Formax Atlas C100 High-
Speed Automatic Creaser
Instruction Manual
Atlas C100
Auto-Feed High-Speed Creaser
9/2016
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OPERATOR MANUAL
First Edition
INDEX
INTRODUCTION
PAGE 3The Atlas C100
SAFETY Do’s & Don’ts 4
Labeled Photograph
THE CONTROLS
The switch panel
Features on the switch panel
QUICK START GUIDE 9
OPERATING
Setting the machine
Programming the machine
Reading stored programmes
Paper jamming
THE STACKER ASSEMBLY
Setting the Stacker unit
PERFORATING
Equipment, spares
Setting the machine
6
7
8
18
26
28
29
22
23
25
THE BLADE ASSEMBLY
Setting the blade pressure
Setting the blade alignment
REPLACING CREASING BLADE SETS
Installing new blade sets
Spares
TROUBLE SHOOTING 35
DISPATCH KIT 40
ACCESSORIES & OPTIONS 41
RECOMMENDED SPARES 42
FUSE POSITIONS AND RATINGS 44
PRODUCT RECYCLING & DISPOSAL 45
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CREASING
31
32
33
34
INTRODUCTION
The Atlas C100 is a fully automatic suction feeding creasing
system designed for use with both conventional litho and digital printers.
The feed on the Atlas C100 can also be manually operated for use
with heavy stock, very small or very large sheets, embossed or even irregular
sheets.
The crease is programmed from the leading edge of the sheet using the
controls on the front panel.
The blade and anvil are mechanically controlled over their entire length
and can be adjusted to accommodate various weights of media.
IMPORTANT
The operating environment should be controlled to a temperature between
16° C and 27° C Maximum
Specification
Feeding System ................................................ Bottom suction feed
Max. Sheet Size ................................................700mm x 330mm (27.5” x 12.6”)
Min. Sheet Size (in automatic mode)................. 210mm x 140mm (8.5” x 5.5”)
Max. Paper Thickness .......................................0.4mm (varies according to hardness,
type of fold, and substrate)
Max. No. Creases per Sheet ............................ 16
Min. Distance Between Creases .......................0.1mm
Max. No. Stored Programmes .......................... Unlimited
Min. Crease Distance from Leading Edge ........ 2.5mm
Min. Crease Distance from Tail Edge ................35mm
In Hand Feed Mode up to 2499.9mm to Last Crease can be Programmed.
Speed per Hour (A4 in half)...............................8500
Speed per Hour (A5 in half)...............................11000
Dimensions ....................................................... L: 1450mm H: 1224mm W: 522mm
L: (57”) H: (48.2”) W: (20.5”)
Weight ...............................................................121Kgs (+50Kgs packing)
Power Requirement .......................................... 1 phase 220 / 240v AC
*As part of our continued product improvement plan, specifications and information
published in this manual are subject to change without notice.
All specifications are dependant on application, type of stock, temperature, RH and print
engine used.
Specifications quoted were measured on uncoated and unprinted stock.
E & OE.
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Page 3
Safety Do’s & Don’ts
Safety Do’s & Don’ts
REGLES DE SECURITE : « A FAIRE » ET « A NE PAS FAIRE »
Do - read this operator manual fully before operating the machine.
Lire ce mode d'emploi avant d'utiliser la machine.
Do - operate with the designated AC current only. Use an exclusive outlet, as
overloading may cause fire or an electric shock.
Respecter l'alimentation électrique indiquée. Brancher sur une prise séparée
car une surcharge peut entraîner un incendie ou un choc électrique.
Do - install the power cord out of the way to avoid a tripping hazard.
Installer le cordon d'alimentation de manière à ne pas pouvoir
trébucher par dessus.
Do - make sure that the mains inlet connector is always easily accessible.
Ménager un accès libre à la prise de courant.
Do not - install the machine in an unstable place such that it tilts or shakes.
Ne pas installer la machine sur une surface non plane, afin d'éviter
qu'elle ne penche ou ne vibre.
Do not - unplug the plug or unplug the power cord from the outlet with a wet hand,
this can cause an electric shock.
Ne pas installer la machine sur une surface non plane, afin d'éviter
qu'elle ne penche ou ne vibre.
Do not - unscrew and remove any covers from the machine, as it can cause an
electric shock or injury.
Ne démonter et enlever aucun carter de la machine, par crainte de décharge
électrique ou de blessure.
Do not - place receptacles containing liquids on any surface.
Ne pas placer de récipient contenant un liquide sur la machine.
Do not - adjust any part of the machine whilst rollers are running
N'effectuer aucun réglage pendant que les rouleaux fonctionnent.
Do not - operate the machine with loose or trailing clothing or loose hair.
Ne pas porter de vêtements flottants et rassembler les cheveux longs
lors de l'utilisation de la machine.
Do not - under any circumstances adjust the paper gate when the machine is
switched on.
En aucune circonstance, régler le séparateur de papier lorsque la
machine est branchée.
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Warning Labels
Do - be aware of any finger traps and rotating parts when operating
the machine.
Attention au risque de se coincer les doigts, et aux pièces en
mouvement lors du fonctionnement de la machine.
Do - read this operator manual fully before operating the machine.
