Contents Chapter One – Description ........... 1 General Description ....................2 Which Side Is Which? ..................... 3 Features........................4 Folder Components ..................5 Document Guides ..................5 Feed Roll....................5 In-Feed Table.................... 5 Folding Plates ................... 5 Folding Rollers ..................5 Jam Detection and Document Counting Circuitry ..........
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Chapter Two – Installation............ 10 Site Requirements ....................11 Floor Space Requirements ................11 Power Requirements..................11 Places to Avoid ....................11 Unpacking the PS100 ..................... 12 To Unpack the PS100 ..................12 Inspecting the PS100....................14 Setting up the PS100 and Verifying Operation............14 Training the Operator....................
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Chapter Six – Operation Errors..........39 Troubleshooting Guide.................... 40 Chapter Six – Preventative Maintenance ......43 Before You Begin....................44 Cleaning the PS100 ....................44 Lubricating the PS100..................... 45 Inspecting the PS100....................45 Chapter Seven – Illustrated Parts List ........ 46 Recommended Spares for Engineers ..............
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Diagrams Figure 1. Types of Fold Produced by the PS100............2 Figure 2. The Sides of the PS100 ................3 Figure 3. The Features of the PS100 .................4 Figure 4. The PS100’s Components (Operator Side View) ........9 Figure 5. The PS100’s Components (Non-Operator Side View) ........9 Figure 6.
Chapter 1 Description This chapter introduces you to the Pressure Seal PS100 Folder/Sealer. Use the information here to familiarise yourself with component names and locations, and to gain a better understanding of the physical and performance characteristics of the PS100.
General Description The Pressure Seal PS100 Folder/Sealer is a compact, portable unit requiring no more than desktop space to operate. Because of it’s compact size, the PS100 fits a variety of work spaces and can be moved easily (the PS100 weighs 80kg) anywhere it’s needed.
Which side is which? The terms “infeed”, “outfeed” and “operator side” are used throughout this manual to identify the sides of the PS100 (see figure 2 below). • The infeed is the side into which documents are fed. • The outfeed is the side out of which the finished mailers exit. •...
Features This section guides you through the features of the Pressure Seal PS100 Folder/Sealer. The component names introduced in this section are used throughout this manual. sealer pressure bolts sealer rollers feed roll batch counter fixed document guide stop switch...
Folder Components Document guides The document guides keep the documents aligned so the feed roll feeds each one squarely. The guide nearest the operator side of the PS100 is adjustable to accommodate various sheet widths Feed roll This provides reliable single-sheet document feeding into the folding area. The roll requires no adjustment.
Jam detection and document counting circuitry Conveyor and outfeed sensors These monitor the flow of paper and should a misfeed occur they immediately shut down the PS100, minimising the risk of spoiled documents. The sensors also provide input to the counters. Operator Controls Batch counter There are two types of batch counter available.
Power and safety components Mains lead Supplies electrical power to the PS100. Top cover Provides access to the folding and sealing components. The cover has a safety interlock that disables operation of the PS100 when the cover is removed. The cover must be removed to reset an error condition.
Technical information Folder/Sealer specifications Construction Formed sheet metal steel side frames with ABS shell Size 685mm(L) x 495mm(W) x 375mm(H) (excluding output tray of 115mm) Footprint 675mm(W) x 495mm(L) Weight 80kg Power 110v AC, 60HZ, 5A 230V AC, 50HZ, 2.7A Speed 4,000 documents per hour maximum Environment...
System overview This section illustrates the locations of the major parts of the PS100 Folder/Sealer. Refer to figures 4 and 5 below. fold rollers outfeed sensor fold roller gears infeed sensor sealer roller gears filter clutch/clutch gear clutch drive gear Figures 4 and 5.
Chapter 2 Installation This chapter describes the site requirements and the sequence of tasks you must perform to successfully install the PS100 Folder/Sealer. Installation tasks include: • Site requirements • Unpacking the PS100 • Inspecting the PS100 • Setting up the PS100 and verifying operation •...
• Avoid electrical outlets controlled by wall switches or timers. • Avoid locations subject to direct sunlight, excessive heat, moisture or dust. • Store Pressure Seal documents away from UV light sources. UV light degrades adhesives, shortening document shelf life.
