PS100 Folder and Sealer

Transcription

1 Pressure Seal Group Operator s Manual PS100 Folder and Sealer

2 PS 100 Contents 1. Introduction Introduction to the PS Which Side Is Which? How to use this manual Safety precautions Operating environment Power requirements If the machine is damaged Features General Folder components Form guides Feed roll In-feed tray Folding plates Folding rollers Operator controls Batch counter Illuminated Power Switch Run switch Stop switch Power and safety components Mains lead Top cover Sealing and stacking components Pressure bolts Sealing rollers Stacker Iss. 1. Page v

3 PS Set-up Setting up the PS Removing the top cover Removing the folding plates Setting up the folder Setting the document stop Setting the adjustable document guide Replacing the folding plates First fold plate Second fold plate Operation Operating the PS Loading documents Verifying folder settings Processing forms Interrupting operation Operation Errors Error Conditions Clearing Mishandled Documents When the stop light flashes If it is in either the first or second fold plate: If the form is jammed in the sealing rollers: Pressure bolt adjustment Troubleshooting Cleaning the machine Cleaning procedure Page vi Iss. 1.

4 PS Specifications Folder/Sealer Specifications Construction Sealer Size Weight Power Speed Environment Feeder Capacity Colour Noise Document Specification Weights Sizes Fold Configuration Appendix A - Form Loading Guide Appendix B - Form Curl Service Visit Log Iss. 1. Page vii

5 1. Introduction Introduction to the PS100 The PS100 folder/sealer produces finished mailable documents or self-mailers from cut-sheet Pressure Seal documents. In one smooth operation the PS100 folds and seals single sheets into self-mailers quickly and economically. Pressure activated cohesives provide an instantly secure seal on the document, whether you use a V, C or Z fold. Figure 1: Types of fold produced Features of the PS100 folder/sealer include: Simple to load and operate Easy to change the fold style C, V, offset V and Z fold styles No adjustment required when changing the weight of forms used Automatic stop when the in-feed tray is empty In-feed forms counter with manual reset Paper flow error detection This PS100 folder/sealer operator manual describes the set-up and operating instructions for the PS100 folder/sealer. This manual is written as a reference for an operator who is familiar with mailing operations and who has received some basic training in operating the PS Iss. 1. Page 1

6 1. Introduction PS 100 Which Side Is Which? The terms infeed, outfeed and operator side are used throughout this manual to identify the sides of the PS100 (see fig.2 below). The infeed is the side into which the documents are fed. The outfeed is the side out of which the finished mailers exit. The operator side of the PS100 is the side on your right when you re facing the infeed of the PS100. Figure 2: The sides of the machine Page Iss. 1.

7 PS Introduction How to use this manual Here is a summary of what is contained in this manual and where: Features (page 7) - describes the major components you use to set up and operate the machine. New operators should read this section to gain a basic understanding of how the machine works. Experienced operators should read this section when they have a specific question about the function of a particular feature. Set-up (page 13) - outlines the tasks required to set up the machine. Provides easy step procedures for removing the top cover and folding plates and setting up the folder. New operators should read each procedure as they perform the task. Experienced operators should refer to relevant parts of the procedure to find answers to specific questions. Operation (page 21) - provides easy step-by-step procedures for loading and starting the machine. Operation errors (page 27) - lists common operating problems and possible causes and solutions. Cleaning (page 35) - provides details of the cleaning required to keep the machine in the best possible condition. Specifications (page 37) - provides the technical details of the folder/sealer. Form loading guide (page 39) - explains how to load forms based on the form design, type of fold, condition of forms (if they are curled or not - see Appendix B on page ), and how the folded/sealed forms should be orientated when they reach the conveyor Iss. 1. Page 3

