90-125 Docufold Pro Operators Manual Iss.2

90-125 Docufold Pro Operators Manual Iss.2

DocuFold Pro

AUTOMATIC PAPER FOLDING MACHINE

OPERATORS MANUAL

Morgana Systems Limited United Kingdom

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

Website: www.morgana.co.uk

ISSUE 2 AUGUST 2011

90-125

INDEX

INTRODUCTION & SPECIFICATION

SAFETY Do’s & Don'ts

THE DocuFold Pro

Labelled Photograph

OPERATING THE DocuFold Pro

Adjusting the Paper Gate

Setting the Suction Slot

Setting the Vacuum Bleed

Setting the Adjustable Side Lay

Setting the Back Stop

Setting the Air Distribution Knob

Setting the Air Separation Knob

Fold Plates

Roller Tilt

Delivery Roller

Emergency Stop Switch

Overlap

TOUCHSCREEN OPERATION

Touchscreen Layout

Paper Settings Page

Batch Size selection

Speed Selection

Fold Settings Pages (Pre-defined fold types)

Setting Fold Positions Manually (Set by Position)

Delivery Settings Pages

Status Screen

Run Job

Store Pages

Tools Menu

PLUG IN PERFORATOR

Setting Perforators

Scoring

Folding Card

Paper Jams

Roller Assembly - Removal

Roller Adjustment

Sensor Cleaning

Fold Plates - Maintenance

PAGE 4

5

7

28

31

31

32

32

32

33

34

34

16

17

19

20

13

14

15

15

21

24

27

9

9

9

10

9

9

8

8

11

12

12

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Page 2

PAPER

DocuFold Pro

INDEX

FOLDING TIPS AND TROUBLESHOOTING

Sheets Difficult To Feed

Double Sheet Feeding

Fold Is Not Square Or Consistent

Paper Will Not Stack Consistently

Paper Will Not Deflect When Using One Fold Or Perforating

Total Batch Counter Not Working

‘Overlap Error Keeps Appearing

Machine Will Not Reset

No Power To Machine

Mains Switch Cuts Out

Fold Roller Replacement

ERROR SCREENS

DISPATCH KIT

ACCESSORIES AND OPTIONS

RECOMMENDED SPARES

FUSE POSITIONS & RATINGS

PRODUCT RECYCLING AND DISPOSAL

38

41

42

43

45

46

36

36

36

36

35

35

35

35

36

37

37

37

FOLDER

Page 3

INTRODUCTION

Docufold Pro

The Morgana Docufold Pro is a brand new concept automatic paper folding machine designed to be used in today's environment of document production. The Morgana

DocuFold Pro can be used by non-skilled personnel by following this easy to use operator's guide. There are very few operator adjustments required and in conjunction with our new

'Smart screen' you will get started very quickly, but we do recommend that you take a little time to read this manual, to ensure that you fully understand the machine. We have also included a TIPS & TROUBLE SHOOTING section. Be sure to read this section calling a service engineer to avoid any unnecessary expense.

before

On the DocuFold Pro. The fold plates and delivery roller will move automatically according to the type of fold selected. Please be aware that different weights, humidity, temperature or the grain direction of the paper may make the paper fold in a different position according to the material.

Some manual adjustment may sometimes be necessary to obtain the exact fold plate position for each type of paper.

IMPORTANT

The operating environment should be controlled to a temperature between

16° C and 27° C Maximum

Specification

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

Max. Sheet Size ................................................ 674mm x 365mm (26.5” x 14.4”)

Min. Sheet Size (in automatic mode)................. 160mm x 140mm (6.3” x 5.5”)

Max. Paper Weight ........................................... 240gsm Max. (0.24mm thick) according to hardness, type of fold, grain direction and substrate

Min. Paper Weight ............................................ 56gsm (0.08mm thick)

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

Max. Fold Length long plate.............................. 320mm (12.6”)

Max. Fold Length short plate............................. 225mm (8.85”)

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

Speed per Hour (A4 Material) ............................27500 sheets (Stream Feed)

17250 sheets (Pulsed Feed)

Speed per Hour (A3 Material) ............................18000 sheets (Stream Feed)

13250 sheets (Pulsed Feed)

Note: The production speed varies according to the material size.

Dimensions ....................................................... L: 1240mm H: 1370mm W: 555mm

L: (48.8”) H: (53.9”) W: (21.8”)

Weight ............................................................... 132Kgs (+50Kgs packing)

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

1 phase 220v 60Hz

Sound Power Level .......................................... 96.0 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

DocuFold Pro

Safety Do’s & Don’ts

Safety Do’s & Don’ts

REGLES DE SECURITE : « A FAIRE » ET « A NE PAS FAIRE »

Do - read this operator manual fully before operating the machine.

Lire ce mode d'emploi avant d'utiliser la machine.

Do - operate with the designated AC current only. Use an exclusive outlet, as overloading may cause fire or an electric shock.

Respecter l'alimentation électrique indiquée. Brancher sur une prise séparée car une surcharge peut entraîner un incendie ou un choc électrique.

Do - install the power cord out of the way to avoid a tripping hazard.

Installer le cordon d'alimentation de manière à ne pas pouvoir trébucher par dessus.

Do - make sure that the mains inlet connector is always easily accessible.

Ménager un accès libre à la prise de courant.

