6635 Kitimat Rd, unit 34; Mississauga, Ontario; Canada

L5N 6J2; Tel: (905) 858-7663

Fax: (905) 858-4419 Toll Free 1-800-265-3376

CREASEMASTER PLUS

Reference Manual

GRAPHIC WHIZARD

6635 Kitimat Rd, Unit 34 Mississauga, Ontario L5N 6J2 Phone # (905) 858-7663 Fax # (905) 858-4419 Toll Free: 1-800-265-3376 Web Site: www.graphicwhizard.com Version 03-01

CM+ - Reference Manual Table of Contents

Machine Assembly 2.1 Power Supply Instructions 2.2 Initial Operation 2.3 Nozzle Positioning 2.4 Vacuum/Blower Adjustments 2.5 Paper Gate Adjustments 2.6 Optional Conveyor Outfeed Plate 2.7 Additional Switches and Controls

Operating Keyboard 3.1 Running a Job 3.2 Stopping a Job 3.3 Changing Programs 3.4 Programming a Job 3.5 The Batch Function 3.6 The Repeat Function 3.7 Motor Speed Control

Setting Up a Job 4.1 Aligning the Air Feed Side Rails 4.2 Setting Idler Tire Pressure 4.3 Perforating/Slitting 4.4 Main Rollers 4.9 Setting Impression Control

Maintenance 6.1 Machine Cleaning 6.2 Lubrication

Registration Holes for aligning Op side Side Rail

CM+ Layout

1.0 General Operation

The CreaseMaster + is an impact die score machine that effectively eliminates substrate cracking experienced with rotary scoring. The CM+ is microprocessor controlled, making it easy to set up and program. It has the programmability to hold a maximum of 99 jobs with 10 hits and 1 job with 100 hits. Inverted and regular scoring can be accomplished in one pass. These jobs can all be stored and recalled for future use. Perforations are done between the air feed table and main rollers, producing a straight perforation, avoiding tail whip. Perforating wheels are offered in a wide range of teeth configurations and can be quickly changed using the retaining ring pliers supplied. A photocell recognises the lead edge of the sheet and the microprocessor stops the sheet at the specific location(s) where scores are required. Pneumatics allows for non-stop, tireless operation. Finished stock is then delivered to an exit tray.

2.0 Machine Assembly

Remove and unpack all machine parts from the shipping carton.

2.1 Power Supply Instructions

Before connecting the power cord to a wall receptacle, make certain the supply voltage is what the machine has been set up for. The voltage is marked on the sticker containing the serial number of the machine. If there is any discrepancies, please call your dealer first before plugging in the machine. The switch module is located behind the main operator side panel, directly underneath the infeed. It also houses the main fuse.

CHANGING THE FUSE IN THE SWITCH MODULE

SCREWDRIVER

FUSES

FUSE HOLDER

ON/OFF

SWITCH

CORD RECEPTACLE

INSERT TWO SLOW BLOW

FUSES RATED 250V 5A FOR A SUPPLY VOLTAGE OF 120V. THESE FUSES ARE 1/4 INCH WIDE BY 1 1/4 INCHES LONG.

LIP

INSERT SCREWDRIVER

INTO LIP OF THE FUSE FRAME.

OPEN THE FUSE FRAME

DOOR AND PULLOUT THE RED FUSE HOLDER.

INSERT THE FUSE HOLDER

BACK INTO THE UNIT FRAME WITH THE 115V SHOWING THROUGH THE WINDOW.

With the CM+, the score dies are pneumatically driven. The air pressure is regulated from the air source (whether shop air or a stand-alone compressor) on the machine at the regulator/gauge/manifold assembly. The optimum pressure setting at the regulator is 100-120 psi. If scoring a job with many scores, you may need to increase the Impression Control to maintain a consistent impression.

• Ensure that the feed adjuster is all the way up and in the proper position. Refer to diagram below

Infeed Assembly

Mark a sheet in the center of leading edge Position the center of the sheet at the center of the vacuum feed belt Move the operator-side guide up to the edge of the paper Remove the sheet and, using the register holes in the feed table, align the operator-side guide (inside edge) to the nearest holes for square and secure it on both ends

• Slide a single sheet up to the front of the side guide

Bring the non- operator side guide snug up to the single sheet and secure the front of the guide