8 1. Introduction PS 100 Safety precautions Although the design of your folder/sealer includes safeguards for set-up and operation, you must adhere to the following precautions. No one should use the machine unless they have been trained to do so. Pressure Seal Systems Ltd accept no responsibility for unauthorized use. Operating environment Dress safely. Loose clothing, long hair and jewellery can become tangled in moving parts. Keep your work area and the machine clean and clear of dust or debris. Details of how to clean the machine thoroughly are given in Chapter 6. Do not place the machine on an unstable stand or table. The machine may fall, causing serious damage or injury. To avoid personal injury and damage to the machine, it should always be lifted by two people. Do not allow anything to rest on the mains lead. Do not relocate the machine where anyone will walk on the lead. Operate the machine only with the top cover in place; the forms properly loaded in the in-feed tray and the out-feed tray/conveyor initially empty. Keep hands clear of the in-feed and out-feed areas when the machine is running. Except as explained elsewhere in this operator manual, do not attempt to service the machine. Doing so may expose you to dangerous voltages or other risks. Do not remove the protective side covers from the machine. Refer servicing to qualified service personnel. Only trained, authorised service personnel should remove the protective side covers - and then only for servicing purposes. Page Iss. 1.

9 PS Introduction Power requirements The PS100 must be operated from the type of power source indicated on the marking label. If you are unsure of the type of power available, consult your Pressure Seal representative or local power company. If an extension lead is used with the PS100, make sure that the total of the ampere ratings of the products plugged into the extension lead does not exceed the extension lead ampere rating. If the machine is damaged Unplug the machine from the wall outlet and refer servicing to qualified personnel under the following conditions: If the mains lead is damaged or frayed If liquid has been spilled into the machine If the machine has been exposed to rain or water If the machine has been dropped or damaged If the machine does not operate normally when the operating instructions are followed. Adjust only those controls that are covered by the operating instructions, since improper adjustment of other controls may result in damage. If the machine exhibits a distinct change in performance, indicating a need for a service Iss. 1. Page 5

10 2. Features General This section guides you through the features of the folder/sealer. The component names introduced in this section are used throughout this manual. Please refer to Figure 3 below as you read about the features of the machine. Figure 3: Features of the machine Iss. 1. Page 7

11 2. Features PS 100 Folder components Form guides The form guides keep the forms aligned so the feed roll feeds each one squarely. The form guides on the machine are adjustable to accommodate various sheet widths. Feed roll The feed roll provides reliable single-sheet form feeding into the folding area. The feed roll requires no adjustment. In-feed tray The in-feed tray holds the stack of forms allowing them to be fed by the feed roll. The spring-loaded tray presses the forms against the feed roll, automatically providing the correct pressure to allow only one form at a time to be fed into the folder. Folding plates These provide for simple "V" (centre or half) folds, "Z" (zigzag) folds or "C" (letter) folds. The plates are adjustable to accommodate various form lengths. Folding rollers The folding rollers work in conjunction with the folding plates to produce folds. The rollers feed the form into and out of the folding plates. The top roller is removable, which aids recovery of mishandled forms (see page 28). Page Iss. 1.

12 PS Features Operator controls Batch counter There are two types of batch counter available. The standard counter indicates the number of documents in the current batch (since it was last reset) and has a push button reset. There is an additional counter available for the cumulative total, and this may only be reset by a service engineer. Illuminated Power Switch The power switch is illuminated when the PS100 is connected to the mains supply. Run switch The run switch lights when: All documents are properly loaded on the feed table, and there are no mishandled documents anywhere in the PS100 The safety cover is fitted When the run switch lights: Momentarily pressing the run switch processes one document. Pressing and holding the run switch for two seconds processes all of the documents Iss. 1. Page 9

13 2. Features PS 100 Stop switch Pressing the stop switch stops the PS100 after the document currently being fed is processed. You can stop the PS100 at any time while documents are processing. The stop switch flashes when there is an operating error. To clear an error condition: Remove the lid from the PS100 Clear any mishandled documents When the top cover is replaced, the PS100 automatically resets the error detection. Figure 4: Operator controls Page Iss. 1.