Unpacking the PS100 The PS100 is shipped fully assembled in a wooden crate. Although some variation in packing is possible, the unit should arrive at the customer site as described below. Warning: The PS100 weighs 80 kg. Therefore, two people are required to lift the PS100 from the crate’s skid onto the work surface.
Inspecting the PS100 1. Visually inspect the exterior of the PS100 for damage. 2. Remove the left and right (operator) sides covers and inspect all electrical connections. Make sure none have come loose during shipping. 3. Replace the covers. 4. Power up the PS100. (See “powering up the PS100” in the operator manual for detailed procedures.) 5.
Training the operator Operator training is an important part of the installation process, and is the key to proper machine performance. By doing a thorough job in this area, you can reduce the number of service calls for typical performance issues such as document mishandling.
Chapter 3 Electrical Operation This chapter provides a comprehensive look at the electrical components and circuits of the PS100 Folder/Sealer. In Chapter 3 you’ll find the following information on the PS100’s electrical operation. • Electrical components list • Theory of operation •...
Electrical components list The PS100’s electrical system includes the following primary components. • Infeed sensor • Outfeed sensor • Motor • Counter • Circuit board • Power switch • Cover switch • Run switch • Stop switch • Clutch • Filter Page 17...
Theory of Operation When power is applied to the board: The LED connector should have +24V across it The +SI- (sensor infeed) and +SO- (sensor outfeed) will become active The two green LED’s will illuminate (indicating +24V and +5V respectively) The counter will become active If paper is placed over the infeed sensor: The RUN switch will light, (The RUN LED connector will have +24V across it)
Interrupt operation The PS100 stops during normal operation when any of the following occurs: • Stop switch is pressed • Power switch is turned off • Top cover is removed • Power cord is disconnected from source • Feed table is emptied (infeed sensor not detecting documents) •...
WHITE XTAL BLUE YELLOW BLACK YELLOW SIL R1 BROWN BLUE YELLOW ORANGE BLUE SIL R2 BLUE BLACK BLUE BROWN PUSH BUT YELLOW ORANGE YELLOW ORANGE +24V BLUE BROWN CHOKE 1 CHOKE 2 MOTOR POWER COUNTER TO POWER TO BOARD RUN AND STOP SWITCHES UP TO FROM...
XTAL WHITE BLUE YELLOW BLACK YELLOW BROWN SIL R1 BLUE YELLOW ORANGE BLUE BLUE SIL R2 BLACK BROWN BLUE PUSH BUT YELLOW ORANGE YELLOW ORANGE +24V BLUE BROWN LINK CHOKE 1 CHOKE 2 MOTOR RUN AND STOP SWITCHES FROM 100043 COUNTER POWER TO POWER...
Board functions The circuit board controls almost all of the functions of the PS100. • The fuse next to the transformer is for the low voltage (+24V and +5V) part of the circuit. • The second fuse is for the motor •...
FUSE +24V LIVE 24V REG 5V REG NEUTRAL FUSE PHASE MOTOR CONTROL MOTOR CHOKE 1 CHOKE 2 MOTOR +24V OUTPUTS STOP LED RUN LED CLUTCH COUNTER LED 3 TO OPTO ON MOTOR CIRCUIT C11 UNMARKED SIL R1 INPUTS SIL R2 +24V PUSH BUT LED 2...
FUSE +24V LIVE 24V REG 5V REG NEUTRAL MOTOR CONTROL PHASE RELAY MOTOR CHOKE 1 CHOKE 2 MOTOR +24V OUTPUTS STOP LED RUN LED CLUTCH COUNTER LED 3 IC2A TO RELAY ON MOTOR CIRCUIT IC2D IC2B IC2C SIL R1 INPUTS SIL R2 +24V PUSH BUT...
Troubleshooting electrical components Use the following information for diagnosing PS100 electrical component failures Symptom Problem LED1 and/or LED2 not lit 400mA fuse blown Power conversion components failed Motor will not run 3.15mA fuse blown (green LED lit) Potentiometer failed Component failed Connector loose (motor, start, cover) Motor blown Motor will not stop running...
Chapter 4 Assemblies and Adjustments This chapter describes how to remove, replace and where applicable adjust the major mechanical and electrical components of the PS100 Folder/Sealer. By following these procedures, you can quickly and correctly service a customer’s PS100. Refer to figures 4 and 5 on page 9, and the illustrated parts list in chapter 6 of this manual to help you understand the text-only procedures in this chapter.
