Neopost AS850 User manual

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AS850 Operating Instructions
Table of Contents
1 About the Machine
1.1 MachineRatingSheet .......................................................................... 2
1.2 GeneralSafetyNotes ........................................................................... 3
1.3 TechnicalSpecification ........................................................................ 5
1.4 ControlPanelLayout ............................................................................ 6
1.5 ButtonExplanation ............................................................................... 7
1.6 MachineLayoutDiagram ..................................................................... 8
2 Machine Operation
2.1 MachineSetupandOperation.............................................................. 9
2.2 SettingtheOutputConveyorRoller ....................................................... 12
2.3 CalibratingforDoubleDocuments........................................................ 12
2.4 Loading the Paper ............................................................................... 13
2.5 Hand-feedOperation............................................................................ 14
2.6 ClearingaDocument Jam.................................................................... 14
2.7 DoubleDocumentCondition ................................................................ 15
2.8 SupervisorMode.................................................................................. 15
3 Operator Maintenance
3.1 Operator'sTroubleshootingGuide........................................................ 16
3.2 CleaningRollersandSensors .............................................................. 18
3.3 Display Panel Error Messages............................................................. 19
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AS850 Operating Instructions
1 ABOUT THE MACHINE
1.1 MACHINE RATING SHEET
1. CAUTION: Inorder toensure correctsafetyand operation,this machinemust
beinstalled andmaintained byan authorized ServiceEngineer.
2. CAUTION: Shouldany coverorsafety interlockbe damaged, themachine
must notbe used untilservice repairs havebeen completed.
3. CAUTION: This machine must be earthed. Thewirecolours inthe power
cordare:
(Green/Yellow230v)(Green115v) whichmustbeconnectedtoEarth(Ground).
(Blue230v) (White115v) whichmustbeconnectedtoNeutral.
(Brown230v) (Black115v) whichmust be connectedto Live(Line).
4. CAUTION: Thismachine must not beusedif the power cordbecomes dam-
aged.It must be replaced witha similar power cord:
(Part No. 162-311 Euro, 162-210 UK, 162-321 US).
5. CAUTION: Forcontinued protection against riskoffire, replace withsame
typeand ratingoffuse. Thefuse rating/type forthis machineis:
T 3.15AAmps 230Volts (Part No. 135-103).
T 6.3AAmps 115Volts (Part No. 135-106).
6. Model Details: ModelName: Pressure Sealer
ModelNumber: AS850
InputVoltage: 230 Volts @ 50 Hz 115 Volts @ 60 Hz
Inputcurrent: 2 Amps4 Amps
InputPower: 480Watts480Watts
SoundReading: 80dBA
(measuredatadistance1meterfromthenearestcoverand1.6metersfromtheground)
7. Theusefor thismachine is pressuresealing documents.
8. Theweightof thismachine is: 176 kgs (unpackaged)
210 lgs (packaged, with accessories)
Liftingorhandlingmustonlybecarriedoutbycompetentpersonsusingappropriate
means.
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AS850 Operating Instructions
1.2 GENERAL SAFETY NOTES
Caution!
Please, read these notes with care.
Save these instructions for later use.
All notes and warnings found on the machine are to be followed.
Installing A safe, level position is necessary, when installing the machine. Injuries may
be caused by tipping, rolling away or falling. The machine is to be protected
from moisture. The machine is very heavy: do not attempt to lift it!
Electrical The AS850 Pressure Sealer may only be connected to a voltage of 230V/50Hz
or 115V/60 Hz,depending upon model.
The mains plug may only be connected with a socket having an installed
protective contact! The protective effect may not be compromised by the use
of an extension line without a protective grounding conductor. All interruptions
of the protective grounding conductor, within or outside of the machine, are
prohibited. The device is double pole fused! When fuse failure occurs,
electrical machine parts can still carry voltage. When making the connection
to the mains power, be aware of the connection values on the nameplate.
Inspect the voltage setting on the device’s power input module. Run the supply
lines in such a way, that no-one may trip over them. Do not place any objects
upon the supply line. When the machine is not in use over a long period of
time, it should be disconnected from the power supply. In this way, damage
would be prevented in the event of excess voltage. Protect the device from
moisture. When moisture enters the machine, there is the danger of electrical
shock. Never open the machine except the top cover. For reasons of electrical
safety, the machine may only be opened by authorized Service Agents.
