Pressure Seal Group PS 600 User manual

Operator’s ManualOperator’s Manual
PS 600
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 600

Contents
1. Introduction
General ........................................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...............................6
2. Features
General ........................................7
Folder components ..................................8
Form feeder ...................................8
Folding plates ..................................8
Folding rollers ..................................8
Operator controls ...................................9
LCD display ...................................9
On/Start Button..................................9
Off/Stop button .................................10
+ button () ...................................10
– button () ...................................10
Reset button ..................................10
Select button ..................................10
Speed control slider...............................10
Power and safety components ............................11
Mains lead ...................................11
Rear cover ...................................11
PS 600
22-01-03 Iss. B. Page v

Sealing and stacking components ..........................11
Pressure bolts .................................11
Sealing rollers..................................11
Conveyor ....................................11
3. Set-up
Setting up the machine ................................13
Removing/fitting the first folding plate.........................14
Removing/fitting the second folding plate .......................15
Setting up the folder .................................16
V fold set-up ..................................16
C fold set-up ..................................18
Z fold set-up ..................................20
Setting up the In-feed Bed ..............................22
Setting up the form conveyor.............................23
4. Operation
General .......................................25
Loading forms ....................................26
Starting up and testing the machine .........................27
Verifying folder settings .............................28
Processing forms ..................................29
Interrupting operation ..............................29
5. Operation Errors
Error Conditions ...................................31
Clearing mishandled forms ..............................32
Jam in folder ..................................32
Jam after folder .................................33
Pressure sealer bolt release ...........................34
Troubleshooting ...................................36
PS 600
Page vi 22-01-03 Iss. B.

6. Cleaning the machine
Cleaning procedure..................................39
7. Specifications
Folder/Sealer Specifications .............................41
Construction ..................................41
Sealer......................................41
Size.......................................41
Weight .....................................41
Power .....................................41
Speed .....................................41
Environment ..................................41
Feeder Capacity.................................42
Noise ......................................42
Form Specification ..................................42
Sizes ......................................42
Fold Configuration ...............................42
Appendix A - Form Loading Guide
Appendix B - Form Curl
Service Visit Log
PS 600
22-01-03 Iss. B. Page vii

1. Introduction
General
This folder/sealer produces finished mailable documents or "self-mailers" from cut-sheet
Pressure Seal forms. In one smooth operation it folds and seals single sheets into
self-mailers quickly and economically. Pressure activated cohesives provide an instantly
secure seal on all sides of the form, whether you use a “C”, “V” or “Z” fold.
Features include:
•Simple to load and operate
•Easy to change the fold styles
•C, V, offset V and Z fold styles
•Minimal adjustment required when changing the weight of forms used
•Automatic stop when the in-feed tray is empty
•Exit forms electronic counter with reset
•Form flow error detection
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.
22-01-03 Iss. B. Page 1
Figure 1:Types of fold produced

Which side is which?
The terms "in-feed", "out-feed", "operator side" and “non-operator side” are used
throughout this manual to identify the sides of the machine.
•The in-feed is the side into which the forms are loaded.
•The out-feed is the side out of which the finished mailers exit.
•The operator side of the machine contains the control panel and is the side facing you
when the in-feed of the machine is on your left.
•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.
1. Introduction PS 600
Page 222-01-03 Iss. B.
Non-operator side
Operator side
Out-feed
In-feed
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 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 25) - provides easy step-by-step procedures for loading and starting
the machine.
•Operation errors (page 31) - lists common operating problems and possible causes
and solutions.
•Cleaning (page 39) - provides details of the cleaning required to keep the machine in
the best possible condition.
•Specifications (page 41) - provides the technical details of the folder/sealer.
•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 ), and how the folded/sealed forms should be orientated when they reach the
conveyor.
PS 600 1. Introduction
22-01-03 Iss. B. 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 mechanical means.
•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 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 600
Page 422-01-03 Iss. B.

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
Pressure Seal representative or local power company.
PS 600 1. Introduction
22-01-03 Iss. B. Page 5
Voltage Setting Label
Figure 3:Voltage Setting Label Location

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
1. Introduction PS 600
Page 622-01-03 Iss. B.