• Place a 1-inch lift of paper in the rear of the feeder and snug the nonoperator side guide to the lift and secure on rear end. Double check that the single sheet slides back and forth easily, but not side to side
• Remove the single and slide the lift up to the feed adjuster
• Position the back stop at the rear of, and under the lift of paper
• The nozzles should be positioned according to the following diagram
• Note: Very wide stock will require the nozzles to be closer to the Paper Gate than the siderails.
• Switch the pump on by turning on the switch located on the STAND (below feed table on top of stand)
• Turn the vacuum all the way down ( CCW )
• While turning the hand wheel, slowly increase the vacuum till a sheet(s) moves out from under the stack approximately ½”
• If more than one sheet has started to move, adjust front nozzles till the extra sheets float back into the stack.
• The feeder should now be ready to run

• With light to medium stock, the Paper Gate should not be adjusted down, as the front nozzles will hold the stack in position. Heavier and/or wider stock may require the feed adjuster to be lowered to the point that it will hold back the second sheet but allow the first sheet to pass

Optional Conveyor Outfeed Plate

The conveyor outfeed plate sits in the machine in the same fashion as the exit tray. Make sure that the spur gears mesh and do not force the conveyor outfeed plate into position. The pile tray is mounted on the end of the conveyor outfeed plate, with two Phillips screws and acts as a backstop for the finished stock.

Additional Switches and Controls

The main on/off switch is located under the air feed beside the main fuseholder and power cord. The Pump switch is located on the top of the stand under the air feed table. On the left-hand side of the operating keyboard, there are two potentiometer knobs that control the crash strength of the score dies, known as Impression Controls and can be adjusted to best suit the requirements of the job. For example, you may require stronger impressions for card stock than for 80lbs(399g/m^2) stock. This adjustment can be done while the machine is stopped or running.

3.0

Operating Keyboard

PERF SHIELD (RED)

PHOTOCELL (GRN)

FLASHES IF RAM ERROR

FLASHES IF LCD ERROR

IMPRESSION 1

SETUP

GRAPHIC

WHIZARD

NO FUNCTION

IMPRESSION 2 C

START

BAT

ANADA

REP

STOP

ESC

ACC

The operating keyboard is comprised of a two line LCD display, various buttons and two Impression Controls which consist of two potentiometer knobs that control the crash strength of the score dies, and can be adjusted to best suit the requirements of the job. The four buttons under the LCD display will perform whatever function is shown directly above them on the bottom line of the LCD display. They may not always be active (this is the case for the other buttons as well). Three specific function buttons (SET UP, BAT, REP) are situated beside the display. A numeric keypad, an ‘ESC’ (escape), ‘ACC’ (accept), ‘START’ and ‘STOP’ button rounds out the rest of the keyboard. The 'ESC' button can be used at almost any time (except during actual running) in order to return to the previously viewed menu. The functions of the rest of the buttons will be discussed later in this section. Once you have plugged the machine in, turn the on/off switch to the 'on' position. The microprocessor does an internal system check and the above will flash on the screen.

Running a Job

The Idle Mode is displayed below. From this menu, you can change the motor speed, modify your paper count and select your program. In this menu you can also enter the Batch size (see 3.5)

DISPLAY:

PERF SHIELD (RED)

PHOTOCELL (GRN)

ON = PERF SHIELD OPEN

ON = NO PAPER

IMPRESSION 1

SETUP

IMPRESSION 2

START

BAT

REP

STOP

ESC

ACC

DISPLAY FUNCTIONS:

DISPLAY

ssssss = motor speed bar graph

PGMxxx = solenoid program in RAM

cccccc = paper count

↓ = decrement motor speed

↑ = increment motor speed

• 1 = decrement paper count

aaa = CLR -> clear paper count normally; aaa = BAT -> Enter Mode - Set Batch Size when batch mode is enabled

The <<</>>> will adjust the motor speed, F1 will decrement the paper count, F2 will clear the paper count but if it is already at 0 it will send you to the Batch mode (Section 3.5). SETUP will select a program (Section 3.3) and START will begin the job. You will now be in the Run Mode. When the machine is first turned on, it defaults to Program 01 (PGM001), which is shown on the menu. Pressing the 'START' button will automatically begin Program 01. The main operating menu will change as the machine is running.

