70-131 Autocreaser Pro 50 Operators Manual Iss1

70-131 Autocreaser Pro 50 Operators Manual Iss1
AutoCreaser Pro 50
DOCUMENT
CREASING MACHINE
OPERATORS MANUAL
Morgana Systems Limited United Kingdom
Telephone: ( 01908 ) 608888 Facsimile: ( 01908 ) 692399
Website: www.morgana.co.uk
ISSUE 1
MAY
2010
70-131
INDEX
INTRODUCTION
The Morgana AutoCreaser Pro 50
PAGE 3
SAFETY Do’s & Don’ts
4
THE AUTOCREASER Pro 50
Labeled Photograph
6
THE CONTROLS
The switch panel
Features on the switch panel
7
8
QUICK START GUIDE
9
OPERATING THE AUTOCREASER Pro 50
Setting the machine
Programming the machine
Reading stored programmes
Paper jamming
18
24
25
27
THE STACKER ASSEMBLY
Setting the Stacker unit
28
PERFORATING
Equipment, spares
Setting the machine
30
31
THE BLADE ASSEMBLY
Setting the blade pressure
Setting the blade alignment
33
34
REPLACING CREASING BLADE SETS
Installing new blade sets
Spares
35
36
TROUBLE SHOOTING
DISPATCH KIT
ACCESSORIES & OPTIONS
RECOMMENDED SPARES
FUSE POSITIONS AND RATINGS
PRODUCT RECYCLING AND DISPOSAL
37
42
43
44
46
47
Page 2
CREASING
AutoCreaser Pro 50
INTRODUCTION
AutoCreaser Pro 50
The Morgana AutoCreaser Pro 50 is a fully automatic suction feeding creasing
system designed for use with both conventional litho and digital printers.
The feed on the AutoCreaser Pro 50 can also be manually operated for use
with heavy stock, very small or very large sheets, embossed or even irregular
sheets.
The crease is programmed from the leading edge of the sheet using the
controls on the front panel.
The blade and anvil are mechanically controlled over their entire length
and can be adjusted to accommodate various weights of media.
IMPORTANT
The operating environment should be controlled to a temperature between
16° C and 27° C Maximum
Specification
Feeding System ................................................ Bottom suction feed
Max. Sheet Size ................................................700mm x 500mm (27.5” x 19.7”) [900mm x
500mm (35.4” x 19.7”) with Optional
extension table].
Min. Sheet Size (in automatic mode)................. 210mm x 140mm (8.5” x 5.5”)
Max. Paper Thickness........................................ 0.4mm (varies according to hardness,
type of fold, and substrate)
Max. No. Creases per Sheet ............................ 16
Min. Distance Between Creases ....................... 0.1mm
Max. No. Stored Programmes .......................... Unlimited
Min. Crease Distance from Leading Edge ........ 2.5mm
Min. Crease Distance from Tail Edge ................35mm
In Hand Feed Mode up to 2499.9mm to Last Crease can be Programmed.
Speed per Hour (A4 in half) ..............................8500
Speed per Hour (A5 in half) ..............................11000
Dimensions ....................................................... L: 1500mm H: 1224mm W: 682mm
L: (59”)
H: (48.2”) W: (26.8”)
Weight ............................................................... 156Kgs (+50Kgs packing)
Power Requirement .......................................... 1 phase 220 / 240v AC
*As part of our continued product improvement plan, specifications and information
published in this manual are subject to change without notice.
All specifications are dependant on application, type of stock, temperature, RH and print
engine used.
Specifications quoted were measured on uncoated and unprinted stock.
E & OE.
SYSTEM
Page 3
Safety Do’s & Don’ts
Safety Do’s & Don’ts
REGLES DE SECURITE : « A FAIRE » ET « A NE PAS FAIRE »
Do - read this operator manual fully before operating the machine.
Lire ce mode d'emploi avant d'utiliser la machine.
Do - operate with the designated AC current only. Use an exclusive outlet, as
overloading may cause fire or an electric shock.
Respecter l'alimentation électrique indiquée. Brancher sur une prise séparée
car une surcharge peut entraîner un incendie ou un choc électrique.
Do - install the power cord out of the way to avoid a tripping hazard.
Installer le cordon d'alimentation de manière à ne pas pouvoir
trébucher par dessus.
Do - make sure that the mains inlet connector is always easily accessible.
Ménager un accès libre à la prise de courant.
Do not - install the machine in an unstable place such that it tilts or shakes.
Ne pas installer la machine sur une surface non plane, afin d'éviter
qu'elle ne penche ou ne vibre.
Do not - unplug the plug or unplug the power cord from the outlet with a wet hand,
this can cause an electric shock.
Ne pas installer la machine sur une surface non plane, afin d'éviter
qu'elle ne penche ou ne vibre.
Do not - unscrew and remove any covers from the machine, as it can cause an
electric shock or injury.
Ne démonter et enlever aucun carter de la machine, par crainte de décharge
électrique ou de blessure.
Do not - place receptacles containing liquids on any surface.
Ne pas placer de récipient contenant un liquide sur la machine.
Do not - adjust any part of the machine whilst rollers are running
N'effectuer aucun réglage pendant que les rouleaux fonctionnent.
Do not - operate the machine with loose or trailing clothing or loose hair.
Ne pas porter de vêtements flottants et rassembler les cheveux longs
lors de l'utilisation de la machine.
Do not - under any circumstances adjust the paper gate when the machine is
switched on.
En aucune circonstance, régler le séparateur de papier lorsque la
machine est branchée.
Page 4
CREASING
AutoCreaser Pro 50
Warning Labels
Do - be aware of any finger traps and rotating parts when operating
the machine.
Attention au risque de se coincer les doigts, et aux pièces en
mouvement lors du fonctionnement de la machine.
Do - read this operator manual fully before operating the machine.
Lire ce mode d’emploi avant d’utiliser la machine.
Do not - operate the machine with loose or trailing clothing.
