Pressure Seal Group PS 100 User manual

Operator’s ManualOperator’s Manual
PS 100
Folder and Sealer
Telephone: [phone]
E-mail: [email protected]
Website: www.pressure-seal.com
Pressure Seal Group

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. Changes
are periodically made to the information contained in this manual; these changes will be
incorporated in new editions of this publication.
Correspondence regarding this publication should be addressed directly to:
Pressure Seal Systems Group Ltd
Pressure Seal house
1 The Dean
New Alresford
Hampshire
England
SO24 9BQ
PS 100

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PS 100

Contents
1. Introduction
Introduction to the PS100 ...............................1
Which Side Is Which? .................................2
How to use this manual ................................3
Safety precautions...................................4
Operating environment.................................4
Power requirements ..................................5
If the machine is damaged...............................5
2. Features
General ........................................7
Folder components ..................................8
Form guides ...................................8
Feed roll .....................................8
In-feed tray....................................8
Folding plates ..................................8
Folding rollers ..................................8
Operator controls ...................................9
Batch counter ..................................9
Illuminated Power Switch.............................9
Run switch....................................9
Stop switch ...................................10
Power and safety components ............................11
Mains lead ...................................11
Top cover....................................11
Sealing and stacking components ..........................11
Pressure bolts .................................11
Sealing rollers..................................11
Stacker .....................................11
PS 100
14-11-02 Iss. 1. Page v

3. Set-up
Setting up the PS100.................................13
Removing the top cover ...............................14
Removing the folding plates .............................15
Setting up the folder .................................16
Setting the document stop ..............................16
Setting the adjustable document guide ........................18
Replacing the folding plates .............................19
First fold plate..................................19
Second fold plate ................................19
4. Operation
Operating the PS100 .................................21
Loading documents .................................22
Verifying folder settings .............................24
Processing forms ..................................25
Interrupting operation ..............................25
5. Operation Errors
Error Conditions ...................................27
Clearing Mishandled Documents ...........................28
When the stop light flashes ...........................28
If it is in either the first or second fold plate: ..................28
If the form is jammed in the sealing rollers: ...................30
Pressure bolt adjustment ...............................31
Troubleshooting ...................................32
6. Cleaning the machine
Cleaning procedure..................................35
PS 100
Page vi 14-11-02 Iss. 1.

7. Specifications
Folder/Sealer Specifications .............................37
Construction ..................................37
Sealer......................................37
Size.......................................37
Weight .....................................37
Power .....................................37
Speed .....................................37
Environment ..................................37
Feeder Capacity.................................38
Colour .....................................38
Noise ......................................38
Document Specification ...............................38
Weights.....................................38
Sizes ......................................38
Fold Configuration ...............................38
Appendix A - Form Loading Guide
Appendix B - Form Curl
Service Visit Log
PS 100
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PS 100
Page viii 14-11-02 Iss. 1.

1. Introduction
Introduction to the PS100
The PS100 folder/sealer produces finished mailable documents or “self-mailers” from
cut-sheet Pressure Seal documents. In one smooth operation the PS100 folds and seals
single sheets into self-mailers quickly and economically. Pressure activated cohesives
provide an instantly secure seal on the document, whether you use a “V”, “C” or “Z” fold.
Features of the PS100 folder/sealer include:
•Simple to load and operate
•Easy to change the fold style
•C, V, offset V and Z fold styles
•No adjustment required when changing the weight of forms used
•Automatic stop when the in-feed tray is empty
•In-feed forms counter with manual reset
•Paper flow error detection
This PS100 folder/sealer operator manual describes the set-up and operating instructions
for the PS100 folder/sealer. This manual is written as a reference for an operator who is
familiar with mailing operations and who has received some basic training in operating
the PS100.
14-11-02 Iss. 1. Page 1
Figure 1:Types of fold produced

Which Side Is Which?
The terms “infeed”, “outfeed” and “operator side” are used throughout this manual to
identify the sides of the PS100 (see fig.2 below).
•The infeed is the side into which the documents are fed.
•The outfeed is the side out of which the finished mailers exit.
•The operator side of the PS100 is the side on your right when you’re facing the infeed
of the PS100.
1. Introduction PS 100
Page 214-11-02 Iss. 1.
Figure 2:The sides of the machine

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. Provides easy
step procedures for removing the top cover and folding plates and setting up the
folder. New operators should read each procedure as they perform the task.
Experienced operators should refer to relevant parts of the procedure to find answers
to specific questions.
•Operation (page 21) - provides easy step-by-step procedures for loading and starting
the machine.
•Operation errors (page 27) - lists common operating problems and possible causes
and solutions.
•Cleaning (page 35) - provides details of the cleaning required to keep the machine in
the best possible condition.
•Specifications (page 37) - provides the technical details of the folder/sealer.
•Form loading guide (page 39) - 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 ), and how the folded/sealed forms should be orientated when they reach the
conveyor.
PS 100 1. Introduction
14-11-02 Iss. 1. Page 3

