Professional Documents
Culture Documents
DOCUMENT
CREASING MACHINE
SERVICE MANUAL
Morgana Systems Limited United Kingdom
Telephone: ( 01908 ) 608888 Facsimile: ( 01908 ) 692399
Website: www.morgana.co.uk
ii ..........Fasteners
All threaded fasteners are isometric & all nuts are isometric
hexagon. All screws are hardened high tensile steel.
Page 2 CREASING
AutoCreaser 50 INTRODUCTION
WARNING
SYSTEM Page 3
INDEX
Introduction………………………………………………………………………….
¡ Introduction
¡¡ Fasteners
¡¡¡ Identification
iv New Machine Preparation
Section 1…… Covers………….…. .................................................................
Page 4 CREASING
AutoCreaser 50
AutoCreaser 50
SYSTEM Page 5
SECTION 1
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.
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 fit-
tings. This allows access to the suction valves and the electronic plate assembly.
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 handles from the tilt lever, and gapset lever and remove the knurled knob
. infeed guard can now be lifted upwards and removed.
the
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AutoCreaser 50
SECTION 2
2. Remove 2 cap head screws, holding body of valve to machine, with 4 mm Allen
key.
3. Remove valve, be careful not to loosen 0’ ring seal, which has a light coating of
grease to ensure a good seal.
Fig. 3
Resistance readings on the coil should be 10 ohms. To read the volts to the coil, have the
coil connected to the system and read the volts across the coil connections with the feed on.
SYSTEM Page 7
SECTION 3
3.3 Remove ‘0’ ring seal, remove long Allen screw 408 -01-050-030.
3.5 Remove 4 screws securing the bearing center support plate posi-
head from front of feed frame & 2 cap head, from under the feed frame.
DO NOT adjust or remove red bolt, as this is factory set.
3.6 Remove bearing center support plate 93-010. Be careful when removing
this as two bearings and shims can fall out.
3.7 Remove suction drum and belt, leave in feed drum idler and feed drum
roller, You can now remove belts.
Page 8 CREASING
AutoCreaser 50
SECTION 4
REMOVAL OF UNIT
4.1 First access 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 Cut and remove cable ties from cable mounting, retaining wiring loom.
Ensure that the mains is unplugged.
4.4 From the rear of the machine, remove two button socket screws with their
washers.
4.5 Remove the ’unlock’ knob from the front of the machine.
4.6 Remove the polycord drive belt from the suction drum.
4.7 The unit can 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 9
4.8 Place the unit on a solid and clear bench ensuring no wires are trapped beneath
the metal side plates.
4.10 Replace the unit ensuring the wiring harness is threaded as it was removed
4.12 Fit the tilt lever to the inside front frame with the bottom button head and screw
in tilt knob.
4.13 Slide rear spacer bar down in position (see below). Fix the bottom screw in and
align the top screw and fit loosely. Replace 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.
Page 10 CREASING
AutoCreaser 50
SECTION 5
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 in a hole in the shaft)
5.3 Refitting the belt is a reverse procedure. To 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 11
SECTION 6
6.12 Replace the roller in the reversemanner taking care to level the sideplates
on a flat surface before finally tightening the tie bar fixings.
Page 12 CREASING
AutoCreaser 50
SECTION 7
SYSTEM Page 13
SECTION 8
8.1 Remove the drip tray by removing the four securing screws fixed to the tie bars.
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.
Page 14 CREASING
AutoCreaser 50
SECTION 9
IMPORTANT:-
Check that the switch positions on SW1, SW2, SW3, and SW4 are correct, see wiring diagrams
on Pages 19 and 22.
SYSTEM Page 15
Removal/ replacement of Gapset Mechanism
Operator Block Replacement
The end housings of the top infeed roller are used to adjust the gap and contain the
bearings, they can be removed as follows.
1. Remove the double sided drive belt.
2. Remove the bottom infeed roller flanged pulley from the shaft by unscrewing the
two allen screws and drawing off from the shaft.
3. Align the lug of the eccentric with the aperture through the sideplate and slide
the roller assembly carefully thro the hole.
4. Remove the pulley from the shaft end and draw off the eccentric bearing
housing.
5. The second bearing remains in the other side plate and can be removed as
follows.
6. Remove the shoulder bolt securing the drive pulley located on the end of the
bottom infeed roller, remove the pulley and the washers.
7. Remove the securing circlip from the outside of the eccentric and withdraw the
housing from the side plate.
1. The operator block on the nearside is located on its shaft by the socket set
screw in a hole. Using the lever at the infeed end, the roller should be adjusted
down to pinch a strip of paper 80 gsm x 20 wide (slight slip should be felt).
2. The operator block on the far side is clamped by a socket set screw onto the
shaft.