Ne pas porter de vêtements flottants lors de l'utilisation de la machine
Do not - operate the machine with loose hair.
Rassembler les cheveux longs lors de l'utilisation de la machine.
Do - be aware of any finger traps and rotating parts when operating
the machine.
Attention au risque de se coincer les doigts, et aux pièces en
mouvement lors du fonctionnement de la machine.
Do - be aware of sharp points and blades.
Attention aux éléments tranchants et aux couteaux.
Do - be aware of rotating rollers.
Attention aux rouleaux en fonctionnement
Do - be aware of low current anti-static shock.
Attention aux faibles chocs d'électricité statique
SYSTEM
Page 5
AUTOCREASER Pro 50
AutoCreaser Pro 50
DOCUMENT CREASING MACHINE
Key to photograph below
1
2
3
4
5
6
Roller tilt handle
Stacker assembly
Suction slot knob
Touchscreen
Air separation knob
Air distribution knob
2
7
8
9
10
11
12
1
Adjustable side lay
Back Stop
Fixed side lay
Roller tilt knob
Paper Gate
Exit Guard
15
12
5
11
13
14
15
16
Switch Panel
Fuses
Gap Set Knob and Lever
Vacuum Bleed Knob
4
8
7
9
10
3
16
Page 6
14
6
13
CREASING
AutoCreaser Pro 50
THE CONTROLS
The Switch Panel houses the Compressor switch, System switch, and an
industry standard Emergency Stop switch which will stop all power going to
the machine when activated.
THE SWITCH PANEL
Compressor Switch
System Switch
Emergency Stop Switch
SYSTEM
Page 7
THE CONTROLS
Features on the Switch Panel
System switch
When activated the system switch will operate the motors in order to begin the
creasing sequence.
Compressor switch
Allows the operator to switch off the compressor unit in order to utilise the machine
to manually feed sheets.
Page 8
CREASING
AutoCreaser Pro 50
Quick Start Guide
Setting the machine to operate in automatic sheet feed mode
1.
Set the gap between the paper gate and the vacuum roller to approximately twice
the thickness of the stock to be creased.
2.
Place the stock to be creased onto the loading table against the fixed side lay.
3.
Release the clamps on the adjustable side lay and slide up to the paper stack
allowing a gap of approximately 0.5mm (1/64 inch) between the paper and the side
lay.
4.
Position the backstop and slide it up to the paper stack, also allowing a gap (as
stated in the above step).
5.
Turn the Emergency Stop button clockwise to switch the power on. After the
system start up procedure the touch screen will be displayed as shown below.
IMPORTANT.
If you have not been trained to operate this machine, we strongly advise that you select
the red cross icon.
We recommend that you either seek training or ask a trained operator to run the machine
for you.
Select the green tick icon only if you have been trained to operate this machine.
If you have not been trained to operate this machine and you select the green tick icon,
Morgana Systems Ltd accept no responsibility for personal injury, damage to the
machine or damage to materials being processed by the machine.
SYSTEM
Page 9
Quick Start Guide
The touch screen is laid out into 3 main areas as shown below:
Status of
machine &
data entry
area. Also
used for
quick links
to setting
pages.
Setting
page
Tabs to enable switching between setting
pages - choose either Paper Settings,
Crease Setting, Store or Tools
Settings Pages.
Paper Settings Page.
Vacuum Suck - There
are two selections
available - 1 short
suck & 2 continuous
for stream feeding.
Highlighted number is
type currently
selected. The status
area also shows
currently selected
suck.
Batch Button - Image
is identical to that
shown in the status
area. On selection the
status area is replaced
with a calculator for
inputting new values.
Batches of any
numerical value.
Page 10
Fold Selection - For quick setting of crease positions on standard size sheets.
Highlighted fold is type currently selected, other folds may be selected.
Currently selected fold is shown in the status area.
Page Length - On
selection the status
area is replaced with
a calculator for
inputting new values.
Min Length = 190mm
Arrows may be
selected to increase
or decrease the page
size in 0.1mm
increments
CREASING
AutoCreaser Pro 50
Quick Start Guide
Crease settings Pages.
To get to the crease setting page click the lower tab
the status area.
or
from
If you have selected a predefined standard crease type from the paper settings
page the crease positions will be set for you. These positions can be fine tuned
by ± 0.1 mm increments by pressing side arrow buttons
Number of creases – if
more than 6 creases are
added a scroll bar will
appear for to enable
viewing of all creases
Arrows may be selected
to increase or decrease
the page size in 0.1mm
Crease position - On selection
the status area is replaced with
a calculator for inputting new
values.
for each crease.
Cross box for deletion of crease.
On deletion of crease following
creases will move up by one
place. You will be asked to
confirm deletion of the crease.
Press to remove all
creases – you will be
asked to confirm
deletion.
increments
Plus box for inserting
additional creases. On
selection following
creases will move down
by one place a
maximum number of 6
creases can be seen at
any one time further
creases can be
accessed by use of the
scroll bar.
Scroll bar - use to bring
required crease into
view.
Crease on/off selector
green is on & red is off.
This is also indicated in
the status area.
Additional creases
added – scroll bar
appears for more than
six creases.
SYSTEM
Page 11
Quick Start Guide
Individual deletion of crease confirmation screen
Select green tick icon to confirm deletion of crease.
Remove all creases confirmation screen.
Turn Crease on/off.
Creasing turned off Greyed out areas are
unselectable. Status
area will show
creasing is off with
red icon
Page 12
CREASING
AutoCreaser Pro 50
Quick Start Guide
Run Job
Click to start machine with
settings currently shown you will receive a
notification if system
switch is not on. Press
again to stop Job
System Switch Not On
Push System Switch down to start the machine.
The machine running screen will appear.
Click to stop machine
SYSTEM
Page 13
Quick Start Guide
Status Screen
Paper length - input from
the paper setting screen
Clicking in this area will take you
to the paper setting page
Number of creases - this
may alter automatically if
a pre - defined fold is
selected. Adjustments
may be made in the
crease setting screen
- can be one of the
following.