Operating Never reach into the machine when it is running! This could only occur if a
safety interlock were to fail.
The danger of injuries exists, through pulling in and crushing on the rotating
rollers. In addition, keep long hair and parts of loose clothing far from the
machine in operation. If a safety interlock fails, your Service Agent must
contactedimmediately!
In order to prevent damage to the machine, only factory authorized accessory
parts should be used.
Cleaning Prior to cleaning the exterior of the machine, it should be disconnected from
the power supply. When cleaning the machine, do not use liquid or spray
cleaners, but only a cloth dampened with water.
the
machine
danger
safety
the
machine
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AS850 Operating Instructions
Allow In the following cases, the mains plug must be unplugged and the device left
for the authorized Service Agents:
•When the mains cable or plug is worn or damaged.
•When water or other liquid has entered the device.
•When the device does not function properly, in spite of following the
instructions provided.
•When the device has fallen down or the housing is damaged.
•When there are noticeable differences in the normal operation of the
machine.
Spare Parts When repair work is carried out, only original spare parts or spare parts
corresponding to the original parts may be used.
Repairs Do not disassemble the machine any further than is described in this
handbook. Other than the top cover, the opening of the machine by
unauthorized personnel is not permitted. Repairs may only be carried out by
an authorized Service Agent.
Modification is not permitted:
For safety reasons, your own reworking and modifications are not permitted.
Please contact your Service Agent, for all questions relating to service and
repair. In this way, you ensure the operational safety of your machine.
machine to
be checked
by the
Service
Agent
)
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AS850 Operating Instructions
Machinetype Lowvolumepressuresealer
Speed Variable,up to8500documentsperhour
Volumetoamaximumof: 15,000documentsperday
70,000documents perweek
250,000documentspermonth
3milliondocumentsperyear
Documentdimensions(foldedflat):
Paperweight: 90 - 140gsm (24 - 38 lbs bond)
1.3 TECHNICAL SPECIFICATION
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AS850 Operating Instructions
91235 46 87
10 11 1212
1.4 CONTROL PANEL LAYOUT
1. Stopbutton
2. Startbutton
3. Speed decrease button
4. Speedincreasebutton
5. Speed indicator
6. Setupbutton
7. Handfeedbutton
8. Jogreversebutton
9. Jogforwardbutton
10. Zeroreset(in-count)button
11. Zeroreset(out-count)button
12. Displaypanels
Adetaileddescription ofeachbutton functionisgiven
inthefollowingsection.
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AS850 Operating Instructions
Stopbutton: Allowsdocumentscurrentlypassingthroughmachine
tocontinuetooutput,thenhaltsoperatingcycle.
Startbutton: Startsmachineintocontinuousrunning,andalsocan-
celsanyerrorswhich maybeindicatedafterthecauseof theproblem
hasbeenclearedbytheoperator.
Speed decrease button: Decreases speed in steps down to 0,
shownonspeedindicatordisplay.
Speed increase button: Increases speed in steps up to 9, shown on
speed indicator display.
Speed indicator: Indicates speed in steps from 0 to 9 (max.)
Setup button: Feeds through a single document in order to calibrate
documentlengthandweight.Thisisfordoubledocumentdetection.
Documentis divertedbefore sealingtoenable foldlengths tobe
checked.
Hand feed button: Allows single document to be fed through pres-
surerollers.Note:documentmustbepre-foldedbyhand,andplaced
infolderbypasschute.
Jog reverse button: "Jogs" document back through machine in
smallsteps. Usedfor clearing jams.Note:afteroperating, thereis a 2
secondpause before button canbeoperated again.
Jog forward button: "Jogs"documentforward through machinein
smallsteps. Usedfor clearing jams.Note:afteroperating, thereis a 2
secondpause before button canbeoperated again.
Zero reset (in-count) button: Zeroescounterdisplay fordocuments
fedin(machinemustbestopped).Note:countwillmaintainuntilzero
resetis pressed,even when machineis stoppedor switched off.
Zero reset (out-count) button: Zeroescounter display for docu-
mentsfedout(machinemustbestopped).Note:countwillmaintain
untilzeroresetispressed,evenwhenmachineisstopped orswitched
off.
