70 070 autocreaser 50 service manual

ISSUE 2 August 2006

70-070

DOCUMENTCREASING MACHINE

Morgana Systems Limited United Kingdom

Website: www.morgana.co.ukTelephone: ( 01908 ) 608888 Facsimile: ( 01908 ) 692399

SERVICE MANUAL

AutoCreaser 50

CREASING

INTRODUCTION

i ...........IntroductionThe purpose of this manual is to explain the procedure for dis-mantling and re-assembly of the major assemblies on the MorganaAuto Creasing machine.

All the engineering adjustments are shown at the end of eachrelevant section.

Operator's adjustments and routine maintenance are explained inthe appropriate operators guide which should always be used inconjunction with this manual.

It is always a good idea to have a copy of the machines illustratedparts manual available when servicing, as its illustrations providean invaluable reference to the construction of the individualassemblies used to build the machine.

ii ..........FastenersAll threaded fasteners are isometric & all nuts are isometrichexagon. All screws are hardened high tensile steel.

Cap head, Button head, Socket countersunk, Shoulder bolts andGrubscrews have internal hexagon drives which require isometrichexagon wrenches (allen keys). Ball drivers may be used, but careshould be takenparticularly when releasing screws fordismantlingto avoid breaking the driver as they cannot cope withfull tightening torques.

NOTE ..... Do not substitute fasteners with low grade alternativeswhich may fail or become irremovable.

MORGANA AUTO CREASER 50

SYSTEM

AutoCreaser 50

Pan head and Cross-head countersunk screws all have metricTaptite threads and Pozi-drive recesses. Use No.2 point Pozidrivor Supadriv drivers for all screws M4 & above, and No.1 pointdrivers for M3 & below.

WARNING

WORK SHOULD BE CARRIED OUT BY A TRAINED ANDCOMPETENT ENGINEER AND ALL SAFETYPROCEDURES SHOULD BE ADHERED TO.

SWITH OFF MAINS POWER BEFORE COMMENCING

DO NOT USE PHILLIPS DRIVERS - THESE WILL DAMAGETHE SCREWS & MAY SLIP, CAUSING DAMAGE ORINJURY.

iii ........ IdentificationFor general identification of areas of the machines, the followingterms 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 PreparationRemove all packaging materials

All metal parts, including the folding rollers have a protectivecoating and any excess should be removed.

Connect the power cable to the mains supply. The machinerequires 230V 50Hz 10 Amps or 115 60Hz 15 Amps.

INTRODUCTION

CREASING

INDEX

Introduction. Introduction Fasteners Identificationiv New Machine Preparation

Section 1 Covers...................................................................

Section 2 Vacuum Valve.Valve Plunger ReplacementsValve Coil

Section 3.Vacuum Drum .........................................................................Suction Drum and Belt Removal/Replacement

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 Refurbishment.....Section 9.Electrics.....

Removal/Refitting PCBs

Diagnostics

Autocreaser 50 Wiring DiagramAutocreaser 50 Control PCB Connection Diagram

Section 10..Optical Sensors...

Section 11...Trouble ShootingCalibration of Creasing Position

Setting the Measurement System (Metric / Inch)

Trouble Shooting

Removal/Replacement of Gapset MechanismReplacement of Joystick Controller

Fuse Positions and Ratings

Setting the Language (English, French, German)

SYSTEM

AutoCreaser 50

DOCUMENT CREASING MACHINE

Key to photograph below

1 Roller tilt handle 6 Air distribution knob 11 Paper Gate2 Stacker assembly 7 Adjustable side lay 12 Exit Guard3 Suction slot knob 8 Back stops 134 The display unit 9 Fixed side lay 145 Air separation knob 10 Roller tilt knob

AutoCreaser 50

FusesControl Panel

15 Gap Set Knob and Lever

CREASING

SECTION 1

1.1 The Front Cover

The front cover which is situated below the feed bed also covers the compressor and issecured 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 buttonand mains socket, pull out to release the tongues.

1.2 The Rear Cover

The rear cover is at the opposite side and is secured by four screws. This cover is removed bylifting 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.

1.3 The Creaser Mechanism Cover

The creaser mechanism is situated towards the delivery end of the machine and is covered bya 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 knobthe infeed guard can now be lifted upwards and removed.

