PSMailers PSM7000 Operating Manual

PSMailers
™
PSM7000
Operating Manual
A Message to Our Customers
Thank you for purchasing the PSM7000. The PSMailers
product line is the result of over 30 years of experience in
the document processing industry. Through interfacing with
customers like yourself and from hands-on experience in the
field, our Research and Development Team has focused on
a solution providing both the dependability you expect from
today’s technology, while returning operational efficiency to
your organization.
The result of our experience and research is a powerful tool to
improve your bottom line. We hope you enjoy this machine.
User comments and suggestions are always welcomed by our
development team.
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Table of Contents
Operator Safety ................................................................... 5
Specifications ...................................................................... 6
Unpacking & Setup ........................................................... 7-8
Unpacking .......................................................................... 7
Setup .................................................................................. 8
Machine Overview .......................................................... 9-11
Machine Diagram ............................................................... 9
Capabilities ......................................................................... 9
Controls ............................................................................ 10
Fold Plates ........................................................................ 11
Identifying Your Fold .....................................................11
Feed Table Setup .......................................................... 12-15
Setting the Paper Guide Width ......................................... 12
Setting the Feed Gauge ................................................... 13
Setting the Exit Guide Wheels .......................................... 14
Setting the Fold Plates ..................................................... 15
Machine Operation ....................................................... 16-18
Loading the Feed Table .................................................... 16
Operating the PSM7000 .....................................................17
Operating in Batch Mode (Optional Counter) ..................17
Setting the Batch Total ...........................................17
Running in Batch Mode .........................................17
Resetting the Batch Count ....................................18
Operating in Manual Mode ...........................................18
Resetting the Count.......................................................18
Maintenance ...................................................................... 19
Troubleshooting ............................................................ 20-23
Automatically Clearing a Paper Jam ................................ 20
Manually Clearing a Paper Jam ........................................ 20
Diagnosing the Paper Jam ...........................................21
Misaligned Folds .............................................................. 21
Paper Feed Problems ....................................................... 22
Double Feeds ...............................................................22
Won’t Feed ...................................................................23
Machine Won’t Run .......................................................... 23
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Operator Safety
•
Please review and follow all the safety precautions to
ensure safe equipment operation. The user is responsible for
safe operating conditions. Read all operating instructions prior
to operating machine.
Warning: Do not attempt to handle the equipment alone. It
requires two people to handle and lift the equipment out of
the packaging.
Warning: This unit contains moving parts. Watch for Caution,
Warning, and Electrical stickers detailing proper operating
conditions and user safety.
•
Never remove guards or product safety switches. Removal of
guards or switches will cause the unit to run improperly and
can result in personal injury.
•
Keep all hands, fingers and objects away from moving parts.
Never attempt to reach into the machine while the power is
on. Turn off the machine and disconnect the power cord before
cleaning or servicing the machine, and before removing either
fold plate. Injury may occur if proper operating procedure is
not followed.
•
Plug the power cord into 115 VAC, 60 Hz outlet only. Voltage
up to 120 V will not damage the machine.
•
The power cord and plug must be accessible at all times for
disconnection.
•
This unit is equipped with a 3-wire, grounded electrical cord.
If the cord becomes damaged and needs to be replaced, it
must be replaced with an authorized part available through
the manufacturer or an authorized service agent.
•
All machine maintenance should be performed only by factory
authorized service personnel using factory authorized replacement parts. Contact your sales rep for more information.
•
Keep the PSM7000 away from extreme heat and moisture.
•
Never operate the PSM7000 while tired, drowsy, or under
the influence of medication, drugs, or alcohol. Failure to do
so can result in personal injury.
•
Never operate the PSM7000 with loose clothing or jewelry.
Contain all long hair and neck ties prior to operating machine.
Failure to do so could result in clothing, jewelry, or hair
becoming entangled in moving parts.
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Specifications
The PSM7000 is designed to fold and seal up to 7,000 documents
per hour, ensuring a good seal and a clean fold on every form,
every time, whether the paper is perforated or plain.
The adjustable fold plates allow the machine to meet your
changing document processing requirements. Below are the
detailed machine specifications.