Display panels: Displays in or out count, and also error messages.
1.5 BUTTON EXPLANATION
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AS850 Operating Instructions
1.7 MACHINE LAYOUT DIAGRAM
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Feed Bridge
- page 9
Side guides
- page 9
Fold plates (underneath
cover - see also page 9)
Control panel -
page 6
Emergency stop
button
Output conveyor
- page 12
TO STOP THE MACHINE IN AN EMERGENCY, HIT
THE RED EMEGENCY STOP BUTTON.
Note that the button locks down and must be
twisted to release.
Handfeed chute -
page 14
Calibrationdoublesexit
- page 12
Back rests
- page 9

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AS850 Operating Instructions
2 MACHINE OPERATION
2.1 MACHINE SETUP
2.1.1 Pluginmachine,switchonatpowerswitchandreleaseemergencystopbutton.
2.1.2 Adjusttheseparatorgaptosuitthedocumentform,asshownbelow.
Feedbridge
Back rests
Turntheseparatoradjustoruntilthere
issufficientgapbetweenthesepara-
tor roller and the pick-up roller below it
to allow one form only to pass
through.Thisisachievedbymoving
theformback andforthbetweenthe
rollers until resist- ance is just felt and
the rollers lightly grip the form.
Separator
roller
Centrallyplace forms inthe infeedtray
withthefomweightontop.Move both
side guides to leave a gap of 3mm
(1/16")either sideof theform. Note:
guides will self centre.
Infeedtray
Squareness
adjuster Back stop
2.1.3 Establishfoldtypeandlength required,raisethetopcover andsetthefold
platesas described below and overleaf:
Fineadjustmentknob Lock screw
Fold plate 1 Fold plate 2
Pointer(align
insideedge
withscale)
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Formfeed
weight
)See also
followingpage

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AS850 Operating Instructions
How to set the fold plates
•Adjustthestopsby looseningthelockscrews,slidingthestoptotherequired
positionasindicatedbythe pointeragainst thescale,andretighteningthe lock
screws.Usethefineadjustmentknobtoadjustthefoldpositionbysmallamountsif
arunningtestshowsthistobeneeded.
•Ifrequired,adjustthesquarenessofthestopbylooseningthesquarenessadjuster
lockscrewandturningtheknurledcamknobbelowit.Thismayberequiredifthe
documentsarebeingfolded'skewed'.Retightenthelockscrewafteranyadjust-
mentis made.
•Thescalesaccordwiththeexactmeasured positionoftherequiredfoldonthe
document,andtheinside edge ofthepointerisalignedwiththescalemeasure-
ment(seediagram on previous page). For example, if thefirstfoldis required at
102mm(4") down fromthe leading edgeof the document,set fold plate1 at this
position.The crease thenbecomes the leadingedge for thesecond fold position,
so if the second fold is required at 114mm (4½") from the crease, set fold plate 2
atthisposition.Notethatifthesquarenessadjusterhasbeenmovedatanytime,
thepointerpositionwillchange,andthiswillhavetobecompensatedforwhen
measuringfoldpositions:runningtestswillshowtowhatextent.
•Thefoldplatesareremovableandareretainedbyclips.Ifthedocumentrequires
onlyasinglecenterfold,slideoutfoldplate2.Turnitroundtheotherwayandalso
turnitover,thenslide itback intoposition. Thisthenactsasa blankingplate and
thedocumentwillbypassit.Setthestopoffoldplate1to halfthelengthofthe
document.
•Thethreetypesoffoldwhichmaybeusedareshownoverleaf:
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AS850 Operating Instructions
3. Single (or Half) Fold 'V'
Belowareshownthethreetypesoffoldwhichmaybeused:
1. Letter (or Wallet) Fold 'C'
2. Accordian Fold 'Z'
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AS850 Operating Instructions
2.2 SET THE OUTPUT CONVEYOR ROLLERS
Rollerbar
Bridge
(foldoutwards)
Scale
Pointer
2.2.1 Foldthebridgeoutwardsand slidethe rollerbar toalignthepointerwiththe
measurementonthescalethataccordswiththefinishedlengthofthesealed
document.Inmostcasesthisisthesameasthelengthofthesecondfold.
