Formax Atlas C100 User manual

Atlas C100
Auto-Feed High-Speed Creaser
OPERATOR MANUAL
First Edition
9/2016

Page 2 CREASING
INDEX
THE STACKER ASSEMBLY
26
PERFORATING
28
29
THE BLADE ASSEMBLY
31
32
REPLACING CREASING BLADE SETS
33
34
TROUBLE SHOOTING 35
DISPATCH KIT 40
ACCESSORIES & OPTIONS 41
RECOMMENDED SPARES 42
FUSE POSITIONS AND RATINGS 44
PRODUCT RECYCLING & DISPOSAL 45
Setting the Stacker unit
Equipment, spares
Setting the machine
Setting the blade pressure
Setting the blade alignment
Installing new blade sets
Spares
INTRODUCTION
7
QUICK START GUIDE 9
OPERATING
22
23
25
PAGE 3The Atlas C100
The switch panel
Setting the machine
Programming the machine
Reading stored programmes
Paper jamming
SAFETY Do’s & Don’ts 4
6
THE CONTROLS
8
Labeled Photograph
Features on the switch panel
18

Page 3
SYSTEM
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.
The operating environment should be controlled to a temperature between
16° C and 27° C Maximum
IMPORTANT
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.

Page 4 CREASING
Safety Do’s & Don’ts
Safety Do’s & Don’ts
Do - read this operator manual fully before operating the machine.
Do - operate with the designated AC current only. Use an exclusive outlet, as
overloading may cause fire or an electric shock.
Do - install the power cord out of the way to avoid a tripping hazard.
Do - make sure that the mains inlet connector is always easily accessible.
Do not - install the machine in an unstable place such that it tilts or shakes.
Do not - unplug the plug or unplug the power cord from the outlet with a wet hand,
this can cause an electric shock.
Do not - unscrew and remove any covers from the machine, as it can cause an
electric shock or injury.
Do not - place receptacles containing liquids on any surface.
Do not - adjust any part of the machine whilst rollers are running
Do not - operate the machine with loose or trailing clothing or loose hair.
Do not - under any circumstances adjust the paper gate when the machine is
switched on.
REGLES DE SECURITE : « A FAIRE » ET « A NE PAS FAIRE »
Lire ce mode d'emploi avant d'utiliser la machine.
Respecter l'alimentation électrique indiquée. Brancher sur une prise séparée
car une surcharge peut entraîner un incendie ou un choc électrique.
Installer le cordon d'alimentation de manière à ne pas pouvoir
trébucher par dessus.
Ménager un accès libre à la prise de courant.
Ne pas installer la machine sur une surface non plane, afin d'éviter
qu'elle ne penche ou ne vibre.
Ne pas installer la machine sur une surface non plane, afin d'éviter
qu'elle ne penche ou ne vibre.
Ne démonter et enlever aucun carter de la machine, par crainte de décharge
électrique ou de blessure.
Ne pas placer de récipient contenant un liquide sur la machine.
N'effectuer aucun réglage pendant que les rouleaux fonctionnent.
Ne pas porter de vêtements flottants et rassembler les cheveux longs
lors de l'utilisation de la machine.
En aucune circonstance, régler le séparateur de papier lorsque la
machine est branchée.

Page 5
SYSTEM
Warning Labels
Do - be aware of any finger traps and rotating parts when operating
the machine.
Do - read this operator manual fully before operating the machine.
Do not - operate the machine with loose or trailing clothing.
Do not - operate the machine with loose hair.
Do - be aware of any finger traps and rotating parts when operating
the machine.
Do - be aware of sharp points and blades.
Do - be aware of rotating rollers.
Do - be aware of low current anti-static shock.
Attention au risque de se coincer les doigts, et aux pièces en
mouvement lors du fonctionnement de la machine.
Ne pas porter de vêtements flottants lors de l'utilisation de la machine
Rassembler les cheveux longs lors de l'utilisation de la machine.
Attention au risque de se coincer les doigts, et aux pièces en
mouvement lors du fonctionnement de la machine.
Attention aux éléments tranchants et aux couteaux.
Attention aux rouleaux en fonctionnement
Attention aux faibles chocs d'électricité statique
Lire ce mode d’emploi avant d’utiliser la machine.

