Fellowes Standard Morgana FRN-6 Service Manual
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Fellowes Standard Morgana FRN-6 Service Manual

Fellowes Standard Morgana FRN-6 Service Manual

Suction feed rotary numbering machine
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Standard Horizon SRN-9x
Suction Feed Rotary
Numbering Machine
Instruction Manual

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  • Page 1 Standard Horizon SRN-9x Suction Feed Rotary Numbering Machine Instruction Manual...
  • Page 2 SERVICE MANUAL Standard - Morgana FRN-6 and SRN-9x Read this manual, and thoroughly familiarize yourself with its contents before operating or servicing this equipment.

  • Page 4: Introduction

    S E R V I C E INTRODUCTION ROTARY NUMBERING MACHINES SERVICE MANUAL ..Introduction The purpose of this Manual is to explain the procedure for dis- mantling and re-assembly of the major assemblies on both the Friction-Feed and Suction Feed Rotary Numbering Machines. All the engineering adjustments are shown at the end of each relevant section.

  • Page 5: Identification

    M A N U A L INTRODUCTION Cap Head, Button Head, Socket Countersunk, Shoulder Bolts and Grub-Screws have internal hexagon drives which require ISO- Metric Hexagon Wrenches (Allen Keys). Ball Drivers may be used, but care should be taken -particularly when releasing screws for dismantling- to avoid breaking the driver as they cannot cope with full tightening torques.

  • Page 6: Table Of Contents

    S E R V I C E INDEX Introduction ............Page 2 ¡ Introduction ¡¡ Fasteners ¡¡¡ Identification Section .. 1 ..Covers ........Page 6 Side Covers - Friction Machine Covers - Suction Machine Section .. 2 ..Friction Feed......Page 8 Friction Feed Drive Shaft Drive Shaft Adjustment Feed Clutch...
  • Page 7 M A N U A L INDEX Actuator - Measurement Actuator - Adjustment Collar Position - Measurement Collar Position - Adjustment Clutch Position Switch Section .. 10 ..Main Print Shaft ...... Page 36 10.1 Main Print Shaft - Removal 10.2 Main Print Shaft - Re-assembly Section ..

  • Page 8: Side Covers - Friction Machine

    S E R V I C E Section 1 SIDE COVERS Operator Side Cover Clutch Side Cover Facia Plate Two M6 Nuts Each Side Two M4 Screws Each Side Handwheel M6 Nut & Washer Side Covers - Friction Machine........Fig 1.11 1.1 ..

  • Page 9: Covers - Suction Machine

    M A N U A L COVERS Section 1 M6 Nut & Washer Two M6 Nuts Each Side Hand Wheel Base Access Panel Screws - Five M4 Screws Two Each Side Each Side Covers - Suction Machine..........Fig 1.21 1.2 ..Suction Machine Each side cover is secured by five screws and two nuts as shown in Fig.1.21.

  • Page 10: Friction Feed Drive Shaft

    S E R V I C E Section 2 FRICTION FEED Gears Inside Housing Pull Housings Together To Release Pins Grub Screw Two Cap Head Bolts Each Side Friction Feed .............. Fig 2.11 2.1 ..Friction Feed Drive Shaft The friction feed drive shaft is removed after unscrewing the four cap head bolts as shown in Fig.

  • Page 11: Drive Shaft Adjustment

    M A N U A L FRICTION FEED Section 2 0,2mm / 0.008” End Float Grub Screw Idler Gear Drive Hub Support Tube Cover Tube Waved Washers M6 Nut Location Dowel Pin Holes Through Hub & Shaft Friction Tyre & Clutch Assembly Drive Shaft ..............

  • Page 12: Feed Clutch

    S E R V I C E Section 2 FRICTION FEED Sleeve Gear Assembly 13mm A/F Spanner/Wrench Flats Drive Slots (Output) Drive Dog Feed Clutch Drive Slots (input) Drive Pin Upper Input Roller Clutch Spindle Tang Anchor Pin Side Frame Assembly (Clutch Side) Integral Flying Lead...

  • Page 13: Vacuum Roller

    M A N U A L SUCTION FEED Section 3 3.1 ..Vacuum Roller Assembly (See Fig. 3.11 Overleaf) The vacuum roller is mounted on the bed stiffener beneath the loading table. To replace the vacuum roller, the loading table, manifolds, and papergate must be removed.(See Fig 3.11) -Remove the side-covers and the base access panel.

