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Formax Atlas C100 Operator's Manual

Auto-feed high-speed creaser
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Atlas C100
Auto-Feed High-Speed Creaser
OPERATOR MANUAL
First Edition
9/2016

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Summary of Contents for Formax Atlas C100

  • Page 1 Atlas C100 Auto-Feed High-Speed Creaser OPERATOR MANUAL First Edition 9/2016...

  • Page 2: Table Of Contents

    INDEX INTRODUCTION The Atlas C100 PAGE 3 SAFETY Do’s & Don’ts Labeled Photograph THE CONTROLS The switch panel Features on the switch panel QUICK START GUIDE OPERATING Setting the machine Programming the machine Reading stored programmes Paper jamming THE STACKER ASSEMBLY...

  • Page 3: 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.

  • Page 4: Safety Do's & Don'ts

    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.
  • Page 5 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.

  • Page 6: Labeled Photograph

    DOCUMENT CREASING MACHINE Key to photograph below Roller tilt handle 6 Air seperation knob Paper Gate Stacker assembly 7 Adjustable side lay Exit Guard Suction slot knob 8 Back stop Switch Panel Touchscreen 9 Fixed side lay Fuses Air distribution knob 10 Roller tilt knob Page 6 CREASING...

  • Page 7: The Controls

    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 SYSTEM Page 7...

  • Page 8: Features On The Switch Panel

    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.

  • Page 9: Quick Start Guide

    Quick Start Guide Setting the machine to operate in automatic sheet feed mode Set the gap between the paper gate and the vacuum roller to approximately twice the thickness of the stock to be creased. Place the stock to be creased onto the loading table against the fixed side lay. 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.
  • Page 10 Quick Start Guide The touch screen is laid out into 3 main areas as shown below: Status of Setting machine & page data entry area. Also used for quick links to setting pages. Tabs to enable switching between setting pages - choose either Paper Settings, Crease Setting, Store or Tools Settings Pages.
  • Page 11 Quick Start Guide Crease settings Pages. To get to the crease setting page click the lower tab 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 ±...
  • Page 12 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. Creasing turned off - Greyed out areas are unselectable. Status area will show creasing is off with red icon Page 12 CREASING...
  • Page 13 Run Job Click to start machine with settings currently shown - you will receive a notification if system switch is not on. Press again to stop Job System Switch Not On Push System Switch down to start the machine. The machine running screen will appear. Click to stop machine SYSTEM Page 13...
  • Page 14 Quick Start Guide Status Screen Clicking in this area will take you Currently selected Vacuum Paper length - input from to the paper setting page Suck setting - for stream the paper setting screen setting choose selection 2 Number of creases - this may alter automatically if Currently selected fold type a pre - defined fold is...
  • Page 15 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 Pre - set Batch sizes for quick insertion – Standard sizes for insertion. country origin would be shown Paper size Batch size Crease position...
  • Page 16 Quick Start Guide Tools Screen 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.
  • Page 17 BLANK PAGE SYSTEM Page 17...

  • Page 18: Operating

    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.
  • Page 19 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.
  • Page 20 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.
  • Page 21 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.

  • Page 22: Programming The Machine

    Programming the machine Switch the power ‘on’ by turning the Emergency stop button clockwise to release the safety latch. Setting the page length Set the page length of the paper as described on page 10. Setting the vacuum suck Set the vacuum suck as described on page 10. Setting number 1 for short suck and setting number 2 for continuous suck (stream feed).
  • Page 23 Keyboard for entering job name. Return to Store Menu & click save icon to save job to store Save confirmation screen. 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.
  • Page 24 Toggle between search Jobs matching results &full list of characters in text box jobs will be shown in this area - selecting job from this area will show job settings in the right hand status area. Job selected will Press to load job be shown in text box.

  • Page 25: Paper Jamming

    Delete job confirmation screen. Tocancel 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 at the bottom of the touch screen, the display will change to that shown...

  • Page 26: The Stacker Assembly

    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 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.
  • Page 27 The Stacker Assembly 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. For shorter sheets, the back stop can be used (as shown in FIG 13.1) to adjust the position of the paper stack.

  • Page 28: Perforating

    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.

  • Page 29: Setting The Machine

    Perforating All of the blades and anvils are supplied with fixings. *Perforator stripper Standard Part Number 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. Setting the machine Turn the mains supply to the machine ‘off’.
  • Page 30 Perforating 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. Slide the drive hub towards the perforating drive wheel until there is a clearance of 0.5mm.

  • Page 31: The Blade Assembly

    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.

  • Page 32: Setting The Blade Alignment

    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.
  • Page 33 Replacing Blade Set Before removing the blade assembly, ensure that the lower blade / anvil is NOT at ‘top dead centre’, Switch the machine off. Remove the stacker unit and lift the exit guard. Blade Extractor Tools Using a 6mm allen key, loosen the socket head screws located inside the blade adjustment cams.

  • Page 34: Spares

    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.

  • Page 35: Trouble Shooting

    Trouble Shooting Paper crease out of square Check that the sheets are all square and exactly the same size before loading the stack on to the table. Check that the roller tilt mechanism is correctly set and locked in position. Check that the adjustable side lay has been correctly positioned ie.
  • Page 36 Trouble Shooting Check that the air distribution has been correctly set. Check that the air separation has been set high enough to feed the sheets. 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...
  • Page 37 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.
  • Page 38 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.
  • Page 39 Trouble Shooting Recommended weekly operator maintenance Clean all sensors Clean in feed rollers and output drive hubs using the cleaning kit provided (Cleaning kit part number 90-018) Remove and clean the blade assembly With the blade assembly removed, clean the slots and surrounding area within the creasing unit.

  • Page 40: Dispatch Kit

    7-95-24 DISPATCH KIT ITEM PART NUMBER DESCRIPTION 70-148 OPERATORS MANUAL 90-018 ROLLER CLEANING KIT 650-040 POWER CORD CE UK C19 3Pin 16A 2.5Mtrs. 617-003 STEEL BALL - Ø20 78-007 MAGNETIC BACK STOP ASSY. SCREW - SOCKET CAP HEAD - M3 x 6 LG 403-01-030-006 409-01-040-004 SCREW - SKT.

  • Page 41: Accessories & Options

    ACCESSORIES AND OPTIONS ITEM PART NUMBER DESCRIPTION 1-99-10 PERFORATING BLADE SET 20T (Card) 1-99-12 PERFORATING BLADE SET 28T (Single sheets) 1-99-41 PERFORATING BLADE SET 56T (Fine perforations) 1-99-35 ANVIL SET USED WITH ABOVE BLADE SETS 76-213-03 BLADE SET - EXTRA NARROW 70-082-02 ANTI-STATIC KIT 94-073-02...

  • Page 42: Recommended Spares

    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 SWITCH - 240 VOLT COIL - 20A - BLACK ROCKER 75-472-01 MINI ITX MOTHERBOARD (CONFIGURED) 75-455-01...
  • Page 43 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.

  • Page 44: Fuse Positions And Ratings

    FUSE POSITIONS & RATINGS (POSITION ET CLASSIFICATION DES FUSIBLES) ANTI-STATIC UNIT (IF FITTED) PSU (5V / 24V) (FUSIBLE ANTI-STATIQUE (FUSIBLE PSU (5V/24 V) (si installé) F3.15AH 250 (613-023) T315mAH 250 (681-011) PSUs (24V & 48V) SPARE FUSE (FUSIBLE PSUs (24 V & 48 V) POSITION T4.0AH 250 (681-015) (POSITION PORTE...

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