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| home > support > dfs 3600 > service manual |
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MACHINE OPERATION The InfoSeal 3600 Folder Sealer provides rapid access to the paper pathway, easy fold adjustments, a 250 sheet feeder, and folds at a rate of 60 sheets per minute. The machine opens much like a clam-shell, when the cover (upper half) is raised, providing access to the paper pathway. The drive system is located in the bottom section (fixed half) and can be manually operated with the cover raised to facilitate clearing paper jams or cleaning rollers. The operator is protected from inadvertent start-up of the machine during manual operation by an electrical interlock system. The system also prevents water pump operation when the cover is open. The InfoSeal 3600 employs a simple monitoring system to stop the machine when a paper jam occurs. A "double sheet" detection system is also included to prevent the feeding of two forms together from the sheet feeder into the paper pathway. The system can be calibrated to adjust for different paper weight. Calibration is accomplished from the operator keypad and is required only when changing from one paper weight to another. When a "double sheet" is detected, the machine stops before folding the "double", allowing removal from the machine in salvageable condition. The control panel (keypad) is the operator interface to selection of machine cycle mode; "slow" provides a machine cycle rate of 2700 forms per hour, "fast" delivers 3600 forms per hour, and "test" produces one (single cycle) font. "fold only" controls the water pump. The water pump delivers water from the reservoir to the wick system and operates at an intermittent cycle rate of 30 seconds on and 120 seconds off to maintain proper wick saturation. The InfoSeal 3600 provides easy adjustment of the first and second fold positions with rapid approximate positioning and subsequent fine adjustment to "zero in". All standard fold positions are clearly marked. The "V" fold position, when chosen, automatically provides bypass of the second fold.
MAIN OPERATING FEATURES Top Cover Removal Removal of the Top (semi-transparent) Cover is necessary to make a rapid (approximate) adjustment of the first fold position. The fine adjustment of the fold position may be made without removal of the cover. If the cover must be removed, the following procedure should be used. Lift the Cover, together with the attached first Fold Buckle Chute, to it's uppermost limit where it will latch in position prevent inadvertent closure. The Cover must be spread slightly at it's connection (pivot) points to disengage it from the Chute. Exercise care when spreading the Cover at the connection points. The Cover may need removal when cleaning the rubber rollers or when removing paper in the event of a paper jam.
Side Cover Removal Removal of the machine Side Covers is necessary to allow cleaning, replacement, or adjusting of the machine components. The Covers themselves may be cleaned with mild soap and water without removing them from the machine.
Each Side Cover is fastened to the machine Side Frame with five
Pan head Phillips machine screws (part # 2004). The screws are accessible
from the paper pathway side (inside) of the frame. The Top Cover
must be removed to have access to these screws. The sketch above
indicates the location of the mounting screws.
CONTROL PANEL The Operator Keypad is located in the top face of the operator side cover and consists of the following features: 6 Operating buttons Note: The Operator keypad will not function with the Top Cover or Motor Cover open.
CONTROL PANEL
CONTROL PANEL OPERATION Operating Modes: Power-upImmediately after power is turned on the machine performs a check of all the status indicators and the numerical display. All indicators should be illuminated. After that, the software version is displayed. i.e., 3.13. The unit then enters normal operation. Warm up Ready
There are three possible run modes; test, slow, and fast. These modes may be selected at any time while the machine is stopped or running. The selected mode will go into effect immediately. The active mode is always indicated by illumination at the corresponding button. The stop button may also be pressed at any time and the machine win stop after processing any forms within the paper pathway. If a paper jam or a double sheet is detected the machine will stop immediately. The reason will be noted by illumination of the appropriate status indicator. Test Mode Slow mode Fast Mode Shutdown: After approximately 15 minutes of inactivity, noted by a blinking warm up indicator, the machine will enter a shutdown state. During "shutdown" the drive and pump motors are shut off. This state may be terminated by pressing any of the run buttons. Status Indicators: The status indicators consist of several LED fights and a numerical display window which are described on page 8. Jam (illuminated) Double Sheet (steady illumination) Add Water Warm Up (steady illumination) Warm Up (blinking) Ready Test (illuminated) Slow (illuminated) Fast (illuminated) Fold Only (illuminated) Stop (illuminated) Panel Buttons: Reset Test Slow Fast Fold Only Stop Double On / Off TEST MODES Test mode may be entered by simultaneously pressing the test and stop buttons while the software version (3.13) is displayed in the numerical display window during "power up".When in the test mode the display is used to indicate internal CPU addresses and paper path sensor activity. The first two digits of the display indicate the address and the last two digits indicate the contents of that address. Address may be incremented by pressing the reset button and decremented by pressing the fold only button. The paper path sensor functionality may also be checked in this mode. When the above indicated decimal points are illuminated, paper is present at that location. Paper may be fed manually through the machine to verify the sensor activity.
