Morgana Digifold Pro CB User manual

ISSUE

3March

2011

DOCUMENT

FOLDING MACHINE

OPERATORS MANUAL

Website: www.morgana.co.uk

Facsimile: ( 01908 ) 692399( 01908 ) 608888Telephone:

United KingdomMorgana Systems Limited

174-025

DigiFold Pro

Page2

INDEX

10

11

12

AdjustingthePapergate

SettingtheSuctionSlot

SettingtheVacuumBleed

SettingtheAdjustableSideLay

SettingtheBack-Stop

SettingtheAirDistribution

SettingtheAirSeparationPressure

SettingthePositionsoftheDriveWheelsandHubs

TOUCHSCREENOPERATION 14

15

17

20

21

23

24

26

27

29

30

31

32

35

THEBLADEASSEMBLY 37

TouchscreenLayout

PaperSettingsPage

RollerGapSet&TiltMechanismPage

Creasesin‘SetByFold’mode

Creasesin‘SetByPosition’mode

Foldsin‘SetByFold’mode

Foldsin‘SetByPosition-’mode

Exampleof‘SetByPosition’mode

DeliverySettingsPage

StatusScreen

RunningtheJob

Settingthemachinetooperateinmanualsheetfeedmode

StorePages

ToolsMenu

Adjustingthebladepressure

CreaseSettingsPages

FoldSettingsPages

FOLDING

INTRODUCTION&SPECIFICATION

PAGE4

SAFETYDo’s&Don’ts5

THEDigifoldPro

7

THESWITCHPANEL

8

9

TheMorganaDigiFoldPro

LabeledPhotograph

Detaileddiagramanddescription

Featuresontheswitchpanel

OPERATINGTHEDigiFoldPro

Page3SYSTEM

INDEX

REPLACINGCREASINGBLADESETS PAGE38

41

PERFORATING 42

43

44

REMOVINGPAPERJAMS45

49

ERRORSCREENS

0250

0350

0450

0551

0651

0751

0852

0952

1052

1152

1253

1353

DISPATCHKIT56

ACCESSORIESANDOPTIONS57

RECOMMENDEDSPARES58-59

Installingnewbladesets

SpareBlades

Equipment,Spares

Settingthemachine

RecommendedPositionoftheDriveWheelsandHubs

PaperCrunch

DoubleSheetFeed

BladeNotHome

BladeBusy

BladeHomeFailure1

BladeHomeFailure2

FlyingHomeFailure

Clip1NOTClear

Clip1NOTBlocked

Clip2NOTClear

Clip2NOTBlocked

Overlap

TROUBLESHOOTING 47

47

48

0150

MACHINECALIBRATIONHISTORYSHEET60

FUSEPOSITIONS&RATINGS61

PRODUCTRECYCLINGANDDISPOSAL62

Papercreaseoutofsquare

Paperfoldoutofsquare

PaperJamming

Machinewillnotstart

Papernotfeeding

Crackingoftheprintedmaterialalongthecrease

UsingtheCorrectBladeSet

SheetdidNotArrive

CreasePositionInaccuracy 47

DigiFoldPro

INTRODUCTION

It is to note that to prevent cracking, when using dry ink or toner based print

engines, the material be fully acclimatised for at least 48 hours before putting an

image onto the paper.

Feeding System ................................................ Bottom suction feed

Max. Sheet Size ................................................700mm x 385mm (27.5” x 15”) [900mm x

385mm (35.4” x 15”) with Optional

extension table].

Min. Sheet Size .................................................210mm x 140mm (8.3” x 5.5”) (dependant

on stiffness of paper and type of fold).

Max. Paper Thickness ................................... 0.40mm (varies according to hardness,

type of fold, and substrate).

Min. Paper Thickness ....................................... 0.11mm

Max. No. Folds per Sheet.................................. 2

Max. No. Stored Programmes ...........................Unlimited

Min. Repeat Crease Distance.............................40mm (1.6”)

Min. Repeat Fold Distance ................................70

Min. Fold Distance from Leading Edge .............50mm (1.96”) (depending on paper weight)

Min. Crease Distance from Tail Edge.................50mm (1.96”)

IMPORTANT

must

IMPORTANT

Note:

the operating environment should be controlled to a temperature between

16° C and 27° C Maximum.