Do - Fit the yellow outrigger feet, (supplied in the Dispatch Kit), to the front and back of the machine as shown on Page 7; to comply with safety regulations.

Fixer les pieds stabilisateurs jaune, (fourni dans le kit d'expédition), à l'avant et l'arrière de la machine comme indiqué sur la page 7; pour se conformer aux règlements de sécurité.

Do not - install the machine in an unstable place such that it tilts or shakes.

Ne pas installer la machine sur une surface non plane, afin d'éviter qu'elle ne penche ou ne vibre.

Do not - unplug the plug or unplug the power cord from the outlet with a wet hand, this can cause an electric shock.

Ne pas installer la machine sur une surface non plane, afin d'éviter qu'elle ne penche ou ne vibre.

Do not - unscrew and remove any covers from the machine, as it can cause an electric shock or injury.

Ne démonter et enlever aucun carter de la machine, par crainte de décharge

électrique ou de blessure.

Do not - place receptacles containing liquids on any surface.

Ne pas placer de récipient contenant un liquide sur la machine.

Do not - adjust any part of the machine whilst rollers are running

N'effectuer aucun réglage pendant que les rouleaux fonctionnent.

Do not - operate the machine with loose or trailing clothing or loose hair.

Ne pas porter de vêtements flottants et rassembler les cheveux longs lors de l'utilisation de la machine.

Do not - under any circumstances adjust the paper gate when the machine is switched on.

En aucune circonstance, régler le séparateur de papier lorsque la machine est branchée.

Page 5

Warning Labels

Do - be aware of any finger traps and rotating parts when operating the machine.

Attention au risque de se coincer les doigts, et aux pièces en mouvement lors du fonctionnement de la machine.

Do - read this operator manual fully before operating the machine.

Lire ce mode d’emploi avant d’utiliser la machine.

Do not - operate the machine with loose or trailing clothing.

Ne pas porter de vêtements flottants lors de l'utilisation de la machine

Do not - operate the machine with loose hair.

Rassembler les cheveux longs lors de l'utilisation de la machine.

Page 6

Do - be aware of any finger traps and rotating parts when operating the machine.

Attention au risque de se coincer les doigts, et aux pièces en mouvement lors du fonctionnement de la machine.

Do - be aware of sharp points and blades.

Attention aux éléments tranchants et aux couteaux.

Do - be aware of rotating rollers.

Attention aux rouleaux en fonctionnement

Do - be aware of low current anti-static shock.

Attention aux faibles chocs d'électricité statique

PAPER

DocuFold Pro

Docufold Pro

AUTOMATIC PAPER FOLDING MACHINE

Key to drawing below

A Moving side lay knob H System switch

B Paper gate knob J Front pins

C Suction slot knob

D Air distribution knob

E Air separation knob

F Back Stop

G Moving side lay

K Upper fold plate

P Lead screw

Q Touch screen

R Roller Tilt lever

S Emergency stop switch

T Compressor switch

L Vacuum bleed knob U Extension table

N Delivery roller V Fixed side lay

X Fuses

Y Roller assy. release knob

Z Outrigger Foot

A Q B E F A V D

K

J

R

Y

U

P

N

T

S

C

L

FOLDER

Z H X

G

Page 7

Operating the DocuFold Pro

ADJUSTING THE PAPER GATE

Adjust the height of the paper gate using knob (B) (clockwise to lower, anti-clockwise to raise) so that the clearance above the vacuum roller is two thicknesses of the paper to be folded. Do not make this adjustment, when the face of the paper gate is above a hole in the vacuum roller, if it is, rotate the vacuum roller by hand to bring the metal between holes below the paper gate.

B

TWO THICKNESSES

OF PAPER

WARNING.

DO NOT ADJUST THE

PAPER GATE WHILE THE

MACHINE IS RUNNING OR

THE SUCTION DRUM MAY

BECOME DAMAGED.

On this machine, the paper gate is fixed in an optimum position and cannot be moved backwards and forwards (horizontally).

SETTING THE SUCTION SLOT

The suction slot inside the suction drum, may be adjusted by releasing knob (C) and swinging the knob in the desired position. Lighter stocks including bond will run best with the knob set to the left. For heavier stocks and curled-up stock, move the knob (C) to the right until a satisfactory position is obtained.

Paper Gate

Air Seperation

Knob

Back Stop

Vacuum

Bleed Knob

Suction

Slot Knob

Adjustable

Side Lay

Page 8

PAPER

DocuFold Pro

Operating the DocuFold Pro

SETTING THE VACUUM BLEED (L).

Situated on the front of the feed table, the Vacuum Bleed Knob is used to allow more control of the suction on the vacuum drum.

When light weight paper of 90gsm and lower is being fed through the machine turn the knob clockwise to reduce the possibility of marking, or damage to the leading edge of the paper.

SETTING THE ADJUSTABLE SIDE LAY

Place a single sheet of the job onto the loading table.

Release the side lay clamp screws (A) and slide the side lay just up to the sheet so that there is about half a millimetre clearance or 1/64 inch

Tighten the clamp screws.

SETTING THE BACK STOP (F)

This is placed up to the end of the paper stack and clamped to the moving side lay (G).