3. With a second strip of paper 80 gsm x 20 wide between the rollers on the far
side, adjust this block down using an allen key as a lever in the screw until the
same tension is felt whilst pulling the paper (slight slip should be felt). Lock the
screw and retest by pulling both strips of paper, when the correct equal feel is
achieved then finally lock both screws.
Page 16 CREASING
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Replacing the Joystick Controller
Located on the leg, this switch is an assembly made up of four micro switches which
are generally very reliable once installed. Should it require replacing follow the
procedure below.
1. Remove both the rear cover and the compressor cover, giving access to the
yellow leg and the electric circuit board assembly.
2. The switch is fitted to the leg with four M2.5 slotted head screws, one on each
corner, which can only be accessed from the interior of the compressor
enclosure. Undo the four screws and unplug the green plug from the main
control board located at the rear of the machine.
3. Remove the switch and lead taking note of the route taken by the cable and the
relevant cable tie positions.
4. Refitting is generally the reverse procedure but note, the white wire on the
switch must be at the top.
5. To fit the switch, first pull the rubber gaitor to the front of the switch lever knob.
6. Locate the four screws with plain flat washers through the holes and position
into the threaded stand-offs. Tighten the screws, do not overtighten as this is a
plastic housing assembly.
7. Fix the cable using the same path and fixing points and plug into the p.c.b. in the
correct orientation.
SYSTEM Page 17
DIAGNOSTICS.
To set the measurement system for Imperial (Inch) or Metric (mm) the following proce-
dure 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 scroll down the screen until
‘METRIC or IMPERIAL’ is displayed.
Operate the Joystick to change the selection.
Lift the joystick up until the start screen appears.
Page 18 CREASING
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BRN
BRN
BRN 24
BL
BRN
BRN
1
BRN
BRN BRN
BL
BL
BL
BL
BL BL
BL BL
BRN BRN
BRN BRN
BRN
GRN/YEL
RD
BL
AC/N BL
2
BRN
AC/L GRN
CN1
CN2
AUTOCREASER 50
WIRING DIAGRAM E N
SYSTEM Page 19
1 VALVE (75-233)
2 PSU OUTPUT LEAD (75-190)
3 DRIVE STEPPER (75-186)
4 BLADE STEPPER 1 (75-187)
6 SYSTEM SWITCH COIL (75-185)
7 GUARD (75-232)
8 BLADE HOME (75-231)
9 CRANK ROTATION (76-156)
11 EDGE TX (76-230-02)
12 EDGE RX/JAM TX (76-154)
13 JAM RX (76-155)
24 ENGINEERING (75-255)
49 JOYSTICK ASSY. (75-246)
75-183 DISPLAY 61 CONTROL PCB TO RELAY LEAD (75-248)
62 CONTROL PCB TO CONTROL PCB LEAD
JOYSTICK (75-249)
RD
CRUNCH GRN
YLW
YLW
RD
SCR ENGINEERING
BL EDGE BLK
GRN 11
YLW
GRN GRN
BLADE BL
RD
4 BLADE STEPPER
BL
YLW
8 BRN
HOME
GRN
RD BRN
3 BL
BL
DRIVE STEPPER GUARD
YLW BL
61 BL
2
PSU 62 ORANGE
GRN
DOUBLE
RD
AIR 1
62 ORANGE
AUTOCREASER 50
CONTROL PCB
CONNECTION DIAGRAM
SHEET 1 OF 2
(PRE SERIAL No. 710046JEAJ)
Page 20 CREASING
AutoCreaser 50
SYSTEM Page 21
CREASERUNIT
GUARD
SWITCH
EMERGENCY STOP PSU
OUTPUTLEAD DOUBLE BLK
45 75-195
AIR
1
BRN BL BRN
26
BRN BRN
N
CONTROL PCB MK3
L SHORTING
BL EMERGENCY LINK LEAD
BL STOP 75-261 STACKERGUARD
SWITCH 75-040
BL BL BRN
BL
33
BL BL EMERGENCY STOP
BL BL INPUTLEAD 75-228 VALVE LEAD
BRN BRN 75-233
BRN BRN
BRN
SYSTEM SWITCHCOILLEAD
CHASSISEARTHLEAD 75-185
75-196 EARTHLEAD
DISTRIBUTION 46 39 GRN/YEL 76-232
BLOCK EARTH
BONDINGPOINT
51 GRN/YEL
E
POWER SUPPLY RD
INPUTLEAD 52 +24V
PSU 2
BL
75-192 AC/N BL
+5V
BRN
AC/L GRN PSU OUTPUTLEAD
PSUMAINSLEAD 37 CN1 (24V) 0V 75-190
75-184
40 CN2
CONTROL LEG
ASSEMBLY BLADESIGNALLEAD
4
75-291-01 75-187
BLADE
BLADEMOTOR EARTH LEAD
76-236
E COMP. LEAD
75-124
BLADE
76-153
M 59
AUX. OUTPUTLEAD N L
29 42
75-127
SW1 = Posn. 1 DUAL
ANTISTATIC KIT
COMP SW2 1 = OFF
SW2 2 = ON STEPPER
