Morgana Digifold 5000P, Operator'S Manual

Page 1: ...009 DOCUMENT CREASING FOLDING MACHINE OPERATORS MANUAL Serial Number 170237 Onwards Website www morgana co uk Facsimile 01908 692399 01908 608888 Telephone United Kingdom Morgana Systems Limited 174 011 Digifold 5000P ...

Page 2: ...ing the Paper Length Setting the Process Setting the Crease Positions Setting the Fold Positions Crease Fold Crease Only Fold Only or No Crease or Fold Crease Fold Crease Only Fold Only or No Crease or Fold 19 20 20 20 21 21 24 Setting the Fold Type Setting the Batch Quantity Storing the Program Adjusting the Crease Positions Adjusting the Fold Positions Setting the Process Example of Set by Posit...

Page 3: ...nt Spares Setting the machine Display reads Display reads Display reads Display reads Display reads Display reads Display reads Display reads Display reads TROUBLE SHOOTING 41 41 41 41 42 42 43 Clip 1 was not clear 44 Clip 2 was not clear 44 Clip 2 wasnt Blocked 44 Paper Jam Inch Motor Drive 44 45 MACHINE CALIBRATION HISTORY SHEET 50 FUSE POSITIONS RATINGS 51 PRODUCT RECYCLING AND DISPOSAL 52 Pape...

Page 4: ...e between 16 C and 27 C Maximum varies according to hardness type of fold and substrate mm 2 75 depending on paper weight Min Crease Distance from Tail Edge 50mm 1 96 Min Fold Distance from Tail Edge 50mm 1 96 depending on paper weight Min Fold Length 70mm 2 75 Speed per Hour A4 Material 5000 sheets Dimensions L 1980mm H 1265mm W 655mm L 78 H 49 8 W 25 8 Weight 190Kgs 50Kgs packing Power Requireme...

Page 5: ...nder 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 M...

Page 6: ... 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 fonctio...

Page 7: ... Air separation knob 11 Paper Gate 2 Vacuum bleed knob 7 Adjustable side lay 12 Top Cover 3 Suction slot knob 8 Back stop 13 Display 4 Control panel 9 Fixed side lay 14 Extension table fixing screws 5 Air distribution knob 10 Fuses 1 3 10 5 6 7 8 9 11 12 13 14 2 4 Digifold 5000P Digifold 5000P ...

Page 8: ...ay Unit and the Switches on the Control Panel allow the operator to read edit create and initiate numerous creasing and folding programs within the memory The Control Panel houses the Selection Switch Compressor switch System switch and an industry standard Emergency Stop switch which will stop all power going to the machine when activated ...

Page 9: ...roll through stored addresses and programs increase or decrease the batch quantity and set crease and fold positions 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 Digifold 5000P ...

Page 10: ... Roller Gap 1 Knob Roller Gap 2 Knob Roller Gap 3 Knob FIG 10 1 Air Seperation Knob Adjusting the Paper Gate Set the height of the Paper Gate to approximately two thicknesses of paper by turning the knob K An excessive gap is a most likely cause of double sheet feeding Setting the Suction Slot The suction slot is located inside the vacuum roller and can be adjusted by releasing and moving the suct...

Page 11: ...er result may be obtained by using the settings below or by experimentation For sheets longer than A3 17 in order to supply air to the centre of the stack ports 2 3 and 4 open For A5 sheets or 8 inches long ports 1 and 2 open For A4 sheets or 11 inches long ports 1 and 3 open For A3 sheets or 17 inches long ports 1 and 4 open For sheets longer than A3 17 in order to supply air to the ends of the s...

Page 12: ...This could be due to an inaccuracy in the media or if the blade tilt mechanism has been incorrectly set The mechanism will be set to zero square when the machine is supplied The Blade Tilt Mechanism can be adjusted if necessary as follows With the machine switched see page 18 move the Selection Switch to the right to select The blade tilt can then be adjusted by rotating the Blade Tilt Knob see FI...

Page 13: ...chine switched see page 18 move the Selection Switch to the right to select The gap settings Gap_1 Gap_2 Gap_3 can then be adjusted by rotating the Roller Gap Set Knobs see FIG 10 1 on page 10 When setting roller gaps you first adjust the gap to a value greater than that required and then decrease the value to the required setting Do not set the gap from a value lower than that required i Measure ...

Page 14: ...3X Double X 2X 4X HALF LETTER DOUBLE CLOSED GATE ENGINEERING GATE CONCERTINA FOLD TYPES The table below shows the recommended roller gap settings for the different types of folds Example 1 When producing a fold if GAP 1 is 0 2 X then set GAP 2 to 0 4 2 x X and set GAP 3 to 0 4 2 x X Example 2 When producing a fold if GAP 1 is 0 3 X then set GAP 2 to 0 3 X and set GAP 3 to 0 9 3 x X Half K1 Gate Op...

