AutoCreaser 50

DOCUMENT
CREASING MACHINE
SERVICE MANUAL
Morgana Systems Limited United Kingdom
Telephone: ( 01908 ) 608888 Facsimile: ( 01908 ) 692399
Website: www.morgana.co.uk

ISSUE 2 August 2006

70-070
 INTRODUCTION

MORGANA AUTO CREASER 50

i ...........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.

It 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.

ii ..........Fasteners
All threaded fasteners are isometric & 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 tightening torques.

NOTE ..... Do not substitute fasteners with low grade alternatives

which may fail or become irremovable.

Page 2 CREASING
AutoCreaser 50 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 & above, and No.1 point
drivers for M3 & below.

WARNING

WORK SHOULD BE CARRIED OUT BY A TRAINED AND

COMPETENT ENGINEER AND ALL SAFETY
PROCEDURES SHOULD BE ADHERED TO.

SWITH OFF MAINS POWER BEFORE COMMENCING

DO NOT USE PHILLIPS DRIVERS - THESE WILL DAMAGE

THE SCREWS & MAY SLIP, CAUSING DAMAGE OR
INJURY.

iii ........ 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

Remove 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 115 60Hz 15 Amps.

SYSTEM Page 3
 INDEX

Introduction………………………………………………………………………….
¡ Introduction
¡¡ Fasteners
¡¡¡ Identification
iv New Machine Preparation
Section 1…… Covers………….…. .................................................................

Section 2…… Vacuum Valve…………………………………………………….

Valve Plunger Replacements
Valve 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
Removal/Replacement of Gapset Mechanism
Replacement of Joystick Controller
Diagnostics
Setting the Measurement System (Metric / Inch)
Setting the Language (English, French, German)
Autocreaser 50 Wiring Diagram
Autocreaser 50 Control PCB Connection Diagram
Section 10…..Optical Sensors…….……………………………………………..

Section 11…...Trouble Shooting…………………………………………………

Calibration of Creasing Position
Trouble Shooting
Fuse Positions and Ratings

Page 4 CREASING
AutoCreaser 50

AutoCreaser 50

DOCUMENT CREASING MACHINE

Key to photograph below

1 Roller tilt handle 6 Air distribution knob 11 Paper Gate

2 Stacker assembly 7 Adjustable side lay 12 Exit Guard
3 Suction slot knob 8 Back stops 13 Control Panel
4 The display unit 9 Fixed side lay 14 Fuses
5 Air separation knob 10 Roller tilt knob 15 Gap Set Knob and Lever

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.

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 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 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

Page 6 CREASING
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 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.

4. Remove bottom of valve to release plunger and spring.

Check the rubber valve seating washer is secure and not split and the metal
washer 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 & the
metal 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, similar
to a faulty electrical component.

6. Refit in reverse order.

Note:–
Do not over tighten aluminum parts and use grease to stop binding.

Fig. 3

2.2 Valve Coil.

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.

This should be 12 volts.

SYSTEM Page 7
 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 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.

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.

Page 8 CREASING
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 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.

4.9 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 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

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 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

REMOVAL/REPLACEMENT OF TOP INFEED ROLLLER

6.1 With the unit on a bench
6.2 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.

REMOVAL/REPLACEMENT OF BOTTOM INFEED ROLLLER

6.5 Remove the drive belt and top infeed roller assembly and bottom
flanged 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 sideplates
on a flat surface before finally tightening the tie bar fixings.

Page 12 CREASING
AutoCreaser 50

SECTION 7

DRIVE HUB:- REPLACE RUBBER TORSION BUSH (SHOCK

ABSORBER).

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

SYSTEM Page 13
 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 Re-assemble in reverse order.

Link Plate Micro Switch Assembly

Page 14 CREASING
AutoCreaser 50

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.

Disconnect the mains.

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

BOARD REPLACEMENT. STEPPER DRIVE PCB

The Stepper Driver board supplys the power to both Blade motor and main Drive motor and
can 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.

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

1. With the creaser mechanism raised up as previously discussed, and securely

supported, access to the two operator blocks can be found.
2. Removal of the blocks are achieved by unscrewing the locating allen screws
in the rear, these fix the blocks to the shaft, which can then be slid sideway
from the side plates. Note:- The operator side block is located with a hole in
the shaft and the rear block is clamped to the shaft with these screws.

Eccentric Bearing Housings

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.

Refitting is the reverse procedure to the above.

Setting the gap set

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
AutoCreaser 50
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 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 is
between the Arrows. (Take note of this figure)
Operate the Joystick to reset count to zero.

Lift the joystick up until the start screen appears.

NOTE. This also removes all stored programmes,

including the ‘Lead Edge Trim’ and ‘Stretch’ settings.

SET THE MEASUREMENT SYSTEM (METRIC / IMPERIAL SETTINGS).

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.

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 is
displayed.
Operate the joystick to change to the required language.
Remove the Engineers Plug.

