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Morgana AutoCreaser Pro 50 Service Manual
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Morgana AutoCreaser Pro 50 Service Manual

Creasing machine
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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

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Summary of Contents for Morgana AutoCreaser Pro 50

  • Page 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...
  • 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 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.
  • Page 4 Removal/Replacement of Gapset Mechanism Diagnostics Setting the Measurement System (Metric / Inch) Setting the Language (English, French, German) Autocreaser Pro 50 Wiring Diagram Autocreaser Pro 50 Control PCB Connection Diagram Section 10 ….. Optical Sensors - Cleaning and Setting………………………….. Section 11 …...Trouble Shooting…………………………………………………...
  • Page 5 AutoCreaser Pro 50 AutoCreaser Pro 50 DOCUMENT CREASING MACHINE Key to photograph below Roller tilt handle Adjustable side lay Switch Panel Stacker assembly 8 Back Stop Fuses Suction slot knob 9 Fixed side lay Gap Set Knob and Lever Touchscreen...
  • 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 50 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 50 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 50 SYSTEM Page 11...
  • Page 12 BLANK PAGE Page 12 CREASING...
  • Page 13 AutoCreaser Pro 50 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 50 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 50 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 50 REPLACEMENT OF PROCESSOR BOARD 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 Processor PCB.

  • Page 22: Installation Procedure

    Installation Procedure. 1. Note the current machine calibration settings. 2. Power down the machine and remove the power cord. 3. Change the USB Flash Drive (Red or Green depending on what is currently fitted). NOTE. It is important to choose the right colour in accordance with the machine you are upgrading.
  • Page 23 AutoCreaser Pro 50 BLANK PAGE SYSTEM Page 23...
  • Page 24 SECTION 9 ITX BOARD REPLACEMENT. 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 50 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 SECTION 9 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 sideways from the side plates.
  • Page 27 AutoCreaser Pro 50 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.
  • Page 28 STEPPER INPUT LEAD 75-423 PSU LINK LEAD 75-284 ANTISTATIC ANTISTATIC UNIT TRANSFORMER AND LEAD ASSY. YEL/GRN 75-512 YEL/GRN 40 BL PSU EARTH LINK 75-296 YEL/GRN PSU MAINS LINK 75-297 AutoCreaser Pro 50 CONTROL SYSTEM ASSEMBLY Wiring Diagram Page 28 CREASING...

  • Page 29: Controller Pcb

    AutoCreaser Pro 50 PSU ASSEMBLY (76-272) DRIVE SIGNAL LEAD (75-436) BLADE SIGNAL LEAD (75-437) SYSTEM SWITCH COIL LEAD (75-364) STACKER GUARD SWITCH LEAD (75-232) HOME SWITCH LEAD (75-231) BLADE POSITION SENSOR LEAD (76-156) EDGE DETECT LEAD (76-230-02) DUAL SENSOR LEAD (76-154)

  • Page 30: 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 50 Operators Manual (70-171), Trouble Shooting section, for instructions of how to clean the Lead Edge Sensors; and the Clean Lead Edge Sensor Warning screens.
  • Page 31 AutoCreaser Pro 50 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 32: Section 11 Trouble Shooting

    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 33 AutoCreaser Pro 50 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.
  • Page 34 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 yellow wire of CN16 To Adjust these voltages Adjust VR4 Edge sensor &...
  • Page 35 AutoCreaser Pro 50 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...
  • Page 36 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 37 Check 500mA fuse, below the Mains Input connector (See Page 39). 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 35). Replace the ATX PSU.
  • Page 38 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. Page 38 CREASING...
  • Page 39 AutoCreaser Pro 50 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) SYSTEM Page 39...

  • Page 40: Revision History

    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 30 re-written, reference Optical Sensors - Cleaning and Setting. ECO2811 23/01/13 Pages 28 &...