14 PS Features Power and safety components Mains lead The mains lead supplies electrical power to the PS100. There is a 5-amp fuse in the three-pin plug. Top cover The top cover provides access to the folding and sealing components. The cover has two safety switches that disable operation of the PS100 when it is removed. Sealing and stacking components Pressure bolts These allow you to release the pressure on the sealing rollers for clearing mishandled documents with the allen key that is provided. Sealing rollers The sealing rollers provide the pressure required to tightly seal the edges of the document. Stacker This final component collects the self-mailers and stacks them for easy removal. It is adjustable for different forms Iss. 1. Page 11

15 Setting up the PS Set-up This section provides instructions for: Removing the top cover Removing the folding plates Setting up the folder Follow all the instructions in this section the first time you use the PS100 and whenever you need to process a different style document. Refer to the first two topics in this section when you need to access folding and sealing components. When any work is being carried out on the machine or any adjustments are being made, the machine should be disconnected from the mains Iss. 1. Page 13

16 3. Set-up PS 100 Removing the top cover Remove the top cover by placing one hand at the outfeed end and the other close to the infeed of the PS100. The outfeed end should be lifted first as the top cover is held in place by a retaining lip above the feed table. When installing the top cover, make sure that it is firmly seated on top of the unit. The safety switches for the top cover prevent the PS100 from operating if the cover is not properly installed. Figure 5: Removing the top cover Page Iss. 1.

17 PS Set-up Removing the folding plates 1. Remove the top cover 2. Grasp each folding plate as shown in the below diagram and lift to disengage the notches in the plate from the mounting studs. Pull the folding plate out of the PS100 at approximately 45. Figure 6: Removing the fold plates Iss. 1. Page 15

18 3. Set-up PS 100 Setting up the folder Once you ve removed the top cover and folding plates, setting up the PS100 s folder involves three steps: Setting the document stop on each folding plate Setting the adjustable document guide Replacing the folding plates and top cover Setting the document stop The location of the document stop along the scales on each folding plate determines where the folds are made on the documents. The first fold plate controls the first fold, and the second fold plate controls the second fold. To set the document stop: 1. Measure the length of the document to each fold. Determine the settings for the type of fold you want as shown in the diagram below. Figure 7: Document fold lengths Page Iss. 1.

19 PS Set-up 2. For each folding plate, adjust the document stop to the settings you determined in step 1. With the folding plates removed: Loosen the locking knobs at each end of the document stop. Using the knobs as handles, slide the stop along the rods until the stop aligns with the correct settings on the scales. Make sure both scales are showing the same settings otherwise the document will not fold squarely. Tighten the two locking knobs. Figure 8: Document stop setting components Iss. 1. Page 17

20 3. Set-up PS 100 Setting the adjustable document guide With the first fold plate removed, set the adjustable document guide on the feed table to fit the width of the documents you re processing. To set the adjustable document guide: 1. Loosen the adjustment knob on the underside of the feed table. Move the document guide to the right. 2. Place a document on the feed table, and align the left edge with the fixed document guide. Hold the document in place. 3. Using your other hand, align the adjustable guide with the right side of the document. 4. Secure the guide in place by tightening the adjustment knob. When you finish there should be just enough clearance to allow the document to move freely between the guides. Too much or too little clearance can cause mishandling. Figure 9: Document stop setting components Page Iss. 1.

21 PS Set-up Replacing the folding plates The PS100 may be set for C, V or Z fold forms. The fold plates used determine the fold type. First fold plate Insert the fold plate by identifying the locating pins nearest the fold roller and hooking the plate onto the pins, ensuring that both the hooks locate onto both the pins on either side of the machine. Lay the fold plate flat and push the edge down until the fold plate clicks firmly into position. Second fold plate For C and Z folds, locate the pins nearest the fold roller and hook the plate onto the pins, making sure that both hooks locate onto each pin either side of the machine. Lay the fold plate flat and push the edge down until the fold plate clicks firmly into position. For V folds only, the second fold plate should be located with the hooks on the same pins near the fold roller, but with the plate rotated through 180. Lay the fold plate flat and push the edge down until it locks firmly into position above the first fold plate. Figure 10: Adjusting the form guides Iss. 1. Page 19

22 Operating the PS Operation Operating the PS100 is a simple three-step process: 1. Verify that the machine is set for the fold style required by the documents. 2. Place the forms in the in-feed tray and adjust the forms width guide plate if necessary. 3. Start the machine. It is not recommended that any internal adjustments be made to the PS100. If adjustments are needed, contact an authorised service representative. This section explains in detail how to: Load documents Start up and test the PS100 Process documents Any problems that arise from the operation of the PS100 are addressed in the next chapter, which includes a troubleshooting guide Iss. 1. Page 21

