1. Manuals
  2. Brands
  3. Formax Manuals
  4. Binding Machine
  5. Atlas C150
  6. Operating instructions manual

Formax Atlas C150 Operating Instructions Manual

Automatic air-feed programmable creaser
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Atlas C150
Automatic Air-Feed Programmable Creaser
OPERATOR MANUAL
4/2021

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Atlas C150 and is the answer not in the manual?

Questions and answers

Related Manuals for Formax Atlas C150

Summary of Contents for Formax Atlas C150

  • Page 1 Atlas C150 Automatic Air-Feed Programmable Creaser OPERATOR MANUAL 4/2021...
  • Page 2 WARNING This is a Class A product. In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures. The product (System) which is connected to this machine will be class A. NOTE The domestic environment is an environment where the use of broadcast radio and television receivers may be expected within a distance of 10 m of the apparatus concerned.
  • Page 3 Introduction This manual contains instructions on the operation and maintenance of this machine. To get the maximum versatility from this machine all operators should carefully read and follow the instructions in this manual. Keep this manual in a handy place near the machine. Please read the Safety Information before using this machine.
  • Page 4 Safety Information When using this machine, the following safety precautions should always be followed. Safety During Operation WARNING To avoid hazardous situations such as electric shock or danger while exposed • to moving, rotating or cutting devices, do not remove any covers, guards or screws other than those specified in this manual.
  • Page 5 CAUTION: • The machine and its peripherals must be installed and maintained by a customer service representative who has completed the training course on those models. • Always follow all warnings marked on, or supplied with, the equipment. • When you disconnect the power plug from the wall outlet, always pull the plug (not the cable).
  • Page 6 Page intentionally blank.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS What You Can Do with This Machine................. 9 Guide to Components ....................10 ....................10 Feeder Module ......................11 Creaser Module ....................... 12 User Interface ......................13 Tools and Accessories ....................14 Optional Parts ......................15 Basics ......................... 17 Paper .........................
  • Page 8 How to Get Support ....................63 Remarks........................65 Do’s and Don’ts ......................65 Where to Put Your Machine ..................66 Machine Environment ....................66 Power Connection ....................66 Access to Machine....................67 Maintaining Your Machine ..................68 Recommended Weekly Operator Maintenance ............68 Limitations of the A ..............

  • Page 9: What You Can Do With This Machine

    An option is available to upgrade the Atlas C150 with an additional static creaser to produce up and down creases in a single pass to rapidly create high quality products such as...

  • Page 10: Guide To Components

    _________________________________________________________________________ Guide to Components 1. Stacker 11. Paper table extension 2. Stacker paper guides 12. Power inlet and fuse 3. Crease skew adjustment 13. Storage shelf 4. Top cover 14. Magnetic paper guides 5. Registration area 15. Feeder skew adjustment 6.

  • Page 11: Feeder Module

    _________________________________________________________________________ Feeder Module 1. User interface (UI) 11. Separated paper (SP) sensor Q12 2. USB port for software updates 12. Feeder skew adjustment wheel 3. Front separation fan 13. Feeder skew adjustment locking knob 4. Paper separation pads 14. Registration (alignment) belts 5.

  • Page 12: Creaser Module

    _________________________________________________________________________ Creaser Module 1. Crease skew adjustment knob 2. Static creaser 3. Creaser exit sensor Q25 4. Crease depth adjustment lever 5. Rotary tool carrier 6. Paper path – can be replaced with another static creaser 7. Creaser input sensor Q20 8.

  • Page 13: User Interface

    _________________________________________________________________________ User Interface has a Graphical User Interface (GUI) which allows for setting up jobs and viewing / modifying machine settings and properties. Detailed descriptions of each menu and sub-menu are found in Section 2 of this Operator Manual. NOTE: Depending on modules and features installed, the screen may look different from what you see here.

  • Page 14: Tools And Accessories

    _________________________________________________________________________ Tools and Accessories The following tools and accessories are included with the Atlas C150. Component no Description 601-167 Digital thickness gauge 1-99-12 28T rotary perforation blade (7 TPI) 1-99-35 Rotary perforation / slitting anvil 201-111686 Screwdriver torx T20 201-111685...

