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Page 28

CREASING

GUARD

SWITCH

STACKER GUARD

SWITCH 75-040

DISTRIBUTION

BLOCK

EARTH LEAD 76-232

SYSTEM SWITCH COIL LEAD 75-364

76-230-02

76-154

76-155

BLK

JAM

DUAL

SENSOR

EDGE

DETECT

CREASER UNIT

BRN

EARTH

BONDING

POINT

BLADE POSITION

SENSOR 76-156

75-356

DIAGNOSTIC

LEAD

BLADE

PSU MAINS LEAD 75-184

BLADE MOTOR

76-241

DRIVE MOTOR

76-240

BLADE SIGNAL LEAD 75-437

DRIVE SIGNAL LEAD

75-436

BLADE

DRIVE

SIGNAL

BLADE

SIGNAL

EARTH LEAD

76-236

DRIVE

DUAL

STEPPER

DRIVER

PNK

VIO

BRN

GRN/YEL

FUSE

BRN

PSU OUTPUT LEAD 75-429

T500mA

T4.0A

BRN

GRN/YEL

BRN

GRN/YEL

DRIVE

EARTH LEAD

76-256

CONTROL SYSTEM ASSEMBLY

72 volts DC Nominal

Between Pink & Violet

Wires (REF.)

SW1 = Posn. 1

SW2 1 = ON
SW2 2 = ON

SW4 = Posn. 1

SW3 1 = ON
SW3 2 = ON

PSU EARTH LINK

75-296

PSU MAINS LINK

75-297

GRN/YEL

CONTROLLER PCB

ENGINEERING

JOYSTICK

AIR

BLADE

DRIVE

DOUBLE

GUARD

POWER

RELAY 1 RELAY 2

SLIDE

CREASE EDGE

CREASE CRUNCH

HOME

HOME SLO

PSU LINK LEAD

75-284

FUSE

T315mA

HOME

SWITCH

HOME SWITCH

75-231

BRN

BOOKLET

MAKER

INTERFACE

FUSE LEAD

75-259

48V

WRL

VAC

SLOT

VAC

PSU

48V

PSU

24V

-V

BRN

YEL/GRN

VIO

PNK

GRN/YEL

TRUNKING

40 BL

BRN

-V

VIO

VALVE

MOTOR & SENSOR

VACUUM DRUM

MOTOR

DISPLAY

VALVE

CONTROLLER

VACUUM DRUM

SENSOR

VACUUM SENSOR LEAD 76-255

YEL/GRN
YEL/GRN

STEPPER INPUT LEAD 75-423

EARTH

BONDING POINT

EARTH LEAD 75-432

EARTH

BONDING POINT

TOUCHSCREEN

BLK

YEL

BLK

MOTORISED VALVE

STEPPER

SW4 1 = OFF

SW4 2 = ON

SW4 3 = OFF

SW4 4 = ON

SW5 1 = OFF

SW5 2 = OFF

SW5 3 = OFF

SW5 4 = OFF

173-54-01

SHORTING

LINK

EARTH LEAD 97-149

TO EARTH STUD

SERVICE PANEL

EARTH LEAD 97-150

TO EARTH STUD ON

COMPRESSOR PANEL

MINI ITX

MOTHER BOARD

BLACK
WIRES

IRE

VACUUM DRUM

STEPPER

VIO

SW4 1 = ON

SW4 2 = OFF

SW4 3 = OFF

SW4 4 = OFF

SW5 1 = OFF

SW5 2 = OFF

SW5 3 = OFF

SW5 4 = OFF

FERRITE

GRN/YEL

BRN

MAINS IN

FAN ASSY.

75-316-02

GRN/YEL

BRN

GRN/YEL

BRN

EMERGENCY

STOP

COMP.

SWITCH

SYSTEM

SWITCH

SYSTEM SWITCH

INPUT LEAD

75-191

COMP.

LEAD

75-124

BRN

WHI
WHI

COMP. SWITCH

INPUT LEAD

75-534

BRN

MAINS

FILTER

BRN

GRN/YEL

BRN

GRN/YEL

TRANSFORMER ASSY.

FUSE

T15A

BRN

YEL

110V MAINS SUPPLY LEAD 76-317

ORG
ORG

IMPORTANT

SET SLIDE SWITCH TO
115V IF SWITCHABLE

ATX PSU

MAINS IN

ON / OFF

RED
ORG

YEL

ANTISTATIC

UNIT

ANTISTATIC

TRANSFORMER

AND LEAD ASSY.

