AutoCreaser Pro 33
Contents
1.2. dr DRUM VALVE 27024 SEE COLOUR CODE SHEET DRAWING 53 EARTH LEAD 75 321 aa ON PAGE 25 54 MANS FILTER TO DISTR BLOCK 75 320 p 26 STACKER GUARD SWTCH 75 040 55 TRANSFORMER MAINS SUPPLY 76 325 Ce VP 29 COMPRESSOR LEAD 75 124 58 STEPPER INPUT LEAD 75 423 31 SYSTEM SWTCH INPUT LEAD 75 191 59 BLADE MOTOR EARTH LEAD 76 236 ee 33 EMERGENCY STOP INPUT LEAD 75 228 69 PSU LINK LEAD 75 284 x ell 34 FUSE LEAD 76 322 70 PSU EARTH LINK 75 296 B 37 MAINS SUPPLY LEAD 76 317 71 PSU MAINS LINK 75 297 39 EARTH CHASSIS TO CREASING 76 232 78 SUPPLY LINK LEAD 75 514 Se 40 PSU MAINS LEAD 75 184 79 VACUUM SIGNAL LEAD 75 420 41 DRIVE MOTOR LEAD 76 240 80 VALVE SIGNAL LEAD 75 421 42 BLADE MOTOR LEAD 76 241 81 VACUUM DRUM MOTOR 75 425 CREASER UNIT 43 SYSTEM SWTCH OUTPUT LEAD 75 193 82 VALVE MOTOR 75 426 44 COMPRESSOR SWTCH INPUT LEAD 75 534 83 SENSOR LEAD 75 427 H 45 EMERGENCY STOP OUTPUT LEAD 75 195 84 EARTH LEAD 76 256 TOUCHSCREEN 46 CHASSIS EARTH LEAD 75 435 86 INTERFACE LEAD 76 271 48 PSU OUTPUT LEAD 75 429 H 50 MANS INPUT FUSE LEAD 76 327 52 E
3. AND LEAD ASSY _ vio 52 PSU YELIN O posue 40 BL Bh Ol Z BRN 1 ap ir vo Ng lc 24V 1 s PSU PSU MAINS LINK TT 75 297 BL Oz 7 aw AutoCreaser Pro 33 CONTROL SYSTEM ASSENBLY Wiring Diagram SYSTEM Page 25 PSU ASSEMBLY 76 272 DRIVE SIGNAL LEAD 75 436 BLADE SIGNAL LEAD 75 437 SYSTEM SWTCH COIL LEAD 75 364 STACKER GUARD SWTCH LEAD 75 232 HOME SWITCH LEAD 75 231 BLADE POSITION SENSOR LEAD 76 156 EDGE DETECT LEAD 76 230 03 DUAL SENSOR LEAD 76 154 PAPER AM DETECTOR LEAD 76 155 VACUUM SENSOR LEAD 76 255 24 ENGNEERING LEAD 75 356 79 VACUUM SIGNAL LEAD 75 420 80 VALVE SIGNAL LEAD 75 421 86 INTERFACE LEAD 76 271 O JOYSTICK DISPLAY o o o ENGINEERING CREASE EDGE CREASE CRUNCH SLIDE POS BOOKLET MAKER INTERFACE BLADE CONTROLLER HOME SLOT 1 DOUBLE 21 1 JE E 4 z m l l l nl RELAY 1 RELAY 2 O AUTOCREASER Pro 33 CONTROL PCB CONNECTION DIAGRAM Page 26 CREASING AutoCreaser Pro 33 SYSTEM Page 27 SECTION 10 Cleaning Sensors With blades removed the optical sensors are accessible for cleaning on either side of the creaser unit use a soft brush or cloth to remove any dust that may have collected onto the sensor lens Setting the Sensors The Sensors all have indicator LED s on the Main Control Board a
4. Meter across L amp N terminals No LED Stepper PCB Low or No Power from PSU Meter across V amp V of SP 150 24 reading 24V dc Page 30 Meter across V amp V of SP 150 48 reading 48V dc Replace PSU if no or low reading Meter across V of SP 150 48 amp V of SP 150 24 reading 72V dc If voltage is correct but no light on stepper then check cable integrity CREASING AutoCreaser Pro 33 Section 11 Trouble Shooting Fault Reason Solution Edge amp Crunch Sensors Check supply voltage Black lead of meter on tab IC8 Main PCB Transmitters Should read 1 3Vdc Hedleadof meter on red wire of CN8 and yellow wire of CN16 ToAdjustthese voltages Adjust VR4 Edge sensor amp VR8 Crunch sensor Crunch Sensor Check voltage 1Vdc Meter across Red Black of CN16 Obstruct Receiver Beam and Voltage will rise to approx 4 2 Vdc Voltage will increase decrease by adjusting intensity of transmitter pot VR8 Edge Sensor Check voltage 0 46Vdc Meter across Red Blue of CN8 Obstruct Receiver Beam and Voltage will rise to approx 5 Vdc Voltage will increase decrease by adjusting intensity of transmitter pot VR4 oafety Circuit Faulty Check Voltage on Any Switch or Wire Open circuit will be OVdc No Drive CN7 210 12 Vdc To Check PCB Blacklead of meter on tab IC8 Main PCB Redlead o meter on brown wire plug6 CN7 should read 12Vdc To Check Cable Unplug CN7 meter set to Ohms place probes across plug If no continuity then check each
5. morgana AutoCreaser Pro 33 CB UL DOCUMENT CREASING MACHINE SERVICE MANUAL Morgana Systems Limited United Kingdom Telephone 01908 608888 Facsimile 01908 692399 Website www morgana co uk ISSUE 2 APRIL 2012 70 172 INTRODUCTION morgana MORGANA AutoCreaser Pro 33 Introduction The purpose of this manual is to explain the procedure for dis mantling and re assembly of the major assemblies on the Morgana Auto Creasing machine All the engineering adjustments are shown at the end of each relevant section Operator s adjustments and routine maintenance are explained in the appropriate operators guide which should always be used in conjunction with this manual lt is always a good idea to have a copy of the machines illustrated parts manual available when servicing as its illustrations provide an invaluable reference to the construction of the individual assemblies used to build the machine Fasteners All threaded fasteners are isometric amp all nuts are isometric hexagon All screws are hardened high tensile steel Cap head Button head Socket countersunk Shoulder bolts and Grubscrews have internal hexagon drives which require isometric hexagon wrenches allen keys Ball drivers may be used but care should be taken particularly when releasing screws for dismantling to avoid breaking the driver as they cannot cope with full