2.3 CALIBRATE FOR DOUBLE DOCUMENTS
2.3.1 Whensettingupforthefirsttime,loadonedocumentandpressthesetupbutton
to begin the calibration cycle. A message CONF CALCONF CAL
CONF CALCONF CAL
CONF CAL on the display panel will
requestconfirmationthatyouwishtocalibrate:pressagaintoconfirm.Ames-
sage CALCAL
CALCAL
CAL will be displayed and the document will be fed, calibrating its length
andthickness.This actsasa gaugeforalldocumentsof thatsize,and henceis
onlydoneagainifthedocumentsizeischanged.Thegaugeddocumentwillbe
ejectedviathecalibrationexitbelowthefeedtray.
2.3.2 At the end of a successful calibration cycle, a message CAL PASSCAL PASS
CAL PASSCAL PASS
CAL PASS will be
displayed.Intheeventofacalibration failure,anerror messagewillbedis-
played.(Seesection3.3).
Note: Ifthe 'Auto-calibrate'DIP switchon theCPU circuitboard hasbeen set,the ma-
chinewillautomaticallyenterthesetupmodeeitherafterpower-uporwhenre-starting
afterhopperemptycondition.SettingoftheswitchisnotanOperatorfunction-itmust
besetby a Customer Service Engineer.
See also 'Double Document Condition' on page 15.
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AS850 Operating Instructions
2.4 LOADING THE PAPER
2.4.1 Placeastackofdocumentsinthe infeedtray, orientatedaccording tofold type
andprint direction.Ensure thatthe leadingedges ofthe stackof formsare
against the feed bridge.
2.4.2 Setthe requiredspeed using thespeed increaseordecrease) buttons.The
speedincrementsinsteps 0-9,asshownon theindicatorpanelbetween the
twobuttons.Thespeedmaybevariedwhilstmachineisrunning.
2.4.3 Pressthestartbuttonandthedocumentswillbeginfeeding.Notethatthecount
ofthedocumentsfedinandfedoutis displayedon theleft andright display
panelsrespectively.
Whentherunofdocumentshasfinished,eitherorbothofthecountdisplays
maybezeroedbypressing'incount'or'outcount'buttons.
2.4.4 Whenthedocumentrunhasfinished(orthefeedertrayrunsout)themachine
will stop operating after about 3 seconds and the message Error FA1 will show
onthedisplay.Pressthestopbuttontoclearthedisplay.
Adjust the back rests to support
the backs of the forms. Further re-
adjustmentmayberequiredfor
reliablefeeding.
NOTE: IN THE EVENT OF ANY EMERGENCY,
PRESS THE RED EMERGENCY STOP KNOB
ADJACENT TO THE CONTROL PANEL.
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AS850 Operating Instructions
2.5 HANDFEED OPERATION
Ifrequired,asingledocumentmaybehandfedforsealingonly.Firstfoldthe
documentasdesired(seeprevioussection)and placeit inthe chutein thecenter
ofthetopcover.Pressthehandfeedbuttonandthefoldeddocumentwillpass
throughthesealingrollers.
2.6 CLEARING A DOCUMENT JAM
Adocument jam maybecaused by anumberof conditions, suchas a damaged
orcrumplededge,incorrectfoldetc.Whateverthecause,ajamwillresultinthe
machinestoppingautomatically,andanerrormessagewillbeshownonthe
displaypanel.
Tofreethejammeddocument,switchthemachineoff,raisethetopcoverto
ascertainthelocationofthejammedform;thiswilldeterminewhethertheform
shouldbemovedforwardsor backwardstocleartherollersforretrieval.Close
thecovers,switch backonandpressthe jogforwardor backwardsbuttonsas
required.Thiswilloperatethemachineinshort,slow'spurts'toclearan edgeof
thedamageddocument.Raisethecoveragainandpullthefreeddocumentout.It
maybenecessarytorepeat thisoperationmorethanonceuntilthedamaged
documentisfullyclear.
NOTE: THE MACHINE WILL NOT RUN WITH THE COVER OPEN.
Outfeedguidefixings.
Accessto theoutfeed
roller area can be gained
byremovingtheguide/
staticbrushcarrier.Re-
place before
runningmachine.