SETTING THE AIR DISTRIBUTION KNOB (D)

Depending on the length of the sheet, the air distribution knob (D) should be rotated to supply the air to the correct ports as follows -

Position 1 - This is for short sheets A5 or 8" long with only port 1 open.

Position 2 - This is for sheets A4 or 11" long with the front port and port 2 open.

Position 3 - This is for the longest sheets A3 or 17" with the front port and port 3 open.

Position 0 - In this position, only port 2 is open and can be used on long sheets with the curl up where you need to blow air into the centre of the stack.

These setting positions are only a guide and some experimentation may obtain a better result with non-standard settings.

(Note) Position 1 feeds most paper stocks and sizes; thus the air distribution knob can be left in this position for most jobs.

Port 1

Port 3

Air Distribution

Knob

SETTING THE AIR SEPARATION KNOB (E)

This knob controls the amount of air that is fed to the paper. The machine would normally run with this knob set at the 'High' position. If the machine is run with less than approximately 20 sheets on the loading table, or running the job to the last sheet, this knob should be set to the low position.

FOLDER

Page 9

Operating the DocuFold Pro

FOLD PLATES

ALWAYS UNPLUG POWER CONNECTIONS BEFORE REMOVING FOLD PLATES.

Fitting

Fit the fold plates into their respective positions (long fold plate upper and short plate lower), by locating the front pins (J) into the long slots and carefully sliding forwards (without twisting) until the rear pins can be located into the short slots. When fully in position, pull down the fold plate to lock into position. Connect the push-in power connectors - short lead to upper plate & long lead to lower plate.

Settings

The fold plate lengths are set automatically.

Fold plate Tilt

See roller tilt.

Page 10

DocuFold Pro

Operating the DocuFold Pro

Roller Tilt

Lever (R) should always be set in the ‘0’ (square) position. To adjust folding out of square you can move the roller assembly in the + or - direction by releasing knobs (Y) and moving lever (R) - always re-tighten Knobs (Y)

+

-

Page 11

Operating the DocuFold Pro

Delivery Roller

The delivery roller will adjust automatically according to the paper length and the fold type selected.

Manual or fine adjustment for the position of the delivery roller can be made as shown on Page 19.

You should adjust the roller position so that when the work is stopped by the delivery roller, it lies flat on the delivery without lying on the sloping plate, (See Diagram below), and without the green belts showing between the sloping plate and the folded sheet.

Sloping plate

Emergency Stop Switch (S)

This switch also serves as the main isolator.

It is important that the machine is switched off at the end of the days running, press this switch to isolate the machine.

To switch back on, rotate the switch head clockwise.

Overlap

The machine has a built in system that will detect any sheet that overlaps another sheet by at least 20mm. When this happens feeding will stop and the main switch will switch off, preventing serious jams. The error screen (shown below) will be displayed on the touchscreen..

Note that this is not a double detector and will not detect all double sheet feeds. However the overlap system is an indication of a tendency to double sheet feed and therefore the paper gate should be lowered slightly and the paper stack should be fanned out more thoroughly.

Page 12

DocuFold Pro

Operating the DocuFold Pro

TOUCHSCREEN OPERATION

1. 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.

If you have not been trained to operate this machine and you select the green tick icon,

Morgana Systems Ltd accept no responsibility for personal injury, damage to the machine or damage to materials being processed by the machine.

WARNING:-

Wait at least 10 seconds, after making any selection on the Touchscreen panel, before switching the machine OFF. Failure to do so could result in the data storage being corrupted, and the machine not operating.

The touch screen is laid out into 3 main areas as shown below:

Setting 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, Fold settings, Delivery setting, Store or Tools.

Page 13

Operating the DocuFold Pro

Setting Pages.

Paper settings Page

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 status area.

Vacuum suck – There are three selections available – 1 short suck, 2 long suck & 3 continuous for stream feeding.

Highlighted number is type currently selected.

The status area also shows the currently selected suck.

Select the Ruler icon to set the fold positions manually.

Perforating / scoring with fold button.

Speed Selector – On selection a speed adjustment screen will appear.

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.

Batch sizes of 1 to

998 may be set.

Page Length – On selection the status area is replaced with a calculator for inputting new values. Length range = 190mm – 900mm

Perforating / scoring button.

Arrows may be selected to increase or decrease the page size in 0.1mm

increments.

Paper size Selection.

Pre-set Paper sizes for quick insertion – Standard sizes for country origin would be shown.

Paper length input

Page 14

PAPER

Batch size Selection.

Operating the DocuFold Pro

Pre-set Batch sizes for quick insertion.

Speed Selection

Feed Speed selection slider – 20 positions to choose from.

Note: Motor speed will not change until you select run.

FOLDER

Page 15

Operating the DocuFold Pro

Fold Settings Pages.

T o get to the Fold setting page click the lower tab

.

Pre- defined Standard Folds.

I f you have selected a pre-defined standard Fold Type from the paper settings page the recommended fold positions will be shown in parenthesis and can be micro adjusted as required.

Fold 1 micro adjust – On selection the status area is replaced with a calculator for inputting new values.

Micro adjust range is -5.0

to +5.0 with increments of

0.1mm

Page 16

Folding can be micro adjusted for fine adjustment.

Micro adjust range is -5.0

to +5.0 with increments of

0.1mm

PAPER

DocuFold Pro

Operating the DocuFold Pro

Setting Fold Positions Manually (Set By Position).

