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:
InfoSealPS
PS 400
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PS 400
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 roll .....................................8
In-feed tray ....................................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
Top cover ....................................11
PS 400
03-19-02 Iss. 1. Page v
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 folding 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
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 400
Page vi 03-19-02 Iss. 1.
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 400
03-19-02 Iss. 1. Page vii
Page intentionally blank
PS 400
Page viii 03-19-02 Iss. 1.
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.
03-19-02 Iss. 1. 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 400
Page 2 03-19-02 Iss. 1.
Non-operator side
Operator side
Out-fee
d
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 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 400 1. Introduction
03-19-02 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.
I
No 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.
I
To 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.
I
Except 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 400
Page 4 03-19-02 Iss. 1.
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 400 1. Introduction
03-19-02 Iss. 1. 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:
q
If the mains lead is damaged or frayed
q
If liquid has been spilled into the machine
q
If the machine has been exposed to rain or water
q
If the machine has been dropped or damaged
q
If 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.
q If the machine exhibits a distinct change in performance, indicating a need for a
service
1. Introduction
PS 400
Page 6 03-19-02 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 4 below as you read about the features of the machine.
03-19-02 Iss. 1. Page 7
S
ealer 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 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 32).
2. Features
PS 400
Page 8 03-19-02 Iss. 1.
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 reset button (see Figure 5).
P
There is an additional counter located inside the machine indicating the cumulative
total. This may only be reset 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 400 2. Features
03-19-02 Iss. 1. Page 9
+
Select
Reset
On/Start
Raise Form
In-feed Tray
Lower Form
In-feed Tray
Reset
Butto
n
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 resets the batch counter on the LCD display 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 400
Page 10 03-19-02 Iss. 1.
+
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, one at the out-feed and one on the operator's side, which disables
operation of the machine when it 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.
PS 400 2. Features
03-19-02 Iss. 1. Page 11
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2. Features PS 400
Page 12 03-19-02 Iss. 1.
3. Set-up
Setting up the machine
This section provides instructions for:
•
Removing the top cover
•
Removing the folding 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 folding and sealing components.
I
When any work is being carried out on the machine or any
adjustments are being made, the machine should be disconnected
from the mains.
03-19-02 Iss. 1. Page 13
Removing the top cover
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
À should 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
PS 400
Page 14 03-19-02 Iss. 1.
1
Figure 6: Removing the top cover
Removing the folding 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 location plates.
3. To install the fold plates, ensure their location flags are located between the
location plates as shown in Figure 7.
PS 400 3. Set-up
03-19-02 Iss. 1. Page 15
Location
Plates
Second Fold Plate
First Fold Plate
Location
Flag
Figure 7: Removing/Installing the fold plates
Setting up the folder
Once you've removed the top cover and folding plates (see pages 14 and 15 respectively),
setting up the machine’s folder is carried out as follows:
P
Folding 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 folding 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 folding 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 folding plates, ensuring the second folding plate is in the ‘no
fold’ position.
5. Replace the top cover.
3. Set-up
PS 400
Page 16 03-19-02 Iss. 1.
PS 400 3. Set-up
03-19-02 Iss. 1 Page 17
Second Fold Plate
(no fold)
Leading Edge
Fold Perforation
First Fold Plate
First Fold
Dimension
First Fold
Dimension
Setting
Locking Knobs
150
65
140 130 120
Figure 8: V Fold Set-up
InfoSealPS
C fold set-up
Refer to Figure 9.
1. Measure the length of the folds required.
2. Adjust the form stop for each folding 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 folding 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 folding plates.
5. Replace the top cover.
3. Set-up
PS 400
Page 18 03-19-02 Iss. 1.
PS 400 3. Set-up
03-19-02 Iss. 1. Page 19
First Fold Plate
Locking Knobs
Locking
Knobs
First Fold
Dimension
Second Fold
Dimension
First Fold
Dimension
Setting
Second Fol
d
Dimension
Setting
Second Fold Plate
150
65
140 130 120
150
65
140 130 120
Leading Edge
Fold Perforations
Figure 9: C Fold Set-up
Z fold set-up
Refer to Figure 9.
