the thumb screw.
   Lift lid back into position and replace the top safety cover, waste bin, and catch tray.
   Plug in the power cord and power on the machine.
   Align blade cassette notch with mounting pin.

Align the gears on the blade cassette with the machine gears.

TROUBLESHOOTING

KNIFE ERROR

This type of error may occur when there is residual paper inside the paper path of the machine. This may be a result of using card stock that is too thick, or too much curl in the card stock when it enters the machine.

1. When the LCD shows “KNIFE ERROR,” use the arrow buttons to remove the paper.
2. Press the Blue arrow to advance the paper, press the yellow arrow to reverse the paper, press the red or green arrows to raise and lower the blades.
3. The catch tray and/or blade cassette may need to be removed to completely remove the paper from the cutter .
4. After clearing the paper jam, press the “Mode/Set” button to return to the standby screen.
   

MARK NOT FOUND

The Mark Detection Mode allows for improved cutting accuracy. If the machine is not detecting the black mark it may be because the mark is not printed or does not conform to the set requirement. Note that some of the pre-set jobs include marks. If a mark is not being used, press the yellow arrow button to select EDGE mode.

1. When the LCD shows “MARK NOT FOUND,” use the yellow arrow button to reverse the paper for removal.
2. Remove the paper from the infeed. Confirm that the mark is properly sized and positioned.
3. After clearing the paper, press the “Mode/Set” button to return to the standby screen.
   

POOR PAPER FEEDING / MISFEEDING

This issue may occur for one of two reasons:

1. The paper side guides may be positioned too tightly or too loosely against the edge of the card stock. Loosen the thumbscrews and slide the guides in or out so there is a minimum of 1mm between the edge of the paper and the guides.
   In this case use the micro-adjusting nut to adjust the tension on the card stock.

2. Paper quality/quantity issues. Please see examples below:

   • The card stock is too thick (over 350gsm) or too thin (below 180gsm).
   • The card stock is too small or too large.
   • Too many sheets are being placed on the infeed: stack should be no greater than .375”/10mm high, or exceed 40 sheets of 200gsm card stock
   • The paper has excessive curling or the curl is in the wrong direction.
     

Do not use paper that is curled in this direction (X), known as “laterally curled stock.” This can result in misfeeding, inaccurate cutting and paper jams.
Paper stock that is longitudinally curled (shown on right), can be used, although the degree of curl is limited to within 5mm, and an attempt must be made to flatten the curl.

SERVICE / BLADE ASSEMBLY REPLACEMENT

There are no user-serviceable parts within the machine. For service, please contact your authorized Formax Dealer. Recommended Blade Replacement Schedule:
LONG/GUILLOTINE BLADE ASSEMBLY: Recommend replacement after performing approximately 1,000,000 cuts. ROTARY BLADE ASSEMBLY: Recommend replacement after performing approximately 1,000,000 cuts.

Job 1 Business Cards with Gutter Template

(Without Mark, set first cut at 8.9 mm from top edge of sheet)
Sheet Size: 12” x 18” Card Size: 3.5” x 2”/88.9mm x 50.8mm – Use 3.5” Blade Cassette
NOTE : Template below is NOT TO SCALE. Visit www.formax.com/formax- flashcardxl-templates for full-size downloadable templates

Job 2 Full Bleed Business Cards Template

(Without Mark, set first cut at 19.1 mm from top edge of sheet)
Sheet Size: 12” x 18” Card Size: 3.5” x 2”/88.9mm x 50.8mm – Use 3.5” Blade Cassette
NOTE : Template below is NOT TO SCALE. Visit www.formax.com/formax- flashcardxl-templates for full-size downloadable templates

Job 3 Brochure Template

(Without Mark, set first cut at 12.7 mm from top edge of sheet)
Sheet Size: 12” x 18” Card Size: 8.5” x 11”/215.9mm x 279.4mm – Use 11” Blade Cassette
NOTE : Template below is NOT TO SCALE. Visit www.formax.com/formax- flashcardxl-templates for full-size downloadable templates

Job 4 Postcard Template

(Without Mark, set first cut at 12.7 mm from top edge of sheet)
Sheet Size: 12” x 18” Card Size: 5” x 7”/127.0mm x 177.8mm – Use 5” Blade Cassette
NOTE : Template below is NOT TO SCALE. Visit www.formax.com/formax- flashcardxl-templates for full-size downloadable templates

Job 5 Brochure Template

(Without Mark, set first cut at 19.1 mm from top edge of sheet)
Sheet Size: 12” x 18” Card Size: 11” x 17”/279.4mm x 431.8mm – Use 11” Blade Cassette
NOTE: Template below is NOT TO SCALE. Visit www.formax.com/formax- flashcardxl-templates for full-size downloadable templates

Job 6 Postcard Template

(Without Mark, set first cut at 25.4 mm from top edge of sheet)
Sheet Size: 12” x 18” Card Size: 3.5” x 5”/88.9mm x 127.0mm – Use 3.5” Blade Cassette
NOTE : Template below is NOT TO SCALE. Visit www.formax.com/formax- flashcardxl-templates for full-size downloadable templates

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