Morgana DIGIFOLD, Operating Manual

Page 1: ...ISSUE 9 JULY 2006 120 101 DOCUMENT CREASING FOLDING MACHINE Morgana Systems Limited United Kingdom Website www morgana co uk Telephone 01908 608888 Facsimile 01908 692399 OPERATORS MANUAL ...

Page 2: ...le Side Lay Setting the Back Stop Setting the Air Distribution Setting the Air Separation Pressure Setting the Positions of Drive Wheels and Hubs Setting the Extension Table Setting the Delivery Conveyor System Adjusting the Batch Count Adjusting the Roller Gap Storing Programs Reading Stored Programs Clearing Stored Program Feeding Sheets Manually Setting the Delivery Conveyor System Adjusting th...

Page 3: ...on TROUBLE SHOOTING 29 29 29 29 30 30 30 31 31 h 31 Clip P 32 Clip 1 32 Clip 2 32 33 MACHINE CALIBRATION HISTORY SHEET 39 Paper crease out of square Paper fold out of square Paper Jamming Machine will not start Paper not feeding Machine not counting Cracking of the printed material along the crease Paper marking or scratching No suction Display reads Display reads Display reads Display reads Recom...

Page 4: ...ax No Stored Programmes 6 Min Repeat Crease Distance 4mm depending on paper weight Min Repeat Fold Distance 70 Min Crease Distance from Leading Edge 25mm Min Fold Distance from Leading Edge 70mm depending on paper weight Speed per Hour A4 Material One Crease or One Fold 1800 sheets Speed per Hour A4 Material Two Creases or Two Folds 1400 sheets IMPORTANT Note the operating environment should be co...

Page 5: ...ution knob 11 Paper Gate 2 Delivery assembly 7 Adjustable side lay 12 Exit Guard 3 Suction slot knob 8 Back stop 13 High Level Display 4 Control panel 9 Fixed side lay 14 Extension table fixing 5 Air separation knob screws Page 5 SYSTEM 14 6 7 11 13 5 4 3 2 12 9 8 Digifold ...

Page 6: ... as shown in the diagram below For the purposes of the instructions these buttons will be described as The front face of the control panel houses the Compressor switch System switch Feed switch Suction switch Setting dial and Set up switch Under the control panel is an industry standard Emergency Stop switch which will stop all power going to the machine when activated Push Buttons 1 2 3 4 Page 6 ...

Page 7: ...rator can scroll through the stored memory addresses Also used for cycling the folder blade feed forward Allows the operator to enter and subsequently edit or read a stored program Also resets the batch quantity Allows the operator to scroll through stored memory addresses and programs increase or decrease the batch quantity and set a crease fold position Allows the operator to vary the length of ...

Page 8: ...loading table against the fixed side lay See page 17 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 See page 17 4 Place the backstop on to the adjustable side lay and slide up to the paper stack also allowing a gap as stated in the above step before clamping See page 19 5 Now follow ...

Page 9: ...EES or FoLd flick the Set Up switch upwards to select on or oF for each as required Turn the Setting Dial anti clockwise to select the Main display flick the Set Up switch down press the pushbutton and turn the Setting Dial Flick the Set Up switch up to its Mid position Switch the System switch on Switch the Compressor switch on Switch the Feed switch on to begin feeding sheets Step 2 OPERATION IN...

Page 10: ...r crease position 1 9 Cr crease position 9 F1 fold 1 position F2 fold 2 position rPoS delivery roller position Shin shingle amount delivery wheel turns rESEt reset Sub Menu in Set by mode set by position PoS tYPE L type of fold i e L letter fold Len 100 paper length PAPEr 3 type of paper 0 light 3 heavy Cr1 0 0 crease 1 position rPoS 150 delivery roller position Shin 41 shingle amount delivery whe...

Page 11: ...Page 11 SYSTEM Operating the Digifold Digifold ...

Page 12: ... and turn the Setting Dial clockwise to adjust the paper length in 10 0mm or 0 1mm increments Release PB1 or PB2 8 Turn the Setting Dial clockwise to select paper type PAPEr i e stiffness of paper not necessarily the paper thickness 9 Hold down PB1 and turn the Setting Dial to adjust the paper type Release PB1 i e PAPEr 0 is for lightest stock PAPEr 1 is for light stock of 120 gsm upwards PAPEr 2 ...

Page 13: ...urn the Setting Dial clockwise until F1 is displayed This will be the calculated length of the fold position Press and hold PB1 and the display shows 0 0 To adjust hold down PB1 and turn the Setting Dial to adjust in either direction ie 3 1mm to 3 1mm Max Release PB1 NOTES If a crease position is micro adjusted the fold will move with it If a fold position is micro adjusted then only the fold will...