Covers and panels This section shows you how to remove and replace the PS100’s: • Right (operator) side cover • Left (non-operator) side cover • Infeed panel • Outfeed panel outfeed cover non operator side cover output tray operator side cover infeed cover Figure 11.
Removing the infeed panel 1. Press the PS100’s power switch to the off position and then unplug the power cord from the wall outlet. 2. Remove the top cover. 3. Remove the four snake eye screws that hold the infeed panel in place (two at the top and two beneath the machine), and then remove the infeed panel.
Removing the right (operator) side cover Removing the right side cover allows access to the clutch gear, clutch, fold roller gears, sealing roller gears, circuit board and operator controls. 1. Press the PS100’s power switch to the off position and then unplug the power cord from the wall outlet.
Document feed system This section shows you how to remove and replace the PS100’s: • Feed roll and paper separator • Clutch Removing the feed roll and paper separator 1. Press the PS100’s power switch to the off position and then unplug the power cord from the wall.
Replacing the feed roll and paper separator Replace the feed roll and paper separator after every 200,000 documents. Loosen the two securing screws and slide the old feed roll from the shaft. Reverse the procedure to install a new feed roll. Using a flat blade screwdriver, pry the old paper separator from the mounting frame, and install a new one in the frame.
Document folding system This section describes how to remove and replace the PS100’s fold rollers Removing the fold rollers Typically, the fold rollers only require periodic cleaning to remove the build-up of paper, dust, toner and paper coatings. However, extensive use over a long period of time may eventually make roller replacement necessary.
Document sealing system This section shows you how to remove and adjust the PS200’s: • Sealer chain • Sealer Removing the sealer chain The sealer sprocket drives the sealer chain on the sealer drive shaft. The chain drives the sealing rollers. 1.
Replacing the sealer The PS100’s sealing rollers, bearings and bearing blocks are replaceable. Removing the sealer: 1. Press the PS100’s power switch to the off position and then unplug the power cord from the wall outlet. 2. Remove the top cover, outfeed panel, and the right and left side covers. 3.
Electrical system This section shows you how to remove and replace the following electrical components: • Lid switch • Infeed sensor • Outfeed sensor • Motor Removing the cover switch 1. Press the PS100’s power switch to the off position and then unplug the power cord from the wall outlet.
Removing the infeed sensor 1. Press the PS100’s power switch to the off position and then unplug the power cord from the wall outlet. 2. Remove the top cover and infeed cover. 3. Remove the two countersunk screws that mount the infeed microswitch bracket to the underside of the infeed table.
Removing the outfeed sensor 1. Press the PS100’s power switch to the off position and then unplug the power cord from the wall outlet. 2. Remove the top cover. 3. Remove the top half of the sealer by unscrewing the four pressure adjustment bolts.
Removing the motor 1. Press the PS100’s power switch to the off position and then unplug the power cord from the wall outlet. 2. Remove the top cover, right and left side covers, infeed and outfeed panels. 3. Grasp the tie bar above the feed table and tip the machine onto its outfeed end. Be careful, the unit is heavy! 4.
Chapter 5 Operation Errors The red flashing error light indicates a problem with the PS100. 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.
Symptom Possible Cause Solution Documents not feeding Infeed tray side guides too Set the guides so there is just tight enough clearance to allow the document freedom of movement between the guides The feed pad or infeed roller Check both of the components may be worn and replace if necessary Check the shaft and replace if...
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Symptom Possible Cause Solution Sealer/folder rollers not Gear or sprocket loose on Change gear or sprocket rotating shaft Chain broken or connecting Check link, reinstate link dislodged necessary or replace chain Documents not folding Check fold plate installation Ensure fold plates squarely correctly installed on all of the...
Symptom Possible Cause Solution Documents not sealing Check sealer roller pressure Increase the pressure slightly on the sealer rollers by turning the pressure bolts. Refer to appendix A for paper Check orientation of the orientation. fold/ glue pattern If paper is out of date, discard. Check the life of paper Forms not ejecting properly Check the paper for static...
Chapter 6 Preventative Maintenance The PS100 requires preventative maintenance every six months or every two hundred thousand documents, whichever occurs first. This chapter provides you with the preventative maintenance procedures you must perform to successfully maintain the performance of the customer’s PS100 folder/sealer.
