1.1 PURPOSE

This service manual provides information necessary to support the installation and site repair of the Pitney Bowes Model F310 Folder/Sealer and its accessories. It is also a training manual for Pitney Bowes Customer Service Representatives.

1.2 EQUIPMENT COVERED

This manual applies to the F310 Folder/Sealer and the following accessory equipment:

Model F312 Sheet Feeder Kit

Model F390000 Burster Interface Kit (3370)

Models 3372 and 3324 Interface Kits

1.3 RELATED PUBLICATIONS

The following Pitney Bowes publications apply to Model F310:

Operating Guide-SV-11532

Product Reference Guide-SV-11533

Parts List-SV-11533-PL

1.4 CONTENTS

This manual is organized as follows:

                    Section 1-Introduces the manual and provides some safety tips.

                    Section 2- Lists material and equipment specifications.

                    Section 3- Presents the theory of operation and describes the mechanical and electronic components.

                    Section 4- Provides installation, setup, and checkout instructions.

                    Section 5-Lists preventive maintenance and lubrication procedures.

                    Section 6-Presents troubleshooting procedures.

Section 7-Describes disassembly and adjustment procedures.

Section 8-Provides installation instructions for kits and accessories.

Section 9-Outlines operator training procedures.

1.5 SAFETY SUMMARY

Warning messages are used throughout this manual to alert you to potentially hazardous conditions. These warnings are explained below:

WARNING--calls attention to improper practices that could cause injury.

CAUTION--calls attention to improper practices that could damage the equipment or material being run.

IMPORTANT--calls attention to practices that could adversely affect equipment operation, if instructions are not followed exactly.

You must familiarize yourself with proper procedures and methods before you install, operate, or service the equipment to avoid personal injury or damage to the equipment. If you are responsible for training service people or equipment operators, it is incumbent on you to explain safety precautions to your students and encourage safety awareness.

WARNING:    As the power cord is considered to be the main power disconnect, the power outlet must be located in close proximity to the machine, easily accessible, and be unobstructed.

The following general precautions cannot be over-emphasized:

HIGH VOLTAGE is present at certain points in the equipment; INJURY or DEATH could result if you fail to observe safety precautions.

Know how to turn off power in the work area and how to summon help in case of emergency.

Do not work on equipment under power unless absolutely necessary.

When working on a live circuit, use extreme caution. Don’t grasp two sides of a live circuit at the same time.

Always use the right tools for the job.

Treat every circuit like a gun, which may be loaded. It may not be "live," but be sure. Check with a neon tester, a voltmeter, or simply unplug the machine.

Use one hand when reaching into a circuit. By keeping one hand free, lethal current is less likely to pass through vital organs. Observe this rule when connecting or disconnecting plugs or leads, and when making any adjustments on a live circuit. Don’ t underestimate the danger of shock: 1 mA (1/1000 ampere) is uncomfortable; 5 mA (1/200 ampere) is dangerous-the victim may jump back and be injured; 12 mA (1/83 ampere) causes hand muscles to contract- the victim cannot free himself; 24 mA (1/40 ampere) has proven fatal; and 100 mA (1/10 ampere) is likely to be fatal.

Don’t reach into a circuit with metal tools, or while wearing rings or a watch. Even in low voltage circuits, a metal object can short circuit two terminals.

Don’t bypass safety devices. Three-wired outlets (120 Vac) are designed to ground equipment to make it safe. If a hot wire shorts to a grounded frame, the only result is an open fuse. If a hot wire shorts to an ungrounded frame, the frame itself becomes hot and potentially dangerous.

A fuse is a weak link in a circuit, designed to break down before anything else does. The designers determine the maximum safe current in a circuit. Too large a fuse can pass excessive current, damaging expensive equipment.

Access interlock switches are designed to remove power from a circuit when an access door, cover, or panel is opened. When such a switch is "cheated" or otherwise disabled, a safety device has been bypassed. If you bypass an interlock for service or diagnostic purposes, use extreme caution.

If you use air pressure to clean a machine, use low pressure (30 psi or less) and wear eye protection (goggles or face masks).

For electrical fires, use Type C, BC, or ABC extinguishers only. Don’t use soda-acid or other liquid stream extinguishers. They will cause great damage to electrical equipment and also present a shock hazard to the user.

2.0 Specifications

Dimensions:

footprint: 25" wide x 20" deep

overall width: 26.5" alone; 40" with stacker tray; 43.5" with sheet feeder; 59" with sheet feeder and stacker tray

overall depth: 21"

overall height: 21.5"; 25.5" with sheet feeder

Required floor space: 60" x 30" plus at least 36" access clearance on all sides

Recommended table height: 30"

Weight:

Shipping weight: 135 lb

Installed weight: 110 lb

Electrical:

120 Vac; 60 Hz, 3.0 A

Speed:

w/sheet feeder: up to 11,000 sheets/hr (typ)

w/3370 or 3324 burster: up to 7200 sheets/hr (typ)

Speeds are nominal using 11"-long 20-lb. bond.

Actual speed will vary with the type and condition of the system, the material used, operator skill and the environmental conditions.

Water:

Total capacity: 2.5 gallons of water or E-Z Seal, © (P/N 602-0)

Refill capacity: When Add Water lamp lights, add approx. 2 gallons

Caution: Do not fill above ½" from top of filler

Environment:

Ambient temperature: 10-30 ºC (50-86 ºF)

Relative humidity: 20-80% (noncondensing)

Acoustical noise: 72 dBA idling; 79 dBA running

Folds:

2-panel half fold or 3-panel letter fold

Forms over 14 inches long; letter fold only

Forms:

Size: 8 ½" wide, 7" to 17" long (sheet feeder)

9 ½" wide, 7" to 12" long (burster)

Weight: 20-lb. minimum to 28 lb. maximum

Forms may be die-cut (no more than two openings per form)

Glassine patches must be continuously sealed

Pocket (two-way) forms with built-in return envelopes must be run with the pocket trailing

Glue must be of adequate thickness and positioned correctly for proper sealing

See Figure 2-2 for dimensional requirements.