23 4. Operation PS 100 Loading documents When you load documents make sure: There are no mishandled documents in the folder or sealer (the stop switch is not flashing) All rubber and metal rollers are clean and free of foreign matter 1. Fan the stack of documents to make sure that they aren t sticking together. 2. Align the stack so the documents feed correctly into the PS100. Document orientation depends upon document design, the type of fold desired, presence of curl, and how the folding plates are set up. 3. Align the stack of documents so that the ends and sides of the stack are smooth and square. 4. Raise the feed table and feed the stack between the document guides and into the PS100 until the stack meets resistance. 5. Lower the feed table. The run switch lights, indicating the stack is properly loaded on the feed table. Make sure that the stack of documents is flat and not bowed due to the document guides being too tight. Page Iss. 1.

24 PS Operation Starting up and testing the PS100 This procedure describes how to start up and test the PS100 to make sure it s ready to fold and seal your documents. Always perform this procedure at the start of each document processing session to ensure the best results. Before you start up and test the PS100, make sure all of the following conditions are satisfied: The top cover is firmly seated on the top of the unit. The folding plates are adjusted and installed properly for the fold you want. The document guides are set correctly to provide enough, but not too much, clearance at the sides of the document stack. The power switch is illuminated. Documents are properly loaded and the run switch is lit Iss. 1. Page 23

25 4. Operation PS 100 Verifying folder settings 1. Momentarily press the run switch. The PS100 processes one document. 2. Check the document for proper fold and seal. Check that the folds are in the proper place. If the first fold is in the wrong place, adjust the first folding plate. If the second fold is in the wrong location, adjust the second folding plate. Figure 11: First and second folds Page Iss. 1.

26 PS Operation Processing forms Before proceeding, make sure you ve started up and tested the PS100 and that the test document is properly folded and sealed. 1. Reset the counter (if required). 2. Press and hold the run switch until the next document is processed. The PS100 processes the documents loaded on the feed table. The PS100 automatically stops after the last document is processed. The run switch light turns off indicating the feed table is empty. 3. Remove the sealed documents from the stacker. 4. When you have finished processing documents, disconnect the PS100 from the mains power supply. Interrupting operation Press the Off/Stop switch at any time to cease processing. Do not stop the machine by removing the lid as this may damage the machine Iss. 1. Page 25

27 5. Operation Errors Error Conditions The red flashing error light indicates a problem. It is possible that a form is resting between the folder and the sealer, there is a misfeed or slipping of the folding mechanism or there is a form resting between the folding and sealing mechanisms or in the sealing mechanism. The following section describes how to clear mishandled documents, and also includes a simple troubleshooting guide Iss. 1. Page 27

28 5. Operation Errors PS 100 Clearing Mishandled Documents When the stop light flashes To clear a flashing error condition: Switch off the mains power and unplug from the mains. Remove the lid and locate the form that is jammed. If it is in either the first or second fold plate: Remove the fold plate in question by using the following procedure: Lift off the first fold plate as follows: a) Lift up the left hand edge of the plate until it releases from the left hand holding clips. b) Pull it clear of the hook pins located under the right hand edge of the plate. Remove the second fold plate as follows: a) Lift up the right edge of the plate until it releases from the holding clips b) Pull it clear of the hook pins under the left edge of the plate. Lift the two snap levers holding the top-folding roller in place, (see figure 12) and lift out the roller. Remove the jammed form. Page Iss. 1.

29 PS Operation Errors Replace the top-folding roller. Note that the flat faces on the two end bearings must be held vertically for them to drop into the housing slots. Close the two snap levers to hold the roller in place. Replace the first and second fold plates. Replace the top cover and restore mains power. Reload and restart the PS100. Figure 12: Removing the top folding roller Iss. 1. Page 29

30 5. Operation Errors PS 100 If the form is jammed in the sealing rollers: a) Remove all documents from the in-feed tray. b) Momentarily press the run switch to eject the mishandled document out of the rollers. If the document doesn t eject, repeat step b. It may take several attempts. If, after several attempts, the mishandled document doesn t eject, continue with the next procedure. It may be necessary to stabilise the forms before folding and sealing them. This can be achieved by allowing them to rest in the same room as the PS100 for an hour or more after printing. When the jammed form is removed from the sealer, check the sealer rollers for any form particles that may have become stuck with adhesive. Page Iss. 1.

