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 dismantling 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 takenparticularly when releasing screws for dismantlingto 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.

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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

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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

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AutoCreaser 50

AutoCreaser 50

DOCUMENT CREASING MACHINE

Key to photograph below 1 2 3 4 5 Roller tilt handle Stacker assembly Suction slot knob The display unit Air separation knob 6 7 8 9 10 Air distribution knob Adjustable side lay Back stops Fixed side lay Roller tilt knob 11 12 13 14 15 Paper Gate Exit Guard Control Panel Fuses Gap Set Knob and Lever

SYSTEM

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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 fittings. 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

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SECTION 2

2.1 Valve Plunger Replacement.

1. 2. Remove coil cable. Remove 2 cap head screws, holding body of valve to machine, with 4 mm Allen key. Remove valve, be careful not to loosen 0 ring seal, which has a light coating of grease to ensure a good seal. 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 . 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. Refit in reverse order.

3.

4.

5.

6.

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

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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 posihead 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.

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SECTION 4 MAIN CREASER MECHANISM REMOVAL OF UNIT
4.1 4.2 4.3 4.4 First access should be gained by removing the top infeed and outfeed guards (See Section 1) Detach guard micro switch by removing two screws, taking care not to drop them. Cut and remove cable ties from cable mounting, retaining wiring loom. Ensure that the mains is unplugged. From the rear of the machine, remove two button socket screws with their washers. Remove the unlock knob from the front of the machine.

4.5

4.6 4.7

Remove the polycord drive belt from the suction drum. 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

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4.8

Place the unit on a solid and clear bench ensuring no wires are trapped beneath the metal side plates. Assemble loosely the green drive belt to the pulley

4.9

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.

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SECTION 5 REMOVAL/REPLACEMENT PULLEYS
5.1

STEPPER

DRIVE

BELT/

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) 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.

5.3

SYSTEM

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SECTION 6 REMOVAL/REPLACEMENT OF TOP INFEED ROLLLER

6.1 6.2 6.3 6.4 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 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.

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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

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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

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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

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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.

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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

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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 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 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.

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BRN

BRN BRN BL BRN 24

BRN

BRN BRN BRN BL BL BL BL BL BL BRN BRN BRN BL BL BRN BRN

GRN/YEL

RD BL BRN

AC/N AC/L CN1 CN2

BL GRN

AUTOCREASER 50 WIRING DIAGRAM (PRE SERIAL No. 710046JEAJ)

SYSTEM

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75-183
JOYSTICK

DISPLAY

1 2 3 4 6 7 8 9 11 12 13 24 49 61 62

VALVE (75-233) PSU OUTPUT LEAD (75-190) DRIVE STEPPER (75-186) BLADE STEPPER 1 (75-187) SYSTEM SWITCH COIL (75-185) GUARD (75-232) BLADE HOME (75-231) CRANK ROTATION (76-156) EDGE TX (76-230-02) EDGE RX/JAM TX (76-154) JAM RX (76-155) ENGINEERING (75-255) JOYSTICK ASSY. (75-246) CONTROL PCB TO RELAY LEAD (75-248) CONTROL PCB TO CONTROL PCB LEAD (75-249)

RD
CRUNCH

YLW RD SCR BL GRN

GRN YLW

ENGINEERING EDGE

11

BLK

GRN RD 4 BL YLW

BLADE BLADE STEPPER HOME

YLW GRN BL

BRN

GRN RD 3 BL YLW 61 BL

DRIVE STEPPER

GUARD

BRN BL BL 2

PSU

62 ORANGE GRN

DOUBLE AIR

RD

75-261

CONTROL BOARD MK3

62 ORANGE

AUTOCREASER 50 CONTROL PCB CONNECTION DIAGRAM (PRE SERIAL No. 710046JEAJ)