Page 15: ...oller shafts are arranged across the width of the media being creased this is done to ensure that the media is accurately driven and supported through the rollers A suggested layout is shown below see FIG 15 1 The suggested layout is different and is shown on page 38 see FIG 38 1 The drive wheels and hubs are fixed to the rollers by grub screws when Folding when perfing Digifold 5000P Operating th...

Page 16: ...ds as shown below 2 Move the Selection Switch down to or and then rotate the Selection Switch to adjust its value 3 When the optimum settings for the roller position and shingle length are achieved they can be stored with the job see on page 20 not Turning the delivery system ON or OFF Adjusting the Roller Position and Shingle Length See FIG 17 1 If the delivery is turned off the roller will feed ...

Page 17: ...Page 17 SYSTEM Shingle Length Roller Position FIG 17 1 Digifold 5000P Operating the Digifold ...

Page 18: ...he right to select We recommend that you either seek training or ask a trained operator to run the machine for you Move the Selection Switch to the left to select only if you have been trained to operate this machine If you have not been trained to operate this machine and you select Morgana Systems Ltd accept no responsibility for personal injury damage to the machine or damage to materials being...

Page 19: ...ct 4 The paper length can now be set by moving the Selection Switch to the left to select or to the right to select The or whichever has been selected can then be adjusted by rotating the Selection Switch clockwise to increase or anti clockwise to decrease 5 Move the Selection Switch down to select Move the Selection Switch to the right to select or Set Paper Paper Length Tens Decimals Tens Decima...

Page 20: ... to the required type and then moving the Selection Switch to the right The fold options are or 10 Move the Selection Switch to the right to select The batch quantity can now be set by moving the Selection Switch down and then rotating the Selection Switch clockwise or anti clockwise to adjust the The Batch Counter controls the feed of the machine If for example the Batch Count is set to 10 the ma...

Page 21: ... sample sheet through the machine by switching the System and Compressor switches on and then moving the Selection Switch down to feed the sheet View the results any adjustments to the fold or crease positions can be adjusted as follows i From the start up menu move the Selection Switch to the left to select ii Move the Selection Switch down to select the crease that needs to be adjusted The creas...

Page 22: ... up one click at a time selecting until the top level display menu is shown Adjust More Adj Folds Back If a crease position is adjusted the fold will move with it If a fold position is adjusted then only the fold will move Adjust a fold only if the fold appears to be giving an out of square result or cracking appears The fold is probably too close to the centre of the crease and will be trying to ...

Page 23: ...ton clockwise to release the safety latch The display is now switched on and will be as shown below If you have not been trained to operate this machine we strongly advise that you move the Selection Switch to the right to select We recommend that you either seek training or ask a trained operator to run the machine for you Move the Selection Switch to the left to select only if you have been trai...

Page 24: ...ay contains any of the following words the machine is in the mode of operation or Change to the mode of operation as follows i Move the Selection Switch up to select and hold momentarily ii Move the Selection Switch down one click at a time to select iii Move the Selection Switch to the right 2 Following the arrows on the display unit move the Selection Switch to the right one click at a time unti...

Page 25: ...moving the Selection Switch to the left to select or to the right to select The or whichever has been selected can then be adjusted by rotating the Selection Switch clockwise to increase or anti clockwise to decrease 7 Move the Selection down to select the 2nd Crease position 8 The 2nd Crease position can then be adjusted by moving the Selection Switch to the left to select or to the right to sele...

Page 26: ...moving the Selection Switch to the left to select or to the right to select The or whichever has been selected can then be adjusted by rotating the Selection Switch clockwise to increase or anti clockwise to decrease 14 Move the Selection down to select the 2nd Fold position 15 The 2nd Fold position can then be adjusted by moving the Selection Switch to the left to select or to the right to select...

Page 27: ... 7 Crease 3 260 0mm 10 2 Fold 1 179 0mm 7 Fold 2 260mm 10 2 All dimensions are from the leading edge of the paper Example of Set by Position Crease 2 Fold 1 0 35 First Fold Second Fold Leading Edge Crease 3 Fold 2 179 0 260 0 Finished Document 9mm 0 35 Leading Edge 9mm 0 35 Leading Edge SETTINGS 9mm 7 10 2 Digifold 5000P Operating the Digifold ...

Page 28: ...activating the System switch to ON Move the Selection Switch down to select Wait until the suction drum rotates before hand feeding the first sheet this allows the machine time for the pre feed checks to be processed Subsequent sheets may be hand fed as soon as the tail edge of the preceding sheet is no longer visible To stop feeding the sheets move the Selection Switch up and then the System swit...

