AS900 PRESSURE SEALER OPERATING INSTRUCTIONS
Contents
1. i World Leaders AS900 PRESSURE SEALER Operating Instructions AS900 PRESSURE SEALER OPERATING INSTRUCTIONS CONTENTS SECTION Machine Specification Sheet 1 1 Technical Specification 1 2 Control Panel Layout 1 3 Button Explanation 1 4 Machine Layout Diagram 2 1 Machine Setup and Operation 2 2 Hand feed Operation 2 3 Clearing a Document Jam 2 4 Double Document Condition 2 5 Supervisor Mode 3 1 Operator s Troubleshooting Guide 3 2 Operator Maintenance 4 1 Display Panel Error Messages Page 1 Issue 1 Apr 2003 Fi World Leaders AS900 PRESSURE SEALER Operating Instructions 1 CAUTION 2 CAUTION 3 CAUTION 4 CAUTION 5 CAUTION MACHINE SPECIFICATION SHEET In order to ensure correct safety and operation this machine must be installed and maintained by an authorised Service Engineer Should any cover or safety interlock be damaged the machine must not be used until service repairs have been completed This machine must be grounded Wire colors in the power cord are 110 120V 220 240V Connect to Green Green Yellow Ground Earth White Blue Neutral Black Brown Live Line This machine must not be used if the power cord is damaged It must be replaced with a similar power cord UK Part no 162 210 EURO Part no 162 311 US Part no 162 321 For continued protection against risk of fire replace with the same type and rating of fuse The fuse rating and type for this machine is 110 120V T62. 3A 250V Part no 135 106 220 240V T3 15A 250V Part no 135 103 6 Model Details Model name Pressure Sealer Model number AS900 Input voltage 110 120V 60Hz 220 240V 50Hz Input current 6 Amps 3 Amps Input power 720 Watts 720 Watts Sound output 80dBa 80dBa measured at 1 meter from the cover and 1 6 meters from the ground Weight 390lbs 176kg unpackaged 4601bs 210kg packaged with accessories Lifting or handling must only be carried out by competent persons using appropriate means 7 The use for the machine is pressure sealing documents Distributor and Service contact ISSUE 1 APR 2003 Page 1a i z World Leaders AS900 PRESSURE SEALER Operating Instructions DONNEES TECHNIQUES DE LA MACHINE 1 ATTENTION 2 ATTENTION 3 ATTENTION 110 Vert Blan Noir 4 ATTENTION 5 ATTENTION 110 220 6 Sp cifications Afin de garantir un fonctionnement en toute s curit cette machine doit tre install e et entretenue par un technicien agr S1 le couvercle ou le m canisme de blocage de s curit est endommag ne pas utiliser la machine tant que les r parations n ont pas t effectu es Cette machine doit tre raccord e la terre Les fils de couleur du c ble d alimentation sont 120V 220 240V Connect Vert Jaune la terre masse c Bleu au neutre Brun la tension Cette machine ne doit pas tre utilis e si le c ble d alimentation
3. TO SAFETY MICROSWITCHES Access to the outfeed roller area can be gained by removing the guide static brush carrier Replace before running machine Outfeed guide fixings Page 13 ISSUE 1 APR2003 Fi World Leaders AS900 PRESSURE SEALER Operating Instructions 2 4 DOUBLE DOCUMENT CONDITION If more than one document is fed at one time such as if two are stuck together they will not pass through the sealing rollers but will be diverted to the divert chute The machine will stop and an error message Error FR3 will appear on the display The diverted docu ment can be retrieved from the divert chute opening at the rear end of the machine This is the default condition The machine can also be set for an alternative double document condition In this mode when a double document is fed it will be directed to the divert chute and the machine will carry on operating normally The diverted document will not register on the count display If a second double document is then fed immediately afterwards the machine will stop and the error message Error FA3 will appear on the display This alternative mode is selected via a DIP switch on the CPU board and should only be set by a Customer Service Engineer Note that in both modes pressing the start button will restart the machine and clear the dis play which will then revert back to document count If several double documents occur in a short space of time the cau
