User manual | Standard AutoCreaser 50 Manual

Standard
AutoCreaser 50
Scoring Machine
Instruction Manual
Provided By
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AutoCreaser 50
DOCUMENT
CREASING MACHINE
OPERATORS MANUAL
Morgana Systems Limited United Kingdom
Telephone: ( 01908 ) 608888 Facsimile: ( 01908 ) 692399
Website: www.morgana.co.uk
ISSUE 7
January
SERIAL No. 710386LBAD ONWARDS
2008
70-069
INDEX
INTRODUCTION
The Morgana Autocreaser 50
PAGE
3
SAFETY Do’s & Don’ts
4
THE AUTOCREASER 50
Labelled Photograph
6
THE CONTROLS
The control panel
Features on the control panel
7
8
QUICK START GUIDE
9
OPERATING THE AUTOCREASER 50
Setting the machine
Programming the machine
Reading stored programmes
Paper jamming
16
17
17
THE STACKER ASSEMBLY
Setting the Stacker unit
18
PERFORATING
Equipment, spares
Setting the machine
20
21
THE BLADE ASSEMBLY
Setting the blade pressure
Setting the blade alignment
23
24
REPLACING CREASING BLADE SETS
Installing new blade sets
Spares
25
26
TROUBLE SHOOTING
DISPATCH KIT
ACCESSORIES & OPTIONS
RECOMMENDED SPARES
27
30
31
32
Page 2
12
CREASING
AutoCreaser 50
INTRODUCTION
AutoCreaser 50
The Morgana Autocreaser 50 is a fully automatic suction feeding creasing
system designed for use with both conventional litho and digital printers.
The feed on the Autocreaser 50 can also be manually operated for use with
heavy stock, very small or very large sheets, embossed or even irregular
sheets.
The Autocreaser 50 is capable of creasing sheet sizes to a maximum of
700mm x 500mm (27.5” x 19.7”) and weights in excess of 350gsm.
The minimum sheet size when the machine is used in automatic mode is
140mm x 210mm (5½ “x 8½”).
Up to sixteen creases can be programmed to a single sheet.
The crease is programmed from the leading edge of the sheet using the
controls on the front panel.
A minimum distance between creases is 0.1mm
The Autocreaser 50 has up to nine available memory addresses for
programmed creasing operations.
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
SYSTEM
Page 3
Safety Do’s & Don’ts
Safety Do’s & Don’ts
Do - read this operator manual fully before operating the machine.
Do - operate with the designated AC current only. Use an exclusive outlet, as
overloading may cause fire or an electric shock.
Do - install the power cord out of the way to avoid a tripping hazard.
Do - beware of finger traps when replacing roller cassette and fold plates.
Do not - install the machine in an unstable place such that it tilts or shakes.
Do not - unplug the plug or unplug the power cord from the outlet with a wet hand,
this can cause an electric shock.
Do not - unscrew and remove any covers from the machine, as it can cause an
electric shock or injury.
Do not - place receptacles containing liquids on any surface.
Do not - adjust any part of the machine whilst rollers are running
Do not - operate the machine with loose or trailing clothing or loose hair.
Do not - under any circumstances adjust the paper gate when the machine is
switched on.
Page 4
CREASING
AutoCreaser 50
BLANK
PAGE
SYSTEM
Page 5
AUTOCREASER 50
AutoCreaser 50
DOCUMENT CREASING MACHINE
Key to photograph below
1
2
3
4
5
6
Roller tilt handle
Stacker assembly
Suction slot knob
The display unit
Air separation knob
Air distribution knob
Page 6
7
8
9
10
11
12
Adjustable side lay
Back Stop
Fixed side lay
Roller tilt knob
Paper Gate
Exit Guard
13
14
15
16
Control Panel
Fuses
Gap Set Knob and Lever
Vacuum Bleed Knob
CREASING
AutoCreaser 50
THE CONTROLS
The Display Unit and the Switches on the Control Panel allow the
operator to read, edit, create and initiate numerous creasing programs
within the memory.