1. Measure the length of the folds required.
2. Adjust the form stop for each folding 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 folding 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 folding plates.
5. Replace the top cover.
3. Set-up
PS 400
Page 20 03-19-02 Iss. 1.
PS 400 3. Set-up
03-19-02 Iss. 1. Page 21
First Fold Plate
First Fold
Dimension
Second Fold
Dimension
First Fold
Dimension
Setting
Second Fold Plate
Locking Knobs Locking
Knobs
Second Fol
d
Dimension
Setting
150
65
140 130 120
150
65
140 130 120
Leading Edge
Fold Perforations
Figure 10: Z Fold Set-up
InfoSealPS
1825 Blue Hills Circle
Roanoke, Va 24012
Adjusting the form guides
Set the adjustable form guides on the in-feed tray to fit the width of the forms you are
processing as follows:
1.
Press the button to lower the in-feed tray.
2. Pull the in-feed tray out, slacken the width adjusting knobs under the in-feed
tray (see inset of Figure 11) and widen the guides if necessary.
3. Place the forms on the feed bed so their centre is in line with the slot in the
centre of the in-feed tray.
4. Push the form guides in to touch the sides of the forms (not too tight or too
loose as this can cause mishandling).
5. Tighten the width adjusting knobs (see inset of Figure 11), slide the in-feed tray
back in and ensure the forms are fully pushed in.
3. Set-up
PS 400
Page 22 03-19-02 Iss. 1.
Form Guides
In-feed Tray
Centre Slot
Underside of
In-feed Tray
Width Adjusting
Knobs
Figure 11: Adjusting the form guides
Setting up the form conveyor
The form conveyor collects the forms from the out-feed and stacks them (either
overlapping or separated) ready for removal. To fit and set-up the conveyor, proceed as
follows:
1. Clip the conveyor over the locating lip on the out-feed of the machine, plug it in
to the mains output socket (see Figure 12) and turn it on.
2. Loosen the securing screw and adjust the entrapment roller according to the
form size (close to out-feed for short forms; further away for larger forms).
3. Adjust the overlap control as required (0 = most overlap; 10 = greatest
separation).
PS 400 3. Set-up
03-19-02 Iss. 1. Page 23
Entrapment
Roller
Entrapment
Roller
Locating
Clip
(x2)
Overlap
Control
Securing
Screw
Mains Output
Socket
Locating
Lip
Figure 12: Conveyor Setup
Page intentionally blank
3. Set-up PS 400
Page 24 03-19-02 Iss. 1.
4. Operation
General
Operating the machine is a simple three-step process:
1. Verify the machine is set for the fold style required by the forms.
2. Place the forms in the in-feed tray and adjust the form guides if necessary (see
page 22).
3. Start the machine.
I
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 authorised
service representative.
This section explains in detail how to:
•
Load forms
•
Start up and test the machine
•
Process forms
Any problems that arise from the operation of the machine are addressed in the next
chapter, which includes a troubleshooting guide.
03-19-02 Iss. 1. Page 25
Loading forms
1. When you load forms make sure:
•
There are no mishandled forms in the folder or sealer (no error messages
indicated on the LCD display - see Error Conditions on page 31).
•
All rubber and metal rollers are clean and free of foreign matter
2. Fan the stack of forms to make sure they are not sticking together.
3. Align the stack so the forms feed correctly into the machine. Form orientation
depends upon form design, the type of fold desired, presence of curl, and how
the folding plates are set up.
4. Align the stack of forms so that the ends and sides of the stack are smooth and
square.
5. Lower the in-feed tray.
6. Feed the stack between the form guides and into the machine until the stack
meets the guide plate.
7. Make sure the ‘Ready’ message is shown on the LCD display, indicating the
stack is properly loaded on the in-feed tray.
8. Make sure the stack of forms is flat and not bowed due to the form guides
being too tight.
4. Operation
PS 400
Page 26 03-19-02 Iss. 1.
Starting up and testing the machine
This procedure describes how to start up and test the machine to make sure it is ready to
fold and seal your forms. Always perform this procedure at the start of each form
processing session to ensure the best results.
Before you start up and test the machine, make sure all of the following conditions are
satisfied:
•
The folding plates are adjusted and installed properly for the fold you want.