75-512

ANTISTATIC

MAINS LEAD

75-260

CONTROL LEG

ASSEMBLY

WHI

RED

ORG

YEL

PUMP

OVERLOAD

GRN/YEL

CONNECTIONS

WHI
WHI

SV190 PUMP (50Hz & 60Hz)

BLU

BRN

GRN/YEL

75-554

75-549

75-550

SLO

GRN/YEL

AutoCreaser Pro 50

Wiring Diagram

53 EARTH LEAD (75-321)

54 MAINS FILTER TO DISTR. BLOCK (75-320)

55 TRANSFORMER MAINS SUPPLY (76-325)

58 STEPPER INPUT LEAD (75-423)

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)

78 SUPPLY LINK LEAD (75-514)

79 VACUUM SIGNAL LEAD (75-420)

80 VALVE SIGNAL LEAD (75-421)

81 VACUUM DRUM MOTOR (75-425)

82 VALVE MOTOR (75-426)

83 VALVE SENSOR LEAD (75-427)

84 EARTH LEAD (76-256)

86 INTERFACE LEAD (76-271)

2 TO 24, SEE COLOUR CODE SHEET DRAWING

ON PAGE 27

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)

34 FUSE LEAD (76-322)

37 110V MAINS SUPPLY LEAD (76-317)

39 EARTH. CHASSIS TO CREASING UNIT (76-232)

40 PSU MAINS LEAD (75-184)

41 DRIVE MOTOR LEAD (76-240)

42 BLADE MOTOR LEAD (76-241)

43 SYSTEM SWITCH OUTPUT LEAD (75-193)

44 COMPRESSOR SWITCH INPUT LEAD (75-534)

45 EMERGENCY STOP OUTPUT LEAD (75-195)

46 CHASSIS EARTH LEAD (75-435)

48 PSU OUTPUT LEAD (75-429)

50 MAINS INPUT FUSE LEAD (76-327)

52 EARTH LEAD (75-432)

Содержание AutoCreaser Pro 50

Страница 1: ...70 173 Issue 4 FEBRUARY 2013 AutoCreaser Pro 50 CB UL SERVICE MANUAL Document Creasing Machine Morgana Systems Limited United Kingdom www morgana co uk Telephone 01908 608888 Facsimile 01908 692399 ...

Страница 2: ...nes 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 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 re...

Страница 3: ...PS DRIVERS THESE WILL DAMAGE THE SCREWS MAY SLIP CAUSING DAMAGE OR INJURY iii iv Identification New Machine Preparation 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 Remove all packaging materials All metal parts in...

Страница 4: ... Refurbishment Electrics The PRO Control System Trouble Shooting i Introduction Fasteners Identification iv New Machine Preparation Suction Drum and Belt Removal Replacement Removal of Unit Removal of Unit Removal Refitting PCBs Removal Replacement of Gapset Mechanism Diagnostics Setting the Measurement System Metric Inch Setting the Language English French German Autocreaser Pro 50 Wiring Diagram...

Страница 5: ... handle 7 Adjustable side lay 13 Switch Panel 2 Stacker assembly 8 Back Stop 14 Fuses 3 Suction slot knob 9 Fixed side lay 15 Gap Set Knob and Lever 4 Touchscreen 10 Roller tilt knob 16 Vacuum Bleed Knob 5 Air separation knob 11 Paper Gate 6 Air distribution knob 12 Exit Guard 13 14 6 8 7 9 4 5 11 1 12 15 2 3 10 16 ...

Страница 6: ...s at the opposite side and is secured by four screws This cover is removed by lifting up and outward to unhook the keyhole locations on the opposite side to the screw fittings This allows access to the electronic plate assembly 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...

Страница 7: ... and using a 3mmA F allen key unscrew until clear of the plate 8 Twist the vacuum drum towards the motor to clear the bearing plate location hole and withdraw the drum assembly clear of the machine Replacing the Vacuum Drum assembly Replacement is the reverse procedure 1 Place the delrin block loosely in position 2 Ensuring the end plug is correctly located in the end of choke tube the vacuum drum...

Страница 8: ...r 1 Remove the Compressor cover below the feed bed and the rear cover 2 Remove the top stainless steel feed bed 3 Remove the moving side guide 4 Unplug the motor or the sensor from the respective PCB at the rear of the machine and feed the wire up through the access holes 5 Unscrew the motor or the sensor from the motor mounting bracket and remove Replacement is the reverse procedure To tension th...

Страница 9: ...SYSTEM AutoCreaser Pro 50 Page 9 BLANK PAGE ...

Страница 10: ...rds the back of the machine 3 1 Remove the two pipe mounting clip plates ITEM 5 on page 11 so that the hoses can be detached from the valve 3 2 Remove the two screws that secure the valve to the underside of the feed bed When refitting the valve ensure that the ends of the hoses are clear of nylon fibres and that the O ring is in place NOTE ...