I f you have selected the Ruler Icon from the paper settings page the fold positions can be set manually.

EXAMPLE 1.

(Set Fold 1 to 210.0, Set Fold 2 to 90.0)

210.0

210.0

90.0

90.0

Paper Length = 297.0mm

Feed Direction

Leading Edge

Fold 2 Fold 1

SETTINGS

Fold 1 = 210.0mm

Fold 2 = 90mm

All dimensions are from the leading edge of the paper

Leading Edge

Fold 1

= 210.0

Fold 2

= 90.0

Finished Document

(on delivery bed)

FOLDER

Page 17

Operating the DocuFold Pro

EXAMPLE 2.

(Set Fold 1 to 90.0, Set Fold 2 to 210.0)

90.0

90.0

210.0

210.0

Paper Length = 297.0mm

Feed Direction

Leading Edge

Fold 1 Fold 2

SETTINGS

Fold 1 = 90.0mm

Fold 2 = 210mm

All dimensions are from the leading edge of the paper

Morgana Logo on underside of this flap

Fold 1

= 90.0

Leading Edge

Finished Document

(on delivery bed)

Fold 2

= 210.0

NOTE.

When only one fold is required on the sheet, set Fold 1 and Fold 2 to the same values.

Page 18

DocuFold Pro

Operating the DocuFold Pro

Delivery Settings Pages.

T o get to the Delivery setting page click the lower tab

.

Roller position may be

Micro adjusted by clicking

Here.

Roller adjustment calculator

Page 19

Operating the DocuFold Pro

Status Screen.

Paper length

- input from the paper setting screen.

Currently selected fold type

- can be one of the following.

Fold Positions & Trim settings Currently selected Vacuum

Suck setting - for slow pulse choose selection 2

- for stream feed choose selection 3

Speed selector - On selection a speed adjustment screen will appear

Clicking in this area will take you to the store page

Green icon indicates settings are saved - a red icon would show that settings have changed but the job has not been saved.

Clicking in this area will take you to the fold settings page.

Batch quantity - this is input from the batch calculator on the paper setting screen - max. 999

Clicking in this area will take you to the delivery setting page.

Select this button to produce

3 test sheets with the settings currently shown.

Current job count - click to zero

A screen will appear to confirm that you want 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

Page 20

DocuFold Pro

Run Job.

Operating the DocuFold Pro

Click to run machine.

System Switch Not On, warning.

Click to confirm System switch is on. Switch

Compressor switch on & then click run button again.

Or click the icon to run three test sheets.

The display will briefly show that the fold plates and delivery roller are moving to their set positions, (as shown below).

Page 21

Operating the DocuFold Pro

The machine running screen will appear.

Run count

Batch Count

Job Count

Click to stop machine.

NOTES:-

1. The folds can be micro adjusted from the run screen, if necessary, while the job is still running.

2. The speed can also be adjusted from the run screen, while the job is still running.

Page 22

DocuFold Pro

Operating the DocuFold Pro

BLANK

PAGE

Page 23

Operating the DocuFold Pro

Store Pages.

To get to the Store setting page click the lower tab status area.

New Jobs.

or from the

Having set up your job you can give the job a name and save it to a store. You can also retrieve previously saved jobs, modify them or delete jobs you no longer require.

To create a new job name click in text area & keyboard will open to input job name.

Load existing job from store

Clicking to search currently stored jobs

Clicking to delete currently stored jobs

Clicking to save job shown.

Keyboard for entering job name.

Return to Store Menu & click save icon job to store to save

Page 24

DocuFold Pro

Save confirmation screen.

Operating the DocuFold Pro

To confirm saving of job click here.

Search for current jobs to load or modify.

You can search for jobs by clicking the search icon search keyboard for text input.

, this will bring up the

Type in job description or first few characters

Press search icon to start search

To change your mind & return to the previous screen click here.

Jobs matching characters in text box will be shown in this area - selecting job from this area will show job settings in the right hand status area. Job selected will be shown in text box.

Toggle between search results & full list of jobs

Press to load job shown in text box.

Page 25

Operating the DocuFold Pro

Loading job confirmation screen.

To cancel loading of

Job press here

To confirm loading of

Job press here

Loaded job may be modified and then re-saved as the same job name.

Overwrite job confirmation screen.

To cancel overwrite of

Job press here.

To confirm overwrite of Job press here

Delete job confirmation screen.

To cancel deletion of

Job press here

To confirm deletion of

Job press here

Page 26

DocuFold Pro

Operating the DocuFold Pro

Tools Menu.

To get to the Tools page click the lower tab

Touch screen software revision

Machine main board software revision

Page 27

Operating the DocuFold Pro

PLUG-IN PERFORATOR

The plug in perforator unit is used for perforating, scoring and when folding card cover stock; and should be stored on the rear stowage hooks.

ALWAYS UNPLUG POWER CONNECTORS BEFORE REMOVING FOLD PLATES

OR PLUG-IN PERFORATOR.

Remove the top fold plate and fit the catch tray in position by hooking it over the opening for the top fold plate. The plug in perforator unit then locates the same as the fold plate and again, take care not to twist when fitting into position. You may need to turn the hand wheel and push the perforator unit inwards to engage the drive gear. Plug in the lower fold plate power connector into the perforator unit.