Lire ce mode d’emploi avant d’utiliser la machine.
Do not - operate the machine with loose or trailing clothing.
Ne pas porter de vêtements flottants lors de l'utilisation de la machine
Do not - operate the machine with loose hair.
Rassembler les cheveux longs lors de l'utilisation de la machine.
Do - be aware of any finger traps and rotating parts when operating
the machine.
Attention au risque de se coincer les doigts, et aux pièces en
mouvement lors du fonctionnement de la machine.
Do - be aware of sharp points and blades.
Attention aux éléments tranchants et aux couteaux.
SYSTEM
Do - be aware of rotating rollers.
Attention aux rouleaux en fonctionnement
Do - be aware of low current anti-static shock.
Attention aux faibles chocs d'électricité statique
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Page 5
DOCUMENT CREASING MACHINE
Key to photograph below
1 Roller tilt handle 6 Air seperation knob 11 Paper Gate
2 Stacker assembly 7 Adjustable side lay 12 Exit Guard
3 Suction slot knob 8 Back stop 13 Switch Panel
4 Touchscreen 9 Fixed side lay 14 Fuses
5 Air distribution knob 10 Roller tilt knob
10
3
2
1
12
11
6
4
7
14
13
8
9
5
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THE CONTROLS
The Switch Panel houses the Compressor switch, System switch, and an
industry standard Emergency Stop switch which will stop all power going to
the machine when activated.
THE SWITCH PANEL
Compressor Switch
System Switch
Emergency Stop Switch
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THE CONTROLS
Features on the Switch Panel
System switch
When activated the system switch will operate the motors in order to begin the
creasing sequence.
Compressor switch
Allows the operator to switch off the compressor unit in order to utilise the machine
to manually feed sheets.
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Quick Start Guide
Setting the machine to operate in automatic sheet feed mode
1. Set the gap between the paper gate and the vacuum roller to approximately twice
the thickness of the stock to be creased.
2. Place the stock to be creased onto the loading table against the fixed side lay.
3. Release the clamps on the adjustable side lay and slide up to the paper stack
allowing a gap of approximately 0.5mm (1/64 inch) between the paper and the side
lay.
4. Position the backstop and slide it up to the paper stack, also allowing a gap (as
stated in the above step).
5. Turn the Emergency Stop button clockwise to switch the power on. After the
system start up procedure the touch screen will be displayed as shown below.
IMPORTANT.
If you have not been trained to operate this machine, we strongly advise that you select
the red cross icon.
We recommend that you either seek training or ask a trained operator to run the machine
for you.
Select the green tick icon only if you have been trained to operate this machine.
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Page 9
Quick Start Guide
The touch screen is laid out into 3 main areas as shown below:
Setting
page
Settings Pages.
Tabs to enable switching between setting
pages
choose either Paper
-
Crease Setting, Store or Tools
Settings,
Paper Settings Page.
Status of
machine
data entry
area. Also
used for
quick links
to setting
pages.
&
Vacuum Suck - There
are two selections
available - 1 short
suck&2continuous
for stream feeding.
Highlighted number is
type currently
selected. The status
area also shows
currently selected
suck.
Batch Button- Image
is identical to that
shown in the status
area. On selection the
status area is replaced
with a calculator for
inputting new values.
Batches of any
numerical value.
Fold Selection - For quick setting of crease positions on standard size sheets.
Highlighted fold is type currently selected, other folds may be selected.
Currently selected fold is shown in the status area.
Page Length - On
selection the status
area is replaced with
a calculator for
inputting new values.
Min Length = 190mm
Arrows may be
selected to increase
or decrease the page
size in 0.1mm
increments
Page 10
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CREASING
Quick Start Guide
Crease settings Pages.
To get to the crease setting page click the lower tab or from
the status area.
If you have selected a predefined standard crease type from the paper settings
page the crease positions will be set for you. These positions can be fine tuned
by ± 0.1 mm increments by pressing side arrow buttons for each crease.
Number of creases – if
more than 6 creases are
added a scroll bar will
appear for to enable
viewing of all creases
Arrows may be selected
to increase or decrease
the page size in 0.1mm
increments
Plus box for inserting
additional creases. On
selection following
creases will move down
by one place a
maximum number of 6
creases can be seen at
any one time further
creases can be
accessed by use of the
scroll bar.
Crease position - On selection
the status area is replaced with
a calculator for inputting new
values.
Cross box for deletion of crease.
On deletion of crease following
creases will move up by one
place. You will be asked to
confirm deletion of the crease.
Press to remove all
creases – you will be
asked to confirm
deletion.
Scroll bar - use to bring
required crease into
view.
Crease on/off selector
green is on & red is off.
This is also indicated in
the status area.
Additional creases
added – scroll bar
appears for more than
six creases.
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Quick Start Guide
Individual deletion of crease confirmation screen
Select green tick icon to confirm deletion of crease.
Remove all creases confirmation screen.
Turn Crease on/off.
Page 12
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Creasing turned off Greyed out areas are
unselectable. Status
area willshow
creasing is off with
red icon
CREASING
Run Job
System Switch Not On
Click to start machine with
settings currently shown -
you will receive a
notification if system
switch is not on. Press
again to stop Job
Push System Switch down to start the machine.
