PSS PS300 User manual

Operator’s Manual
Issue 3
PS300
V-fold Z-fold C-fold

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 guides ...................................8
Feed roller ....................................8
In-feed tray....................................8
Fold plates ....................................8
Fold 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
Jog function ..................................10
Speed control slider...............................10
PS300 Iss. 3. Page v

Power and safety components ............................11
Mains lead ...................................11
Top cover....................................11
Sealing and stacking components ..........................11
Pressure bolts .................................11
Sealing rollers..................................11
Conveyor ....................................11
3. Set-up
Setting up the machine ................................13
Removing the top cover ...............................14
Removing the fold plates ...............................15
Setting up the folder .................................16
V fold set-up ..................................16
C fold set-up ..................................18
Z fold set-up ..................................20
Adjusting the form guides ............................22
Setting up the form conveyor ..........................23
4. Operation
General .......................................25
Operating process ..................................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
Page vi PS300 Iss. 3.

Jam after folder .................................33
Pressure sealer bolt release ...........................34
Troubleshooting ...................................36
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.................................41
Noise ......................................41
Form Specification ..................................42
Sizes ......................................42
Fold Configuration ...............................42
Conveyor Specification ................................42
Construction ..................................42
Size.......................................42
Weight .....................................42
Power .....................................42
Capacity ....................................42
Noise ......................................42
Appendix A - Form Loading Guide
Appendix B - Form Curl
Service Visit Log
PS300 Iss. 3. 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
•No adjustment required when changing the weight of forms used
•Automatic stop when the in-feed tray is empty
•If empty at power-up, the in-feed tray lowers for form loading
•In-feed 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.
PS300 Iss. 3. 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
Page 2PS300 Iss. 3.
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 top cover and fold 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 44), and how the folded/sealed forms should be orientated when they reach the
conveyor.
1. Introduction
PS300 Iss. 3. 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 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 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 an authorized
service representative. Only trained, authorized service
representives should remove the protective side covers - and then
only for servicing purposes.
1. Introduction
Page 4PS300 Iss. 3.

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.
1. Introduction
PS300 Iss. 3. Page 5
Voltage Setting Label
Figure 3:Voltage Setting Label Location

If the machine is damaged
Switch off the machine's power, unplug it from the mains and refer servicing to an
authorized service representative 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
Page 6PS300 Iss. 3.

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.
PS300 Iss. 3. Page 7
Sealer Pressure Bolts
Feed Roller
Form Guides
Sealer Rollers
Control Panel
Conveyor
Top Cover
In-feed Tray
Second Fold Plate
Fold Rollers
First Fold Plate
Figure 4:Features of the machine

Folder components
Form guides
The form guides keep the forms aligned so the feed roller feeds each one squarely. The
form guides on the machine are adjustable to accommodate various sheet widths.
Feed roller
The feed roller provides reliable single-sheet form feeding into the folding area. The feed
roller requires no adjustment.
In-feed tray
The in-feed tray holds the stack of forms allowing them to be fed by the feed roller. The
spring-loaded tray presses the forms against the feed roller, automatically providing the
correct pressure to allow only one form at a time to be fed into the folder.
Fold plates
These provide for simple "V" (centre or half) folds, "Z" (zigzag) folds or "C" (letter) folds.
The fold plates are adjustable to accommodate various form lengths.
Fold rollers
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 is removable, which aids recovery
of mishandled forms (see page 32).
2. Features
Page 8PS300 Iss. 3.

Operator controls
LCD display
The batch counter on the LCD display indicates the number of forms in the current batch
(since it was last reset) and is zeroed by pressing the select button with reset (see Figure 5).
PThere is an additional counter located inside the machine indicating the cumulative
total. This may only be reset by an authorized service representative.
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 On/Start button processes one form.
•Pressing and holding the On/Start button for two seconds starts the continuous
processing of all the forms
2. Features
PS300 Iss. 3. Page 9
+
Select
Reset
On/Start
Raise
In-feed Tray
Lower
In-feed Tray
Reset
Button
Select
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 ( )
This button raises the in-feed tray, enabling forms to be fed into the machine.
– button ( )
This button lowers the in-feed tray, enabling forms to be loaded.
Reset button
This button clears the error messages on the LCD display.
When Reset is pressed with the Select button, the forms counter on the LCD display
returns to zero.
Select button
This is used with the Reset button, see above.
Jog function
Pressing and holding the Off/Stop button followed with the On/Start button operates the
Jog function (see Clearing mishandled forms on page 32).
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
Page 10 PS300 Iss. 3.
+

Power and safety components
Mains lead
The mains lead supplies electrical power to the machine.
Top cover
The top cover provides access to the folding and sealing components. The cover has two
safety switches, these disable operation of the machine when the cover is removed or not
properly installed.
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.
2. Features
PS300 Iss. 3. Page 11

3. Set-up
Setting up the machine
This section provides instructions for:
•Removing the top cover
•Removing the fold plates
•Setting up the folder
•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 the 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.
PS300 Iss. 3. Page 13

Removing the top cover
1. Switch off the machine's power and unplug it from the mains.
2. Remove the top cover by placing one hand at the out-feed end and the other
close to the in-feed of the machine. The out-feed end Àshould be lifted first.
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.
3. Set-up
Page 14 PS300 Iss. 3.
1
Figure 6:Removing the top cover

Removing the fold plates
1. Remove the top cover
2. Grasp the fold plate, tilt it up towards the vertical and draw it up out of the fold
plate locators.
3. To install the fold plates, ensure their location flags are located between the fold
plate locators as shown in Figure 7.
3. Set-up
PS300 Iss. 3. Page 15
Fold Plate
Locators Second Fold Plate
First Fold Plate
Location
Flag
Figure 7:Fold plate locators

Setting up the folder
Once you've removed the top cover and fold plates (see pages 14 and 15 respectively),
setting up the machine’s folder is carried out as follows:
PFold plates can be adjusted in situ.
V fold set-up
Refer to Figure 8.
1. Measure the length of the fold required.
2. Adjust the form stop for the first fold plate to the measurement you determined
previously in step 1 as follows:
Loosen the locking knobs at each end of the form stop.
Using the knobs as handles, slide the stop along the rods until the stop aligns
with the correct settings on the scales. Make sure the scales on each side of
the fold plate show the same settings otherwise the form will not fold squarely.
Tighten the two locking knobs.
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 fold plates, ensuring the second fold plate is reversed to be in
the ‘no fold’ position.
5. Replace the top cover.
3. Set-up
Page 16 PS300 Iss. 3.

3. Set-up
PS300 Iss. 3. Page 17
Second Fold Plate
(no fold)
First Fold Plate
First Fold
Dimension
Setting
Locking Knobs
150
6 5
140 130 120
Leading Edge
Fold Perforation
First Fold
Dimension
Figure 8:V Fold Set-up