  • Page 15: Optional Parts

    (with the cross-perforation kit) creasing and cross-perforation in a single pass. Rotary tools allow the Atlas C150 to perforate, slit or score work in the process direction. This machine is supplied with a rotary tool carrier and a single rotary perforation blade (28 teeth, 7 teeth per inch (TPI)).
  • Page 16 _________________________________________________________________________ Page intentionally blank.

  • Page 17: Basics

    _________________________________________________________________________ 1 Basics Paper Paper Guidelines Paper comes in many different makes, types and finishes. There are many ways to print on the paper and then protect that printed image. The grain direction, fiber structure, substrate thickness, porosity, coating type, bond strength of the coating, water content, relative humidity and many other things can affect how the paper will behave when you crease and fold it.

  • Page 18: Creasing

    _________________________________________________________________________ Creasing About the Crease A crease stops the paper and printed image of a document from cracking when it is folded. The crease is made when a sheet of paper is compressed between the two parts of a mechanism known as a blade set. The blade set uses an ANVIL and a BLADE to form the crease.

  • Page 19: Choose The Correct Blade Set

    _________________________________________________________________________ Choose the Correct Blade Set This machine is supplied with a single standard crease blade set. Several optional blade sets are available. Refer to the table below to see which type of blade set is most suitable for your job.

  • Page 20: Replacing Blade Sets

    _________________________________________________________________________ Replacing Blade Sets This machine is supplied with a single Standard crease blade set. The blade set can be rotated to produce up or down facing creases without flipping the stack of paper. NOTE: Optional blade sets to produce narrower creases or to cross perforate are available (see the “Choose the Correct Blade Set”...
  • Page 21 _________________________________________________________________________ 4. Lift the Bridge Assembly up and remove it. 5. Pull the blade set upwards to remove it. 6. Insert the new blade set. NOTE: A label on the blade set indicates paper movement direction. Ensure the blade set is installed in the correct direction.
  • Page 22 _________________________________________________________________________ 9. From the touchscreen interface choose Tools -> Change Crease Blades. 10. Use this menu to choose the blade set that has just been installed and set its direction (crease up or crease down). Click the green tick mark to confirm.

  • Page 23: Adjusting Crease Depth

    _________________________________________________________________________ Adjusting Crease Depth 1. Run a proof sheet and inspect the output. 2. If the crease is too shallow or too deep use the adjustment lever on the Blade bridge as shown (A – shallower crease, B – deeper crease).

  • Page 24: Setting Crease Tilt Knob

    _________________________________________________________________________ Setting Crease Tilt Knob 1. Run a proof sheet with a single crease and inspect the output. 2. If the crease is skew, adjustment is necessary. NOTE: Wrong crease positions are marked in red, correct crease position is marked in green. Crease Feed direction 3.
  • Page 25 _________________________________________________________________________ 4. Move the knob slightly, either to the left or to the right depending on the direction of the crease skew. 5. Rotate the knob clockwise to secure it. 6. Run another proof sheet to check if the crease is now perpendicular to sheet edge. Repeat steps 2 to 5 if necessary.

  • Page 26: Perforation

    _________________________________________________________________________ Perforation About Perforation A perforation is a series of cuts in the paper that allows it to be easily and neatly separated into two or more pieces. Perforation can be used to create coupons, tickets, return slips and other products. can perforate sheets in two perpendicular directions: In the process direction using rotary tools •...

  • Page 27: Rotary Perforation

    _________________________________________________________________________ Rotary Perforation The rotary perforation process uses circular blades mounted on the rotary tool carrier to perforate sheets in the process direction. NOTE: 1. Perforation and creasing can be carried out simultaneously. However, if any skew adjustment is made to the feeder in order to compensate for the perforation line being “out of square”, this may affect the accuracy of the crease.
  • Page 28 _________________________________________________________________________ A – top shaft D – bottom shaft B – drive wheel E – drive hub C – perforation blade F - anvil NOTE: Up to 5 rotary blades can be mounted on the rotary tool carrier. 3. Using a 2 mm hex key loosen one of the drive wheels [B] and slide it away from any obstructing drive wheels or hubs in order to mount the blade.
  • Page 29 _________________________________________________________________________ 6. Mount a matching pair of anvils [F] and secure them to the drive wheel using a 2.5 mm hex key 7. Position the perforation blade [C] using the ruler on the rotary tool carrier. Secure the drive wheel in place using a 2 mm hex key. 8.
  • Page 30 _________________________________________________________________________ 13. Loosen locking knob G by rotating it counterclockwise. 14. Use the adjustment wheel H to set paper registration wall angle. If the sheet skews inboard away from the operator (L1 > L2) turn the wheel down. If the sheet skews outboard towards the operator (L1 <...