Before you begin 1. Ask the operator about: • How the machine is performing • Problems encountered during operation • Frequency of use and the number of documents processed per month 2. Note any increase in machine usage rate and use this information as a guide for checking the machine 3.
Lubricating the PS100 Lubricate the drive chain and sprockets with chainlube. Inspecting the PS100 1. Check the feed roll, paper separator and fold rollers for cracks, tears or excessive wear. Replace if necessary. 2. Check the top cover switch for proper operation. 3.
Chapter 7 Illustrated Parts List Recommended Spares for Engineers Part number Description Quantity 50-0008-01 Fold plate stub 51-0005-01 Spring anchor bracket 33-0002-01 Infeed tray spring 33-0004-01 Bearing housing pressure spring 33-0005-01 Adjustable side guide spring 33-0003-01 Feed pad adjuster shaft spring 33-0001-01 Locking lever spring 33-0006-01...
PS100 chassis 52-0012-01 23-6002-01 24-6001-01 52-0005-01 52-0009-01 Description Quantity Part Number Notes 23-6002-01 M6 shakeproof washer 24-6001-01 M6x16 socket head cap screw 52-0012-01 PS100 side plate 52-0009-01 Square tie bar 52-0005-01 Round tie bar Page 47...
Motor and mount 24-6005-01 41-0002-01 52-0007-01 23-6002-01 Description Quantity Part Number Notes 23-6002-01 M6 shakeproof washer 24-6005-01 M6x16 socket head cap screw 41-0002-01 Baldor motor 52-0007-01 Motor mounting bracket Page 49...
Sealer 24-6005-01 12-0001-01 23-6001-01 Description Quantity Part Number Notes 12-0001-01 Sealer assembly 23-6001-01 M6 shakeproof washer 24-6005-01 M6x20 socket head cap screw Notes See diagram for sealer assembly Page 53...
Baseplate 11-0003-01 23-6002-01 24-6001-01 Description Quantity Part Number Notes 11-0003-01 Baseplate assembly 23-6002-01 M6 shakeproof washer 24-6001-01 M6x16 socket head cap screw Notes See diagram for baseplate assembly Page 55...
Levers and fold plate stubs 24-4002-01 51-0005-01 52-0003-01 24-4006-01 51-0008-01 52-0002-01 23-4001-01 50-0008-01 Description Quantity Part Number Notes 23-4001-01 M4 shakeproof washer 24-4002-01 M4x12 socket head cap screw 24-4005-01 M4x10 socket head cap screw 24-4006-01 M4x6 socket head cap screw 50-0008-01 Fold plate stub 51-0005-01...
Springs 33-0001-01 24-4002-01 33-0002-01 24-4002-01 23-4001-01 50-0003-01 Description Quantity Part Number Notes 23-4001-01 M4 shakeproof washer 24-4002-01 M4x12 socket head cap screw 24-4005-01 M4x10 socket head cap screw 33-0001-01 Locking lever spring 33-0002-01 Infeed tray spring 50-0003-01 Extended fold plate stub Page 57...
Fold plates 12-0004-01 12-0003-01 Description Quantity Part Number Notes 12-0003-01 First fold plate assembly 12-0004-01 Second fold plate assembly Notes See diagram for the first fold plate assembly See diagram for the second fold plate assembly Page 60...
First fold plate assembly 51-0020-01 24-4008-01 60-0021-01 51-0021-01 23-0003-01 51-0019-01 51-0022-01 Description Part Number Quantity 23-0003-01 M4 nylon washer 24-4008-01 M4 x 6 socket button head screw 51-0019-01 fold plate bottom 51-0020-01 fold plate top 51-0021-01 Stop bar 51-0022-01 Stop bar base clamp 60-0021-01 M4 thumb wheel Page 68...
Second fold plate assembly 24-4008-01 60-0021-01 51-0021-01 51-0018-01 23-0003-01 51-0017-01 51-0022-01 Description Part Number Quantity 23-0003-01 M4 nylon washer 24-4008-01 M4 x 6 socket button head screw 51-0017-01 fold plate bottom 51-0018-01 fold plate top 51-0021-01 Stop bar 51-0022-01 Stop bar base clamp 60-0021-01 M4 thumb wheel Page 69...