Documente Academic
Documente Profesional
Documente Cultură
11/2008
TABLE OF CONTENTS
TOPIC SPECIFICATIONS, UNPACKING & SET-UP CONTROL PANEL OPERATION FOLD PLATE INSTALLATION, ADJUSTMENT SETTING CUSTOM FOLDS SEALER ROLLER CLEARANCE REPLACING INFEED ROLLERS REPLACING SINGULATOR PAD REPLACING SEALER ROLLERS REPLACING CORK PAD REPLACING FOLD ROLLERS BELT ADJUSTMENT AND REPLACEMENT PHOTO EYE REPLACEMENT, SENSITIVITY ADJ DAILY MAINTENANCE, TROUBLESHOOTING DETERMINING FOLD TYPE INSTRUCTIONS FOR FINE-TUNING FOLDS PARTS LIST, SCHEMATIC
PAGE 1 2 2 3 4 5 5 6 6 7 7 7 8 9 - 12 13 14 15 - 24
SPECIFICATIONS
Paper side guides
Top Cover
FUNCTION: The 1500 Pressure Sealer folds and seals many different congurations including C, V, Z and custom folds. It may also use several different sizes of forms. For conguration and/or paper sizes, see listing below.
Maximum foldable paper size: Fold styles: Paper loading capacity: Machine weight Power supply
8.5 W x 14 L (216 W x 356 L mm) C, Z, V and custom folds Up to 150 sheets 24# (90 gsm) 82 lbs. (37 kg) FD model: 120V, 50/60 Hz, 3.5 amps FE model: 220V, 50/60 Hz, 2.5 amps
CONTROL PANEL
1
1 2 3 4 5
Starts machine operation Stops machine operation - Steady green when power is on - Blinks red when cover is open or fault is detected Displays number of forms processed Resets Counter
2
OPERATION
1. Adjust fold plates to desired fold for length of paper (see fold plate adjustment on page 3). To do this, loosen the two thumbscrews (gure 3a & b) on each fold plate. Align center bar (gure 3a & b) so the marks on each side match up. For V folds remove the lower fold plate, turn around 180 and reinstall. 2. Make sure fold plates and cover are reinstalled properly (see page 3). 3. Plug in cord and turn power on (gure 1). 4. Test fold settings. Push the paper feed lever (gure 2) down, place one form onto the in-feed table and press the start button. Examine document and adjust fold plates if necessary (see fold plate adjustment on page 3). 5. Load forms. Push the paper feed lever down and load paper neatly stacked and squared on to the in-feed table. Paper can be stacked up to 300 sheets. Note: Standard Z fold forms can be loaded face up or down with the glue edge leading. All C fold forms must be loaded face up with glue edge leading. 6. Check that the ready light is green and press the start button to begin operation.
Figure 2
Throat
Throat
1. To adjust the rst fold remove the top cover to access the top fold plate. If the rst fold is too long loosen the two thumbscrews on the upper fold plate and slide the bar down. If the fold is too short loosen the thumbscrews and slide the bar up. NOTE: The bar should be on the same marks on each side. 2. To adjust the second fold remove the lower fold plate. If the second fold is too long loosen the two thumbscrews and slide the bar up. If the fold is too short loosen the thumbscrews and slide the bar down. NOTE: The bar should be on the same marks on each side. 3. For quick setup of C, Z , Uneven C and V folds refer to the blue lines on the fold plate. 4. To reinstall the upper fold plate, slide the plate (with thumbscrews facing up and the throat toward the inside of the machine) until the grooves on the underside line up with the four pins on the machine (gure 4a, 4b & 4c).
Figure 4b
Figure 4c
5. To reinstall the lower fold plate, slide the plate (with the thumbscrews facing up and throat toward inside of machine, until it rests on the two silver bars (gure 5a) then turn the the fold plate lock down to lock into place (gure 5b).