The machine running screen will appear.
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Click to stop machine
Page 13
Status Screen
Quick Start Guide
Paper length - input from
the paper setting screen
Number of creases - this
may alter automatically if
a pre - defined fold is
selected. Adjustments
may be made in the
crease setting screen
Green icon indicates
settings are saved - a red
icon would show that
settings have been
changed but the job has
not been saved.
Batch quantity - this is
input from the batch
calculator on the paper
setting screen - max. 999
Clicking in this area will take you
to the paper setting page
Currently selected Vacuum
Suck setting - for stream
setting choose selection 2
Currently selected fold type
- can be one of the
following.
Clicking in this area will take
you to the Crease setting
page
Clicking in this area will take
you to the Job Store page
Current Job count -
to zero
A screen will appear to
confirm that you want to
reset the count.
click
Clicking in this area will take
you to the paper setting
page.
Click to start machine with settings currently
shown - you will receive a notification if
system switch is not on. Press again to stop
Job
Page 14
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Quick Start Guide
The Status Screen will on occasions be replaced with an Input Calculator Screen
as shown below.
Pre -
set Paper sizes for quick
insertion – Standard sizes for
country origin would be shown
Pre - set Batch sizes for quick
insertion.
Paper size Batch size Crease position
input calculator input calculator input calculator
NOTE:
The green tick or the red cross must be selected on the Calculator Screen to
make the left hand side of the touchscreen active again.
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Page 15
Tools Screen
Inch paper in direction
of arrow to clear jams
Quick Start Guide
Machine Speed Adjustment:Speed setting 3 will give the fastest throughput of
stock through the machine.
Use speed setting 1 or 2 for troublesome stocks,
or to synchronise the speed of the AutoCreaser to a
Morgana Autofold Pro, when they are used together.
Click on Up Arrow to
put Anvil into Top
Dead Centre position
(TDC)
Inch paper in direction
of arrow to clear jams
Clicking this icon will
show Machine
program revision &
Touch Screen
software revision.
Main Processor Program
version
Touch screen software
version
Page 16
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BLANK
PAGE
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Operating
Setting the Machine
Adjusting the Paper Gate
Set the height of the Paper Gate to approximately two thicknesses of paper, by turning the
disc j. An excessive gap is a most likely cause of double sheet feeding.
This setting is only intended as a guide, for instance, sheets with an upward curl will
require this setting to be increased.
J
TWO THICKNESSES
OF PAPER
WARNING.
DO NOT ADJUST THE
PAPER GATE WHILE THE
MACHINE IS RUNNING OR
THE SUCTION DRUM MAY
BECOME DAMAGED.
Setting the Suction Slot
The suction slot is located inside the vacuum roller and can be adjusted by releasing and
moving the suction knob horizontally in either direction to the required position.
For light stocks set the knob to the left and for heavier stocks set the knob to the right.
FIG 8.1
Adjustable
Side Lay
Suction
Slot Knob
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Setting the Adjustable Side Lay
Place the paper stack on to the loading table and slide up to the fixed side lay and paper
gate. Release the clamps located at each end of the side lay and slide up towards the
paper stack as demonstrated in fig 8.1. Allow a gap of approximately 0.5mm (1/64 inch)
between the paper and the side lay.
Setting the Back Stop
Position the backstop and slide up towards the paper stack allowing a gap (as specified
in the above step).
Setting the Air Distribution
Depending on the length of the sheet to be creased, the air distribution knob can be
rotated to various positions in order to supply air to different ports. Position 2 is
recommended for most sheet sizes. However, a better result may be obtained by using
the settings below or by experimentation.
Position -
0 For sheets longer than A3 (17”) in order to supply air to the centre of the
1 For A5 sheets or 8 inches long, ports 1 and 2 open.
2 For A4 sheets or 11 inches long, ports 1 and 3 open.
3 For sheets longer than A3 (17”) in order to supply air evenly along the stack,
stack, ports 2 and 3 open.
-
-
-
ports 1 and 4 open.
Port 1
Port 4
Air Distribution
Knob Shown
Set To Posn. 1
Setting the Air Separation Pressure
To control the amount of air supplied to the ports, the air separation knob can be rotated
clockwise to decrease the pressure or anti-clockwise to increase the pressure.
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Setting the Roller Tilt Mechanism
The roller tilt mechanism has been designed to compensate for when the creasing
position on the sheet is not square. This could be due to an inaccuracy in the media or if
the roller tilt mechanism has been incorrectly set. The mechanism will be set to zero
(square) when the machine is supplied.
To set the mechanism, unlock the roller tilt knob located below the roller tilting handle by
turning anti-clockwise. Move the roller tilt handle left or right in order to compensate for
any inaccuracy. When the position is set, ensure to lock the roller tilt knob before
operating the machine. Repeat the above procedure until the creasing position is square.
Setting the positions of drive wheels and hubs
It is important that the drive wheels and drive hubs on the roller shafts are arranged evenly
across the width of the media being creased. This is done to ensure that the media is
accurately driven and supported through the rollers.
The drive wheels and hubs are fixed to the rollers by means of a grub screw. To locate this
grub screw the rollers can be rotated by operating the motor manually.