MATERIAL HANDLING NOTES

Material handling problems with automatic mail handling equipment are often due to out-of-spec material. This is particularly true of self-sealing forms, which contain glue that is extremely sensitive to temperature and humidity. Fortunately, there are a number of easy and effective measures that the owner and operator can take to minimize problems and improve production. Review the recommendations below with them to help them get the most out of their equipment.

When ordering forms, always specify "for mechanical folding and sealing".

Don’t "crash" loaded skids on loading docks, in transport vans or in the final storage area.

Do block loaded skids in transport vans.

Don’t expose cartons to intense sunlight, high humidity, or extremes of temperature.

Do store materials in a controlled environment. We recommend a temperature of 75ºF at 50% relative humidity, but glue formulas do vary, so other limits may be better for some materials.

Do store cartons on skids or shelves to prevent absorption of moisture, never directly on floors or against masonry walls. Very dry forms may accumulate static and be difficult to handle, but damp forms will almost certainly stick together.

Don’t stack cartons too high; this can damage the forms in the cartons on the bottom.

Do use oldest stock first (first in, first out).

Do transfer cartons from the storage area to the work are no more that a few hours before use.

Don’t remove forms from cartons until needed.

Do allow about one hour of stabilization time for each degree of temperature change from the storage area to the processing area.

3.0 Theory of Operation

                3.1 GENERAL

The Model F310 is a one-step self-contained tabletop folder/sealer for self-mailing forms. It accepts either sheet-fed or web-fed forms coated with dry water-activated glue, moistens them, folds them in a buckle-chute folder, and seals them. It works with water-activated glue only, and is not intended for use with heat-sealed forms.

Each form is pre-glued along both sides, with three glue patches across the top. The folder contains five wicks, one on each edge of the paper path, at the entrance to the first buckle chute, and three spaced across the top of the second buckle chute (Figure 3-1). The side wicks moisten the edges of each form on its way into the folder. The center wicks moisten the glue patches across the top of the form on its way out of the second buckle chute (if they are properly positioned).

The wicks are fed by a central tank, which holds enough water for a full day’s operation (about 2 gallons). The tank must be filled before operating the machine. When the tank is low, a warning indicator will light on the operator’s control panel. If the user wishes to fold unglued forms, the wicks may be withdrawn and the F310 used as a normal, non-sealing folder.

Forms are fed foot first, glue patches trailing and glue facing up. On the way into the first buckle chute, the form is moistened along the edges. The first buckle chute makes the first fold; the second buckle chute does two things: it makes the second fold and also moistens the form so it will seal shut. The form is then pressed closed to seal it, and passes through a "curing" station, which maintains pressure for a period of time, so the form stays closed while the glue sets.

When the form is moistened and folded, the edges are glued together and the top is glued across the middle to keep it closed. The folded piece is then pressed in the sealer or curing station to set the glue. The sealer exerts pressure on the form for several seconds. The sealed form is then placed in an output stack for manual processing.

The sheet feeder is removable for use with fanfold forms. To use fanfold forms, the unit must be mated with either a Model 3370 Burster (Kit # F390000) or a 3324 Burster (Kit # 9296190). Both of these bursters are available separately. Converting from sheet feeder to burster takes only a few minutes.

3.2 SEALING PRINCIPLES

Each wick has a reservoir through which water constantly flows. The inlet and outlet are at the bottom of the reservoir, on opposite sides. About half of the wick is under water; the rest protrudes up through a slot in the upper part of the reservoir to address the paper. The pressure of the wick against the paper is controlled by the small red sliding tab on the top of the reservoir. Moving the adjuster tab toward the paper path presses the wick harder against the paper; moving it away lowers the pressure. The tabs are equipped with click-stops; the last one withdraws the wick completely, away from the paper. The wick is enclosed in a nylon mesh jacket, so the fibers don’t rub off on the paper.

Side wicks

The side wicks are at the entrance to the folder (Figure 3-3). Two adjustable spring-steel guides behind the paper path press the paper against the wick. To fold unglued forms, the operator can retract the red wick adjuster tabs so the paper is not moistened.

Center wicks

The center wicks are on the upper side of the second buckle chute (Figure 3-1). The paper is pressed against the wicks only on the way out of the chute, when it is being pulled by the exit rollers, so the movement of the paper in the chute is not retarded by friction.

Under the chute, there are three hammers, which rock on axles (Figure 3-4). When the paper enters the chute, it passes by the hammers without moving them. On the way out, however, the paper drags against the lower part of the hammers, rocking the upper part forward. The upper part (the "head") presses the paper against the wick, which applies water to the area opposite the glue spots on the folded form (not to the glue spots directly, so the form will open easily without tearing).

When the trailing edge of the paper has cleared the wicks, it is still pulling the hammer toward the wick. For this reason, the hammer head does not press directly against the wick, but rather against the body of the reservoir. This prevents the hammer from exerting pressure on the wick and releasing too much water. Any water, which escapes when the paper leaves the wicks, is trapped in the drip felt beneath the hammers.

The pressure of the center wicks is controlled by two adjustments. First, the wicks have the same red sliding adjuster tabs as those on the sides. This is an operator adjustment. Second, the hammers are adjusted by means of a small setscrew in the center of each hammer (Figure 3-4). These are preset in the factory; and their adjustment is a service function, which generally need only be performed when hammers are replaced.