For all applications, the unit is set on the bench, using the scale to indicate the positions of the blades and hubs. It is important to spread the hubs evenly across the width of the work to reduce the risk of paper jams.

NOTE:-

When perforating or scoring without folding

and replaced with the lower fold plate.

, the upper fold plate must be removed

Ensure that the tilt roller is at zero, plug the upper plate connector into the lower plate.

To prevent damage to the unused upper plate when scoring or perforating, store safely on the stowage hooks at the reverse side of the machine.

Press the start button, the built in deflector on the fold plate will close automatically to the deflect position.

Note: - the Docufold Pro will automatically recognise that the lower plate is in the upper plate position and that the plug-in perforator unit is in the lower plate position.

Press the start button again to run the job, or the ‘3’ button to run three test sheets.

Note: - Always run perforating or scoring jobs on pulse feed.

NOTE:-

When perforating or scoring with folding , the upper fold plate remains in position, at the top.

FITTING PERFORATER BLADES

The perforator blades are split into two matching halves and are fitted to the upper hubs as shown in the drawing using the four screws supplied.

Page 28

PAPER

DocuFold Pro

Operating the DocuFold Pro

FOLDER

Page 29

Operating the DocuFold Pro

SCALE PERFORATING BLADE

22 21 20 19 18 17 16

PERFORATOR STRIPPER UPPER TYRE AND HUB ASSEMBLIES FRAME PAD

14 13 12 11 10 9 8 7 6 5 4 3 2 1

0

ANVIL

UPPER PERF SHAFT

LOWER PERF SHAFT LOWER HUBS (SOLID) EDGE OF SHEET

RECOMMENDED PERFORATOR SET - UP

DRIVE HUB

SCALE UPPER PERF SHAFT SCORER UPPER TYRE AND HUB ASSEMBLIES

22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

FRAME PAD

1,0 mm

( 3/64")

LOWER PERF SHAFT

1,0 mm

( 3/64")

1,0 mm

( 3/64")

1,0 mm

( 3/64")

LOWER HUBS (SOLID)

1,0 mm

( 3/64")

EDGE OF SHEET

RECOMMENDED SCORER SET - UP

DRIVE HUB

Page 30

PAPER

DocuFold Pro

Operating the DocuFold Pro

SETTING PERFORATORS

Upper and lower hubs can be positioned on the shaft by unscrewing the 2mm-grub screw.

Slide the hub with the blade attached along, the shaft into position to correspond to the work using the scale as a guide. For example, to perforate 20mm from the edge of an A4 sheet, you would set the blade at 190mm (210 minus 20). When positioned re-tighten the

2mm-grub screw. Important - Do Not Over Tighten This Grub Screw

Slide the hub with the anvil, up to the perforator blade and the remaining upper and lower hubs, set as the drawing, remembering to spread them to support the sheet fully across its width.

Clip the perforator stripper adjacent to the upper hub as shown. Plug the unit into position, fit the sheet smoother into position to hold the sheets down and run the machine at the slow speed to check position.

Adjust the backstop and side guide to suit the work.

For work longer than the backstop will allow, remove the backstop and use the extended backstop that is located underneath the catch tray.

There is a full range of perforator blades available as follows:

For fine perforation 56 tooth - Part Number 1.99-41

For Paper 28 tooth - Part Number 1.99-12

For heavier Stock 20 tooth - Part Number 1.99-10

For use with blades Anvil - Part Number 1.99-35

Slitter set for cutting - Part Number 1.99-13

SCORING

It is possible to score work using the plug in perforator. The scorers are split in two halves, fitted to the upper shaft and set as shown in the drawing using the scale on the unit as a guide to position. The lower hubs are moved up to but just clear of the scoring blade. The actual gap is critical and may require some experimentation to obtain a satisfactory score line. As with perforating, the remaining hubs must be spread to support the sheet fully across its width.

Scorers available:

Type A

Type B

Type D

Part Number

Part Number

Part Number

6.99-05

6.99-06

6.99-09 for most card for deep score for paper

FOLDER

Page 31

Operating the DocuFold Pro

FOLDING CARD

For best results, the card material should always be printed cross grain as this causes less resistance when folding. Pre scoring of card stock is also recommended

By using the plug in perforator unit to deliver card, the problem of the stock curling will be minimised. Put the upper plate into the upper plate position and the plug-in perforator unit into the lower plate position. Plug in power connectors - upper into upper fold plate and lower into perforator unit.

Set the backstop and the moving side lay to suit the work. Set the paper length.

Press the start button, the upper plate will automatically move to half the length of the stack of cover stock.

Fine adjustments may be necessary to the fold position as described on page 16.

It is recommended that when folding card, the machine be set to batch after twenty sheets, which will allow easy off loading. For longer runs an optional rear delivery belt stacker (Assy. No. 9-09-01) is recommended to be used.

In the event of a paper jam, the sensor will cut out the main switch. The main fold rollers are linked to a clutch, which will prevent sheets continuing to feed.

PAPER JAMS

If for some reason a piece of paper jams in the machine, remove and check inside the fold plates. If there is paper jammed around the fold rollers take hold of a roller and wind them by hand to remove the jam. If it is impossible to wind the roller by hand, remove the roller assembly as described below. After clearing a paper jam, always check inside the fold plate (see Fold Plate Section) to make sure no torn pieces of paper are jammed inside the plate.