6. rear this will extract the outer race of the needle bearing from the front side plate The roller can now be withdrawn inwards through the mechanism Remove the bearing retaining screw on the inside of the rear side plate the deep grooved ball race can now be extracted Page 16 CREASING AutoCreaser Pro 33 SECTION 7 DRIVE HUB REPLACE RUBBER TORSION BUSH SHOCK ABSORBER 7 1 Loosen grub screws one half of hub 7 2 Slide hub outward amp remove rubber torsion bush 7 3 Replace in reverse order Rubber Torsion Bush SYSTEM Page 17 SECTION 8 DRIVE LINK REFURBISHMENT 8 1 Remove the drip tray by removing the four securing screws fixed to the tie bars 8 2 Remove both tie bars and drip tray 8 3 Remove the micro switch assembly to gain access to the rear drive link 8 4 Using a short dumpy posi drive screwdriver unscrew the three screws from the side of the link plate Slide the side off O Rings should be maintained in position The plastic drive link can be removed by sliding it forward 8 5 Replace the drive link and outer plate 8 6 He assemble in reverse order Link Plate Micro Switch Assembly Page 18 CREASING AutoCreaser Pro 33 SECTION 9 ELECTRICS The PRO Control System The Morgana PRO control system is essentially a computer system just like the PC you use at home Unlike your Microsoft Windows PC the PRO system uses a LINUX operating system and runs only one program which is the m
7. ARTHLEAD 75 432 FPS 39 RED 2 gt xe siete 75 356 o RM 76 230 03 PE 75 548 1 ara JOYSTICK DISPLAY DETECT E BH T CONTROLLER PCB El E m 33 22 9 ey 2 76 55 JAM E MAINS IN L 2 BLACK ue 4 33 amp 50 sm 2 YELLOWWRES j E FUSE LEAD SSRI 2 86 ar e N SENSOR 76 156 A 75 259 COMP SWTCH e ei e EE al pS r FUSE INPUT LEAD MINI ITX 3 12412 T3bmA 55 FUSE 15 534 79 9 7 Dom MOTHER BOARD e male CH en ES inu 15 a 231 HOME M 173 54 01 E LA gan 50 a 31 BL SHORTING 8 E ep 180 39 E BRN N L N L LINK H BRN FUSE SYSTEM SWTCH COIL LEAD 75 364 T40A ORG EH 1 Yo z FUSE c 3 5 GUARD DADO a HEP ma t mme es RNYEL BL BL GWNYEL 43 bn 29 ojojo 26 des x a e 11 79 STACKER GUARD NGGI SWITCH 75 040 EVERGENCY ad Rue c BONDING PONT law 45 2 WAN o Lu VEN EARTH LEAD 76 232 GRNYEL SW 1 ON LL EARTH 46 Vow SW 2 OFF F O SWI 3 OFF SW 4 OFF 5 2 1 SVb 1 0FF EARTHLEAD 75 432 52 Oi Ge lt SV5 2 OFF 0 1 5 SW 3 0FF EARTHLEAD 97 09 TO EARTHSTUDON e34 SW 4 OFF SERV
8. F ball ended allen key tighten the two locating screws into the feed table clearance holes 4 Refitthe viave assembly beneath the feed table ensuring the O ring is correctly located and the two M5 posi pan head screws are tight o hefeed bed and compressor cover can then be refitted FIG 2 1 Timing D 4 Belt Tes amp V Vacu um Dru m Papergate _ Mounting Block Assembly Wwe Vacuum Drum Sensor SYSTEM Page 7 VACUUM DRUM FEED BELT REMOVAL REPLACEMENT Drum Drive Belt replacement 1 Following stages 1 to 6 above the belt can be removed from the vacuum drum 2 Remove the slot sensor from the motor mounting bracket 3 The belt can now be removed from the machine Replacement is the reverse procedure To tension the belt loosen the three screws fixing the bracket to the feed table adjust the tension to allow a quarter of a twist along its run and retighten the cap head screws Replacing the drive motor or sensor 1 Remove the Compressor cover below the feed bed and the rear cover 2 Remove the top stainless steel feed bed 3 Remove the moving side guide 4 Unplug the motor or the sensor from the respective PCB atthe rear of the machine and feed the wire up through the access holes 5 Unscrew the motor or the sensor from the motor mounting bracket and remove Replacement is the reverse procedure To tension the belt loosen the three screws fixing the bracket to the feed table adjust t