  • Page 14: Vacuum Roller Adjustment

    S E R V I C E Section 3 SUCTION FEED Paper-Gate Shaft Paper-Gate Feed Drive Shaft Operator Side Manifold Large Timing Pulley Feed Drive Timing Belt Clutch Side Manifold Feed Bed Vacuum Roller Elbow Hose Stiffener Manifold Mounting Bracket Mounting Link Loading Table...
  • Page 15 M A N U A L SUCTION FEED Section 3 -The op side manifold must be set accurately by measuring it's position on the loading table. (Do not rely on the printed scales because they may not be accurate enough due to limitations of the printing process).

  • Page 16: Vacuum Hose

    S E R V I C E Section 3 SUCTION FEED Suction Slot ( Inside Vacuum Roller ) Alignment Tool Drive Shaft Suction Choke Control Bearing Blocks Tapped Hole Vacuum Roller Spigot Grub Screw Bed Stiffener (Sub Frame) Connecting Tube Vacuum Hose Vacuum Hose .............

  • Page 17: Vacuum Belt Adjustment

    M A N U A L SUCTION FEED Section 3 Note ..Remove the tool and the knob before continuing assembly 3.4 ..Vacuum Belt Adjustment The vacuum drive belt takes the drive from the lower input roller to the feed drive shaft and is tensioned by adjusting the bearing blocks.

  • Page 18: 4.1 Twin Grip Drive Belt

    S E R V I C E Section 4 DRIVE BELTS Remove Bolts Completely Before Attempting to Belt Direction Remove Belt Bearing Housing Twin - Grip Drive Belt..........Fig 4.11 4.1 Twin Grip Drive Belt Remove the operator side cover to gain access to this belt which is removed only after taking out the bearing housing bolts.

  • Page 19: Adjustment - Twin Grip Belt

    M A N U A L DRIVE BELTS Section 4 4.2 ..Adjustment - Twin Grip and Clutch Drive Belts These belts are tensioned by adjusting Bearing Housing the bearing housings after slackening Fixing Bolts their fixing bolts. (see note below) The fixing bolt nearest to the feeder end of the machine acts as a pivot whilst the delivery end bolt runs in a...

  • Page 20: Input Rollers - Removal

    S E R V I C E Section 5 INPUT ROLLERS 5.1 ..Input Rollers - Dismantling Before dismantling the input rollers, remove the twin grip belt (Section 4) and, on the friction machine, the feed clutch (Section 2) Remove the M8 nuts from the ends of the input rollers, (clutch side), and, on the suction machine, the feed drive belt and pulley from the lower input roller.
  • Page 21 M A N U A L INPUT ROLLERS Section 5 Slide the roller assembly out of it’s clutch side bearing towards the operator side of the machine and remove the operator side bearing and waved washers* (see Note 1 on page 21) from the end of the shaft.

  • Page 22: Output Shaft - Removal

    S E R V I C E Section 6 OUTPUT SHAFTS Timing Pulley (Flanged) Side Frame (Clutch Side) Side Frame (Operator Side) Output Shaft - Upper Waved Washers * Drive Hub (Upper) (See Note 1 - Page 21) Bearings Flats (for 13mm A/F Wrench) Grub Screws Drive Wheel (Lower) Bearings...
  • Page 23 M A N U A L OUTPUT SHAFTS Section 6 Note: ..Before removing the upper & lower hubs from their shafts, study the hubs and note the orientation of the tapped holes in the hub faces. It is important that the orientation is maintained during re-assembly as it will be impossible follow...

  • Page 24: Ink Transfer Rollers & Shaft - Removal

    S E R V I C E Section 7 INKING Circlip Tie Bar Tie Bar Screw Inking Shaft Pivot Bolt Inking Stop Screw Support Arm - Operator Side Polycord Belt Inking................. Fig 7.11 7.1 ..Removal of Ink Transfer Rollers & Shaft Release the transfer roller clamp screws using a 2mm Allen key.

  • Page 25: Ink Transfer Roller - Pressure Adjustment

    M A N U A L INKING Section 7 Care should be taken to guide the circlip through the radial slot in the sideframe. (The operator side support arm will slide off the tie bar which will remain in the machine). Remove the circlip and continue to draw the support arm and shaft out of the machine from the operator side whilst sliding the transfer rollers off the shaft.

  • Page 26: Numbering Registration

    S E R V I C E Section 8 REGISTRATION 8.1 ..Numbering Registration The main clutch installed in all machines is an incremental control unit and contains four wrap springs. Like all precision components it has to work to a tolerance which is ±...