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 4below as you read about the features of the machine.
22-01-03 Iss. B. Page 7
Compressor Cabinet
Form Guides
Sealer Rollers
Control Panel
Conveyor
In-feed Bed
Second Fold Plate
First Fold Plate
Figure 4:Features of the machine

Folder components
Form feeder
The forms are stacked between the form feed arms of the In-feed bed. Using positive air
pressure to support the main body of the forms, the leading edge of the bottom form is
sucked on to the feed roll, providing reliable single-sheet form feeding into the folding
area.
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 32).
2. Features PS 600
Page 822-01-03 Iss. B.

Operator controls
LCD display
The forms counter on the LCD display indicates the number of forms in the current run
(since it was last reset) and is zeroed by pressing the reset button (see Figure 5).
PThere is an additional counter located inside the machine indicating the cumulative
total. This can only be accessed by a service engineer.
The LCD display also indicates any error messages (see page 31) and the machine’s
current status e.g. Ready, Running, software version, etc.
On/Start Button
The On/Start button switches the machine on and also performs the following:
•Momentarily pressing the run switch processes one form.
•Pressing and holding the run switch for two seconds starts the continuous processing
of all the forms
PS 600 2. Features
22-01-03 Iss. B. Page 9
+
Select
Reset
On/Start
Reserved for
future use Reserved for
future use
Engineering
Feature Button
Reset
Button
Speed Control Slider
FasterSlower
Off/Stop
Figure 5:Operator controls

Off/Stop button
Pressing the Off/Stop button stops the machine after the form currently being fed is
processed. You can stop the machine at any time while forms are processing.
+ button ( )
Reserved for future use.
– button ( )
Reserved for future use.
Reset button
When the Reset button is pressed with the Select button held down, the forms counter on
the LCD display is set to zero.
Select button
This is an engineering function button and should not be used by operators.
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.
2. Features PS 600
Page 10 22-01-03 Iss. B.
+

Power and safety components
Mains lead
The mains lead supplies electrical power to the machine.
Rear cover
The rear cover is located over the sealer rollers.
Sealing and stacking components
Pressure bolts
These allow you to release the pressure on the sealing rollers for clearing mishandled
forms. These bolts can be loosened using the allen key provided (see page 34).
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.
PS 600 2. Features
22-01-03 Iss. B. Page 11

3. Set-up
Setting up the machine
This section provides instructions for:
•Removing the folding plates
•Setting up the folder
•Setting up the In-feed Bed
•Setting up the conveyor
Follow all the instructions in this section the first time you use the machine and whenever
you need to process a different style of form. 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.
22-01-03 Iss. B. Page 13

Removing/fitting the first folding plate
1. Lift the Folding Plate Cover and release the two Locking Arms (see Figure 6).
2. Remove the Folding Plate by sliding it towards the rear of the machine.
3. Fitting the Second Folding Plate is the reversal of the above procedure.
3. Set-up PS 600
Page 14 22-01-03 Iss. B.
Folding Plate
Cover
First Fold
Plate
Locking Arms
(1 each side)
Figure 6:Removing the first folding plate

Removing/fitting the second folding plate
1. Lift and remove the Small Top Cover (see Figure 7) then raise the In-Feed Bed,
ensuring it is locked into the upright position with the locking arm.
2. Fold down the Front Panel, release the two Locking Arms and then slide the
First Folding Plate out of the machine.
3. Fitting the First Folding Plate is the reversal of the above procedure.
PS 600 3. Set-up
22-01-03 Iss. B. Page 15
Small Top Cover
In-Feed Bed
Second Fold
Plate
Locking Arms
(1 each side)
Front
Panel
Figure 7:Removing the second folding plate

Setting up the folder
Once you've removed the top cover and folding plates (see pages and 15 respectively),
setting up the machine’s folder is carried out as follows:
PFolding plates can be adjusted in situ.
V fold set-up
Refer to Figure 8.
1. Measure the length of the fold required.
2. Fit the Deflector Bar to one fold plate and adjust the form stop for the other to
the measurement you determined previously in step 1 as follows:
Loosen the locking knob at the centre of the form stop.
Slide the stop along the rods until the stop aligns with the correct settings on
the scales. Use the fine adjustment control to make sure the scales on each
side of the folding plate show the same settings otherwise the form will not fold
squarely.
Tighten the locking knob.
3. If the new form is a different width from the last form used, refer to ‘Adjusting
the form guides’ on page 22.
4. Re-install both folding plates.
3. Set-up PS 600
Page 16 22-01-03 Iss. B.