AS800 PRESSURE SEALER OPERATING INSTRUCTIONS
Contents
1. Cos C02 Erro L n incorrectly set or documents need rifling e Fou A E ceo r PAT Attemptto divert a double document has failed and document has passed through sealing rollers instead Diverter solenoid may bestuck Error TOC eer ae Wro Folderinputsensorblocked If no visible obstruction sensor mayrequirecleaning Error FAG gt error CMD Folderexitsensorblocked If no visible obstruction sensor may require cleaning Er c or FA JE aaa A Divert sensor blocked If no visible obstruction sensor may require cleaning Erari FAS w error CAD Ouput sensor blocked If no visible obstruction sensor may require cleaning contd IssuE 1 Page 34 16 Arr 2002 World Leaders AS800 PRESSURE SEALER Operating Instructions Cs si 14 140 CCC Qi J EL I J Diverter has actuated butdocumenthas not passed through Document may be damaged and stuck in diverter Error Hea Documentjammedin feeder rollers Clear jam before continuing 124 4 Document jammed in folder rollers Clear jam before continuing Document jammed insealerrollers Clear jam before continuing 1c Document jammed on conveyor Clear jam before continuing The following messages indicate a machine fault rather than an operating fault 0 PEn H i Folder cover open 0 Pen H c Sealer roller cover open F 0 a 5 Motor has failed to start Contact the2. World Leaders AS800 PRESSURE SEALER Operating Instructions AS800 PRESSURE SEALER OPERATING INSTRUCTIONS CONTENTS SECTION Machine Specification Sheet 1 1 1 Technical Specification 1 1 2 Control Panel Layout 1 1 3 Button Explanation 1 1 4 Machine Layout Diagram 1 2 1 Machine Setup and Operation 1 2 2 Hand feed Operation 1 2 3 Clearing a Document Jam 1 2 4 Double Document Condition 1 2 4 Supervisor Mode 1 3 1 Operator s Troubleshooting Guide Operator Maintenance 1 4 1 Display Panel Error Messages Issue 1 Page gt Arr 2002 World Leaders AS800 PRESSURE SEALER Operating Instructions MACHINE SPECIFICATION SHEET 1 CAUTION In order to ensure correct safety and operation this machine must be installed and maintained by an authorised Service Engineer 2 CAUTION Should any cover or safety interlock be damaged the machine must not be used until service repairs have been completed 3 CAUTION This machine must be earthed The wire colours in the mains cord are Green 110v Green Yellow 220 240V which must be connected to Earth Ground White 110v Blue 220 240v which must be connected to Neutral Black 110v Brown 220 240v which must be connected to Live Line 4 CAUTION This machine must not be used if the mains cord becomes damaged It must be replaced with a similar mains cord Part No 141 162 321 U S PFE Part No 162 210 U K PFE Part No 162 311 EURO 5 CAUTION
3. Indicates speed in steps from 0 to 9 max Setup button Feeds through a single documentin order to calibrate document length and weight This is for double document detection Documentis diverted before sealing to enable fold lengths to be checked Hand feed button Allows single documentto be fed through pressure rollers Note document must be pre folded by hand and placed in folder bypass chute Jogreverse button Jogs document back through machine in small steps Used for clearing jams Note after operating there is a2 second pause before button can be operated again Jog forward button Jogs documentforward through machinein small steps Used for clearing jams Note after operating there is a2 second pause before button can be operated again 10 Zero reset in count button Zeroes counter display for documents fed k in machine must be stopped Note count will maintain until zero reset is pressed even when machine is stopped or switched off Ue Z Zero reset out count button Zeroes counter display for documents 03 fed out machine mustbe stopped Note count will maintain until zero resetis pressed even when machine is stopped or switched off 12 AQAD Display panels Displays inor out count and also error messages IssuE 1 Page 4 APR2002 World Leaders AS800 PRESSURE SEALER Operating Instructions 1 1 4 MACHINE LAYOUT DIAGRAM FOLD BOX FOLDING ROLLERS PRES
4. The diverted document will not register on the count display Ifa second double document is then fedimmediately afterwards the machine will stop and theerrormessage 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 display which will then revert back to document count If several double documents occur ina short space of time the cause should be investigated It may be that that the separator is incorrectly set see section 1 2 1 para 2 or that the stack of documents needs rifling for proper separation 1 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 GUP NFD Press the jo s owa button again to show the total hour count to date to within 1 10th hour in the following formatonthedisplay Hour HHHHH Press the jog forward button again to show the total forms count to date as a ten digit number in the followingformatonthe display nnnn A Anam Press the jog forward button again to cycle back tothe SYP INFO display Press the stop button to exit Supervisor Mo