Clicking in this area will take
you to the Crease setting
page
Clicking in this area will take
you to the Job Store page
Batch quantity - this is
input from the batch
calculator on the paper
setting screen - max. 999
Clicking in this area will take
you to the paper setting
page.
Current Job count - click
to zero
Page 14
Suck setting - for stream
setting choose selection 2
Currently selected fold type
Green icon indicates
settings are saved - a red
icon would show that
settings have been
changed but the job has
not been saved.
A screen will appear to
confirm that you want to
reset the count.
Currently selected Vacuum
Click to start machine with settings currently
shown - you will receive a notification if
system switch is not on. Press again to stop
Job
CREASING
AutoCreaser Pro 50
Quick Start Guide
The Status Screen will on occasions be replaced with an Input Calculator Screen
as shown below.
Pre - set Paper sizes for quick
insertion – Standard sizes for
country origin would be shown
Paper size
input calculator
Pre - set Batch sizes for quick
insertion.
Batch size
input calculator
Crease position
input calculator
NOTE:
The green tick or the red cross must be selected on the Calculator Screen to
make the left hand side of the touchscreen active again.
SYSTEM
Page 15
Quick Start Guide
Tools Screen
Machine Speed Adjustment:Speed setting 3 will give the fastest throughput of
stock through the machine.
Use speed setting 1 or 2 for troublesome stocks,
or to synchronise the speed of the AutoCreaser to a
Morgana Autofold Pro, when they are used together.
Inch paper in direction
of arrow to clear jams
Click on Up Arrow to
put Anvil into Top
Dead Centre position
(TDC)
Inch paper in direction
of arrow to clear jams
Clicking this icon will
show Machine
program revision &
Touch Screen
software revision.
Main Processor Program
version
Touch screen software
version
Page 16
CREASING
AutoCreaser Pro 50
Quick Start Guide
BLANK
PAGE
SYSTEM
Page 17
Operating the Autocreaser Pro 50
Setting the Machine
Adjusting the Paper Gate
Set the height of the Paper Gate to approximately two thicknesses of paper, by turning the
disc j. An excessive gap is a most likely cause of double sheet feeding.
This setting is only intended as a guide, for instance, sheets with an upward curl will
require this setting to be increased.
J
TWO THICKNESSES
OF PAPER
WARNING.
DO NOT ADJUST THE
PAPER GATE WHILE THE
MACHINE IS RUNNING OR
THE SUCTION DRUM MAY
BECOME DAMAGED.
Setting the Suction Slot
The suction slot is located inside the vacuum roller and can be adjusted by releasing and
moving the suction knob horizontally in either direction to the required position.
For light stocks set the knob to the left and for heavier stocks set the knob to the right.
FIG 8.1
Adjustable
Side Lay
Suction
Slot Knob
Page 18
CREASING
AutoCreaser Pro 50
Operating the Autocreaser Pro 50
Setting the Adjustable Side Lay
Place the paper stack on to the loading table and slide up to the fixed side lay and paper
gate. Release the clamps located at each end of the side lay and slide up towards the
paper stack as demonstrated in fig 8.1. Allow a gap of approximately 0.5mm (1/64 inch)
between the paper and the side lay.
Setting the Back Stop
Position the backstop and slide up towards the paper stack allowing a gap (as specified
in the above step).
Setting the Air Distribution
Depending on the length of the sheet to be creased, the air distribution knob can be
rotated to various positions in order to supply air to different ports. Position 2 is
recommended for most sheet sizes. However, a better result may be obtained by using
the settings below or by experimentation.
Position 1 - For sheets longer than A3 (17”) in order to supply air to the centre of the
stack, ports 2, 3 and 4 open.
2 - For A5 sheets or 8 inches long, ports 1 and 2 open.
3 - For A4 sheets or 11 inches long, ports 1 and 3 open.
4 - For A3 sheets or 17 inches long, ports 1 and 4 open.
5 - For sheets longer than A3 (17”) in order to supply air to the ends of the stack,
ports 1 and 5 open.
0 - For sheets longer than A3 (17”) in order to supply air evenly along the stack,
ports 1, 3 and 5 open.
Port 1
Port 5
Air Distribution
Knob Shown
Set To Posn. 1
Setting the Air Separation Pressure
To control the amount of air supplied to the ports, the air separation knob can be rotated
clockwise to decrease the pressure or anti-clockwise to increase the pressure.
SYSTEM
Page 19
Operating the Autocreaser Pro 50
Setting the Roller Tilt Mechanism
The roller tilt mechanism has been designed to compensate for when the creasing
position on the sheet is not square. This could be due to an inaccuracy in the media or if
the roller tilt mechanism has been incorrectly set. The mechanism will be set to zero
(square) when the machine is supplied.
To set the mechanism, unlock the roller tilt knob located below the roller tilting handle by
turning anti-clockwise. Move the roller tilt handle left or right in order to compensate for
any inaccuracy. When the position is set, ensure to lock the roller tilt knob before
operating the machine. Repeat the above procedure until the creasing position is square.
Setting the positions of drive wheels and hubs
It is important that the drive wheels and drive hubs on the roller shafts are arranged evenly
across the width of the media being creased. This is done to ensure that the media is
accurately driven and supported through the rollers.
The drive wheels and hubs are fixed to the rollers by means of a grub screw. To locate this
grub screw the rollers can be rotated by operating the motor manually.
DO NOT ROTATE THE DRIVE ROLLERS BY HAND.
To operate the motors manually, switch the machine ‘on’ at the Emergency Stop switch.
Select the Tools tab
that shown below.
Inch paper in
direction
Left
arrow
of arrow to clear jams
at the bottom of the touch screen, the display will change to
Inch paper
inarrow
direction
Right
of arrow to clear jams
Press the system switch down and then select the right or left arrows, to rotate the rollers in
short pulses.