SHEET 1 OF 2

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SYSTEM

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CREASERUNIT

MAINS IN
E
BL GRN/YEL

JOYSTICK LEAD ASSY. 75-246 49

75-255 DIAGNOSTIC LEAD
DISPLAY JOYSTICK

N
BRN

DISPLAY & LEAD ASSEMBLY 75-183

39 76-155 JAM

COMP. SWITCH INPUTLEAD 75-194 FUSE LEAD 75-197 47

BRN

76-154
CRUNCH

FUSE F3.15A
BRN

SYSTEMSWITCH INPUT LEAD 75-191

BL

DUAL SENSOR

valve coil
BL

FUSE

37
BRN

31

BRN

44

BRN

EDGE 76-230-02 DETECT

24

N
BRN BL BRN

ENGINEERING

EDGE
11

SPAREFUSE

FUSE T4.0A
BLADE
BL EARTH BONDINGPOINT GRN/YEL GRN/YEL BRN

BLADE POSITION SENSOR76-156

43

SYSTEM SWITCH

BL

BRN

29

COMP. SWITCH

BLADESTEPPER HOME
BL BRN

GRN/YEL

SYSTEMSWITCH OUTPUT LEAD 75-193

3

HOME SWITCH 75-231

BL

HOME SWITCH

GRN/YEL

DRIVESTEPPER

GUARD
6

BLK

BRN

45
BRN BRN BRN BL BL BL BL BL BL BRN BRN BRN BL BL BRN BRN BL BL

EMERGENCY STOP OUTPUTLEAD 75-195

BRN

PSU DOUBLE
1 BLK

GUARD SWITCH

AIR

26

EMERGENCY STOP
BRN

SHORTING LINK LEAD 75-261

CONTROL PCB MK3

VALVE LEAD 75-233

STACKERGUARD SWITCH 75-040

33

EMERGENCY STOP INPUTLEAD 75-228

CHASSISEARTHLEAD 75-196 DISTRIBUTION BLOCK POWER SUPPLY INPUTLEAD 75-192 PSUMAINSLEAD 75-184
EARTH BONDINGPOINT

SYSTEM SWITCHCOILLEAD 75-185 46

E

39 51 52
GRN/YEL

GRN/YEL

EARTHLEAD 76-232

BL BRN

AC/N AC/L

PSU
(24V)

+24V +5V 0V CN2

RD BL GRN

2 PSU OUTPUTLEAD 75-190

37 CN1

40

CONTROL LEG ASSEMBLY 75-291-01

BLADESIGNALLEAD 75-187

BLADEMOTOR 76-153
E

BLADE

COMP. LEAD 75-124

L

BLADE

EARTH LEAD 76-236 59

AUX. OUTPUTLEAD 75-127

29

SW1 = Posn. 1 SW2 1 = OFF SW2 2 = ON

COMP ANTISTATIC KIT 70-082

DUAL STEPPER DRIVER

72 volts DC Nominal Between Blue & Brown Wires (REF.)

42

BRN

BL

SW4 = Posn. 1 1 TO 24, 49 26 29 31 33 37 39 40 41 42 43 44 45 46 47 48 51 52 58 59 69 70 71 SEE COLOUR CODE SHEET DRAWING NUMBER (70-090) STACKER GUARD SWITCH (75-040) COMPRESSOR LEAD (75-124) SYSTEM SWITCH INPUT LEAD (75-191) EMERGENCY STOP INPUT LEAD (75-228) PSU INPUT LEAD (75-192) EARTH. CHASSIS TO CREASING UNIT (76-232) PSU MAINS LEAD (75-184) DRIVE MOTOR LEAD(76-152) BLADE MOTOR LEAD (76-153) SYSTEM SWITCH OUTPUT LEAD (75-193) COMPRESSOR SWITCH INPUT LEAD (75-194) EMERGENCY STOP OUTPUT LEAD (75-195) CHASSIS EARTH LEAD (75-196) FUSE LEAD (75-197) PSU OUTPUT LEAD (75-295) EARTH LEAD (75-189) EARTH LEAD (75-188) DRIVE MOTOR EARTH LEAD (76-238) BLADE MOTOR EARTH LEAD (76-236) PSU LINK LEAD (75-284) PSU EARTH LINK (75-296) PSU MAINS LINK (75-297) SW3 1 = ON SW3 2 = ON

SEE DRAWING 125-23-01 FOR CONNECTION DETAILS

41 DRIVE MOTOR 76-152
DRIVE

DRIVE

EARTHLEAD 76-238 58

EARTH LEAD 75-188 DRIVE SIGNALLEAD 75-294 PSU MAINS LINK 75-297 52
YEL/GRN BL BRN

DRIVE SIGNAL

3 PSU OUTPUT LEAD 48 75-295 PSU EARTH LINK 75-296

71 40 70 69

PSU LINK LEAD 75-284

-V

+V

-V

+V

AUTOCREASER 50 WIRING DIAGRAM (SERIAL No. 710046JEAJ ONWARDS)