(varies according to hardness,

type of fold, and substrate).

Max. No. Creases per Sheet..............................9

mm (2.75”) (depending on paper weight)

Min. Crease Distance from Leading 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 in half)............................... 6000 sheets

Dimensions ....................................................... L: 2020mm H: 1265mm W: 680mm

L: (79.5”) H: (49.8”) W: (26.8”)

Weight ...............................................................190Kgs (+50Kgs packing)

Power Requirement .......................................... 1 phase 220 / 240v 50Hz

Specification

The production speed varies according to the material size and

the fold type.

1 phase 220v 60 Hz

Sound Power Level .....................80.0 decibels

*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 FOLDING

DigiFold Pro

INTRODUCTION AND SPECIFICATION

Digifold Pro

DigiFold Pro

is a registered trade mark of Morgana systems Ltd. The unique patented

creasing and folding system, makes it possible to fold most delicate stocks from 0.11mm,

up to 0.4mm thick. The reduces the possibility of scratching, marking or

cracking appearing on the substrate, as is often associated with conventional folding

machine methods.

Page5SYSTEM

SafetyDo’s&Don’ts

Do-readthisoperatormanualfullybeforeoperatingthemachine.

Do-operatewiththedesignatedACcurrentonly.Useanexclusiveoutlet,as

overloadingmaycausefireoranelectricshock.

Do-installthepowercordoutofthewaytoavoidatrippinghazard.

Do-makesurethatthemainsinletconnectorisalwayseasilyaccessible.

Donot-installthemachineinanunstableplacesuchthatittiltsorshakes.

Donot-unplugtheplugorunplugthepowercordfromtheoutletwithawethand,

thiscancauseanelectricshock.

Donot-unscrewandremoveanycoversfromthemachine,asitcancausean

electricshockorinjury.

Donot-placereceptaclescontainingliquidsonanysurface.

Donot-adjustanypartofthemachinewhilstrollersarerunning

Donot-operatethemachinewithlooseortrailingclothingorloosehair.

Donot-underanycircumstancesadjustthepapergatewhenthemachineis

switchedon.

REGLESDESECURITE:«AFAIRE»ET«ANEPASFAIRE»

Lirecemoded'emploiavantd'utiliserlamachine.

Respecterl'alimentationélectriqueindiquée.Branchersurunepriseséparée

carunesurchargepeutentraînerunincendieouunchocélectrique.

Installerlecordond'alimentationdemanièreànepaspouvoir

trébucherpardessus.

Ménagerunaccèslibreàlaprisedecourant.

Nepasinstallerlamachinesurunesurfacenonplane,afind'éviter

qu'ellenepencheounevibre.

Nepasinstallerlamachinesurunesurfacenonplane,afind'éviter

qu'ellenepencheounevibre.

Nedémonteretenleveraucuncarterdelamachine,parcraintededécharge

électriqueoudeblessure.

Nepasplacerderécipientcontenantunliquidesurlamachine.

N'effectueraucunréglagependantquelesrouleauxfonctionnent.

Nepasporterdevêtementsflottantsetrassemblerlescheveuxlongs

lorsdel'utilisationdelamachine.

Enaucunecirconstance,réglerleséparateurdepapierlorsquela

machineestbranchée.

DigiFoldPro

Page6 FOLDING

WarningLabels

Do-beawareofanyfingertrapsandrotatingpartswhenoperating

themachine.

Do-readthisoperatormanualfullybeforeoperatingthemachine.

Donot-operatethemachinewithlooseortrailingclothing.

Donot-operatethemachinewithloosehair.

Do-beawareofanyfingertrapsandrotatingpartswhenoperating

themachine.

Do-beawareofsharppointsandblades.

Do-beawareofrotatingrollers.

Do-beawareoflowcurrentanti-staticshock.

Attentionaurisquedesecoincerlesdoigts,etauxpiècesen

mouvementlorsdufonctionnementdelamachine.

Nepasporterdevêtementsflottantslorsdel'utilisationdelamachine

Rassemblerlescheveuxlongslorsdel'utilisationdelamachine.

Attentionaurisquedesecoincerlesdoigts,etauxpiècesen

mouvementlorsdufonctionnementdelamachine.