DO NOT ROTATE THE DRIVE ROLLERS BY HAND.
To operate the motors manually, switch the machine ‘on’ at the Emergency Stop switch.
Select the Tools tab at the bottom of the touch screen, the display will change to
that shown below.
Inch paper in direction
of arrow to clear jams
Press the system switch down and then select the right or left arrows, to rotate the rollers in
short pulses.
Lift the exit guard to see if the grub screws in the drive wheels and hubs can be seen. If the
grub screws cannot be seen, lower the exit guard and rotate the rollers by selecting the
right or left arrows. Loosen the drive wheels and hubs with a 2mm allen key. Arrange the
drive wheels and hubs as shown in FIG 10.1. In order to avoid marking on some types of
media ensure a gap between the drive wheels and hubs.
This procedure should be repeated when installing perforating blades and anvils onto the
drive wheels and hubs.
Left arrow
Inch paper in direction
of arrow to clear jams
Right arrow
Page 20
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FIG 10.1
Set Feed
The length of suction on the sheet of paper being fed can be adjusted by setting the feed
type as follows:-
Select 1 for short suck, select 2 for continuous suck (stream feeding).
Vacuum Suck
Select 1 for short suck
Select 2 for continuous suck
(Stream feeding)
NOTES.
Stream Feed
1. will give the quickest through put of stock through the machine.
2. When the first crease is less than 37mm from the leading edge of the paper the feed will
be noticeably slower.
SYSTEM
Page 21
Programming the machine
1. Switch the power ‘on’ by turning the Emergency stop button clockwise
to release the safety latch.
Setting the page length
2. Set the page length of the paper as described on page 10.
Setting the vacuum suck
3. Set the vacuum suck as described on page 10. Setting number 1 for short suck and
setting number 2 for continuous suck (stream feed).
Setting the batch quantity
4. Select the button. On selection the status area is replaced with a calculator for
inputting new values.
Setting the crease positions
5. (i) Select the lower tab or from the status area to get to the
Crease Settings Page.
(ii) Set the creases as described on pages 11 and 12.
Storing the Job
6. The job that has been set can now be stored as follows.
(i) Select the lower tab or from the status area to get to the
Store Settings Page.
(ii) The job can be given a name and stored as described below. You can also retrieve
previously saved jobs, modify them or delete jobs that are no longer required.
To create a new job name click in text area &
keyboard will open to input job name.
Load existing job from
store
Clicking to search
currently stored jobs
Clicking to delete
currently stored jobs
Page 22
Clicking to save job
shown.
CREASING
Keyboard for entering job name.
Save confirmation screen.
Return to Store Menu &
click save icon to save
job to store
To confirm saving
of Job click here.
Search for current jobs to load or modify.
You can search for jobs by clicking the search icon , this will bring up the search
keyboard for text input.
Typein job description
or first few characters
To change your mind &
return to the previous
screen click here.
SYSTEM
Press search icon
to start search
Page 23
Jobs matching
characters in text box
will be shown in this
area - selecting job
from this area will
show job settings in
the right hand status
area. Job selected will
be shown in text box.
Loading job confirmation screen.
Toggle between search
results &full list of
jobs
Press to load job
shown in text box.
The loaded job can be run or modified and saved as the same job name.
Overwrite job confirmation screen.
To cancel overwrite of
Job press here.
To confirm overwrite
of Job press here.
Page 24
CREASING
Delete job confirmation screen.
To cancel deletion of
Job press here.
To confirm deletion of
Job press here.
Running the machine
Run the job as described on page 13. The machine will complete its creasing operation if a
sheet has already been fed through the paper gate.
Paper jamming
In the event of a paper jam occurring whilst the machine is operating, select the Tools
tab at the bottom of the touch screen, the display will change to that shown
below. Press the system switch down and then select the right or left arrows, to inch the
paper forwards or backwards.
Inch paper in direction
Inch paper in direction
of arrow to clear jams
Left arrow
Right arrow
of arrow to clear jams
Setting the machine to operate in manual sheet feed mode
In order to feed heavy stock, very small or very large sheets, embossed or even irregular
shaped sheets, it may be necessary to feed the sheets manually. The machine can be
programmed and set up in exactly the same way as explained when operating the machine
automatically. However, the paper gate must be raised to its highest position for the sheets
to be fed freely. Operating the machine in manual sheet feed mode will also require the
suction length to be continuous in order to accommodate various types of stock. Therefore,
the feed should be set to (Vacuum Drum position 2) see page 10.
The machine can now be started by activating the System switch to ‘on’.
the Compressor switch.
Stream Feed
Do not activate
Select the icon on the touch screen and begin to slide the sheets individually through
the paper gate until they are driven by the drive belts.
To stop feeding the sheets, select the icon on the touch screen and switch the
System Switch off.
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The Stacker Assembly
The stacker unit on the machine is used to catch the sheets once they have been
creased or perforated.
Setting the Stacker assembly
1. Assemble the stacker unit to the machine as shown in fig 13.1 below.
Important
Ensure that the stacker unit has been assembled to the machine properly. However,
if it has not, the connection on the magnetic switch will be broken and the machine
will not operate (see Trouble shooting pages for details).