PSM7000 Specifications
Variable Speed
Yes, 7,000/hour
Duty Cycle
75,000 sheets/month
Fold Types
C, V, Z, EZ, EC return envelope
Fold Patterns
11˝ Half (V)
14˝ Half (V)
11˝ Letter (C)
14˝ Return Envelope (EC)
11˝ (Z)
14˝ (Z)
14˝ Eccentric Z (EZ)
Paper Sizes
Up to 14˝ long, up to 8.5˝ wide
Counter
Manual/Batch
Conveyor
18˝ conveyor included
Feed System
Bottom feed system
Drive System
AC fixed
Electrical
115 VAC, 60 Hz, 5A
Dimensions
12˝H x 21.5˝W x 30˝D
Weight
70 Lbs.
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Unpacking & Setup
Unpacking
When opening the PSM7000 packaging, inspect it for any
shipping damage. The shipper should be notified at once and
the packing materials saved if there is any serious damage.
Warning: Do not attempt to remove the equipment from
the packaging alone. Two people are required at all times
to remove packaging and move the equipment.
Please make sure the following items are present in the packaging.
If any items are missing please contact your sales rep before
continuing.
1. This manual (1)
2. PSM7000 (1)
3. AC Power Cord (1)
4. Upper & Lower Fold Plates
(1 each)
5. Paper Guides (2)
Figure 1: Upper Fold Plate
6. Tool Kit
a. Breaker Bar
b. 7/16˝ Socket
c. 3/16˝ T-Handle Hex Driver
Figure 2: Lower Fold Plate
Figure 3: PSM7000
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Unpacking & Setup
Setup
Warning: Do not attempt to remove the equipment from
the packaging alone. Two people are required at all times to
move the equipment.
Place the PSM7000 on a sturdy table or cart. Check to verify that
both fold plates are properly installed (see Figures 4 & 5). Both fold
plates should rest snugly on the placement pins.
First insert the power cord into the PSM7000 and then into a
standard 115 VAC, 60 Hz outlet.
The power cord must be accessible for disconnect.
Figure 4: Upper Fold Plate
in Proper Position
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Figure 5: Lower Fold Plate
in Proper Position
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Machine Overview
Machine Diagram
Lower Fold Plate
(back of unit,
not shown)
Paper Guides
Feed Table
Control Panel
Feed Gauge
Upper Fold
Plate
Feed Guide
Adjuster
Knobs
Exit Guide
Wheel
Adjustment
Knob
Conveyor
Catch Plate
Access
Panel
Exit Guide
Wheels
Adjustable
Paper Stops
Figure 6: Machine Diagram
Capabilities
Your PSM7000 is designed to be a versatile folding and sealing
machine. Its capabilities include:
•
Folding plain paper and forms from 20 lb. paper to 80 lb.
stock.
•
Folding all standard fold patterns (see fold diagrams,
page 11).
•
Single fold capability: when the bottom fold plate is in the
half fold position, the upper fold plate can be set to lengths
other than the standard V-Fold depending on your special
needs.
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Machine Overview
Controls
Familiarize yourself with all machine controls prior to
operating the machine.
➊
➎
➋
➏
➌
➐
➍
Figure 7: Control Panel
The PSM7000 Control
Panel has 7 buttons and
a 2-line digital display to
communicate with the user
(Figure 7). When the machine
is turned on, the display looks
like Figure 8.
➊
Figure 8: Default Mode
Reverse button is used to clear a jam (lower fold plate must
be removed).
➋ & ➌ Speed Up / Speed Down buttons are used to set the
Batch Count.
➍
➎
➏
➐
10
Run button is used to start the machine.
Mode button cycles through the operating modes.
Clear button is used to clear counts.
Stop button is used to stop the machine
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Machine Overview
Fold Plates
The PSM7000 is equipped with adjustable fold plates. The red
thumbscrews can be loosened to allow you to move the paper
stop to the correct position for your form, then tightened to hold
the stop in place. All standard folds are marked on the scales of
both the upper and lower fold plates. Set both fold plates to the
desired setting (i.e. 11˝ Z-Fold) in order to perform that fold.
