Pressure Seal Group Operator’s Manual PS 600 Folder and Sealer Telephone: E-mail: Website: +44 (0) 19 6273 5777 service@pseal.co.uk www.pressure-seal.
PS 600 This manual is protected under the Copyright Laws of the United Kingdom. All rights reserved. Reproduction of this material without the express written consent of Pressure Seal Systems Ltd is prohibited. PRESSURE SEAL SYSTEMS MAY MAKE IMPROVEMENTS AND OR CHANGES IN THE PRODUCT DESCRIBED IN THIS MANUAL AT ANY TIME AND WITHOUT NOTICE. This publication could contain technical inaccuracies or typographical errors.
PS 600 Contents 1. Introduction General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Which side is which? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 How to use this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Operating environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Power requirements . . . . . . .
PS 600 Sealing and stacking components Pressure bolts . . . . . . . Sealing rollers. . . . . . . . Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 11 11 11 3. Set-up Setting up the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PS 600 6. Cleaning the machine Cleaning procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 7. Specifications Folder/Sealer Specifications Construction . . . . . Sealer. . . . . . . . . Size. . . . . . . . . . Weight . . . . . . . . Power . . . . . . . . Speed . . . . . . . . Environment . . . . . Feeder Capacity . . . . Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. Introduction General This folder/sealer produces finished mailable documents or "self-mailers" from cut-sheet Pressure Seal forms. In one smooth operation it folds and seals single sheets into self-mailers quickly and economically. Pressure activated cohesives provide an instantly secure seal on all sides of the form, whether you use a “C”, “V” or “Z” fold.
PS 600 1. Introduction Which side is which? The terms "in-feed", "out-feed", "operator side" and “non-operator side” are used throughout this manual to identify the sides of the machine. • • • The in-feed is the side into which the forms are loaded. The out-feed is the side out of which the finished mailers exit. The operator side of the machine contains the control panel and is the side facing you when the in-feed of the machine is on your left.
PS 600 1. 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.
1. Introduction PS 600 Safety precautions Although the design of your folder/sealer includes safeguards for set-up and operation, you must adhere to the following precautions. I 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.
PS 600 1. Introduction Power requirements The machine must be operated from the type of power source indicated on the voltage setting label (see Figure 3). If you are unsure of the type of power available, consult your Pressure Seal representative or local power company. Voltage Setting Label Figure 3: Voltage Setting Label Location 22-01-03 Iss. B.
PS 600 1. Introduction If the machine is damaged Unplug the machine from the wall outlet and refer servicing to qualified personnel under the following conditions: q If the mains lead is damaged or frayed q If liquid has been spilled into the machine q If the machine has been exposed to rain or water q If the machine has been dropped or damaged q If the machine does not operate normally when the operating instructions are followed.
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 4 below as you read about the features of the machine. Conveyor In-feed Bed Form Guides Control Panel Compressor Cabinet Sealer Rollers First Fold Plate Second Fold Plate Figure 4: Features of the machine 22-01-03 Iss. B.
2. Features PS 600 Folder components Form feeder The forms are stacked between the form feed arms of the In-feed bed. Using positive air pressure to support the main body of the forms, the leading edge of the bottom form is sucked on to the feed roll, providing reliable single-sheet form feeding into the folding area. 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.
PS 600 2. Features Operator controls LCD display The forms counter on the LCD display indicates the number of forms in the current run (since it was last reset) and is zeroed by pressing the reset button (see Figure 5). P There is an additional counter located inside the machine indicating the cumulative total. This can only be accessed by a service engineer. The LCD display also indicates any error messages (see page 31) and the machine’s current status e.g. Ready, Running, software version, etc.
2. Features PS 600 Off/Stop button Pressing the Off/Stop button stops the machine after the form currently being fed is processed. You can stop the machine at any time while forms are processing. + button ( + ) Reserved for future use. – button ( ) Reserved for future use. Reset button When the Reset button is pressed with the Select button held down, the forms counter on the LCD display is set to zero. Select button This is an engineering function button and should not be used by operators.
PS 600 2. Features Power and safety components Mains lead The mains lead supplies electrical power to the machine. Rear cover The rear cover is located over the sealer rollers. Sealing and stacking components Pressure bolts These allow you to release the pressure on the sealing rollers for clearing mishandled forms. These bolts can be loosened using the allen key provided (see page 34). Sealing rollers The sealing rollers provide the pressure required to tightly seal the edges of the form.
3. Set-up Setting up the machine This section provides instructions for: • • • • Removing the folding plates Setting up the folder Setting up the In-feed Bed Setting up the conveyor Follow all the instructions in this section the first time you use the machine and whenever you need to process a different style of form. Refer to the first two topics in this section when you need to access folding and sealing components.