The Run Mode menu looks like this:

DISPLAY:

PERF SHIELD (RED)

PHOTOCELL (GRN)

ON = PERF SHIELD OPEN

(WILL EXIT TO Mode - Idle)

ON = NO PAPER

IMPRESSION 1

SETUP

SOL CH1 ADJUST

PULSE WIDTH

PGMxxx

cccccc

START

BAT

IMPRESSION 2

HALT

REP

SOL CH2 ADJUST

PULSE WIDTH

STOP

ESC

ACC

DISPLAY FUNCTIONS:

DISPLAY

ssssss = motor speed bar graph

PGMxxx = solenoid program in RAM

cccccc = paper count

↓ = decrement motor speed

↑ = increment motor speed

HALT = motor emergency stop, exit to Mode - Idle

aaa = CLR -> clear paper count normally; aaa = BAT -> Display current batch size when batch mode is enabled

KEYPAD FUNCTIONS:

DECREMENT MOTOR SPEED

INCREMENT MOTOR SPEED

MOTOR EMERGENCY

STOP

Exit to Mode - Idle

IF BATCH SIZE IS ZERO

CLEAR PAPER COUNT

STOP

ELSE:

Exit to Mode - Idle

DISPLAY BATCH SIZE

ACC

ESC

MOTOR EMERGENCY STOP

MOTOR EMERGENCY STOP

Exit to Mode - Idle

Exit to Mode - Idle

SETUP

MOTOR EMERGENCY

STOP

Exit to Mode - Idle

BAT

IF BATCH SIZE IS ZERO

MOTOR EMERGENCY STOP

Exit to Mode - Idle

ELSE:

DISPLAY BATCH SIZE

DIG 0-9

MOTOR EMERGENCY STOP

Exit to Mode - Idle

REP

MOTOR EMERGENCY

STOP

Exit to Mode - Idle

START

Here are methods of stopping the machine.

1. Once the program is running, there are several built in safety emergency stops. Pressing the STOP button, any of the digits 0-9, F1, STOP, ACC, ESC, REP, and if the Batch size is 0, BAT will cause the machine to finish the stock it is currently working on, move the next stock into the starting position and then stop the motor. This automatically sends you into Idle Mode.

2. If you want to stop the machine while stock is still left in it, simply turn off the Pump. After about one second, the machine will automatically stop (since it is no longer seeing any new sheets). This is how it also stops when all of the stock in the feed table is gone.

The CM+ allows you several choices in programming:

PROGRAM 00

= Perf, automatically turns the score dies off. PROGRAM 01 – 99 = Allows for a maximum of 10 hits per die. PROGRAM 100 = Allows for a maximum of 100 hits per die.

Whenever you wish to change programs, the LCD display must be in Idle Mode (Section 3.1) press the 'SET UP' button. The following screen will appear:

DISPLAY:

PERF SHIELD (RED)

PHOTOCELL (GRN)

ON = PERF SHIELD OPEN

ON = NO PAPER

IMPRESSION 1

SETUP

NO FUNCTION

SELECT

PROGRAM

START

BAT

IMPRESSION 2

EDIT

REP

NO FUNCTION

STOP

ESC

ACC

Once you select the program number desired, you may either 'RUN' the existing program or 'EDIT' it by pressing the corresponding function key (F1 to RUN & F2 to EDIT). If RUN is selected, the machine will exit to Idle Mode where you press START. The ESC key will also return to Idle Mode in case you wish to change the counter before beginning a job. 3.4 Programming a Job

If you wish to program a job, EDIT an existing program, press F2. After selecting EDIT, if the program already exists, the machine will ask whether you would like to erase it, start new ('NEW') or modify it ('MOD').

DISPLAY:

PERF SHIELD (RED)

PHOTOCELL (GRN)

ON = PERF SHIELD OPEN

ON = NO PAPER

IMPRESSION 1

SETUP

NO FUNCTION

PROGRAM : X X X

EXISTS

START

BAT

IMPRESSION 2 M

EXIT

BACK

REP

NO FUNCTION

STOP

ESC

ACC

This selection is done with the corresponding function key (<<< and >>> respectively). When modifying a program, previously programmed scores can be removed from the program while additional scores may be added. Once you make your selection, the machine will instruct you to 'INSERT PAPER/ PRESS START'. The LCD display will then show the following:

DISPLAY:

PERF SHIELD (RED)

PHOTOCELL (GRN)

ON = PERF SHIELD OPEN

ON = NO PAPER

IMPRESSION 1

SETUP

NO FUNCTION

START

BAT

IMPRESSION 2

REP

NO FUNCTION

STOP

ESC

ACC

DISPLAY FUNCTIONS:

DISPLAY

xxx = solenoid program number

ccccc = current paper position in motor steps from paper lead edge

<<< = motor moves in forward direction

>>> = motor moves in backward direction

= full block character displayed when hit programmed

C1 = solenoid channel 1 head 1

3 = solenoid channel 1 head 2 = SOL3

C2 = solenoid channel 2 head 1

4 = solenoid channel 2 head 2 = SOL4

The sheet you inserted is automatically moved to position '5' under the laser. Position '0' is the lead edge of the sheet passing the photocell/laser. Position '5' is the first location that a score will imprint on the paper. (Note: Each step represents approximately 1 / 50 th of an inch).