ELECTRONIC ASSEMBLY Cable Connections: The electronic assembly used in the InfoSeal consists of one controller circuit board, one power circuit board, and eleven cable assemblies. The power circuit board and the controller circuit board, together with the control panel keypad, are mounted to the operator side machine frame under the external cover. The cable assemblies are designated CA 01 through CA 11. CA 01 CA 02 CA 03 CA 04 CA 05 CA 06 CA 07 CA 08 CA 09 CA 10 CA 11
DRIVE MOTOR, CHAIN, and SPROCKET
Removal of the drive chain and sprockets is accomplished from the side of the machine opposite the keypad. The Side Cover must be removed to expose the motor mounting screws. One of the two screws is a pivot screw and the other is used to maintain the chosen mounting position. The screws must be loosened to allow the motor with the assembled drive sprocket to be rotated around the pivot screw. When the motor is swung counterclockwise to the limit of the screw adjustment slot, slack will be created in the drive chain, allowing removal of the chain and two sprockets from their respective shafts. The drive sprocket is retained to the Motor Shaft Adapter by two screws in the sprocket hub. The driven sprocket is retained to it's roller shaft by a drive pin described on page 18. The operating and servicing positions of the motor are shown above. GEAR ASSEMBLY and REMOVAL
The Roller Drive Gear is held on the Roller Shaft with a Dowel Pin inserted through the Roller Shaft and nested in a slotted recess in the gear. The pin acts as a key and provides a means to drive the shaft when the Sear is rotated. The pin also positions the gear axially on the shaft to maintain alignment with the other gears in the drive train. A helical Compression Spring is located between the Shaft Bearing and the inner face of the gear to provide a force sufficient to sustain continuous engagement with the driving pin. Removal of the gear from the shaft can be accomplished by pushing the gear inward toward the Machine Side Frame, against the spring pressure, and allowing the Dowel Pin to be removed from the hole in the shaft. The pin is fitted (.002" loose) in the hole and will fall out when the shaft is rotated to a position where the pin is vertical. All of the roller driving gears are held to their respective shafts by the method depicted. ROLLER ASSEMBLY and REMOVAL
When it is necessary to remove rollers it may be accomplished easily without dismantling major machine framework. The complexity of removal depends on the roller to be removed. The driven rollers are all positioned beneath pressure rollers. If a driven roller is to be removed, the pressure roller above it must be removed first. The pressure rollers generally are the easiest to remove as they have no gears attached. If a gear is attached it must be removed first. In all cases the bearing retainer (disk) and bearing must be removed next to provide a clear hole in the (gear side) machine frame into which the roller shaft may be moved axially. The roller may then be tipped upward for removal from the machine as depicted above. Refer to page 18 for gear removal. The assembly of rollers is accomplished by reversing the removal sequence described above. PAPER FEED WHEELS and CLUTCH ASSEMBLY
When replacement of the Paper Feed Wheels or Clutch is necessary, the following procedure should be used. With the Side Covers removed, the three feed rolls and Clutch Assembly can be seen in their entirety. The Clutch is located on the drive side of the machine above the motor drive sprocket and is engaged with the large 3-1/2" diameter gear. When the clutch coil is energized, the Paper Feed Wheel roller shaft becomes coupled to the roller shaft driven by the chain. Disassembly of these components is readily accomplished by first removing the clutch restraining bracket (dog) and then the bearing retainer (disk) on the opposite end of the roller shaft (keypad side). Remove the small screw (#2-56) which retains the clutch. The shaft may now be moved axially, together with the attached three wheels and hold down plate, toward the keypad side until it is free of the clutch. When moving this shaft axially, it will be necessary to remove the pressure exerted by the pressure pad located under the center wheel. Be careful not to dislodge the swiveling