Page 29: ... machine switched see page 18 move the Selection Switch to the left one click at a time until the display contains the words as shown below 2 Move the Selection Switch down to Rotate the blade adjustment cams until they are just tight and then back off slightly before tightening the socket head screws ON Select Tools Set Blade Pressure Blade is moving to TOP DEAD CENTRE Blade Pressure May Now Be A...

Page 30: ...Page 30 CREASING FOLDING 5mm SOCKET ALLEN KEY The Blade Assembly The diagram below demonstrates the adjustment of blade pressure ...

Page 31: ...Page 31 SYSTEM BLANK PAGE The Blade Assembly Digifold 5000P ...

Page 32: ...screws one each end of the Blade Set as shown in FIG 32 1 below 4 Remove the Sheet Guide Assembly by pulling upwards on the two flanges one each end as shown in FIG 32 2 and FIG 32 3 below 5 The Blade Set can now be removed from the machine using the Blade Extractor Tools shown in FIG 32 4 below Replacing Blade Sets FIG 32 1 FIG 32 2 FIG 32 3 Flange Sheet Guide Assembly FIG 32 4 Blade Extractor To...

Page 33: ...at each end of the Blade Set as shown in FIG 33 1 below 7 Lever the Blade Assembly in the direction shown in FIG 33 2 to unclip and release the Blade Set FIG 33 1 FIG 33 2 Note The Position of The Blade Extractor Tool Under The Lip of The Blade Adjuster Assembly Digifold 5000P ...

Page 34: ...as shown in FIG 34 1 below 11 Slide the new blade set into the slots of the creasing unit as shown in FIG 34 2 12 Rotate the blade adjustment cams until they are just tight and then back off slightly Reset blade to Top Dead Centre and make final adjustments 10 Slide the blade adjustment assemblies and the blade adjustment cams onto the dowels of the new blade set Socket Head Socket Head Blade Adju...

Page 35: ...lade and anvil pre set for your machine Standard Blade set Part number 176 213 02 Narrow Blade set Part number 176 213 01 Consisting of a standard blade and a narrow anvil pre set for your machine NOTE Blade sets are individually set for each machine at the point of manufacture Replacement Blade sets will therefore need to be set up by a factory trained service engineer Do not attempt to use a Bla...

Page 36: ...quired to install the perforator are contained in the despatch kit supplied with the machine they are listed below 1 off Set of standard perforation 56 tooth blades 1 off Set of standard hardened anvils 1 off Perforator stripper 1 off Scoring wheel 1 off 3mm bondhus wrench allen key 1 off 2mm bondhus wrench allen key The perforator blades are split into two matching halves and are fitted to the dr...

Page 37: ...es and mount on to the drive wheel Do not secure the blade 7 Mount the other half of the blade to the drive wheel as shown FIG 37 1 Secure the blades to the wheel ensuring not to over tighten grub screw 8 Mark on a single sheet the desired perforating position Feed the sheet through the machine manually until the mark can be seen Use this mark to assist in fixing the position of the perforating dr...

Page 38: ...ub towards the perforating drive wheel until there is a clearance of 0 5mm 0 020 13 To prevent damage to the blades or the anvils do not force the drive wheel against the hub 14 Fix the perforator stripper adjacent to the drive wheel and blade as shown 15 Operate the machine and test the perforations for form For multiple perforations repeat the above procedure Demonstrates a typical set up for pe...

Page 39: ...the jammed paper 1 Unlock and lower the delivery unit open the top cover and the perforator unit see FIG 39 1 below 2 If the paper is jammed in the fold rollers try to rotate the top fold roller using both hands Position the thumbs under the tie bar and spread the fingers out above the tie bar The top fold roller can only be rotated in one direction by hand To rotate the top fold roller in the oth...

Page 40: ...lease knob and then slide it to the left as far as it will go to dis engage the gears see FIG 40 1 below If the release knob cannot be moved freely to the left rotate the top fold roller with one hand whilst moving the release knob to the left with the other hand The fold rollers can then be rotated by hand in both directions When the jammed paper has been cleared from the machine the drive gear b...

Page 41: ...dge of the paper A minimum distance of 50mm 1 96 is recommended Crease Position Inaccuracy Paper fold out of square Check that the crease profile has not been set too deep Check that the correct Blade Set is fitted Standard Blade Set for material thickness of 0 25mm 0 010 and above Narrow Blade Set for material thickness of 0 25mm 0 010 and below Note the best fold squareness is achieved when the ...

Page 42: ...cking of the material along the crease may be caused by the following Pressure too heavy on the top blade reduce pressure Cracking on one edge caused by misalignment of the anvil and blade Paper not feeding Check that the paper stack is not too high or too heavy for the feeder The height of the paper stack should be defined by the weight and the size of the stock being creased Ensure that the adju...