9. I gi suction Drum and Belt Removal Replacement Section 3 Removal of Butterfly Valve Removal of Unit Section 4 Main Creaser Mechanism Removal of Unit Section 5 Removal Replacement Stepper Drive Belt Pulleys Section 6 Infeed Roller Removal Replacement Section 7 Drive Hub Replace Rubber Torsion Bush shock absorber Section 8 Drive Link 1 Section 9 Electrics The PRO Control Removal Refitting PCBs Diagnostics Setting the Measurement System Metric Inch Setting the Language English French German Autocreaser Pro 33 Wiring Diagram Autocreaser Pro 33 Control PCB Connection Diagram Section 11 Trouble Shooting skk tata t at co RE S OE CD AEG Calibration of Creasing Position Trouble Shooting Fuse Positions and Ratings Page 4 CREASING AutoCreaser Pro 33 AutoCreaser Pro 33 DOCUMENT CREASING MACHINE Key to photograph below Roller tilt handle 6 seperation knob 11 Paper Gate Stacker assembly 7 Adjustable side lay 12 Exit Guard Suction slo
10. ICE PANEL VACUUM DRUM nr X STEPPER 2 LZ n MANS BRN 21 FILTER 5 ey ee Gl 37 LT BENE B 2 8 E RTT ON OFF 43 Tal S M ncm d ss rt 01 V 9 78 B C Bg ATXPSU IMPORTANT DISTRIBUTION MAINS IN BLOCK TRANSFORMER ASSY SET SLIDE SWITCH 115V IF SWITCHABLE 40 PSU MAINS LEAD 75 184 58 10 MAINS SUPPLY LEAD 76 317 NI BLADE SIGNAL LEAD 75 437 75 550 GRN YEL 4 8 M 82 e aun NN e el x x BLADE N 2 gt ea a SIGNAL YEL z D vA DW olololololo MOTORISED VALVE BLADE 12727 STEPPER Ema o SW 1 0FF A oH fet 4 SW 2 0N SW 3 OFF SWI 1 el PUMP SW 4 ON Swe 1 ON wa OVERLOAD 18 SW2 2 ON lt wi SW 3 OFF PSU OUTPUT LEAD 75 429 48 ES 72 volts DC Nominal 29 SW 4 OFF BRE CT CONTROL LEG i d n Led Nc Y CIL IR ASSEMBLY fo ne rates SS hee callin SW4 1 DUAL Ye Swsi oN STEPPER 3 2 DRIVER 4 91115 5 lt U N 5 EARTH LEAD Lb Ep DRIVE MOTOR ANTISTATIC MAINS LEAD DRIVE SIGIAL LEAD SIGNAL 75 260 SVI30 PUMP 60 60Hz CONNECTIONS STEPPER INPUT LEAD 75 423 WHI P2 A 0 PSU LINK LEAD 75 284 WHI i E E JL BLU gt K BRN in O ANTISTATIC GRN YEL J2 RD 48V ANTISTATIC O UNIT 48 PK 69 gt _ TRANSFORMER bee NG 1
11. NS amp RATINGS TRANSFORMER ASSY T500mAH 250V 681 020 PSUs 24V amp 48V T4 0AH 250V 681 015 Page 36 2 ANTI STATIC UNIT IF FITTED T315mAH 250V 681 011 ndi D MAINS IN e efr F15AH 250V 652 047 CREASING AutoCreaser Pro 33 REVISION HISTORY Rev Mod No Mod Description Date Mod By SYSTEM Page 37
12. TION 2 VACUUM DRUM REMOVAL REPLACEMENT 1 Remove the Compressor cover below the feed bed 2 Remove the top stainless steel feed bed 3 Remove the moving side guide 4 From the underside of the fed table loosen the valve assembly by unscrewing the two Mb posi pan head screws allow the assembly to hang on its two pipes 5 Inside the feed table to the rear locate the two M4 soc cap head screws that position the black delrin housing in place this is the support block for the drum and the choke 6 Using a 4mm A F ball ended allen key loosen the two screws until they are flush with the underside of the mounting block this will enable the delrin block to slide to the rear ofthe machine 7 Locate the M4 soc set screw in the bearing plate that is used to lock the choke tube to the choke and using a 3mm A F allen key unscrew until clear of the plate 8 Twist the vacuum drum towards the motor to clear the bearing plate location hole and withdraw the drum assembly clear of the machine Replacing the Vacuum Drum assembly Heplacementis the reverse procedure 1 Place the delrin block loosely in position 2 Ensuring the end plug is correctly located in the end of choke tube the vacuum drum can be manoeuvred into position ensure the wavey washer is correctly positioned between the drum and the bearing plate 3 Ensure the drive belt is in place and thew O ring is in the lock slide the delrin bloc k over the choke tube end Using the 4mm A
13. achine control program for the particular machine that it is installed on VGA Touchscreen Display Digital lt gt Analogue Touch Panel Interface PCB Machine Control Comms Processor PCB USB Stick Flash Drive Hard Drive 240V AC Transformer 9 Assembly 5V DC 12VDC OV E Stop RED YELLOW BLACK Block Diagram of the PRO Control System SYSTEM Page 19 SECTION 9 ELECTRICS REMOVAL REFITTING PCB POWER SUPPLY ASSEMBLY All the Electric controls and pcbs are located within the rear cover mounted on a common base plate REPLACEMENT OF MAIN CONTROL This PCB controls all functions of the machine and houses the Main Program PCB The use of an antistatic wrist band should be used during work on the main control PCB Switch the mains power off and disconnect from the mains supply Unplug all the green plugs from the PCB Using a posi drive screw driver unscrew the five fixing screws and carefully remove the PCB REPLACEMENT OF PROCESSOR BOARD This Small PCB is plugged onto the face of the Main Control PCB and houses the Program Chip The use of an antistatic wrist band should be used during work on this Processor PCB owitch the mains power off and disconnect from the mains supply To remove care should be used lifting from the bottom and gently rocking from side to side seems to work the best Heplacement is the reverse procedure care should be taken that the