See Setting the Fold Plates (page 15) for more information.
Identifying Your Fold
1. Identify your paper size. 11˝ forms are the standard letter
size; 14˝ forms are the standard legal size. Measure the
form if necessary.
2. Identify the fold shape from the diagrams below.
Note: The Eccentric Z (EZ) and the The Eccentric C (EC)
folds are a similar shape as the standard Z-Fold and C-Fold,
but the lengths of the folds are not equal.
C-Fold
V-Fold
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Z-Fold
EZ-Fold
Eccentric Z-Fold
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EC-Fold
Eccentric
C-Fold
PSM7000
11
Feed Table Setup
Setting the Paper Guide Width
1. Loosen the Feed Guide Adjuster Knobs but
don’t fully remove them (1-2 turns clockwise
will loosen them).
2. Place a 1/2˝ stack of the form to be run on
the feed table.
3. Line the paper stack up against the
stationery paper guide.
4. Push the moveable paper guide up against the paper stack
so all the paper is aligned and the paper guide is snug
against the side of the stack.
5. Hold the moveable paper guide in place with one hand and
tighten the feed guide adjuster knobs with the other.
Paper Guides
Feed Guide
Adjuster Knobs
Figure 9: Feed Table Paper Guide Adjustment
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Feed Table Setup
Setting the Feed Gauge
Make sure that the power switch is in the off position.
Feed Gauge
Adjustment Screw
To properly
set the Feed
Gauge
System,
refer to
Figure 10.
Feed Gauge Belt
Feed Gauge Roll
(#3 Roller)
Move Feed Belt,
with your hand,
in this direction
to hand feed the
form into the
machine
Figure 10: Feed Gauge Cross Section
1. Remove all paper from the feed table.
2. Insert the provided 3/16˝ T-Handle Hex Driver (inside tool kit)
into Feed Gauge Adjustment Screw.
3. Turn the T-Handle 1/4 turn clockwise to loosen the Feed
Gauge Wheel.
4. Place one form on the feed table and hand feed the form
about 2˝ into the machine by moving the feed belt with
your hand.
5. Turn the T-Handle 1/4 turn counter-clockwise.
6. Pull the paper out of the machine. You should feel resistance,
but not too much. Repeat steps 4-6 until there is a moderate
amount of resistance when pulling the form out. If it feels too
tight, turn the T-Handle 1/4 turn clockwise.
7. Return the T-Handle to the tool kit.
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Feed Table Setup
Setting the Exit Guide Wheels
Exit Guide Wheel
Adjustment Knob
Exit Guide Wheels
Figure 11: Exit Guide Wheels
The placement of the Exit Guide Wheel is important for the
proper functioning of the conveyor (see Figure 11). To set the
location:
1. Take a folded form and place it so one edge is just touching
the steel roll.
2. Loosen the red Exit Guide Wheel Adjustment Knob.
3. Move the Exit Guide Wheels so they just touch the front
edge of the form (see Figure 12).
4. Tighten the Exit Guide Wheel Adjustment Knob.
Folded Forms
Figure 12: Exit Guide Wheel Adjustment
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Feed Table Setup
Setting the Fold Plates
1. Remove the fold plate from the machine.
2. Loosen the thumbscrews by turning
counter-clockwise
3. Line up the tips on both
sides of the paper stop
with the appropriate line
on the scale so that the
appropriate white line on
the scale is just visible
(see Figure 13).
Paper Stop
Indicator Point
Figure 13: Paper Stop Alignment
a. If you are doing a V-Fold, you do not have to set the
paper stop on the Lower Fold Plate.
4. Make sure that the paper stop is set up square by doublechecking that the scales on both sides show the same fold
selected or the same inch reading.
5. Tighten the thumbscrews, being careful that the paper stop
does not slide out of square.
6. Return the Fold Plate to the machine, making sure it is
resting properly on the placement pins.
a. If you are doing a V-Fold, replace the Lower Fold Plate
backwards, so that the flat face is facing in and the slot
is facing out.