  • Page 31: Cross-Perforation

    _________________________________________________________________________ Cross-perforation This machine can perforate across the full width of sheets with the optional cross perforation kit. patent pending “radius rock-perf motion” together with precision perforation software requires less force compared to a straight downward stroke. The rocking motion will give a superior and more even result over the full width of the sheet.
  • Page 32 _________________________________________________________________________ Page intentionally blank.

  • Page 33: Setting Up A Job

    _________________________________________________________________________ 2 Setting Up a Job Getting Started Turning the Machine On and Off 1. Ensure the main power cord is plugged in the machine [A] and the wall socket. 2. Ensure the CAN termination plug [B] is plugged in. 3.

  • Page 34: Paper Stack Preparation

    _________________________________________________________________________ Paper Stack Preparation Before loading paper in this machine, it is recommended to fan the sheets as shown. 1. Hold the paper stack on a flat surface. 2. Bend the paper stack. 3. Use your fingers and thumbs to pinch the paper stack.
  • Page 35 _________________________________________________________________________ 5. Flex the paper back and forth a couple of times to break surface tension and pre-separate the sheets. 6. Realign the sheets into a stack before putting them in the machine. NOTE: If the sheets you are using are too stiff or too large format to carry out the above procedure, fan the front edge of the sheets when loading them in the machine.

  • Page 36: Loading Paper

    _________________________________________________________________________ Loading Paper 1. Take a stack of printed paper and place it on the feeder table in the desired orientation. NOTE: If using sheets longer than 450 mm (17.7”), but shorter than 700 mm (27.6”) extend the built- in pull-out table. If using sheets longer than 700 mm (27.6”) see the “Feeder Table Extension” section within this manual.

  • Page 37: Feeder Table Extension

    _________________________________________________________________________ Feeder Table Extension Install table extension if using sheets longer than 700 mm (27.6”): 1. Ensure the built-in pull-out table [A] is fully stowed. 2. Hook the table extension [B] into the lift [C] as shown. NOTE: The feeder table extension has a built-in pull out part that can be used to feed sheets up to 1300 mm (51”).

  • Page 38: The Home Screen

    _________________________________________________________________________ The Home Screen Overview Element Description Home button Returns to this screen Media button Set paper size and thickness for this job Jobs button Save / load job Tools button Access additional machine settings Counter button Set batch counter behavior Crease switch Switch creasing on or off Pattern button...

  • Page 39: Paper Size

    _________________________________________________________________________ Paper Size To set paper size and type: 1. Choose Media from the top menu in the Home screen NOTE: Changing paper size thickness will reset any fine adjustments that may have been entered other screens. 2. Select one of the pre- defined paper sizes.
  • Page 40 _________________________________________________________________________ 3. Set paper thickness and paper weight NOTE: Measure paper thickness using the included vernier caliper. 4. Advanced: Enter paper surface finish and curl if necessary. 5. Confirm the settings by clicking the green tick mark.

  • Page 41: Pre-Set Patterns

    _________________________________________________________________________ Pre-set Patterns To set up one of the pre-defined creasing patterns: 1. Click the Pattern button on the Home screen NOTE: Choosing a new pre-set pattern will reset any fine adjustments that may have been entered other screens. 2. Select one of the pre- defined creasing patterns.
  • Page 42 _________________________________________________________________________ 3. Click the Proof button to single sheet. Inspect the output: If the job is as desired • click the green tick mark to confirm the job and return to the Home screen. If the job requires • adjustment click the Adjust pattern button 3.1.

  • Page 43: Custom Job

    _________________________________________________________________________ Custom Job To fully customize the number and position of creases on the sheet set up a custom job: 1. Click the Pattern button on the Home screen NOTE: Choosing a new pattern will reset any fine adjustments that may have been entered on other screens.