70-082
M DRIVER
72 volts DC Nominal
BRN
M 58
24V 48V
AUTOCREASER 50 PSU PSU
WIRING DIAGRAM
(SERIAL No. 710046JEAJ ONWARDS)
CONTROL SYSTEM ASSEMBLY
75-01-02
Page 22 CREASING
AutoCreaser 50
1 VALVE (75-233)
2 PSU OUTPUT LEAD (75-190)
3 DRIVE STEPPER (75-294)
4 BLADE STEPPER 1 (75-187)
6 SYSTEM SWITCH COIL (75-185)
7 GUARD (75-232)
8 BLADE HOME (75-231)
9 CRANK ROTATION (76-156)
11 EDGE TX (76-230-02)
12 EDGE RX/JAM TX (76-154)
13 JAM RX (76-155)
24 ENGINEERING (75-255)
49 JOYSTICK ASSY. (75-246)
75-183 DISPLAY
JOYSTICK
RD
CRUNCH GRN
YLW
YLW
RD
SCR ENGINEERING
BL EDGE BLK
GRN 11
YLW
GRN GRN
BLADE BL
RD
4 BLADE STEPPER
BL
YLW
8 BRN
HOME
GRN
RD BRN
BL BL
3 DRIVE STEPPER GUARD
YLW BL
BLK
WHI
2
PSU
GRN
DOUBLE
RD
AIR 1
AUTOCREASER 50
CONTROL PCB
CONNECTION DIAGRAM SHEET 1 OF 2
(SERIAL No. 710046JEAJ ONWARDS)
SYSTEM Page 23
Page 24 CREASING
AutoCreaser 50
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 of collected onto
sensor lens.
SYSTEM Page 25
SECTION 11 Trouble Shooting
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 front
edge of the sheet to compensate for the inaccuracy of manufacture of the input roller
diameters.
The first crease should be 50 mm from the lead edge (less than 1 revolution of the in-
feed roller) & the last crease should be 370 mm from the lead edge.
Turn On machine.
Insert the Engineers Plug into the Socket located at the rear of the machine.
Run the machine and measure the last crease position at 370 mm.
Select Tools on the Display and scroll down the screen until
‘STRETCH’ and a numeric value is between the Arrows.
Operate the Joystick to change the value (Left to Increase), a higher value
will move the crease further from the lead edge. (0 is a good start value)
Lift the joystick up until the start screen appears.
Run machine and check crease position, repeat above procedure until accurate
crease position is achieved.
AutoCreaser 50
Section 11 Trouble Shooting (Pre Serial No. 710046JEAJ)
Fault Reason Solution
Display shows Faint blocks Check ribbon cable for damage Change Display PCB orAssembly.
or unrecognizable characters Communication fault ReplacemainPCB
or faulty processor
No Display If LED1 & LED2 are lit onmainPCB Adjust VR1 (contrast)
Check CN4 is correctly fitted Adjust VR2 (backlit)
If still no display Change Display PCB or Assembly.
If missing lines Change Display PCB orAssembly.
No Control of Menu Check Joystick wires Repair damaged wires or Replace Joystick assembly
Check Joystick Switch m/c off. Black lead ofmeter to blue wire small PSU.
Red lead ofmeter to each terminal CN10 (main PCB)
First 4 pins will show reading of 4.7 Kohms
Move joystick 4 posn. Check all pins.
If any pins show 4.7 K ohms withoutmoving joystick
Suspect a fault joystick and replace the assembly.
Valve Energises
on Power up & stays on. failure of Processor or control PCB Replace Main Board.
Valve Voltage check Small PSU CN2 Black lead of meter to green wire.
CN5=24V dc when Inactive. Red lead of meter to either wire.
One wire will drop to 12Vdc when activated
IfMotors Run but Display Shows CheckRelay & connectors To Check Relay- 5Vdc should be on Cn2
‘Operate System Switch Before Running’. Main PCB when System Switch is operated.
SYSTEM Page 27
Section 11 Trouble Shooting (Pre Serial No. 710046JEAJ)
Fault Reason Solution
Motors Erratic Wrongly wired Check colours with wiring diagram.
Incorrect voltage Black lead of meter on tab IC13 (Stepper PCB)
Should read approx Red lead of meter on each pin CN3 (drive)
30vdcWhenrunning Red lead of meter on each pin CN2 (Blade)
Sensor - Transmitter Check supply voltage Black lead of meter on tab IC8 (Main PCB)
Should read 1.3Vdc Red lead of meter on red wire of CN8
(Closest red wire to CN3) And also yellow wire of CN12
ToAdjust these voltages Adjust VR3 Edge sensor & VR5 Jam sensor.