SYSTEM

AutoCreaser 50

SECTION 2

2.1 Valve Plunger Replacement.

1. Remove coil cable.

2. Remove 2 cap head screws, holding body of valve to machine, with 4 mm Allenkey.

3. Remove valve, be careful not to loosen 0 ring seal, which has a light coating ofgrease to ensure a good seal.

4. Remove bottom of valve to release plunger and spring.Check the rubber valve seating washer is secure and not split and the metalwasher under the nut should be fitted.

5. Set spool dimension to 44.2 mm. See fig 3. below.Note: The seating washer is available as a spare Morgana Part No. 04-070 & themetal washer is also available as a spare Morgana Part No. 481-125.A damaged washer or incorrect setting of these parts can cause loss of feed, similarto a faulty electrical component.

6. Refit in reverse order.Note:Do not over tighten aluminum parts and use grease to stop binding.

2.2 Valve Coil.

Resistance readings on the coil should be 10 ohms. To read the volts to the coil, have thecoil connected to the system and read the volts across the coil connections with the feed on.

This should be 12 volts.

Fig. 3

CREASING

SECTION 3

SUCTION DRUM AND BELT REMOVAL \ REPLACEMENT

3.1 Remove feed bed and side guide.

3.2 Remove valve assembly as in last paragraph.

3.3 Remove 0 ring seal, remove long Allen screw 408-01-050-030.

3.4 Remove choke shaft from non-operator side.

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 removingthis as two bearings and shims can fall out.

3.7 Remove suction drum and belt, leave in feed drum idler and feed drumroller, You can now remove belts.

3.8 Replace in reverse order, again be careful of bearings and shims.When fitting bearing support, make sure it is up against red bolt.

SYSTEM

AutoCreaser 50

SECTION 4

MAIN CREASER MECHANISM

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 theirwashers.

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 gettrapped during the lifting.

CREASING

4.8 Place the unit on a solid and clear bench ensuring no wires are trapped beneaththe 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 Fit the tilt lever to the inside front frame with the bottom button head and screwin tilt knob.

4.13 Slide rear spacer bar down in position (see below). Fix the bottom screw in andalign the top screw and fit loosely. Replace cable ties to mountings. Align theroller set square with the fixed lay edge while the front tilt lever is in the centreposition. (Use the rear slots to adjust square) Tighten the screws and replacethe top covers.

SYSTEM

AutoCreaser 50

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 itto 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 drivemotor down to allow feel of belt tightness; then re-adjust the motor / gear meshto allow minimum backlash.

CREASING

SECTION 6

REMOVAL/REPLACEMENT OF TOP INFEED ROLLLER

REMOVAL/REPLACEMENT OF BOTTOM INFEED ROLLLER

6.1 With the unit on a bench6.2 Remove the drive belt and flanged pulley from the bottom infeed roller.6.3 Viewing on the outside of the sideplate, align the lug on the eccentric

with cutout in the sideplate.6.4 Using a soft mallet gently tap the roller assembly from the opposite

side supporting its length as it emerges.

6.5 Remove the drive belt and top infeed roller assembly and bottomflanged pulley as above.

6.6 Remove the earth wire from the rear of the drive motor.6.7 cut cable ties on tie bar / drivemotor and jam sensor / hexagonal stud.6.8 Remove all side plate fixing screws and nuts from the tie bars.6.9 Remove two posi pan head screws from side plate, securing the lower sensor bar.6.10 Withdraw the sideplate with care, supporting the shafts.6.11 The bottom infeed roller can be removed with the bearing attached.

Note the position of the spring washers.

6.12 Replace the roller in the reversemanner taking care to level the sideplateson a flat surface before finally tightening the tie bar fixings.

SYSTEM

AutoCreaser 50

SECTION 7

DRIVE HUB:- REPLACE RUBBER TORSION BUSH (SHOCKABSORBER).

7.1 Loosen grub screws in one half of hub.

7.2 Slide hub outward & remove rubber torsion bush.

7.3 Replace in reverse order.

Rubber Torsion Bush

CREASING

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 sideof 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 Re-assemble in reverse order.

Micro Switch AssemblyLink Plate

SYSTEM

AutoCreaser 50

SECTION 9

.

.

ELECTRICS: REMOVAL/REFITTING PCB/POWER SUPPLY ASSEMBLYAll the Electric controls and pcbs are located within the rear cover,mounted on a common base plate.

Disconnect the mains.Unplug all plugs from the PCBs and disconnect wires.The total assembly can be removed from the machineby unscrewing the six posi pan head screws from the edge of the plate.

The Stepper Driver board supplys the power to both Blade motor and main Drive motor andcan be removed whilst located on the machine.Switch 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 four fixing screws attaching the board to the plate and remove from the machine.