When running unglued forms, the entire hammer assembly may be swung up and latched away from the paper path (Figure 3-4). To run glued forms, the hammer assembly is unlatched and lowered into the normal position, using the release lever on the upper part of the buckle chute.

3.3 DESCRIPTION

System

The F310 is a system product comprised of three modules: a feeder, a folder, and a sealer (Figure 3-5). The folder and sealer are integrated into a single enclosure; the feeders are separate.

Two feeders are available; each is actually a separate product, which can be purchased with the folder/sealer module. The sheet feeder consists of a modular deck assembly, which can be easily removed from the folder. The deck includes the side guides and the feed wheel assembly.

An interface kit is also available for attaching the F310 to a 3370 or 3324 burster.

The folder includes the fold roller assembly, buckle chutes and output stacker. It also includes the moistening wicks, which apply water to the forms while they are being folded.

The sealer consists of a series of belts on a pair of rollers, which apply pressure to the folded forms to set the glue. The folder and sealer are packaged together in a console cabinet, which also houses the water pump and tank supplying water to the wick assemblies. A separate stacker tray is attached to the output end of the main cabinet.

Feeders

Optional Input Feed devices include a sheet feeder (Model F312), 3370 Burster Interface Kit (P/N F390000), or a 3324 Burster Interface Kit (P/N 9296190).

Sheet Feeder

The sheet feeder is a friction-feed device, which separates the top sheet from a stack of documents and feeds it into the folder entrance rollers. The segmented feed roller is coated with a high-friction rubber compound, and bears against a segmented separator stone located under the feeder deck. The friction of the separator stone retards all the sheets in the stack except for the top one. The feed roller remains stationary, while the separator stone is raised or lowered to control feeding by the feed gap adjustment knob (Figure 3-5).

The separator stone is covered by a movable stone shield (Figure 3-5) which may be adjusted for separation control after the feed roller has been set for the material in use. The feeder should be set up under dynamic conditions to optimize feeding.

When using the F312 sheet feeder, correct folder speed depends on the type of fold, the material being run and the length of the sheet. Typical operating speeds for 11-inch forms range from 8-10,000 sheets per hour.

Burster interface

The folder may be interfaced with the 3370 Burster with accessory kit F390000 (see PB publication SV 11534 for installation and setup instructions). When used with a burster, folder speed must be reduced until it matches that of the burster (about 4000 sheets per hour). If the folder speed is too low, forms will pile up or jam at the entrance to the folder; if the folder speed is too high, you will hear a loud chattering sound as the entrance rollers try to pull the unburst forms out of the burster prematurely. 11-inch forms should generally be run at a speed between 6 to 8 on the F310 speed control dial.

The 3370 or 3324 includes a control cable which plugs into the F310 and halts the burster instantly if an F310 interlock is opened; be sure the customer understands the purpose and importance of connecting this to prevent damage to forms.

Folder

The Buckle Chutes

The folder is of the conventional buckle chute type as shown in Figure 3-3.

The buckle chutes are referred to as the first (left) and second (right) chutes as seen from the operator’s position. Each chute is equipped with an adjustable stop, which is set to the correct fold panel length using scales on either side of the chute. Two thumbscrews on each stop assembly lock the adjustment in place (Figure 3-6). These may also be used to correct skew, although most of the time the feeder skew adjustments are used for this purpose.

The first buckle chute is open on one end and closed on the other. When a single fold is called for, the operator must reverse the chute to deflect the sheet. The second buckle chute is not operator-removable. (see Chapter 7 for disassembly instructions).

Folding Principles

Buckle chute settings for the most common folds are shown in Figure 2-2. The following describes the process of folding a single sheet as shown in details A through E of Figure 3-7, using the F312 sheet feeder attachment:

With all setup adjustments complete and the folder running, the feed roller separates a single sheet from the top of the stack and feeds it into the entry roller assembly (A). Sheet alignment is maintained by adjusting the skew control knob (Figure 3-5).

The sheet then feeds under the first fold roller into the first buckle chute (B) (for a single fold, the operator will have reversed the first buckle chute, since it is not required). The lead edge of the sheet strikes the buckle chute stop, causing the sheet to buckle along the intended fold line. The fold line then enters the bite of the first and second fold rollers, which compresses the fold, making the crease (C). The lead edge of the sheet--which is not the crease line--is directed into the second buckle chute (D), and the second fold line then enters the bite of the second and third fold rollers (E), and the folded sheet is fed into the exit rollers and onto the stacker belt (F).

Setup

The setup procedure in the F310 Operating Guide provides an initial adjustment, which should be satisfactory for 20 lb. bond papers. Nominal buckle chute settings are listed on a label affixed to the top of the second buckle chute.

Folder Roller Composition

The folder rollers of the F310 are covered with a proprietary material, which should be cleaned with mild soap and water only, followed by clear water. Due to the presence of water-soluble glue on the forms, the rollers will require more frequent cleaning than those of other PB products.

Sealer

The sealer consists of five wide belts, running on a driven and an idler roller, both above and below the paper path. The pressure between the upper and lower belts subjects the folded material to at least six pounds of pressure for several seconds, which sets the glue and ensures that the mail piece will not come open during subsequent handling. The sealer pressure is not operator-adjustable, but the upper belt and roller assembly can be unlatched and swung upward to allow access to the paper path.

A stacker/deflector is located between the exit rollers and the sealer to maintain a neat, shingled stream. It consists of a sheet of clear Mylar, attached to the lower safety cover, which directs each emerging folded form into the sealer rollers.

Power Train

The main drive motor is mounted to the front side frame and drives the center fold roller through a V-belt. Drive is transferred to the folder entry and exit rollers through a gear train located behind the main fold roller drive pulley on the front of the machine (Figure 3-8A), and to the stacker and sealer roller drive chain through a gear train on the rear of the machine, powered by the main fold roller shaft (Figure 3-8B).