For a custom form, the fold plate scales measure distance
in inches from the fold, so the paper stop can be set to the
appropriate measurement. If you are unclear about which
figures to use, measure the lengths of the folds on your form
(the distance from the perforations or fold marks to the edge of
the paper) or contact your sales rep for more information.
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Machine Operation
Loading the Feed Table
Before loading the feed table, square up the stack of paper you
are going to load by placing it on edge on a flat surface. Place the
stack onto the table so the front of the stack butts up against the
feed gauge cover (do not push hard).
The proper orientation of the paper when loaded onto the feed
table depends on the type of fold you are doing and the layout
of your form. The diagrams below show the order in which folds
will be performed when run through the machine with the righthand paper edge being loaded into the machine first (red arrow
shows paper path).
All forms should be loaded with glue on the leading edge facing
up (the glue is usually visible as yellow, blue or red stripes
around the edge of the form). With Z- and EZ-Folds you have
multiple ways to load the form and still have glue on the leading
edge facing up, either one will work. With EZ-Folds though, care
must be taken to ensure the upper fold plate is set to the proper
length for the leading fold (the bottom fold plate setting remains
the same either way).
Feed Table Capacities
11˝ Forms: 150 Sheets; 14˝ Forms: 100 Sheets
➋
➊
➋
➊
Z-Folds & EZ-Folds
➊
V-Folds
C-Folds & EC-Folds
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Machine Operation
Operating the PSM7000
The PSM7000 can operate in two modes: Manual and Batch.
•
Manual Mode: the machine runs forms and keeps a running
count until stopped by the operator.
•
Batch Mode: the Batch Total is set and the machine runs
forms until the Batch Total is reached, at which point the
machine stops.
Operating in Batch Mode (optional counter)
To enter Batch Mode, press
the Mode button until the
screen displays Batch Mode
(Figure 14).
Setting the Batch Total
Figure 14: Batch Mode
1. Make sure that the machine is in Batch Mode
2. Use the Up or Down button to change the Batch Total
(displayed in the lower right corner of the screen). Both
buttons can be held down to continuously change the
count, and if the change is over 20, holding the button
down causes the count to change in steps of 10, though
at this point releasing and pressing the button once will
still increase the count one at a time.
3. Press the Mode button once to lock in the number.
Running in Batch Mode
When the Batch Total is set, press the Run button to start the
machine. The machine will run and the Batch Count of forms
processed will be displayed in the middle of the lower line of
the screen (Figure14). Press Stop to stop the machine. This
will not reset the Batch Total or the Batch Count. Press Run
again to start the machine.
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Machine Operation
Resetting the Batch Count
The Batch Count is the running tally of forms processed for this
batch. To reset it during or at the end of a batch, press the Clear
button. The screen will ask you to confirm the reset by pressing
the Clear again. Pressing any other button will cancel the reset.
Operating in Manual Mode
To enter Manual Mode, press
the Mode button until the
screen displays Manual Mode
(Figure 15).
Resetting the Count
Figure 15: Manual Mode
To reset the count when in Manual Mode press the Clear button.
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Maintenance
Regular maintenance on the PSM7000 will ensure the machine
continues to function properly and will extend the life of the
machine. Perform the following steps every 10,000 forms or
once a month:
1. Disconnect the power cord from the machine.
2. Remove both fold plates.
3. Vacuum any paper dust or toner that has accumulated on
the feed table and on the rollers.
Make sure that the power cord has been disconnected
before continuing!
4. Open the access panel in the side cover opposite the
control panel.
5. Insert the 7/16˝ socket at the end of the breaker bar (inside
the tool box) over the hex shaped end on the #3 roller
(Figure 10, page 13). This bar can now be used to rotate
the rollers.
6. Clean the stainless steel rollers with a household cleaner
to remove any accumulated toner. As you clean, use the
breaker bar to rotate the rollers so that the entire roller
surface is cleaned.
7. Clean the rubber rollers and the feed belts using a rubber
roll rejuvenator (available at your local office supply store).
Use the breaker bar to rotate the rolls and feed belt as you
clean so all the rubber surfaces are cleaned.
8. Return the breaker bar to the tool kit and replace the access
panel.