Refitting is a reverse procedure to the above.

Check that the switch positions on SW1, SW2, SW3, and SW4 are correct, see wiring diagramson Pages 19 and 22.

BOARD REPLACEMENT. STEPPER DRIVE PCB

IMPORTANT:-

CREASING

Removal/ replacement of Gapset Mechanism

Operator Block Replacement

Eccentric Bearing Housings

Setting the gap set

1. With the creaser mechanism raised up as previously discussed, and securelysupported, access to the two operator blocks can be found.

2. Removal of the blocks are achieved by unscrewing the locating allen screwsin the rear, these fix the blocks to the shaft, which can then be slid sidewayfrom the side plates. Note:- The operator side block is located with a hole inthe shaft and the rear block is clamped to the shaft with these screws.

The end housings of the top infeed roller are used to adjust the gap and contain thebearings, 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.

Refitting is the reverse procedure to the above.

1. The operator block on the nearside is located on its shaft by the socket setscrew in a hole. Using the lever at the infeed end, the roller should be adjusteddown 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 theshaft.

3. With a second strip of paper 80 gsm x 20 wide between the rollers on the farside, adjust this block down using an allen key as a lever in the screw until thesame tension is felt whilst pulling the paper (slight slip should be felt). Lock thescrew and retest by pulling both strips of paper, when the correct equal feel isachieved then finally lock both screws.

SYSTEM

AutoCreaser 50

Replacing the Joystick Controller

Located on the leg, this switch is an assembly made up of four micro switches whichare generally very reliable once installed. Should it require replacing follow theprocedure below.

1. Remove both the rear cover and the compressor cover, giving access to theyellow leg and the electric circuit board assembly.

2. The switch is fitted to the leg with four M2.5 slotted head screws, one on eachcorner, which can only be accessed from the interior of the compressorenclosure. Undo the four screws and unplug the green plug from the maincontrol board located at the rear of the machine.

3. Remove the switch and lead taking note of the route taken by the cable and therelevant cable tie positions.

4. Refitting is generally the reverse procedure but note, the white wire on theswitch 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 aplastic housing assembly.

7. Fix the cable using the same path and fixing points and plug into the p.c.b. in thecorrect orientation.

CREASING

SET THE MEASUREMENT SYSTEM (METRIC / IMPERIAL SETTINGS).

DIAGNOSTICS.

To set 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 scroll down the screen until M/C TotalX10 and a numeric value isbetween the Arrows. (Take note of this figure)Operate the Joystick to reset count to zero.

Lift the joystick up until the start screen appears.

This also removes all stored programmes,including the Lead Edge Trim and Stretch settings.

NOTE.

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 untilMETRIC or IMPERIAL is displayed.Operate the Joystick to change the selection.Lift the joystick up until the start screen appears.

SET THE LANGUAGE (ENGLISH, FRENCH, GERMAN)

To set the language.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 English, Francais, or Deutsch isdisplayed.Operate the joystick to change to the required language.Remove the Engineers Plug.

SYSTEM

AutoCreaser 50

AUTOCREASER 50WIRING DIAGRAM

1

24

NE

AC/L

AC/N

CN2

CN1

GRN/YEL

BRN

BLBL

GRN

RD

BRN

BRN

BRN

BRN

BRN

BRN

BL

BLBRN

2

BRN

BL

BRN

BL

BRN

BL

BRN

BL

BL

BRN

BL

BRN

BL

(PRE SERIAL No. 710046JEAJ)

CREASING

AUTOCREASER 50CONTROL PCB

CONNECTION DIAGRAMSHEET 1 OF 2

BLK

RD

RD

RDGRN

BLYLW

GRNYLW

RDGRN

BLYLW

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)61 CONTROL PCB TO RELAY LEAD (75-248)62 CONTROL PCB TO CONTROL PCB LEAD

(75-249)

ENGINEERING

1

2

3

4

8

11

GRN

BL

BRNBL

BRN

BLGRNYLW

YLWRD

SCRBL

BLADE STEPPER

DRIVE STEPPER

DOUBLE

CRUNCH

JOYSTICK

DISPLAY

EDGE

BLADE

HOME

GUARD

PSU

AIR

CONTROL BOARD MK3

GRN

61 BL

62 ORANGE

62 ORANGE

75-183

75-261

(PRE SERIAL No. 710046JEAJ)

SYSTEM

AutoCreaser 50

CREASING

(SERIAL No. 710046JEAJ ONWARDS)