Figure 3-6 Buckle Chutes

The sealer rollers are chain-driven by the main fold roller shaft with an adjustable-tension chain on the rear of the machine (Figure 3-8).

A hand wheel on the main fold roller shaft allows the operator to hand-crank the machine when the hand wheel is pushed and held in.

Water System

Pump

A water pump mounted inside the F310 console delivers water to the wick reservoirs. The pump is a constant-flow type with a magnetically coupled rotor. Pump flow is 3 GPM, which is reduced by a 0.070" orifice at the pump and 0.040" orifices at the inlet to each reservoir. These orifices are more sensitive to clogging than the rest of the system; if flow is reduced the orifices may have to be cleaned by running a few ounces of liquid bleach through the system.

The water pump is mounted at the lower left rear of the unit under the entrance rollers (Figure 3-9), and may be accessed through the left (rear) end panel. It is connected to the main water tank and the wick reservoirs by clear plastic plumbing.

CAUTION: The pump extends below the main bottom plate. Be sure all four legs of the machine remain on the table and the pump guard plate is in place, or the pump fitting may strike the tabletop.

The pump is always running when the power switch is on; it is not affected by the speed control. For this reason, the machine should always be switched OFF when left unattended, and not just turned down to zero.

Tanks and reservoirs

The water tank is located under the sealer deck, and occupies most of the lower portion of the machine. It has a splash inlet on the top, which recycles any surplus water that gets into the machine during operation. The tank hold 2.5 gallons, but should be filled with no more than 2 gallons to reduce the chances of spillage.

As shown in Figure 3-10, the pump draws water from the main tank and circulates it through the wick reservoirs and back into the tank at constant pressure. The water flow rate is fixed; the moisture applied to each form is determined by the position of the sliding red wick adjustment tabs on the top of each wick housing.

Electrical System

Principle of Operation

Refer to the system schematic (Figure 3-11). Power is received from a 120Vac wall plug (J1), through a 3.0A ac circuit breaker (CB1) and the front panel on-off switch (S1), which is connected through connector J2/P2. The primary connections are made at terminal blocks TB1 and TB2. The ac input enters at TB1-1 and TB1-7. The motor control board (PCB1) controls the main drive motor (M1). M1 is driven by outputs A1 and A2 on the motor control board, through TB2-4 and TB2-5 and connector J4/P4. The water pump motor (M2) is supplied by outputs L1 and L2 on the motor control board through TB1-3 and TB1-6/10 and connector J5/P5.

Motors

The main drive motor is a 0-99vdc sealed unit which draws 1.4A during normal operation and a maximum of 1.5A at startup. The water pump motor is a 120Vac unit, which draws 0.4A during normal operation at 3200 RPM. Neither motor requires lubrication, and they should not be opened for service; they are replacement items.

Interlocks

The 24Vac from TB3-1 passes through the interlock switches (P/N 3187613) on the folder and sealer safety covers. In the N/O position, the circuit is grounded at TB3-3, but if a switch closes, the circuit is routed through TB3-2 to the Interlock Fault lamp (L1) and the shutdown coil (K1), which immediately halts both the drive motor and the pump.

Overload Protection

A 3.0 A circuit breaker (CB1) is mounted on the end panel under the feed deck. It is a pushbutton type, which can be reset by the operator. The main drive motor is current-limited by the motor control board (see Chapter 7 for adjustment).

The water pump motor is magnetically coupled to the impeller, making an overload unlikely even under locked-rotor conditions.

4.1 UNPACKING

 

                    4.1.1 Folder

The F310 folder/sealer is packed inside a carton, which is strapped to a skid. Follow the procedures below to unpack and assemble the folder.

WARNING:    The F310 weighs over 100 pounds. Two people are required to lift it. Do not attempt to pick it up alone.

1. Removing strapping. Leave carton on skid.

2. Remove carton top cover and top cardboard and Styrofoam shipping insert. Retain these for future shipping.

3. Remove accessory box containing stacker tray with legs, hardware and power cord.

4. Remove top cardboard/Styrofoam shipping insert and lift off carton side panels.

5. Using two people, lift the machine off the carton bottom and set on a sturdy table capable of supporting at least 150 pounds. Leave enough clear area     around the machine to keep tools and components when servicing the unit and for the operator to store input and output.

4.1.2 Stacker

The stacker tray is packed in the accessory box and requires assembly. The package contains the tray, two legs, and a bag of hardware, as well as the F310 power cord. To assemble:

1.  Remove all parts from the box and place the tray on a table upside-down (curved side up, with the four small studs protruding upward).

2.  Using the hardware in the plastic bag, bolt the legs firmly onto the studs on the underside of the tray (the orientation of the legs doesn’t matter).

4.1.3 Sheet Feeder

The F312 sheet feeder is packed in a separate box. Follow the procedures below to unpack the sheet feeder.

1. Set the box on a table and open it.

2. Remove the top cardboard shipping insert.

3. Lift out the feeder and remove the installation instruction sheet.

4. Retain carton and inserts for future shipping.

 

Figure 4-1 Filling Reservoir and Installing Stacker

    5.1 GENERAL

This section of the manual provides inspection and maintenance procedures for the Model F310 Folder/Sealer.

             5.2 EQUIPMENT INSPECTION

1. Check with the operator. Discuss and note any equipment problems reported by the operator.

2. Functional check. Watch the equipment run and analyze its operation. If you notice any operator errors, explain correct loading and running procedures as required.

3. Check fold quality. If the fold is not square and crisp or the fold dimensions are off, check setup adjustments. Review them with the operator if necessary. Make sure the feeder and buckle chutes are properly set up for the material being run.