  • Page 27: Clutch Problems

    M A N U A L REGISTRATION Section 8 The small pulley that drives the clutch belt (under the cover, next to the handwheel), has it's grub screw outside the cover and can be released by the operator, so must therefore be carefully checked. Loose pulleys may be detected by holding the large clutch pulley whilst carefully trying to turn the machine backwards and forwards by hand.

  • Page 28: Clutch Assembly - Removal

    S E R V I C E Section 9 CLUTCH ASSEMBLY Clutch Drive Belt Main Shaft Grub Screw Micro-Switch Spring Bracket Solenoid Coil Solenoid Cables Bellcrank Assembly Clutch Assembly ............Fig 9.11 9.1 ..Removal of the Clutch Assembly Remove all numbering heads from the machine, (to avoid them swinging down and damaging the platen) and remove the clutch drive belt from the clutch pulley.

  • Page 29: Over-Travel - Measurement

    M A N U A L CLUTCH ASSEMBLY Section 9 9.2 ..Over-travel - Measurement The clutch and brake springs have a combined adjustment to ensure that when the brake spring engages, the clutch spring is released. Note ..This adjustment is critical to the accuracy of the numbering machine and is measured by the over-travel which is checked as follows:- Rotate the output hub (Fig.

  • Page 30: A Over-Travel - Adjustment (Old Style Clutch)

    S E R V I C E Section 9 CLUTCH ASSEMBLY To Reduce Overtravel, Move Tangs in This Direction Clutch Spring Tang Brake Spring Tang Input Hub Output Hub Input Hub Circlip Stop Collar Control Collar Clutch Manufacturers Default Setting Marks Actuator Over-travel Adjustment (Old Style Clutch)……………..Fig 9.31 9.3A ..
  • Page 31 M A N U A L CLUTCH ASSEMBLY Section 9 Carefully dis-engage the control collar from the tang of the brake spring and replace the tang in the next slot as shown in Fig. 9.31. Move the tang of the clutch spring into the next slot in the control collar as shown in Fig 9.31.

  • Page 32: Over-Travel Adjustment (New Style Clutch)

    S E R V I C E Section 9 CLUTCH ASSEMBLY Inner Control Ring Inner Collar Control Collar Clip Input Hub Actuator Over-travel Adjustment (New Style Clutch)…………..Fig 9.32 R O T A R Y PAGE 30...
  • Page 33 M A N U A L CLUTCH ASSEMBLY Section 9 9.3B ..Over-travel - Adjustment (New Syle Clutch) The over-travel adjustment on the new style clutch can be done without removing the clutch from the machine as follows:- (See Fig 9.32). 1.

  • Page 34: Actuator Measurement

    S E R V I C E Section 9 CLUTCH ASSEMBLY 9.4 ..Actuator Measurement The actuator controls the stopping and starting position of the numbering heads. If the actuator is adjusted too far away from the stop collar, the solenoid will not have enough power to operate the clutch consistently.

  • Page 35: Actuator Adjustment

    M A N U A L CLUTCH ASSEMBLY Section 9 9.5 ..Actuator Adjustment The actuator should only be adjusted after the over-travel has been checked and if necessary adjusted, see sections 9.2 and 9.3. Slacken the two solenoid fixing screws, using a 4mm allen key, and move the solenoid body "up"...

  • Page 36: Collar Position - Adjustment

    S E R V I C E Section 9 CLUTCH ASSEMBLY Clutch Pulley Retaining Ring Clutch Backplate Stop Collar Control Collar Splines (Slots for Brake Spring Tang) Collar Position............Fig 9.61 9.7 ..Collar Position - Adjustment Locate the stop collar and lever the retaining ring out of it's groove in the control collar using a small screwdriver under the shaped end of the ring.

  • Page 37: Clutch Position Switch

    M A N U A L CLUTCH ASSEMBLY Section 9 Reaction Plate - (On Clutch Backplate) Micro-Switch Fixing Screws Micro-Switch - (Rotation Sensor) Micro-Switch Operating Arm Operating Arm Pivot Switch Operating Point - 3mm or 1/8” From Tip of Stop Collar Clutch Position Switch ..........

  • Page 38: Main Print Shaft - Removal

    S E R V I C E Section 11 MAIN PRINT SHAFT 10.1..Main Print Shaft - Removal The main print shaft may be removed with the clutch assembly in place, but you should remove any numbering heads and loosen the grub screws in the collars.