There are two side guides on the stacker unit; a left handed (fixed) guide and a right
handed (movable) guide held on by a magnetic strip. There is also a left hand extension
guide. The guides will control the way in which the paper is collated by setting their
positions on the stacker bed.
2. Place a single sheet (from the stack to be creased / perforated) on to the stacker bed
against the fixed ‘left hand’ guide.
3. Position the ‘right hand’ side guide on to the stacker bed leaving a minimum
clearance of approximately 1mm each side of the sheet.
FIG 13.1
LEFT HAND
BACK STOP
LEFT HAND
SIDE GUIDE
Page 26
RIGHT HAND
SIDE GUIDE
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RIGHT HAND
BACK STOP
CREASING
The Stacker Assembly
4. Whilst the sheet is between the two guides on the stacker bed, set the distance
between the top of the sheet and the backstop flanges to approximately 5mm.
5. For shorter sheets, the back stop can be used (as shown in FIG 13.1) to adjust the
position of the paper stack.
TIPS
l The magnetic back stop supplied with the machine
can also be used as a tool holder as demonstrated
in the photograph (left).
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Page 27
Perforating
Once the machine is set-up, the Atlas C100 can be used to perforate or crease.
Note
1. Perforating and creasing can be carried out simultaneously. However, if any
adjustment is made to the roller tilt mechanism in order to compensate for the
perforation line being ’out of square’, this may effect the accuracy of the crease. If
this occurs creasing and perforating must be carried out as separate operations.
2. By adjusting the outfeed drive tyres relative to the drive hubs it is possible to stear
the sheet, (i.e. By placing the tyre on top of the hub one side of the paper will stear
faster on that side).
The components and tools required to install the perforator are contained in the despatch
kit supplied with the machine, they are listed below.
1 off Set of standard perforation ‘56 tooth’ blades.
1 off Set of standard hardened anvils.
1 off Perforator stripper.
1 off Scoring wheel
1 off 3mm bondhus wrench / allen key
1 off 2mm bondhus wrench / allen key
The perforator blades are split into two matching halves
and are fitted to the drive wheels as shown in the
photograph using the four screws supplied.
A hardened anvil is fitted to the drive hub as shown in the
photograph also using the four screws supplied. Again the
anvils are made from matching halves.
Important: The perforator blades are very sharp and
care must be taken whilst handling.
Do not mix the matching pairs of blades or anvils.
Perforating ‘Spares’ kits
For perforating and other types of paper, various spares kits are available which can be
assembled to the machine in the same fashion. They are listed below along with a range
of scoring wheels,
Perforating blades 1-99-41
56 teeth Part Number - Standard stock /
fine perforations.
28 teeth Part Number - Medium stock /
20 teeth Part Number - Heavy stock /
Anvils 1-99-35
Page 28
Standard Part Number - For all blade types
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1-99-12
1-99-10
medium perforations.
coarse perforations.
CREASING
Perforating
All of the blades and anvils are supplied with fixings.
*Perforator stripper 78-013
*It is recommended that for multiple perforations, a separate perforator stripper is used for
every perforating blade set fitted in the creasing unit.
Standard Part Number
Setting the machine
1. Turn the mains supply to the machine ‘off’.
2. Remove the stacker unit and open the exit guard.
3. Locate and remove the blades / anvils from the despatch kit supplied with the
machine.
4. Using the 2mm allen key (supplied), loosen the drive wheel that is to accommodate
the blades.
5. Slide the drive wheel away from any obstructing drive wheels or hubs in order to
mount the blades.
6. Using the 2.5mm allen key (supplied), take one
of the matching pairs and mount on to the drive
FIG 16.1
wheel. Do not secure the blade.
FIG 16.2
7. Mount the other matching pair to the drive wheel
as shown (fig 16.1). Secure the blades to the
wheel ensuring not to over tighten grub screw.
8. Mark on a single sheet the desired perforating
position. Feed the sheet through the machine
manually until the mark can be seen. Use this
mark to assist in fixing the position of the
perforating drive wheel to the roller drive shaft.
9. Using the 2mm allen key, loosen the drive hub
nearest the perforating drive. Slide the drive hub
away from any obstructing drive wheels or hubs
in order to mount the anvils.
10. Using the 2.5mm allen key, take one of the
matching pairs of anvils and mount to the drive
hub. Do not secure the anvil.
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Page 29
Perforating
11. Mount the other anvil ensuring that they have matched on the drive hub. Secure the
anvil to the hub ensuring not to over tighten grub screw as shown in fig 16.2.
12. Slide the drive hub towards the perforating drive wheel until there is a clearance
of 0.5mm.
13. To prevent damage to the blades or the anvils, do not force the drive wheel against
the hub.
14. Fix the perforator stripper adjacent to the drive wheel and blade as shown.
15. Operate the machine and test the perforations for form.
It is important that the drive hubs are arranged evenly across the width of the paper
in order to reduce the risk of jamming.
For multiple perforations repeat the above procedure.
2
1
5
4
Fig 17.1 Demonstrates a typical set-up for perforating sheets.
1- 4-
Perforating drive wheel with mounted blades Drive hub with mounted anvils
2- 5-
Perforator stripper Standard drive hub
3-
Standard drive wheel
Always remove blades and anvils once the perforating operation has been
completed to avoid marking on digital or delicate media.