  • Page 44: Saving And Loading Jobs

    _________________________________________________________________________ Saving and Loading Jobs To store a customized job or to load a previously saved job: 1. Choose Jobs from the top menu Home screen NOTE: The current job name is displayed in the box on the right. Asterisk (*) following the job name indicates that there are unsaved changes to this job.

  • Page 45: Counters

    _________________________________________________________________________ Counters Once the machine cycle is started by default this machine will continue processing sheets until there is no more paper on the table. Alternatively, the machine can be configured to run in batch mode: • Stop mode – the machine will stop after the specified number of sheets has been processed.

  • Page 46: The Tools Screen

    _________________________________________________________________________ The Tools Screen Overview The Tools screen allows the operator to adjust advanced machine settings. To access the Tools screen: 1. Choose Tools from the top menu on the Home screen 2. Select desired function. Element Description Feeder settings Allows the adjustment of feeder fan, lift and sensor settings in case the automatic settings do not provide satisfactory feeding performance.

  • Page 47: Feeder Settings

    _________________________________________________________________________ Feeder Settings Element Description AUTO settings Toggles automatic feeder mode. In AUTO mode feeder settings are calculated automatically depending on paper size and weight. In most cases AUTO settings will provide optimum feeding performance. Switching AUTO settings off allows the operator to make adjustments to fans.

  • Page 48: Clear Jams

    _________________________________________________________________________ Clear Jams Use this screen to jog rollers and tools to help with removing paper jams in the machine. Element Description Open creaser 2 Opens the crease tool in case it has remained closed after a paper jam. Open creaser 1 Opens the crease tool in case it has remained closed after a paper jam.

  • Page 49: Change Crease Blades

    _________________________________________________________________________ Change Crease Blades When replacing creasing blades choose the currently installed creasing blades on this screen. Element Description Blade buttons Choose the type of blade currently installed in each creaser: [Standard], [Narrow], [Extra Narrow] or [Perforation]. Based on this setting machine parameters will be adjusted to suit the blade.

  • Page 50: Checking The Installed Software

    _________________________________________________________________________ Checking the Installed Software 1. To check currently installed machine software version, go to Tools -> Software version...

  • Page 51: Troubleshooting

    _________________________________________________________________________ 3 Troubleshooting Misfeeds / Jams General If a misfeed or a jam condition should occur, it is indicated on the machine display. A message with the jam description, error code and approximate jam location is displayed. Misfeed / Jam in the Feeder 1.

  • Page 52: Fault Codes

    _________________________________________________________________________ Fault Codes General When there is a misfeed or a fault condition in this machine, a message and a fault code will be displayed on the screen. Some fault codes may be rectified by the operator, while others may only be rectified by a certified service technician. NOTE: Clicking on the fault code will open a short description of the issue.

  • Page 53: List Of Fault Codes

    _________________________________________________________________________ List of Fault Codes FE-101 – Misfeed This code is displayed if the ultrasonic double sheet detector (US DSD) Q10 was not activated in time after the start of the feed cycle. This means that the sheet has failed to exit the feeder table area.
  • Page 54 _________________________________________________________________________ FE-103 – Sheet too long When a sheet exits the feeder the ultrasonic double sheet detector (US DSD) Q10 measures its length to ensure the sheet matches machine settings. Error code FE-103 is displayed if the sensor Q10 is covered longer than expected. This can be either because the sheet is too long or because there is insufficient grip on the registration belts and the sheet cannot be fed forward.
  • Page 55 _________________________________________________________________________ FE-108 – Paper table overloaded In order to stop paper table movement in case it is overloaded paper stack height sensor Q4 measures the amount of paper on the table when feed cycle starts. If the media used is longer than 700 mm (27.6”) the permitted paper stack height is limited to 100 mm (3.9”).
  • Page 56 _________________________________________________________________________ CR-201 – Sheet late from feeder output sensor Q10 to creaser input sensor Q20 If the sheet takes more time than expected to cover the distance between feeder output sensor Q10 and creaser input sensor Q20, the machine displays error code CR-201. This means that the sheet has exited the feeder table area but has not entered the creaser in time.
  • Page 57 _________________________________________________________________________ CR-205 – Creaser 1 home sensor Q21 not activated To produce creases at the specified positions accurately the creaser mechanism needs to initialize by moving to its home position. Creaser 1 position is measured by home sensor Q21. If the creaser mechanism cannot reach its home position or if the sensor cannot detect it, the machine will display error code CR-205.
  • Page 58 _________________________________________________________________________ • Fan the paper stack to ensure sheets are not stuck together and there is no excessive buildup of static electricity. CR-208 – Creaser output sensor Q25 blocked Creaser output sensor Q25 monitors the sheet as it exits the machine. If the sensor is not uncovered in time, error CR-208 will be displayed.