4. allow the stack to expand When the backstop reaches the end of the track the machine will stop to allow the documents to be removed from the track After removal push the backstop back to its home posi tion by lifting the rollers using the green latch Press the Stop and then the Run button on the machine control panel to resume operating contd ISSUE 1 Page 10 Apr 2003 i z World Leaders AS900 PRESSURE SEALER Operating Instructions 5 When setting up for the first time load one document and press the setup button to begin calibration cycle A messagefgnr CALon the display panel will request confirmation that you wish to calibrate Press again to confirm A message CAL will be momen tarily displayed and the document will be fed The double document and form length sensors will measure the length and average thickness of the document This will act as a gauge for all future documents of that size and hence is only done once until the document size is changed The gauged document will be ejected into the divert chute At the end ofa successful calibration cycle the message CAL PASS will be displayed In the event of a calibration failure the relevant error message will be displayed See section 4 1 Note If the Auto calibrate DIP switch on the CPU circuit board has been set the machine will automatically enter the setup mode either after power up or when re starting after hopper empty condition S
5. est endommag Il y a lieu de le remplacer par un c ble similaire UK N de pi ce 162 210 EURO N de pi ce 162 311 US N de pi ce 162 321 Pour ne pas compromettre la protection contre les risques d incendie remplacer par un fusible de m me type at de m mes caract ristiques nominales 120V T6 3A 250V N de pi ce 135 106 240V T3 15A 250V N de pi ce 135 103 Nom du mod le Pressure Sealer Num ro du mod le AS900 Tension d entr e 110 120V 60Hz 220 240V a 50 Hz Courant d entr e 6A 3A Puissance d entr e 720W 720W Niveau de bruit 80 dBA 80 dBA mesur en ins rant un seule feuille dans une enveloppe une distance de 1 m tre du capot le plus proche et 1 6 m tre du sol Poids 176kg 3901bs d ball e 210kg 4601bs avec accessoires Le levage ou la manipulation de la machine ne peut tre effectu que par des personnes qualifi es utilisant l outillage appropri 7 Cette machine est con ue tout sp cialement pour fermer avec la pression les documents Page 1b ISSUE 1 APR 2003 Fi World Leaders AS900 PRESSURE SEALER Operating Instructions 1 1 TECHNICAL SPECIFICATION Machine type Medium volume pressure sealer Speed Variable up to 8500 documents per hour based on 8 2 x 11 Z folded documents Volume to a maximum of 15 000 documents per day 70 000 documents per week 250 000 documents per month 3 million documents per year Document dimensions folded
6. friction First fold is up the vertical plate Second fold is up the vertical plate There is no nesting feature S9ZIS WOJ posn Ajquonbo J owios 107 Sd un308 29E d PLO SH SAJEJIPUI MOOG UMOUS ISH SU L 11V1S HHNSSHdd 006SV SUORONJIJSUJ SUINLIIdG EEE Z z gt md je io z td QO am Z O f re x S 3 f World Leaders AS900 PRESSURE SEALER Operating Instructions 4 Set the rollers and adjustments of the High Capacity Output Conveyor as shown below Roller bar Documents Sliding backstop Adjustable stop Speed control Setthe roller bar so that the leading edge of the documentreaches the nip of the roller while the form is still being fed out of the machine This will provide grip against the conveyor belt and feed the forms into the stacker Adjust the speed control so that the forms are overlapping each other by about half their depth as they travel along the top surface Slacken the lockscrews at each end of the adjustable stop and slide it so that there is 3 4mm clearance above the leading edges of the documents as they are fed into the upright position As the documents stack up on the output side the sliding backstop will automatically increment to
7. incorrectly set ii Documents sticking together ISSUE 1 APR2003 Possible remedy Adjust separator as in section 2 1 para 2 Possible remedy Clean allrubberrollers as in section 3 2 Possible remedy 1 Reset side guides ii Check forms and re stack iii Remove damaged documents Possible remedy i Re measure fold lengths and re adjust as shown in section 2 1 para 3 ii Reset side guides iii Adjust squareness of stop as shown in section 2 1 para 3 Possible remedy i Test documents from a different batch 11 Contact service department Possible remedy i Adjust separator as in section 2 1 para 2 ii Rifle document stack contd Page 16 i World Leaders AS900 PRESSURE SEALER 7 Double documents fail to divert Possible cause i Documents jamming in diverter ii Diverter not working 8 Double document will not set Possible cause Documents already held in hold point 9 Documents jamming on output conveyor Possible cause Roller position onconveyorset incorrectly 10 Bad folding or jamming in folder Possible cause Folderrollersneed cleaning 11 Error message showing on display panel when there are no documents in machine Possible cause 1 Dirty sensors ii Cover s not properly closed 12 Forms jamming behind back stop on High Capacity Conveyor Possible cause Adjustable stop incorrectly set Operating Instructions Possible remedy i Check edges of d