Lift the exit guard to see if the grub screws in the drive wheels and hubs can be seen. If the
grub screws cannot be seen, lower the exit guard and rotate the rollers by selecting the
right or left arrows. Loosen the drive wheels and hubs with a 2mm allen key. Arrange the
drive wheels and hubs as shown in FIG 10.1. In order to avoid marking on some types of
media ensure a gap between the drive wheels and hubs.
This procedure should be repeated when installing perforating blades and anvils onto the
drive wheels and hubs.
Page 20
CREASING
AutoCreaser Pro 50
Operating the Autocreaser Pro 50
FIG 10.1
Set Feed
The length of suction on the sheet of paper being fed can be adjusted by setting the feed
type as follows:Select 1 for short suck, select 2 for continuous suck (stream feeding).
Vacuum Suck
Select 1 for short suck
Select 2 for continuous suck
(Stream feeding)
NOTES.
1. Stream Feed will give the quickest through put of stock through the machine.
2. When the first crease is less than 37mm from the leading edge of the paper the feed will
be noticeably slower.
SYSTEM
Page 21
Operating the Autocreaser Pro 50
Setting the infeed roller gap set
The gap between the infeed rollers must be adjusted to suit the stock being used. The gap
set can be adjusted as follows:1. Place a sample sheet of the stock to be used onto the feed bed.
2. From the start up menu, move the selection switch to the left to select Tools.
3. Press the system switch down.
4. Move the selection switch to the left, one click at a time, until the sheet is gripped in
the infeed rollers. Test the grip of the sheet in the rollers by trying to remove the
sheet by hand, the sheet should be lightly gripped by the rollers. If the grip on the
sheet is too light or too heavy it can be adjusted as follows:(i) Turn the gap set locking knob anti-clockwise to unlock.
(ii) Move the gap set lever up to increase the gap or down to decrease the gap.
(iii) Turn the gap set locking knob clockwise to lock.
Gap Set
Lever
Gap Set
Locking
Knob
Page 22
CREASING
AutoCreaser Pro 50 Operating the Autocreaser Pro 50
BLANK
PAGE
SYSTEM
Page 23
Operating the Autocreaser Pro 50
Programming the machine
1.
Switch the power ‘on’ by turning the Emergency stop button clockwise
to release the safety latch.
Setting the page length
2.
Set the page length of the paper as described on page 10.
Setting the vacuum suck
3.
Set the vacuum suck as described on page 10. Setting number 1 for short suck and
setting number 2 for continuous suck (stream feed).
Setting the batch quantity
4.
Select the
button. On selection the status area is replaced with a calculator for
inputting new values.
Setting the crease positions
5. (i) Select the lower tab
or
from the status area to get to the
Crease Settings Page.
(ii) Set the creases as described on pages 11 and 12.
Storing the Job
6.
The job that has been set can now be stored as follows.
(i) Select the lower tab
or
from the status area to get to the
Store Settings Page.
(ii) The job can be given a name and stored as described below. You can also retrieve
previously saved jobs, modify them or delete jobs that are no longer required.
To create a new job name click in text area &
keyboard will open to input job name.
Load existing job from
store
Clicking to search
currently stored jobs
Clicking to delete
currently stored jobs
Clicking to save job
shown.
Page 24
CREASING
AutoCreaser Pro 50
Operating the Autocreaser Pro 50
Keyboard for entering job name.
Return to Store Menu &
click save icon
job to store
to save
Save confirmation screen.
To confirm saving
of Job click here.
Search for current jobs to load or modify.
You can search for jobs by clicking the search icon
keyboard for text input.
, this will bring up the search
Typein job description
or first few characters
Press search icon
to start search
To change your mind &
return to the previous
screen click here.
SYSTEM
Page 25
Operating the Autocreaser Pro 50
Jobs matching
characters in text box
will be shown in this
area - selecting job
from this area will
show job settings in
the right hand status
area. Job selected will
be shown in text box.
Toggle between search
results &full list of
jobs
Press to load job
shown in text box.
Loading job confirmation screen.
The loaded job can be run or modified and saved as the same job name.
Overwrite job confirmation screen.
To cancel overwrite of
Job press here.
To confirm overwrite
of Job press here.
Page 26
CREASING
AutoCreaser Pro 50
Operating the Autocreaser Pro 50
Delete job confirmation screen.
Tocancel deletion of
Job press here.
To confirm deletion of
Job press here.
Running the machine
Run the job as described on page 13. The machine will complete its creasing operation if a
sheet has already been fed through the paper gate.
Paper jamming
In the event of a paper jam occurring whilst the machine is operating, select the Tools
tab
at the bottom of the touch screen, the display will change to that shown
below. Press the system switch down and then select the right or left arrows, to inch the
paper forwards or backwards.
Inch paper
inarrow
direction
Right
of arrow to clear jams
Inch paper in
direction
Left
arrow
of arrow to clear jams
Setting the machine to operate in manual sheet feed mode
In order to feed heavy stock, very small or very large sheets, embossed or even irregular
shaped sheets, it may be necessary to feed the sheets manually. The machine can be
programmed and set up in exactly the same way as explained when operating the machine
automatically. However, the paper gate must be raised to its highest position for the sheets
to be fed freely. Operating the machine in manual sheet feed mode will also require the
suction length to be continuous in order to accommodate various types of stock. Therefore,
the feed should be set to Stream Feed (Vacuum Drum position 2) see page 10.
The machine can now be started by activating the System switch to ‘on’. Do not activate
the Compressor switch.
Select the
icon on the touch screen and begin to slide the sheets individually through
the paper gate until they are driven by the drive belts.
To stop feeding the sheets, select the
System Switch off.
SYSTEM
icon on the touch screen and switch the
Page 27
The Stacker Assembly
The stacker unit on the machine is used to catch the sheets once they have been
creased or perforated.
Setting the Stacker assembly
1.
Assemble the stacker unit to the machine as shown in fig 13.1 below.
Important
Ensure that the stacker unit has been assembled to the machine properly. However,
if it has not, the connection on the magnetic switch will be broken and the machine
will not operate (see Trouble shooting pages for details).