ROLLER ASSEMBLY - REMOVAL

The complete roller assembly unit can be removed from the machine simply by unscrewing the knobs (Y) on each side and taking hold of the rear roller and lifting out the unit. This is beneficial to clear paper jams, to clean the roller and for maintenance.

With the roller assembly removed, the safety circuit prevents the machine from running.

Replace the roller unit in the reverse sequence. Clean the rollers with a stiff brush between the grooves using QD wash supplied by Morgana.

Page 32

PAPER

DocuFold Pro

Operating the DocuFold Pro

ROLLER ADJUSTMENT

The unique fold roller design of your Morgana Docufold Pro will fold most paper stocks without the need for adjustment. If you have a requirement to fold very delicate or thicker stock or refeeding to produce a cross-fold the fold roller gap can be easily adjusted as follows: -

1. Remove the roller assembly from the machine as described above.

2. Loosen the Cap Head Screw on the operators side of the roller that you wish to adjust (any of the 3 outer rollers) using the 5 mm Bondus ‘L’ wrench provided & release the M8 lock nut on the non-operators side with the 13 A/F spanner provided.

3. Insert the 4 mm hex ball driver into the socket screw at the end of the roller shaft and rotate in the required direction to adjust the roller gap.

4. The graphics on the inside of the roller side plate show which way to turn the roller to adjust the gap relative to the centre roller.

5. Re-tighten the half nuts & cap head screws to lock the roller into position.

6. Repeat procedure for each roller that you wish to adjust and then replace the roller assembly into the machine.

7. Reset the roller tilt knob (R) back to the zero central position and screw in the Clamping knobs (Y).

Section Through Roller Assembly

FOLDER

Centre Roller (Fixed)

3 Outer Rollers (Adjustable)

Page 33

SENSOR CLEANING

The sensors to detect and count the sheets are located on the ends of the ball holder just next to the fold roller unit. If the counter is failing the sensor can be accessed for cleaning by removing the roller assembly as described on page 32. Clean by using a soft brush or damp cloth.

FOLD PLATES - MAINTENANCE

The fold plates can be opened up for maintenance, removing paper jams, cleaning, etc by removing the two bolts shown below. The fold plate can then be hinged open.

Bolt

Bolt

Page 34

PAPER

DocuFold Pro

FOLDING TIPS AND TROUBLE SHOOTING:

SHEETS DIFFICULT TO FEED

Check that you have not got too many sheets in the feeder. Heavy-coated stock will not feed as high a pile as for example 80-gsm copier paper.

Make sure the moving side lay is not pushed in too tightly against the paper. Similarly, if the moving side lay is set too far away from the paper stack, this will allow the air to escape instead of blowing through the paper.

Make sure that the gap under the paper gate (B) is not set too low.

Turn the Air separation knob (E) to the high position.

Make sure that air distribution knob (D) is set correctly.

If the paper width varies you may need to trim the sheets to the same size.

If the paper is curling upwards the suction drum may not be able to pull the sheet downward to wrap around the drum for efficient feeding. You may need to bend the sheets downward prior to loading.

DOUBLE SHEET FEEDING

Make sure the gap under the paper gate (B) is not set too high.

Make sure the air distribution knob (D) and the air separation knob (E) are at the correct setting.

In extreme cases you may need to separate the sheets prior to loading.

Make sure you run on Pulse not Stream.

FOLD IS NOT SQUARE OR CONSISTENT

Check the sheets are all exactly the same size and are square before folding as you can only fold accurately if the material is consistent.

Make sure you have no foreign bodies such as fragments of torn paper inside the fold plates or the fold rollers.

Check that the fold plates are locked and located securely and that the roller tilt mechanism is set to zero and locked.

FOLDER

Page 35

PAPER WILL NOT STACK CONSISTENTLY:

Make sure the feed is consistent before attempting adjustments to the Delivery Roller.

Set the delivery roller position as described in the manual. Sometimes a small repositioning of the roller will improve the stacking. See Delivery Roller (Page 19)

If the paper is too curly when being delivered, place the catch tray and plug in perforating unit with blades disengaged into position and deliver out the back. This applies to single fold applications only. If two folds are required, you may need to reduce the weight of stock to achieve the desired results.

PAPER WILL NOT DEFLECT WHEN USING ONE FOLD OR PERFORATING:

Check to make sure that the second plate is being used as the deflector.

Make sure that the plate is located securely and that the deflector bar is wound right to the end.

Set the tilt roller mechanism to zero.

Check that the material is not too heavy to deflect.

TOTAL AND BATCH COUNTER NOT WORKING:

Clean the sensors as described in the manual.

OVERLAP ERROR KEEPS APPEARING ON TOUCHSCREEN

If the overlap keeps tripping in and cutting off the machine, first check you are not feeding doubles and reset the feeder.

Overlap tripping can also mean that the machine is slowing slightly which may mean the material is too heavy.

Check that you have no foreign bodies or torn paper stuck inside the plates or machine.

MACHINE WILL NOT RESET

Your Docufold Pro is a mini computer; you must have a clean consistent power supply. Switch off at power switch (S), wait 20 seconds and re-power.