14. become active and display the boot up sequence If the touchscreen remains blank check that there is mains power to the machine and to the E stop switch then use the RAP that follows Is there power to the ATX PSU e Check that there is V AC across the ATX PSU power cord Yes No Identify reason for no power to ATX PSU e Check 500mA fuse below the Mains Input connector See Page 36 IMPORTANT If this fuse has blown replace it must be replaced with a T500mA fuse Morgana part number 681 020 Is there a V DC output from the ATX PSU See page 32 Yes No Replace the ATX PSU Does the cooling fan run on the mini ITX motherboard See page 32 Yes No Replace the mini ITX motherboard Is there a V DC power to the Touchscreen Yes No Repair the wiring connection Replace the Touchscreen Assembly Page 34 CREASING AutoCreaser Pro 33 FAULT Pump will not operate when the Compressor switch is switched on Check the fuse on the PCB in the Pump Overload assembly The Pump Overload assembly is located on the inside of the yellow leg below the baffle plate FUSE T315mA 10 oj YELLOW ORANGE ood Fo Fo Morgane Systems Ltd PUMP OVERLOAD BOARD O o c If this fuse has blown it must be replaced with a T315mA fuse Morgana part number 681 011 SYSTEM Page 35 FUSE POSITIO
15. cable ties to mountings Align the roller set square with the fixed lay edge while the front tilt lever is in the centre position Use the rear slots to adjust square Tighten the screws and replace the top covers liii lii Page 14 CREASING AutoCreaser Pro 33 SECTION 5 REMOVAL REPLACEMENT STEPPER DRIVE BELT PULLEYS 5 1 Loosen the adjuster nut from the inside unit and slide the belt off 5 2 Loosen the securing socket set screws in the drive pulley on the roller for it to be removed NOTE there is one screw located ina hole in the shaft 5 3 Hefittingthe belt is a reverse procedure tighten the belt first adjust the drive motor down to allow feel of belt tightness then re adjust the motor gear mesh to allow minimum backlash SYSTEM Page 15 SECTION 6 REMOVAL REPLACEMENT OF TOP INFEED ROLLLER With the unit on a bench Remove the drive belt and flanged pulley from the bottom infeed roller Viewing on the outside of the sideplate align the lug on the eccentric with cutout in the sideplate Using a soft mallet gently tap the roller assembly from the opposite side supporting its length as itemerges REMOVAL REPLACEMENT OF BOTTOM INFEED ROLLLER 6 5 6 6 6 7 6 8 6 9 Remove the drive belt and top infeed roller assembly and the bottom flanged pulley as above Remove the cap head screw from the rear of the roller shaft and then remove the pulley Genily tap the roller from the
16. correct orientation is observed Note When changing the above board it may be necessary to recalibrate the machine Take note of any calibration settings Processor Board REPLACEMENT OF USB FLASH DRIVE The USB Flash Drive controls all functions of the graphics and touch screen operation The External USB Flash Drive and the Internal USB Flash Drive devices shown in FIG 2 below have the same functionality Either one of these devices could be supplied as a replacement IMPORTANT When fitting an Internal USB Flash Drive its orientation is important Note the position of the Lock Recess shown in FIG 2 below The lock must also be in the unlocked position Ensure that the device fits securely and is fully inserted If the Internal Flash Drive is fitted the wrong way round it will not be damaged it just won t work Power down the machine and turn it round Page 20 CREASING AutoCreaser Pro 33 Installation Procedure 1 Note the current machine calibration settings 2 Power down the machine and remove the power cord 3 Change the USB Flash Drive Red or Green depending on what is currently fitted NOTE lt is important to choose the right colour in accordance with the machine you upgrading See 2705 for further information on when to use Red or Green USB Flash Drives As a general rule replace like for like i e Green for Green and Red for Red 4 Power the machine up 5 To access the machine menu ope