Attentionauxélémentstranchantsetauxcouteaux.

Attentionauxrouleauxenfonctionnement

Attentionauxfaibleschocsd'électricitéstatique

Lirecemoded’emploiavantd’utiliserlamachine.

Page7SYSTEM

DOCUMENTFOLDINGMACHINE

Keytophotographbelow

1Deliveryassembly6AirSeparationKnob11PaperGate

2Vacuumbleedknob7Adjustablesidelay12Topcover

3Suctionslotknob8Backstop13Touchscreen

4Switchpanel9Fixedsidelay14OptionalExtensionTable

5Airdistributionknob10Fuses

112 6

11 13 8

95

14

10

4

3

2

7

DigiFoldPro

TheSwitchPanel

Page8

THESWITCHPANEL

SystemSwitch

CompressorSwitch

EmergencyStopSwitch

FOLDING

TheSwitchPanelhousestheCompressorswitch,Systemswitch,andan

industrystandardEmergencyStopswitchwhichwillstopallpowergoingto

themachinewhenactivated.

TheSwitchPanel

Page9SYSTEM

FeaturesontheSwitchPanel

Systemswitch

Compressorswitch

Whenactivatedthesystemswitchwilloperatethemotorsinordertobeginthe

creasingsequence.

Allowstheoperatortoswitchoffthecompressorunitinordertoutilisethemachine

tomanuallyfeedsheets.

DigiFoldPro

Page10

Adjustable

SideLay

Suction

SlotKnob

Vacuum

BleedKnob

FOLDING

JTWOTHICKNESSES

OFPAPER

WARNING.

DONOTADJUSTTHE

PAPERGATEWHILETHE

MACHINEISRUNNINGOR

THESUCTIONDRUMMAY

BECOMEDAMAGED.

AdjustingthePaperGate

SettheheightofthePaperGatetoapproximatelytwothicknessesofpaper,byturningthe

discj.Anexcessivegapisamostlikelycauseofdoublesheetfeeding.

Thissettingisonlyintendedasaguide,forinstance,sheetswithanupwardcurlwill

requirethissettingtobeincreased.

BladeTilt

Knob

RollerGap1

Knob

RollerGap2

Knob

RollerGap3

Knob AirSeperation

Knob

SettingtheSuctionSlot

Thesuctionslotislocatedinsidethevacuumrollerandcanbeadjustedbyreleasingand

movingthesuctionknobhorizontallyineitherdirectiontotherequiredposition.

Forlightstockssettheknobtotheleftandforheavierstockssettheknobtotheright.

OperatingtheDigiFoldPro

Page11SYSTEM

Port1 Port5

KnobShown

SetToPosn.1

AirDistribution

SettingtheVacuumBleed

SettingtheAdjustableSideLay

SettingtheBackStop

SettingtheAirDistribution

SettingtheAirSeparationPressure

Placethepaperstackontotheloadingtableandslideuptothefixedsidelayandpaper

Gate.Releasetheclampslocatedateachendofthesidelayandslideuptowardsthe

paperstackasdemonstratedinfig10.1.Allowagapofapproximately0.5mm(1/64inch)

betweenthepaperandthesidelay.

Positionthebackstopandslideuptowardsthepaperstackallowingagap(asspecified

intheabovestep).

Dependingonthelengthofthesheettobecreased,theairdistributionknobcanbe

rotatedtovariouspositionsinordertosupplyairtodifferentports.Position2is

recommendedformostsheetsizes.However,abetterresultmaybeobtainedbyusing

thesettingsbeloworbyexperimentation.

ForsheetslongerthanA3(17”)inordertosupplyairtothecentreofthe

stack,ports2,3and4open.

ForA5sheetsor8incheslong,ports1and2open.

ForA4sheetsor11incheslong,ports1and3open.

ForA3sheetsor17incheslong,ports1and4open.

ForsheetslongerthanA3(17”)inordertosupplyairtotheendsofthestack,

ports1and5open.

ForsheetslongerthanA3(17”)inordertosupplyairevenlyalongthestack,

ports1,3and5open.

Tocontroltheamountofairsuppliedtotheports,theairseparationknobcanberotated

clockwisetodecreasethepressureoranti-clockwisetoincreasethepressure.

