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Pressure Seal Systems PS400 Operator's Manual

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PS400
Operator's Manual
Issue 1
V-fold
Z-fold
C-fold

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Summary of Contents for Pressure Seal Systems PS400

  • Page 1 PS400 Operator’s Manual Issue 1 V-fold Z-fold C-fold...
  • Page 3 Reproduction of this material without the express written consent of Pressure Seal Systems 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. Changes are periodically made to the information contained in this manual;...
  • Page 4 Page intentionally blank...

  • Page 5: Table Of Contents

    Jog function ........10 Speed control slider....... 10 Page v PS400 Iss. 1.
  • Page 6 Jam in folder ........32 Page vi PS400 Iss. 1.
  • Page 7 Noise ........42 Appendix A - Form Loading Guide Appendix B - Form Curl Service Visit Log Page vii PS400 Iss. 1.
  • Page 8 Page intentionally blank...

  • Page 9: 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 PS400 Iss. 1.

  • Page 10: 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 Figure 2: The sides of the machine Page 2 PS400 Iss. 1.

  • Page 11: How To Use This Manual

    Form loading guide (page 43) - 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 44), and how the folded/sealed forms should be orientated when they reach the conveyor. Page 3 PS400 Iss. 1.

  • Page 12: 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 accept no responsibility for unauthorized use. Operating environment •...

  • Page 13: 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 PS400 Iss. 1.

  • Page 14: 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 PS400 Iss. 1.

  • Page 15: Features

    Please refer to Figure 4 below as you read about the features of the machine. Sealer Pressure Bolts Sealer Rollers Feed Roller Conveyor Top Cover Form Guides Control Panel In-feed Tray Second Fold Plate Fold Rollers First Fold Plate Figure 4: Features of the machine Page 7 PS400 Iss. 1.

  • Page 16: Folder Components

    The fold rollers work in conjunction with the fold plates to produce folds. The rollers feed the form into and out of the fold plates. The top roller can be lifted out of position, aiding in the recovery of mishandled forms (see page 32). Page 8 PS400 Iss. 1.

  • Page 17: 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 PS400 Iss. 1.

  • Page 18: 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 PS400 Iss. 1.

  • Page 19: Power And Safety Components

    Sealing rollers The sealing 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. Page 11 PS400 Iss. 1.
  • Page 20 2. Features Page intentionally blank Page 12 PS400 Iss. 1.

  • Page 21: Set-Up

    Refer to the first two 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 PS400 Iss. 1.

  • Page 22: Removing The Top Cover

    When installing the top cover, make sure it is firmly seated on top of the unit. The safety switches for the top cover prevent the machine from operating if the cover is not properly installed. Page 14 PS400 Iss. 1.

  • Page 23: Removing The Fold Plates

    Fold Plate Locators Second Fold Plate First Fold Plate Figure 7: Fold plate locators To install the fold plates, ensure their location flags are located between the fold plate locators as shown in Figure 7. Page 15 PS400 Iss. 1.

  • Page 24: Setting Up The Folder

    If the new form is a different width from the last form used, refer to ‘Adjusting the form guides’ on page 22. Re-install both fold plates, ensuring the second fold plate is reversed to be in the ‘no fold’ position. Replace the top cover. Page 16 PS400 Iss. 1.
  • Page 25 3. Set-up Leading Edge First Fold Dimension Fold Perforation First Fold Dimension Setting Locking Knobs First Fold Plate Second Fold Plate (no fold) Figure 8: V Fold Set-up Page 17 PS400 Iss. 1.

  • Page 26: C Fold Set-Up

    Tighten the two locking knobs. If the new form is a different width from the last form used, refer to ‘Adjusting the form guides’ on page 22. Re-install both fold plates. Replace the top cover. Page 18 PS400 Iss. 1.
  • Page 27 3. Set-up Leading Edge First Fold Dimension Second Fold Fold Perforations Dimension Second Fold Dimension Setting First Fold Dimension Setting Locking Knobs Locking Knobs Second Fold Plate First Fold Plate Figure 9: C Fold Set-up Page 19 PS400 Iss. 1.

  • Page 28: Z Fold Set-Up

    Tighten the two locking knobs. If the new form is a different width from the last form used, refer to ‘Adjusting the form guides’ on page 22. Re-install both fold plates. Replace the top cover. Page 20 PS400 Iss. 1.
  • Page 29 3. Set-up Leading Edge First Fold Dimension Second Fold Fold Perforations Dimension Second Fold Dimension Setting First Fold Dimension Setting Locking Knobs Locking Knobs Second Fold Plate First Fold Plate Figure 10: Z Fold Set-up Page 21 PS400 Iss. 1.

  • Page 30: Adjusting The Form Guides

    Form Guides In-feed Tray Underside of In-feed Tray Centre Slot Pull Out for Width Adjusting A3 Paper/17in Forms Knobs Figure 11: Adjusting the form guides Page 22 PS400 Iss. 1.

