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PSS PS600 Operator's Manual

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PS600
Operator's Manual
Issue 1
V-fold
Z-fold
C-fold

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Summary of Contents for PSS PS600

  • Page 1 PS600 Operator’s Manual Issue 1 V-fold Z-fold C-fold...

  • Page 2: Table Of Contents

    Mains lead ........11 Page v PS600 Iss. 1.
  • Page 3 Processing forms ........31 Interrupting operation ......31 Page vi PS600 Iss. 1.
  • Page 4 Sizes ........50 Fold Configuration ....... 50 Page vii PS600 Iss. 1.
  • Page 5 Air Flow........51 Appendix A - Form Loading Guide Service Visit Log Page viii PS600 Iss. 1.

  • Page 6: Introduction

    This operator manual describes the set-up and operation of the machine and is written as a reference for an operator who is familiar with mailing operations and has received some basic training in operating this model. Page 1 PS600 Iss. 1.

  • Page 7: Which Side Is Which

    The non-operator side contains the mains connection and on/off switch and is at the back of the machine as you stand facing the operator side. Non-operator Side Out-feed In-feed Operator Side Note: Cabinets may vary Figure 2: The sides of the machine Page 2 PS600 Iss. 1.

  • Page 8: How To Use This Manual

    Cleaning (page 45) - provides details of the cleaning required to keep the machine in the best possible condition. • Specifications (page 49) - provides the technical details of the PS600. • Form loading guide (page 53) - explains how to load forms based on the form design, type of fold, condition of forms, and how the folded/sealed forms should be orientated when they reach the conveyor.

  • Page 9: Safety Precautions

    1. Introduction Safety precautions Although the design of your PS600 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 accept no responsibility for unauthorized use.

  • Page 10: 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 authorized service representative or local power company. Page 5 PS600 Iss. 1.

  • Page 11: If The Machine Is Damaged

    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 Page 6 PS600 Iss. 1.

  • Page 12: Features

    2. Features General This section guides you through the features of the PS600. 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.

  • Page 13: In-Feed Components

    In the event of a mishandled form, the rollers can be driven by hand using the hand wheel on the operator side of the machine (see Clearing Mishandled Forms on page 34). Page 8 PS600 Iss. 1.

  • Page 14: Operator Controls

    The On/Start button switches the machine on and also performs the following: • Momentarily pressing the On/Start button processes one form. • Pressing and holding the On/Start button for two seconds starts the continuous processing of all the forms Page 9 PS600 Iss. 1.

  • Page 15: Off/Stop Button

    Speed control slider This slider controls the speed at which forms are processed by the machine. Moving the slider to the right speeds up form processing. Moving the slider to the left slows down form processing. Page 10 PS600 Iss. 1.

  • Page 16: Power And Safety Components

    2. Features Power and safety components The PS600 will automatically switch to a standby/power saving mode after 15 minutes of non form processing. Pressing on/start will return the machine to 'Ready' status. Mains lead The mains lead supplies electrical power to the machine. The compressor and conveyor are powered from the machine.

  • Page 17: Sealing And Stacking Components

    The sealer rollers provide the pressure required to tightly seal the edges of the form. Conveyor This final component collects the self-mailers and stacks them for easy removal. It is adjustable for different forms. See page 25 for conveyor fitting details. Page 12 PS600 Iss. 1.

  • Page 18: Set-Up

    Refer to the relevant topics in this section when you need to access the 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. Page 13 PS600 Iss. 1.

  • Page 19: Removing/Replacing The Fold Plates

    Release Lever (one each side) Release Lever 'Open' Release Lever 'Closed' Mounting Stud First Fold Plate First Fold Plate First Fold Plate Cover Figure 7: Fold plate locators Page 14 PS600 Iss. 1.

  • Page 20: Second Fold Plate

    In-feed Cover Suction Feeder Release Lever (one each side) Release Lever 'Closed' Release Lever 'Open' Second Fold Plate Cover Mounting Second Locking Pin Stud Second Fold Plate Fold Plate Figure 8: Fold plate locators Page 15 PS600 Iss. 1.

  • Page 21: Setting Up The Folder

    Tighten the locking knob. If the new form is a different width from the last form used, refer to ‘Setting up the in-feed’ on page 22. Re-install both fold plates as previously described on page 14. Page 16 PS600 Iss. 1.
  • Page 22 Fold Plate Shown). Then pull the securing bar in to position to secure the Form Deflector. Form Stop Removal is the reverse of fitting. Locking Knob Fine Adjustment Second Fold Plate Figure 9: V Fold Set-up Page 17 PS600 Iss. 1.