pressure plate. If the clutch is to be replaced, the wiring harness plug must be disconnected from the controller board under the keypad. It must be pulled gently back through the protective tube traversing the width of the machine until free at the drive side. The harness may now be separated from the clutch wiring at the splice (covered by shrink tubing). Install the new clutch, assemble fresh shrink tubing, solder the harness wiring to the new clutch wiring, and shrink the tubing. Reassemble the harness, clutch, and roller shaft in reverse order. If the Feed Wheels are to be replaced, the clutch and roller shaft must removed, as described above. The Feed Wheels are held in position on the shaft by set screws which must be loosened to allow the removal of the wheels as the shaft is slid out. Note the side to side relationship of the wheel hubs when reassembling. PAPER PLATFORM Operation and Adjustments
The Paper Platform is mounted to a shaft, providing a pivot point about which the platform may rotate. A bias spring, attached to the shaft mounted Spring Arm, provides a rotational force to the shaft and therefore to the platform. The pressure provided by the spring must be adjusted to support the platform plus 250 forms to ensure contact of the topmost form with the three paper feeding wheels. As the paper is consumed the platform load is lessened. It is important to adjust the position of the Spring Arm to provide only enough pressure to support 250 sheets. A photo sensor is mounted on the left hand Paper Guide, under the plane of the platform, and monitors the presence of paper on the platform. The machine will not cycle without paper on the platform. The Paper Guides are independently adjustable laterally to centrally locate a stack of forms without pinching them between the guides. If the guides are not reasonably centered, the forms will not track through the machine on center and the glue on the form will not be adequately activated (wet). A means for controlling "skew" of the form as it enters the paper pathway is provided by an adjusting knob at the extreme right side of the paper platform as viewed from the input end of the machine. The initial setting of this adjustment can be made by observing the leading edge of the platform to be central to the center feed wheel or slots in the mating paper stop. A Platform Extension is located in the center of the platform. When extended, it provides additional support for longer forms. PAPER SEPARATOR Operation and Adjustments
It will be necessary to open the access door located under the Paper Platform to view the Paper Separator Assembly (located above the drive motor). The Paper Separator Arm is centrally mounted to a shaft, providing a pivot point about which the arm may rotate. A bias spring, attached to the shaft mounted Spring Arm, provides a rotational force to the shaft and therefore to the separator arm. The force provided by the spring must be adjusted to provide sufficient pressure at the Pressure Plate (regulator shoe ) to separate two sheets of paper. The Pressure Plate is located directly under the center paper feed wheel (see page 20). When paper is fed from the paper platform, occasionally more than one sheet may advance. The Pressure Plate will separate multiple sheets as they proceed into the paper pathway. The pressure plate friction surface, when used in conjunction with the rubber feed wheel, provides a separating capability similar to that derived from the moistened thumb and forefinger when separating paper sheets manually. The Pressure Plate is loosely mounted on the end of the Paper Separator Arm and is retained only by it's constant pressure against the feed wheel. When the friction surface insert requires replacement, the Pressure Plate may be removed easily by rotating the Separator Arm against the spring pressure sufficiently far enough to provide removal space. DIVERTER ASSEMBLY For Single Fold ("V" fold)