Bars
Figure 5a
Figure 5b
Panel A
Panel B
ROLLER CLEARANCE
1. Turn power off and unplug power cord. 2. Loosen locking nuts on the top plates (g. 6). 3. Insert a feeler gauge (0.001) into space between the rollers. 4. Turn adjusting bolts while checking clearance with the feeler gauge. 5. Tighten the locking nuts in place after proper clearance has been set. NOTE: Double-check spacing with feeler gauge. Left to right ne-tuning is required. Figure 6
1. 2. 3. 4. 5. 6. 7. 8. 9.
Turn power off and unplug the power cord. Remove top cover and non-operator cover. Loosen lock bolt inside top cover. Pull up clamp. Remove retaining ring on gear (see folder roller, page 7). Remove gear and chain (see folder roller, page 7). Loosen individual rollers (one screw each). Pull roller bar through each roller in the direction of the removed gear. To reassemble repeat above steps in reverse.
Singulator Pad
Cork Pad Figure 7 1. 2. 3. 4. 5. Remove in-feed rollers (see page 5). Remove rubber singulator pad (g. 7). A screwdriver or knife may be need to pry the pad off. Clean singulator mount. Apply super glue to singulator pad and singulator mount. Apply singulator pad to singulator mount, let sit for at least ve minutes before reinstalling in-feed rollers. 6. Reinstall in-feed rollers (see page 5).
1. Turn power off and unplug power cord. 2. Remove covers and upper fold plate. 3. Remove belts (see belt replacement page 7). 4. Remove top plates by unscrewing four screws. 5. Loosen or remove the ve lower screws on each side. 6. Remove rst roller by lifting up and out of machine. 7. Remove the two springs. 8. To remove second roller tilt stainless steel center plate away from roller. 9. Remove second roller the same way as the rst roller. 10. To reassemble repeat above steps in reverse. 11. Adjust belt tension (see belt replacement page 7).
1. 2. 3. 4. 5. 6. 7. 8.
Turn power off and unplug power cord. Remove covers and remove upper fold plate. Remove control panel. Remove belt (see belt replacement, below). Remove sprocket and chain. Remove bearing springs on both ends of rollers bearing plate (operator side). Pull out rollers. To reassemble, repeat above steps in reverse.
NOTE: Roller clearance must be set before adjusting belt tension. 1. Loosen pivot screw on idler lever. 2. Turn adjusting screw until belt is loose enough to remove. 3. Install new belt. 4. Turn adjusting screw until belt has 5/16 play, tighten pivot screw. NOTE: Be sure not to over tighten belt, it will affect roller clearance
7
Figure 8 A single photo eye (g. 8), located just before the pressure rollers, is used for counting, last form time out and fault/double feed detection. 1. Loosen the screw on the guide plate. 2. Carefully remove the screw and the photo eye. 3. Unplug the wires and discard old photo eye. 4. Reverse the previous step to install the new photo eye. 5. Adjust the photo eye to 1/8 below the guide plate. 6. Tighten the screw to ensure the photo eye does not move.
DAILY MAINTENANCE
1. It is recommended to let forms cool for one-half hour, from the laser printer, before folding and sealing. This allows toner to set on the forms, and static electricity to discharge. A 402 Series Jogger is recommended for best results. The Jogger squares the forms and dissipates heat and static electricity created by laser printers. 2. If toner builds up on the metal sealer rollers, clean the rollers with a lint-free cloth dampened sparingly with a mild household cleaner. 3. Clean in-feed wheels and fold rollers with Formax-recommended roller cleaner & rejuvenator to remove paper dust and toner. A damp cloth with water is the best alternative. CAUTION: Do not use any chemicals other than the roller cleaner & rejuvenator or water.
TROUBLESHOOTING
A. Clearing Paper Jams:
WARNING: Turn machine off and unplug cord from its receptacle.