  • Page 23: C Fold Set-Up

    Tighten the locking knob. If the new form is a different width from the last form used, refer to ‘Setting up the in-feed’ on page 22. Re-install both fold plates as previously described on page 14. Page 18 PS600 Iss. 1.
  • Page 24 First Fold Dimension Second Fold Fold Perforations Dimension Dimension Setting Fine Adjustment First Fold Plate Dimension Locking Knob Setting Form Stop Form Stop Locking Knob Fine Adjustment Second Fold Plate Figure 10: C Fold Set-up Page 19 PS600 Iss. 1.

  • Page 25: Z Fold Set-Up

    Tighten the locking knob. If the new form is a different width from the last form used, refer to ‘Setting up the in-feed’ on page 22. Re-install both fold plates as previously described on page 14. Page 20 PS600 Iss. 1.
  • Page 26 First Fold Dimension Second Fold Fold Perforations Dimension Dimension Setting Fine Adjustment First Fold Plate Dimension Locking Knob Setting Form Stop Form Stop Locking Knob Fine Adjustment Second Fold Plate Figure 11: Z Fold Set-up Page 21 PS600 Iss. 1.

  • Page 27: Setting Up The In-Feed

    Ensure the scales at each end of the form guides shows the same setting. Form Guide In-feed Bed Scale Back Stop Form Guides Form Guide Adjusters In-feed Angle Scale (2 each side) In-feed Angle Adjuster Figure 12: Adjusting the form guides Page 22 PS600 Iss. 1.

  • Page 28: Initial Form Feed Set-Up

    Separator Gate Height Adjuster Separator Gate Separator Gate Suction Feed Roller Adjuster Air Jet Screws (7 each side) 21mm Forms Mounting Bar Suction Feed Roller Vacuum Pick-up Point Vacuum Pick-up Control Figure 13: Initial form feed set up Page 23 PS600 Iss. 1.

  • Page 29: Advanced Form Feed Set-Up

    A combination of adjusting the vacuum pick-up point and the separator gate position will provide the ideal set-up for the forms being processed. Forwards for Lighter/Thinner Forms Separator Gate Initial Set Up Vacuum Pick-up Backwards for Heavier/Thicker Forms Control Figure 14: Advanced form feed set up Page 24 PS600 Iss. 1.

  • Page 30: Setting Up The Form Conveyor

    Adjust the overlap control as required (0 = most overlap; 10 = greatest separation). Mains Output Socket Power Entrapment Connector Roller Securing Screw Run Switch Locating Locating Clip (x2) Overlap Control Circuit Breaker Figure 15: Conveyor Setup Page 25 PS600 Iss. 1.

  • Page 31: Operation

    Place the forms in the suction feeder and adjust the settings as necessary (see page 22). Start the machine. 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 authorized service representative. Page 27 PS600 Iss. 1.

  • Page 32: Loading Forms

    Make sure the stack of forms is flat and not bowed due to the side guides being too tight. The air pressure from the compressor should cause the stack float lightly on the feeder. Make sure the Ready message is shown on the LCD display. Page 28 PS600 Iss. 1.

  • Page 33: Starting Up And Testing The Machine

    The sealer cover is closed • The conveyor is in place and set up to exit the forms as required • The forms are properly loaded and the Ready message is shown on the LCD display Page 29 PS600 Iss. 1.

  • Page 34: Verifying Folder Settings

    If the second fold is in the wrong place, adjust the second fold plate. Make certain the first fold is correct before adjusting the second. (glue edge) (glue edge) Figure 16: First and second folds Page 30 PS600 Iss. 1.

  • Page 35: Processing Forms

    Remove the sealed forms from the conveyor. When you have finished using the machine, turn it off at the mains power supply. Interrupting operation Press the Off/Stop switch at any time to cease processing. Page 31 PS600 Iss. 1.

  • Page 36: Operation Errors

    Form jammed in between the sealer rollers SEALER ERROR: Sealer jammed JAM AT EXIT: Form jammed at the out-feed of the machine OUT OF PAPER: Suction feeder is empty REAR COVER OPEN: Sealer cover open or not properly closed Page 33 PS600 Iss. 1.

  • Page 37: Clearing Mishandled Forms

    Remove the jammed form from the suction feeder. Refer to Setting up the In-feed and carry out any adjustments as necessary to improve form feeding. Restore power to the machine. Reload and restart the machine. Page 34 PS600 Iss. 1.

  • Page 38: Jam In Folder

    When the jammed form is removed from the folder, check the fold rollers for any form particles that may have become stuck with adhesive. Replace the fold plate(s) and restore power to the machine. Restart the machine. Page 35 PS600 Iss. 1.

  • Page 39: Jam After Folder/Jam In Sealer

    Press the Reset button to clear the error message. Restart the machine. Sealer Error If the Sealer error message is displayed, proceed as follows: Carry out the Pressure sealer bolt release procedure on page 39. Page 36 PS600 Iss. 1.