3
FIG 17.1
Page 30
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The Blade Assembly
Adjusting the blade pressure (no paper required)
1. (i) Switch the power ‘on’ by turning the Emergency stop button clockwise to release the
safety latch.
(ii) Select the Tools tab at the bottom of the touch screen, the display will
change to that shown below.
(iii) Select the up arrow to move the blade to the Top Dead Centre position.
Click on Up Arrow to
put Anvil into Top
Dead Centre position
(TDC)
2. Raise the exit guard
3. Using a 6mm allen key, unlock the shoulder bolts (labelled with scale transfer)
positioned at each end of the creasing blade.
4. Turn the adjustment cam to adjust the blade pressure. Increasing the gradient on the
scale will increase the blade pressure.
5. Ensure that the shoulder bolts are locked after setting.
The diagram below demonstrates the adjustment of the blade pressure
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Page 31
The Blade Assembly
Adjusting the blade alignment
It is extremely important that the blade and anvil assembly within the creasing unit is
correctly aligned. Misalignment of the blade or anvil can lead to damaged profiles and
subsequently poor quality creasing so it must, therefore, be corrected immediately.
If the blade set is misaligned, the media being driven will be subject to scoring or even
tearing at any point along the crease line.
blade set, adjustment should only be made in small increments.
demonstrates how the blade alignment can be carried out.
Adjustment can be made at either of the blade or anvil. The two clearance holes positioned above the roller tilt mechanism are the front alignment (one for blade, one for anvil).
The two holes are repeated on the back of the machine for the back alignment.
1. Remove the stacker unit.
2. Unlock and centralise the roller tilt mechanism in order to locate the heads of the
front alignment screws.
Please note that to avoid damage to the
The below sketch
3. Using a 3mm allen key, loosen the cap head type locking screws located on the
front face at both ends of the blade /anvil as shown below.
4. Using a 4mm allen key, locate the two front or back alignment screws in the side
frame in order to adjust the blade / anvil.
5. The upper screw of the two, will adjust the upper blade / anvil whereas the
lower screw will adjust the lower blade / anvil both in very small increments.
6. In order to obtain the required position, adjust either the blade or the anvil by a
small amount and then operate the machine to test the form of the crease.
Repeat the exercise until centralisation is located.
7. Using a 3mm allen key, lock the cap head type screws (as per step 3) on both the
upper and lower blade / anvil.
Page 32
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Replacing Blade Set
1. Before removing the blade assembly, ensure that the lower blade / anvil is NOT
at ‘top dead centre’, Switch the machine off.
2. Remove the stacker unit and lift the exit guard.
Blade Extractor Tools
3. Using a 6mm allen key, loosen the socket
head screws located inside the blade
adjustment cams. Remove the screws and
the blade adjustment cams.
4. Insert the blade extractor tools (70-055-01 &
70-055-02) into the holes in the adjustment
links, as shown. Push downwards on the
handles of the blade extractor tools to
release the blade assembly from the power
links.
5. Slide the blade assembly out of the creasing
unit and lay it on a flat surface.
6. Slide the adjustment links away from the
dowels located in the ends of the blades /
anvils as shown in the photograph (left)
7. Place the new blade set into position.
Check that the eccentric shoulder bolts on
the link plates have been positioned as
shown in fig 20.1.
FIG 20.1
8. (Upper blade / anvil only)
Slide the adjustment links onto the dowels.
9. Slide the new blade set into the slots of the
creasing unit as shown in fig. 21.1.
Locate the blade extractor tools into the holes in
the adjustment links as shown. Pull the handles
of the blade extractor tools upwards to engage
the blade assembly back into the power links.
10. Set the cam graphics for both ends of the blade /
anvil to their lowest point on the scale (ie. When
the mark on the scale reaches the mark on cam
holder) Fasten the socket head screws on the
adjustment cams until they are tight.
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Page 33
Replacing Blade Set
FIG 21.1
11. Push the exit guard down and replace the stacker assembly before operating the
machine.
12. Switch the machine on and test the crease for form.
If the pressure and the alignment of the crease is not to a satisfactory level,
see pages 31 - 33 to adjust the creasing line.
‘Spares’ kits
In the event of any damaged or lost components within the blade assembly, spares kits
are available on request. However, components within the blade set can not be ordered
separately ie single blade or anvil.
Standard Blade set Part number 76 - 213 - 01
Consisting of a standard blade and anvil, blade brushes, blade links and alignment bolts.
Extra Narrow Blade set Part number 76 - 213 - 03
Consisting of a narrow blade and anvil, blade brushes, blade links and alignment bolts.
Page 34
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CREASING
Paper crease out of square
l
Check that the sheets are all square and exactly the same size before loading the
stack on to the table.
Trouble Shooting
l
l
Check that the roller tilt mechanism is correctly set and locked in position.
Check that the adjustable side lay has been correctly positioned ie. No further than
0.5mm from the paper stack.
Paper jamming
l
l
Check that the leading edge of the paper is not being damaged by the paper gate. If
this is occurring, check that the suction slot and the paper gate have been correctly
set.
Check that the first crease position is not too close to the leading edge of the paper.
A minimum distance of 32mm is recommended.