1. If a jam occurs between the metal rollers remove any remaining forms from the hopper. 2. Open the top cover and remove the upper fold plate. 3. Remove the jam clearing handle (located under the upper fold table), apply the handle to the upper metal roller (gure 9) and turn clockwise until the paper jam is clear. NOTE: Do not turn the roller counter-clockwise to force the forms to exit: rollers may be damaged. 4. Remove the damaged form, return tool to holder and reinstall upper fold plate. 5. Reinstall cover and press the black reset button (gure 10).
Figure 9
Figure 10
Breaker reset
If a jam occurs in the fold plates, remove fold plate and remove paper. Reinstall fold plate.
9
TROUBLESHOOTING
B. Fold Quality Needs Improving:
1. Make sure paper is squared and installed correctly. Side guides should be evenly balanced and snug against the paper. 2. If folds are still incorrect adjust fold plates (see fold plate adjustment on page 3).
Figure 12
10
1. If paper pulls left or right adjust the skew adjuster. To adjust the skew, turn the skew adjuster (gure 13) left or right until the paper is feeding correctly.
Figure 13
3. If double feeding continues to occur, the next step is to check the gate tip pressure. 4. With the in-feed tray pushed down and free of forms, spin the center in-feed roller. You are looking for a minimal drag. 5. Make sure singulator mount is sitting straight on bracket. If crooked, loosen the two screws and adjust until straight. 6. To evaluate operation of the singulator/gate tip assembly: a. Turn off machine and unplug. b. Remove lower fold plate. c. Reach hand up underneath paper feed tray. You will feel the gate tip adjusting screw; back off the screw about 3 turns. d. Press down on the gate tip and remove your nger. The gate tip should go down and spring up again. If it doesnt work smoothly, determine where its binding and correct the problem. NOTE: Increase the spring tension on the singulator assembly by moving the springs up one more notch. 7. After you have determined that the singulator assembly is operating smoothly, readjust the gate tip adjusting screw. Back off pressure on the gate-tip until it moves freely up and down. With paper in-feed tray in lowered position, turn screw to tighten until the gate-tip no longer moves up and down. 8. Reinstall the lower fold plate. Place a stack of unprinted forms on the feed tray and test run. You are looking for consistent feeding with no hesitation and no double feeding. 9. If needed, ne tune adjustments can be made by turning the gate tip adjusting screw in small increments until you get the desired results.
Fuse
Beam Adjust
Beam Lamp
12
Glue
Glue
11 Z Fold 11 Z Fold
Glue
Glue
11 C Fold 11 C Fold
13
Leading Edge
2. Take a folded sheet from the catch tray and lay it on top of a pressure seal form lining the leading edge of this sheet up with leading edge of the pressure seal form.
Fold A
Fold B
Leading Edge
3. If the folds on this test sheet do not line up with the perforated folds on the form, the fold plates need to be adjusted up or down to make the folds line up. Refer to Fig. 1 for a Z fold and Fig. 2 for a C fold. - If fold A on the test form is right of the perforation on the pressure seal form move the top fold plate stop up. If fold A is below move the top fold plate stop fold stop down. - If fold B on the test form is right of the perforation on the pressure seal form move the bottom fold plate stop down. If fold B is to the left move the bottom fold plate stop up.