•
The form guides are set correctly to provide enough, but not too much, clearance at
the sides of the form stack
•
The top cover is firmly seated on the top of the unit.
•
Forms are properly loaded and the Ready message is shown on the LCD display.
PS 400 4. Operation
03-19-02 Iss. 1. Page 27
Verifying folder settings
1. Momentarily press the On/Start button. The machine processes one form.
2. Check the form for proper fold and seal. Check that the folds are in the proper
place.
•
If the first fold is in the wrong place, adjust the first folding plate.
• If the second fold is in the wrong place, adjust the second folding plate.
Make certain the first fold is correct before adjusting the second.
4. Operation PS 400
Page 28 03-19-02 Iss. 1.
Figure 13: First and second folds
InfoSealPS
18
25 Blue Hills Circle
Roan
oke, Va 240
12
InfoSealPS
18
25
Blu
e Hill
s Cir
cle
Roano
ke,
Va 2401
2
InfoSealPS
1825 B
l
ue Hills Ci
r
cle
Roano
ke, V
a 24
012
Processing forms
Before proceeding, make sure you have started up and tested the machine and that the
test form is properly folded and sealed.
1. Press the Reset button to zero the counter (if required).
2. Press and hold the run switch for 2 seconds until the next form is processed.
The machine processes all the forms loaded, until the in-feed tray is empty.
The machine stops automatically after the last form is processed. The Empty
message is shown on the LCD display, indicating the in-feed tray is empty.
3. Remove the sealed forms from the conveyor.
4. 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.
PS 400 4. Operation
03-19-02 Iss. 1. Page 29
Page intentionally blank
4. Operation PS 400
Page 30 03-19-02 Iss. 1.
5. Operation Errors
Error Conditions
In the event of a problem existing that prevents the machine from operating, a suitable
error message will be shown on the LCD display as follows:
LOAD PAPER: Start pressed with no paper
INFEED TRAY OUT: Tray not in properly
JAM IN FOLDER: Form jammed in one of the folding plates
JAM AFTER FOLDER: Form jammed after the folding plates
OUT OF PAPER: Paper has run out
COVER OPEN: Cover removed or not properly installed
03-19-02 Iss. 1. Page 31
Clearing mishandled forms
Jam in folder
If the ‘Jam in folder’ error message is displayed, proceed as follows:
1. Switch off the mains power and unplug from the mains and then remove the top
cover (see page 14).
2. Remove the fold plates using the procedure described on page 15.
3. Lift the two snap levers holding the top-folding roller in place, (see Figure 14)
and lift out the top folding roller.
5. Operation Errors
PS 400
Page 32 03-19-02 Iss. 1.
Snap Lever
(x2)
Top Folding
Roller
Figure 14: Removing the top folding roller
4. Remove the jammed form.
5. Replace the top-folding roller.
P
The flat faces on the two end bearings must be held vertically for them to drop
into the housing slots. Close the two snap levers to hold the roller in place.
6. Replace the fold plates
7. Replace the top cover and restore the mains power
8. Reload and restart the machine
Jam after folder
If the ‘Jam after folder’ error message is displayed, proceed as follows:
1. Remove all forms from the in-feed tray.
2. Momentarily press the run switch to eject the mishandled form out of the
rollers.
If the form doesn't eject, repeat step 2. It may take several attempts.
If, after several attempts, the mishandled form doesn't eject, carry out the
Pressure bolt release procedure on page 34.
P
It may be necessary to stabilise the forms before folding and sealing them.
This can be achieved by allowing them to rest in the same room as the
machine for an hour or more after printing.
3. When the jammed form is removed from the sealer, check the sealer rollers for
any form particles that may have become stuck with adhesive.
PS 400 5. Operation Errors
03-19-02 Iss. 1. Page 33
Pressure sealer bolt release
The pressure sealer bolts on the machine not only allow you to recover from severe form
mishandling situations, they also provide accurate sealing pressure. The pressure on the
sealing rollers can be relieved then reset to the original factory setting in the event
mishandled forms lodge between the sealing rollers, stopping the machine processing.