There are two side guides on the stacker unit; a left handed (fixed) guide and a right
handed (movable) guide held on by a magnetic strip. There is also a left hand extension
guide. The guides will control the way in which the paper is collated by setting their
positions on the stacker bed.
2.
Place a single sheet (from the stack to be creased / perforated) on to the stacker bed
against the fixed ‘left hand’ guide.
3.
Position the ‘right hand’ side guide on to the stacker bed leaving a minimum
clearance of approximately 1mm each side of the sheet.
LEFT HAND
BACK STOP
LEFT HAND
SIDE GUIDE
FIG 13.1
RIGHT HAND
SIDE GUIDE
Page 28
RIGHT HAND
BACK STOP
CREASING
AutoCreaser Pro 50
The Stacker Assembly
4.
Whilst the sheet is between the two guides on the stacker bed, set the distance
between the top of the sheet and the backstop flanges to approximately 5mm.
5.
For shorter sheets, the back stop can be used (as shown in FIG 13.1) to adjust the
position of the paper stack.
TIPS
l
l
SYSTEM
One of the back stops supplied with the machine (on the
stacker assembly) can also be used as a tool holder as
demonstrated in the photograph (left).
The scale on the bed can be used to measure the desired
creasing or perforating position on the sheet.
Page 29
Perforating
Once the machine is set-up, the Autocreaser Pro 50 can be used to perforate or crease.
Note
Perforating and creasing can be carried out simultaneously. However, if any
adjustment is made to the roller tilt mechanism in order to compensate for the
perforation line being ’out of square’, this may effect the accuracy of the crease. If
this occurs creasing and perforating must be carried out as separate operations.
The components and tools required to install the perforator are contained in the despatch
kit supplied with the machine, they are listed below.
1 off Set of standard perforation ‘56 tooth’ blades.
1 off Set of standard hardened anvils.
1 off Perforator stripper.
1 off Scoring wheel
1 off 3mm bondhus wrench / allen key
1 off 2mm bondhus wrench / allen key
The perforator blades are split into two matching halves
and are fitted to the drive wheels as shown in the
photograph using the four screws supplied.
A hardened anvil is fitted to the drive hub as shown in the
photograph also using the four screws supplied. Again the
anvils are made from matching halves.
Important: The perforator blades are very sharp and
care must be taken whilst handling.
Do not mix the matching pairs of blades or anvils.
Perforating ‘Spares’ kits
For perforating and other types of paper, various spares kits are available which can be
assembled to the machine in the same fashion. They are listed below along with a range
of scoring wheels,
Perforating blades 56 teeth Part Number 1-99-41 - Standard stock /
fine perforations.
28 teeth Part Number 1-99-12 - Medium stock /
medium perforations.
20 teeth Part Number 1-99-10 - Heavy stock /
coarse perforations.
Anvils
Page 30
Standard Part Number 1-99-35 - For all blade types
CREASING
AutoCreaser Pro 50
Perforating
All of the blades and anvils are supplied with fixings.
*Perforator stripper Standard Part Number 78-013
*It is recommended that for multiple perforations, a separate perforator stripper is used for
every perforating blade set fitted in the creasing unit.
Setting the machine
1.
Turn the mains supply to the machine ‘off’.
2.
Remove the stacker unit and open the exit guard.
3.
Locate and remove the blades / anvils from the despatch kit supplied with the
machine.
4.
Using the 2mm allen key (supplied), loosen the drive wheel that is to accommodate
the blades.
5.
Slide the drive wheel away from any obstructing drive wheels or hubs in order to
mount the blades.
6.
Using the 2.5mm allen key (supplied), take one
of the matching pairs and mount on to the drive
wheel. Do not secure the blade.
7.
Mount the other matching pair to the drive wheel
as shown (fig 16.1). Secure the blades to the
wheel ensuring not to over tighten grub screw.
8.
Mark on a single sheet the desired perforating
position. Feed the sheet through the machine
manually until the mark can be seen. Use this
mark to assist in fixing the position of the
perforating drive wheel to the roller drive shaft.
9.
Using the 2mm allen key, loosen the drive hub
nearest the perforating drive. Slide the drive hub
away from any obstructing drive wheels or hubs
in order to mount the anvils.
FIG 16.1
10. Using the 2.5mm allen key, take one of the
matching pairs of anvils and mount to the drive
hub. Do not secure the anvil.
FIG 16.2
SYSTEM
Page 31
Perforating
11.
12.
13.
14.
15.
Mount the other anvil ensuring that they have matched on the drive hub. Secure the
anvil to the hub ensuring not to over tighten grub screw as shown in fig 16.2.
Slide the drive hub towards the perforating drive wheel until there is a clearance
of 0.5mm.
To prevent damage to the blades or the anvils, do not force the drive wheel against
the hub.
Fix the perforator stripper adjacent to the drive wheel and blade as shown.
Operate the machine and test the perforations for form.
It is important that the drive hubs are arranged evenly across the width of the paper
in order to reduce the risk of jamming.
For multiple perforations repeat the above procedure.
Shaft support blocks are mounted on the top and bottom shafts. If they are in a
position that obstructs perforating, they can be slid along just enough to clear the hubs.
They should be mounted as near to the centre of the machine as possible, to
maximise support. The depth of perforation can be adjusted by first loosening the
socket set screws, in the support block, with a 2.5mm allen key. Insert the 2.5mm
allen key into the grub screw, push the allen key up to decrease the perforating depth
or down to increase the depth of perforation. Re-tighten the socket set screws.
(Note. This adjustment can also be carried out on the bottom shaft)
Typical set-up for perforating sheets.
1
2
4
6
5
8
3
7
8
FIG 17.1
1 - Perforating drive wheel with mounted blades
5 - Standard drive hub
2 - Perforator stripper
6 - Upper shaft support block
3 - Standard drive wheel
7 - Lower shaft support block
4 - Drive wheel with mounted anvils
8 - Grub screw
Always remove blades and anvils once the perforating operation has been
completed to avoid marking on digital or delicate media.