PSU

24V

PSU

48V

CONTROL SYSTEM ASSEMBLY 75-01-02

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1 2 3 4 6 7 8 9 11 12 13 24 49 VALVE (75-233) PSU OUTPUT LEAD (75-190) DRIVE STEPPER (75-294) BLADE STEPPER 1 (75-187) SYSTEM SWITCH COIL (75-185) GUARD (75-232) BLADE HOME (75-231) CRANK ROTATION (76-156) EDGE TX (76-230-02) EDGE RX/JAM TX (76-154) JAM RX (76-155) ENGINEERING (75-255) JOYSTICK ASSY. (75-246)

75-183
JOYSTICK

DISPLAY

RD
CRUNCH

YLW RD SCR BL GRN

GRN YLW

ENGINEERING EDGE

11

BLK

GRN RD 4 BL YLW

BLADE BLADE STEPPER HOME

YLW GRN BL

BRN

GRN RD BL 3 YLW BLK WHI

DRIVE STEPPER

GUARD

BRN BL BL 2

PSU

GRN
DOUBLE AIR

RD

75-261

CONTROL BOARD MK3

AUTOCREASER 50 CONTROL PCB CONNECTION DIAGRAM (SERIAL No. 710046JEAJ ONWARDS)

SHEET 1 OF 2

SYSTEM

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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

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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 infeed 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
Erratic register of the Creaser No Power or No Display

Reason
Damaged roller surface Check Gap Setting Faulty motor

Solution
Replace rubber rollers Reset & tighten to ensure rollers are driving card. Remove and replace motor assembly.

Fuse Blown Replace with correct value. 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 Check Joystick Repair damaged wires or Replace Joystick assembly 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. Valve Voltage check

failure of Processor or control PCB Replace Main Board. 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 Check 240/110VACinputtoLargePSU Meter across blue/brown wires.(bottom of PSU) Low or No Power from PSU Meter across blue/brown wires.(top of PSU) =72vdc Low voltage (36vdc) Resistor not connected or broken. Replace Low or No Power toMotors

No Drive orMotors Pulsing No LED on Stepper PCB

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

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

Fault
Motors Erratic

Reason
Wrongly wired Incorrect voltage Should read approx 30vdcWhenrunning

Solution
Check colours with wiring diagram. Black lead of meter on tab IC13 (Stepper PCB) Red lead of meter on each pin CN3 (drive) 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. 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, Jam

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) Check Voltage on Any Switch orWire,Opencircuit will be 0Vdc 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. Check link on CN11 is correct. CN3 Replace link, check wiring diagram.

Safety Circuit Faulty No Drive.

Error Double Sheet Detected Slot Sensor Blade

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 Check continuity acrosswires(make and break switch)

Home Position Switch

Remove plug from CN13

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Section 11 Trouble Shooting (Serial No. 710046JEAJ Onwards)
Fault
Erratic register of the Creaser No Power or No Display

Reason
Damaged roller surface Check Gap Setting Faulty motor

Solution
Replace rubber rollers Reset & tighten to ensure rollers are driving card. Remove and replace motor assembly.

Fuse Blown Replace with correct value. 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 Check Joystick Repair damaged wires or Replace Joystick assembly 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. Valve Voltage check

failure of Processor or control PCB Replace Main Board. 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

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

Fault Reason Solution
To Check -5Vdc should be across pins 5&6 on CN2 Main PCB when System Switch is operated. Check 6 core cable from CN2 of control board to CN4 of stepper board IfMotors Run but Display Shows Check connectors Operate System Switch Before Running. If System switch activates but display shows Activate System Switch Before Running. Motors Erratic faulty cable or terminals

Wrongly wired Incorrect voltage Should read approx 30vdcWhenrunning

Check colours with wiring diagram. Black lead of meter on tab IC13 (Stepper PCB) Red lead of meter on each pin CN3 (drive) 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. 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, Jam

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) Check Voltage on CN7 =11/12 Vdc To Check PCB. To Check Cable Any Switch orWire,Opencircuit will be 0Vdc Black lead of meter on tab IC8 (Main PCB) Red lead of meter on brown wire plug6 CN7 should read 12Vdc Unplug CN7 (meter set to Ohms) place probes across plug If no continuity then check each switch. Replace link, check wiring diagram.

Safety Circuit Faulty No Drive.

Error Double Sheet Detected Slot Sensor Blade

Check link on CN11 is correct. 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 Check continuity acrosswires(make and break switch)

Home Position Switch

Remove plug from CN13

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CREASING

AutoCreaser 50
FUSE POSITIONS & RATINGS

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

ANTI-STATIC UNIT (IF FITTED) T315mA (681-011)

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

SPARE FUSE POSITION

SYSTEM

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