17. crease positions and using the Ape Stretch And Lead Edge Settings in the Tools menu adjust the crease positions until they are correct Change the value a higher value will move the crease further from the lead edge NOTE Always Set the Stretch first i e 320mm between creases Insert the Engineers Plug into the Socket located at the rear of the machine Run machine and check crease positions repeat above procedure until accurate crease position is achieved SYSTEM Page 29 Section 11 Trouble Shooting Fault Erratic register of the Creaser No Power or No Display Reason Solution Damaged roller surface Replace rubber rollers Check Gap Setting Reset amp tighten to ensure rollers are driving card Faulty Drive motor Remove and replace motor assembly Fuse Blown Replace with correct value Check Power supply input on Voltages should read 240V or 110VAC Check cables for continuity to Emergency stop button Replace Faulty wire or connection Check power supply output Black lead of meter to Black wire Voltage CN2 5V Red lead of meter to Red wire Voltage on CN2 24V dc Red lead of meter to Yellow wire If supply has input but no output Replace PSU Check voltage on main If no voltage then check for damaged PCBCN6 Brown and Blue wire or connection Replace as required No Drive or Motors Pulsing Low or No Powerto Motors Check green light is illuminated on both PSUs Check 240 110V AC inputto Large PSUs
18. crease value AV Display Channel Brightness Contrast Horizontal Vertical SYSTEM Page 23 DIAGNOSTICS and CALIBRATION TOOLS To enter the engineers tools menu Turn the Machine on Insert the Engineers Plug into the Socket located at the rear of the machine select Tools on the Display and continue to select required tool SET THE TOTAL COUNT TO ZERO To set the total counter to zero Turn the Machine on Insert the Engineers Plug into the Socket located at the rear of the machine Select Tools on the Display and select this button this value denotes the Machine total count Counter button SET THE MEASUREMENT SYSTEM METRIC IMPERIAL SETTINGS To set the measurement system for Imperial Inch or Metric mm the following procedure Is necessary Turn the machine on mane Insert the Engineers Plug into the Socket located at the rear of the machine Select Tools on the Display and select METRIC IMPERIAL by toggling the button Return to the main screen and remove the engineers plug SETTING THE VACUUM DRUM POSITION To set the vacuum drum start position the following procedure Is necessary 3m C Turn the machine on Insert the Engineers Plug into the Socket located at the rear of the machine select Tools on the Display and select Vac Drum Trim by toggling the button Input a value and run repeat until start position is correct under the papergate Return to the main screen and rem
19. grc lt 5 _ D ton g oO oc 602 o gt o D O 2 ud oq c 55 Z SYSTEM Page 11 morgana Page 12 CREASING AutoCreaser Pro 33 SECTION 4 MAIN CREASER MECHANISM REMOVAL OF UNIT 4 1 Firstaccess should be gained by removing the top infeed and outfeed guards See Section 1 4 2 Detach guard micro switch by removing two screws taking care not to drop them 4 3 Cutandremove cable ties from cable mounting retaining wiring loom Ensure thatthe mains is unplugged 4 4 Fromtherearofthe machine remove two button socket screws with their washers 4 5 Removethe unlock knob from the front of the machine 4 6 Remove the polycord drive belt from the suction drum 4 7 Theunitcan be lifted by two people vertically out of the main frame with care One person should be guiding the wiring and plugs to ensure they do not get trapped during the lifting SYSTEM Page 13 4 8 Place the unitonasolid and clear bench ensuring no wires are trapped beneath the metal side plates 4 9 Assemble loosely the green drive belt to the pulley 4 10 Replace the unit ensuring the wiring harness Is threaded as it was removed 4 11 Attach the belt to the drive shaft 4 12 Fitthe tilt lever to the inside front frame with the bottom button head and screw in tilt knob 4 13 Sliderear spacer bar downin position see below Fixthe bottom screw in and align the top screw and fit loosely Replace
20. he tension to allow a quarter of a twist along its run and retighten the cap head screws Note care should be taken not to over tighten the slot sensor as it is plastic Feed Belt Bearings and Shims Center M5 Socket Support Screw Plate Page 8 CREASING AutoCreaser Pro 33 SYSTEM Page 9 SECTION 3 Removal of Butterfly Valve Assembly The Butterfly Valve assembly is located on the underside of the feed bed towards the back of the machine 3 1 Remove the two pipe mounting clip plates ITEM 5 on page 11 so that the hoses can be detached from the valve 3 2 Remove the two screws that secure the valve to the underside of the feed bed NOTE When refitting the valve ensure that the ends of the hoses are clear of nylon fibres and that the O ring is in place Page 10 CREASING AutoCreaser Pro 33 2 lt x 0 x 2 ale 3 9 a DA ar a Hi Qr 2 92 o 0 O o t v o2 o 5 LL CIL 2 LL 2 1 Items 7 Should Be Secured Into Item 4 using 2 Magnet Polarity Orientation is IMPORTANT m o E 2 i2 9 o