PS 600 3. Set-up Removing/fitting the first folding plate 1. Lift the Folding Plate Cover and release the two Locking Arms (see Figure 6). 2. Remove the Folding Plate by sliding it towards the rear of the machine. 3. Fitting the Second Folding Plate is the reversal of the above procedure. Folding Plate Cover Locking Arms (1 each side) First Fold Plate Figure 6: Removing the first folding plate Page 14 22-01-03 Iss. B.
PS 600 3. Set-up Removing/fitting the second folding plate 1. Lift and remove the Small Top Cover (see Figure 7) then raise the In-Feed Bed, ensuring it is locked into the upright position with the locking arm. 2. Fold down the Front Panel, release the two Locking Arms and then slide the First Folding Plate out of the machine. 3. Fitting the First Folding Plate is the reversal of the above procedure.
3. Set-up PS 600 Setting up the folder Once you've removed the top cover and folding plates (see pages and 15 respectively), setting up the machine’s folder is carried out as follows: P Folding plates can be adjusted in situ. V fold set-up Refer to Figure 8. 1. Measure the length of the fold required. 2.
PS 600 3. Set-up Leading Edge To set the plates for a V fold, fit a Deflector Bar to one plate (see below) and set the required fold dimension on the other.
3. Set-up PS 600 C fold set-up Refer to Figure 9. 1. Measure the length of the folds required. 2. Adjust the form stop for each folding plate to the measurement you determined previously in step 1 as follows: Loosen the locking knob at the centre of the form stop. Slide the stop along the rods until the stop aligns with the correct settings on the scales.
PS 600 3. Set-up Leading Edge First Fold Dimension Second Fold Dimension Fold Perforations Second Fold Dimension Setting 6 150 140 5 130 120 Locking Knob Fine Adjustment Form Stop Fine Adjustment Locking Knob Second Fold Plate Form Stop First Fold Plate First Fold Dimension Setting 6 150 140 5 130 120 Figure 9: C Fold Set-up 22-01-03 Iss. B.
3. Set-up PS 600 Z fold set-up Refer to Figure 9. 1. Measure the length of the folds required. 2. Adjust the form stop for each folding plate to the measurement you determined previously in step 1 as follows: Loosen the locking knob at the centre of the form stop. Slide the stop along the rods until the stop aligns with the correct settings on the scales.
PS 600 3. Set-up Leading Edge First Fold Dimension Second Fold Dimension Fold Perforations Second Fold Dimension Setting 6 150 140 5 130 120 Locking Knob Fine Adjustment Form Stop Fine Adjustment Locking Knob Second Fold Plate Form Stop First Fold Plate First Fold Dimension Setting 6 150 140 5 130 120 Figure 10: Z Fold Set-up 22-01-03 Iss. B.
PS 600 3.
PS 600 3. Set-up Setting up the form conveyor The form conveyor collects the forms from the out-feed and stacks them (either overlapping or separated) ready for removal. To fit and set-up the conveyor, proceed as follows: 1. Clip the conveyor over the locating lip on the out-feed of the machine, plug it in to the mains output socket (see Figure 12) and turn it on. 2.
4. Operation General Operating the machine is a simple three-step process: 1. Verify the machine is set for the fold style required by the forms. 2. Place the forms in the in-feed tray and adjust if necessary (see page 22). 3. Start the machine. I Apart from adjusting the fold plates and clearing mishandled forms, no internal adjustments should be made to the machine. If adjustments are needed, contact an authorised service representative.
4. Operation PS 600 Loading forms 1. When you load forms make sure: • There are no mishandled forms in the folder or sealer (no error messages indicated on the LCD display - see Error Conditions on page 31). • All rubber and metal rollers are clean and free of foreign matter 2. Fan the stack of forms to make sure they are not sticking together. 3. Align the stack so the forms feed correctly into the machine.
PS 600 4. Operation Starting up and testing the machine This procedure describes how to start up and test the machine to make sure it is ready to fold and seal your forms. Always perform this procedure at the start of each form processing session to ensure the best results. Before you start up and test the machine, make sure all of the following conditions are satisfied: • • The folding plates are adjusted and installed properly for the fold you want.
PS 600 4. Operation Verifying folder settings 1. Momentarily press the On/Start button. The machine processes one form. 2. Check the form 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 place, adjust the second folding plate. P Make certain the first fold is correct before adjusting the second.
PS 600 4. Operation Processing forms Before proceeding, make sure you have started up and tested the machine and that the test form is properly folded and sealed. 1. Press the Reset button to zero the counter (if required). 2. Press and hold the run switch for 2 seconds until the next form is processed. The machine processes all the forms loaded, until the in-feed tray is empty. The machine stops automatically after the last form is processed.