Page 14: ...n the example on page 16 not Set By Position center line of crease ideal fold line ideal fold line Typical main display screen Set by Position 2cF 0 creases crease on fold on count number of 1 Turn the Emergency Stop button clockwise to switch the power on and select the main display screen 2 Set the Set Up switch to its Mid position 3 Turn the Setting Dial clockwise until display reads SEt FoLd o...

Page 15: ...ing the Setting Dial clockwise to 10 Hold down PB1 or PB2 and turn the Setting Dial to adjust the fold position in 10 0mm or 0 1 mm increments Release PB1 or PB2 and turn the Setting Dial clockwise is the last fold position Note the fold positions may be in any order i e can be larger than Once the has been selected if returned to the default length of 100 will be found and any previous settings w...

Page 16: ... Cr3 260 0mm F1 179 0mm F2 260mm All dimensions are from the leading edge of the paper Example of Set by Position Cr2 F1 9mm First Fold Second Fold Leading Edge Cr3 F2 179 0 260 0 Finished Document 9mm Leading Edge 9mm Leading Edge SETTINGS Operating the Digifold Page 16 CREASING FOLDING ...

Page 17: ... P AP E R GAT E W HIL E T HE MACHINE IS RU NNING OR T HE S U CT ION DR U M MAY B E COME DAMAGE D Se ting the suction slot t Setting the Adjustable Side Lay 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...

Page 18: ...settings or by experimentation 1 For A5 sheets or 8 inches long port 1 open 2 For A4 sheets or 11 inches long front port and port 2 open 3 For A3 sheets or 17 inches long front port and port 3 open 0 For longer sheets in order to supply air to the centre of the stack port 2 open To control the amount of air supplied to the ports the air separation knob can be rotated clockwise to decrease the pres...

Page 19: ... off automatically Loosen the drive wheels and hubs by using a 2mm allen key Arrange the drive wheels and hubs as shown in FIG 18 1 In order to avoid marking on some types of media ensure a gap between the drive wheels and drive hubs hAndLE Setting the extension table The extension table can be fixed to the machine in order to feed through longer sheets The table can be supported by the two fixing...

Page 20: ...e Set by Fold mode of operation the Roller Position rPoS and Shingle Length Shin are automatically set relative to the paper length and type of fold selected 1 Flick the Set Up switch down 2 Turn the Setting Dial anti clockwise to rPoS roller position or Shin shingle length as required 3 Press and hold pushbutton PB1 and turn the Setting Dial the numbers displayed are pre selected lengths in milli...

Page 21: ...multiples of 10 Beware if pushbutton PB1 is not held down the display will register the adjustment to the batch quantity but will not change within the program 4 The Batch Count can be stored with the job if required see Storing Programs on page 22 The Roller Gap adjusts the gap between the large fold rollers see FIG 20 1 The Roller Gap may require adjustment if thick paper is being folded or if c...

Page 22: ... press the pushbutton PB4 The display reads StorE 1 StorEd Hold down pushbutton PB4 and turn the Setting dial in either direction to cycle through the memory addresses When any one of the 6 addresses are displayed release PB4 to view the stored program at that memory address A typical program will show see page 14 for explanation To view or edit any of the creases or folds within the program refer...

Page 23: ...heets to be fed freely Operating the machine manually will also require the suction length to be continuous in order to accommodate various types of stock Therefore the suction length switch must be positioned at III The machine can now be started by activating the System switch to on Flick the Feed switch to on and begin to slide the sheets individually through the paper gate until they are drive...

Page 24: ... the mating connectors 2 Locate the Support Hoop into the channel on the underside of the delivery unit WARNING The Digifold will start if the delivery unit is not fitted onto the machine not Assemble the delivery unit as shown in FIG 23 1 The Delivery Unit FIG 23 1 Delivery Unit Location Hooks Hooks to be Located onto shaft in these positions Support Hoop Connector Page 24 CREASING FOLDING ...

Page 25: ...allen key unlock the shoulder bolts labelled with scale transfer positioned at each end of the creasing blade 6 Turn the adjustment cam to adjust the blade pressure Increasing the gradient on the scale will increase the blade pressure 7 Ensure that the shoulder bolts are locked after setting The diagram below demonstrates the adjustment of blade pressure Adjusting the blade alignment It is extreme...

Page 26: ...ated on the front face at both ends of the blade anvil as shown below 3 Using a 4mm allen key locate the two front or back alignment screws in the side frame in order to adjust the blade anvil 4 The upper screw of the two will adjust the upper blade anvil whereas the lower screw will adjust the lower blade anvil both in very small increments 5 In order to obtain the required position adjust either...

Page 27: ...ccentric shoulder bolts on the link plates have been positioned as shown in fig 26 1 8 Upper blade anvil only Slide the adjustment links onto the dowels into the holes in the adjustment links as shown Push downwards on the handles of the blade extractor tools to release the blade assembly from the power links 9 Slide the new blade set into the slots of the creasing unit as shown in fig 27 1 Locate...