Sensor - Receiver, Jam Check voltage 2.9Vdc Meter across Red/Black of CN12 (Obstruct
Beam and Voltage will rise to approx 5 Vdc)
Voltage will increase/decrease by adjusting intensity of transmitter (pot VR5)
Sensor - Receiver, Edge Check voltage 0.466Vdc Meter across Red/Blue of CN8(Obstruct
Beam and Voltage will rise to approx 5 Vdc)
Note- Voltage will increase/decrease by adjusting intensity of transmitter
(Pot VR3 or VR4 depending on SW1 switch position)
Safety Circuit Faulty Check Voltage on Any Switch orWire,Opencircuit will be 0Vdc
No Drive. CN7 =11/12 Vdc
To Check PCB. Black lead of meter on tab IC8 (Main PCB)
Red lead of 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 switch.
Error Double Sheet Check link on CN11 is correct. Replace link, check wiring diagram.
Detected
Home Position Switch Remove plug from CN13 Check continuity acrosswires(make and break switch)
Page 28 CREASING
AutoCreaser 50
Section 11 Trouble Shooting (Serial No. 710046JEAJ Onwards)
Fault Reason Solution
Display shows Faint blocks Check ribbon cable for damage Change Display PCB orAssembly.
or unrecognizable characters Communication fault ReplacemainPCB
or faulty processor
No Display If LED1 & LED2 are lit onmainPCB Adjust VR1 (contrast)
Check CN4 is correctly fitted Adjust VR2 (backlit)
If still no display Change Display PCB or Assembly.
If missing lines Change Display PCB orAssembly.
No Control of Menu Check Joystick wires Repair damaged wires or Replace Joystick assembly
Check Joystick Switch m/c off. Black lead ofmeter to blue wire small PSU.
Red lead ofmeter to each terminal CN10 (main PCB)
First 4 pins will show reading of 4.7 Kohms
Move joystick 4 posn. Check all pins.
If any pins show 4.7 K ohms withoutmoving joystick
Suspect a fault joystick and replace the assembly.
Valve Energises
on Power up & stays on. failure of Processor or control PCB Replace Main Board.
Valve Voltage check Small PSU CN2 Black lead of meter to green wire.
CN5=24V dc when Inactive. Red lead of meter to either wire.
One wire will drop to 12Vdc when activated
No Drive orMotors Pulsing Low or No Power toMotors Check green light is illuminated on both PSUs
Check 240/110VAC input to Large PSUs
(Meteracross L & N terminals)
No LED on Stepper PCB Low or No Power from PSU Meter across V+ & V- of SP-150-24 reading 24V dc
Meter across V+ & V- of SP-150-48 reading 48V dc
Replace PSU if no or low reading
Meter across V+ of SP-150-48 & V- of SP-150-24 reading 72V dc
If voltage is correct but no light on stepper then check cable integrity.
SYSTEM Page 29
Section 11 Trouble Shooting (Serial No. 710046JEAJ Onwards)
Fault Reason Solution
IfMotors Run but Display Shows Check connectors To Check -5Vdc should be across pins 5&6 on CN2
‘Operate System Switch Before Running’. Main PCB when System Switch is operated.
Sensor - Transmitter Check supply voltage Black lead of meter on tab IC8 (Main PCB)
Should read 1.3Vdc Red lead of meter on red wire of CN8
(Closest red wire to CN3) And also yellow wire of CN12
ToAdjust these voltages Adjust VR3 Edge sensor & VR5 Jam sensor.
Sensor - Receiver, Jam Check voltage 2.9Vdc Meter across Red/Black of CN12 (Obstruct
Beam and Voltage will rise to approx 5 Vdc)
Voltage will increase/decrease by adjusting intensity of transmitter (pot VR5)
Sensor - Receiver, Edge Check voltage 0.466Vdc Meter across Red/Blue of CN8(Obstruct
Beam and Voltage will rise to approx 5 Vdc)
Note- Voltage will increase/decrease by adjusting intensity of transmitter
(Pot VR3 or VR4 depending on SW1 switch position)
Safety Circuit Faulty Check Voltage on Any Switch orWire,Opencircuit will be 0Vdc
No Drive. CN7 =11/12 Vdc
To Check PCB. Black lead of meter on tab IC8 (Main PCB) Red lead of
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 switch.
Error Double Sheet Check link on CN11 is correct. Replace link, check wiring diagram.
Detected
Home Position Switch Remove plug from CN13 Check continuity acrosswires(make and break switch)
Page 30 CREASING
AutoCreaser 50
ANTI-STATIC UNIT
PSU (5V / 24V) (IF FITTED)
F3.15A (613-023) T315mA (681-011)
SYSTEM Page 31