  • Page 39: Main Print Shaft - Re-Assembly

    M A N U A L MAIN PRINT SHAFT Section 10 Note ..Always support the shaft and use a hub puller to remove the operator-side bearing from the shaft and take care not to lose the keys from the collars 10.2 ..

  • Page 40: Platen Removal

    S E R V I C E Section 11 PLATEN Platen Eccentric Fixing Bolts Adjuster Plate Platen Adjustment Lock Shaft (Spacers Behind) Cam Return Spring Retaining Bolt Clutch Side Shown - See Fig 11.31 for Operator Side Adjuster Plate Tension Spring Platen Mechanism .............Fig 11.11 11.1..

  • Page 41: Platen Re-Assembly

    M A N U A L PLATEN Section 11 The platen may now be withdrawn through the operator side-frame with the pulley and eccentric housings in place. WARNING: THE PLATEN SURFACE IS EASILY DAMAGED. TAKE EXTRA CARE DURING REMOVAL AND REPLACEMENT NOT TO DAMAGE THE SURFACE OF THE PLATEN.

  • Page 42: Platen Adjustment

    S E R V I C E Section 11 PLATEN 11.3..Platen - Adjustment Set the operator adjuster cam shaft to the position shown in Fig. 11.31, and tighten the lock. Set the numbering head mounting collars towards the sides of the machine and lay a piece of 80gsm/20lb paper over the platen on each side.
  • Page 43 M A N U A L PLATEN Section 11 Loosen the eccentric fixing bolts and use the bolts to rotate the eccentric behind the adjusting plate until the numbering head makes light contact with the paper. Note ..This adjustment can be difficult to do, but please persevere - it is important.

  • Page 44: Sensor - All Machines

    S E R V I C E Section 12 SENSOR 12.1..Sensor - All Machines Sensor maintenance is dealt with in the operators manual and only involves careful cleaning of both units and their lenses. The sensors are mounted so that they are exactly aligned without any adjustment so no provision is made to adjust them.

  • Page 45: Sensor Replacement

    M A N U A L SENSOR Section 12 12.2 ..Sensor Replacement If you need to replace the sensors the diagrams in this section will help you, as although all machines use the same arrangement, the wiring to the sensor assemblies follows different routes. You are advised to replace the sensors as an assembly with their mounting hardware to ensure correct alignment.

  • Page 46: Guard Position

    S E R V I C E Section 13 GUARDS 13.1..Guard Position Both the main guard and the exit guard are held in place by magnets which are adjustable, to allow the guards to close correctly. Lateral height adjustment is achieved by screwing the magnets in or out of their mounting blocks as required.

  • Page 47: Strippers

    M A N U A L GUARDS Section 13 13.2 ..Stripper The guard at the feed end supports the stripper plate which has been designed to minimize the risk of damaged stock wrapping around the input rollers. It is important that the stripper is correctly adjusted and this can be achieved by releasing its three fixing screws to obtain a clearance of 0.75mm or 0.030"...

  • Page 48: Compressor - Suction Machine

    S E R V I C E Section 14 COMPRESSOR In-line Filter Housing Control Box Compressor Power Lead Wing Nut Inlet Filter Valve Connector Housing and Lead Manifold Hoses Vacuum Hose Filter Elements End Panel Screws Compressor Transit Bolt Support Bridge Assembly Compressor Installation ..........Fig 14.11 14.1..

  • Page 49: Filters

    M A N U A L COMPRESSOR Section 14 14.2 ..Filters It is important that the filter cartridges are replaced when necessary as they can have a dramatic affect on performance. DO NOT TRY TO CLEAN THEM. Knocking dust out of them only gives a short term improvement - they re-clog very quickly.

  • Page 50: Suction Control Valve

    S E R V I C E Section 15 SUCTION CONTROL VALVE 15.1..Suction Control Valve The Suction Control Valve is mounted on the Compressor Filter Vacuum port by a short piece of reinforced hose which protects it to some extent from heat and vibration. Although generally reliable, these valves operate in a relatively harsh environment at speeds of up to 150 Hz.
  • Page 51 M A N U A L SUCTION CONTROL VALVE Section 15 Coil Fixing Nut Coil Mounting Tube Solenoid Coil Hose To Pressure Side of Compressor (adaptor) Hose To Vacuum Roller (via suction control valve) Valve Body Armature Compression Spring Sealing Washer Plunger Assembly Bottom Port Re-inforced Hose To Vacuum Side...
  • Page 52 S E R V I C E Section 16 CONTROL SYSTEM (FRN) Wiring Diagram - Friction Control.......Fig 16.11 R O T A R Y PAGE 50...