AUTOCREASER 50WIRING DIAGRAM

valvecoil

GUARDSWITCH

STACKERGUARDSWITCH 75-040

MAINS IN

EMERGENCYSTOP

COMP.SWITCH

SYSTEMSWITCH

DISTRIBUTIONBLOCK

HOMESWITCH

MCOMP

SYSTEMSWITCHINPUT LEAD

75-191

EMERGENCY STOPINPUTLEAD 75-228

COMP. LEAD75-124

PSU OUTPUTLEAD75-190

VALVE LEAD75-233

POWER SUPPLYINPUTLEAD75-192

AUX. OUTPUTLEAD75-127

HOME SWITCH75-231

EARTHLEAD76-232

SYSTEM SWITCHCOILLEAD75-185

76-230-02

76-154

76-155

L

N L N L

N

E

BLKBRN

BL

BLK

JAM

DUALSENSOR

EDGEDETECT

1

3

4

6

11

24

26

29

31

37

39

40

CREASERUNIT

E

N L

BRN

BL

BL BRN

BRNBL

E

EARTHBONDINGPOINT

EARTHBONDINGPOINT

BLADE POSITIONSENSOR76-156

75-255DIAGNOSTICLEAD

GRN/YEL

BRN

BLLN

E

1 TO 24, 49 SEE COLOUR CODE SHEET DRAWING NUMBER (70-090)26 STACKER GUARD SWITCH (75-040)29 COMPRESSOR LEAD (75-124)31 SYSTEM SWITCH INPUT LEAD (75-191)

33 EMERGENCY STOP INPUT LEAD (75-228)37 PSU INPUT LEAD (75-192)39 EARTH. CHASSIS TO CREASING UNIT (76-232)40 PSU MAINS LEAD (75-184)41 DRIVE MOTOR LEAD(76-152)42 BLADE MOTOR LEAD (76-153)43 SYSTEM SWITCH OUTPUT LEAD (75-193)44 COMPRESSOR SWITCH INPUT LEAD (75-194)45 EMERGENCY STOP OUTPUT LEAD (75-195)46 CHASSIS EARTH LEAD (75-196)47 FUSE LEAD (75-197)48 PSU OUTPUT LEAD (75-295)51 EARTH LEAD (75-189)52 EARTH LEAD (75-188)58 DRIVE MOTOR EARTH LEAD (76-238)59 BLADE MOTOR EARTH LEAD (76-236)69 PSU LINK LEAD (75-284)70 PSU EARTH LINK (75-296)71 PSU MAINS LINK (75-297)

MBLADE

PSUMAINSLEAD75-184

BLADEMOTOR76-153

DRIVE MOTOR76-152

BLADESIGNALLEAD75-187

DRIVE SIGNALLEAD75-294

42

SEE DRAWING 125-23-01FOR CONNECTION DETAILS

BLADE

DRIVESIGNAL

3

4

EARTH LEAD76-236

59

BRNBL

DISPLAY & LEADASSEMBLY75-183

ANTISTATIC KIT70-082

41

DRIVE

DUALSTEPPERDRIVER

PSU0V

+5V

+24V

AC/L

AC/N

CN2

CN1

GRN/YEL

BRN

BLBL

GRN

RD

YEL/GRNBRNBL

BRN

BL

(24V)

BRNBL

BRNBL

BRN

BRN

GRN/YEL

GRN/YEL

FUSE

FUSE

SPAREFUSEFUSE

BRN

BRN

BRN

BRN

BL

BLBRN

EARTH LEAD75-188

51

SYSTEMSWITCHOUTPUT LEAD

75-193

43

COMP. SWITCHINPUTLEAD

75-194

44

45

EMERGENCY STOPOUTPUTLEAD

75-195

52

CHASSISEARTHLEAD75-196

37

FUSE LEAD75-197

PSU OUTPUT LEAD75-29548

JOYSTICK LEAD ASSY.75-246

49

2

47

F3.15A

T4.0A

GRN/YEL

33

BRN

BRNBL

BL

BRN

BL

BRN

BL

BRN

46

52

BL

GRN/YEL

BL

29

BRN

BL

GRN/YEL

BRN

BL

39

MDRIVE EARTHLEAD

76-238

58

CONTROL LEGASSEMBLY

CONTROL SYSTEM ASSEMBLY

72 volts DC NominalBetween Blue & BrownWires (REF.)