The Diverter Assembly provides the means to bypass the 2nd Fold Buckle Chute when the form is to be folded into two equal panels. Operation of the diverter is controlled by selecting the "V" fold option using the selector knob located below the keypad. This selection will automatically move the Diverter Blade to a position where it will prevent a form, in process, from entering into the 2nd Fold Buckle Chute. When the "V" fold option is not selected, the Diverter Blade remains in a position which allows the form to enter into the 2nd Fold Chute. The Diverter Blade, Bearing Blocks, and Bearings are shown assembled to the #2 folding roller depicted on page 4 and above. When the Diverter assembly is to be assembled into the machine it is important to use the following procedure. The Diverter Blade must be disconnected from a Bearing Block at one end by removing two screws. Do not remove this loose Bearing Block from the roller shaft. Remove the Bearings, if still assembled. The roller must be axially displaced within the attached Bearing Block to facilitate assembly into the machine (see Paper Platform). When the roller, with the loose but retained components, is in place in the machine, the loose Bearing Block may then be re-attached. When assembled, the Diverter Blade must rest against the upper edge of the 2nd Fold Buckle Chute. Two sets of bearings, one set at each end, must now be assembled through their mounting holes in the machine side frames. Note that one bearing on each end should be wholly within it's corresponding bearing block and the remaining bearings, one on each end, will locate in the side frames where they will be restrained by retaining disks. The Diverter Assembly should rotate freely on the bearings within the bearing blocks when actuated by selector knob. WATER TANK Removal and Cleaning
The Water Tank assembly consists of a cylindrical tube and two End Caps. Hose fittings and a Mounting Strap are fastened to the outer face of each cap. Additionally, a Water Level Switch is installed in the keypad side End Cap and a Sight Glass on the drive side End Cap. The tank must be empty and the Side Covers removed before the tank can be serviced. Water can be easily drained by positioning the machine at the edge of a desk (or table) as shown above, placing a container under the Drain Valve, and then opening the valve. Emptying the tank may also be done with the covers in place. To clean the tank, proceed as follows: Remove the screws which fasten the Mounting Strap to the Machine Frame (can be either end). The End Cap, with fittings, hose, and strap attached, may be pulled out of the tank cylinder. When the Cap on the keypad side of the machine is removed, avoid damaging the wiring connected to the Water Level Switch. The inside. of the tank is now exposed and may be cleaned with any mild detergent. The tank cylinder may also be pulled from the opposite End Cap (still fastened to the Machine Frame) for cleaning in a sink. This End Cap may be also be similarly removed from the Machine Frame for cleaning. The Sight Glass should be pulled out of the valve mounting block on the drive side before removing the End Cap. Lubricate all 0-rings with white silicone grease before re-installing the tank. WICK REPLACEMENT – LOWER
The Lower Wick Holder assembly is assigned the task of activating the printed glue lines located on each edge of the 11" (or 14") long dimension of an InfoSeal form. The Wick Holder can accommodate four wicks, each assembled in the configuration shown above (B-B). The holder, when required, can be provided with two pairs of wicks, one pair located at each end of the holder, for use when running "one part - two way" forms. The holder is generally shipped with only two wicks, one at each end of the holder, with the innermost of each pair of holes blocked to prevent water from spilling into an empty wick passageway. The wicks used in this Wick Holder are 1/4" square in cross section and 3" long. The wicks are a tight fit in the holes provided in the holder and can present some assembly difficulty. The wick must be inserted into the proper hole from the underside of the holder. Do not assemble it from the top side. The reason for this procedure is to avoid damage to the end of the wick which contacts the paper. The wick must be started into the hole using a probe to push the wick into the hole. When the wick emerges from the other end of the hole it may be gripped by a pair of needle nosed pliers and pulled to a position where the application end may be positioned in the elongated recess provided on the underside of the holder. Some finger pressure will be required to seat the wick into the recess. WICK REPLACEMENT - UPPER