14
PARTS LIST
3 6
ITEM 1 2 3 4 5 6 -
DESCRIPTION NON-OPERATOR COVER OPERATOR COVER TOP COVER PAPER TRAY EXTENSION FORMAX INLAY W/COUNTER INLAY W/COUNTER SIDE COVER MOUNTING SCREWS 14 MAGNETIC EXTENSION TRAY
QTY. 1 1 1 1 1 1 8 1
15
1500 SCHEMATIC
317-0029 / 317-0051
313-8835 / 313-0057
395-0899
ELECTRICAL COMPONENTS
ITEM -
PART #
DESCRIPTION
QTY. 1 1 1 1 1 1 1 1 1 1 1 1 1
310-0039 POWER SUPPLY CORD 310-0180 WIRE HARNESS 1500 310-0181 WIRE HARNESS LOW VOLT 310-0134 PHOTO EYE HARNESS 311-0087 ROCKER SWITCH 312-7700 SPEED CONTROL 312-0016 SPEED CONTROL (FE 1500 only) 313-8835 MOTOR 313-0057 MOTOR (FE 1500 only) 317-0029 CIRCUIT BREAKER 3.5A 317-0051 CIRCUIT BREAKER 2.5A (FE 1500 only) 319-0096 IEC INLET 395-0899 PROXIMITY SENSOR
16
5 7 4
2
ITEM 1 2 3 4 5 6 7 PART# 360-1686 360-1673 395-0873 316-0011 360-1852 319-0159 373-5869 DESCRIPTION CROSS-MEMBER, REAR BASE CATCH TRAY ASSEMBLY STATIC BRUSH ROLLER GUARD MAGNET, ACTUATOR STATIC BRUSH MOUNTING SCREWS QTY. 1 1 1 1 1 1 2
17
8 7 6 26 27 25 26b
26b
22
10
31 32
30
11
1 2
5 4
ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 PART # 310-0134 360-1700 375-0044 360-1847 395-0884 360-1848 395-0887 395-0885 371-0076 385-0060 360-1687 360-1855 332-0121 378-0115 377-0057 334-0359 360-1728 378-0119 330-0090 DESCRIPTION PHOTO SENSOR HARNESS SENSOR BRACKET SHOULDER SCREW TRAY PUSH DOWN PAPER GUIDE OP SIDE ASSY PAPER TRAY EXTENSION PAPER TRAY ASSY WITH CORK PAPER GUIDE DRIVE SIDE ASSY BUSHING SELF ALIGN VINYL BUSHING CROSS-MEMBER, FRONT CONTROL PANEL MOUNT BRACE SHAFT NUT SELF LOCK 8-32 CURVED WASHER SKEW PIVOT PIVOT BRKT. NUT 1/4 - 28 COLLAR .250
34 28 29
QTY. 1 1 6 1 1 1 1 1 2 2 1 1 1 1 2 1 1 4 1
33
ITEM 20 21 22 23 24 25 26 26b 27 28 29 30 31 32 33 34 -
13
PART # 360-1729 395-0886 395-0881 395-1022 330-0087 331-0145 350-0081 350-0099 352-0009 360-1643 373-5893 360-1685 375-5987 332-0131 360-1846 378-0115 375-0107 376-2805
12
DESCRIPTION SKEW PIVOT BRKT. SKEW ADJ THUMBSCREW FEEDER PAPER RAMP ASSY PAPER TRAY SHAFT SPRING PAPER GUIDE ROLLER ROD, FEED GREY CENTER HARD-COMPOUND FEED WHEEL BLACK SOFT-COMPUND FEED WHEEL CORK PAD RETAINER BRKT. SCREW PPH 6-32 x 3/8 PAPER RAMP GUIDE SCREWS FOR PAPER RAMP GUIDE SKEW ADJUSTMENT SHAFT FEED SHAFT LOCKING BRACKET SHOULDER SCREW NUT CENTER FEED TIRE SCREW FEED TIRE SET SCREW 8 - 32 QTY. 1 1 1 1 2 1 1 2 1 1 1 1 2 1 1 4 1 2
17 16 14 23
32
20 21 15 19
24
18
18
Detail A Shunts 3 7
**
ITEM 1 2 3 4 5 6 7
DESCRIPTION SPRING BRACKET - DR SIDE SPRING BRACKET - OP SIDE FRAME OP SIDE EXTENSION SPRING, 188 O.D. EXTENSION SPRING, 375 O.D. SHOULDER SCREW #8-32 ROCKER SW D.P.S.T. (non-illuminated)