4. Check variable speed control. The unit should stop completely when the speed is set to zero.

5. Listen for unusual noises. Listen for any unusual noises--scraping, grinding, etc.

6. Check for mechanical binds. Cycle the machine using the hand wheel. Make sure the fold rollers and stacker belt turn freely, without restriction.

7. Check the condition of the sealer belts. Make sure they are tracking properly (centered on the roller cams) and not worn.

            5.3 CHECKLIST

See Table 5-1 for preventive maintenance and lubrication procedures and schedules.

Begin an inspection by removing the feeder and the upper buckle chute, then remove the side covers. When inspection and cleaning are complete, reassemble the machine and test.

CAUTION: Do not use oil on the plastic bushings, only silicone-based lubricants intended for use on plastic parts. One drop is enough.

Table 5-1 Preventive Maintenance and Lubrication

Task

How Often

Notes

Ö Clean and remove paper dust.

Six months

Use brush or vacuum.

Ö Clean rollers.

Six months

Use mild soap and water.

Ö Clean belts.

Six months

Use denatured alcohol. Check tension and reset if necessary. Replace if worn.

Ö Check gear, pulley, and roller setscrews.

Six months

Use 3/32" Allen key.

Ö Check sheet feeder feed roller alignment.

Six months

Use 3/32" Allen key

Ö Inspect rollers for damage or wear.

Six months

When replacing rollers check the bearings.

Ö Check sealer belts for slippage.

Six months

Replace as required.

Ö Check plastic bearings.

Six months

Replace if necessary. Look for wear and too much play on shafts. Use one drop of silicone lubricant.

Ö Clean sealer belts.

12 months

Replace and center belts as required. Also check setscrew on stacker belt drive gear. Use 3/32" Allen key.

Ö Check buckle chutes.

12 months

Look for nicks, warps, and other damage along the entry. Make sure stop is set parallel to entry.

Ö Check motor and pump for leaks or wear.

24 months

Remove entry end cover, turn power ON and check pump for noisy operation. With power OFF, use soft brush to clean dust from motor and controller PCB.

Ö Check counter switch operation.

Six months

Check for double counts with different papers at low and high speeds.

Ö Check sealer drive chain tension.

12 months

Also check plastic gear teeth.

This information in the table below is intended to serve as a guide to fault isolation. The chart is by no means exhaustive, but it does cover many of the common problems you are likely to encounter in the field. The chart progresses from the most likely to the least likely fault.

Mechanically, the folder is a relatively simple device. Field problems are more like to involve setup errors and paper handling technique.

The Motor Controller PCB is serviced by replacement only; it is not field-repairable.

Table 6-1 F310 Diagnostics

Removing stalled paper

IMPORTANT:  If stalled form will take more than a few seconds to clear, turn off switch to shut off the pump, so the paper won't soak up water through the wicks.

To remove stalls in the feeder area:

q Lift and remove sheet feeder or burster interface paper guide.

q Lift out first buckle chute.

q Retract wicks into their reservoirs.

q Turn hand wheel in both directions until paper emerges from the folder-input rollers.

Folder will not run

q Main power switch OFF. Turn on.

q No power at wall outlet. Check the facility fuse or circuit breaker.

q Check the circuit breaker located under feed deck. Push it in if it has popped out. If the folder still fails to run, or the circuit breaker pops out repeatedly. (Check for binds—anything that would cause an overload condition.)

q SPEED control set at zero. Turn control up.

q Fold rollers stopped because of a stall. Turn the hand wheel—it should rotate with some resistance. Check for stalled material and improperly installed buckle chutes. Turn the main power switch OFF, clear material and turn ON.

Table 6-1 F310 Diagnostics (cont.)

Folder will not run (cont.)

q Open fuse on motor controller PCB.

q Speed control pot, motor controller PCB and associated circuitry.

q Bad motor; replace.

q Check the following:

Ö Check for 120Vac across J/P-4 and J/P-2 with voltmeter. Voltage should be present. If not:

Ö Check wiring at motor control board terminals L1 and L2 for 120 Vac.

Ö Check motor control board terminals A1 and A2 for 90 vdc.

Ö Check voltage at folder POWER switch between J/P-2 (hot) and J/P-9 (ground return) with switch closed. Check voltage into switch and voltage out when turned on.

Ö Check voltage out of circuit breaker.

Ö Check TB1-4 and TB1-5 for 90 Vdc, using folder SPEED control with POWER switch ON. If voltage is present:

Ö Make sure wires are secure in board connector terminals. Make sure connectors are properly attached to board.

Ö Faulty SPEED control pot. Check for approximate DC voltage levels on speed control terminals with POWER switch ON.

q Change motor control board if 120vac are present at terminals 2 and 3, but 90vdc is not present at terminals A1 and A2.

q If all board voltages are present, remove motor drive belt: turn motor pulley by hand to check for binds. If OK, check motor and connections.

Pump will not run

q Check TB1-1 and TB1-3 for 120Vac.

q Check J/P-5 to ground for 120Vac.

Pump is very noisy

q Pump not getting water. Check tank; if full, check pump input line for binds or obstructions.

q Out of Water lamp inoperative. Check tank and refill if necessary.

Table 6-1 F310 Diagnostics (cont.)

Fails to feed or feed erratically

q The side guides may be too tight, confining the stack. Check for 1/32-1/16" clearance between the stack and one side guide. Note that too much clearance can cause the paper to skew as it enters the folder.

q Too much separator stone exposed. Slide the cover forward a little. Note that too little stone may cause double feeds.

q Drive gear loose or broken.

q Main drive belt or timing belt broken or slipping.

q Feeder not properly installed; feeder drive gear may not be engaged. Re-seat feeder (see the F310 Operating Guide).

q Broken drive belt or timing belt (check whether other rollers are turning). Replace.

q Feed gap improperly adjusted. For heavy stocks, widen the gap; for lighter stocks, narrow the gap (see the F310 Operating Guide).

