Pressure Seal Systems PS300 Operator's Manual

Operator’s Manual

Issue 3

PS300

V-fold Z-fold C-fold

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 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

1 The Dean

New Alresford

Hampshire

SO24 9BQ

United Kingdom

A Division of Group UK Ltd

Page intentionally blank

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

Page intentionally blank

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 2 PS300 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.

I No 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.

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 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 an authorized
service representative. Only trained, authorized service
representives should remove the protective side covers - and then
only for servicing purposes.

1. Introduction

Page 4 PS300 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:

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

Page 6 PS300 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 4 below 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 8 PS300 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).

P There 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

+

S

e

le

ct

Re

set

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 but ton clears the er ror mes sages on the LCD dis play.

When Re set is pressed with the Se lect button, the forms coun ter on the LCD dis play

returns to zero.

Select button

This is used with the Re set but ton, see above.

Jog function

Press ing and holding the Off/Stop button followed with the On/Start button op er ates the

Jog func tion (see Clear ing mis han dled 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 pro vides ac cess to the fold ing and seal ing com po nents. The cover has two

safety switches, these dis able op er a tion of the ma chine when the cover is re moved or not

prop erly in stalled.

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

Page intentionally blank

2. Features

Page 12 PS300 Iss. 3.

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.

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.

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 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

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:

P Fold 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

C fold set-up

Refer to Figure 9.

1. Measure the length of the folds required.

2. Adjust the form stop for each 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.

5. Replace the top cover.

3. Set-up

Page 18 PS300 Iss. 3.

3. Set-up

PS300 Iss. 3. Page 19

First Fold Plate

Locking Knobs

Locking

Knobs

First Fold

Dimension

Second Fold

Dimension

First Fold

Dimension

Setting

Second Fold

Dimension

Setting

Second Fold Plate

150

6 5

140 130 120

150

6 5

140 130 120

Leading Edge

Fold Perforations

Figure 9: C Fold Set-up

Z fold set-up

Refer to Figure 10.

1. Measure the length of the folds required.

2. Adjust the form stop for each 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.

5. Replace the top cover.

3. Set-up

Page 20 PS300 Iss. 3.

3. Set-up

PS300 Iss. 3. Page 21

First Fold Plate

First Fold

Dimension

Second Fold

Dimension

First Fold

Dimension

Setting

Second Fold Plate

Locking Knobs

Locking

Knobs

Second Fold

Dimension

Setting

150

6 5

140 130 120

150

6 5

140 130 120

Leading Edge

Fold Perforations

Figure 10: Z Fold Set-up

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

Page 22 PS300 Iss. 3.

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 and plug

the conveyor's power connector into the machine's mains output socket (see

Figure 12).

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).

3. Set-up

PS300 Iss. 3. Page 23

Entrapment

Roller

Power

Connector

Locating

Clip
(x2)

Overlap

Control

Mains Output

Socket

Locating

Lip

Securing

Screw

Run Switch

Circuit Breaker

Figure 12: Conveyor Setup

Page intentionally blank

3. Set-up

Page 24 PS300 Iss. 3.

4. Operation

General

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.

Operating process

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 authorized
service representative.

PS300 Iss. 3. 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 fold 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

Page 26 PS300 Iss. 3.

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 fold 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.

• The conveyor is in place.

• The forms are properly loaded and the Ready message is shown on the LCD display.

4. Operation

PS300 Iss. 3. 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 fold plate.

• If the second fold is in the wrong place, adjust the second fold plate.

P Make certain the first fold is correct before adjusting the second.

4. Operation

Page 28 PS300 Iss. 3.

(glue edge)

(glue edge)

Figure 13: First and second folds

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. Hold down the Select button and press the Reset button to zero the counter (if

required).

2. Press and hold the On/Start button 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.

4. Operation

PS300 Iss. 3. Page 29

Page intentionally blank

4. Operation

Page 30 PS300 Iss. 3.

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: In-feed tray not fully inserted

JAM IN FOLDER: Form jammed in one of the fold plates

JAM AFTER FOLDER: Form jammed after the fold plates

OUT OF PAPER: Paper has run out

COVER OPEN: Cover removed or not properly installed

PS300 Iss. 3. Page 31

Clearing mishandled forms

Jam in folder

If the Jam in folder error message is displayed, proceed as follows:

1. Switch off the machine's power and unplug it 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 fold roller in place, (see Figure 14) and

lift out the top fold roller.

5. Operation Errors

Page 32 PS300 Iss. 3.

Snap Lever

(x2)

Top fold

Roller

Figure 14: Removing the top fold roller

4. Remove the jammed form.

5. Replace the top fold 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 power to the machine.

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. Use the Jog function (press and hold the Off/Stop button followed with the

On/Start button) 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.

5. Operation Errors

PS300 Iss. 3. 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. Switch off the machine's power and unplug it from the mains.

2. Remove the top cover and second fold plate.

3. Using the 8mm allen key provided, turn the four pressure bolts anticlockwise to

relieve the sealing roller pressure. (The allen key is situated on the back plate.)

4. Re-install the top cover, reconnect the power and switch the machine on.

5.

Use the Jog function (press and hold the Off/Stop button followed with the

On/Start button) to eject the mishandled forms.

