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Morgana AutoCreaser Pro 33 Service Manual
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Morgana AutoCreaser Pro 33 Service Manual

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70-172
Issue 5
APRIL 2013
Serial No. 740866 Onwards.
AutoCreaser Pro 33
(CB/UL)
SERVICE MANUAL
Document Creasing Machine
Morgana Systems Limited
United Kingdom
www.morgana.co.uk
Telephone: ( 01908 ) 608888
Facsimile: ( 01908 ) 692399

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Summary of Contents for Morgana AutoCreaser Pro 33

  • Page 1 70-172 Issue 5 APRIL 2013 Serial No. 740866 Onwards. AutoCreaser Pro 33 (CB/UL) SERVICE MANUAL Document Creasing Machine Morgana Systems Limited United Kingdom www.morgana.co.uk Telephone: ( 01908 ) 608888 Facsimile: ( 01908 ) 692399...
  • Page 2 ... 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.
  • Page 3 AutoCreaser Pro 33 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.
  • Page 4 Removal/Refitting PCBs Diagnostics Setting the Measurement System (Metric / Inch) Setting the Language (English, French, German) Autocreaser Pro 33 Wiring Diagram Autocreaser Pro 33 Control PCB Connection Diagram Section 10 …..Optical Sensors - Cleaning and Setting………………………….. Section 11 …...Trouble Shooting…………………………………………………...
  • Page 5 AutoCreaser Pro 33 AutoCreaser Pro 33 DOCUMENT CREASING MACHINE Key to photograph below Roller tilt handle 6 Air seperation knob Paper Gate Stacker assembly 7 Adjustable side lay Exit Guard Suction slot knob 8 Back stop Switch Panel Touchscreen 9 Fixed side lay...
  • Page 6 SECTION 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.
  • Page 7 AutoCreaser Pro 33 SECTION 2 VACUUM DRUM REMOVAL / REPLACEMENT. 1.Remove the Compressor cover below the feed bed. 2.Remove the top stainless steel feed bed. 3.Remove the moving side guide. 4.From the underside of the fed table loosen the valve assembly by unscrewing the two M5 posi pan head screws, allow the assembly to hang on its two pipes.
  • Page 8 VACUUM DRUM FEED BELT REMOVAL / REPLACEMENT. Drum Drive Belt replacement. 1.Following stages 1 to 6 above, the belt can be removed from the vacuum drum. 2.Remove the slot sensor from the motor mounting bracket. 3.The belt can now be removed from the machine. Replacement is the reverse procedure.
  • Page 9 AutoCreaser Pro 33 BLANK PAGE SYSTEM Page 9...
  • Page 10 SECTION 3 Removal of Butterfly Valve Assembly. The Butterfly Valve assembly is located on the underside of the feed bed, towards 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.
  • Page 11 AutoCreaser Pro 33 SYSTEM Page 11...
  • Page 12 BLANK PAGE Page 12 CREASING...
  • Page 13 AutoCreaser Pro 33 SECTION 4 MAIN CREASER MECHANISM REMOVAL OF UNIT 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.
  • Page 14 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 4.10 Replace the unit ensuring the wiring harness is threaded as it was removed 4.11 Attach the belt to the drive shaft.
  • Page 15 AutoCreaser Pro 33 SECTION 5 REMOVAL/REPLACEMENT STEPPER DRIVE BELT/ PULLEYS Loosen the adjuster nut from the inside unit and slide the belt off. Loosen the securing socket set screws in the drive pulley on the roller for it to be removed (...
  • Page 16 SECTION 6 REMOVAL/REPLACEMENT OF TOP INFEED ROLLLER 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.
  • Page 17 AutoCreaser Pro 33 SECTION 7 DRIVE HUB: REPLACE RUBBER TORSION BUSH (SHOCK ABSORBER). 7.1 Loosen grub screws in one half of hub. Slide hub outward & remove rubber torsion bush. Replace in reverse order. Rubber Torsion Bush SYSTEM Page 17...
  • Page 18 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.
  • Page 19 SECTION 9 ELECTRICS: The PRO Control System. The Morgana PRO control system is essentially a computer system just like the PC you use at home. Unlike your Microsoft Windows PC, the PRO system uses a LINUX operating system and runs only one program, which is the machine control program for the particular machine that it is installed on.
  • Page 20 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. REPLACEMENT OF MAIN CONTROL P.C.B. This PCB controls all functions of the machine and houses the Main Program PCB. The use of an antistatic wrist band should be used during work on the main control PCB.
  • Page 21 AutoCreaser Pro 33 SECTION 9 REPLACEMENT OF PIC PROCESSOR BOARD. (see TB2822) This Small PCB is plugged onto the face of the Main Control PCB and houses the Program Chip. The use of an antistatic wrist band should be used during work on this PIC Processor PCB.

  • Page 22: Installation Procedure

    SECTION 9 Installation Procedure. 1. Note the current machine calibration settings. 2. Power down the machine and remove the power cord. 3. Replace the USB Flash Drive. 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.
  • Page 23 AutoCreaser Pro 33 SECTION 9 Lock Recess External USB Sockets Internal USB Flash Drive FIG.1 FIG.1 above shows the internal and external USB Flash Drive positions for the latest Gigabyte ITX mother board type GA-C807N. Lock Recess Internal USB Flash Drive...
  • Page 24 SECTION 9 ITX BOARD REPLACEMENT. (see TB2822) The ITX mother board supplies the graphics to the touch screen display, to remove.- 1. Switch the mains power off. 2. Cut cable ties and unplug the all plugs. 3. Unscrew the four fixing screws attaching the board to the plate and remove from the machine.