Страница 11: ...ER QTY Description 1 1 2 175 164 01 Valve Block Tube Stepper 3 173 65 01 1 Valve Motor Lead Assembly 175 176 01 1 4 2 Pipe Mounting Clip 5 175 166 01 Solid Butterfly 1 6 401 02 040 008 Dowel Pin Ø3 x 12 Lg 7 601 168 2 8 1 602 178 175 177 01 Upper Valve Spacer 9 1 1 10 11 12 603 108 6 Screw Pan Pozi Taptite M4 x 8 Lg 404 01 030 008 4 Screw Socket Countersunk Hd M3 x 8 Lg 13 173 67 01 409 01 030 008...

Страница 12: ...Page 12 CREASING BLANK PAGE ...

Страница 13: ...le 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...

Страница 14: ...ach 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...

Страница 15: ...f 5 2 Loosen the securing socket set screws in the drive pulley on the roller for it to be removed 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 NOTE Page 15 ...

Страница 16: ...r assembly from the opposite side supporting its length as it emerges 6 5 Remove the drive belt and top infeed roller assembly and the bottom flanged pulley as above 6 6 Remove the cap head screw from the rear of the roller shaft and then remove the pulley 6 7 Gently tap the roller from the rear this will extract the outer race of the needle bearing from the front side plate 6 8 The roller can now...

Страница 17: ...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 Page 17 AutoCreaser Pro 50 ...

Страница 18: ...ars 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 ...

Страница 19: ...ly one program which is the machine control program for the particular machine that it is installed on ELECTRICS The PRO Control System Block Diagram of the PRO Control System ITX Motherboard Controller PCB ATX PSU E Stop 240V AC 5V DC 12V DC 0V RED YELLOW BLACK Comms GUI USB Stick Flash Drive Hard Drive Touch Panel VGA Digital Analogue Interface PCB Machine Control Processor PCB Touchscreen Displ...

Страница 20: ...board it is important that the switch must be set in the correct position For machines with Serial No 730419 or higher the switch must be set over to the left in the position these machines were fitted with as standard For machines with Serial numbers earlier than 730419 the switch must generally be set over to the right in the position unless the machine has been upgraded to include Earlier Machi...

Страница 21: ...above board it may be necessary to recalibrate the machine Take note of any calibration settings The USB Flash Drive controls all functions of the graphics and touch screen operation The External USB Flash Drive and the Internal USB Flash Drive devices shown in FIG 2 below have the same functionality Either one of these devices could be supplied as a replacement When fitting an Internal USB Flash ...

Страница 22: ... for like i e Green for Green and Red for Red 4 Power the machine up 5 To access the machine menu open the calculator and type 608888 then press X to exit the calculator screen 6 Choose the machine type from the list and perform a power cycle when prompted 7 Re enter the calibration settings NOTE FIG 1 and FIG 2 above show the Internal USB Flash Drive position for the current Gigabyte ATX mother b...

Страница 23: ...SYSTEM Page 23 AutoCreaser Pro 50 BLANK PAGE ...

Страница 24: ...xing screws attaching the PSU to the bracket and slide the units apart Refitting is a reverse procedure to the above ensure the power switch is in the on position prior to replacing the compressor cover BOARD REPLACEMENT STEPPER DRIVE PCB BOARD REPLACEMENT SMALL STEPPER DRIVE PCB s The Stepper Driver board supplies the power to both Blade motor and main Drive motor and can be removed whilst locate...

Страница 25: ...re commencing to check the horizontal and vertical position of the display The position of the display within the surround is achieved by operating the centre button at the rear of the housing press this a number of times to obtain the correct orientation required move to the next button to move the position to centralize horizontal 2 With the engineering plug plugged into the engineers socket at ...

Страница 26: ...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 th...

Страница 27: ...chine Select Tools on the Display and continue to select required tool To set the vacuum drum start position the following procedure Is necessary Turn the machine on Insert the Engineers Plug into the Socket located at the rear of the machine Select Tools on the Display and select Vac Drum Trim by toggling the button Input a value and run repeat until start position is correct under the papergate ...

Страница 28: ...NEL MINI ITX MOTHER BOARD 2 BLACK WIRES 2 YELLOW WIRES VACUUM DRUM STEPPER BK VIO 78 81 79 SW4 1 ON SW4 2 OFF SW4 3 OFF SW4 4 OFF SW5 1 OFF SW5 2 OFF SW5 3 OFF SW5 4 OFF FERRITE GRN YEL BL BRN MAINS IN L N E FAN ASSY 75 316 02 GRN YEL BRN BL BL GRN YEL BRN EMERGENCY STOP COMP SWITCH SYSTEM SWITCH SYSTEM SWITCH INPUT LEAD 75 191 COMP LEAD 75 124 L N L N N 31 BRN BL BRN BL BRN BL BRN BL WHI WHI 43 C...