The Control Panel houses the Selection Switch, Compressor switch,
System switch, and an industry standard Emergency Stop switch which
will stop all power going to the machine when activated.
THE CONTROL PANEL
Selection Switch
Compressor Switch
System Switch
Emergency Stop Switch
SYSTEM
Page 7
THE CONTROLS
Features on the Control Panel
Selection Switch
Allows the operator to scroll through stored addresses and programs, increase or
decrease the batch quantity and set a crease position.
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 50
Quick Start Guide
1.
Setting the machine to operate in automatic mode
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.
The display unit is now illuminated, a typical start up display menu is
shown below.
Tools
Setup
Zero
Total
20
Program 3
Feed
Batch Off
2 Creases
NOTE:The arrows on the display denote the direction in which the selection
switch must be moved in order to access the various sub-menus.
SYSTEM
Page 9
Quick Start Guide
6.
Following the arrows on the display unit; move the selection switch to
the right to select Setup (i.e. Setting the crease positions), a typical
display is shown below.
More
Home
1st Crease 148.0
2nd Crease
0.0
Set Creases
7.
Following the arrows on the display unit; move the selection switch down
to set the creases. The 1st Crease is now selected.
Set Creases
Back
Tens
Decimals
( 1st Crease 148.0 )
2nd Crease
0.0
8. Move the Selection Switch to the left to select Tens or to the right to
select Decimals. The Tens or Decimals (whichever has been selected)
can then be adjusted by rotating the Selection Switch, (clockwise to
increase or anti-clockwise to decrease).
9.
To set the 2nd Crease position move the selection switch down; the 2nd
Crease is selected and can be set as described in step 8. above.
Set Creases
Back
Tens
Decimals
( 2nd Crease 000.0 )
3rd Crease
0.0
10. Further creases can be set in this way, up to a maximum of sixteen
creases.
Page 10
CREASING
AutoCreaser 50
Quick Start Guide
11. When the required creases have been set, move the selection switch up
step by step until the display contains the word Feed, see below.
Tools
Setup
Zero
Total
20
Program 3
Feed
Batch Off
2 Creases
12. Press the Compressor Switch down.
13. Press the System Switch down, the display will momentarily read Please
Wait Initiating and then return to show Feed.
14. Move the selection switch down to begin feeding the sheets.
In order to manually feed sheets see instructions on page 17.
SYSTEM
Page 11
Operating the Autocreaser 50
Setting the Machine
Adjusting the Paper Gate
The standard setting for horizontal adjustment of the paper gate is 6.5mm (1/4") away
from the mounting block. Turn disc J to make this adjustment. This setting is only intended
as a guide, for instance, sheets with an upward curl will require this setting to be increased. Set the height of the Paper Gate to approximately two thicknesses of paper, by
turning knob K. An excessive gap is a most likely cause of double sheet feeding.
6.5mm (1/4")
K
J
T W O T H ICK NE S S E S
OF P AP E R
W AR NI NG.
DO NOT ADJU S T T H E
P AP E R GAT E W H IL E T H E
MACH INE I S R U NNING OR
T H E S U CT ION DR U M MAY
B E COME DAMAGE D.
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
Vacuum
Bleed Knob
Page 12
CREASING
AutoCreaser 50
Operating the Autocreaser 50
Setting the Vacuum Bleed
Situated on the front of the feed table, the Vacuum Bleed Knob is used to allow more
control of the suction on the vacuum drum.
When light weight paper of 90gsm and lower is being fed through the machine turn the knob
clockwise to reduce the possibility of marking, or damage to the leading edge of the paper
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 BackStop
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 1 is
recommended for most sheet sizes. However, a better result may be obtained by using
the below settings or by experimentation.
Position 1 – For A5 sheets or 8 inches long, port 1 open.
2 – For A4 sheets or 11 inches long, front port and port 2 open.
3 – For A3 sheets or 17 inches long, front port and port 3 open.
0 – For longer sheets in order to supply air to the centre of the stack, port
2 open
Setting the Air Separation Pressure
To control the amount of air supplied to the ports, the air separation knob can be adjusted
by first rotating the knob to unlock its position, then push the knob down to the required
position and rotate the knob to re-lock its position.