1. Unplug the power cord from the wall outlet.
2. Remove the top cover and second folding plate.
3. Using the 8mm allen key provided, turn the four adjustment screws
anticlockwise to relieve the sealing roller pressure. (The allen key is situated on
the lip above the in-feed tray, beneath the lid.)
4. Install the top cover, reconnect the power and switch the machine on.
5. Operation Errors
PS 400
Page 34 03-19-02 Iss. 1.
Pressure
Bolts
(x4)
Tighten
Release
Figure 15: Relieving the sealing roller pressure
5. Press the run switch momentarily to clear any mishandled forms.
6. When you are sure that all mishandled forms have been cleared, unplug the
mains lead from the wall outlet.
7. Remove the top cover and tighten each adjustment screw down until you feel a
significant increase in resistance. This is a predetermined stop.
I
Do not overtighten the adjustment screws! Stop tightening
the screws as soon you feel a significant increase in
resistance.
8. Install the top cover and power up the machine.
PS 400 5. Operation Errors
03-19-02 Iss. 1. Page 35
Troubleshooting
The table below lists the possible causes and any corrective actions required for
conditions that may occur with your machine. For conditions not covered below, contact
your Pressure Seal Systems distributor.
Condition Possible Cause Corrective Action
The power-on indicator
does not light.
Mains lead not plugged into
an AC outlet.
Plug mains lead into an AC
outlet.
Mains plug fuse blown. Replace fuse. If the
replacement fuse blows,
contact your Pressure Seal
distributor for advice.
Board fuse blown. Contact your Pressure Seal
distributor for advice.
The machine does not
operate when the On/Start
button is pressed (power
on)
Form misfeed, jam detected:
error message displayed.
Clear mishandled forms.
Top cover not firmly seated
on top of the unit.
Firmly seat the top cover on
the unit.
No forms loaded. Load forms.
Board fuse blown. Contact your Pressure Seal
distributor for advice.
Forms are mishandled in the
folder or damaged during
sealing.
Fold plate form stop(s)
adjusted improperly.
Check and adjust the
position of the fold plate
form stop(s). See page 16.
Debris in folding plates;
folding plates not installed
properly; fold plate form
stop(s) adjusted improperly.
Remove debris; properly
install fold plates; check
position of the fold plate
form stop(s).
5. Operation Errors PS 400
Page 36 03-19-02 Iss. 1.
Condition Possible Cause Corrective Action
Forms are mishandled in the
folder or damaged during
sealing.
Dirty folding rollers. Clean rollers with cleaning
solution. See page 39.
Folding roller adjusted
improperly or worn; sealing
rollers adjusted improperly.
Contact your Pressure Seal
distributor for advice.
Forms not sealing. Pressure on sealing rollers
is relieved.
Reset pressure on the
sealing rollers. See page 34.
Forms have been incorrectly
stored, or are older than
their shelf life (one year).
Use fresh forms.
Fold plate form stop(s)
adjusted improperly causing
poor registration of adhesive
strips.
Check and adjust position of
the fold plate form stop(s).
See page 16.
Sealing rollers adjusted
improperly.
Contact your Pressure Seal
distributor for advice.
Forms are misfeeding. In-feed tray form guides are
set too tight or too loose.
Set the guides so there is
just enough clearance to
allow the form to move
freely between the guides.
Debris in folding plates;
folding plates not installed
properly; fold plate form
stop(s) adjusted improperly.
Remove debris; properly
install folding plates; check
and adjust the position of
the fold plate form stop(s).
Worn feed roll. Contact your Pressure Seal
distributor for advice.
PS 400 5. Operation Errors
03-19-02 Iss. 1. Page 37
Condition Possible Cause Corrective Action
Forms are wrinkled or badly
folded.
Forms not feeding squarely
against form stop(s).
Adjust the form stop(s) to
squarely deflect the forms;
ensure the stop setting is
identical on both scales.
See page 16.
Dirty folding rollers. Clean folding rollers.
Fold plate form stop(s)
adjusted improperly.
Check and adjust the
position of the fold plate
form stop(s). See page 16.
Folding rollers adjusted
improperly or worn; sealing
rollers adjusted improperly.
Contact your Pressure Seal
distributor for advice.
Two or more forms are
feeding into the folder
together.