The Upper Wick Holder assembly is mounted within the first Fold Buckle Chute and is employed to activate the printed glue spots located at the leading edge of an InfoSeal form. The holder accommodates three wicks as depicted above. The holder need not be removed from the chute to replace wicks. The wicks are each 1/4" thick, approximately 9/16" wide, and 1-3/8" long. It is necessary to remove the three Pressure Roll Retainers and the Pressure Rolls to gain access to the wicks. Each wick must be assembled over it's Support Plate and fitted into one of the three pockets in the holder. It is beneficial to use a pair of needle nosed pliers to grip the wick and plate together when placing them into the pocket. Note that the wick should be equally distributed over it's plate. The wick, when assembled, will allow water to pass freely under if it's ends are equally above the holder bottom. The depth of the water will always be sufficient to keep the ends of the wicks wet. The placement of wicks into the holder can be accomplished by working through the open area between the laminations of the first Fold Buckle Chute. Paper will stop against the wick instead of the Paper Stop Plate, as intended, when dry wicks are first installed. This will normally correct itself when the wicks become sufficiently saturated. It is best to allow the pump to run for more time than programmed "on" time when wicks are new. The pump may be cycled manually to gain additional pump "on" time. FIRST FOLD BUCKLE CHUTE
The first Fold Buckle Chute is a series of flat plates assembled in a laminated fashion to create a guideway through which InfoSeal forms travel until stopped by a Stop Plate mounted to the Upper Wick Holder described on page 26. When a form, driven through the guideway, contacts the plate it will buckle and fold at the point where the form is unsupported by the guideway. The adjustable position of the wick holder and attached Stop Plate can be used to control the fold point. The buckle chute assembly, shown above, is mounted in the folder on a shaft spanning the machine between the two Machine Frames (keypad and drive side). The shaft is the pivot point about which the buckle chute, with attached wick system rotates upwardly when it is necessary to gain access to the interior of the machine. The buckle chute is assembled or removed from the machine by pulling the hinge shaft out of the chute assembly and side frame. The shaft is retained between the side frames by a washer and screw at each end and the central position of the chute assembly is maintained by spacers at each end of the shaft. The water feed hose is attached to the swivel fitting in the wick holder (keypad side) and must be removed before the chute is disassembled. Caution: Be sure that the hose is reconnected before starting the machine. UPPER BELT ASSEMBLY
The Upper Belt Assembly has four Locating Pins which locate loosely in four slots in the Machine Frames (keypad and drive side) and are pulled downwardly by four extension springs attached to the Machine Frames. The belt assembly is self contained and is used to maintain pressure on the glued areas of the InfoSeal form as it proceeds to the exit end of the machine. Five matched belts are mounted over four rollers. The two end rollers have equally spaced crowned areas for maintaining belt alignment. A plain cylindrical roller is centered between the two end rollers for belt support and the fourth one is an eccentrically mounted belt tightening roller. The belts are driven only by contact with a lower set of five matching gear driven belts mounted between the Machine Frames. Finished forms are delivered to a collating rack at the exit end of the machine. The Upper Belt Assembly may be removed if required by disconnecting the four springs from their attachment screws in the machine frames and lifting the assembly out of the four locating slots. OPERATOR SIDE FRAME- (1) REQ-D.
DRIVE SIDE FRAME (1) REQ’D.
PAPER FEED PLATFORM (1) REQ’D.
CROSS MEMBER - PAPER STOP (1) REQ’D.
CROSS MEMBER -EXIT (1) REQ’D.
WICK HOLDER -single (1) REQ’D.
WICK HOLDER -double (1) REQ’D.
BOTTOM CHUTE (1) REQ’D.
UPPER CHUTE (1) REQ’D.
BELT TAKE-UP - lower (1) REQ'D.
UPPER BELT TAKE-UP -upper (1) REQ'D.
UPPER BELT ASSEMBLY
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