5. contd Page 13 ane World Leaders AS800 PRESSURE SEALER 7 Double documents fail to divert Possiblecause 1 Documents jamming in diverter ii Diverternot working 8 Double document will not set Possiblecause Documents already held in hold point 9 Documents jamming on output conveyor Possiblecause Roller position on conveyor set incorrectly 10 Bad folding or jamming in folder Possiblecause Folderrollers need cleaning 11 Error message showing on display panel when there are no documents in machine Possiblecause 1 Dirty sensors ii Cover s not properly closed Issue 1 Arr 2002 Operating Instructions Possibleremedy 1 Check edges of documents for curling or damage ii Solenoid malfunction contact Service Dept Possibleremedy Open covers and remove offending document If necessary use jog buttons as described in section 1 2 3 Possibleremedy Resetroller as shown in section 1 2 1 para 4 Possibleremedy Clean folder rollers as in section 1 3 2 Possibleremedy i Clean allsensors Refer to sections 1 3 2 for sensor positions ii Check both top covers are fully closed Page 14 World Leaders AS800 PRESSURE SEALER Operating Instructions 1 3 2 OPERATOR MAINTENANCE After a period ofrunning especially ifthe 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 sensor
6. folded flat 4 9 5 102 241mm E E EEN AAE Seat Se A A A AAT 44 LO I I ro I I I I GORE eg fa aa Sig aaa Daye Ngee ES Oak e es wee a NI N D I I I LD I I I I k I I sF I I Pos oa SS Stes SSS Sets a4 R Issue 1 Page 2 APR2002 World Leaders AS800 PRESSURE SEALER Operating Instructions 1 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 PO ADO OLSSON A detailed description of each button function is given in the following section Page E 3 Issue 1 Arr 2002 World Leaders AS800 PRESSURE SEALER Operating Instructions 1 1 3 BUTTON EXPLANATION 1 an N Stop button Allows documents currently passing through machine to continue to output then halts operating cycle De am N Start button Starts machine into continuous running and also cancels 3 gt J any errors which may be indicated after the cause of the problem has been cleared by the operator 3 Speed decrease button Decreases speed in steps down to 0 shown on speed indicator display Speed increase button Increases speed in steps upto 9 shownon speed indicator display u m Speed indicator
7. the count of the documents fed in and fed out is dis played 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 incount or outcount buttons gt 9 Whenthedocumentrun has finished or the feeder tray runs out the machine will stop operat ing after about 3 seconds and the messageg ror FR 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 THE RED EMERGENCY STOP KNOB ADJACENT TO THE CONTROL PANEL Issue 1 Page z 10 APR2002 World Leaders AS800 PRESSURE SEALER Operating Instructions 1 2 2 HANDFEED OPERATION Ifrequired 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 L and the folded document will pass through the sealing rollers Insert document crease downwards 1 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 ajam will result in the machine stopping automatically 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
8. the stop of fold plate 1 tohalfthe length of the document The three types of fold which may be used are shown overleaf l 1 Page eu a 2062 World Leaders AS800 PRESSURE SEALER Operating Instructions Below are shown the three types of fold which may be used 1 Letter or Wallet Fold 2 1 E F 3 _ gt s 1 Issue 1 pees Page 8 World Leaders AS800 PRESSURE SEALER Operating Instructions 4 Settheoutputconveyorrollers and bridge as shown below Rollerbar Bridge fold outwards Pointer Scale Fold the bridge outwards to provide a stop for the accumulating stack of forms Slide the roller bar to align the pointer with the measurement on the scale that accords with the finished length of the folded and sealed document In most cases this is the same as the length of the second fold 5 When setting up for the first time load one document and press the setup button Y to begin calibration cycle A message CONF CAL onthe display panel will request confirma tion that you wish to calibrate Press again to confirm A message fi will be mo mentarily displayed and the document will be fed The double document and form length sensors will measure the length and average thickness of the document T
9. For continued protection against risk of fire replace with same type and rating of fuse The fuse rating and type for this machine is T 3 15 A Amps 220 240Volts PFE Part No 141 135 103 T 6 3 A Amps 110Volts PFE Part No 141 135 106 6 Model Details Model Name Pressure Sealer Model Number AS800 Input Voltage 220 240 Volts 50 Hz Input Voltage 110 Volts 60 Hz Input current 2 Amps Input current 4 Amps Input Power 480 Watts Input Power 480 Watts Sound Reading 75dBA measured ata distance metre from the nearest cover and 1 6 metres from the ground 7 Theuse for this machine is pressure sealing documents 8 The weightofthismachineis 176 kgs unpackaged 210 kgs packaged with accessories Lifting or handling must only be carried out by competent persons using appropriate means Distributor and Service contact Issue 1 pees Page la World Leaders AS800 PRESSURE SEALER Operating Instructions IMPORTANT NOTICE Before connecting the machine to a power source please read the Machine Specification Sheet opposite Ensure that the power cord is undamaged Issue 1 Arr 2002 World Leaders AS800 PRESSURE SEALER Operating Instructions 1 1 1 TECHNICAL SPECIFICATION Machinetype Low volume pressure sealer Speed Variable up to 6000 documents per hour Volume toamaximum of 7 000 documents per day 21 000 documents per week 1 million documents per year Document dimensions