CONTROL PCB MK3

ENGINEERING

JOYSTICK

DISPLAY

BLADESTEPPER

DRIVESTEPPER

DOUBLE

CRUNCH

EDGE

BLADE

HOME

GUARD

PSU

AIR

SW1 = Posn. 1

SW2 1 = OFFSW2 2 = ON

SW4 = Posn. 1

SW3 1 = ONSW3 2 = ON

40

SHORTINGLINK LEAD75-261

N+V

L E-V

PSU48V

N+V

L E-V

PSU24V

69PSU LINK LEAD75-284

PSU EARTH LINK75-296

7071

PSU MAINS LINK75-297

75-291-01

75-01-02

SYSTEM

AutoCreaser 50

SHEET 1 OF 2

BLK

RD

RD

RDGRN

BLYLW

GRNYLW

RDGRN

BLYLW

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)

ENGINEERING

1

2

3

4

8

11

GRN

BL

BRNBL

BRN

BLGRNYLW

YLWRD

SCRBL

BLADE STEPPER

DRIVE STEPPER

DOUBLE

CRUNCH

JOYSTICK

DISPLAY

EDGE

BLADE

HOME

GUARD

PSU

AIR

CONTROL BOARD MK3

GRN

75-183

75-261

BLKWHI

AUTOCREASER 50CONTROL PCB

CONNECTION DIAGRAM(SERIAL No. 710046JEAJ ONWARDS)

CREASING

SYSTEM

AutoCreaser 50

SECTION 10

Cleaning Sensors

With blades removed the optical sensors are accessible for cleaning on either side of thecreaser unit - use a soft brush or cloth to remove any dust that may of collected ontosensor lens.

SECTION 11 Trouble Shooting

Calibration of creasing position

The length between the leading edge of the sheet and the 1st crease position can becalibrated 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 frontedge of the sheet to compensate for the inaccuracy of manufacture of the input rollerdiameters.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.

Adjust the 1st crease position as follows:-

Adjust the Last crease position as follows:-

Turn On machine.Insert the Engineers Plug into the Socket located at the rear of the machine.Run the machine and measure the first crease position at 50 mm.Select Tools on the Display and scroll down the screen untilLEAD EDGE TRIM and a numeric value is between the Arrows.Operate the Joystick to change the value (Left to Increase), a higher valueWill 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 accuratecrease position is achieved.

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 untilSTRETCH and a numeric value is between the Arrows.Operate the Joystick to change the value (Left to Increase), a higher valuewill 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 accuratecrease position is achieved.

AutoCreaser 50

Page 27SYSTEM

Section 11 Trouble Shooting (Pre Serial No. 710046JEAJ)Fault Reason Solution

Erratic register of Damaged roller surface Replace rubber rollersthe Creaser Check Gap Setting Reset & tighten to ensure rollers are driving card.

Faulty motor Remove and replace motor assembly.

No Power Fuse Blown Replace with correct value.or No Display Check small Power supply input on CN1

Check cables for continuity toEmergency stop button.

Faulty wire or connection.Check small power supply output Black lead ofmeter to green wire.Voltage on CN2=5V dc R

Voltages should read 240V or 110VAC

Replace

ed lead of meter to blue wire.Voltage on CN2=24V dc Red lead of meter to red wire.If supply has input but no output Replace PSUCheck voltage onmain If no voltage then check for damagedPCB CN6 wire or connection. Replace as required.

Display shows Faint blocks Check ribbon cable for damage Change Display PCB orAssembly.or unrecognizable characters Communication fault ReplacemainPCB

or faulty processorNo 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 orAssembly.If missing lines Change Display PCB orAssembly.

No Control of Menu Check Joystick wires Repair damaged wires or Replace Joystick assemblyCheck 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 KohmsMove joystick 4 posn. Check all pins.If any pins show 4.7 K ohms withoutmoving joystickSuspect a fault joystick and replace the assembly.

Valve Energiseson 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 Low or No Power toMotors Check 240/110VACinputtoLargePSUPulsing Meter across blue/brown wires.(bottom of PSU)No LED on Stepper PCB Low or No Power from PSU Meter across blue/brown wires.(top of PSU) =72vdc

Low voltage (36vdc) Resistor not connected or broken. Replace

IfMotors Run but Display Shows CheckRelay & connectors To Check Relay- 5Vdc should be on Cn2Operate System Switch Before Running. Main PCB when System Switch is operated.

CREASING

Fault Reason SolutionMotors Erratic Wrongly wired Check colours with wiring diagram.