Forms in stack are sticking
together.
Fan form stack and reload
forms.
5. Operation Errors PS 400
Page 38 03-19-02 Iss. 1.
6. Cleaning the machine
Cleaning procedure
The machine’s folding and sealing mechanisms should be cleaned in the following
manner:
P
To avoid leaving finger-marks on the machine’s internal rollers, it is recommended
that disposable gloves are worn during cleaning. People susceptible to dust
allergies may be more comfortable wearing a protective mask.
1. Be sure that the room is well ventilated.
2. Switch off the mains power and unplug or disconnect from the mains.
3. Lift off the top cover.
4. Remove the first fold plate.
5. Remove the second fold plate.
6. Lift the two levers holding the top folding roller (see Figure 14), and lift out the roller.
7. Remove as much paper dust as possible using a soft brush. Try to avoid letting
the dust drift down into the lower machinery.
I
If compressed air is used to clear the paper dust, use only a
recommended canned air blower.
8. Moisten a clean, lint-free cloth with the cleaning solution.
I
Avoid breathing the fumes or getting the solution in an open
wound or other sensitive areas such as the eyes or mouth.
Read the label on the container carefully before use.
03-19-02 Iss. 1. Page 39
9. Wipe clean the surface of all the folding and sealing rollers using the moistened
cloth. It will be necessary to rotate each roller, taking care not to let anything get
caught between them. A moderate amount of effort may be required to turn the
sealing rollers. Wipe off any fingerprints from the rollers as they are turned.
10. Replace the top-folding roller.
P
The flat faces of the bearing holder must be held vertically for the roller to
drop into the holding slots.
11. Close the two snap levers to hold the roller in place.
12. Replace the first and second fold plates.
13. Replace the top cover and then restore the mains power.
6. Cleaning the machine
PS 400
Page 40 03-19-02 Iss. 1.
7. Specifications
Folder/Sealer Specifications
Construction
Formed sheet metal steel side frames with ABS shell
Sealer
Integral four-roller system
Size
28" x 21" x 14" - 750mm(L) x 530mm(W) x 350mm(H)
(excluding output tray of 115mm)
Weight
Approximately 90kg
Power
240V ac, 3.7A, 50HZ
Speed
12,000 forms per hour (11" Z Fold) (variable)
Environment
Operating 10° - 40° C
5% - 50% humidity
Non-operating 5° - 50° C
5% - 80% humidity
03-19-02 Iss. 1. Page 41
Feeder Capacity
500 sheets
Noise
72dB
Form Specification
Sizes
W 6.7in x 4in minimum
W 11.8in x 14in maximum
Cut-sheet
Fold Configuration
Z, V and C folds
7. Specifications
PS 400
Page 42 03-19-02 Iss. 1.
Appendix A - Form Loading
Guide
Many variables must be considered when setting up the folder/sealer, and loading forms
for processing. These include the form design, type of fold and how the folded/sealed
forms should be orientated when they reach the conveyor.
03-19-02 Iss. 1. Page 43
Settings Settings Settings
First folding plate:
Half of the form length.
First folding plate:
One third of the form length.
First folding plate:
Two thirds of the form
length.
Second folding plate:
Rotate through 180 degrees.
Second folding plate:
One third of the form length.
Second folding plate:
One third of the form length.
Feeding problems:
Rotate form 180 degrees.
Feeding problems:
Print backside of form first.
Feeding problems:
Flip form, then rotate 180
degrees.
InfoSealPS
InfoSealPS
1825 Blue Hills Circle
Roanoke, Va 24012
Appendix B - Form Curl
Many variables must be considered when setting up the folder/sealer, and loading forms
for processing. These include the form design, type of fold, condition of forms (if they are
curled or not), and how the folded/sealed forms should be orientated when they reach the
conveyor.
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.
Page 44
03-19-02 Iss. 1.
Figure 16 Curled Documents
Serial number:
Date Work done and comments
Head Office: InfoSealPS, 1825 Blue Hills Circle, Roanoke, VA 34012
888-952-4636 Fax: 888-652-4636
03-19-02 Iss. 1. Page 45
Engineer's
signature
Customer's
signature
Names of Trainees:
Install Date:
Training Date:
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