Doubles feed; Poor sheet separation

q Aerate paper stacks before loading.

q Too little separator stone exposed. Slide the cover back a little. Note that too much stone may cause poor feeding or skewing.

q Feed gap is too large. Set up the feeder under running conditions, with a stack in place. With the unit on, retard feeding by placing your hand on the stack. By releasing pressure on the stack, you can feed several sheets at a time to evaluate feeding and fold quality. Remember that these adjustments are interactive. Start with the nominal setup outlined in the F310 Operating Guide.

Fold is skewed

q Leading edge of form is not perpendicular to folder rollers. If both folds are skewed, this is probably the cause. On a sheet feeder, adjust the sheet feeder skew control. With the 3370 burster, turn the alignment adjusting knob.

q Too much side guide clearance. Set 1/32-1/16" clearance between the stack and one side guide.

Table 6-1 F310 Diagnostics (cont.)

Fold is skewed (cont.)

q Too much feed gap. Lower the feed roller.

q Buckle chute is skewed. If only one fold is bad, this is probably the reason. Straighten the appropriate buckle chute stop.

q If both folds are crooked, don’t move the chute stops. Keep them straight and parallel. Instead, use the FEED ALIGNMENT knob on the near side of the sheet feeder or the burster interface to change the feed angle. This will correct both folds at once, and you won’t have to readjust the buckle chute stops. There are two methods:

Sheet feeder

Running at a low speed, slowly turn the feed alignment knob in the direction indicated, until the folds are straight.

3370 Burster

1.  Turn off the burster. Hand-feed a form out of the burster until it just touches the entrance rollers of the folder.

2.  Turn the alignment wheel on the interface until the leading edge of the form is parallel to the surface of the first roller.

3.  Crooked folds can also be caused by poor feeding. Review your setup; sometimes readjusting the separator stone can correct bad folds.

4.  You can also adjust the buckle chute stops to make fold adjustments. See instructions under One Crooked Fold, above.

IMPORTANT:  Set the speed control to at least 6 when running with the burster. If stalls occur at the folder input, increase the folder speed.

q Side guides are not set square (at right angles) to the feed wheel. The side guides may be adjusted together with the SKEW ADJUST control.

q Too much side guide clearance. Total clearance should be 1/32-1/16".

q Paper is not square. Correct with the SKEW ADJUST control on the sheet feeder or burster interface until leading edge of paper aligns with rollers.

Table 6-1 F310 Diagnostics (cont.)

Incorrect fold; fold length off

q Buckle chute setup is wrong. See the instructions for setting up common folds.

q Buckle chute setting is slightly off. Adjust the chute stop. Slight changes in fold length may be due to variations in the paper stock.

q Buckle chute settings are wrong. Correct and advise customer. See the F310 Operating Guide.

q First buckle chute not seated properly.

Folded sheets don’t evenly fan out on the stacker belt

q Paper feed is erratic. Check the feeder setup.

q Sealer belts are stretched or not tracking properly. If a belt is worn or stretched, replace it.

Material stalls in the folder

q Check metal guides on side wicks for adjustment.

q Check wicks for torn or frayed mesh covering.

q Check area where stall occurred for scratches, nicks, cuts, or binds on rollers or guides.

q Hand crank: do belts and rollers turn freely?

q Determine where the stall has occurred and remove the stalled piece as follows:

1. Find the stalled piece. If it is in the first buckle chute, remove the chute by lifting it up and pulling it out of the folder. Remove the stalled piece and place the buckle chute in position. Turn power on and resume normal operation.

2. If the stall is in the exit rollers or stacker area, you can easily move the exit guide to provide better access if necessary. If the stall is under the sealer rollers, raise them to a vertical position by pulling the raised flange up and to the right and lifting the roller assembly.

3. If the stalled material cannot easily be removed, put your hand on the forms in the feeder (so another form won’t feed) and turn the HAND WHEEL in either direction to "walk" the stalled material out of the folder. Make sure no paper fragments remain in the folder or buckle chutes.

q Some material was not cleared from the buckle chutes following a stall.

q First buckle chute not seated properly.

7.1 Introduction

This section of the manual explains how to remove and replace key components of the Model F310 Folder. In most cases, we assume that the equipment has been disconnected from the power and the appropriate covers have already been removed to gain access to the part in question. Cover removal is explained in paragraph 7.3. See the Model F310 Parts List (SV 11533-PL) for exploded views of all assemblies.

WARNING:    Avoid working on a "live" machine if at all possible. Always disconnect the AC line cord before you start disassembly. If you must make adjustments under dynamic conditions, remember that 115 Vac or 90vdc is present at several points in the machine. Keep well clear of any moving parts. Refer to the safety summary in the introduction to this manual for helpful guidelines.

NOTE: part replacement is never a substitute for careful diagnosis. Before replacing any parts, isolate the problem by following the troubleshooting information in Section 6. This will save a lot of time and frustration.  

7.2 Bypassing the Safety Interlocks

If absolutely necessary, the safety interlocks can be bypassed to operate the machine while open for service. This should be done only when absolutely necessary, and never when customers are in the area. Review the safety information in Chapter 1 before operating while open.

WARNING:    Exposed rollers are hazardous! They can capture fingers, tools, and clothing and cause injury. Do not allow non-PB people near the machine in this condition. We are liable if they're injured.

1. Open or remove the safety covers. Each cover contacts a magnetic switch mounted on the side frame. The buckle chute cover magnet is on the far (rear) side; the sealer cover magnet is on the near (front) side.
2. Place a small magnet against the switch. It will adhere to the switch and permit operation with the covers off.