8. HE RED EMERGENCY STOP KNOB ADJACENT TO THE CONTROL PANEL ISSUE 1 Page 12 APR2003 i z World Leaders AS900 PRESSURE SEALER Operating Instructions 2 2 HANDFEED OPERATION If required a single document may be hand fed for sealing only First fold the document as desired see previous section and place it in the folder bypass chute immediately in front of the folder cover Press the handfeed button n and the folded document will pass through the sealing rollers SE Insert document crease downwards 2 3 CLEARING A DOCUMENT JAM A document jam may be caused by a number of conditions such as a damaged or crumpled edge incorrect fold etc Whatever the cause a jam will result in the machine stopping auto matically and an error message will be shown on the display panel To free the jammed document switch the machine off raise the folder and feed roller covers to ascertain the position of the jammed form This will determine whether the form should be moved forwards or backwards to clear the rollers for retrieval Close the covers switch back on and press the jog forward gt or jog backwards 4 buttons as required This will oper ate the machine in short slow spurts to clear an edge of the damaged document Raise the covers again and pull the freed document out It may be necessary to repeat this operation more than once until the damaged document is fully clear NOTE THE MACHINE WILL NOT RUN WITH THE COVERS OPEN DUE
9. eed in steps up to 9 shown on speed indicator display Speed indicator Indicates speed in steps from 0 to 9 max Setup button Feeds through a single document in order to calibrate document length and weight This is for double document detection Document is diverted before sealing to enable fold lengths to be checked Hand feed button Allows single document to be fed through pressure rollers Note document must be pre folded by hand and placed in folder bypass chute Jog reverse button Jogs document back through machine in small steps Used for clearing jams Note after operating there is a 2 second pause before button can be operated again Jog forward button Jogs document forward through machine in small steps Used for clearing jams Note after operating there is a 2 second pause before button can be operated again Zero reset in count button Zeroes counter display for documents fed in machine must be stopped Note count will maintain until zero reset is pressed even when machine is stopped or switched off Zero reset out count button Zeroes counter display for documents fed out machine must be stopped Note count will maintain until zero reset is pressed even when machine is stopped or switched off Display panels Displays in or out count and also error messages Page 4 j World Leaders AS900 PRESSURE SEALER Operating Instructions 1 4 MACHINE LAYOUT DIAGRAM The following diagram
10. etting of the switch is not an Operator function it must be set by a Cus tomer Service Engineer Page 11 ISSUE 1 APR 2003 f World Leaders AS900 PRESSURE SEALER Operating Instructions 6 Place a stack of documents in the insert tray Forms must be orientated according to fold type and print direction Ensure that the leading edges of the stack of forms are against the stack guide Adjust the stack bridges to support the backs of the forms Further re adjustment may be required for reliable feeding 7 Set the required speed using the speed increase or speed decrease buttons The speed increments in steps 0 9 as shown on the indicator panel between the two buttons The speed may be varied whilst machine is running 8 Now that form calibration fold plates and speed are all set press the start button cz and the documents will begin feeding Note that the count of the documents fed in and fed out is displayed on the left and right display panels respectively When the run of documents has finished either or both of the count displays may be zeroed by pressing in count or out count buttons Zoa 9 When the document run has finished or the feeder tray runs out the machine will stop operating after about 3 seconds and the message Error FA will show on the display Press the stop button to clear the display NOTE IN THE EVENT OF ANY EMERGENCY OR TO STOP THE MACHINE FOR ANY OTHER REASON PRESS T