Page 32
CREASING
AutoCreaser Pro 50
The Blade Assembly
Adjusting the blade pressure (no paper required)
1. (i) Switch the power ‘on’ by turning the Emergency stop button clockwise to release the
safety latch.
(ii) Select the Tools tab
at the bottom of the touch screen, the display will
change to that shown below.
(iii) Select the up arrow to move the blade to the Top Dead Centre position.
Click on Up Arrow to
put Anvil into Top
Dead Centre position
(TDC)
2. Raise the exit guard
3. Using a 6mm allen key, unlock the shoulder bolts (labelled with scale transfer)
positioned at each end of the creasing blade.
4. Turn the adjustment cam to adjust the blade pressure. Increasing the gradient on the
scale will increase the blade pressure.
5. Ensure that the shoulder bolts are locked after setting.
The diagram below demonstrates the adjustment of the blade pressure
SYSTEM
Page 33
The Blade Assembly
Adjusting the blade alignment
It is extremely important that the blade and anvil assembly within the creasing unit is
correctly aligned. Misalignment of the blade or anvil can lead to damaged profiles and
subsequently poor quality creasing so it must, therefore, be corrected immediately.
If the blade set is misaligned, the media being driven will be subject to scoring or even
tearing at any point along the crease line. Please note that to avoid damage to the
blade set, adjustment should only be made in small increments. The below sketch
demonstrates how the blade alignment can be carried out.
Adjustment can be made at either of the blade or anvil. The two clearance holes positioned above the roller tilt mechanism are the front alignment (one for blade, one for anvil).
The two holes are repeated on the back of the machine for the back alignment.
1. Remove the stacker unit from the machine
2. Unlock and centralise the roller tilt mechanism in order to locate the heads of the
front alignment screws.
3. Using a 3mm allen key, loosen the cap head type locking screws located on the
front face at both ends of the blade /anvil as shown below.
4. Using a 4mm allen key, locate the two front or back alignment screws in the side
frame in order to adjust the blade / anvil.
5. The upper screw of the two, will adjust the upper blade / anvil whereas the
lower screw will adjust the lower blade / anvil both in very small increments.
6. In order to obtain the required position, adjust either the blade or the anvil by a
small amount and then operate the machine to test the form of the crease.
Repeat the exercise until centralisation is located.
7. Using a 3mm allen key, lock the cap head type screws (as per step 3) on both the
upper and lower blade / anvil.
Page 34
CREASING
AutoCreaser Pro 50
Replacing Blade Set
1.
Before removing the blade assembly, ensure that the lower blade / anvil is NOT
at ‘top dead centre’, Switch the machine off.
2.
Remove the stacker unit and lift the exit guard.
Blade Extractor Tools
3.
Using a 6mm allen key, loosen the socket
head screws located inside the blade
adjustment cams. Remove the screws and
the blade adjustment cams.
4. Insert the blade extractor tools (70-055-01 &
70-055-02) into the holes in the adjustment
links, as shown. Push downwards on the
handles of the blade extractor tools to
release the blade assembly from the power
links.
5. Slide the blade assembly out of the creasing
unit and lay it on a flat surface.
6. Slide the adjustment links away from the
dowels located in the ends of the blades /
anvils as shown in the photograph (left)
7. Place the new blade set into position.
Check that the eccentric shoulder bolts on
the link plates have been positioned as
shown in fig 20.1.
8. (Upper blade / anvil only)
Slide the adjustment links onto the dowels.
FIG 20.1
9. Slide the new blade set into the slots of the
creasing unit as shown in fig. 21.1.
Locate the blade extractor tools into the holes in
the adjustment links as shown. Pull the handles
of the blade extractor tools upwards to engage
the blade assembly back into the power links.
10. Set the cam graphics for both ends of the blade /
anvil to their lowest point on the scale (ie. When
the mark on the scale reaches the mark on cam
holder) Fasten the socket head screws on the
adjustment cams until they are tight.
SYSTEM
Page 35
Replacing Blade Set
FIG 21.1
11. Push the exit guard down and replace the stacker assembly before operating the
machine.
12. Switch the machine on and test the crease for form.
If the pressure and the alignment of the crease is not to a satisfactory level,
see pages 33 - 35 to adjust the creasing line.
‘Spares’ kits
In the event of any damaged or lost components within the blade assembly, spares kits
are available on request. However, components within the blade set can not be ordered
separately i.e. single blade or anvil.
Standard Blade set
Part number 76 - 237 - 02
Consisting of a standard blade and anvil, blade brushes, blade links and alignment bolts.
Narrow Blade set
Part number 76 - 237 - 03
Consisting of a narrow blade and anvil, blade brushes, blade links and alignment bolts.
Page 36
CREASING
AutoCreaser Pro 50
Trouble Shooting
Paper crease out of square
l
Check that the sheets are all square and exactly the same size before loading the
stack on to the table.
l
Check that the roller tilt mechanism is correctly set and locked in position.
l
Check that the adjustable side lay has been correctly positioned ie. No further than
0.5mm from the paper stack.
Paper jamming
l
Check that the leading edge of the paper is not being damaged by the paper gate. If
this is occurring, check that the suction slot and the paper gate have been correctly
set.
l
Check that the first crease position is not too close to the leading edge of the paper.
A minimum distance of 32mm is recommended.
Machine will not start
l
Check the power supply to the machine.
l
Check that the emergency stop button has been released.
l
Check that the exit guard is down.
l
Check that the stacker unit is located correctly and has not been disconnected from
the magnetic switch.
l
Check that the lower blade / anvil is connecting to the home switch (mounted below
the lower blade / anvil).