        7.3 Removing Machine Covers

Figure 7-1 is an exploded view of the F310 covers.

Remove the sheet feeder (if installed) by opening the first safety cover and lifting sheet feeder up from the rear and off of the mounting pins.

7.3.1 Removing Side Covers (Figure 7-1)

1. Remove hand wheel by prying off the center disk on the hand wheel, exposing the retaining ring. Remove the retaining ring with TruArc© pliers; the hand wheel and the spring behind it will come off.
2. Using a Phillips screwdriver, unscrew the six screws along the outside bottom and inside top edge of each cover.

7.3.2 Removing Front Cover (Figure 7-1)

          Remove the two screws from the top and bottom front edges of each side frame and slide the front cover off around water filler.

7.3.3 Removing Back Cover (Figure 7-1)

1. Remove the four screws from the top and bottom of the rear cover plate and remove the plate.

CAUTION:  Do not remove the plate from the machine until the power and burster interface wires are freed.

    2.    Detach power harness from circuit breaker.

3.    Detach the burster interface cable receptacle from the cover plate by removing two nuts and bolts. Leave the receptacle on the wires and remove the cover plate.

        7.4 Removing Upper Buckle Chute

1. Lift the left safety cover, which covers the buckle chutes and fold rollers.

    2.   Lift the buckle chute straight up and tilt forward slightly to remove.

        7.5 Removing Rollers

Most of the rollers on the machine can be removed by compressing the bearing retainer springs and removing them from each bearing, then lifting the bearing and removing it through the side frame opening. Most rollers can then be easily removed. Specific rollers require additional steps:

7.5.1 Upper Folder Entrance Roller (Figure 7-2)

Remove the E-clip from the spring-loaded tensioner on the center of the roller shaft on each.

7.5.2 Lower Folder Entrance Roller Figure (Figure 7-2)

Using a 3/32" Allen wrench, remove the setscrew from the 21-tooth pulley on the front end of the roller shaft.

7.5.3 Folder Exit Rollers (Figure 7-3)

You must remove the folder exit rollers to replace the counter switch. In order to do so, first remove the cover above them. Three of the cover screws are easily accessible; to remove the left front screw, rotate the main drive gear until the hole is aligned with the screw to permit access.

7.5.3.1 Upper Folder Exit Roller

Remove the screw securing the counter switch adjusting arm from the center of the roller shaft.

7.5.3.2 Lower Folder Exit Roller

Using a 3/32" Allen wrench, remove the setscrew from the timing gear on the front end of the roller shaft.

1. Remove the sheet feeder and place it face up on the table with the input end toward you and the feed roller away from you.
2. Rotate the feed roller until the setscrew on the left-hand retainer faces upward. Loosen the setscrew with a 3/32" Allen wrench.
3. Slide the roller to the right, against the spring far enough to take up the play in the entire assembly (move the feed roller about 1/8" further than you want it to end up).
4. Be sure the retainer is tight against the roller and tighten the setscrew.

7.7 Adjusting Second Buckle Chute to Prevent Roller Binding (Figure 7-6)

Operating the unit with the lower edge of the second buckle chute pressing against the fold roller can damage the roller and overheat the motor. This adjustment should be made at setup, before, turning on the machine.

1. Remove side covers and loosen the forward screw of each pair securing the buckle chute.
2. Pivot the chute upward and rearward slightly until the lower edge does not touch the roller surface. Don’t leave a gap larger than 1/16". Retighten the screws.

7.8 Belt and Chain Adjustments

7.8.1 Adjusting the Timing Belt (Figure 7-8)

Loosen the two screws on the sliding tensioner and press it downward until firm pressure in the center of the belt deflects it ¼-½ " ±⅛".

7.8.2 Adjusting the Motor Drive Belt (Figure 7-9)

1. Loosen the four bolts securing the drive motor to the side frame.
2. Slide the motor to the left until firm pressure in the center of the belt deflects it ½" ±⅛" and tighten the motor mounting bolts.

 

Figure 7-9 Adjusting Motor Drive Belt

Figure 7-10 Adjusting Drive Gear Backlash

Figure 7-14 Motor Control Board

Figure 7-15 Adjusting Counter Switch

Figure 7-16 Replacing Counter Switch

Figure 7-17 Adjusting the Edge-Wick Spring Deflectors

7.10.4 Moistening Dried-out Wicks

Water remains in the wick reservoirs when the machine is not on. Under some circumstances, such as long idleness in low humidity, this water will evaporate. If the wicks have been used without EZ-Seal and allowed to dry out, they may not re-moisten properly. The operator can usually correct this be starting the machine with a small quantity of pure EZ-Seal in the tank. The wicks should moisten within 5-10 minutes. If this is unsuccessful, remove the wicks, submerge them in warm water with the correct concentration of EZ-Seal and squeeze them slightly to wet them.

7.11 Pump and Water Tank

7.11.1 Removing the Water Pump (Figure 7-20)

1. Drain the machine.

2. Slide the machine off the edge of the table for access to the pump safety cover on the underside. Remove four screws and the cover. Take off the back cover panel per paragraph 7.3.3. Disconnect all plumbing and wiring from the pump. Remove the two screws at the bottom of the pump mounting bracket and take the pump and bracket through the rear.

7.11.2 Cleaning the water pump

With the pump removed, take the bottom plate off the pump to expose the impeller. Clean the impeller and impeller chamber and reassemble.

7.11.3 Draining the Water Tank

You can drain the tank by tipping the machine forward with the stacker tray removed and pouring the water into a suitable receptacle. However, it is easier to remove the hose from the tank to the pump and allow the water to drain, or remove the pump output line, direct it into a receptacle, turn the power switch ON and pump the water out.