Page 36

PAPER

DocuFold Pro

NO POWER TO MACHINE

If the touchscreen display fails to come on, check that isolator switch (S) is not pressed in.

To release, turn knob clockwise.

Check power supply to the machine.

MAIN SWITCH CUTS OUT:

The feeder will cut out automatically after 100 seconds if the main switch is left on without the feed switch being activated.

The compressor inside the machine requires up to 28 amps to start running. You must have the machine plugged directly into a 30-amp ring main. Do not attempt to run the machine with an extension lead.

The main switch will cut out if you have a paper jam or overlap is indicated.

FOLD ROLLER REPLACEMENT:

Your Morgana Docufold Pro has been designed to make fold roller replacement an easy and low cost operation. Your local sales agent will be able to supply you with a complete replacement roller assembly which allows you to change the roller assembly yourself as described in the roller assembly removal section of this manual. You will need to send back to your agent the existing roller assembly.

FOLDER

Page 37

Error Screens

Sheet did not arrive.

If the machine stops and error message 01 is displayed on the touch screen, this indicates that the paper did not arrive at the end of the suck process; so the machine timed out. Press the green tick button and then press the start button.

Overlap

If the machine stops and error message 13 is displayed on the touch screen, 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). Check that the paper gate has been set correctly.

Upper fold plate set out of range.

If the touchscreen shows the error screen shown below, this indicates that the fold that has been set for the upper fold plate is out of range.

Page 38

DocuFold Pro

Error Screens (continued)

Lower fold plate set out of range.

If the touchscreen shows the error screen shown below, this indicates that the fold that has been set for the lower fold plate is out of range.

Incorrect fold plate fitted for perforating or scoring (without folding) .

If the touchscreen shows the error screen shown below, this indicates that the wrong fold plate is fitted. When perforating or scoring (without folding) the

short fold plate

must be fitted in the upper slot position.

Incorrect fold plate fitted for perforating or scoring (with folding) .

If the touchscreen shows the error screen shown below, this indicates that the wrong fold plate is fitted. When perforating or scoring (with folding) the

long fold plate

must be fitted in the upper slot position.

Page 39

Error Screens (continued)

Perforating / Scoring unit not fitted .

If the touchscreen shows the error screen shown below, this indicates that the machine has been set for perforating or scoring (

without folding

) and the perforating

/ scoring unit has not been fitted.

Perforating / Scoring unit not fitted .

If the touchscreen shows the error screen shown below, this indicates that the machine has been set for perforating or scoring (

with folding

) and the perforating

/ scoring unit has not been fitted.

System switch not on .

If the touchscreen shows the error screen shown below, this indicates that the system switch must be switched to the ON position.

Page 40

PAPER

DocuFold Pro

DISPATCH KIT

9-95-10 (UK)

9-95-11 (USA)

ITEM PART NUMBER QTY

1

9 0 - 1 2 5

1

DESCRIPTION

DOCUFOLD PRO OPERATORS MANUAL

2 9 0 - 0 1 8 1

ROLLER CLEANING KIT

3

6 5 0 -0 4 0

6 5 0 -0 4 1

1

1

POWER CORD - C19 - 3Pin - UK

POWER CORD - C19 - 3Pin - USA

4

5

6

7

8

9

10

11

6 5 0 -0 1 6

6 1 7 - 0 0 4

6 20 - 00 7

6 2 0 - 0 20

6 20 - 00 4

6 2 0 - 0 06

6 2 0 - 02 5

6 2 0 - 0 27

1

L6 - 15P Re-Wirable Plug (Used on USA Only)

5

GLASS BALL

1

1

1

HEX BALL DRIVER - 2mm

HEX BALL DRIVER - 2.5mm

HEX BALL DRIVER - 4.0mm

1

ALLEN KEY - 3mm

1

1

BONDUS 'L' WRENCH - 2.5mm

BONDUS 'L' WRENCH - 5.0mm

12

6 2 0 - 0 32 1

COMBINATION SPANNER - 13 A/F

1

DISPATCH BOX

13 6 2 4 - 0 18

14

15

16

1 - 99 - 35

1 - 99 - 41

6 - 99 - 0 5

1

1

1

ANVIL SET

PERFORATING SET - 56T - SLITTING

SCORING SET - TYPE A

17

18

7 1 - 0 8 3 -0 1

4 01 - 02 -0 5 0 - 0 08

2

2

OUTRIGGER FOOT

SCREW - PAN POZI TAPTITE - M5 X 8 LONG

WARNING......

THE BLADES FOR ANVIL, PERFORATING, & SCORING SETS ARE

SUPPLIED AS MATCHED PAIRS AND SHOULD NEVER BE MIXED -UP OR

LEFT UN-PROTECTED AS SERIOUS DAMAGE WILL RESULT.

FOLDER

Page 41

ACCESSORIES & OPTIONS

ITEM

1

2

9

10

11

3

4

5

6

7

8

PART NUMBER

6-99-06

6-99-09

DESCRIPTION

SCORING SET - TYPE B

SCORING SET - TYPE D

1-99-10

1-99-11

1-99-12

1-99-41

1-99-13

1-99-35

98-018-02

69-033

6-99-36

PERFORATING SET - 20T SLITTING

PERFORATING SET - 20T SLITTING - HEAVY DUTY

PERFORATING SET - 28T SLITTING

PERFORATING SET - 56T SLITTING

SLITTING BLADE SET

ANVIL SET

PERFORATOR STRIPPER SET - LONG

SHEET SMOOTHER - STACKER - LONG

PAPER PROFILE ROLLERS - SET (SPLIT)

ACCESSORIES....