Machine will not start
l
l
l
l
Check the power supply to the machine.
Check that the emergency stop button has been released.
Check that the exit guard is down.
Check that the stacker unit is located correctly and has not been disconnected from
the magnetic switch.
l
Check that the lower blade / anvil is connecting to the home switch (mounted below
the lower blade / anvil).
Paper not feeding
l
l
l
l
Check that the paper stack is not too high or too heavy for the feeder. The height of
the paper stack should be defined by the weight and the size of the stock being
creased.
Ensure that the adjustable side lay is not pressed against the paper stack. However,
if the clearance between the adjustable side lay and the paper stack is too great, the
air supply will escape instead of blowing through the paper thus making it difficult to
feed.
Check that the clearance between the paper gate and the suction roller is not set too
low.
On digital media, the feeding performance may be improved if the leading edge of
the stack is trimmed before loading onto the Machine.
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Page 35
Trouble Shooting
l
Check that the air distribution has been correctly set.
l
Check that the air separation has been set high enough to feed the sheets.
l
For heavy stocks, very small or very large sheets, embossed or even irregular stock,
it may be required to feed the sheets manually - see page 25 for instructions.
Machine not counting
Open the exit and remove the blade set
(see pages 33-34) to access the dual
sensor post located in between the drive
rollers. Using a soft brush, clean the
visible sensor on the end of the post.
Use the brush to clean the sensors
between the post and the bottom paper
guide which are not visible.
Photograph (left) shows the dual sensor
post containing the sensors.
Paper jammed under paper gate.
If paper gets jammed under the paper gate the vacuum drum will stop rotating, this is a
safety feature. Remove the paper and re-adjust the paper gate.
Page 36
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CREASING
Trouble Shooting
Error Screens
Sheet did not arrive.
If the machine stops and error message 01 is displayed on the touch screen, this
indicates that the paper did not arrive at the end of the suck process; so the machine
timed out. Press the green tick button and then press the start button.
Paper Crunch
If the machine stops and error message 02 is displayed on the touch screen, this
indicates that a paper jam has been detected.
Press the system switch down and then select the right or left arrows, to inch the
paper forwards or backwards. See page 39 that describes how to remove paper jams.
Press the green tick button and then press the start button.
Double Sheet Feed
If the machine stops and error message 03 is displayed on the touch screen, this
indicates that a double sheet feed has been detected. Check that the paper gate has
been set correctly. Press the green tick button and then press the start button.
Blade Not Home
If the machine stops and error message 04 is displayed on the touch screen, this
indicates that the lower blade / anvil has not made contact with the HOME switch.
i.e. blade still in top position. Switch the machine off and remove the blade set and
ensure that the area is free from obstructions. Return the blade set to the creasing unit
and switch the machine on. Operate the machine in the normal sequence, if the
display continues to read error message 04 it is advised to contact a Service Engineer
immediately.
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Page 37
Trouble Shooting
Error Screens (Continued)
Blade Not Home
If the machine stops and error message 04 is displayed on the touch screen, this
indicates that the lower blade / anvil has not made contact with the HOME switch.
i.e. blade still in top position. Switch the machine off and remove the blade set and
ensure that the area is free from obstructions. Return the blade set to the creasing unit
and switch the machine on. Operate the machine in the normal sequence, if the
display continues to read error message 04 it is advised to contact a Service Engineer
immediately.
Overlap
If the machine stops and error message 13 is displayed on the touch screen, this
indicates that the ‘Lead Edge Sensor’ has seen a sheet subsequent to the first
one as being longer. Again this could actually be a longer sheet, OR it could be a
sensor problem (if it is a recurring problem). Check that the paper gate has been set
correctly.
Page 38
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CREASING
Trouble Shooting
Recommended weekly operator maintenance
l
Clean all sensors
Clean in feed rollers and output drive hubs using the cleaning kit provided
l
(Cleaning kit part number 90-018)
Remove and clean the blade assembly
l
With the blade assembly removed, clean the slots and surrounding area within
l
the creasing unit.
Technician Maintenance
It is recommended that your machine is fully serviced at least once every six months
by a factory trained Service Engineer.
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Page 39
7-95-24
DISPATCH KIT
ITEM PART NUMBER QTY DESCRIPTION
70-148
1
2 90-018 1 ROLLERCLEANING KIT
3
650-040 1 POWER CORD CE UK C19 3Pin 16A 2.5Mtrs.
617-003 5 STEEL BALL - Ø20
4
78-007 1 MAGNETIC BACK STOP ASSY.
5
6
403-01-030-006
7
409-01-040-004
620-007 1 HEXAGON BALL DRIVER 2mm
8
9
620-020 HEXAGON BALL DRIVER 2.5mm
10
620-004 1 ALLEN KEY 4mm
1 OPERATORS MANUAL
12 SCREW-SOCKETCAPHEAD-M3x6LG
1 SCREW-SKT.SETFLATPT.-M4x4LG
1
11
12
13
14
15
16
17
18
19 624-017 3 SLITTER/SCORER PK - STYLE 0212/40X40X20
620-026 1 BONDUS L WRENCH 4mm
620-028 1 BONDUS L WRENCH 3mm
620-033 1 BONDUS L WRENCH 6mm
624-018 1 DISPATCH BOX
70-055-01 1 BLADE EXTRACTION TOOL - OP SIDE
70-055-02 1 BLADE EXTRACTION TOOL - LAY SIDE
08-041-02 1 SLITTING ANVIL - UNDERSIZE.