21. mp their operation can be checked from the Tools Menu The sensitivity of the Sensors can be adjusted individually by adjusting the appropriate Potentiometer on the Main Control Board using a small insulated electrical screwdriver The Detectors have no adjustments Check the operation of each Sensor or Detector in turn by entering the Tools Menu amp toggling down until the display reads Sensor Check The Lead Edge Sensor registers the lead edge of the sheet to within 0 1mm Its correct setting is extremely critical to the performance of the machine and any adjustment of its sensitivity will require re calibration of the machine 10 1 Ensure the Red LEDS on the Main Control Board is Off Place an 80gsm sheet on the Loading Table with its Lay Edge against the Fixed Side Lay Slide the sheet up to the Input Rollers amp rotate the machine by hand to drive the sheet through the Lead Edge Sensor the display should read Paper Edge and LED3 should come on as the sheet passes through the sensor beam 10 2 Ensure there is no paper in the machine before setting the sensitivity This is done by adjusting the Crease Edge pot VR4 on the Main Circuit Board Turn the pot fully anti clockwise Turn the pot clockwise until LED3 is just On and then back anti clockwise 60 i e about 10 clock minutes Note If LED3 does not illuminate when VR4 is turned fully clockwise then set at the 6 o clock position VR4 VR4 VR4 Fully anti clock
22. n the calculator and type 608888 then press X to exit the calculator screen 6 Choose the machine type from the list and perform a power cycle when prompted 7 Re enter the calibration settings Recess Internal USB Headers Internal USB Flash Drive External USB Sockets External USB Flash Drive FIG 1 FIG 2 FIG 1 and FIG 2 above show the Internal USB Flash Drive position for the current Gigabyte ATX mother board FIG 3 and FIG 4 below show the Internal USB Flash Drive positions for the previously used Jetway and Asrock mother boards SYSTEM Page 21 SECTION 9 ITX BOARD REPLACEMENT The ITX mother board supplies the graphics to the touch screen display to remove 1 Switch the mains power off 2 Cut cable ties and unplug the all plugs 3 Unscrew the four fixing screws attaching the board to the plate and remove from the machine Note the RAM should stay with the board Refitting is a reverse procedure to the above If using the existing USB stick the machine calibration will be as before but using a new stick will lose the settings and will mean recalibrating the machine ITX BOARD PSU REPLACEMENT The ITX PSU supplies power to the mother board and the main control PCB and is housed within the compressor compartment to remove 1 Switch the mains power off 2 Remove both the compressor cover and rear cover 3 Cut cable ties and unplug all plugs including the mains supply plug in the rear 4 U
23. nd check the voltage using a multi meter If the voltage is less than 1 5V replace the ITX mother board If the voltage is more than 1 5V refit the battery to the board CAUTION 1 RISK OF EXPLOSION IF BATTERY IS REPLACED BY AN INCORRECT TYPE 2 DISPOSE OF BATTERIES ACCORDING TO THE MANUFACTURERS INSTRUCTIONS ii With the power to the machine turned on link pins 3 amp 4 of the connector shown in FIG 2 with a small flat bladed screwdriver The fan on the board will start spinning wait for 30 seconds and the machine will restart and boot up as normal NOTE When the power to the machine is turned off and back on again the procedure of linking pins 3 amp 4 must be repeated to restart the machine This is therefore only a short term fix to get the customer and running if a replacement IT X mother board is not readily available Page 32 CREASING AutoCreaser Pro 33 PINS 3 amp 4 IMPORTANT RECYCLING NOTE The ITX mother board has a lithium battery fitted the board together with its battery must be recycled in compliance with agreed national Procedures Please contact your local disposal authority for information CAUTION DISPOSE OF BATTERIES ACCORDING TO THE MANUFACTURERS INSTRUCTIONS SYSTEM Page 33 FAULT No Touchscreen Display Machine will not boot up When you release the E stop switch the control system should receive power and begin to boot up After a short period of time you will see the touchscreen