31 PS Operation Errors Pressure bolt adjustment Figure 13: Relieving the sealing roller pressure 1. Using the 8mm allen key provided, turn the four adjustment screws anticlockwise to relieve the sealing roller pressure. (The allen key is situated on the lip above the in-feed tray, beneath the lid.) 2. Install the top cover, reconnect the power and switch the machine on. 3. Press the run switch momentarily to clear any mishandled forms. 4. When you are sure that all mishandled forms have been cleared, unplug the mains lead from the wall outlet. 5. Remove the top cover and tighten each adjustment screw down until you feel a significant increase in resistance. This is a predetermined stop. Do not overtighten the adjustment screws! Stop tightening the screws as soon you feel a significant increase in resistance. 6. Install the top cover and power up the machine Iss. 1. Page 31

32 5. Operation Errors PS 100 Troubleshooting The table below lists the possible causes and any corrective actions required for conditions that may occur with your PS100. For conditions not covered below, contact your Pressure Seal Systems distributor. Condition Possible Cause Corrective Action The illuminated power switch does not light. Mains lead not plugged into an AC outlet. Plug mains lead into an AC outlet. The PS100 does not operate when the run switch is pressed (power switch illuminated.) Documents are mishandled in the folder or damaged during sealing. Board fuse blown. Document misfeed, jam detected: stop switch is flashing. Top cover not firmly seated on top of the unit. No documents loaded. Board fuse blown. Fold plate document stop(s) adjusted improperly. Documents have excessive curl due to moisture, excessive toner or poor storage. Debris in folding plates; folding plates not installed properly; fold plate document stop(s) adjusted improperly. Contact your Pressure Seal distributor for advice. Clear mishandled documents (p. 24). Firmly seat the top cover on the unit (p. 12). Load documents (p.19). Contact your Pressure Seal distributor for advice. Check and adjust the position of the fold plate document stop(s) (p.14). Store documents in area with low humidity; de-curl by placing documents on a flat surface with a heavy weight for several hours. Remove debris; properly install fold plates; check position of the fold plate document stop(s). Page Iss. 1.

33 PS Operation Errors Condition Possible Cause Corrective Action Documents are mishandled in the folder or damaged during sealing. Dirty folding rollers. Folding roller adjusted improperly or worn; sealing rollers adjusted improperly. Clean rollers with cleaning solution. Contact your Pressure Seal distributor for advice. Documents not sealing. Pressure on sealing rollers is relieved. Documents are older than their shelf life (one year). Reset pressure on the sealing rollers (p.27). Use fresh documents. Fold plate document stop(s) adjusted improperly causing poor registration of adhesive strips. Sealing rollers adjusted improperly. Check and adjust position of the fold plate document stop(s) (p.14). Contact your Pressure Seal distributor for advice. Documents are misfeeding. Feed table document guides are set too tight. Debris in folding plates; folding plates not installed properly; fold plate document stop(s) adjusted improperly. Worn feed roll. Set the guides so there is just enough clearance to allow the document to move freely between the guides (p. 16). Remove debris; properly install folding plates; check and adjust the position of the fold plate document stop(s). Contact your Pressure Seal distributor for advice Iss. 1. Page 33

34 5. Operation Errors PS 100 Condition Possible Cause Corrective Action Documents are wrinkled or badly folded. Documents not feeding squarely against document stop(s). Adjust the document stop(s) to squarely deflect the documents; ensure the stop setting is identical on both scales. Two or more documents are feeding into the folder together. Dirty folding rollers. Feed table document guides are set too tight. Fold plate document stop(s) adjusted improperly. Folding rollers adjusted improperly or worn; sealing rollers adjusted improperly. Documents in stack are sticking together. Worn feed roll. Clean folding rollers. Set guides to allow the document to move freely between the guides. Check and adjust the position of the fold plate document stop(s) (p. 14) Contact your Pressure Seal distributor for advice. Fan document stack and reload documents. Contact your Pressure Seal distributor for advice. Page Iss. 1.