Position1-

2-

3-

4-

5-

0-

Situatedonthefrontofthefeedtable,theVacuumBleedKnobisusedtoallowmore

controlofthesuctiononthevacuumdrum.

Whenlightweightpaperisbeingfedthroughthemachineturntheknobclockwiseto

reducethepossibilityofmarking,ordamagetotheleadingedgeofthepaper.

OperatingtheDigiFoldPro

DigiFoldPro

Page12 FOLDING

FIG15.1

WHEEL&HUBARRANGEMENT,(WHENFOLDING)

Settingthepositionsofdrivewheelsandhubs

Itisimportantthatthedrivewheelsanddrivehubs,ontherollershafts,arearrangedacross

thewidthofthemediabeingcreased;thisisdonetoensurethatthemediaisaccurately

drivenandsupportedthroughtherollers.Asuggestedlayout,,isshown

below(seeFIG15.1).Thesuggestedlayout,isdifferent,andisshownon

page44(seeFIG38.1).

Thedrivewheelsandhubsarefixedtotherollersbygrubscrews.

whenFolding

whenperfing,

OperatingtheDigiFoldPro

Page13SYSTEM

BLANK

PAGE

OperatingtheDigiFoldPro

DigiFoldPro

TOUCHSCREENOPERATION

1.TurntheEmergencyStopbuttonclockwisetoswitchthepoweron.Afterthe

systemstartupprocedurethetouchscreenwillbedisplayedasshownbelow.

WARNING:-

Waitatleast10seconds,aftermakinganyselectionontheTouchscreen

panel,beforeswitchingthemachineOFF.Failuretodosocouldresultinthe

datastoragebeingcorrupted,andthemachinenotoperating.

Thetouchscreenislaidoutinto3mainareasasshownbelow:

Page14 FOLDING

Statusof

machine &

dataentry

area.Also

usedfor

quicklinks

tosetting

pages.

Setting

page

Tabstoenableswitchingbetweensetting

pages -chooseeitherPaper Settings,Gap

settings,CreaseSetting,Foldsettings,

Deliverysettings,StoreandTools.

OperatingtheDigiFoldPro

IMPORTANT.

Ifyouhavenotbeentrainedtooperatethismachine,westronglyadvisethatyouselect

theredcrossicon.

Werecommendthatyoueitherseektrainingoraskatrainedoperatortorunthemachine

foryou.

Selectthegreentickicononlyifyouhavebeentrainedtooperatethismachine.

Ifyouhavenotbeentrainedtooperatethismachineandyouselectthegreentickicon,

MorganaSystemsLtdacceptnoresponsibilityforpersonalinjury,damagetothe

machineordamagetomaterialsbeingprocessedbythemachine.

Page15SYSTEM

Pre-setPapersizesfor

quickinsertion-Standard

sizesforcountryorigin

wouldbeshown.

Paperinput

PageThickness-On

selectionofstatus

areaisreplacedwith

acalculatorfor

inputtingnewvalues

Range=0.1to0.4mm

Incrementsof0.01mm

Arrowsmaybe

selectedtoincrease

ordecreasethepage

sizein0.1mm

increments

BatchButton-Image

isidenticaltothat

showninthestatus

area.Onselectionthe

statusareaisreplaced

withacalculatorfor

inputtingnewvalues.

Batchsizesof1to

998maybeset.

PaperType-Asa

guidechooseas

follows:

0-approx0.1thk

3-approx0.3+thk

1-approx0.2thk

2-approx0.3thk

PaperLength-Onselectionthestatusareaisreplacedwitha

calculatorforinputtingnewvalues.Lengthrange=190mm-900mm

FoldSelection-Forquicksettingoffoldpositionsonstandardsizesheets.

Highlightedfoldistypecurrentlyselected,otherfoldsmaybeselected.

Currentlyselectedfoldisshowninthestatusarea.

NOTE:-

SelecttheRulerIcontosetFoldpositionsmanually(’SetbyPosition’mode).

SettingPages.

PapersettingsPage

SeePage25

PapersizeSelection.

DigiFoldPro OperatingtheDigiFoldPro

Page16 FOLDING

Pre-setBatchsizesforquick

insertion.