10. SURE ROLLERS RECEIVING CONVEYOR FEED TABLE N NM SENSORS DIVERT CHUTE Issue 1 Page 5 a 2062 World Leaders AS800 PRESSURE SEALER Operating Instructions 1 2 1 MACHINE SETUP AND OPERATION 1 Pluginmachine switch on at power switch and release emergency stop button 2 Adjustthe 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 Griproller Centrally place a form in the 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 de scribed below Fine adjustmentknob Lock screw Squareness adjuster Fold plate 1 Pointer align inside edge with scale 5 Stop Fold plate 2 IssuE 1 Page _ 6 Arr 2002 World Leaders AS800 PRESSURE SEALER Operating Instructions 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 andret
11. Service Department F A ii 5 EC Motor has stalled Contact the Service Department Fr LI Motor has failed to stop Contact the Service Department z co E L contd Page S 17 Issue 1 Arr 2002 World Leaders AS800 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 L J Unexpected arrival atasensor Remove all documents passing through machine and restart cycle If message still occurs con tactthe Service Department im Mm J Unexpected departure from a sensor Remove all documents passing through mae andrestart cycle Ifmessage still occurs contact the Service Department ma N Eg LU Documenttracking failure Remove all documents passing through machine and restart cycle If message still occurs con tactthe Service Department Pertaining to folder input sensor Pertaining to folder output sensor Pertaining toroller sensor w u Pertainingtohold point sensor a Pertaining to divert sensor l 1 pees Page 18
12. 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 buttons as required This will operate the machine in short slow spurts to clear an edge of the damaged document Raise the covers again and pull the freed document out Itmay be necessary to repeat this operation more than once until the damaged documentis fully clear NOTE THE MACHINE WILL NOT RUN WITH THE COVERS OPEN DUE TO SAFETY MICROSWITCHES Access to the outfeed roller area can be gained Outfeed guide fixings by removing the guide static brush carrier Replace before running machine l 1 Page T A 206 World Leaders AS800 PRESSURE SEALER Operating Instructions 1 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 document 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 documentis fed it will be directed to the divert chute and the machine will carry on operating normally
13. de IssuE 1 Page 21D Arr 2002 World Leaders AS800 PRESSURE SEALER Operating Instructions 1 3 1 OPERATOR S TROUBLESHOOTING GUIDE 1 Documents not feeding Possible cause Separator gap incorrectly set 2 Slow feeding of documents Possible cause Feed rollersneed cleaning 3 Documents jam in folder Possible cause 1 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 i Defective adhesive on document ii Sealing rollers incorrectly set 6 Repeated double document condition Possible cause i Separator gap incorrectly set ii Documents sticking together Possible remedy Adjust separator as in section 1 2 1 para 2 Possible remedy Clean allrubberrollers as in section 1 3 2 Possibleremedy 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 1 2 1 para 3 ii Reset side guides iii Adjust squareness of stop as shown in section 1 2 1 para 3 Possible remedy i Test documents from a different batch ii Contact service department Possible remedy i Adjust separator as in section 1 2 1 para 2 ii Rifle document stack
14. his 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 via the divert chute Atthe end of a successful calibration cycle amessage CAL PASS will be displayed In the event of a calibration failure the relevant error message will be displayed See section 1 4 1 Note If the Auto calibrate DIP switch onthe 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 Setting of the switch is not an Operator function itmust be set by a Customer Service Engineer Page 9 ne World Leaders AS800 PRESSURE SEALER Operating Instructions 6 Placeastack 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 but tons 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 Nowthat form calibration fold plates and speed are all set press the start button gt gt and the documents will begin feeding Note that
15. ightening the lock screws A fine adjust mentis provided by turning the knob shown This will adjust the fold position by small amounts ifa 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 adjustment 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 ifthe first foldis 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 posi tion so if the second fold is required at 4 2 114mm from the crease set fold plate 2 at this posi tion 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 Ifthe documentrequires only a single center fold slide 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
16. s 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 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 Atthe same time that the sensors are cleaned all visible rubber rollers and feed wheels should also be cleaned Ensure that the roller and wheels are cleaned round their full circumference Issue 1 Page Apr 2002 World Leaders AS800 PRESSURE SEALER Operating Instructions 1 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 I i E rror FA Documents not being fed This message occurs ifno document is fed after about 3 seconds such as if the feed tray is empty E A ca Hand feed load has failed May be caused by incorrect insertion error of the document into the hand feed chute N NE gt Double document feed has occurred Separator gap may be
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