5. Operation Errors

Page 34 PS300 Iss. 3.

Pressure

Bolts

(x4)

Tighten

Release

Figure 15: Relieving the sealing roller pressure

6. When you are sure that all mishandled forms have been cleared, switch off the

machine's power and unplug it from the mains.

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 pressure bolts! Stop tightening the

bolts as soon as you feel a significant increase in resistance.
Ensure all 4 bolts are correctly reset.

8. Re-install the top cover and the second fold plate.

9. Restore power and restart the machine.

5. Operation Errors

PS300 Iss. 3. 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

an authorized service representative.

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 an authorized
service representative for
advice.

Board fuse blown. Contact an authorized

service representative 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 an authorized

service representative 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 fold plates; fold
plates not installed properly.

Remove debris; properly
install fold plates.

Top fold roller not properly
installed.

Ensure the top fold roller's
snap levers are closed,
holding the roller in place.
See page 32.

5. Operation Errors

Page 36 PS300 Iss. 3.

Condition Possible Cause Corrective Action

Forms are mishandled in the
folder or damaged during
sealing.

Dirty fold rollers. Clean rollers with

recommended cleaning
solution. See page 39.

Fold roller adjusted
improperly or worn; sealing
rollers adjusted improperly.

Contact an authorized
service representative 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 an authorized
service representative 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. See
page 22.

Fold plates not installed
properly.

Install fold plates properly.
See page 15.

Worn feed roller. Contact an authorized

service representative for
advice.

5. Operation Errors

PS300 Iss. 3. 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 fold rollers. Clean fold rollers.

Fold plate form stop(s)
adjusted improperly.

Check and adjust the
position of the fold plate
form stop(s). See page 16.

Fold rollers adjusted
improperly or worn; sealing
rollers adjusted improperly.

Contact an authorized
service representative for
advice.

Two or more forms are
feeding into the folder
together.

Forms in stack are sticking
together.

Fan form stack and reload
forms.

Worn feed roller Contact an authorized

service representative for
advice.

5. Operation Errors

Page 38 PS300 Iss. 3.

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 both fold plates.

5. Lift the two snap levers holding the top fold roller (see Figure 14 on page 32), and

lift out the roller.

6. Remove as much paper dust as possible using a soft brush (DO NOT USE

CANNED COMPRESSED AIR). Try to avoid letting the dust drift down into the

lower machinery.

I Warning: only use the recommended cleaning kit on this

machine (part number 70-0019-00, available from an
authorized service representative). Pressure Seal Systems
cannot be held responsible for any damage to the machine
caused by the use of unauthorized solvents and cleaners.

PS300 Iss. 3. Page 39

I Avoid breathing the fumes or getting the cleaning solution in an

open wound or other sensitive areas such as the eyes or mouth.
Read the label on the container carefully before use.

7. Moisten a clean, lint-free cloth with the cleaning solution.

8. Wipe clean the surface of all the fold 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.

9. Replace the top fold roller.

P The flat faces of the bearing holder must be held vertically for the roller to

drop into the holding slots.

10. Close the two snap levers to hold the roller in place.

11. Replace the first and second fold plates.

12. Replace the top cover and then restore the mains power.

6. Cleaning the machine

Page 40 PS300 Iss. 3.

7. Specifications

Folder/Sealer Specifications

Construction

Steel with ABS

Sealer

Integral four-roller system

Size

700mm(L) x 530mm(W) x 380mm(H)
(excluding output tray of 115mm)

Weight

Approximately 90kg

Power

110/230V AC ±10%

3.7A @ 230V ±10%

Speed

9000 forms per hour (A4 Z fold)

Environment

Operating 10° - 40° C

5% - 50% humidity

Non-operating 5° - 50° C
(idle - power off) 5% - 80% humidity

Feeder Capacity

500 sheets

Noise

72dB

PS300 Iss. 3. Page 41

Form Specification

Sizes

W 170mm (6.7in) x L 100mm (4in) minimum
W 300mm (11.8in) x L 355mm (14in) maximum
Cut-sheet

Fold Configuration

Z, V and C folds

Conveyor Specification

Construction

Steel

Size

515mm (L) x 335mm (W)

Weight

Approximately, 13kg

Power

110/230V AC ±10%

0.5A @ 230V ±10%

Capacity

500 sheets

Noise

40dB

7. Specifications

Page 42 PS300 Iss. 3.

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.

PS300 Iss. 3. Page 43

Settings Settings Settings

First fold plate:

Half of the form length.

First fold plate:

One third of the form length.

First fold plate:

Two thirds of the form
length.

Second fold plate:

Rotate through 180 degrees.

Second fold plate:

One third of the form length.

Second fold 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.

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 PS300 Iss. 3.

Figure 16 Curled Documents

Service Visit Log

Serial number:

Date Work done and comments

Engineer’s
signature

Customer’s
signature

PS300 Iss. 3. Page 45

Notes

1 The Dean

New Alresford, Hampshire

S024 9BQ

United Kingdom

Tel: [phone]

Fax: [phone]

Website: www.pressure-seal.com

Registered Office: Pallion Trading Estate, Sunderland, Tyne and Wear SR4 6ST

Registered in England Number 511336

A Division of Group UK Ltd