paper folding machine

paper folding machine
PAPER FOLDING
MACHINE
OPERATORS MANUAL
Morgana Systems Limited
Snowdon Drive Winterhill
Milton
Keynes Buckinghamshire MK6 1AP United Kingdom
Telephone: ( 01908 ) 608888
Facsimile: ( 01908 ) 692399
ISSUE 3 MARCH 2002
90-011
N
J
H
K
L
M
I
A
C B
E
AA
F
A
FIXED
SIDELAY
Z
Y
D
Q
G
X
T
U
V
W
S
PAPER FOLDING MACHINE
PAGE 2
PAPER
FOLDER
PAGE 3
OPERATORS INTRODUCTION TO THE MORGANA JUNIOR/DOCUFOLD
The Morgana Junior/Docufold is a brand new concept paper folding machine. Designed to be
used in today's environment of document production, the Morgana Junior can be used by non
skilled personnel by following this easy to use operators guide. There are very few operator
adjustments required on the machine and our KWIK START section will get you 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 before calling a service engineer to avoid any unnecessary
expense.
KWIK START GUIDE:
1. Set the paper gate gap (knob B) to two thickness of the paper to be folded.
2. Place the paper to be folded onto the loading table against the fixed side lay.
3. Unclamp the moving side lay (knobs A) and slide up against the side of the paper but allow
approximately a 1/2 mm or 1/64 inch gap between the moving side lay and the paper.
4. Clamp the backstop (F) onto the moving side lay at the back of the paper stack.
(Note) Do not attempt to load too many sheets onto the loading table during set up as this
may affect the feeding operation.
5. Look at the diagram showing the various fold types and standard paper sizes. Select the
type of fold that you require to make.
6. Unlock the fold plate locking the knob (H) on the fold plates and press button L on the 1st
fold plate. This will display the fold plate setting position. Turn the dial J to the dimension
required as indicated on the fold type diagram. Lock knob H. Repeat this operation for the
2nd fold plate.
7. Fold a sheet of paper by hand to the finished folded size and set the delivery stacking roller.
8. Make sure you have power to the machine and that knob (S) is turned onto the ON position.
Start the machine with switch (T) and by pressing the feed switch on and off quickly you
will feed a single sheet. Check the fold for correct length and adjust if necessary. If correct,
zero the counter by pressing switch W upwards. Select batch size if required by turning
knob (V). Press feed switch and the machine will start the folding operation.
PAGE 4
PAPER
MORGANA JUNIOR/DOCUFOLD OPERATOR INSTRUCTIONS
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.
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.
On this machine, the paper gate is fixed in an optimum position and cannot be moved
backwards and forwards (horizontally).
SUCTION OPENING
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.
SETTING THE ‘SHORT SUCK’ OR ‘LONG SUCK’ MODE OF OPERATION.
The Morgana Junior can be set to a ‘Short Suck’ mode of operation, which improves the
feed of A4 sheets (in landscape orientation), and also improves the feed of sheets smaller
than A4. The ‘Short Suck’ mode of operation is particularly useful for perforating or scoring
applications.
Operation
Set the “Feed’ switch (U) on the operator panel to the up position (‘Off’).
Set the “Reset Pulse’ switch (W) on the operator panel to the down position (‘Stream’).
Turn the ‘Batch’ knob (V) on the operator panel to select “P1’ or ‘P2’ in the Batch Counter
Display Window.
P1 = Short Suck mode of operation.
FOLDER
P2 = Long Suck mode of operation.
PAGE 5
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.
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.
BACK STOP (F)
This is placed up to the end of the paper stack and clamped to the moving side lay (G).
FOLD PLATES
Fitting
Fit the fold plates into their respective positions (long fold plate upper and short plate lower), by
locating the front pins (I) 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.
Settings
Set the fold length by releasing the lock knob (H) and rotating the dial (J). The fold length may
be read on a manual plate directly off the scale (K) or for the digital fold plate by pressing the
'ON' button (L). More precise movements will be registered by pressing 'micro' button M which
will display increments (of one tenth of a millimetre, or for imperial machines one hundredth of
an inch). To preserve battery life, the display will switch off after 30 seconds.