24. nscrew the four fixing screws attaching the bracket to the main frame and remove from the machine 5 Remove the four fixing screws attaching the PSU to the bracket and slide the units apart Refitting is a reverse procedure to the above ensure the power switch is in the on position prior to replacing the compressor cover BOARD REPLACEMENT STEPPER DRIVE PCB The Stepper Driver board supplies the power to both Blade motor and main Drive motor and can be removed whilst located on the machine owitch the mains power off Cut cable ties and unplug the four green plugs Take note of the two spade terminals on each board and remove Unscrew the five fixing screws attaching the board to the plate and remove from the machine Refitting is a reverse procedure to the above IMPORTANT Check that the switch positions on SW1 SW2 SW3 and SW4 are correct see wiring diag BOARD REPLACEMENT SMALL STEPPER DRIVE PCB s The two Small Stepper Driver boards supply power to the Motorised Valve and the Vacuum Drum Motor 1 Switch the mains power off 2 Unplug the green plugs and spade terminals 3 Unscrew the four fixing screws attaching the board to the plate and remove from the machine Refitting is a reverse procedure to the above IMPORTANT Check that the switch positions on SW4 and SW5 are correct see wiring diag Page 22 CREASING AutoCreaser Pro 33 SECTION 9 Replacing the Touch Screen Assembly Replacing the Touch Sc
25. ove the engineers plug SETTING THE VACUUM DRUM SUCTION DELAY To set the vacuum drum suction start time the following procedure Is necessary Turn the machine on Insert the Engineers Plug into the Socket located at the rear of the machine Select Tools on the Display and select Vac Suck Trim by toggling the button A Input a value and run repeat until start delay is correct Return to the main screen and remove the engineers plug Page 24 CREASING AutoCreaser Pro 33
26. reen Assembly Ensure the mains power is turned off but with the plug in the socket this maintains an earth to reduce static damage 1 2 3 4 Remove the rear cover to expose the electrical panel Unplug the USB connector and nine way d type plug from the ITX board then carefully remove the white power connector this is tight and the wires can easily be pulled from the plug Through the rear of the metal support loosen the two socket head screws using a 4mm A F Allen key Carefully lift the unit up and through the top cover aperture Replacement is the opposite procedure Calibration of the Touch Screen 1 UP owitch on the power and await for the main screen to appear before commencing to check the horizontal and vertical position of the display The position of the display within the surround is achieved by operating the centre button at the rear of the housing press this a number of times to obtain the correct orientation required move to the next button to move the position to centralize horizontal With the engineering plug plugged into the engineers socket at the rear of the machine select the tools menu on the screen Continue the selection until the graphic for calibrating the touch panel is seen and follow the procedure on Screen Note a plastic pointer should be used a soft leaded pencil or biro cap may be used with gentle pressure Display Increase value ON OFF DOWN De
27. switch Error Double Sheet Check link on CN13 is correct Replace link check wiring diagram Detected Error 3 olot Sensor Blade CN3 Blacklead of meter on Yellow ground Red lead of meter on Green 0 2Vdc obstructed Approx 4Vdc not obstructed Hed lead of meter on Blue 5Vdc Home Position Switch Remove plugfrom CN13 Check continuity across wires make and break switch SYSTEM Page 31 FAULT NO SYNC appears on touchscreen Machine will not boot up 1 CHECK THE ATX POWER SUPPLY AS FOLLOWS 1 Disconnect the 20 24 way power supply connector from the Motherboard ii Using a piece of tinned copper wire short out the GREEN and BLACK wires of the connector as shown in FIG 1 below TINNED COPPER WIRE LINK iii With the ATX power supply switched on use a multi meter to measure the voltage across the RED and BLACK wires of one of the 4 way connectors The measured voltage should be between 4 75V to 5 25V Anything below 4 7V should be regarded as suspect and the power supply should be replaced iv With the AT X power supply switched on use a multi meter to measure the voltage across the YELLOW and BLACK wires of one of the 4 way connectors The measured voltage should be between 11 75V to 12 25V Anything below 11 7V should be regarded as suspect and the power supply should be replaced 2 CHECK THE ITX MOTHER BOARD AS FOLLOWS 1 Remove the 3V lithium disc battery from the IT X mother board a