9. Replace the fold plates.
10. Make sure that the power switch is in the OFF position.
11. Connect the power cord to the machine.
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Troubleshooting
Automatically Clearing a Paper Jam
If paper becomes jammed in the machine:
1. Remove all paper from the Feed Table.
2. If the Breaker Power Switch has tripped (light is off), flip to
the ON (lit) position.
3. Remove the Lower Fold Plate.
4. Press the Reverse button.
5. The paper should exit from the back (where the lower fold
plate normally sits). If it doesn’t, try pressing the Reverse
button again. If the paper is not moving or you cannot see it,
then you need to manually clear the jam (see next section).
6. Replace the Lower Fold Plate.
Manually Clearing a Paper Jam
1. Disconnect the power cord from the machine.
Make sure that the power cord has been disconnected
before continuing!
2. Remove all paper from the Feed Table.
3. Remove the Lower Fold Plate from the machine.
4. Remove the access panel in the side cover.
5. Place the Breaker Bar socket (inside the tool box) over the
hex end of the #3 roller (Figure 10, page 13).
6. Rotate the breaker bar clockwise until the jammed form is
out of the machine.
7. Replace the lower fold plate.
8. Replace the paper on the feed table.
9. Return the breaker bar to the tool kit.
10. Replace the side cover access panel.
11. Make sure that the power switch is in the OFF position.
12. Connect the power cord to the machine.
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Troubleshooting
Diagnosing the Paper Jam
The table below outlines the different problems which cause
paper jams and the symptoms which will help you to identify
the cause.
Paper Jam Troubleshooting
Causes
Double Feed
Buckled Form
Bad Fold
Two forms folded
together)
• Bad feed gauge
setting
• Too much paper
on feed table
Extra fold in the
form
• Wrong fold plate
setting
Form is crooked
• Feed table
paper guide set
improperly
• Fold plates set
improperly
Turn feed gauge
screw 1/4 CCW
Check both fold
plates to ensure
they are set to the
correct mark on
the scale
Check both fold
plates to ensure
that both paper
stops are square
Solution
Misaligned Folds
If your forms are running through the machine OK but they’re
folding a little bit crooked or are not folding right on the
perforation, you need to tweak the fold plate settings. The
location of perforations on forms generally fluctuates by
about 1/16˝ in either direction. Forms manufacturers do this to
avoid the forms sticking together too much. Because of this
fluctuation, it is sometimes necessary to fine tune the placement
of the paper stop on one of the fold plates. The first step is to
identify which fold plate is misaligned. Watch the form as it is
fed into the machine, and then compare it to the finished form.
If you’re having trouble visualizing which fold is off, refer to the
section Loading the Feed Table (page 16).
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Troubleshooting
Once you’ve identified which fold plate needs to be adjusted,
remove it from the machine. If the fold is crooked, check to
make sure that the paper stop is parallel to the front edge of
the fold plate. Check that the indicator points on the paper
stop indicate the same reading on the two scales of the fold
plate. Also check the feed table to make sure that paper guides
are snug against the paper stack. If the fold is just a bit off of
the perforation, adjust the paper stop by the amount that the
fold is off. If the fold is happening early, then move the paper
stop away from the open end of the fold plate. If the fold is
happening late, then move the paper stop towards the open
end of the fold plate.
Paper Feed Problems
Double Feeds
If you’re having problems feeding two forms at a time
occasionally:
1. Turn the Feed Gauge Adjustment Screw 1/4 turn
counter-clockwise.
2. Try running the forms again.
3. If the problem persists:
a) Try another 1/4 turn on the Feed Gauge
Adjustment Screw.
b) Try reducing the size of the paper stack
on the Feed Table.
c) Try resetting the Feed Gauge.
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Troubleshooting
Machine Won’t Feed
If your machine won’t feed forms through:
1. Try reducing the size of the paper stack on the Feed Table.
2. Try resetting the Feed Gauge.
3. Check for toner build-up on Feed Belts.
Machine Won’t Run
If your machine won’t run when the run/stop switch is operated:
1. Check that the machine Breaker Power Switch is not in the
tripped position. If it is, press it in. If the breaker button will
not stay pressed in, wait a minute and try again.
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