  • Page 40: Jam At Exit

    Refer to Setting up the form conveyor on page 25 and carry out any adjustments as necessary to improve the exiting of the forms. Press the Reset button on the operator controls to clear the error message. Restart the machine. Page 37 PS600 Iss. 1.

  • Page 41: Opening The Sealer Cover

    Lift the sealer cover. Closing the cover is the reverse of the above procedure, ensuring both cover retainer clips are locked in position. Sealer Cover 1st Fold Plate Back Panel Retainer Clips Figure 17: Opening the sealer cover Page 38 PS600 Iss. 1.

  • Page 42: Pressure Sealer Bolt Release

    Using the 8mm allen key provided, turn the four pressure bolts anticlockwise to relieve the sealer roller pressure. (The allen key is situated inside the second fold plate cover.) Tighten Release Allen Key Pressure Bolt (x4) Figure 18: Relieving the sealer roller pressure Page 39 PS600 Iss. 1.

  • Page 43: Rear Cover Open

    Close the sealer cover, ensuring both cover retainer clips are locked into position. See Opening the Sealer Cover on page 38. Press the Reset button on the Operator controls to clear the error message. Restart the machine. Page 40 PS600 Iss. 1.

  • Page 44: Troubleshooting

    See page 16. Debris in fold plates. Remove fold plates, remove debris and re-instal fold plates. Fold plates not installed Re-install fold plates, see properly. pages 14 and 15. Page 41 PS600 Iss. 1.
  • Page 45 See page 22. Separator gate adjusted Adjust separator gate improperly. correctly (see page 23). Fold plates not installed Re-install fold plates, see properly. pages 14 and 15. Page 42 PS600 Iss. 1.
  • Page 46 Separator gate adjusted Adjust separator gate improperly. correctly (see page 23). Poor air pressure on suction Close all air jets outside the feeder. form stack and ensure others are open. Page 43 PS600 Iss. 1.

  • Page 47: Cleaning The Machine

    The replacement procedure is the reverse of the above. Panel Socket Plug Connector From Suction Suction Feeder Feeder Locking Mounting Stud Vacuum Pipe Second Fold Plate Cover Pressure Pipe Connecting Block Figure 19: Removing the suction feeder Page 45 PS600 Iss. 1.

  • Page 48: Cleaning Procedure

    Warning: only use the recommended cleaning kit on this machine (part number 70-0019-00, available from an authorized service representative). Pressure Seal Systems cannot be held responsible for any damage to the machine caused by the use of unauthorized solvents and cleaners. Page 46 PS600 Iss. 1.
  • Page 49 Close the sealer cover and replace both fold plates. 10. Re-install the suction feeder as described on page 45. 11. Ensure all covers are in place and restore power to the machine. 12. Restart the machine. Page 47 PS600 Iss. 1.

  • Page 50: Specifications

    Up to 18,000 forms per hour (A4 Z fold) Environment Operating 10° - 40° C 5% - 50% humidity Non-operating 5° - 50° C (idle - power off) 5% - 80% humidity Feeder Capacity 500 sheets Noise 88dB Page 49 PS600 Iss. 1.

  • Page 51: Form Specification

    W 300mm (11.8 in) x L 420mm (16.5 in) maximum Cut-sheet Fold Configuration Z, V and C folds Conveyor Specification Construction Steel Size 515mm (L) x 335mm (W) Weight Approximately, 13kg Power 110/230V AC ±10% 0.5A @ 230V ±10% Capacity 500 sheets Noise 40dB Page 50 PS600 Iss. 1.

  • Page 52: Compressor Specification

    Compressor Specification Size 585mm (L) x 328mm (W) x 290mm (H) Weight 46kg Power 230V AC 50 Hz (Europe) 220V AC 60Hz (USA) Air Flow 40 m /h @ 50Hz 48 m /h @ 60Hz Page 51 PS600 Iss. 1.

  • Page 53: Appendix A - Form Loading Guide

    This ap pen dix at tempts to ad dress these vari ables in a way that helps you un der stand the best way to set up your PS600 and to load the doc u ments prop erly. Fig ure 20 shows ac cept able (flat or curl up), and un ac cept able (curl down) curl con di tions.
  • Page 54 One third of the form length. One third of the form length. Feeding problems: Feeding problems: Feeding problems: Rotate form 180°. Print backside of form first. Flip form, then rotate 180°. Figure 21: Document loading guidelines Page 54 PS600 Iss. 1.

  • Page 55: Service Visit Log

    Service Visit Log Serial number: Engineer’s Customer’s Date Work done and comments signature signature Page 55 PS600 Iss. 1.

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