11. flat 4 9 5 102 241mm RSS RE SS ee se 178 356mm 14 7 Electrical Specification 230v 115v Current 3A 6A Fuse T3 15A T6 3A Sound Level 80 dBA measured at 1 metre from nearest cover and 1 6m from the ground ISSUE 1 Page 2 APR 2003 i z World Leaders AS900 PRESSURE SEALER Operating Instructions 1 2 CONTROL PANEL LAYOUT 12 10 11 12 Stop button Start button Speed decrease button Speed increase button Speed indicator Setup button Hand feed button Jog reverse button Jog forward button 10 Zero reset in count button 11 Zero reset out count button 12 Display panels O PTO gI R OE A detailed description of each button function is given in the following section Page 3 Issue 1 APR 2003 f World Leaders AS900 PRESSURE SEALER Operating Instructions 1 3 BUTTON EXPLANATION 1 Po i j 2 ITN 4 un m 10 20 ll vr 12 Hoodoo ISSUE 1 APR 2003 Stop button Allows documents currently passing through machine to continue to output then halts operating cycle Start button Starts machine into continuous running and also cancels any errors which may be indicated after the cause of the problem has been cleared by the operator Speed decrease button Decreases speed in steps down to 0 shown on speed indicator display Speed increase button Increases sp
12. ide out fold plate 2 Turn it round the other way and also turn it over then slide it back into position This then acts as a blanking plate and the document will bypass it Set the stop of fold plate 1 to half the length of the document The three types of fold which may be used are shown overleaf Page 7 ISSUE 1 APR2003 Fi World Leaders AS900 PRESSURE SEALER Operating Instructions Below are shown the three types of fold which may be used 1 Letter or Wallet Fold R i 2 3 EM 2 1 Issue 1 Page 8 APR2003 6 o6e4 002 dY anss FOLD FOLD FORM TOP MID BOT FINAL DEPTH PANEL PANEL PANEL FORMS LOADED INTO HOPPER PLATE PLATE ADDRES 1 2 FOLD STYLE Tar sae aa s Mato Parton Tan aas w 3 11 16 311 16 3 5 8 Address Panel Down Internal Panel 3 5 8 3 11 16 Leading Eccentric C Ceridian 33 4 313 16 37 16 Address no Infemal Rane 37 16 313 16 414 414 21 2 Address Panel Down 8 Trailing 81 2 41 4 B ff k k R kW W GB l Z Return Envelope 42 3 42 3 42 3 Address Panel Down amp Trailing 91 3 42 3 Z Return Envelope 42 3 42 3 42 3 Address Panel Up 8 Leading 91 3 42 3 C Ret Env Xplor 97 43 8 413 16 4 13 16 Address Panel Down 8 Trailing 43 8 4 13 16 14 Double V Ret Env 4 6 3 4 7 1 4 Address Panel Down amp Trailing 6 3 4 3 5 8 Down Notes Forms feed from bottom of stack by
13. may require cleaning Ouput sensor blocked If no visible obstruction sensor may require cleaning Conveyor jog switch has been operated Conveyor full condition detected contd ISSUE 1 APR2003 Page 19 z i i World Leaders IN MAILROOM TECHNOLOGY AS900 PRESSURE SEALER Operating Instructions E 3 A Diverter has actuated but document has not passed through error MA Document may be damaged and stuck in diverter E rren m 100 Document jammed in feeder rollers Clear jam before continuing E Fra r J Ags Document jammed in folder rollers Clear jam before continuing E rro r JAY Document jammed in sealer rollers Clear jam before continuing E rror J AS Document jammed on conveyor Clear jam before continuing 0 PEA Folder cover open 0 p E r B c Sealer roller cover open FAIL 5 E Motor has failed to start Contact the Service Department F 4 IL 5 E c Motor has stalled Contact the Service Department F Ai L 5 E 2 Motor has failed to stop Contact the Service Department contd ISSUE 1 Page 20 APR 2003 i z World Leaders AS900 PRESSURE SEALER Operating Instructions Of the following three messages in the left hand display panel any of the five messages shown below may occur in the right hand display ict Unexpected arrival at a sensor Remove all documents passing through machine and restart cycle If message still occurs c