Safety precautions
Although the design of your folder/sealer includes safeguards for set-up and operation,
you must adhere to the following precautions.
INo 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.
•Keep your work area and the machine clean and clear of dust or debris. Details of
how to clean the machine thoroughly are given in Chapter 6.
•Do not place the machine on an unstable stand or table. The machine may fall,
causing serious damage or injury.
ITo avoid personal injury and damage to the machine, it should
always be lifted by two people.
•Do not allow anything to rest on the mains lead. Do not relocate the machine where
anyone will walk on the lead.
•Operate the machine only with the top cover in place; the forms properly loaded in the
in-feed tray and the out-feed tray/conveyor initially empty.
•Keep hands clear of the in-feed and out-feed areas when the machine is running.
IExcept as explained elsewhere in this operator manual, do not
attempt to service the machine. Doing so may expose you to
dangerous voltages or other risks. Do not remove the protective
side covers from the machine. Refer servicing to qualified service
personnel. Only trained, authorised service personnel should
remove the protective side covers - and then only for servicing
purposes.
1. Introduction PS 100
Page 414-11-02 Iss. 1.

Power requirements
The PS100 must be operated from the type of power source indicated on the marking
label. If you are unsure of the type of power available, consult your Pressure Seal
representative or local power company.
If an extension lead is used with the PS100, make sure that the total of the ampere
ratings of the products plugged into the extension lead does not exceed the extension
lead ampere rating.
If the machine is damaged
Unplug the machine from the wall outlet and refer servicing to qualified personnel under
the following conditions:
qIf the mains lead is damaged or frayed
qIf liquid has been spilled into the machine
qIf the machine has been exposed to rain or water
qIf the machine has been dropped or damaged
qIf the machine does not operate normally when the operating instructions are
followed. Adjust only those controls that are covered by the operating instructions,
since improper adjustment of other controls may result in damage.
qIf the machine exhibits a distinct change in performance, indicating a need for a
service
PS 100 1. Introduction
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1. Introduction PS 100
Page 614-11-02 Iss. 1.

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 3below as you read about the features of the machine.
14-11-02 Iss. 1. Page 7
Figure 3:Features of the machine

Folder components
Form guides
The form guides keep the forms aligned so the feed roll feeds each one squarely. The
form guides on the machine are adjustable to accommodate various sheet widths.
Feed roll
The feed roll provides reliable single-sheet form feeding into the folding area. The feed roll
requires no adjustment.
In-feed tray
The in-feed tray holds the stack of forms allowing them to be fed by the feed roll. The
spring-loaded tray presses the forms against the feed roll, automatically providing the
correct pressure to allow only one form at a time to be fed into the folder.
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.
Folding rollers
The folding rollers work in conjunction with the folding plates to produce folds. The
rollers feed the form into and out of the folding plates. The top roller is removable, which
aids recovery of mishandled forms (see page 28).
2. Features PS 100
Page 814-11-02 Iss. 1.

Operator controls
Batch counter
There are two types of batch counter available. The standard counter indicates the
number of documents in the current batch (since it was last reset) and has a push button
reset. There is an additional counter available for the cumulative total, and this may only
be reset by a service engineer.
Illuminated Power Switch
The power switch is illuminated when the PS100 is connected to the mains supply.
Run switch
The run switch lights when:
•All documents are properly loaded on the feed table, and there are no mishandled
documents anywhere in the PS100
•The safety cover is fitted
When the run switch lights:
•Momentarily pressing the run switch processes one document.
•Pressing and holding the run switch for two seconds processes all of the documents
PS 100 2. Features
14-11-02 Iss. 1. Page 9

Stop switch
Pressing the stop switch stops the PS100 after the document currently being fed is
processed. You can stop the PS100 at any time while documents are processing.
The stop switch flashes when there is an operating error. To clear an error condition:
•Remove the lid from the PS100
•Clear any mishandled documents
When the top cover is replaced, the PS100 automatically resets the error detection.
2. Features PS 100
Page 10 14-11-02 Iss. 1.
Figure 4:Operator controls

Power and safety components
Mains lead
The mains lead supplies electrical power to the PS100. There is a 5-amp fuse in the
three-pin plug.
Top cover
The top cover provides access to the folding and sealing components. The cover has two
safety switches that disable operation of the PS100 when it is removed.
Sealing and stacking components
Pressure bolts
These allow you to release the pressure on the sealing rollers for clearing mishandled
documents with the allen key that is provided.
Sealing rollers
The sealing rollers provide the pressure required to tightly seal the edges of the
document.
Stacker
This final component collects the self-mailers and stacks them for easy removal. It is
adjustable for different forms.
PS 100 2. Features
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2. Features PS 100
Page 12 14-11-02 Iss. 1.

3. Set-up
Setting up the PS100
This section provides instructions for:
•Removing the top cover
•Removing the folding plates
•Setting up the folder
Follow all the instructions in this section the first time you use the PS100 and whenever
you need to process a different style document. Refer to the first two topics in this
section when you need to access folding and sealing components.
IWhen any work is being carried out on the machine or any
adjustments are being made, the machine should be disconnected
from the mains.
14-11-02 Iss. 1. Page 13