  • Page 53: Control System - Access

    M A N U A L CONTROL SYSTEM (FRN) Section 16 16.1 ..Control System - Access The control system circuit board (PCB) is mounted on the inside of the control panel which is under the feed bed and also houses the mains power inlet socket, isolator, system switch &...

  • Page 54: Troubleshooting - Machine Won't Run

    S E R V I C E Section 16 CONTROL SYSTEM (FRN) The following sections should be used in conjunction with the troubleshooting section in the operators guide. 16.2..Trouble Shooting - Machine Will Not Run System Switch does not latch Check that the guards and feed bed are correctly fitted and that both fuses are intact and firmly installed.

  • Page 55: Troubleshooting - Machine Won't Number

    M A N U A L CONTROL SYSTEM (FRN) Section 16 Check the coil resistance of the feed clutch, which should be between 206 ohms and 248 Ohms, and replace the clutch if this is incorrect Check the voltage to the feed clutch which should be 24VDC and replace PCB if this is incorrect.
  • Page 56 S E R V I C E Section 17 CONTROL SYSTEM - SUCTION Wiring Diagram - Loom ..........Fig 17.11 R O T A R Y PAGE 54...

  • Page 57: Control Box

    M A N U A L CONTROL SYSTEM - SUCTION Section 17 Cooling Fan Fuse - 1 amp Sensor Socket Control Panel Motor Fuse - 3.15 amp Control Fuse - 1 amp Control PCB Rear Panel Fixing Screws Bracket Fixing Screws Fan - 4 Way Mounting Bracket Motor - 4 Way...
  • Page 58 S E R V I C E Section 17 CONTROL SYSTEM - SUCTION BOTTOM Wiring Diagram - Suction Control.......Fig 17.13 R O T A R Y PAGE 56...

  • Page 59: Control System - Access

    M A N U A L CONTROL SYSTEM - SUCTION Section 17 17.2 ..Control System - Access Access to the control box is by removing the base access panel under the loading table. To remove the unit you will also need to remove the operator side cover (see section 1.2), and disconnect all the plugs from their sockets on the rear panel and from the side of the enclosure.

  • Page 60: Motor Speed Control Board

    S E R V I C E Section 17 ELECTRICAL - SUCTION 17.4..Motor Speed Control Board The motor speed control board (PCB 2)) is mounted on four supports and may be removed by depressing their tangs after disconnecting all the cables from the terminal block. To help with re-installation of the PCB the following table, together with the circuit diagram on the previous, page will help you to re-connect the cables correctly:-...

  • Page 61: Troubleshooting - Machine Won't Run

    M A N U A L ELECTRICAL - SUCTION Section 17 The following sections should be used in conjuction with the troubleshooting section in the operators guide. 17.5 ..Trouble Shooting - Machine Will Not Run ‘Mains Power on’ Does Not Illuminate. Check that mains power of the correct voltage is reaching the machine and rear isolator.
  • Page 62 S E R V I C E Section 17 ELECTRICAL - SUCTION If the PCB 'clicks' when a guard is opened or closed, replace the system switch. If there is no audible 'click' then replace the PCB. Motor will not run Check the motor fuse is intact and rated at 3.15 amps.

  • Page 63: Troubleshooting - Machine Won't Feed

    M A N U A L ELECTRICAL - SUCTION Section 17 voltage drop. 17.6 ..Trouble Shooting - Machine Will Not Feed Suction Valve Will Not Operate - Check the security of the 3 way plug at the rear of the Control Box, and the valve connector on the valve coil Check the wiring to the valve connector, the 3 way plug &...

  • Page 64: Troubleshooting - Machine Won't Number

    S E R V I C E Section 17 ELECTRICAL - SUCTION If all else fails, replace the control PCB. 17.7..Trouble Shooting - Machine Will Not Number Sheets feed but will not number:- Check that the numbering ‘on/off’ switch on the control panel is down to the ‘on’ position. Check that the sensor cables are properly installed and clamped into the correct positions in their 4-way plug and that there are no stray strands of wire which could short out...
  • Page 65 M A N U A L N U M B E R E R PAGE 63...
  • Page 67 Standard Business Systems SM_FRN6-SRN9x 10 Connector Road, Andover, MA 01810 Issue 3 August 2004 (978) 470-1920 (978) 470-2771...

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