14. ocuments for curling or damage ii Solenoid malfunction contact Service Dept Possible remedy Open covers and remove offending document If necessary use jog buttons as described in section 22 Possible remedy Resetroller as shown in section 2 1 para 4 Possible remedy Clean folder rollers as in section 3 2 Possible remedy 1 Clean allsensors Refer to sections 3 2 for sensor positions ii Check both top covers are fully closed Possible remedy Ensure stop is not set too low see section 2 1 Page 17 ISSUE 1 APR 2003 Fi World Leaders AS900 PRESSURE SEALER Operating Instructions 3 2 OPERATOR MAINTENANCE After a period of running especially if the machine is heavily used the sensors will tend to become obscured with paper dust This may lead to erratic operation of the machine and so the sensors must be regularly cleaned This particularly applies if the machine appears to be malfunctioning in any way and cleaning of the sensors should always be carried out before alerting the Service Department of any faults The sensors should always be cleaned before starting a long continuous machine run The locations of the sensors are illustrated below 2 3 5 1 Folder Input Sensors 4 Divert Sensors 2 Folder Output Sensors 5 Doubles Detect Sensors 3 Output Sensors 6 Folder Hold Point Sensors ROLLER CLEANING At the same time that the sensors are cleaned all visible rubber rollers and feed wheel
15. on tact the Service Department Unexpected departure from a sensor Remove all documents OR passing through machine and restart cycle If message still occurs contact the Service Department r Kg Ff Document tracking failure Remove all documents passing through machine and restart cycle If message still occurs con tact the Service Department C ny LL Pertaining to folder input sensor r s Pertaining to folder output sensor m N ru Pertaining to roller sensor W Pertaining to hold point sensor m Li Pertaining to divert sensor Page 21 ISSUE 1 Apr 2003 z i i World Leaders AS900 PRESSURE SEALER Operating Instructions BLANK PAGE Issue 1 Apr 2003 Page 22
16. s should also be cleaned Ensure that the roller and wheels are cleaned round their full circumference ISSUE 1 Page 18 APr 2003 FEE AS900 PRESSURE SEALER World Leaders IN MAILROOM TECHNOLOGY Operating Instructions 4 1 CONTROL PANEL ERROR MESSAGES If any of the following error messages occur do not attempt to continue the run but switch off the machine and take the remedial action stated If this or any other obvious solutions do not clear the fault the service department must be contacted Error FA m cree r IF A c Mao re Er l or t r 2 C o eo Er l ar t r i Error coc LI t oe J 11 1 Error FAG E cro rj FAT E Crac m RA Eri or FS Ero ceo LI ui Fook 7 Documents not being fed This message occurs if no document is fed after about 3 seconds such as if the feed tray is empty Hand feed load has failed May be caused by incorrect insertion of the document into the hand feed chute Double document feed has occurred and has been diverted Separator gap may be incorrectly set or documents need rifling Attempt to divert a double document has failed and document has passed through sealing rollers instead Diverter solenoid may be stuck Folder input sensor blocked If no visible obstruction sensor may require cleaning Folder exit sensor blocked If no visible obstruction sensor may require cleaning Divert sensor blocked If no visible obstruction sensor
17. se should be investigated It may be that that the separator is incorrectly set see section 2 1 para 2 or that the stack of documents needs rifling for proper separation 2 5 SUPERVISOR MODE The Supervisor Mode will allow the display of the total machine running time to date The total forms count to date can also be displayed Press the stop and jog forward gt buttons simultaneously to enter the mode Successful entry into the mode will be confirmed by the display SUP INFO Press the jog forward button again to show the total hour count to date to within 1 10th hour in the following format on the display Hour HHHHH Press the jog forward button again to show the total forms count to date as a ten digit number in the following format on the display MAAN ANAAN contd ISSUE 1 Page 14 Apr 2003 i World Leaders AS900 PRESSURE SEALER Operating Instructions Press the jog forward button again to show the stacker pulse delay time in seconds the exam ple display shows 2 second delay time PdL 200050 The delay time can be adjusted by pressing the or o buttons Press the jog forward button again to show the stacker pulse length time in seconds the example display shows 0 8 seconds length time PLEn 20080 The length time can be adjusted by pressing the or buttons Press the jog forward button again to cycle back tothe SUP AFO display Press the jog forward button again to adj