QTY. 1 1 1 2 2 2 1
1
DETAIL A
ITEM 1 2 3 4 5 6 PART # 360-1649 352-0008 334-0358 360-1648 395-0892 342-0079 378-0127 DESCRIPTION SINGULATOR ARM SINGULATOR PAD SINGULATOR MOUNT SINGULATOR BRACKET T KNOB COMPRESSION SPRING FEED RAMP NUT FOR T KNOB QTY. 2 1 1 1 1 1 1
DETAIL A
19
9 10
13
14
15 4 16 17 12 17
5 11
ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 -
1
PART # 395-0761 395-0878 334-0357 342-0063 365-0145 332-0141 365-0146 375-0102 375-0103 378-0118 374-0096 378-6549 365-0201 365-0200 334-0371 377-2611 374-5832 332-0120 375-0088 DESCRIPTION DRIVE ROLLER ASSY. ROLLER, UPPER ASSY. BRACKET SIDE, FRAME CAP. SPRING, BEARING BLOCK PULLEY, 13T .38 PITCH JAM CLEARING TOOL TIMING BELT DOUBLE SIDED BOLT 3/8X1 1/4 SOC. HD. SC 3/8 X 1 1/4 HEX HD. 3/8-40 HEX JAM NUT #10-32 X 1.00, SOC HD CAP -20 KEP. NUT PULLEY, 11T .38 PITCH IDLER PULLEY, 11T.38 PITCH ASSY. BRACKET; IDLER ADJUST LOCK WASHER -20 x 1 SOC.HD LOWER FOLD PLATE SUPPORTS SCREWS FOR LOWER FOLD PLATE SUPPORTS QTY. 1 1 2 2 2 1 1 4 2 2 8 1 1 1 1 1 2 2 4
18
20
6 4 3
7
ITEM 1 2 3 4 5 6 7 PART # 379-1073 371-0084 371-0090 350-0093 342-0081 350-0092 360-1843 DESCRIPTION 3/8 RET. RING BUSHING FOLDER ROLLER FLANGE BUSHING DRIVE ROLLER COMP. SPRING FOLDER ROLLER BEARING PLATE QTY. 4 7 1 1 6 3 1
2 6 1 4
21
19
15
4 18 7 14 20 21
13
6 6a ITEM 1 2 3 4 5 6 6 6a 7 8 9 10 11 11 12 13 13 14 15 16 17 18 19 20 21 22 PART # 319-0213 379-0014 334-0356 379-0008 360-1645 319-0096 390-1484 319-0161 375-0044 379-2839 360-2305 372-6544 313-8835 313-0057 365-0163 317-0029 317-0051 365-0178 360-1659 365-0180 367-0030 367-0201 367-4073 367-0029 367-1092 378-6549 319-0159
16
12
11
8 17
10 22
DESCRIPTION QTY. PROXIMITY SENSOR 1 E CLIP 2 SIDE PLATE 2 RETAINING RING 1 SPRING BRKT. 1 IEC POWER RECEPTACLE 1 IEC POWER RECEPTACLE (FE 1500 only) 1 RECEPTACLE FILTER (FE 1500 only) 1 SHOULDER SCREW 8-32 2 RETAINING RING 2 FRAME, DRIVE SIDE 1 NON-SWIVEL GLIDE 4 MOTOR 1 MOTOR (FE 1500 only) 1 PULLEY 9L050 1 CIRCUIT BREAKER 3.5A 1 CIRCUIT BREAKER 2.5A (FE 1500 only) 1 PULLEY 28L050 1 SPRING BRKT. 1 GEAR BELT 210 LO50 1 COMBO SPROCKET 1 35 T. SPROCKET ASSY. 1 10 T. SPROCKET 1 CHAIN PITCH 2 MASTER LINK 2 -20 KEP NUT 4 COVER MAGNET 1
22
14 8 3 4 5 6 2 1 7 7
14 13 3 4 5 6 12 11
10 11
23
2 ITEM 1 1a 2 3 4 BATTERY MOUNT PART # 390-1233 390-1479 319-0214 319-0217 317-0040 DESCRIPTION CONTROL BOARD CONTROL BOARD (FE 1500 only) LCD COUNTER COUNTER BATTERY .25 AMP FUSE 5 x 20 QTY. 1 1 1 1 1
24