Insertdocument
creasedownwards.
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AS850 Operating Instructions
2.7 DOUBLE DOCUMENT CONDITION
Ifmorethanonedocumentisfedatonetime,suchasiftwoarestucktogether,theywill
notpassthroughthesealingrollers,butwillbedivertedtothedivertchute.Themachine
will stop, and an error message Error FA3Error FA3
Error FA3Error FA3
Error FA3 will appear on the display. The diverted
documentcanberetrievedfromthedivertchuteopeningattherearendofthemachine.
Thisisthedefaultcondition.
Themachinecanalsobesetforanalternativedoubledocumentcondition.Inthismode,
whenadoubledocumentisfed,itwillbedirected tothedivert chuteandthe machine
willcarryonoperatingnormally.Thediverteddocumentwillnotregisteronthecount
display.Ifaseconddoubledocumentisthenfedimmediatelyafterwards,themachine
will stop and the error message Error FA3Error FA3
Error FA3Error FA3
Error FA3 will appear on the display. This alternative
mode is selected via a DIP switch on the CPU board, and can only be set by a Cus-
tomerServiceEngineer.
Notethatinbothmodes,pressingthestartbuttonwillrestartthemachineandclearthe
display,whichwillthenreverttodocumentcount.
Ifseveraldoubledocumentsoccurinashortspaceoftime,thecauseshouldbeinvesti-
gated.Itmaybethatthattheseparatorisincorrectlyset(seesection1.2.1)orthatthe
stackofdocumentsneeds'rifling' forproperseparation.
2.8 SUPERVISOR MODE
TheSupervisorModewillallowthedisplayofthetotalmachinerunningtimetodate.The
totalformscountto datecanalsobedisplayed.Pressthestopandjog-forwardbuttons
simultaneouslytoenterthemode.Successfulentryintothemodewillbeconfirmedby
the display: SUP INFOSUP INFO
SUP INFOSUP INFO
SUP INFO
Pressthejog-forwardbuttonagaintoshowthetotalhourcounttodate(towithin1/10th
hour) in the following format on the display: Hour HHHH.HHour HHHH.H
Hour HHHH.HHour HHHH.H
Hour HHHH.H
Pressthejog-forwardbuttonagaintoshowthetotalformscounttodate asaten-digit
number in the following format on the display: nnnnn nnnnnnnnnn nnnnn
nnnnn nnnnnnnnnn nnnnn
nnnnn nnnnn
Press the jog-forward button again to cycle back to the SUP INFOSUP INFO
SUP INFOSUP INFO
SUP INFO display.
PressthestopbuttontoexitSupervisorMode.
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AS850 Operating Instructions
3 OPERATOR MAINTENANCE
3.1 OPERATOR'S TROUBLESHOOTING GUIDE
1. Documents not feeding.
Possible cause: Possibleremedy:
Separatorgapincorrectlyset Adjustseparator asinsection 2.1.2.
2. Slow feeding of documents
Possible cause: Possibleremedy:
Feedrollersneedcleaning Cleanallrubberrollers asinsection3.2.
3. Documents jam in folder.
Possible cause: Possibleremedy:
i) Side guides incorrectly set i) Reset side guides.
ii)Documentsincorrectlystacked ii) Check forms and re-stack.
iii) Curled or damaged edges on iii)Removedamaged documents.
document
4. Documents incorrectly folded.
Possible cause: Possibleremedy:
i)Foldlengths settoolongorshort i)Re-measurefoldlengthsandre-adjustas
showninsection2.1.3.
ii) Side guides set too wide ii) Reset side guides.
iii)Documentsnotsquare('skewed') iii) Adjust squarenessofstop as shownin
section2.1.3.
5. Documents not sealing
Possible cause: Possibleremedy:
i)Defectivecohesiveondocument i)Testdocumentsfromadifferentbatch.
ii)Sealingrollersincorrectlyset ii) Contactserviceagent.
6. Repeated double documents
Possible cause: Possibleremedy:
i)Separator gap incorrectlyset i)Adjust separator as in section 2.1.2.
ii)Documentsstickingtogether ii)'Rifle'documentstack.
contd.