Incorrect voltage Black on tab IC13 (Stepper PCB)Should read approx

lead of meterRed 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 CN12ToAdjust these voltages Adjust VR3 Edge sensor & VR5 Jam sensor.

Sensor - Receiver, Jam Check voltage 2.9Vdc Meter across Red/Black of CN12 (ObstructBeam 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(ObstructBeam 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 0VdcNo 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 probesacross plug If no continuity then check each switch.

Error Double Sheet Check link on CN11 is correct. Replace link, check wiring diagram.Detected

Slot Sensor Blade CN3 Black lead of meter on Yellow (ground)Red lead of meter on Green = 0.2Vdc obstructed

Approx 4Vdc not obstructed.Red lead of meter on Blue = 5VdcRed lead of meter on Red = 1.2Vdc

Home Position Switch Remove plug from CN13 Check continuity acrosswires(make and break switch)

Section 11 Trouble Shooting (Pre Serial No. 710046JEAJ)

AutoCreaser 50

Page 29SYSTEM

Section 11 Trouble Shooting (Serial No. 710046JEAJ Onwards)Fault Reason Solution

Erratic register of Damaged roller surface Replace rubber rollersthe Creaser Check Gap Setting Reset & tighten to ensure rollers are driving card.

Faulty motor Remove and replace motor assembly.

No Power Fuse Blown Replace with correct value.or No Display Check small Power supply input on CN1

Check cables for continuity toEmergency stop button.

Faulty wire or connection.Check small power supply output Black lead ofmeter to green wire.Voltage on CN2=5V dc R

Voltages should read 240V or 110VAC

Replace

ed lead of meter to blue wire.Voltage on CN2=24V dc Red lead of meter to red wire.If supply has input but no output Replace PSUCheck voltage onmain If no voltage then check for damagedPCB CN6 wire or connection. Replace as required.

Display shows Faint blocks Check ribbon cable for damage Change Display PCB orAssembly.or unrecognizable characters Communication fault ReplacemainPCB

or faulty processorNo 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 orAssembly.If missing lines Change Display PCB orAssembly.

No Control of Menu Check Joystick wires Repair damaged wires or Replace Joystick assemblyCheck 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 KohmsMove joystick 4 posn. Check all pins.If any pins show 4.7 K ohms withoutmoving joystickSuspect a fault joystick and replace the assembly.

Valve Energiseson 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 PSUsCheck 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 dcReplace PSU if no or low reading

Meter across V+ of SP-150-48 & V- of SP-150-24 reading 72V dcIf voltage is correct but no light on stepper then check cable integrity.

CREASING

Fault Reason Solution

If System switch activates faulty cable Check 6 core cablebut display shows or terminals from CN2 of control boardActivate System SwitchBefore Running.

Motors Erratic Wrongly wired Check colours with wiring diagram.Incorrect voltage Black on tab IC13 (Stepper PCB)Should read approx

IfMotors Run but Display Shows Check connectors To Check -5Vdc should be across pins 5&6 on CN2Operate System Switch Before Running. Main PCB when System Switch is operated.

to CN4 of stepper board

lead of meterRed 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 CN12ToAdjust these voltages Adjust VR3 Edge sensor & VR5 Jam sensor.

Sensor - Receiver, Jam Check voltage 2.9Vdc Meter across Red/Black of CN12 (ObstructBeam 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(ObstructBeam 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 0VdcNo Drive. CN7 =11/12 Vdc

To Check PCB. Black lead of meter on tab IC8 (Main PCB) Red lead ofmeter on brown wire plug6 CN7 should read 12Vdc

To Check Cable Unplug CN7 (meter set to Ohms) place probesacross plug If no continuity then check each switch.

Error Double Sheet Check link on CN11 is correct. Replace link, check wiring diagram.Detected

Slot Sensor Blade CN3 Black lead of meter on Yellow (ground)Red lead of meter on Green = 0.2Vdc obstructed

Approx 4Vdc not obstructed.Red lead of meter on Blue = 5VdcRed lead of meter on Red = 1.2Vdc

Home Position Switch Remove plug from CN13 Check continuity acrosswires(make and break switch)

Section 11 Trouble Shooting (Serial No. 710046JEAJ Onwards)

SYSTEM

AutoCreaser 50

FUSE POSITIONS & RATINGS

PSU (5V / 24V)F3.15A (613-023)

PSUs (24V & 48V)T4.0A (681-015)

(IF FITTED)T315mA (681-011)

SPARE FUSEPOSITION

ANTI-STATIC UNIT

70 070 autocreaser 50 service manual

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