Fold plate Tilt
If the fold needs to be tilted, this can be achieved by releasing knob (N) and turning the dial (J),
(Do not release lock knob (H)). Moving the dial to the + direction will increase the fold length
on the operator side.
PAGE 6
PAPER
Roller Tilt
Lever (AA) 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 (AA) – always re-tighten Knobs (Y).
You can move knob (AA) on it’s own or in conjunction with the fold plate tilt, + on the fold
plate tilt moves paper in the same direction as + on the roller tilt.
+
FOLDER
-
PAGE 7
Deflect
The second (short) fold plate has the ability to be shut off into a deflect position to enable
single folds to be achieved without removing the fold plate from the machine. To set the plate
to deflect, first ensure that the tilt is set at zero, then after releasing the lock knob (H), keep
winding the dial (J) to minimum length until it stops, then tighten the lock (H). The digital
plate will show a series of dashes --- in the window.
Stacking Roller
The stacking roller must be set according to the length of the folded work. The roller is moved
by releasing knob (P) while sliding the block Q to the required position. You should adjust the
roller position so that when the work is stopped by the stacking roller, it lies flat on the delivery
without lying on the sloping plate (R) and without the green belts showing between the sloping
plate (R) and the folded sheet.
Emergency Stop Switch (S)
This switch also serves as the main isolator and when 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.
Main Switch (T)
The main switch (T) will run the whole machine. This switch incorporates a circuit that
switches off every 100 seconds whilst the feed switch U is in the off position. The main switch
may disengage seemingly at random but this is a normal function and may be instantly reengaged.
Feed Switch (U)
Switches the feed on and off.
Batch Knob (V)
The batch knob is a rotary switch and turning the knob slightly so that it moves one position
will cause the display to show the set batch quantity. Moving the knob further will change the
batch quantity in multiples of 10 up to 990. Stopping the feed in the middle of a batch will not
affect the batch. When the machine batches, the feed will stop and the display will show the
batch quantity with a series of dashes. Feeding will resume after a short period. If batching is
not required, turn the batch knob (V) until it reads 0 in the display panel. When 0 is shown
after turning batch knob (V) the counter will only total count.
PAGE 8
PAPER
Reset Switch W
This switch has two functions:
1. To set the type of feed, either pulse or stream
2. To zero the total and batch counts
The switch has three positions:
• Operating the switch upwards will zero the total count and if part way through a batch, it
will reset the batch count.
• After operating the switch upwards, it will spring back to its centre (default) position. In
this position the feeder pauses between each sheet fed, leaving a gap between sheets. This
is called pulse feed.
• Operating the switch to its lowest position will change the feed to continuous with the
sheets following directly behind each other. This is called stream feed.
(Note) – In the pulse position a gap of 160 mm will be set between each sheet as it is being fed
into the machine. This gap prevents sheets over lapping inside the fold plates, which lessens the
chance of static being generated and will decrease paper jams.
Zigzag / concertina, engineering and gate folds should only be run on pulse. By holding switch
(W) down, the feed mode will switch to stream feed which will feed paper with little or no gap
between the sheets. Stream feed will increase productivity but folding accuracy may be slightly
impaired. Only use stream on letter, half or double parallel folds.
The pulse feed will cope with all types of fold including perforating.
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 and the display will show 'O-LAP'. 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.
Speed Control (X)
The machine has two running speeds, which are selected by the handle (X). Pushing the handle
sharply into the machine will select the fast speed. Pulling the handle sharply outwards will
select the slow speed. The slow speed is recommended when running work that is difficult to
stack, for example when perforating or folding an engineering type fold.
FOLDER
PAGE 9
PLUG-IN PERFORATOR
The plug in perforator unit is used for perforating scoring and when folding card cover stock.
Remove the second fold plate and fit the catch tray in position by hooking it over the opening
for the second 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.