35 6. Cleaning the machine Cleaning procedure The machine s folding and sealing mechanisms should be cleaned in the following manner: To avoid leaving finger-marks on the machine s internal rollers, it is recommended that disposable gloves are worn during cleaning. People susceptible to dust allergies may be more comfortable wearing a protective mask. 1. Be sure that the room is well ventilated. 2. Switch off the mains power and unplug or disconnect from the mains. 3. Lift off the top cover. 4. Remove the first fold plate. 5. Remove the second fold plate. 6. Lift the two levers holding the top folding roller (see Figure 12), and lift out the roller. 7. Remove as much paper dust as possible using a soft brush. Try to avoid letting the dust drift down into the lower machinery. If compressed air is used to clear the paper dust, use only a recommended canned air blower. 8. Moisten a clean, lint-free cloth with the cleaning solution. Avoid breathing the fumes or getting the solution in an open wound or other sensitive areas such as the eyes or mouth. Read the label on the container carefully before use Iss. 1. Page 35

36 6. Cleaning the machine PS Wipe clean the surface of all the folding and sealing rollers using the moistened cloth. It will be necessary to rotate each roller, taking care not to let anything get caught between them. A moderate amount of effort may be required to turn the sealing rollers. Wipe off any fingerprints from the rollers as they are turned. 10. Replace the top-folding roller. The flat faces of the bearing holder must be held vertically for the roller to drop into the holding slots. 11. Close the two snap levers to hold the roller in place. 12. Replace the first and second fold plates. 13. Replace the top cover and then restore the mains power. Page Iss. 1.

37 7. Specifications Folder/Sealer Specifications Construction Formed sheet metal steel side frames with ABS shell Sealer Integral four-roller system Size 685mm(L) x 495mm(W) x 375mm(H) (excluding output tray of 115mm) Footprint 675mm x 495mm Weight 80kg Power 115/230V ac 10%, 50/60Hz Speed 4000 forms per hour (A4 Z fold) Environment Operating Non-operating C 5% - 50% humidity 5-50 C 5% - 80% humidity Iss. 1. Page 37

38 7. Specifications PS 100 Feeder Capacity 150 sheets Colour Graphite Noise 72dB Document Specification Weights 60gsm minimum; 145gsm maximum Sizes W 175mm (6.9in) x L 100mm (4in) W 216mm (8.5in) x L 355mm (14in) Cut-sheet minimum maximum Fold Configuration Z, V and C folds Page Iss. 1.

39 Appendix A - Form Loading Guide Many variables must be considered when setting up the folder/sealer, and loading forms for processing. These include the form design, type of fold and how the folded/sealed forms should be orientated when they reach the conveyor. Settings Settings Settings First folding plate: Half of the form length. Second folding plate: Rotate through 180 degrees. Feeding problems: Rotate form 180 degrees. First folding plate: One third of the form length. Second folding plate: One third of the form length. Feeding problems: Print backside of form first. First folding plate: Two thirds of the form length. Second folding plate: One third of the form length. Feeding problems: Flip form, then rotate 180 degrees Iss. 1. Page 39

40 Appendix B - Form Curl Many variables must be considered when setting up the folder/sealer, and loading forms for processing. These include the form design, type of fold, condition of forms (if they are curled or not), and how the folded/sealed forms should be orientated when they reach the conveyor. Figure 14 shows acceptable (flat or curl down), and unacceptable (curl up) curl conditions. In some cases, forms that are curled up can be processed by loading them differently. Figure 14 Curled Documents Page Iss. 1.

41 Serial number: Service Visit Log Date Work done and comments Engineer s signature Customer s signature Head Office: Pressure Seal House, 1 The Dean, New Alresford, Hampshire, SO24 9BQ Tel: +44 (0) Fax: +44 (0) service@pseal.co.uk Iss. 1. Page 41