18. shows the main parts of the AS900 Pressure Sealer Full details of any adjustments or setting required for the parts are shown in Section 2 1 onwards OLDING ROLLERS JF RESSURE ROLLERS Page 5 Issue 1 APR 2003 Fi World Leaders AS900 PRESSURE SEALER Operating Instructions 2 1 MACHINE SETUP AND OPERATION 1 Plug in machine switch on at power switch and release emergency stop button 2 Adjust the separator gap to suit the document form as shown below Turn the separator adjustor until there is sufficient gap between the grip roller and the pick up roller below it to allow one form only to pass through This is achieved by moving the form back and forth between the rollers until resist ance is just felt and the rollers lightly grip the form Stack guide Grip roller Centrally place a form inthe insert tray and move both side guides to leave a gap of 1 16 1 2mm either side of the form Note guides will self center Stack bridges Insert tray 3 Establish fold type and length required raise the folder cover and set the fold plates as described below Fine adjustment knob Lock screw Squareness adjuster Fold plate 1 Pointer align f W inside edge ALI THR wth scale p Stop ET i E Li ee U U ser le Fold plate 2 contd ISSUE 1 Page 6 APR 2003 i z World Leaders AS900 PRESSURE SEALER Operating Ins
19. tructions The fold plate stops are adjusted by loosening the lock screws sliding the stop to the required position as indicated by the pointer against the scale and retightening the lock screws A fine adjustment is provided by turning the knob shown This will adjust the fold position by small amounts if a running test shows this to be needed Additionally the squareness of the stop can be adjusted by loosening the squareness adjuster lock screw and turning the knurled cam knob below it This may be required if running tests reveal that the documents are being folded skewed Retighten the lock screw after any adjust ment is made The scales accord with the exact measured position of the required fold on the document and the inside edge of the pointer is aligned with the scale measurement see diagram on previous page For example if the first fold is required at 4 102mm down from the leading edge of the document set fold plate 1 at this position The crease then becomes the leading edge for the second fold position so if the second fold is required at 4 2 114mm from the crease set fold plate 2 at this position Note that if the squareness adjuster has been moved at any time the pointer position will change and this will have to be compensated for when measuring fold positions Running tests will reveal to what extent The fold plates are removable and are retained by clips If the document requires only a single center fold sl
20. ust the pulse delay of the High Capacity Conveyor The message PgEL nnn appears on the display where n nn is the time in seconds adjusted in 10ms steps by pressing the or buttons Press the jog forward button again to adjust the pulse length of the High Capacity Conveyor The message PLEn nnn appears on the display where n nn is the time in seconds adjusted in 10ms steps by pressing the or buttons Both Pulse delay and Pulse length are used to adjust the movement of the Conveyor relative to the machine in order to control the looseness of the folded insert stack Press the stop button to exit Supervisor Mode Page 15 IssuE 1 APR2003 f World Leaders IN MAILROOM TECHNOLOGY AS900 PRESSURE SEALER Operating Instructions 3 1 OPERATOR S TROUBLESHOOTING GUIDE 1 Documents not feeding Possible cause Separator gapincorrectly set 2 Slow feeding of documents Possible cause Feedrollersneed cleaning 3 Documents jam in folder Possible cause i Side guides incorrectly set ii Documents incorrectly stacked iii Curled or damaged edges on document 4 Documents incorrectly folded Possible cause i Fold lengths set too long or short ii Side guides set too wide iii Documents out of square skewed 5 Documents not sealing Possible cause 1 Defective adhesive on document ii Sealing rollers incorrectly set 6 Repeated double document condition Possible cause i Separator gap
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