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Formax Atlas C200 Operator's Manual

Auto-feed high-speed creaser
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Atlas C200
Auto-Feed High-Speed Creaser
9/2016
OPERATOR MANUAL
First Edition

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Summary of Contents for Formax Atlas C200

  • Page 1 Atlas C200 Auto-Feed High-Speed Creaser OPERATOR MANUAL First Edition 9/2016...

  • Page 3: Table Of Contents

    INDEX INTRODUCTION PAGE 3 SAFETY Do’s & Don’ts THE ATLAS C200 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 4: Introduction

    INTRODUCTION s a fully automatic suction feeding creasing system designed for use with both conventional litho and digital printers. The feed on th can also be manually operated for use with heavy stock, very small or very large sheets, embossed or even irregular sheets.

  • Page 5: 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 6 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 7 DOCUMENT CREASING MACHINE Key to photograph below Roller tilt handle Adjustable side lay Switch Panel Stacker assembly 8 Back Stop Fuses Suction slot knob 9 Fixed side lay Gap Set Knob and Lever Touchscreen 10 Roller tilt knob Vacuum Bleed Knob Air separation knob 11 Paper Gate Air distribution knob...

  • Page 8: The Controls

    THE CONTROLS THE SWITCH PANEL 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. Compressor Switch System Switch Emergency Stop Switch Features on the Switch Panel System switch When activated the system switch will operate the motors in order to begin the creasing sequence.
  • Page 9 THE CONTROLS BLANK PAGE Page 8 CREASING...

  • Page 10: 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 11 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 12 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 13 Quick Start Guide Creasing turned off - Greyed out areas are unselectable. Status area will show creasing is off with red icon Page 12 CREASING...
  • Page 14 Quick Start Guide 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.
  • Page 15 Quick Start Guide Cover Crease Mode. 1. Select the Paper Settings Tab. 2. Enter the Paper Length and then select the Cover Crease button. Cover Crease button Paper Length 3. Select the Crease Settings Tab. Spine Offset Spine Width Hinge Distance Arrow Button 4.
  • Page 16 Quick Start Guide 6. Enter the Hinge Dimension. Hinge Dimension 7. Select the arrow button to highlight the Spine Offset and the Spine Width dimensions. 8. Run the sheets of paper through the machine to make the Spine creases. TO MAKE THE HINGE CREASES. 9.
  • Page 17 Quick Start Guide Status Screen Currently selected Vacuum Suck setting - for stream Paper length - input from Clicking in this area will take you setting choose selection 2 the paper setting screen to the paper setting page Currently selected fold type - can be one of the Lead Edge Sensor Strength, following.
  • Page 18 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 19 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 spee Click on Up Arrow to put Anvil into Top Dead Centre position Inch paper in direction...
  • Page 20 Quick Start Guide Touch Screen Calibration. Switch the mains power on and wait for the main screen to appear before commencing to check the horizontal and vertical position of the display. The position of the display within the surround is achieved by operating the button at the rear of the housing, press this a number of times to obtain the correct orientation required, move to the next button to move the position to centralize horizontal.

  • Page 21: Setting The Machine

    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 22 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 23 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 24 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 25 etting the infeed roller gap set The gap between the infeed rollers must be adjusted to suit the stock being used. The gap set can be adjusted as follows:- 1. Place a sample sheet of the stock to be used onto the feed bed. 2.
  • Page 26 SYSTEM Page 25...

  • Page 27: 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 28 Keyboard for entering job name. Delete all characters Delete last character to save click save icon 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 29 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 30: 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 31: 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 32 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 33: Perforating

    Perforating Note 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.

  • Page 34: Setting The Machine

    Perforating All of the blades and anvils are supplied with fixings. *Perforator stripper 78-013 Standard Part Number *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 35 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 36: 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 37 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 Please note that to avoid damage to the tearing at any point along the crease line.
  • Page 38 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 39 The Blade Assembly 9. Slide the new blade set into the slots of the creasing unit as shown in fig. 21.1. FIG 21.1 NOTE. The blade set can be fitted with the ANVIL at the bottom or with the ANVIL at the top. The blade set is supplied from the factory with the ANVIL at the bottom as shown in FIG22A.
  • Page 40 ro 50 Replacing Blade Set 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 33 - 35 to adjust the creasing line.