The first two function keys step the paper either forward or backward (Note: you cannot back the sheet back further than position '5'). The other two function keys fire either die #1(C1=male on top) or die #2(C2=male on bottom). Once a die fire button has been pressed, the score die will fire when the stock has advanced under the chosen die and the LCD display will light up with one solid bar around the corresponding die fired (eg.„C1).

Once all scores desired have been programmed, step the sheet through until all scores have occurred, press the 'ACC' button and the sheet will be discharged from the machine. The next sheet will be forwarded to step '5' (if there is another sheet already in the feed tray) or you will be instructed to 'INSERT PAPER/PRESS START'. The LCD display will return to Idle Mode and you are set to run the job. Simply press the 'START' button to begin.

Pressing the 'BAT' key before running a program will enter the batch menu.

FUNCTION:

1. Allows user to set or clear the batch size, max. batch size = 999999
2. Sets a new batch size by pressing <ACC>. The paper count and batch quantity are reset to 0 .

PERF SHIELD (RED)

PHOTOCELL (GRN)

ON = PERF SHIELD OPEN

ON = NO PAPER

IMPRESSION 1

SETUP

BATCH

SIZE

NO FUNCTION

START

BAT

IMPRESSION 2

REP

NO FUNCTION

STOP

ESC

ACC

DISPLAY:

DISPLAY FUNCTIONS:

DISPLAY

xxxxx = batch size

SET = sets the batch size

CLR = sets the batch size to zero

At this point you may select the size of the batch desired by entering the desired batch size through the keypad. Press the 'ACC' key when the quantity desired has been chosen. Press the 'F2' key (CLR) if you wish to clear a quantity entered to disengage the batch function. Once again, the 'ESC' key will return you back to the main operating menu without activating the batch function. Pressing “F1” will reset the paper count and batch quantity. When running a job with the batch function, the machine will stop after the last sheet has been processed, leaving the sheet partially in the exit rollers, allowing you to insert a slipsheet. The LCD display will then show the number of batches completed.

FUNCTION:

1. Displays the number of batches that have been completed of Batch Size

DISPLAY:

PERF SHIELD (RED)

PHOTOCELL (GRN)

ON = PERF SHIELD OPEN

ON = NO PAPER

IMPRESSION 1

SETUP

NO FUNCTION

BATCH

START

BAT

EXIT

IMPRESSION 2

REP

NO FUNCTION

STOP

ESC

ACC

DISPLAY FUNCTIONS:

DISPLAY

xxxxx = batch quantity

EXIT = exit to Mode - Idle

CLR = clear batch quantity

This screen will show you how many batches you have completed. Multiply the 'BATCH QTY' by the 'BATCH SIZE', and you have the total quantity of your run. When the machine stops after each batch has been completed, you may insert a slip sheet in the exit tray and simply press the 'START' button to continue with the next set.

The repeat function key (REP) is a future feature.

The motor speed can be changed while the machine is running or idle. This function is performed by using the first two function keys under the LCD display screen (marked << and >>) when you are in the main operating menu. The bottom line of the LCD display shows a down arrow to slow down the motor and an up arrow to speed it up.

4.0 Setting Up a Job

Aligning the Air Feed Side Rails

Refer to section 2 ‘ Initial Operation’.

Setting Idler Tire Pressure

Unlike other GW equipment, the idler tires are wide and ride on a mating rubber tire on the boss shaft. These tires must be tight to each other for proper score location. Because the vacuum belt travels slower than the rest of the shafts (for sheet separation), it is imperative that these tires have a firm grip on the stock.to counter the drag from the vacuum belt.

Warning: all feed and exit tires and perf/ boss wheels use setscrews to secure their positions. When tightening setscrews, do not over-tighten them. This may scar the metal shafts and inhibit the free sliding movement of the feed tire hubs or perf/score/slit boss wheels.

Perforating, and/or slitting can be performed with or without score. As previously mentioned, if no scoring is desired, program '00' has been set aside for this task. The perforator blades are available with 2, 4, 6, 8 and 12 teeth per inch as well as Microperf. The blades can be easily interchanged using the ring pliers supplied with the machine.