                    7.11.4 Removing the water tank (Figure 7-21)

1. Drain the machine completely.

2. Remove the back cover plate, the stacker tray and the front cover plate (under the stacker) per paragraph 7.3. From under the feed deck, remove the three wick reservoir return lines at the top of the tank and the line to the pump at the bottom rear. Disconnect the wiring from the tank sensor to the ADD WATER lamp, and pull the wire clamps off the top rear of the tank (this is not tank-related wiring). Slide the tank out through the front (right) end of the machine.

Figure 7-21 Removing Water Tank

8.1 Description

The F310 has only one accessory, the F390000 Burster/Sealer Interface Kit, consisting of two pieces. The upper portion is a paper guide, which rests on the exit deck of the 3370 Burster and the input deck of the F310. Its purpose is to guide the burst pages accurately into the entrance rollers of the F310. The lower portion is an alignment bracket, which attaches permanently to the 3370 Burster and can easily be connected to and disconnected from the F310. Its purpose is to align the two machines.

8.2 Installation

1.    Install the triangular alignment bracket first (Figure 1, right). Be sure the 3370 is mounted on its pedestal (see the 3370 Operating Guide, PB Form SV 10432).

2.    Remove the alignment pins from the output end of the 3370 and attach the square end of the alignment bracket to the holes they were in, using the two screws provided in the kit.

3.    Assemble the tapped cylinder nut in the parts bag with its bracket as shown, and screw the bracket and nut into the small hold on the right side of the F310 input deck with the screws provided (Figure 2, below).

Figure 8-1 Installing the Alignment Bracket

8.3 Disconnecting the Burster Interface to Attach the Sheet Feeder

1. Turn off both machines.

2. Unplug the 3370 control cord, which connects the burster and the folder.

3. Lift the paper guide and remove it.

4. Unscrew the knurled center thumbscrew from the alignment bracket, and unscrew the alignment arm completely from the cylinder nut on the F310.

5. Swing the alignment arm out of the way and push the two units about 6 inches apart. The alignment bracket will remain attached to the burster. Be sure to leave enough space between the machines to attach the sheet feeder to the F310.

9.0 Operator Training

9.1 GENERAL

This section provides guidelines for operator training. The purpose of the outline is to establish a uniform training procedure in the field.

Please note that several adjustments are interactive. For this reason, operator training is most important, especially if the customer has had little or no experiences with similar devices.

9.2 TRAINING OUTLINE

9.2.1 General Overview and Sequence of Operation.

Explain in general terms the functions performed by the F310. Explain what happens, why it happens, and when it happens.

As you explain these functions, relate your description to specific areas of the machine following the flow of material, e.g., the feeder, water system, folder, buckle chutes, exit rollers, and sealer.

9.2.2 Material Specifications

Carefully review the material specifications, fold types and material handling guidelines presented in Section 3 of the F310 Operating Guide and Section 2. Emphasize that material must fall within these published specifications to assure proper operation of the equipment and the greatest productivity.

If the application involves folding very light or heavy stock, be sure to emphasize the deviations from the standard setup procedures, which are required to handle the paper.

9.2.3 Operator Safety

Safe operation of the equipment is of paramount importance both to the customer and to Pitney Bowes and cannot be overemphasized. Draw the operator’s attention   to Section 5 of the F310 Operating Guide.

9.2.4 Controls and Indicators

Referring to Section 6 of the F310 Operating Guide, explain the function of all controls and indicators. Point out and demonstrate the:

1.    MAIN POWER switch

2.    SPEED control

3.    Hand wheel

4.    Circuit breaker

5.    Feeder adjustment

6.    Buckle chute adjustments

7.    Sealer/stacker adjustments

8.    Seal/no seal

9.    Resettable counter

10.  Stalled material removal

9.2.5 Setup

Explain and demonstrate the correct procedures for setting up the equipment. See Section 7 of the F310 Operating Guide and have the operator perform each step after you demonstrate it.

IMPORTANT: encourage the operator to ask questions and have the operator repeat the procedures which he or she seems unsure of.

Check the water supply. Remind the operator that running out of water will not stop the machine, and that water should be added as soon as the ADD WATER lamp goes on. Emphasize the usefulness of EZ-Seal.

Be sure that water flow is good and that the wicks are moist.

Set side guides to width of document using sample material. Explain the need to maintain a small clearance (1/32") for good feeding. Emphasize that the side guides or burster exit must be square with respect to the feed wheel to void skewing.

Set feed speed. Note that paper longer than 11" may have to be run at slower speeds.

Set up the buckle chutes. Begin by pointing out the fold chart and explain how the dimensions given there relate to the scales on each buckle chute. Demonstrate buckle chute removal. Explain how to reverse the left (first) chute when a single fold is called for.

Set the SPEED control at the halfway mark (or between 6 and 8 with the burster).

Show the operator how to fan and shingle a stack. Run several sample sheets. Place your hand on the stack and apply pressure to prevent feeding. Turn the main power switch ON. Release pressure on the stack to feed several sheets. Apply pressure again to stop feed, then turn MAIN POWER switch off.

Position the stacker rollers as described. Explain that proper adjustment is required to assure neat, uniform stacking.

Check fold accuracy of the sample sheets. Explain and demonstrate how to correct a skewed fold or wrong fold length. If feeding problems were encountered during the test, adjust the feed gap as required. Be sure to explain what you are doing and why you are doing it.

9.2.6 Loading and Running

Demonstrate and explain the procedure for loading forms on the feed deck. Emphasize the importance of aerating the paper stack properly before loading. Demonstrate how to add paper to a stack on the feed deck.

Show the operator how to stop the machine by applying pressure to the stack and turning