  • Page 31: Setting Up The Form Conveyor

    Adjust the overlap control as required (0 = most overlap; 10 = greatest separation). Locating Power Entrapment Connector Roller Securing Screw Mains Output Socket Run Switch Locating Clip (x2) Overlap Control Circuit Breaker Figure 12: Conveyor Setup Page 23 PS400 Iss. 1.
  • Page 32 3. Set-up Page intentionally blank Page 24 PS400 Iss. 1.

  • Page 33: Operation

    Place the forms in the in-feed tray and adjust the form guides if 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 25 PS400 Iss. 1.

  • Page 34: Loading Forms

    Make sure the Ready message is shown on the LCD display, indicating the stack is properly loaded on the in-feed tray. Make sure the stack of forms is flat and not bowed due to the form guides being too tight. Page 26 PS400 Iss. 1.

  • Page 35: Starting Up And Testing The Machine

    • The top cover is firmly seated on the top of the unit. • The conveyor is in place. • The forms are properly loaded and the Ready message is shown on the LCD display. Page 27 PS400 Iss. 1.

  • Page 36: 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 13: First and second folds Page 28 PS400 Iss. 1.

  • Page 37: Processing Forms

    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. Do not stop the machine by removing the lid as this may damage the machine. Page 29 PS400 Iss. 1.
  • Page 38 4. Operation Page intentionally blank Page 30 PS400 Iss. 1.

  • Page 39: Operation Errors

    JAM IN FOLDER: Form jammed in one of the fold plates JAM AFTER FOLDER: Form jammed after the fold plates OUT OF PAPER: Paper has run out COVER OPEN: Cover removed or not properly installed Page 31 PS400 Iss. 1.

  • Page 40: Clearing Mishandled Forms

    Lift the two snap levers holding the top fold roller in place, (see Figure 14) and lift the top fold roller out of position. Top Fold Snap Lever Roller (x2) Figure 14: Removing the top fold roller Page 32 PS400 Iss. 1.

  • Page 41: Jam After Folder

    This can be achieved by allowing them to rest in the same room as the machine 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 33 PS400 Iss. 1.

  • Page 42: Pressure Sealer Bolt Release

    Re-install the top cover, reconnect the power and switch the machine on. Pressure Bolts (x4) Release Tighten Figure 15: Relieving the sealing roller pressure Use the Jog function (press and hold the Off/Stop button followed with the On/Start button) to eject the mishandled forms. Page 34 PS400 Iss. 1.
  • Page 43 Do not overtighten the pressure bolts! Stop tightening the bolts as soon as you feel a significant increase in resistance. Ensure all 4 bolts are correctly reset. Re-install the top cover and the second fold plate. Restore power and restart the machine. Page 35 PS400 Iss. 1.

  • Page 44: Troubleshooting

    Debris in fold plates; fold Remove debris; properly plates not installed properly. install fold plates. Top fold roller not properly Ensure the top fold roller's installed. snap levers are closed, holding the roller in place. See page 32. Page 36 PS400 Iss. 1.
  • Page 45 See page 22. Fold plates not installed Install fold plates properly. properly. See page 15. Worn feed roller. Contact an authorized service representative for advice. Page 37 PS400 Iss. 1.
  • Page 46 Two or more forms are Forms in stack are sticking Fan form stack and reload feeding into the folder together. forms. together. Worn feed roller Contact an authorized service representative for advice. Page 38 PS400 Iss. 1.

  • Page 47: Cleaning The Machine

    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 48 10. Close the two snap levers to hold the roller in place. 11. Replace the first and second fold plates. 12. Replace the top cover and then restore the mains power. Page 40 PS400 Iss. 1.

  • Page 49: Specifications

    12,000 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 72dB Page 41 PS400 Iss. 1.

  • Page 50: Form Specification

    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 42 PS400 Iss. 1.
  • Page 51 Rotate through 180 degrees. One third of the form length. One third of the form length. Feeding problems: Feeding problems: Feeding problems: Rotate form 180 degrees. Print backside of form first. Flip form, then rotate 180 degrees. Page 43 PS400 Iss. 1.
  • Page 52 Figure 16 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 16 Curled Documents Page 44 PS400 Iss. 1.
  • Page 53 Service Visit Log Serial number: Engineer’s Customer’s Date Work done and comments signature signature Page 45 PS400 Iss. 1.
  • Page 54 Notes...
  • Page 56 1 The Dean New Alresford, Hampshire S024 9BQ United Kingdom Tel: +44 (0)1962 735777 Fax: +44 (0)1962 736759 Website: www.pressure-seal.com A Division of Group UK Ltd Registered Office: Pallion Trading Estate, Sunderland, Tyne and Wear SR4 6ST Registered in England Number 511336...

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