Remove the accessory holder (see Figure 8) from the machine. Simply remove the retaining clip from the blade hub and pop off the blade. Place the new blade on the blade hub and put the retaining clip back on. Ensure that the retaining clip sits completely in the groove in the blade hub in order to prevent any movement of the blade.

Using the small hexdriver, move the bottom boss wheel to the approximate location of the desired perforation or slit. (Note: Keep all of the setscrews of the boss wheels in line on the shaft.) Move the accessory holder to the position desired where the perf/slit blade will ride on the flat surface of the boss wheel (see Figure

9. and tighten the position locking set screw into the keyway of the square shaft (using the large hexdriver). Since you can control the depth of a perf/slit, it is critical that you locate your perf/slit wheel to the flat of the boss wheel. Tighten the pressure adjustment screw located on the top of the accessory holder and turn the handwheel at the same time. When the perf/slit blade turns with the handwheel, test a few sheets. Continue to make adjustments until the desired perforation depth is obtained.

To ensure a straight perforation or slit, run a few sheets through the machine. Using a straight edge, check if the perforation line is straight. If not, you may have the main tires placed unevenly across the sheet with one tire on the non-operator side. Next, flip the first inch of the lead edge of the sheet over and check to see if the perforation lines up. If it doesn't, double check that there is no excess play in the feed rails. You may not be feeding the sheet into the machine squarely. To ensure that the sheet is running through the machine square, you can feed a sheet into the machine using the handwheel and align the lead edge of the sheet with a straight edge in the machine (such as the edge of the bottom boss shaft). To adjust the squareness of feed, you can move the front or back of the operator side feed rail on the feed table to make sure the sheet travels through the machine squarely. If you adjust the operator side feed rail, you must adjust the non-operator side tray guide as well. Run a few more sheets through and check the sheet again. Continue until the perforation lines up. Now, take the lead edge of the sheet and fold it over to the last inches of the sheet. Again, you are checking to see that the perforation lines up. If it does not line up, again check that the perforation itself is straight. If not, check the main rollers for equal distribution over the sheet and also check that the feed tires have equal pressure along the sheet. The feed pressure adjustment screws dictate the paper travel. The general rule to remember is that a perforation

runs away from a tighter tire. If the perforation runs towards the non-operator side, then loosen the operator screw by an χth of a turn and tighten the non-operator side by an χth of a turn. Vice versa for a perforation that skews towards the operator side. Make adjustment to the exit rollers in the same way you make adjustments to the main rollers if the perf starts straight and then tails off. If the perforation is straight but the perforation does not line up, you may still not be feeding the sheet through square.

The main rollers are comprised of a bottom solid roller and 6 adjustable rollers on top. The top rollers are mounted on a spring loaded shaft, to maintain pressure down to the bottom solid roller. The adjustable top rollers must be distributed along the shaft so that there is a roller on each end of the shaft, with the remainder distributed along the shaft. To ensure proper transport, a majority of the rollers should be on the stock, but do not load all rollers to one end of the shaft where you may encounter stock skew.

After setting up the machine and then programming a job (Section 3.4), test sheets will have to be run to verify you are getting the correct impression, in other words: location; crash strength; etc.

The Impression Control Dials, located on the control panel regulate the strength of the crash. Simply turn the dial clockwise if more impression is required.

5.0 RUNNING A JOB

Once the job has been programmed, and the ACC button pressed, with stock in the feeder and the pump running, press START and the job will run.

6.0 Maintenance

The CM+ is designed to be trouble-free through years of use. Only minor maintenance operations are required to keep it running like new.

After each job, or midway through a very large job, clean the feed tires. You can use warm water to clean off paper dust or drying powder, or blanket wash or alcohol if there is ink on the feed tires. Any type of rubber roller rejuvenator is also good to clean the feed tires; the rejuvenator will also soften the rubber. This will prevent glazing of the rubber. Brand new tires will require extra cleaning for the first job or two until the rubber beds in.

In addition, always watch that paper dust or dirt does not block the photocell sensor eyes. The “green” light on the control panel marked “PHOTOCELL” can verify correct photocell operation. If dirty, simply wipe the photocell sensor eyes but do not use solvents. Either use a cotton swab or blow clean with compressed air. Ensure that the trays and guides are clean.

The CM+ utilises seven oil-impregnated bronze bushings to support all shafts except on the drive side where the lower shafts use bearings instead. An occasional drop of light machine oil these bushings will maintain their lubricating qualities. Wipe off any excess oil to avoid spoiling a job.