Страница 29: ... VALVE SIGNAL LEAD 75 421 86 INTERFACE LEAD 76 271 AutoCreaser Pro 50 SYSTEM Page 29 AUTOCREASER Pro 50 CONTROL PCB CONNECTION DIAGRAM GRN BL SCR 24 9 7 6 4 BL BRN WHI WHI BL YEL RD GRN RD BL GRN YEL 11 BL RD BK RD 12 8 BL BRN JOYSTICK CONTROLLER PCB ENGINEERING AIR HOME SLOT 2 CREASE EDGE RELAY 1 GUARD POWER RELAY 2 CREASE CRUNCH HOME SLOT 1 BLADE DRIVE DOUBLE SLIDE POS RED YEL BLK YEL BL 3 WHI R...

Страница 30: ... 2 below is not necessary for machines that have Lead Edge Auto Sensing i e machines with a Serial No 730419 or higher or earlier machines that have been upgraded Upgraded machines will have a main processor revision of A1 3x1or higher and a touchscreen software revision of AC5 0x3 or higher 10 1 Ensure the Red LED3 on the Main Control Board is Off Place an 80gsm sheet on the Loading Table with it...

Страница 31: ...st the transmitter is housed in the Side Plate of the machine on the Lay Side Crunch Sensor 10 3 Ensure there is no paper in the machine before adjusting the sensitivity control pot on the Main Circuit Board fully anticlockwise 10 4 Ensure the appropriate Yellow LED is off and feed a folded sheet of paper down between the Input Roller the Creasing Blade until it crumples the display will show Erro...

Страница 32: ...revolution of the in feed roller the last crease should be 370 mm from the lead edge 320mm Stretch Insert the Engineers Plug into the Socket located at the rear of the machine Run machine and check crease positions repeat above procedure until accurate crease position is achieved st Crease Positions NOTE Using the test stock if available setup Crease at 50 and 370 Check the crease positions and us...

Страница 33: ... lead of meter to Red wire Voltage on CN2 24V dc Red lead of meter to Yellow wire If supply has input but no output Replace PSU Check voltage on main If no voltage then check for damaged PCB CN6 Brown and Blue wire or connection Replace as required No Drive or Motors Pulsing Low or No Power to Motors Check green light is illuminated on both PSUs Check 240 110VAC input to Large PSUs Meter across L ...

Страница 34: ...tensity of transmitter pot VR4 Safety Circuit Faulty Check Voltage on Any Switch or Wire Open circuit will be 0Vdc No Drive CN7 10 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 CN13 is...

Страница 35: ... voltage should be between 11 75V to 12 25V Anything below 11 7V should be regarded as suspect and the power supply should be replaced i Remove the 3V lithium disc battery from the ITX mother board and check the voltage using a multi meter If the voltage is less than 1 5V replace the ITX mother board If the voltage is more than 1 5V refit the battery to the board 1 RISK OF EXPLOSION IF BATTERY IS ...

Страница 36: ...d has a lithium battery fitted the board together with its battery must be recycled DISPOSE OF BATTERIES ACCORDING TO THE MANUFACTURERS INSTRUCTIONS in compliance with agreed national Procedures Please contact your local disposal authority for information PINS 3 4 FIG 2 ...

Страница 37: ...at there is V AC across the ATX PSU power cord Identify reason for no power to ATX PSU Check 500mA fuse below the Mains Input connector See Page 39 If this fuse has blown replace it must be replaced with a T500mA fuse Morgana part number 681 020 Is there a V DC output from the ATX PSU See page 35 Replace the ATX PSU Does the cooling fan run on the mini ITX motherboard See page 35 Replace the mini ...

Страница 38: ...he PCB in the Pump Overload assembly The Pump Overload assembly is located on the inside of the yellow leg below the baffle plate If this fuse has blown it must be replaced with a T315mA fuse Morgana part number 681 011 WHITE ORANGE RED YELLOW Morgana Systems Ltd PUMP OVERLOAD BOARD WHITE T315mA FUSE T315mA ...

Страница 39: ...utoCreaser Pro 50 SYSTEM Page 39 FUSE POSITIONS RATINGS T500mAH 250V 681 020 PSUs 24V 48V T4 0AH 250V 681 015 IF FITTED T315mAH 250V 681 011 ANTI STATIC UNIT TRANSFORMER ASSY T15AH 250V 652 047 MAINS IN ...

Страница 40: ... Mod By 3 ECO2809 02 01 13 BAL Note at the bottom of Page 20 added reference the position of switch SW1 when fitting a new Main Control PCB Page 30 re written reference Optical Sensors Cleaning and Setting 4 ECO2811 23 01 13 BAL Pages 28 39 Changes T15A Fuse was F15A ...

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