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.
SYSTEM
Page 13
Operating the Autocreaser 50
To operate the motors manually, switch the machine ‘on’ at the Emergency Stop switch.
Following the arrows on the display unit, move the selection switch to the left to select
Tools, the display will now show the Tools sub-menu. Press the system switch down and
then move the selection switch to the left or to the right, 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 moving the
selection switch to the left or to the right. 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.
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:(i) From the start up menu, move the selection switch to the right to select Setup.
(ii) Move the selection switch to the right, one click at a time, until the display contains
the words Set Feed.
(iii) Move the selection switch down to select the required feed type (Standard Pulse,
Medium Pulse, Short Pulse, or Stream Feed)
(iv) Move the selection switch to the right to select Ok.
Use Standard Pulse for all standard size sheets, general purpose.
Use Medium Pulse for short non-standard sheets.
Use Short Pulse for very short sheets.
Use Stream Feed for high throughput, see note below.
NOTE.
Do not use stream feed for creases less than 32mm from the leading edge of the paper.
Page 14
CREASING
AutoCreaser 50
Operating the Autocreaser 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
SYSTEM
Page 15
Operating the Autocreaser 50
Programming the machine
1.
Switch the power ‘on’ by turning the Emergency stop button clockwise
to release the safety latch. The display is now switched on.
Setting the batch quantity and Dwell Time
2.
(i) Move the selection switch to the right to select Setup.
(ii) Move the selection switch to the right to select More.
(iii) Move the selection switch to the right again to select More.
(iv) Move the selection switch down to select Set Batching.
(v) Rotate the selection switch clockwise or anti-clockwise to adjust the batch quantity
in increments of 5.
(vi) Move the selection switch down to select Dwell Time Secs.
(Vii) Rotate the selection switch clockwise or anti-clockwise to adjust the dwell time,
in seconds, this is the period of time between each successive batch quantity.
Setting the crease positions
3.
Move the selection switch up, one click at a time, until the start up menu is displayed
as shown below.
Tools
Feed
Batch Off
2 Creases
Setup
Zero
Total
20
Program 3
(i) Move the selection switch to the right to select Setup.
(ii) Move the selection switch down to select Set Creases.
(iii) Move the selection switch to the left to select Tens, or to the right to select
Decimals.
(iv) The Tens or Decimals (whichever has been selected) can then be adjusted by
rotating the Selection Switch, (clockwise to increase or anti-clockwise to decrease).
(v) Adjust all other digits for the 1st Crease position as described in steps (iii) and (iv),
(i.e. move the selection switch to the left to select the Tens or to the right to select
Decimals and then rotate the Selection Switch to adjust its value.
(vi) Move the selection switch down to select the 2nd Crease. The second crease will
automatically start at 0000.0. Crease positions can be set in increments of 0.1mm.
(vii) Set the 2nd Crease position as described in steps (iii) to (v) above.
Further creases can be set in this way, up to a maximum of sixteen creases.
Storing the crease positions
4.
Once the crease positions are correctly entered, they can be stored as follows.
(i) Move the selection switch up, one click at a time, until the display contains the word
More.
(ii) Move the selection switch to the right, one click at a time, until the display contains
the word Programs.
(iii) Move the selection switch down to select Save Settings.
(iv) Rotate the Selection Switch to select the Program number (1 to 9).
Page 16
CREASING
AutoCreaser 50
Operating the Autocreaser 50
(v) Move the selection switch to the right to select Select.
(vi) Move the selection switch to the left to select Yes or to the right to select No.
Running the machine
5. To run the job with the selected settings.
(i) Press the Compressor Switch down.
(ii) Press the System Switch down.
(iii) Move the selection switch down to begin feeding the sheets.
To stop feeding the media at anytime during the program, flick the selection switch up.
The machine will complete its creasing operation if a sheet has already been fed
through the paper gate.
Reading stored programs
Any of the nine stored programs can be accessed and read as follows:(i) From the start up menu, move the selection switch to the right to select Setup.