08-066 1 SLITTER PERF BLADE 28T
WARNING......
THE BLADES FOR ANVIL AND PERFORATING SETS ARE SUPPLIED AS
MATCHING PAIRS AND SHOULD NOT BE MIXED OR LEFT
UNPROTECTED OR SERIOUS DAMAGE MAY RESULT.
Page 40
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CREASING
ACCESSORIES AND OPTIONS
ITEM PART NUMBER DESCRIPTION
1-99-10 PERFORATING BLADE SET 20T (Card)1
1-99-12 PERFORATING BLADE SET 28T (Single sheets)2
1-99-41 PERFORATING BLADE SET 56T (Fine perforations)3
1-99-35 ANVIL SET USED WITH ABOVE BLADE SETS4
76-213-03 BLADE SET - EXTRA NARROW5
6 70-082-02 ANTI-STATIC KIT
7 94-073-02 SIDELAY EXTENSION - NARROW SHEET
ACCESSORIES.... OPTIONS....
....May be obtained from ....May also be obtained and
your dealer and fitted to your fitted by your dealer. You should
machine using the instructions not attempt to fit options as
supplied, or by reading your specialist tools and knowledge are
operators manual. required.
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Page 41
RECOMMENDED SPARES
PART NUMBER DESCRIPTION
93-021 FEED BELT
609-011 ‘O’ RING Ø20
94-028 LOCK PIN ASSEMBLY - Side Lay
613-365 EMERGENCY STOP SWITCH
652-011 SWITCH - LOW CURRENT COIL - BLACK ROCKER
652-043
75-472-01 MINI ITX MOTHERBOARD (CONFIGURED)
75-455-01 CONTROL PCB ASSEMBLY
174-06-01
174-19-01
125-21-02 DUAL STEPPER DRIVE PCB ASSEMBLY
75-06-01 TOUCH SCREEN ASSEMBLY - 7”
76-272 PSU ASSEMBLY - ATX12V - 300W
655-015 PSU UNIT - SWITCH MODE - 24V
655-016 PSU UNIT - SWITCH MODE - 48V
76-156 BLADE POSITION SENSOR
76-168 PAPER GUIDE ASSEMBLY - Bottom Sensor
76-166 PAPER JAM SENSOR ASSEMBLY
76-167 UPPER SENSOR ASSEMBLY
76-169 BLADE POSITION SENSOR-LEAD
76-255 LEAD - FOLD COMPENSATION SENSOR
SWITCH - 240 VOLT COIL - 20A - BLACK ROCKER
SMALL STEPPER DRIVER - LOW POWER - PCB ASSY
RS232 ADAPTOR PCB ASSY
98-013 ANTI-STATIC BRUSH
609-022 ‘O’ RING Ø32
606-035 KNOB - Roller Tilt
76-109
76-213-01 BLADE SET - Standard
76-042 DRIVE BELT - FEED BED
607-041 TIMING BELT - 110XL 037
607-042 TIMING BELT 160XL
607-048 TIMING BELT TWIN GRIP - 200 DXL 050
608-019 SHOULDER BOLT
76-082 PERFORATOR - DRIVE HUB ASSEMBLY
175-28-01 BUTTERFLY VALVE - STEPPER
76-240 STEPPER DRIVE MOTOR ASSEMBLY
76-241 STEPPER BLADE MOTOR ASSEMBLY
75-425 LEAD VACUUM DRUM ASSEMBLY
POWER LINK BEARING
Page 42
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CREASING
RECOMMENDED SPARES
PART NUMBER DESCRIPTION
76-083 PERFORATOR - DRIVE WHEEL
76-175-01 INPUT ROLLER - Lower
76-177-01 INPUT ROLLER - Upper
76-019-03 OUTPUT SHAFT
78-013 PERFORATOR STRIPPER ASSEMBLY
613-351 MICRO SWITCH - Guard Circuit
613-191 MICRO SWITCH - Home Circuit
78-071-01 ACTUATOR ASSY. - STACKER
602-085 BEARING-DRAWN CUP NEEDLE ROLLER Ø10xØ14x10
NOTE.....
The items listed above represent parts which are subject to wear, loss, or accidental
damage, and are included for your guidance only.
Replacement of parts fitted to your machine require specialist knowledge and should
therefore be entrusted to your dealer.
MyBinding.com
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Page 43
FUSE POSITIONS & RATINGS
(POSITION ET CLASSIFICATION DES FUSIBLES)
PSU (5V / 24V)
(FUSIBLE PSU (5V/24 V)
F3.15AH 250 (613-023)
ANTI-STATIC UNIT
(IF FITTED)
(FUSIBLE ANTI-STATIQUE
(si installé)
T315mAH 250 (681-011)
PSUs (24V & 48V)
(FUSIBLE PSUs (24V&48V)
T4.0AH 250 (681-015)
SPARE FUSE
POSITION
(POSITION PORTE
FUSIBLE)
Page 44
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CREASING
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