5. Operation Errors Error Conditions In the event of a problem existing that prevents the machine from operating, a suitable error message will be shown on the LCD display as follows: INFEED JAM: Paper cannot enter the machine correctly. Make sure that the infeed table is set up properly. JAM IN FOLDER: There are too many forms in the folder. Take out the top fold plate and try to pull any visible forms out or turn the hand wheel. Then try to jog the remaining pieces of paper out.
5. Operation Errors PS 600 Clearing mishandled forms Jam in folder If the ‘Jam in folder’ error message is displayed, proceed as follows: 1. Switch off the mains power and unplug from the mains and then remove the top cover (see page ). 2. Remove the fold plates using the procedure described on page 15. 3. Lift the two snap levers holding the top-folding roller in place, (see Figure ) and lift out the top folding roller. 4. Remove the jammed form. 5. Replace the top-folding roller.
PS 600 5. Operation Errors Jam after folder If the ‘Jam after folder’ error message is displayed, proceed as follows: 1. Remove all forms from the in-feed tray. 2. Momentarily press the run switch to eject the mishandled form out of the rollers. If the form doesn't eject, repeat step 2. It may take several attempts. If, after several attempts, the mishandled form doesn't eject, carry out the Pressure bolt release procedure on page 34.
5. Operation Errors PS 600 Pressure sealer bolt release The pressure sealer bolts on the machine not only allow you to recover from severe form mishandling situations, they also provide accurate sealing pressure. The pressure on the sealing rollers can be relieved then reset to the original factory setting in the event mishandled forms lodge between the sealing rollers, stopping the machine processing. 1. Unplug the power cord from the wall outlet. 2. Remove the top cover and first folding plate. 3.
PS 600 5. 5. Operation Errors Press and hold the stop button and press start. Folder/sealer jogs mishandled forms out of machine. 6. When you are sure that all mishandled forms have been cleared, unplug the mains lead from the wall outlet. 7. Remove the top cover and tighten each adjustment screw down until you feel a significant increase in resistance. This is a predetermined stop. I 8.
PS 600 5. Operation Errors Troubleshooting The table below lists the possible causes and any corrective actions required for conditions that may occur with your machine. For conditions not covered below, contact your Pressure Seal Systems distributor. Condition Possible Cause Corrective Action The power-on indicator does not light. Mains lead not plugged into an AC outlet. Plug mains lead into an AC outlet. Mains plug fuse blown. Replace fuse.
PS 300 5. Operation Errors Condition Possible Cause Corrective Action Forms are mishandled in the folder or damaged during sealing. Dirty folding rollers. Clean rollers with cleaning solution. See page 39. Folding roller adjusted improperly or worn; sealing rollers adjusted improperly. Contact your Pressure Seal distributor for advice. Pressure on sealing rollers is relieved. Reset pressure on the sealing rollers. See page 34. Forms in wrong way round. Replace forms correctly.
PS 600 5. Operation Errors Condition Possible Cause Corrective Action Forms are wrinkled or badly folded. Forms not feeding squarely against form stop(s). Adjust the form stop(s) to squarely deflect the forms; ensure the stop setting is identical on both scales. See page 16. Dirty folding rollers. Clean folding rollers. Fold plate form stop(s) adjusted improperly. Check and adjust the position of the fold plate form stop(s). See page 16.
6. Cleaning the machine Cleaning procedure The machine’s folding and sealing mechanisms should be cleaned in the following manner: P 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. Remove the first fold plate. 4.
6. Cleaning the machine 7. PS 600 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. 8. Replace the first and second fold plates. 9. Restore the mains power. Page 40 22-01-03 Iss. B.
7. Specifications Folder/Sealer Specifications Construction Formed sheet metal steel side frames with ABS shell Sealer Integral four-roller system Size 1150mm(L) x 630mm(W) x 1250mm(H) (excluding output tray of 115mm) Weight 222kg Power 110/230 V AC ±10% 50/60 Hz 10.35 Amps running current Numa 6 power lead (USA only) Schuko power lead (Europe) Speed Up to 18,000 forms per hour (A4 Z fold) Environment Operating 10° - 40° C 5% - 50% humidity Non-operating 5° - 50° C 5% - 80% humidity 22-01-03 Iss.
7. Specifications PS 600 Feeder Capacity 500 sheets, bottom feed Noise 85dB Form Specification Sizes 203mm to 420mm long x up to 300mm wide Cut-sheet Fold Configuration Z, V and C folds Page 42 22-01-03 Iss. B.
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. Glued edge leading Settings Settings Settings First folding plate: Half of the form length. First folding plate: Two thirds of the form length. First folding plate: One third of the form length. Second folding plate: Fit deflector plate.
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 15 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.
Service Visit Log Serial number: 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)19 6273 5777 Fax: +44 (0) 19 6273 4555 e-mail: service@pseal.co.uk 22-01-03 Iss. B.