Pre-setPaperThicknesssizes

forquickinsertion.

PaperThicknessinput

BatchsizeSelection.

PaperThicknessSelection.

OperatingtheDigiFoldPro

Page17SYSTEM

RollerGapSet&TiltMechanismPage.

Togettotherollergapsettingpageclickthelowertab

Rollergapsmaybeintherangeof0.05mmto1.5mm,withincrementsof0.05mm

Therollergapscanbeadjustedtosuitthethicknessofthematerialbeingcreasedor

folded;andthetypeoffoldbeingproduced.Therollergapsmayalsorequireadjustment

ifcrackingoftheprintisnoticeable.(seeFig13.1below).

SettingtheRollerGaps(Gap1,Gap2&Gap3)

Currentgapsetting

for2ndFoldRoller Currentgapsetting

for1stFoldRoller

Recommendedgapvalues-

basedonpaperthickness.

Currentgap

settingfor3rd

FoldRoller

CurrentsetTiltAngle

RollerGap3

RollerGap1

INFEED

FIG13.1

RollerGap2

K1

K2

DigiFoldPro OperatingtheDigiFoldPro

Page18 FOLDING

Thegapsettings(Gap1,Gap2&Gap3)canthenbeadjustedbyrotatingtheRoller

GapSetKnobs(seeFIG10.1onpage10).

Whensettingrollergaps,youfirstadjustthegaptoavaluegreaterthanthatrequired

andthendecreasethevaluetotherequiredsetting.(Donotsetthegap,fromavaluelower

thanthatrequired).

(i)MeasurethethicknessofthesheetusingaDigitalVernierCalliper.

(ii)SetrollerGAP1tothevernierreading.

(iii)SetrollerGAP2androllerGAP3,(forthetypeoffoldbeingproduced),usingthe

GAPSETGUIDEtableshownbelow.

Example1:-Whenproducingafold,ifGAP1is0.2(X)thensetGAP2to0.4

(2xX)andsetGAP3to0.4(2xX).

Example2:-Whenproducingafold,ifGAP1is0.3(X)thensetGAP2to0.3(X)

andsetGAP3to0.9(3xX).

IMPORTANT. must

PROCEDURE.

HalfK1

Gate

HalfFoldonKnife1

HalfFoldonKnife2 HalfK1

HalfK2

Letter

Concertina

Gate

ClosedGate

Engineering

FOLDTYPE GAP1GAP2GAP3

GAPSETGUIDE

X

2X

X

2X

3X

Double X2X4X

HALF

LETTER

DOUBLE

CLOSEDGATE ENGINEERING

GATE

CONCERTINA

FOLDTYPES

OperatingtheDigiFoldPro

Page19SYSTEM

SettingtheBladeTiltMechanism

Thebladetiltmechanismhasbeendesignedtocompensateforwhenthecreasing

positiononthesheetisnotsquare.Thiscouldbeduetoaninaccuracyinthemediaorif

thebladetiltmechanismhasbeenincorrectlyset.Themechanismwillbesettozero

(square)whenthemachineissupplied.TheBladeTiltMechanismcanbeadjustedif

necessarybyrotatingtheBladeTiltKnob(seeFIG10.1onpage10).

DigiFoldPro OperatingtheDigiFoldPro

Creasetrim-Onselection

thestatusareais

replacedwithacalculator

forinputtingnewvalues.

Creaseon/offselector

greenison&redisoff.

Thisisalsoindicatedin

thestatusarea.

Greyedoutareaindicates

thetrimisnotselectable

Creasesmaybetrimmed

by0.1mmincrements

withintherangeof

5.0mmto+5.0mm.

Statusshowscreasingoff

icon

Thisbuttontoggles

creasingon&off.

Page20 FOLDING

CreaseSettingsPages.

Togettothecreasesettingpageclickthelowertaborfromthe

statusarea.

IfyouhaveselectedapredefinedstandardFoldTypefromthepapersettingspage

thecreasepositionswillbesetforyou.Thesepositionscanbefinetunedby

Trimmingcreasesin‘SetByFold’mode.

Turncreasingoff.

Creasesin‘SetByFold’mode.

±0.1mm

incrementsbypressingthearrowbuttonsforeachcrease.

OperatingtheDigiFoldPro

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