28. t knob 8 Back stop 13 Switch Panel Touchscreen 9 Fixed side lay 14 Fuses Air distribution knob 10 Roller tilt knob o 49 a 6 D 6 so e D S gt SS SS amp 3 QS c3 5 c5 SSS gt 00009000000 fit 940000700 CO 0000900 0 SYSTEM Page 5 SECTION 1 1 1 The Front Cover The front cover which is situated below the feed bed also covers the compressor and is secured by 13 taptite screws and is located by three tongues protruding into the main frame To remove this cover remove all screws and twist forwards to clear emergency stop button and mains socket pull out to release the tongues This allows access tothe suction valve assembly and the compressor 1 2 The Rear Cover The rear cover is at the opposite side and is secured by four screws This cover is removed by lifting up and outward to unhook the keyhole locations on the opposite side to the screw fittings This allows access to the electronic plate assembly 1 3 The Creaser Mechanism Cover The creaser mechanism is situated towards the delivery end of the machine and is covered by a fixed and a hinged guard To remove these guards just remove the four screws M4 x 8 long beneath the infeed guard Pull off the rubber handle from the tilt lever and remove the knurled knob the infeed guard can now be lifted upwards and removed Page 6 CREASING AutoCreaser Pro 33 SEC
29. tightening torques NOTE Do not substitute fasteners with low grade alternatives which may fail or become irremovable Page 2 CREASING AutoCreaser Pro 33 INTRODUCTION Pan head and Cross head countersunk screws all have metric Taptite threads and Pozi drive recesses Use No 2 point Pozidriv or Supadriv drivers for all screws M4 amp above and No 1 point drivers for M3 amp below WARNING WORK SHOULD BE CARRIED OUT BY A TRAINED AND COMPETENT ENGINEER AND ALL SAFETY PROCEDURES SHOULD BE ADHERED TO SWITCH OFF THE MAINS POWER BEFORE COMMENCING DO NOT USE PHILLIPS DRIVERS THESE WILL DAMAGE THE SCREWS amp MAY SLIP CAUSING DAMAGE OR INJURY TN Identification For general identification of areas of the machines the following terms are used Operator side control consul facing Rear of machine opposite to control consul Delivery end to the left of the operator side Feeder end on your right IV New Machine Preparation Hemove all packaging materials All metal parts including the folding rollers have a protective coating and any excess should be removed Connect the power cable to the mains supply The machine requires 230V 50Hz 10 Amps or 115V 60Hz 15 Amps SYSTEM Page 3 INDEX Introduci n Introduction Fasteners iii Identification IV New Machine Preparation Section 1 COV CIS root ER ER E T a a EE a FR P Fa bw Le wa sew rara Section 2 Vacuum DD
30. wise Posn 60 clock Posn 9 o clock Posn The Crunch Sensor uses a beam projected across the machine just in front of the blade and above the paper path when the beam is broken the machine will stop The receiver is housed in the Side Plate of the machine and is on the Operator Side whilst the transmitter is housed in the oide Plate ofthe machine on the Lay Side 10 3 Ensure there is no paper in the machine before adjusting the sensitivity control pot on the Main Circuit Board fully anticlockwise 10 4 Ensure the appropriate Yellow LED is off and feed a folded sheet of paper down between the Input Roller amp the Creasing Blade until it crumples the display should read Crunch and the indicator LED should come on as the paper breaks the beam Page 28 CREASING AutoCreaser Pro 33 SECTION 11 Trouble Shooting Calibration of creasing position The length between the leading edge of the sheet and the 1st crease position can be calibrated in the event of the machine creasing out of position Also the last crease closest to the back of the sheet can be adjusted relative to the 1st crease position this compensates for the inaccuracy of manufacture of the input roller Diameters Crease Positions The first crease should be 50 mm from the lead edge less than 1 revolution of the in feed roller amp the last crease should be 370 mm from the lead edge 320mm Stretch Using the test stock if available setup Crease at 50 and 370 Check the
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