  • Page 25: Replacing The Touch Screen Assembly

    AutoCreaser Pro 33 SECTION 9 Replacing the Touch Screen Assembly Replacing the Touch Screen Assembly. Ensure the mains power is turned off but with the plug in the socket, this maintains an earth to reduce static damage. 1. Remove the rear cover to expose the electrical panel.
  • Page 26 DIAGNOSTICS and CALIBRATION TOOLS. To enter the engineers tools menu. Turn the Machine on. Insert the Engineers Plug into the Socket located at the rear of the machine. Select Tools on the Display and continue to select required tool. SET THE TOTAL COUNT TO ZERO. To set the total counter to zero.
  • Page 27 AutoCreaser Pro 33 VACUUM DRUM VALVE MOTOR MOTOR & SENSOR VACUUM DRUM 2 TO 24, SEE COLOUR CODE SHEET DRAWING 53 EARTH LEAD (75-321) SENSOR ON PAGE 25. 54 MAINS FILTER TO DISTR. BLOCK (75-320) 26 STACKER GUARD SWITCH (75-040)

  • Page 28: Controller Pcb

    PAPER JAM DETECTOR LEAD (76-155) VACUUM SENSOR LEAD (76-255) ENGINEERING LEAD (75-356) VACUUM SIGNAL LEAD (75-420) VALVE SIGNAL LEAD (75 421) INTERFACE LEAD (76-271) JOYSTICK DISPLAY CONTROLLER CONTROLLER PCB POWER RELAY 1 RELAY 2 AUTOCREASER Pro 33 CONTROL PCB CONNECTION DIAGRAM Page 28 CREASING...

  • Page 29: Cleaning The Sensors

    - use a soft brush or cloth to remove any dust that may have collected onto the sensor lens. See the Autocreaser Pro 33 Operators Manual (70-170), Trouble Shooting section, for instructions of how to clean the Lead Edge Sensors; and the Clean Lead Edge Sensor Warning screens.
  • Page 30 SECTION 10 Crunch Sensor uses a beam projected across the machine just in front of the blade and above the paper path, when the beam is broken the machine will stop. The receiver is housed in the Side Plate of the machine and is on the Operator Side, whilst the transmitter is housed in the Side Plate of the machine on the Lay Side.

  • Page 31: Section 11 Trouble Shooting

    AutoCreaser Pro 33 SECTION 11 Trouble Shooting Calibration of creasing position The length between the leading edge of the sheet and the 1 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 1st crease position this compensates for the inaccuracy of manufacture of the input roller Diameters.
  • Page 32 Section 11 Trouble Shooting 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 Drive motor Remove and replace motor assembly. No Power Fuse Blown Replace with correct value.
  • Page 33 AutoCreaser Pro 33 Section 11 Trouble Shooting Fault Reason Solution Edge & Crunch Sensors Check supply voltage Black lead of meter on tab IC8 (Main PCB) - Transmitters Should read 1.3Vdc Red lead of meter on red wire of CN8 and...
  • Page 34 FAULT:- ‘NO SYNC’ appears on touchscreen. (Machine will not boot up). 1. CHECK THE ATX POWER SUPPLY AS FOLLOWS:- (i) Disconnect the 20/24 way ATX power supply connector from the ITX Motherboard. (ii) Using a piece of tinned copper wire, short out the GREEN and BLACK wires of the connector as shown in FIG.1 below FIG.1 TINNED COPPER WIRE LINK...
  • Page 35 AutoCreaser Pro 33 PINS 3 & 4 FIG.2 IMPORTANT RECYCLING NOTE:- The ITX mother board has a lithium battery fitted, the board together with its battery must be recycled in compliance with agreed national Procedures Please contact your local disposal authority for information CAUTION.
  • Page 36 Check 500mA fuse, below the Mains Input connector (See Page 38). IMPORTANT. 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 34). Replace the ATX PSU.
  • Page 37 FUSE YELLOW ORANGE T315mA Morgana Systems Ltd PUMP OVERLOAD BOARD WHITE WHITE If this fuse has blown it must be replaced with a T315mA fuse, Morgana part number 681-011. SYSTEM Page 37...
  • Page 38 FUSE POSITIONS & RATINGS ANTI-STATIC UNIT TRANSFORMER ASSY. (IF FITTED) T500mAH 250V (681-020) T315mAH 250V (681-011) PSUs (24V & 48V) MAINS IN T4.0AH 250V (681-015) T15AH 250V (652-047) Page 38 CREASING...

  • Page 39: Revision History

    AutoCreaser Pro 33 REVISION HISTORY Rev. Mod No. Mod Description Date Mod By Note at the bottom of Page 20 added, reference the position of switch SW1 when fitting a new Main Control PCB. ECO2809 02/01/13 Page 29 re-written, reference Optical Sensors - Cleaning and Setting.