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AS850 Operating Instructions
7. Double documents fail to divert
Possible cause: Possibleremedy:
i)Documentsjammingindiverter i) Checkedgesof documentsforcurling or
damage.
ii)Diverternot working ii)Solenoidmalfunction-contactservice
agent.
8. Double document will not set
Possible cause: Possibleremedy:
Documentsalreadyheldinholdpoint Opencoverandremoveoffendingdocument.
Ifnecessary,use'jog'buttonsasdescribedin
section2.6.
9. Documents jamming on output
conveyor
Possible cause: Possibleremedy:
Rollerpositiononconveyorset Resetrollerasshowninsection2.2.
incorrectly
10. Bad folding or jamming in
folder
Possible cause: Possibleremedy:
Folderrollersneedcleaning Clean folderrollers asin section3.2.
11. Error message showing on
display panel when there are
no documents in machine
Possible cause: Possibleremedy:
i)Dirtysensors i) Clean allsensors. Refer tosections 3.2for
sensorpositions
ii)Covernotproperlyclosed ii)Checkbothtopcovers arefully closed
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AS850 Operating Instructions
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3.2 CLEANING SENSORS AND ROLLERS
Afteraperiodofrunning,especiallyifthemachineisheavilyused,thesensorswilltend
tobecome obscuredwith paperdust. Thismay leadto erraticoperation ofthe machine,
andsothe sensorsmustbe regularlycleanedusingonlya non-flammable airduster(#
E0070A).Cleaningparticularlyappliesif themachineappearstobe malfunctioningin
anyway,andshouldalwaysbecarriedoutbeforealertingtheServiceAgentofany
faults.Thesensorsshouldalwaysbecleanedbeforestartingalongcontinuousmachine
run.
Thelocationsofthesensorsareillustratedbelow:
1. FolderInputSensors 4. OutputSensors
2. FolderOutputSensors 5. Doubles DetectSensors
3. DivertSensors 6. HoldPointSensors
Roller Cleaning
Atthesametimethatthesensors arecleaned,allvisiblerubberrollersand feedwheels
shouldalsobecleanedusingRubberRollerRestorer(#E0483A).Ensurethattheroller
andwheelsarecleanedroundtheirfullcircumference.
34
12
6
5
)Sensorsare in
twohalves - both
halves must be
cleaned

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AS850 Operating Instructions
3.3 CONTROL PANEL ERROR MESSAGES
Ifanyofthefollowingerrormessagesoccur,donotattempttocontinuetherun,but
switchoffthemachineandtaketheremedialactionstated.Ifthisoranyotherobvious
solutionsdonotclearthefault,theServiceAgentmustbecontacted.
Documentsnotbeingfed.This messageoccursifno
documentis fed afterabout3 seconds, suchasif the feed
trayisempty.
Doubledocument feedhasoccurred. Separatorgap may be
incorrectlyset,ordocumentsneed'rifling'.
Hand-feedloadhas failed.May becausedby incorrect
insertionofthedocumentintothehand-feedchute.
Attempttodivertadoubledocument hasfailed,and
documenthaspassedthroughsealingrollersinstead.
Divertersolenoidmaybe stuck.
contd.
Folderinputsensorblocked.If novisibleobstruction,sensor
mayrequirecleaning.
Folderexitsensorblocked.If novisibleobstruction,sensor
mayrequirecleaning.
Divertsensorblocked.If novisibleobstruction,sensormay
requirecleaning.
Ouputsensorblocked.If novisibleobstruction,sensormay
requirecleaning.
VerticalStackerfull-unload.
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AS850 Operating Instructions
Diverterhasactuated,butdocumenthasnotpassed
through.Documentmaybedamagedandstuckindiverter.
Documentjammedinfeederrollers.Clearjambefore
continuing.
Documentjammedinfolderrollers.Clearjambefore
continuing.
Documentjammedinsealerrollers.Clearjambefore
continuing.
Documentjammedonconveyor.Clearjambefore
continuing.
Motorhasfailedtostart.ContactyourServiceAgent.
Foldercoveropen
Thefollowingmessagesindicateamachinefault,ratherthananoperatingfault.
contd.
Motorhasstalled.ContactyourServiceAgent.
Motorhasfailedtostop.ContactyourServiceAgent.
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