Page 6 CREASING
DOCUMENT CREASING MACHINE
Key to photograph below
13
14
9
10
11
12 4
1
2
3
5
6
7
8
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

Page 7
SYSTEM
THE CONTROLS
THE SWITCH PANEL
System Switch
Compressor Switch
Emergency Stop Switch
13
14
9
10
11
12 4
1
2
3
5
6
7
8
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.

Page 8 CREASING
THE CONTROLS
Features on the Switch Panel
System switch
Compressor switch
When activated the system switch will operate the motors in order to begin the
creasing sequence.
Allows the operator to switch off the compressor unit in order to utilise the machine
to manually feed sheets.

Page 9
SYSTEM
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.

Page 10 CREASING
Quick Start Guide
The touch screen is laid out into 3 main areas as shown below:
Settings Pages.
Paper Settings Page.
Status of
machine &
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
Setting
page
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
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.
Arrows may be
selected to increase
or decrease the page
size in 0.1mm
increments

Page 11
SYSTEM
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.
Press to remove all
creases – you will be
asked to confirm
deletion.
Scroll bar - use to bring
required crease into
view.
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.
Crease position - On selection
the status area is replaced with
a calculator for inputting new
values.
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.
Arrows may be selected
to increase or decrease
the page size in 0.1mm
increments
Additional creases
added – scroll bar
appears for more than
six creases.
Crease on/off selector
green is on & red is off.
This is also indicated in
the status area.
Number of creases – if
more than 6 creases are
added a scroll bar will
appear for to enable
viewing of all creases

Page 12 CREASING
Quick Start Guide
Creasing turned off -
Greyed out areas are
unselectable. Status
area will show
creasing is off with
red icon
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 13
SYSTEM
Click to start machine with
settings currently shown -
you will receive a
notification if system
switch is not on. Press
again to stop Job
Click to stop machine
Run Job
System Switch Not On
Push System Switch down to start the machine.
The machine running screen will appear.

Page 14 CREASING
Quick Start Guide
Status 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
click
confirm that you want to
Current Job count -
to zero
A screen will appear to
reset the count. Click to start machine with settings currently
shown - you will receive a notification if
system switch is not on. Press again to stop
Job
Paper length - input from
the paper setting screen
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.
page
Clicking in this area will take
you to the Crease setting
Clicking in this area will take
you to the Job Store page
you to the paper setting
page.
Clicking in this area will take

Page 15
SYSTEM
Quick Start Guide
The Status Screen will on occasions be replaced with an Input Calculator Screen
as shown below.
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.
Pre - set Paper sizes for quick
insertion – Standard sizes for
country origin would be shown
Pre - set Batch sizes for quick
insertion.

Page 16 CREASING
Quick Start Guide
Tools Screen
Clicking this icon will
show Machine
program revision &
Touch Screen
software revision.
Inch paper in direction
of arrow to clear jams
Click on Up Arrow to
put Anvil into Top
Dead Centre position
(TDC)
Inch paper in direction
of arrow to clear jams
Main Processor Program
version
Touch screen software
version
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
SYSTEM
BLANK
PAGE

Page 18 CREASING
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 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.
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.
Adjustable
Side Lay
Suction
Slot Knob
FIG 8.1
Operating

Page 19
SYSTEM
Setting the Adjustable Side Lay
Setting the Back Stop
Setting the Air Distribution
Setting the Air Separation Pressure
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.
Position the backstop and slide up towards the paper stack allowing a gap (as specified
in the above step).
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.
0 For sheets longer than A3 (17”) in order to supply air to the centre of the
stack, ports 2 and 3 open.
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,
ports 1 and 4 open.
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.
Position -
-
-
-
Port 1 Port 4
Knob Shown
Set To Posn. 1
Air Distribution

Page 20 CREASING
Setting the Roller Tilt Mechanism
Setting the positions of drive wheels and hubs
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.
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.
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.
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.
DO NOT ROTATE THE DRIVE ROLLERS BY HAND.
Left arrow Right arrow
Inch paper in direction
of arrow to clear jams
Inch paper in direction
of arrow to clear jams