Page 18 CREASING
AutoCreaser 50

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

(PRE SERIAL No. 710046JEAJ)

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

75-261 CONTROL BOARD MK3

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

MAINS IN JOYSTICK LEAD ASSY.

75-246
GRN/YEL
E
BL
N L
49 DISPLAY & LEAD
ASSEMBLY
75-183
BRN 39
75-255
DIAGNOSTIC JAM
LEAD 76-155
COMP. SWITCH
INPUTLEAD
75-194 DISPLAY
FUSE LEAD JOYSTICK DUAL
75-197 76-154 SENSOR
SYSTEMSWITCH
47 BRN INPUT LEAD
FUSE
F3.15A 75-191 valve CRUNCH
coil EDGE
BRN 76-230-02 DETECT
37 BL
31 BRN BL 44 BRN
FUSE BRN N L 24
N L ENGINEERING
BL
EDGE
BRN 11
BRN BLADE POSITION
FUSE SENSOR76-156
SPAREFUSE T4.0A
BLADE
BL BRN
4 BLADESTEPPER
SYSTEM BL BRN
COMP.
EARTH
GRN/YEL 43 SWITCH 29 SWITCH HOME SWITCH
BONDINGPOINT HOME 75-231
SYSTEMSWITCH HOME
BL
GRN/YEL GRN/YEL OUTPUT LEAD SWITCH
BL
E 75-193 BRN
BRN
GRN/YEL
3 DRIVESTEPPER GUARD BLK
6

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

Between Blue & Brown

Wires (REF.) BL

SW4 = Posn. 1 SEE DRAWING 125-23-01

SW3 1 = ON FOR CONNECTION DETAILS
SW3 2 = ON
1 TO 24, 49 SEE COLOUR CODE SHEET DRAWING NUMBER (70-090)
41
26 STACKER GUARD SWITCH (75-040)
29 COMPRESSOR LEAD (75-124) DRIVE MOTOR
DRIVE
EARTHLEAD
31 SYSTEM SWITCH INPUT LEAD (75-191) 76-238
33
37
39
EMERGENCY STOP INPUT LEAD (75-228)
PSU INPUT LEAD (75-192)
EARTH. CHASSIS TO CREASING UNIT (76-232) EARTH LEAD
DRIVE
76-152

M 58

40 PSU MAINS LEAD (75-184) 75-188

DRIVE
41 DRIVE MOTOR LEAD(76-152) DRIVE SIGNALLEAD SIGNAL
75-294
42 BLADE MOTOR LEAD (76-153) 3
43 SYSTEM SWITCH OUTPUT LEAD (75-193) PSU MAINS LINK
44 COMPRESSOR SWITCH INPUT LEAD (75-194) 75-297 PSU OUTPUT LEAD
45 EMERGENCY STOP OUTPUT LEAD (75-195) 48 75-295
52 YEL/GRN
46 CHASSIS EARTH LEAD (75-196) BL BRN
47 FUSE LEAD (75-197) PSU EARTH LINK
75-296
48 PSU OUTPUT LEAD (75-295) 71
51 EARTH LEAD (75-189) 40 70 PSU LINK LEAD
69 75-284
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) L N E
-V +V
L N E
-V +V
71 PSU MAINS LINK (75-297)

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

75-261 CONTROL BOARD MK3

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

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 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.

Adjust the 1st 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 until
‘LEAD EDGE TRIM’ 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.

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 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

Erratic register of Damaged roller surface Replace rubber rollers

the 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 Voltages should read 240V or 110VAC
Check cables for continuity to
Emergency stop button.
Replace Faulty wire or connection.
Check small power supply output Black lead ofmeter to green wire.
Voltage on CN2=5V dc Red 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 PSU
Check voltage onmain If no voltage then check for damaged
PCB 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 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 Low or No Power toMotors Check 240/110VACinputtoLargePSU

Pulsing 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 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

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 = 5Vdc
Red lead of meter on Red = 1.2Vdc

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

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 AutoCreaser 50
Section 11 Trouble Shooting (Serial No. 710046JEAJ Onwards)
Fault Reason Solution

Erratic register of Damaged roller surface Replace rubber rollers

the 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 Voltages should read 240V or 110VAC
Check cables for continuity to
Emergency stop button.
Replace Faulty wire or connection.
Check small power supply output Black lead ofmeter to green wire.
Voltage on CN2=5V dc Red 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 PSU
Check voltage onmain If no voltage then check for damaged
PCB 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 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.

If System switch activates faulty cable Check 6 core cable

but display shows or terminals from CN2 of control board
‘Activate System Switch to CN4 of stepper board
Before Running’.

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

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 = 5Vdc
Red lead of meter on Red = 1.2Vdc

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

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FUSE POSITIONS & RATINGS

ANTI-STATIC UNIT
PSU (5V / 24V) (IF FITTED)
F3.15A (613-023) T315mA (681-011)

PSUs (24V & 48V) SPARE FUSE

T4.0A (681-015) POSITION

SYSTEM Page 31