  • Page 59: Accuracy Checks

    _________________________________________________________________________ Accuracy Checks Module Alignment Check This machine consists of a feeder module and a creaser module. The alignment between these modules is set at the factory. To check that the modules have not become misaligned during shipping and handling carry out the following procedure: 1.
  • Page 60 _________________________________________________________________________ 7. If the crease is skew, adjustment is necessary. NOTE: Wrong crease positions are marked in red, correct crease position is marked in green. Crease Feed direction 8. To adjust crease skew, loosen the crease adjustment knob by rotating it counterclockwise.

  • Page 61: Separation Pad Check

    _________________________________________________________________________ Separation Pad Check Rubber separation pads are used in the feeder to prevent several sheets from exiting the feeder table area at the same time. Separation pad position is set at the factory. If frequent misfeeds or double sheets occur the separation pad position may need to be adjusted by the following procedure: 1.

  • Page 62: Creaser Calibration Check

    _________________________________________________________________________ Creaser Calibration Check The creasing position is accurately calibrated at the factory. To check that the machine has not lost its calibration during shipping and handling carry out the following procedure: 1. Run a proof sheet with a half fold pattern. 2.

  • Page 63: How To Get Support

    CAUTION: Never attempt any maintenance that is not specifically described in this documentation. Please contact your Formax Dealer for authorized servicing. If you encounter problems running this machine and you cannot solve them by following the advice given in the Troubleshooting section of this manual, please contact your authorized Formax Dealer for further support.
  • Page 64 _________________________________________________________________________ Page intentionally blank.

  • Page 65: Remarks

    _________________________________________________________________________ 4 Remarks Do’s and Don’ts Always follow all warnings marked on, or supplied with, the equipment. • Always exercise care in moving or relocating the equipment. • CAUTION: Unplug the power cord from the wall outlet and the machine before you move or relocate the equipment.

  • Page 66: Where To Put Your Machine

    _________________________________________________________________________ Where to Put Your Machine Machine Environment • Always locate the equipment on a solid support surface with adequate strength for the weight of the machine. • Always keep magnets and all devices with strong magnetic fields away from the machine.

  • Page 67: Access To Machine

    Height Atlas C150 1690 mm / 730 mm / 1160 mm / 66.5 in 28.7 in 45.7 in Atlas C150 with feed 2540 mm / 730 mm / 1160 mm / table fully extended 100 in 28.7 in 45.7 in...

  • Page 68: Maintaining Your Machine

    Maintaining Your Machine CAUTION: Never attempt any maintenance that is not specifically described in this documentation. Please contact your Formax Dealer for authorized servicing. Recommended Weekly Operator Maintenance To maintain the accuracy and reliability of this machine it is recommended to carry out the following maintenance on a weekly basis: 1.
  • Page 69 _________________________________________________________________________...

  • Page 70: Limitations Of The A

    _________________________________________________________________________ Limitations of the Atlas C150 • The intended average monthly sheet volume for the Atlas C150 is 450k. Maximum hourly productivity of this machine is 8,500 sheets. This is measured using • 200 gsm A4 paper short edge feed with a single crease in the middle of the sheet using the first (optional) creaser.

  • Page 71: Specifications

    Height Weight Atlas C150 1690 mm 730 mm 1160 mm 250 kg (66.5”) (28.7”) (45.7”) (551 lbs) Atlas C150 with table extension 2540 mm 730 mm 1160 mm 250 kg (100”) (28.7”) (45.7”) (551 lbs) 1200 mm 800 mm 1305 mm...

  • Page 72: Output Quality

    _________________________________________________________________________ Output Quality Conditions: Paper size is assumed to be perfect • Sheets are assumed to be perfectly 90° • • Tolerances are referring to deviations within one job Letter Ledger ± 0.20 mm ± 0.20 mm Crease position variation ±...

Table of Contents