....May be obtained from your dealer and fitted to your machine using the instructions supplied, or by consulting your operators manual.

OPTIONS....

....May also be obtained and fitted

by your dealer. You should not attempt to fit options yourself as specialist tools and knowledge are required.

Technician Maintenance

It is recommended that your machine is fully serviced at least once every six months by a factory trained Service Engineer.

Page 42

PAPER

DocuFold Pro

RECOMMENDED SPARES

PART NUMBER

75 - 06 - 02

75 - 500 - 03

76 - 272

90 - 06 - 01

90 - 08 - 01

92 - 010

92 - 027-01

93 - 021

93 - 022

93 - 028

93 - 042

94-088

95 - 138

95 - 150 - 01

95 - 151 - 01

95 - 152 - 01

95 - 153 - 01

95 - 187

96 - 028 - 02

96 - 031

96 - 049 - 02

97 - 121

97 - 076

174 - 19 - 01

601 - 021

601 - 111

606 - 030

607 - 005

607 - 022

607 025

607 - 026

607 - 027

607 - 160

609 - 011

609 - 012

609 - 013

DESCRIPTION

TOUCH SCREEN ASSY - 7" (NEW CONTROLLER)

MINI ITX MOTHERBOARD - DOCUFOLD PRO

PSU ASSEMBLY - ATX12V - 300W

CONTROLLER PCB ASSY - DOCUFOLD PRO

PCB - FOLD PLATE MOTOR DRIVE

TRANSPORT BELT Delivery

DRIVE BELT - Delivery - Flat 12mm

FEED BELT

DRIVE BELT - Vacuum Roller

SMOOTHER - Delivery

LOWER SENSOR ASSEMBLY

UPPER SENSOR ASSEMBLY

DC MOTOR PCB ASSY.

HOSE - Exhaust

HOSE - Vacuum

HOSE - Sheet Separation

HOSE - Valve

POT & LEAD ASSEMBLY - DELIVERY ROLLER

FOLD ROLLER ASSEMBLY - Standard

DRIVE BELT - Large Roller Drive

FOLD ROLLER ASSEMBLY - Bottom

POT & LEAD ASSEMBLY - FOLD PLATE

STEPPER MOTOR & LEAD ASSEMBLY

RS232 ADAPTOR PCB ASSY

MAGNETIC ACTUATOR

TAPERED FERRULE - SR1520 - Ø7.9 x Ø13 x 23 LG.

Black

TIMING BELT - 100XL 037

TWIN GRIP TIMING BELT

TIMING BELT

TIMING BELT

TIMING BELT

TIMING BELT - T2.5 /317.5 x 6MM WIDE

'O' RING

‘O’ RING - WHITE SILICON - Ø50 X Ø4

'O' RING

FOLDER

Page 43

RECOMMENDED SPARES

PART NUMBER

609 - 014

609 - 023

613 - 137

613 - 255

613 - 365

652 - 011

652 - 043

655 - 015

DESCRIPTION

'O' RING

‘O' RING

PLUNGER & SPRING ASSY

SOLENOID COIL

EMERGENCY STOP SWITCH

SWITCH - LOW CURRENT COIL - BLACK ROCKER

SWITCH - 240 VOLT COIL - 20A

POWER SUPPLY UNIT - SWITCHED MODE - 24V

NOTE.....

The items listed above represent parts which are subject to wear, loss, or accidental damage, and is included for your guidance only.

Replacement of most of the parts fitted to your machine requires specialist knowledge and should therefore be entrusted to your dealer.

Page 44

DocuFold Pro

FUSE POSITIONS & RATINGS

(POSITION ET CLASSIFICATION DES FUSIBLES)

PSU (5V / 12V)

(FUSIBLE PSU (5V/12 V)

F3.15AH 250 (613-023)

PSU (24V)

(FUSIBLE PSU (24V )

T4.0AH 250 (681-015)

SPARE FUSE

POSITION

(POSITION PORTE

FUSIBLE)

MOTOR SPEED

CONTROLLER PCB

F3.15AH 250 (613-023)

Page 45

PRODUCT RECYCLING & DISPOSAL

European Union

Disposal Information for Commercial Users

Application of this symbol on your equipment is confirmation that you must dispose of this equipment in compliance with agreed national

Procedures.

In accordance with European legislation end of life electrical and electronic equipment subject to disposal must be managed within agreed procedures.

Prior to disposal please contact your local dealer or representative for end of life take back information.

Disposal Information for Domestic Users

Application of this symbol on your equipment is confirm ation that you should not dispose of the equipment in the norm al household waste stream.

In accordance with European legislation, end of life electrical and electronic equipm ent subject to disposal must be segregated from household waste.

Private households within EU Member States m ay return used electrical and electronic equipment to designated collection facilities free of charge. Please contact your local disposal authority for information.

In some Mem ber States when you purchase new equipment your local retailer m ay be required to take back your old equipm ent free of charge. Please ask your retailer for inform ation.

Other Countries

Please contact your local waste authorities and request disposal information.

Page 46

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