Paper not feeding
l
Check that the paper stack is not too high or too heavy for the feeder. The height of
the paper stack should be defined by the weight and the size of the stock being
creased.
l
Ensure that the adjustable side lay is not pressed against the paper stack. However,
if the clearance between the adjustable side lay and the paper stack is too great, the
air supply will escape instead of blowing through the paper thus making it difficult to
feed.
l
Check that the clearance between the paper gate and the suction roller is not set too
low.
l
On digital media, the feeding performance may be improved if the leading edge of
the stack is trimmed before loading onto the machine.
SYSTEM
Page 37
Trouble Shooting
l
Check that the air distribution has been correctly set.
l
Check that the air separation has been set high enough to feed the sheets.
l
For heavy stocks, very small or very large sheets, embossed or even irregular stock,
it may be required to feed the sheets manually - see page 27 for instructions.
l
Check that the gap of the infeed rollers is set correctly (see page 22)
Machine not counting
Open the exit and remove the blade set
(see pages 35-36) to access the dual
sensor post located in between the drive
rollers. Using a soft brush, clean the
visible sensor on the end of the post.
Use the brush to clean the sensors
between the post and the bottom paper
guide which are not visible.
Photograph (left) shows the dual sensor
post containing the sensors.
Paper jammed under paper gate.
If paper gets jammed under the paper gate the vacuum drum will stop rotating, this is a
safety feature. Remove the paper and re-adjust the paper gate.
Page 38
CREASING
AutoCreaser Pro 50
Trouble Shooting
Error Screens
Sheet did not arrive.
If the machine stops and error message 01 is displayed on the touch screen, this
indicates that the paper did not arrive at the end of the suck process; so the machine
timed out. Press the green tick button and then press the start button.
Paper Crunch
If the machine stops and error message 02 is displayed on the touch screen, this
indicates that a paper jam has been detected.
Press the system switch down and then select the right or left arrows, to inch the
paper forwards or backwards. See page 39 that describes how to remove paper jams.
Press the green tick button and then press the start button.
Double Sheet Feed
If the machine stops and error message 03 is displayed on the touch screen, this
indicates that a double sheet feed has been detected. Check that the paper gate has
been set correctly. Press the green tick button and then press the start button.
Blade Not Home
If the machine stops and error message 04 is displayed on the touch screen, this
indicates that the lower blade / anvil has not made contact with the HOME switch.
i.e. blade still in top position. Switch the machine off and remove the blade set and
ensure that the area is free from obstructions. Return the blade set to the creasing unit
and switch the machine on. Operate the machine in the normal sequence, if the
display continues to read error message 04 it is advised to contact a Service Engineer
immediately.
SYSTEM
Page 39
Trouble Shooting
Error Screens (Continued)
Blade Not Home
If the machine stops and error message 04 is displayed on the touch screen, this
indicates that the lower blade / anvil has not made contact with the HOME switch.
i.e. blade still in top position. Switch the machine off and remove the blade set and
ensure that the area is free from obstructions. Return the blade set to the creasing unit
and switch the machine on. Operate the machine in the normal sequence, if the
display continues to read error message 04 it is advised to contact a Service Engineer
immediately.
Overlap
If the machine stops and error message 13 is displayed on the touch screen, this
indicates that the ‘Lead Edge Sensor’ has seen a sheet subsequent to the first
one as being longer. Again this could actually be a longer sheet, OR it could be a
sensor problem (if it is a recurring problem). Check that the paper gate has been set
correctly.
Page 40
CREASING
AutoCreaser Pro 50
Trouble Shooting
Recommended weekly operator maintenance
l
l
l
l
Clean all sensors
Clean in feed rollers and output drive hubs using the cleaning kit provided
(Cleaning kit part number 90-018)
Remove and clean the blade assembly
With the blade assembly removed, clean the slots and surrounding area within
the creasing unit.
Technician Maintenance
It is recommended that your machine is fully serviced at least once every six months
by a factory trained Service Engineer.
SYSTEM
Page 41
7-95-18
ITEM
DISPATCH KIT
PART NUMBER
QTY
DESCRIPTION
1
70-131
1
OPERATORS MANUAL - AUTOCREASER Pro 50
2
90-018
1
ROLLER CLEANING KIT
3
650-040
1
POWER CORD CE UK C19 3Pin 16A 2.5Mtrs.
4
617-004
4
GLASS BALL - Ø20
5
403-01-030-006
12
SCREW - SOCKET CAP HEAD - M3 x 6 LG
6
409-01-040-004
1
SCREW - SKT. SET FLAT PT. - M4 x 4 LG
7
8
620-007
1
HEXAGON BALL DRIVER 2mm
620-020
1
HEXAGON BALL DRIVER 2.5mm
9
620-004
1
ALLEN KEY 4mm
10
620-026
1
BONDUS L WRENCH 4mm
11
620-028
1
BONDUS L WRENCH 3mm
12
620-033
1
BONDUS L WRENCH 6mm
13
624-018
1
DISPATCH BOX
14
70-055-01
1
BLADE EXTRACTION TOOL - OP SIDE
15
70-055-02
1
BLADE EXTRACTION TOOL - LAY SIDE
16
08-041-02
1
SLITTING ANVIL - UNDERSIZE.
17
08-066
1
SLITTER PERF BLADE 28T
18
624-017
3
SLITTER/SCORER PK - STYLE 0212/40X40X20
WARNING......
THE BLADES FOR ANVIL AND PERFORATING SETS ARE SUPPLIED AS
MATCHING PAIRS AND SHOULD NOT BE MIXED OR LEFT
UNPROTECTED OR SERIOUS DAMAGE MAY RESULT.
Page 42
CREASING
AutoCreaser Pro 50
ITEM
ACCESSORIES AND OPTIONS
PART NUMBER
DESCRIPTION
1
2
3
4
5
1-99-10
1-99-12
1-99-41
1-99-35
76-237-02
PERFORATING BLADE SET 20T (Card)
PERFORATING BLADE SET 28T (Single sheets)
PERFORATING BLADE SET 56T (Fine perforations)
ANVIL SET USED WITH ABOVE BLADE SETS
BLADE SET - STANDARD
6
7
70-134
172-04-01
ANTI-STATIC KIT - AUTOCREASER 50 Mk4
NARROW SHEET KIT
ACCESSORIES....