  • Page 41: 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 42 Pro 50 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 29 for instructions.
  • Page 43 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 44 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 45 Trouble Shooting Error Screens (Continued) Clean Lead Edge Sensor - Warning Screens. 1. The Clean Lead Edge Sensor warning screen, shown below, will appear when the Run button is pressed and the strength of the Lead Edge Sensor Beam is at about 50% (i.e.
  • Page 46 Trouble Shooting Error Screens (Continued) Lead Edge Sensor Cleaning. Select the Tools menu on the Touchscreen Display, and then select the clean sensor icon The screen now shown is a visual indication of the strength of the Lead Edge Sensor beam. FLASHING (GREEN/BLACK) TO INDICATE THAT THE SOFTWARE IS INTERROGATING THE SENSOR...
  • Page 47 Trouble Shooting Error Screens (Continued) To clean the lead edge sensors open the exit guard to expose the blade set. Using the Sensor Cleaning Brush , supplied in the dispatch kit, insert the brush between the blade brushes and the top and bottom blades to reach the upper and lower lead edge sensors.
  • Page 48 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 49: Dispatch Kit

    7-95-29 DISPATCH KIT ITEM PART NUMBER DESCRIPTION OPERATORS MANUAL - 70-171 90-018 ROLLER CLEANING KIT 650-040 POWER CORD CE UK C19 3Pin 16A 2.5Mtrs. SCREW - SOCKET CAP HEAD - M3 x 6 LG 403-01-030-006 409-01-040-004 SCREW - SKT. SET FLAT PT. - M4 x 4 LG 620-007 HEXAGON BALL DRIVER 2mm 620-020...

  • Page 50: Accessories & Options

    r Pro 50 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 76-237-03 BLADE SET - NARROW 70-134 ANTI-STATIC KIT 172-04-01...

  • Page 51: Recommended Spares

    RECOMMENDED SPARES PART NUMBER DESCRIPTION 93-021 FEED BELT 607-017 TIMING BELT - 120XL 037 609-011 ‘O’ RING Ø20 94-028 LOCK PIN ASSEMBLY - Side Lay 613-365 EMERGENCY STOP SWITCH 652-011 SWITCH - LOW CURRENT COIL - BLACK ROCKER 75-500-06 MINI ITX MOTHERBOARD - 75-430-01 CONTROL PCB ASSEMBLY 174-06-01...
  • Page 52 RECOMMENDED SPARES PART NUMBER DESCRIPTION 75-040 STACKER SWITCH ASSEMBLY 602-056 BEARING-DRAWN CUP NEEDLE ROLLER-Ø15XØ21X12 602-085 BEARING-DRAWN CUP NEEDLE ROLLER Ø10XØ14X10 76-145-02 GAP CONTROL HUB - LAY SIDE 76-148-01 GAP SET LEVER ASSY - OP SIDE 76-148-02 GAP SET LEVER ASSY - LAY SIDE 76-149-01 LOCKING LINK - GAP CONTROL 76-150-01...

  • Page 53: Fuse Positions And Ratings

    FUSE POSITIONS & RATINGS (POSITION ET CLASSIFICATION DES FUSIBLES) ANTI-STATIC UNIT (IF FITTED) (FUSIBLE ANTI-STATIQUE TRANSFORMER ASSY. (si installé) T500mAH 250V (681-020) T315mAH 250V (681-011) PSUs (24V & 48V) (FUSIBLE PSUs (24 V & 48 V) MAINS IN T4.0AH 250V (681-015) F15AH 250V (652-047) Page 52 CREASING...

  • Page 54: Product Recycling And Disposal

    PRODUCT RECYCLING & DISPOSAL European Union Disposal Information for Commercial Users Application of this symbol on your equipment is confirmation that you must dispose of this equipment in compliance with agreed national Procedures. In accordance with European legislation end of life electrical and electronic equipment subject to disposal must be managed within agreed procedures.
  • Page 55 REVISION HISTORY Rev. Mod No. Mod Description Date Mod By Screen shot graphics changed to show the Lead Edge Sensor Indicator Bar, on all relative pages. New pages inserted to describe how to use the Cover Crease Mode for Perfect Bound Covers. (Pages 14 & 15). New ECO2809 02/01/13 pages inserted to show the Clean Lead Edge Sensor Warning Screens...

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