(ii) Move the selection switch to the right, one click at a time, until the display contains
the word Programs.
(iii) Move the selection switch down to select, Retrieve Program.
(iv) Move the selection switch to the right to select, Select.
(v) Rotate the selection switch clockwise or anti-clockwise to select, Program 1 to
Program 9 and view the program settings.
Paper jamming
In the event of a paper jam occurring whilst the machine is operating the display will
read Paper Jam. In order to remove the paper causing the jam, move the selection switch
to the left or to the right to drive the paper forwards or backwards in short pulses.
Setting the machine to operate in manual mode
In order to feed heavy stock, very small or very large sheets, embossed or even
irregular shaped sheets, it may be required to operate the machine manually.
The machine can be programmed and set up in exactly the same way as explained
when operating the machine automatically. However, when setting up the machine the
paper gate must be raised to its highest position for the sheets to be fed freely.
Operating the machine manually will also require the suction length to be continuous in
order to accommodate various types of stock. Therefore, the feed should be set to
Standard Pulse see page 14.
The machine can now be started by activating the System switch to ‘on’. Do not
activate the Compressor switch. Move the selection switch down to select Feed and
begin to slide the sheets individually through the paper gate until they are driven by the
drive belts. To stop feeding the sheets, move the selection switch up and then the System
Switch up.
SYSTEM
Page 17
The Stacker Assembly
The stacker unit on the Autocreaser 50 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
RIGHT HAND
SIDE GUIDE
Page 18
RIGHT HAND
BACK STOP
CREASING
AutoCreaser 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
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 19
Perforating
Once the machine is set-up, the Autocreaser 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
1 off
1 off
1 off
1 off
1 off
Set of standard perforation ‘56 tooth’ blades.
Set of standard hardened anvils.
Perforator stripper.
Scoring wheel
3mm bondhus wrench / allen key
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 20
Standard Part Number 1-99-35 –
For all blade types
CREASING
AutoCreaser 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 21
Perforating
11.
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.
12. Slide the drive hub towards the perforating drive wheel until there is a clearance
of 0.5mm.
13. To prevent damage to the blades or the anvils, do not force the drive wheel against
the hub.
14. Fix the perforator stripper adjacent to the drive wheel and blade as shown.
15. 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 22
CREASING
AutoCreaser 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. The display is now switched on and will show the start up menu as
shown below.
Tools
Setup
Zero
Total
20
Program 3
Feed
Batch Off
2 Creases
(ii) Move the selection switch to the left to select Tools.
(iii) Move the selection switch down to select Set Blade Pressure.
(iv) Press the system switch down.
(v) Move the selection switch to the right, the machine will activate and the blade will
move to top dead center. The display will now read Blade is moving to TOP DEAD
CENTER and then change to read Blade Pressure May Now Be Adjusted See
Operators Manual.
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 23
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 Autocreaser
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 24
CREASING
AutoCreaser 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.
FIG 20.1
9.
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.
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 25
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 23 –25 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 ie 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 26
CREASING
AutoCreaser 50
Trouble Shooting
Paper crease out of square
•
Check that the sheets are all square and exactly the same size before loading the
stack on to the table.
•
Check that the roller tilt mechanism is correctly set and locked in position.
•
Check that the adjustable side lay has been correctly positioned ie. No further than
0.5mm from the paper stack.
Paper jamming
•
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.
•
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
•
Check the power supply to the machine.
•
Check that the emergency stop button has been released.
•
Check that the exit guard is down.
•
Check that the stacker unit is located correctly and has not been disconnected from
the magnetic switch.
•
Check that the lower blade / anvil is connecting to the home switch (mounted below
the lower blade / anvil).
Paper not feeding
•
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.
•
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.
•
Check that the clearance between the paper gate and the suction roller is not set too
low.
•
On digital media, the feeding performance may be improved if the leading edge of
the stack is trimmed before loading onto the Autocreaser 50.
SYSTEM
Page 27
Trouble Shooting
•
Check that the air distribution has been correctly set.
•
Check that the air separation has been set high enough to feed the sheets.