....May be obtained from
your dealer and fitted to your
machine using the instructions
supplied, or by reading your
operators manual.
SYSTEM
OPTIONS....
....May also be obtained and
fitted by your dealer. You should
not attempt to fit options as
specialist tools and knowledge are
required.
Page 43
RECOMMENDED SPARES
PART NUMBER
DESCRIPTION
93-021
FEED BELT
607-041
TIMING BELT - 110XL 037
609-011
‘O’ RING Ø20
94-028
LOCK PIN ASSEMBLY - Side Lay
613-365
EMERGENCY STOP SWITCH
652-011
SWITCH - LOW CURRENT COIL - BLACK ROCKER
652-043
SWITCH - 240 VOLT COIL - 20A - BLACK ROCKER
75-472-01
MINI ITX MOTHERBOARD (CONFIGURED)
75-430-01
CONTROL PCB ASSEMBLY
174-06-01
SMALL STEPPER DRIVER - LOW POWER - PCB ASSY
174-19-01
RS232 ADAPTOR PCB ASSY
125-21-02
DUAL STEPPER DRIVER PCB ASSEMBLY
75-06-01
TOUCHSCREEN ASSY - 7”
76-272
PSU ASSEMBLY - ATX12V - 300W
655-015
PSU UNIT - SWITCH MODE - 24V
655-016
PSU UNIT - SWITCH MODE - 48V
76-230-02
PAPER GUIDE ASSEMBLY - Bottom Sensor
76-155
PAPER JAM SENSOR ASSEMBLY
76-154
UPPER SENSOR ASSEMBLY
76-156
BLADE POSITION SENSOR LEAD
98-013-03
ANTI-STATIC BRUSH
609-022
‘O’ RING Ø32
606-035
KNOB - Roller Tilt
76-109
POWER LINK BEARING
76-237-03
BLADE SET - Narrow
76-042
DRIVE BELT - FEED BED
607-041
607-042
607-048
TIMING BELT 110XL 037
TIMING BELT 160XL
TIMING BELT TWIN GRIP - 200 DXL 050
608-019
SHOULDER BOLT
76-082
PERFORATOR - DRIVE HUB ASSEMBLY
76-083
76-177-02
PERFORATOR - DRIVE WHEEL
INPUT ROLLER - Upper
76-175-02
INPUT ROLLER - Lower
76-019-02
OUTPUT SHAFT - Wide
Page 44
CREASING
AutoCreaser Pro 50
PART NUMBER
RECOMMENDED SPARES
DESCRIPTION
78-013
PERFORATOR STRIPPER ASSEMBLY
613-351
MICRO SWITCH - Guard Circuit
613-191
MICRO SWITCH - Home Circuit
75-040
STACKER SWITCH ASSEMBLY
602-056
BEARING-DRAWN CUP NEEDLE ROLLER-Ø15XØ21X12
602-085
BEARING-DRAWN CUP NEEDLE ROLLER Ø10XØ14X10
76-156
BLADE POSITION SENSOR LEAD.
76-145-02
GAP CONTROL HUB - LAY SIDE
76-148-01
GAP SET LEVER ASSY - OP SIDE
76-148-02
GAP SET LEVER ASSY - LAY SIDE
76-149-01
LOCKING LINK - GAP CONTROL
76-150-01
LOCKING KNOB - GAP CONTROL
76-255
LEAD - FOLD COMPENSATION SENSOR
173-67-01
LEAD - VALVE SENSOR
78-074-01
PERF. SHAFT SUPPORT ADJUSTER - UPPER
78-074-02
PERF. SHAFT SUPPORT ADJUSTER - LOWER
609-024
‘O’ RING Ø6 x Ø2.5
175-28-01
BUTTERFLY VALVE
76-240
STEPPER DRIVE MOTOR ASSEMBLY
76-241
STEPPER BLADE MOTOR ASSEMBLY
173-061-01
DELIVERY POSITION MOTOR ASSEMBLY
NOTE.....
The items listed above represent parts which are subject to wear, loss, or accidental
damage, and is included for your guidance only.
Replacement of parts fitted to your machine require specialist knowledge and should
therefore be entrusted to your dealer.
SYSTEM
Page 45
FUSE POSITIONS & RATINGS
(POSITION ET CLASSIFICATION DES FUSIBLES)
PSU (5V / 24V)
(FUSIBLE PSU (5V/24 V)
F3.15AH 250 (613-023)
PSUs (24V & 48V)
(FUSIBLE PSUs (24 V & 48 V)
T4.0AH 250 (681-015)
Page 46
ANTI-STATIC UNIT
(IF FITTED)
(FUSIBLE ANTI-STATIQUE
(si installé)
T315mAH 250 (681-011)
SPARE FUSE
POSITION
(POSITION PORTE
FUSIBLE)
CREASING
AutoCreaser Pro 50
PRODUCT RECYCLING & DISPOSAL
European Union
Disposal Information for Commercial Users
Application of this symbol on your equipment is confirmation that you
must dispose of this equipment in compliance with agreed national
Procedures.
In accordance with European legislation end of life electrical and
electronic equipment subject to disposal must be managed within
agreed procedures.
Prior to disposal please contact your local dealer or representative for
end of life take back information.
Disposal Information for Domestic Users
Application of this symbol on your equipment is confirmation that
you should not dispose of the equipment in the normal household
waste stream.
In accordance with European legislation, end of life electrical and
electronic equipment subject to disposal must be segregated
from household waste.
Private households within EU Member States may return used
electrical and electronic equipment to designated collection
facilities free of charge. Please contact your local disposal
authority for information.
In some Member States when you purchase new equipment your
local retailer may be required to take back your old equipment
free of charge. Please ask your retailer for information.
Other Countries
Please contact your local waste authorities and request disposal information.
SYSTEM
Page 47
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