Page 28: ... ordered separately i e single blade or anvil Consisting of a standard blade and anvil blade brushes blade links and alignment bolts If the pressure and the alignment of the crease is not to a satisfactory level see pages 25 and 26 to adjust the creasing line Standard Blade set fitted to Digifold as standard Part number 76 213 01 Spares kits Extra Narrow Blade set optional Part number 76 213 03 Co...

Page 29: ...hine will not start Note the best fold squareness is achieved when the fold is not on the center of the crease but to one side or the other Check that the fold is to one side of the crease center line Check that the roller gap is not too tight and squashing the crease Check that the roller gap is not too large and allowing the paper to slide especially so on glossy paper Check that the rollers are...

Page 30: ... 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 necessary to feed the sheets manually see page 23 Machine not counting Open the top and remove the blade set see pages 27 28 to access the dual sensor post located in between the drive rollers Using a soft brush clean the visible sensor on the end of the post Use the...

Page 31: ...ack to its default setting of off and it must therefore be et back to on again 1 Select the main display screen see pages 11 and 13 to identify main display 2 Set the Set Up switch to its Mid position 3 Turn the Setting Dial clockwise until the display reads F_cLr 4 Flick the Set Up switch upwards to select on If the rollers are marking the media open the roller gap see page 21 If the suction drum...

Page 32: ...window crunch crunch cLiP P cLiP 1 cLiP 2 Note As a safety device to overloading the fold knives will be ejected from their drive location lugs using two red handled allen keys 2 5mm as supplied align the holes in the blade drive gears black lugged gears with the brackets attached to the mechanism side plates each side The gears may be turned by hand Insert the allen key through the slots in the t...

Page 33: ... 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 add a small amount of grease to the slide ways It is recommended that your Morgana Digifold is fully serviced at least once every six months by a factory trained Service Engineer Trouble Shooting Page 33 SYSTEM Digifold ...

Page 34: ...ALLEN KEY 4mm 11 12 620 028 1 BONDUS L WRENCH 3mm 13 620 033 1 BONDUS L WRENCH 6mm 14 624 018 1 DISPATCH BOX 6 620 007 1 HEXAGON BALL DRIVER 2mm 620 026 1 BONDUS L WRENCH 4mm 620 020 HEXAGON BALL DRIVER 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 2 15 70 055 01 1 BLADE EXTRACTION TOOL OP SIDE 16 70 055 02 1 BLADE EXTRACTION TOOL LAY SI...

Page 35: ...ur operators manual OPTIONS May also be obtained and fitted by your dealer You should not attempt to fit options as specialist tools and knowledge are required May be obtained from ITEM PART NUMBER DESCRIPTION 1 76 213 03 BLADE SET 320 Wide Extra Narrow ACCESSORIES AND OPTIONS Page 35 SYSTEM Digifold ...

Page 36: ...noid Coil 613 237 1 Cap Ø15 613 365 1 Emergency Stop Switch 613 385 1 Knob Ø15 609 022 1 O Ring Ø32 606 035 1 Knob Roller Tilt 613 351 1 Micro Switch Guard Circuit 613 191 1 Micro Switch Home Circuit 652 011 1 System Switch 681 007 1 Fuse 3 15A Time Delay 20 x 5mm 75 100 1 Switch Assembly Set up 75 098 1 Switch Assembly Feed 75 101 1 Switch Assembly Rotary Setting Dial 75 077 1 Control PCB Assembl...

Page 37: ...play 124 01 01 1 Pot Lead Assy Gap Set 1 124 01 08 1 Pot Lead Assy Gap Set 2 124 01 02 1 Knife Position Sensor 124 01 16 1 Toroidal Transformer Assembly 124 01 17 1 Toroidal Transformer Assembly 125 01 08 1 Black Box Stepper Driver Daughter Board 125 05 01 1 Runtime PCB Assembly 125 12 02 1 Stepper Driver Daughter Board 126 06 01 1 Access Unit 1st Fold 126 02 01 1 Fold Input Roller 126 03 01 3 Fol...

Page 38: ...nt of parts fitted to your machine require specialist knowledge and should therefore be entrusted to your dealer 128 026 02 1 Belt Paper Transport 126 059 4 Link Paper Guide 126 053 2 Blade Guide 126 053 02 2 Blade Guide Long 126 060 01 1 Paper Sensor Edge Detect RX 126 060 02 1 Paper Sensor Edge Detect TX 126 060 03 1 Paper Sensor Sync 2 RX 126 060 04 1 Paper Sensor Sync 1 RX 126 063 01 1 Sensor ...

Page 39: ...ACHINE CALIBRATION HISTORY Etch dEtr FECh dEtF gAPF cEn Date Total Count Serial Number Date Total Count Date Total Count Etch dEtr FECh dEtF gAPF cEn Etch dEtr FECh dEtF gAPF cEn Page 39 SYSTEM Digifold ...

Page 40: ...Page 40 CREASING FOLDING ...