•
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 17 for instructions.
•
Check that the gap of the infeed rollers is set correctly (see page 15).
Machine not counting
•
Open the exit and remove the blade set
(see pages 25-26) 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.
No suction
•
If the suction drum is not rotating, check all of the drive belts for cleanliness and
splits (including the bottom in-feed roller drive belt).
Control panel reads
• Overlap - Probable Cause - Double Sheet
If the machine is ‘cutting out’ and the control panel reads Overlap - Probable Cause
- Double Sheet check that the machine is not feeding multiple sheets. If so, check
that the paper gate has been correctly set.
• Blade Not Home
If at any time during the creasing process the control panel reads Blade Not Home it
is indicating that the lower blade / anvil has not made contact with the HOME switch ie.
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 Blade Not Home it is advised to contact a Service Engineer
immediately.
• The Paper Path is not clear
If before operating the machine the display reads The Paper Path is not clear this
indicates that there is an obstruction between the upper sensor assembly and the
paper guide sensor (as shown in the above photograph). If there is no obvious
obstruction in the paper path, switch the machine off and repeat the same procedure as
explained above.
Page 28
CREASING
AutoCreaser 50
Trouble Shooting
Recommended weekly Operator maintenance
•
•
•
•
Clean all sensors
Clean in feed rollers and output drive hubs using the Morgana cleaning kit
(Morgana 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 Morgana Autocreaser 50 is fully serviced at least
once every six months by a factory trained Service Engineer.
SYSTEM
Page 29
7-95-10
ITEM
DISPATCH KIT
PART NUMBER
QTY
DESCRIPTION
1
70-069
1
OPERATORS MANUAL - AUTOCREASER 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 30
CREASING
AutoCreaser 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
76-237-03
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 - NARROW - AUTOCREASER 50
6
7
70-082
94-073-03
ANTI-STATIC KIT - AUTOCREASER 50
SIDELAY EXTENSION - NARROW SHEET - A/C 50
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 31
RECOMMENDED SPARES
PART NUMBER
DESCRIPTION
93-021
FEED BELT
93-022
DRIVE BELT - Vacuum Roller
609-011
‘O’ RING Ø20
609-014
‘O’ RING Ø15
94-028
LOCK PIN ASSEMBLY - Side Lay
75-250-01
HOSE - Exhaust
75-251-01
HOSE - Separation Air
75-252-01
HOSE - Evacuation
613-137
PLUNGER AND SPRING
613-255
SOLENOID COIL
609-013
‘O’ RING Ø25
613-365
EMERGENCY STOP SWITCH
652-011
SYSTEM SWITCH
652-009
652-011
COMPRESSOR SWITCH (UK)
COMPRESSOR SWITCH (USA)
144-04-03
JOYSTICK AND LEAD ASSEMBLY
75-345-01
CONTROL PCB ASSEMBLY
125-21-02
DUAL STEPPER DRIVE PCB ASSEMBLY
75-210-05
LCD DISPLAY UNIT - 4 LINE
655-011
PSU UNIT 5V/24V
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
98-013-03
ANTI-STATIC BRUSH
609-022
‘O’ RING Ø32
606-035
KNOB - Roller Tilt
76-109
76-237-02
POWER LINK BEARING
BLADE SET - Standard - Autocreaser 50
76-042
DRIVE BELT - FEED BED
607-042
TIMING BELT 160XL
607-048
TIMING BELT TWIN GRIP - 200 DXL 050
608-019
SHOULDER BOLT
76-082
PERFORATOR - DRIVE HUB ASSEMBLY
76-083
PERFORATOR - DRIVE WHEEL
Page 32
CREASING
AutoCreaser 50
PART NUMBER
RECOMMENDED SPARES
DESCRIPTION
76-203-05
INPUT ROLLER - Upper - Autocreaser 50
76-203-06
INPUT ROLLER - Lower - Autocreaser 50
76-019-02
OUTPUT SHAFT - Wide
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
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 33
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.
Page 34
CREASING
AutoCreaser 50
SYSTEM
Page 35

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