Page 43: ...010 and smaller If the Standard Blade Set is used to crease and fold materials less than 0 25mm 0 010 inaccurate results can be produced If the Narrow Blade Set is used to crease and fold materials greater than 0 25mm 0 010 cracking can occur More importantly this could cause the main motor to temporarily stall This probably won t be that noticeable until you look at the results whereby the crease...

Page 44: ... or the wrong length of paper has passed through the sensor To correct check if paper is present and check that the paper path is clear before restarting See pages 39 and 40 that describe how to remove paper jams If the machine stops and the display window reads this indicates that the sensor did not see the paper at the correct time i e A jam in the paper path To correct Check if paper has jammed...

Page 45: ...rror Calibration too close This indicates that the double detector If installed has picked up a double sheet This indicates that the Lead Edge Sensor has seen a sheet subsequent to the first one as being longer Again this could actually be a longer sheet OR it could be a sensor problem if it is a recurring problem This indicates that the crease blade did not get back to its home position correctly...

Page 46: ...R 2 5mm 7 403 01 030 006 409 01 040 004 12 SCREW SOCKET CAP HEAD M3 x 6 LG 1 SCREW SKT SET FLAT PT M4 x 4 LG 1 15 17 Page 46 CREASING FOLDING 08 041 02 1 SLITTING ANVIL UNDERSIZE 08 066 1 SLITTER PERF BLADE 28T 624 017 3 SLITTER SCORER PK STYLE 0212 40X40X20 16 650 040 1 POWER CORD C19 UK 16A 2 5m 624 025 1 STATIONERY TUBE 330MM X 50MM 170 002 01 QUICK START CHART 1 620 027 1 BONDUS WRENCH 5mm L D...

Page 47: ...TING BLADE SET 56T Fine Perforations 6 1 99 35 ANVIL SET USED WITH ABOVE BLADE SETS 7 172 04 01 NARROW SHEET KIT 172 03 01 DOUBLE SHEET DETECTOR KIT ACCESSORIES OPTIONS May be obtained from May also be obtained and your dealer and fitted to your fitted by your dealer You should machine using the instructions not attempt to fit options as supplied or by reading your specialist tools and knowledge a...

Page 48: ... 47 01 Lead Gap Set 2 Pot 174 01 01 Controller PCB Assembly Chip 174 04 01 Knife Driver PCB Assembly 173 06 02 Power Supply 24V 125 21 02 Dual Stepper Driver Board 173 49 01 Stepper Motor Dynacrease 173 46 01 Lead Gap Set 3 Pot 175 31 01 Input roller Assembly Lower 175 31 02 Input Roller Assembly Upper 175 109 01 Display Unit 4 Line Mk3 Integrated 175 10 01 Edge Sensor Assembly 175 11 01 Sensor Ba...

Page 49: ... 613 351 Micro Switch Guard 613 255 Solenoid Valve 613 365 Emergency Stop Switch Double Pole 626 007 Anti Static Sensor Bar 652 040 Switch Thermal O Load 12A Black 655 011 Power Supply Unit Switched Mode 24V 681 011 Fuse 315mA 20 x 5mm Anti surge Ceramic 76 240 Stepper Motor Drive 681 019 Fuse 6 3A 20 x 5mm Anti surge Ceramic 76 156 Lead Blade position Sensor Page 49 SYSTEM 175 125 01 Connecting L...

Page 50: ...im Follow Stretch K2 Travel K1 Travel Vac Park Trim Stretch Lead Edge Trim Del Roller Trim Knife 1 Trim Date Total Count Vac Suck Trim K2 Deflect Trim Knife 2 Trim K1 Deflect Trim Follow Stretch K2 Travel K1 Travel Vac Park Trim Stretch Lead Edge Trim Del Roller Trim Knife 1 Trim Date Total Count Vac Suck Trim K2 Deflect Trim Knife 2 Trim K1 Deflect Trim Follow Stretch K2 Travel K1 Travel ...

Page 51: ...Us 24V 48V T6 3AH 250 681 019 T315mAH 250 681 011 SPARE FUSE POSITION ANTI STATIC UNIT FUSIBLE PSU 5V 24 V FUSIBLE PSUs 24 V 48 V FUSIBLE ANTI STATIQUE POSITION PORTE FUSIBLE POSITION ET CLASSIFICATION DES FUSIBLES SPARE FUSE POSITION POSITION PORTE FUSIBLE Digifold 5000P ...

Page 52: ...Page 52 CREASING FOLDING PRODUCT RECYCLING DISPOSAL European Union Disposal Information for Commercial Users Disposal Information for Domestic Users Other Countries ...

Page 53: ...Page 53 SYSTEM Digifold 5000P ...