FORMAX FlashCard Business Card Cutter Installation Guide

: August 16, 2024
: FORMAX

FORMAX FlashCard Business Card Cutter

Specifications

Speed: Up to 144 business cards per minute
Cutting Tolerance: 0.1mm
Standard Paper Sizes: 8.5 x 11, 8.5 x 14
Paper Weight: 180 – 350gsm
Paper Stock: Coated, non-coated, laminated
Programmable Jobs: 16 pre-programmed, 11 Custom
Feed Tray Capacity: Up to 40 sheets
Feeding Style: Double friction feed
Minimum Cut Length: 40mm
Registration Mark Reader: Yes
Dimensions: 22 L x 15 D x 10 H
Weight: 33 lbs (15kg)
Power: 110V, 50/60Hz, .6 Amp
Certifications: CE

Product Usage Instructions

Safety Notes:

Follow all safety guidelines provided in the operator manual to ensure safe operation of the FlashCard Business Card Cutter.

Unpacking & Setup:

Remove all components from the box and place the machine on a sturdy surface.
Insert the waste paper bin and catch tray in their respective positions.
Flip the infeed tray extension to the open position.
Ensure the top safety cover is correctly aligned and secure in place.
Connect the power cord to the machine and plug it into a suitable outlet.

Control Panel:

The control panel features an LCD screen and six buttons for operation. Use the buttons to select from pre-programmed cut settings or create custom cuts. The color buttons at the bottom have different functions based on the mode.

Standard Operation:

Follow the instructions provided in the operator manual for standard operation of the FlashCard Business Card Cutter. Ensure proper alignment of paper and settings for accurate cuts.

Changing Blade Cassettes:

To change blade cassettes, follow the steps outlined in the manual. Ensure the machine is powered off before replacing the cassette to avoid accidents.

FAQ

Q: How many pre-programmed jobs are available on the FlashCard Business Card Cutter?

A: The cutter comes with 16 pre-programmed jobs for convenience.

Q: What is the maximum feed tray capacity of the machine?

A: The FlashCard Business Card Cutter can hold up to 40 sheets in the feed tray.

DESCRIPTION

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

SPECIFICATIONS

Speed:	Up to 144 business cards per minute
Cutting Tolerance:	0.1mm
Standard Paper Sizes:	8.5” x 11”, 8.5” x 14”
Paper Weight:	180 – 350gsm
Paper Stock:	Coated, non-coated, laminated
Programmable Jobs	16: 5 pre-programmed, 11 Custom
Feed Tray Capacity:	Up to 40 sheets 200gsm (Stack height no more than

SAFETY NOTES

To prevent operator injury and avoid machine damage:

Be sure the FlashCard 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 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

Remove the FlashCard, operator manual, catch tray, waste paper bin, and power cord from the box. Place the machine on a sturdy surface.
Insert the waste paper bin, with the handle facing outward.
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 orientations, based on the dimensions of the job being cut (below left, right).
Flip the infeed tray extension to the open position.
Be sure the top safety cover is in place. It only fits in one direction, so be sure to align the pin on the underside, with the slot on the machine. A magnet holds the cover in place.
Insert the power cord into the inlet, and plug into an appropriate outlet.

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.

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.

Switch the power on. When the power is turned on, the cutter starts initializing and goes into standby mode.
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.
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.
Tighten the thumbscrews to lock them in position.
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.
Select the Job # that corresponds to the cut needed (see page 17).
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.
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 five (5) pre- programmed jobs. The Job #s and item details are listed below.
In addition, users can program and save up to 11 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 – 3.5” x 2”| 10| 3.5” Blade| 3.5” x 2” Business Cards| 8.5 x 11”| 3.5” x 2”
2| Job 2 – 3.5” x 2”| 10| 3.5” Blade| 3.5” x 2” Full Bleed Business Cards| 8.5 x 11”| 3.5” x 2”
3| Job 3 – 5” x 3.5”| 8| 3.5” Blade| 5” x 3.5” Cards| 8.5 x 11”| 5” x 3.5”
4| Job 4 – 8” x 4”| 3| 8” Blade| 8” x 4” Photo Cards| 8.5 x 14”| 8” x 4”
5| Job 5 – 7” x 5”| 2| 7” Blade| 7” x 5” Post Cards| 8.5 x 11”| 7” x 5”
6| | | | | |
7| | | | | |
8| | | | | |
9| | | | | |
10| | | | | |
11| | | | | |
12| | | | | |
13| | | | | |
14| | | | | |
15| | | | | |
16| | | | | |

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.

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

PROGRAMMING A CUSTOM JOB

Eleven custom jobs can be programmed into the Flashcard. The Jobs can be written in the spreadsheet on page 8 for quick reference. Follow the steps below to program a custom Job.

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.

Remove the catch tray, waste bin, and top safety cover, then lower the outfeed rear cover.
Remove the thumb screw holding the blade cassette in position.
Take the cassette out through the outfeed side of the machine.
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.
Reinsert and tighten the thumb screw.
Lift the rear cover back into position and replace the top safety cover, waste bin, and catch tray.
Plug in the power cord and power on the machine.

PREPARING OPTIONAL BLADE CASSETTE FOR INSTALL

The installation bracket on the optional cassettes is reverse mounted for shipping purposes (below, left). To set for installation, remove the two screws holding the bracket in place. Rotate the bracket around 180 degrees, and reattach the bracket with the two screws, as shown below.

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.

When the LCD shows “KNIFE ERROR,” use the arrow buttons to remove the paper.
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.
The catch tray and/or blade cassette may need to be removed to completely remove the paper from the cutter .
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.

When the LCD shows “MARK NOT FOUND,” use the yellow arrow button to reverse the paper for removal.
Remove the paper from the infeed. Confirm that the mark is properly sized and positioned.
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:

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.
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 Template Full Bleed B-Card with Mark

(Without Mark, set first cut at 12mm from top edge of sheet)
Sheet Size: 8.5” x 11” Card Size: 3.5” x 2” / 88.9mm x 50.9mm Use 3.5” blade
NOTE: Template below is NOT TO SCALE. Visit www.formax.com/formax-flashcard- templates for full-size downloadable templates

Job 2 Template B-Card with Mark
(Without Mark, set first cut at 7.5mm from top edge of sheet)
Sheet Size: 8.5” x 11” Card Size: 3.5” x 2” / 88.9mm x 50.9mm Use 3.5” blade

NOTE: Template below is NOT TO SCALE. Visit www.formax.com/formax- flashcard-templates for full-size downloadable templates

Job 3 Template Full Bleed Post Card
Sheet Size: 8.5” x 11” Card Size: 3.5” x 5” / 88.9mm x 127mm Use 3.5” blade
NOTE: Template below is NOT TO SCALE. Visit www.formax.com/formax-flashcard- templates for full-size downloadable templates

Job 4 Template Full Bleed Photo Greeting Card
Sheet Size: 8.5” x 14” Card Size: 8” x 4” / 88.9mm x 101.6mm Use 8” blade
NOTE: Template below is NOT TO SCALE. Visit www.formax.com/formax-flashcard- templates for full-size downloadable templates

Job 5 Template Full Bleed Greeting Card
Sheet Size: 8.5” x 11” Card Size: 7” x 5” / 177.8mm x 127mm Use 7” blade
NOTE: Template below is NOT TO SCALE. Visit www.formax.com/formax-flashcard- templates for full-size downloadable templates