For all applications, the unit is set on the bench using the scale to indicate 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.
When perforating or scoring without folding, the first fold plate must be removed and replaced
with the second fold plate. Ensure that the tilt is at zero and set the second fold plate to deflect.
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.
A hardened anvil is fitted to the lower hub as shown in the drawing also using the four screws
supplied. Again the anvils are made from matching halves. Note - Do not mix matching halves
of blades or anvils
Important - THE PERFORATOR BLADES ARE VERY SHARP AND GREAT CARE
MUST BE TAKEN WHILST HANDLING.
PAGE 10
PAPER
SCALE
22
PERFORATING BLADE
21
20
19
18
17
PERFORATOR STRIPPER
16
14
13
12
11
10
UPPER TYRE AND HUB ASSEMBLIES
9
8
7
6
5
4
3
2
1
FRAME PAD
0
UPPER PERF SHAFT
ANVIL
LOWER PERF SHAFT
LOWER HUBS (SOLID)
EDGE OF SHEET
DRIVE HUB
RECOMMENDED PERFORATOR SET - UP
SCALE
22
21
UPPER PERF SHAFT
20
19
1,0 mm
( 3/64")
LOWER PERF SHAFT
18
17
16
15
SCORER
14
13
12
11
UPPER TYRE AND HUB ASSEMBLIES
10
9
8
1,0 mm
( 3/64")
LOWER HUBS (SOLID)
7
6
1,0 mm
( 3/64")
1,0 mm
( 3/64")
5
4
3
2
FRAME PAD
1
0
1,0 mm
( 3/64")
EDGE OF SHEET
DRIVE HUB
RECOMMENDED SCORER SET - UP
FOLDER
PAGE 11
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
For Paper
For heavier Stock
For use with blades
Slitter set for cutting
56 tooth
28 tooth
20 tooth
Anvil
-
Part Number 1.99-41
Part Number 1.99-12
Part Number 1.99-10
Part Number 1.99-35
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
PAGE 12
Part Number
Part Number
Part Number
6.99-05
6.99-06
6.99-09
for most card
for deep score
for paper
PAPER
FOLDER
PAGE 13
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. Set the backstop and side guide to suit the work. It is recommended that when
folding card, the machine is set to batch after twenty sheets, which will allow easy off loading.
For longer runs a 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.
PAGE 14
PAPER
ROLLER ADJUSTMENT
The unique fold roller design of your Morgana Junior 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 (AA) back to the zero central position and screw in the Clamping
knobs (Y).
Rotate Roller in this direction to increase Gap
(each graduation equals 0.1 mm of gap adjustment)
Centre Roller
3 Outer Rollers (Adjustable)
Section Through Roller Assembly
FOLDER
PAGE 15
SENSOR CLEANING
The sensors to detect and count the sheets are located on the end of the ball holder just
next to the fold roller unit. If the counter is failing, the sensors can be accessed for
cleaning by removing the roller assembly as described above. Clean by using a soft
brush or damp cloth.
FOLD PLATES - M A INTENANCE
The fold plates can be opened up for maintenance, cleaning, etc by removing the lock
knob (H) and removing the two bolts (Z). The fold plate will then open up to enable
paper jams to be removed or cleaning on digital fold plates, replacement of the battery.
(Battery Part Number 613.379)
PAGE 16
PAPER
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 CONSISTANT
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 tilt mechanism is set to
zero and locked.
Check that the stock is not too heavy, particularly if folding against the grain.
Check that the moving side lay is set up to the paper, without too much gap that will allow the
sheets to twist
FOLDER
PAGE 17
PAPER WILL NOT STACK CONSISTENTLY:
Make sure the feed is consistent before attempting adjustments to the stacker.
Set the stacking roller position as described in the manual. Sometimes a small repositioning of
the roller will improve the stacking.
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 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.
O-LAP KEEPS APPEARING ON COUNTER BOARD
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.
PAGE 18
PAPER
NO POWER TO MACHINE
If control panel 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 Junior/Docufold 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 19
PAGE 20
PAPER
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement