120-101 Digifold Operators Manual Issue 11

120-101 Digifold Operators Manual Issue 11

DOCUMENT

CREASING / FOLDING MACHINE

OPERATORS MANUAL

Morgana Systems Limited

United Kingdom

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

Website: www.morgana.co.uk

ISSUE 11

SEPTEMBER 2007

SERIAL No. 120681KCADC ONWARDS

120-101

INDEX

INTRODUCTION & SPECIFICATION

The Morgana Digifold

SAFETY Do’s & Don’ts

THE DIGIFOLD

Labeled Photograph

THE CONTROL PANEL

Detailed diagram and description

Features on the control panel

QUICK START GUIDE

OPERATING THE DIGIFOLD

Accessing Menus.

Accessing Menus Flow Chart

Set by Fold

Set by Position

Example of Set by Position

Adjusting the Papergate

Setting the Suction Slot

Setting the Adjustable 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

THE DELIVERY UNIT

Setting the Delivery Conveyor System

THE BLADE ASSEMBLY

Adjusting the blade pressure

Adjusting the blade alignment

PAGE 4

5

6

26

27

27

12

20

20

20

21

19

19

19

20

22

23

23

24

24

24

25

13

14

16

18

8

9

10

Page 2

CREASING / FOLDING

Digifold

INDEX

REPLACING CREASING BLADE SETS

Installing new blade sets

Spare Blades

TROUBLE SHOOTING

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

‘h’

Display reads

‘Crunch’

Fold Blade relocation.

Display reads

Display reads

‘Clip P’

‘Clip 1’

Display reads

‘Clip 2’

Recommended weekly operator maintenance

DISPATCH KIT (120-95-01)

ACCESSORIES AND OPTIONS

RECOMMENDED SPARES

MACHINE CALIBRATION HISTORY SHEET

PAGE 29

30

36

37

38 - 40

41

32

33

33

33

34

34

31

31

31

31

32

32

34

34

34

35

SYSTEM

Page 3

INTRODUCTION

INTRODUCTION AND SPECIFICATION

DigiFold

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 90gsm, upto and often above 300gsm. The

DigiFold

reduces the possibility of scratching, marking or cracking appearing on the substrate, as is often associated with conventional folding machine methods. A maximum paper weight cannot be specified, as this can be governed by the hardness of the substrate or the type of fold required to be produced.

It is

IMPORTANT

to note that to prevent cracking, when using dry ink or toner based print engines, the material

must

be fully acclimatised for at least 48 hours before putting an image onto the 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 ................................................630mm x 330mm

Min. Sheet Size .................................................140mm x 160mm (dependant on stiffness of paper and type of fold).

Max. Paper Weight ........................................... 300gsm

+

(varies according to hardness, type of fold, and substrate).

Min. Paper Weight ............................................ 120gsm

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

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

Max. No. Stored Programmes ...........................6

Min. Repeat Crease Distance ........................... 4mm (depending on paper weight)

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

mm (depending on paper weight)

Min. Crease Distance from Leading Edge ........ 25mm

Min. Fold Distance from Leading Edge ............. 70mm (depending on paper weight)

Min. Crease Distance from Tail Edge ............... 25mm

Min. Fold Distance from Tail Edge .................... 70mm (depending on paper weight)

Max. Fold Length .............................................. 560mm

Min. Fold Length ............................................... 70mm

Speed per Hour (A4 Material) One Crease or One Fold..........1800 sheets

Speed per Hour (A4 Material) One Crease & One Fold ..........1800 sheets

Speed per Hour (A4 Material) Two Creases or Two Folds ......1400 sheets

Speed per Hour (A4 Material) Two Creases & Two Folds .......1400 sheets

Speed per Hour (A3 Material) One Crease or One Fold .........1440 sheets

Speed per Hour (A3 Material) One Crease & One Fold ..........1440 sheets

Speed per Hour (A3 Material) Two Creases or Two Folds ......1200 sheets

Speed per Hour (A3 Material) Two Creases & Two Folds ......1200 sheets

Note: The production speed varies according to the material size and the number of creases or folds on the sheet.

Dimensions ....................................................... L: 1830mm H: 1185mm W: 555mm

Weight ............................................................... 180Kgs (+50Kgs packing)

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

Page 4

CREASING / FOLDING

Digifold

Safety Do’s & Don’ts

Safety Do’s & Don’ts

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

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

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

Do - beware of finger traps when replacing roller cassette and fold plates.

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

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

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

Do not - place receptacles containing liquids on any surface.

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

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

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

SYSTEM

Page 5

DOCUMENT CREASING / FOLDING MACHINE

Key to photograph below

6 Air distribution knob 11 Paper Gate

2 Delivery assembly 7 Adjustable side lay 12 Exit Guard

3 Suction slot knob

4 Control panel

5 Air separation knob

8

9

Back stop

Fixed side lay

13

14

High Level Display

Extension table fixing screws

2 12 11 8

6

13

9

14

7 5

3

4

Page 6

CREASING / FOLDING

Digifold

BLANK

PAGE

SYSTEM

Page 7

The Control Panel

The Control Panel on the Digifold allows the operator to read, edit, create and initiate numerous creasing / folding programs within the memory.

The top face of the control panel houses four pushbuttons as shown in the diagram below. For the purposes of the instructions these buttons will be described as

Push Buttons 1, 2, 3, 4

.

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.

Page 8

CREASING / FOLDING

Digifold

The Control Panel

Features on the Control Panel

Push Button 1

Used for adjusting a crease / fold position in increments of 10mm when used with the setting dial.

Also used for inching feed forward when in handle or crunch / Clip 1 or Clip 2 situation.

Push Button 2

Used for adjusting a crease / fold position in increments of 0.1mm when used with the setting dial.

Also used for inching feed in reverse when in handle or crunch / Clip 1 or Clip 2 situation.

Push Button 3

Used for locating the bottom blade or anvil to its ‘Top Dead Center’ position in order to set the blade pressure (whilst the system switch is on).

Also used to return the creaser blade to the ‘Home’ position after a ‘Crunch’ if required.

Push Button 4

Allows the operator to save a created program. When also used with the setting dial the operator can scroll through the stored memory addresses.

Also used for cycling the folder blade / feed forward.

Set-up switch

Allows the operator to enter and subsequently edit or read a stored program. Also resets the batch quantity.

Setting dial

Allows the operator to scroll through stored memory addresses and programs, increase or decrease the batch quantity and set a crease / fold position.

Suction switch

Allows the operator to vary the length of suction on the sheet of paper being fed.

Position I For very short sheets.

Position II For short non-standard sheets.

Position III For all standard size sheets, general purpose.

Feed switch

Allows the operator to start and stop feeding sheets.

System switch

When activated the system switch will operate the motors in order to begin the creasing / folding sequence.

Compressor switch

Allows the operator to switch off the compressor unit in order to utilize the machine to manually feed sheets.

SYSTEM

Page 9

Quick Start Guide

Setting the machine to operate in automatic mode.

(i.e. ,Set by Fold’)

1.

Set the gap between the paper gate and the vacuum roller to approximately twice the thickness of the stock to be creased.

(See page 19)

2.

Place the stock to be creased onto the loading table against the fixed side lay. (See page 19)

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 19)

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 21)

5.

Now follow the step by step instructions shown on page 11.

To manually feed sheets see instructions on page 25.

T o ‘Set by Position’ see instructions on page 16.

Page 10

CREASING / FOLDING

Digifold

Quick Start Guide

OPERATION

INSTRUCTIONS

Step 1

Turn the Emergency Stop button clockwise to switch the power on.

Step 2

Set the Set Up switch to its Mid- position.

Step 3

Step 4

Mid-Posn.

SET MACHINE TO ‘SET BY FOLD’

(’SEt FoLd’ or ‘SEt Pos’)

SET FOLD & CREASE

(’on’ or ‘off’)

Step 5

Select TypIcal

Main Display

LcF 10

Step 6

SET FOLD TYPE

Typical

Display tYPE L

To Change Fold Type

SET PAPER LENGTH

To Change Paper Length

Typical

Display

LEn 100.0

Step 7

Turn the Setting Dial clockwise until the display reads ‘SEt FoLd’ or ‘SEt Pos’, flick the Set Up switch upwards to change from one to the other.

Turn the Setting Dial anti-clockwise until the display reads ‘CrEES’ 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.

Turn the Setting Dial clockwise to select

‘LEn’, press the pushbutton and turn the

Setting Dial to set the paper length in 10mm or 0.1mm increments.

Flick the Set Up switch up to its Midposition

Step 8

Switch the System switch on.

Step 9

Switch the Compressor switch on.

Step 10

Switch the Feed switch on to begin feeding sheets

SYSTEM

Page 11

Operating the Digifold

Accessing Menus.

Main Menu.

1.

The mains switch on the machine must be off.

2.

Set the

Set-up Switch

to its mid position and then turn the mains switch on.

3.

The

Main Menu

functions can then be accessed by turning the clockwise or anti-clockwise as shown.

Setting Dial

Clockwise

Anti-clockwise

CrEES on / oF = crease on or off bAt = batch rG .00 .00 = roller gap

FoLd dELrY on / oF = fold on or off on / oF = delivery on or off

SEt PoS / FoLd = set by position or set by fold

F_cLr on / oF = fold blade clear of paper to reduce the possibility of marking or scratching sensitive paper, on or off

Sub-menus.

To access the sub-menus flick the

Setting Dial

Set-up switch

clockwise or anti-clockwise.

to the down position and turn the

Sub-Menu in Set by

FoLd

mode (set by fold)

Clockwise 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

Cr2 0.0 = crease 2 position

F1 0.0 = fold 1 position

F2 0.0 = fold 2 position

Anti-clockwise rPoS 150 = delivery roller position

Shin 41 = shingle (amount delivery wheel turns)

Sub-Menu in Set by

PoS

mode (set by position).

Clockwise

1 Cr = crease position 1

Anti-clockwise rPoS = delivery roller position

Shin = shingle (amount delivery wheel turns)

9 Cr = crease position 9

F1 = fold 1 position

F2 = fold 2 position rESEt = reset

Page 12

CREASING / FOLDING

Digifold

Operating the Digifold

SYSTEM

Page 13

Operating the Digifold

SET BY FOLD

Typical

Set by Fold

main display screen

LcF 0

2.

3.

1.

4.

5.

fold type

L = letter fold on crease on count

Turn the Emergency Stop button clockwise to switch the power on, and select the main display screen.

Set the Set Up switch to its Mid-position.

Turn the Setting Dial clockwise until display reads ‘SEt FoLd’ or ‘SEt Pos’, flick the

Set Up switch upwards to change from one to the other. (select ‘SEt FoLd’)

Turn the Setting Dial anti-clockwise until the display reads ‘CrEES’ 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 and hold down the pushbutton PB1 and turn the Setting Dial to select fold type i.e. h C G etc. Release pushbutton Pb1.

6.

7.

8.

9.

Turn the Setting Dial clockwise to select paper length ‘LEn’.

Hold down PB1 or PB2, and turn the Setting Dial clockwise to adjust the paper length in 10.0mm or 0.1mm increments. Release PB1 or PB2.

Turn the Setting Dial clockwise to select paper type ‘PAPEr’, i.e. stiffness of paper, not necessarily the paper thickness.

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 is for heavy stock of 180 gsm upwards

PAPEr 3 is for heaviest stock of 200 gsm upwards

NOTE: These paper types are a guide only, all four settings should be tried before adjusting the crease or fold positions.

10.

Set the Delivery Conveyor System as described on page 22.

11.

Adjust the Batch Count as described on page 23, if required.

12.

The program settings can now be stored, if required, as described on page 24.

Page 14

CREASING / FOLDING

Digifold

Operating the Digifold

13.

Run the job by switching the System and Compressor switches on, then switch the Feed switch on.

14.

View the results, the ‘micro adjust’ function can be used to adjust positions.

15.

To ‘micro adjust’ the crease position, turn the Setting Dial clockwise until Cr1 is displayed. This will be the calculated length of the crease position.

Press and hold PB1 and the display shows 0.0

To ‘micro adjust’, hold down PB1 and turn the Setting Dial to adjust in either direction ie +3.1mm to -3.1mm Max.

Release PB1.

16.

To ‘micro adjust’ the fold position, turn 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 move.

‘Micro adjust’ a fold only if the fold appears to be giving an out of square result or cracking appears.

The fold is probably too close to the center of the crease and will be trying to fold from one side of the crease to the opposite side of the crease (see page 16 for explanation).

SYSTEM

Page 15

Operating the Digifold

SET BY POSITION

IMPORTANT NOTES.

1. If the fold is too near, or on the center line of the crease; the fold will try to fold diagonally across the crease profile and pull the fold out of square to the paper.

The best fold squareness is achieved when the fold is not on the center line of the crease, it should be to one side of the crease center line as shown below.

Thus for a crease setting of Cr1 = 100 for example, the fold should be set to a figure slightly smaller or greater than 100.

ideal fold line center line of crease ideal fold line

2. When using

Set By Position,

all dimensions are from the leading edge of the paper as shown in the example on page 18.

Typical

Set by Position

main display screen

1.

2.

3.

4.

5.

2cF 0

number of creases fold on crease on count

Turn the Emergency Stop button clockwise to switch the power on, and select the main display screen.

Set the Set Up switch to its Mid-position.

Turn the Setting Dial clockwise until display reads ‘SEt FoLd’ or ‘SEt Pos’, flick the

Set Up switch upwards to change from one to the other. (select ‘SEt Pos’)

Turn the Setting Dial anti-clockwise until the display reads ‘CrEES’ or ‘FoLd’, flick the

Set Up switch upwards to select ‘on’ or ‘oF’ for each as required.

Turn the Setting Dial anti-clockwise until the main display screen is displayed and switch down the Set-up switch

Page 16

CREASING / FOLDING

Digifold

Operating the Digifold

6.

7.

8.

Turn the Setting Dial clockwise to select

‘1 cr’

Hold down PB1or PB2 and turn the Setting Dial to adjust the crease position in

10.0mm or 0.1 mm increments. Release PB1 or PB2.

(this can be done on all further crease positions)

Turn the Setting Dial clockwise to

Note:- the crease positions

must

‘2 cr’

etc. (there are 9 crease positions in total) increase upwards. (i.e.

‘1 cr’

must be less than must be less than

‘3 cr’

etc)

If any of the nine available crease options (’1 cr’ to ‘9 cr’) are not required for the job being set up, they must be set to ‘0’

9.

Continue turning the Setting Dial clockwise to

‘F1’

.

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.

‘F2’

is the last fold position.

Note:- the fold positions may be in any order. (i.e.

‘F1’

can be larger than

‘F2’

)

If the fold option F2 is not required for the job being set up, it must be set to ‘0’

11.

Set the Delivery Conveyor System as described on page 22.

12.

Adjust the Batch Count as described on page 23, if required.

13.

The program settings can now be stored, if required, as described on page 24.

14.

Run the job by switching the System and Compressor switches on, then switch the Feed switch on.

NOTES:-

Once the

Set by Position

has been selected, if returned to

Set by Fold

the default length of 100 will be found and any previous settings will be lost unless stored.

Deflect knife position.

If “fold off” is selected then both knives will go to the double deflect settings which are determined by the paper type setting.

If in “set by fold” and doing a Half fold then the 1st knife will be set to the deflect position which is determined by the paper type setting.

When using

Set by Position

if only one fold is required, set

F1

at 0.0. If the leading edge of the sheet buckles up, adjust type 1, 1.0 for PAPEr type 2 and 1.5 for PAPEr type 3.

always

set this on

F2

and

F1

to 0.5 for PAPEr

SYSTEM

Page 17

Operating the Digifold

Example of Set by Position.

Paper Length = 350mm

Feed Direction

Leading Edge

SETTINGS

Cr1 = 97.0mm

Cr2 = 179.0mm

Cr3 = 260.0mm

F1 = 179.0mm

F2 = 260mm

Cr1 Cr2

F1

Cr3

F2

All dimensions are from the leading edge of the paper

Cr2

F1

= 179.0

Cr3

F2

= 260.0

9mm

Leading Edge

First Fold

Leading Edge

Second Fold

Page 18

9mm

Leading Edge

9mm

Finished Document

CREASING / FOLDING

Digifold

Operating the Digifold

Adjusting the Paper Gate

The standard setting for horizontal adjustment of the paper gate is 6.5mm (1/4") away from the mounting block. Turn disc J to make this adjustment. This setting is only intended as a guide, for instance, sheets with an upward curl will require this setting to be increased. Set the height of the Paper Gate to approximately two thicknesses of paper, by turning knob K. An excessive gap is a most likely cause of double sheet feeding.

6.5mm (1/4")

K

J

T W O T HICK NE S S E S

OF P AP E R

IMPORTANT:-

To avoid possible damage to the suction drum, when adjusting the paper gate height, ensure that the disc is located over a solid section of the suction drum and not over a slot in the drum.

Do not adjust the paper gate while the machine is running.

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 knob to the right

.

Setting the Adjustable Side Lay

Place the paper stack on to the loading table and slide up to the fixed side lay and paper gate. Release the clamps located at each end of the side lay and slide up towards the paper stack as shown in FIG 16.1. Allow a gap of approximately 0.5mm (1/64 inch) between the paper and the side lay.

SYSTEM

Adjustable

Side Lay

Page 19

Operating the Digifold

Setting the Back-Stop

Place the back-stop on to the adjustable side lay and slide up towards the paper stack allowing a gap (as specified in the above step) before clamping. When the extension table is used for feeding longer sheets, remove clamp type back stop and use the magnetic type back stop as shown in fig. 18.2.

Setting the Air Distribution

Depending on the length of the sheet to be creased, the air distribution knob can be rotated to various positions in order to supply air to different ports. Position 1 is recommended for most sheet sizes. However, a better result may be obtained by using the below settings or by experimentation.

Position

1 - For A5 sheets or 8 inches long, front port and 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

1 and port 2 open.

Setting the Air Separation Pressure

To control the amount of air supplied to the ports, the air separation knob can be adjusted

By first rotating the knob to unlock its position, then push the knob down to the required

Position and rotate the knob to re-lock its position.

Setting the positions of drive wheels and hubs

It is important that the drive wheels and drive hubs on the roller shafts are arranged evenly across the width of the media being creased. This is done to ensure that the media is accurately driven and supported through the rollers.

The drive wheels and hubs are fixed to the rollers by means of a grub screw. To locate this grub screw the rollers can be rotated by operating the motor manually.

DO NOT ROTATE THE DRIVE ROLLERS BY HAND.

Page 20

CREASING / FOLDING

Digifold

Operating the Digifold

To operate the motors manually, switch the machine ‘on’ at the Emergency Stop switch.

Whilst holding down Push Button 1, flick the Set-up switch to ‘set up’.

The display will now read

‘hAndLE’.

Press the System switch to ‘on’ and use Push Button

1 (forward) and Push Button 2 (reverse) to manually rotate the rollers in short pulses.

Rotate the rollers until the grub screw is located. Lift the exit guard and the machine will switch ‘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.

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 screws as shown on page 6.

The back stop can be used to support the paper stack as shown in FIG 18.2 below.

The other back stop supplied with the machine can be used as a tool holder as shown in

FIG 18.3 below.

SYSTEM

Page 21

Operating the Digifold

Setting the Delivery Conveyor System.

WARNING:-

The Digifold will not start if the delivery unit is not fitted onto the machine.

Turning the delivery system ‘on’ or ‘off’

1.

Set the Set Up switch to its mid-position.

2.

3.

Turn the Setting Dial until the display reads ‘dELrY’ on or off.

Flick the Set Up switch upwards to toggle between ‘on’ and ‘off’.

If the delivery is turned off the roller will feed to the far end of the belt conveyor and park there until turned on again.

If the delivery is turned on when using the ‘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.

When using the ‘Set by Position’ mode of operation; the Roller Position (rPoS) and Shingle

Length (Shin) must be adjusted manually to suit the job, as described below.

Adjusting the Roller Position and Shingle Length. (See FIG 19.1)

1.

2.

3.

4.

Flick the Set Up switch down.

Turn the Setting Dial anti-clockwise to ‘rPoS’ (roller position), or

‘Shin’ (shingle length) as required.

Press and hold pushbutton PB1 and turn the Setting Dial, the numbers displayed are pre selected lengths in millimeters (to reduce setting times).

When the optimum settings for ‘rPoS’ and ‘Shin’ are achieved they can be stored with the job (see Storing Programs on page 24).

FIG 19.1

Page 22

‘Shin’

(Shingle Length)

‘rPoS’

(Roller Position)

CREASING / FOLDING

Digifold

Operating the Digifold

Adjusting the Batch Count

The Batch Counter controls the feed of the machine.

If for example the Batch Count is set to 10; the machine will feed 10 sheets of paper, pause for approximately 5 seconds, the conveyor belt will feed the 10 sheets forward (to allow the removal of the sheets from the conveyor) and then feed the next 10 sheets of paper.

The batch count is set as follows:-

1.

2.

3.

Set the Set Up switch to its mid-position.

Turn the Setting Dial until the display reads ‘bAt’.

Press and hold pushbutton PB1, and turn the Setting Dial to set the batch quantity required. (the batch quantity changes in multiples of 10)

NOTE.

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 24)

Adjusting the Roller Gap

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 cracking of the print is noticeable.

The Roller Gap is adjusted as follows:-

1.

2.

3.

Set the Set Up switch to its mid-position.

Turn the Setting Dial until the display reads ‘rG 00 00’.

The Roller Gaps are adjusted by turning the ‘Fold Gap 1’ or ‘Fold Gap 2’ knobs on top of the folder unit. (the Roller Gap changes in increments of 0.05mm)

Roller Gap 2

FIG 20.1

SYSTEM

Roller Gap 1

INFEED

Page 23

Operating the Digifold

Storing Programs

A maximum of 6 programs, of crease / fold settings, can be stored in the machine.

When the crease / fold settings have been correctly entered, the program can be stored as follows:-

1.

Flick the Set Up switch down and then back up to its mid-position, the display reads

‘StorE 1’

2.

Turn the Setting Dial in either direction to cycle through the 6 memory addresses available.

3.

To store a program to the displayed address, press the pushbutton PB4.

The display reads

‘StorEd’

Reading Stored Programs

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

3cF 100

see page 16 for explanation.

To view or edit any of the creases or folds within the program, refer to steps 4. to 9. on the ‘Set By Position’ instructions on pages 16 and 17.

Clearing Stored Programs

Whilst viewing any of the stored programs, set the Set Up switch down and turn the

Setting Dial clockwise until the display reads

‘rESEt’.

Press pushbutton PB4 to clear the stored program.

Page 24

CREASING / FOLDING

Digifold

Operating the Digifold

Feeding Sheets Manually

In order to feed heavy stock, very small or very large sheets, embossed or even irregular shaped sheets, it may be required to operate the machine manually.

The machine can be programmed and set up in exactly the same way as explained when operating the machine automatically. However, when setting up the machine the paper gate must be raised to its highest position for the sheets 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’.

activate the Compressor switch.

Do not

Flick the Feed switch to ‘on’ and begin to slide the sheets individually through the paper gate until they are driven by the drive belts.

To stop feeding the sheets, flick the Feed switch to ‘off’ and then the System switch to

‘Off’.

SYSTEM

Page 25

The Delivery Unit

The delivery unit on the Digifold is used to catch the sheets once they have been creased, or folded.

WARNING:-

The Digifold will not start if the delivery unit is not fitted onto the machine.

Assemble the delivery unit as shown in FIG 23.1.

1. Hook the delivery unit onto the shaft in the positions shown below, being careful to align the mating connectors.

2. Locate the Support Hoop into the channel on the underside of the delivery unit.

Hooks to be Located onto shaft in these positions

Location Hooks

Delivery Unit

Page 26

Connector

Support Hoop

FIG 23.1

CREASING / FOLDING

Digifold

The Blade Assembly

Adjusting the blade pressure (no paper required)

1. Turn the Emergency Stop button clockwise to switch the machine ‘on’.

2. Activate the system switch and the motors will begin to operate.

3. Flick the ‘Feed’ switch to ‘on’ and then back to ‘off’ to ensure that the lower blade / anvil is at its bottom position.

4. Press Push Button 3, the machine will automatically switch off and the lower blade / anvil is set to its top position where the pressure can be adjusted. Raise the exit guard.

5. Using a 6mm 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 extremely important that the blade and anvil assembly within the creasing unit is correctly aligned. Misalignment of the blade or anvil can lead to damaged profiles and subsequently poor quality creasing so it must, therefore, be corrected immediately.

SYSTEM

Page 27

The Blade Assembly

1.

2.

If the blade set is misaligned, the media being driven will be subject to scoring or even tearing at any point along the crease line.

Please note that to avoid damage to the blade set, adjustment should only be made in small increments.

demonstrates how the blade alignment can be carried out.

The sketch below

Adjustment can be made at either of the blade or anvil. The two clearance holes positioned above the roller tilt mechanism are the front alignment (one for blade, one for anvil). The two holes are repeated on the back of the machine for the back alignment.

Remove the stacker unit from the Digifold.

Using a 3mm allen key, loosen the cap head type locking screws located on the front face at both ends of the blade /anvil as shown below.

3.

4.

5.

6.

Using a 4mm allen key, locate the two front or back alignment screws in the side frame in order to adjust the blade / anvil.

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.

In order to obtain the required position, adjust either the blade or the anvil by a small amount and then operate the machine to test the form of the crease.

Repeat the exercise until centralisation is located.

Using a 3mm allen key, lock the cap head type screws (as per step 3) on both the upper and lower blade / anvil.

Page 28

CREASING / FOLDING

Digifold

Replacing Blade Sets

1.

Before removing the blade assembly, ensure that the lower blade / anvil is

NOT

at ‘top dead centre’, ie. Push Button 3 has not been pressed. Switch the machine off.

2.

Remove the delivery unit and lift the top guard.

Blade Extractor Tools

3.

Using a 6mm allen key, loosen the socket head screws located inside the blade adjustment cams. Remove the screws and the blade adjustment cams.

4.

Insert the blade extractor tools (70-055-01 &

70-055-02) 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.

5.

Slide the blade assembly out of the creasing unit and lay it on a flat surface.

6.

Slide the adjustment links away from the dowels located in the ends of the blades / anvils as shown in the photograph (left).

7.

Place the new blade set into position.

Check that the eccentric 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.

FIG 26.1

9.

Slide the new blade set into the slots of the creasing unit as shown in fig. 27.1.

Locate the blade extractor tools into the holes in the adjustment links as shown. Pull the handles of the blade extractor tools upwards to engage the blade assembly back into the power links.

10. Set the cam graphics for both ends of the blade / anvil to their lowest point on the scale (ie. When the mark on the scale reaches the mark on cam holder) Fasten the socket head screws on the adjustment cams until they are tight.

SYSTEM

Page 29

Replacing Blade Sets

11.

Push the exit guard down and replace the delivery assembly before operating the machine.

12.

Switch the machine on and test the crease for form.

If the pressure and the alignment of the crease is not to a satisfactory level, see pages 27 and 28 to adjust the creasing line.

‘Spares’ kits

In the event of any damaged or lost components within the blade assembly, spares kits are available on request. However, components within the blade set can not be ordered separately i.e. single blade or anvil.

Standard Blade set (fitted to Digifold as standard) Part number 76-213-01

Consisting of a standard blade and anvil, blade brushes, blade links and alignment bolts.

Extra Narrow Blade set (optional) Part number 76-213-03

Consisting of a special extra narrow anvil, a standard blade, blade brushes, blade links and alignment bolts.

Page 30

CREASING / FOLDING

Digifold

Trouble Shooting

Paper crease out of square

!

Check that the sheets are all square and exactly the same size before loading the stack on to the table.

!

Check that the adjustable side lay has been correctly positioned ie. No further than

0.5mm from the paper stack.

!

Check that the blade is a slide fit in the side plate slots, adjust if necessary, see adjusting blade alignment.

Paper fold out of square

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 not worn on one end.

Paper jamming

!

Check that the leading edge of the paper is not being damaged by the paper gate. If this is occurring, check that the suction slot and the paper gate have been correctly set.

!

Check that the first crease / fold position is not too close to the leading edge of the paper. A minimum distance of 40mm is recommended.

!

If jamming is occurring in the out feed rollers, open up the roller gap. (See page 23)

!

!

Machine will not start

!

Check the power supply to the machine.

!

Check that the emergency stop button has been released.

Check that the two top guards are down.

Check that the delivery unit is fitted, and located correctly, (the machine will not start if the delivery unit is not fitted).

!

Check that the lower blade / anvil is connecting to the home switch (mounted below the lower blade / anvil).

SYSTEM

Page 31

Trouble Shooting

!

!

!

Paper not feeding

!

Check that the paper stack is not too high or too heavy for the feeder. The height of the paper stack should be defined by the weight and the size of the stock being creased.

!

Ensure that the adjustable side lay is not pressed against the paper stack. However, if the clearance between the adjustable side lay and the paper stack is too great, the air supply will escape instead of blowing through the paper thus making it difficult to feed.

!

Check that the clearance between the paper gate and the suction roller is not set too low.

!

On digital media, the feeding performance may be improved if the leading edge of the stack is trimmed before loading onto the Digifold.

Check that the air distribution has been correctly set.

Check that the air separation has 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 25

Machine not counting

!

Open the top and remove the blade set

(see pages 29-30) 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 brush to clean the sensors between the post and the bottom paper guide which are not visible.

Photograph (left) shows the dual sensor post containing the sensors.

Cracking of the Printed Material along the Crease.

Cracking of the material along the crease may be caused by the following:-

!

!

Pressure too heavy on the top blade - reduce pressure.

Crease too narrow for heavy stock - change the blade to the standard blade set (part number

76-213-01

).

!

Cracking on one edge caused by misalignment of the anvil and blade - realign blades using cams at sides (see FIG 26.1 on page 29).

Page 32

CREASING / FOLDING

Digifold

Trouble Shooting

Cracking of the Printed Material along the Crease. (continued)

!

When using dry ink or toner based print engines, the material must be fully acclimatised for at least 48 hours before putting an image onto the paper.

!

Paper marking or scratching.

If the paper is marking or scratching set ‘F_cLr’ to ‘on’, as described below.

This function is used to withdraw the top fold blade from the nip position, when paper is in the fold roller. This reduces the possibility of marking or scratching sensitive paper. On certain folds, gate types for instance, ‘F_cLr’ should be set to ‘off’ because the trailing edge of the paper will catch on the withdrawn blade.

IMPORTANT NOTE.

If F_cLr’ has been set to ‘on’, any subsequent change to the programme settings will automatically return ‘F_cLr’ back to its default setting of ‘off’; and it must therefore be

s

et back to ‘on’ again.

Setting ‘F_cLr’ to the ‘on’ position.

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 23).

!

!

No suction

If the suction drum is not rotating, check all of the drive belts for cleanliness and splits

(including the bottom in-feed roller drive belt).

Display Window Reads

!

‘h’

If at any time during the creasing / folding process the display window reads

‘h’

, it is indicating that the lower blade / anvil has not made contact with the HOME switch.

i.e. Blade still in top position. Switch the machine off and remove the blade set, ensure that the area is free from obstructions. Return the blade set to the creasing unit and switch the machine on. Operate the machine in the normal sequence, if the letter

’h’

continues to appear it is advised to contact a Service Engineer immediately.

SYSTEM

Page 33

Trouble Shooting

!

’Crunch’ (Paper Jamming)

In the event of a paper jam occurring whilst the machine is operating the display window will read

‘crunch”.

In order to remove the paper causing the jam:-

Push Button 1 and Push Button 2 can be used to manually operate the motor.

Push Button 1 will drive paper forward, in short pulses.

Push Button 2 will drive paper in reverse, in short pulses.

Push Button 4 will cycle the fold knives and drive the roller forward.

When pressed, the push button will activate the rollers for a short movement. For continuous movement, press and release the push button repeatedly.

If the sheet remains jammed, check that the lower blade / anvil is not clamping the sheet. If so, press Push Button 3 to lower the blade / anvil to release the jammed sheet. When the paper jam has been removed, make sure the feed switch is off and then press the Set Up switch up to clear

‘crunch’

from the display window.

Note .- As a safety device to overloading, the fold knives will be ejected from their drive / location lugs.

!

!

!

To replace fold knives.-

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 top cover to lock the mechanism and align the blade drive pins both sides with the lugs on the gears, with a small amount of pressure on the rear face of the blade it will clip into position.

‘cLiP P’

If the Feed switch is turned off while a piece of paper is still feeding (but has not reached the first fold roller), the machine will stop and the display window will read

‘cLiP P’

. Use Push Buttons 1, 2, and 4 to remove the paper causing the jam; as described above under the heading

‘crunch’

.

When the paper jam has been removed, make sure that the Feed switch is off and then press the Set Up switch up to clear

‘cLiP P’

from the display window.

’cLiP 1’

If the machine stops and the display window reads

‘cLiP 1’

this indicates that paper has jammed in the rollers. Use Push Buttons 1, 2, and 4 to remove the paper causing the jam; as described above under the heading

‘crunch’

. If the jammed paper can only be removed by inching the paper forward, the jammed paper will be found on the underside of the delivery unit.

When the paper jam has been removed make sure that the Feed switch is off and then press the Set Up switch up to clear

‘cLiP 1’

from the display window.

’cLiP 2

If the machine stops and the display window reads

‘cLiP 2’

this indicates that paper has jammed in the rollers. Use Push Buttons 1, 2, and 4 to remove the paper causing the jam; as described above under the heading

‘crunch’

.

When the paper jam has been removed, make sure that the Feed switch is off and then press the Set

Up switch up to clear

‘cLiP 2’

from the display window.

Page 34

CREASING / FOLDING

Digifold

Trouble Shooting

Recommended weekly operator maintenance

Clean all sensors

Clean in feed rollers and output drive hubs using the Morgana cleaning kit

(Morgana cleaning 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.

Technician Maintenance

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

SYSTEM

Page 35

120-95-01

DISPATCH KIT

ITEM PART NUMBER QTY

1

120-101

DESCRIPTION

1 OPERATORS MANUAL - DIGIFOLD

2 90-018

3

121-006

1 ROLLER CLEANING KIT

1 TILT LEVER

4 613-316

5 617-004

6

7

403-01-030-006

409-01-040-004

8

9

620-007

620-020

10 620-004

11

620-026

12 620-028

13 620-033

14 624-018

15 70-055-01

16 70-055-02

1 POWER CORD CE UK 3Pin

4 GLASS BALL - Ø20

12 SCREW - SOCKET CAP HEAD - M3 x 6 LG

1 SCREW - SKT. SET FLAT PT. - M4 x 4 LG

1 HEXAGON BALL DRIVER 2mm

2 HEXAGON BALL DRIVER 2.5mm

1 ALLEN KEY 4mm

1 BONDUS L WRENCH 4mm

1 BONDUS L WRENCH 3mm

1 BONDUS L WRENCH 6mm

1 DISPATCH BOX

1 BLADE EXTRACTION TOOL - OP SIDE

1 BLADE EXTRACTION TOOL - LAY SIDE

Page 36

CREASING / FOLDING

Digifold

ACCESSORIES AND OPTIONS

ITEM

1

PART NUMBER

76-213-03

DESCRIPTION

BLADE SET - 320 Wide - Extra Narrow

ACCESSORIES....

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

SYSTEM

Page 37

RECOMMENDED SPARES

PART NO. QUANTITY DESCRIPTION

609-013

609-014

609-022

613-137

613-191

613-237

613-255

613-351

613-365

613-385

652-011

681-007

75-040

75-077

75-082

75-098

75-100

75-101

76-042

76-058

76-082

76-083

76-109

606-028

606-035

607-038

607-040

607-041

607-042

607-045

607-046

607-047

607-146

608-019

609-011

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

2

2

1

1

1

Foot - Black

Knob - Roller Tilt

Twin Grip Timing Belt - 200DXL

Torque Disk - White

Timing Belt - 110XL 037

Timing Belt 160XL

Multi Beam Coupler Size 13

Timing Belt - 540XL 037

Timing Belt - 564XL 037

Timing Belt - 132XL 037

Shoulder Bolt - Adjustment Cams

‘O’ Ring Ø20

‘O’ Ring Ø25

‘O’ Ring Ø15

‘O’ Ring Ø32

Plunger and Spring

Micro Switch - Home Circuit

Cap - Ø15

Solenoid Coil

Micro Switch - Guard Circuit

Emergency Stop Switch

Knob Ø15

System Switch

Fuse - 3.15A - Time-Delay - (20 x 5mm)

Stacker Switch Assembly

Control PCB Assembly - Digifold

Display PCB Assembly

Switch Assembly - Feed

Switch Assembly - Set-up

Switch Assembly - Rotary Setting Dial

Drive Belt - Feed Bed - Ø4 Polycord

Anti-Static Brush - Autocreaser

Perforator - Drive Hub Assembly

Perforator - Drive Wheel

Power Link Bearing

Page 38

CREASING / FOLDING

Digifold

RECOMMENDED SPARES

PART NO. QUANTITY DESCRIPTION

76-203-01

76-203-02

76-204

76-213-01

76-228

76-229

76-230

93-021

93-022

94-028

79-040-01

79-041-01

95-020

79-042-01

79-043-01

124-01-01

124-01-02

124-01-08

124-01-16

124-01-17

124-01-27

125-01-08

125-05-01

125-12-02

126-02-01

126-03-01

126-06-01

126-06-03

126-06-04

126-07-01

126-07-02

126-07-03

126-12-01

126-12-02

126-17-01

126-17-04

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

3

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Input Roller Assy - Upper

Input Roller Assy - Lower

Output Shaft Assembly

Blade Set - 320 Wide - Standard

Upper Sensor Assembly

Paper Jam Sensor Assembly

Paper Guide Assembly - Bottom Sensor

Feed Belt

Drive Belt - Vacuum Roller

Lock Pin Assembly - Side Lay

Hose - Air Seperation

Hose - Vacuum

Lens - Display

Hose - Excess Air Bleed

Hose - Vacuum Blow

Pot & Lead Assy - Gap Set 1

Knife Position Sensor

Pot & Lead Assy - Gap Set 2

Toroidal Transformer Assembly

Toroidal Transformer Assembly

Roller Pot Lead

Black Box - Stepper Driver + Daughter Board

Runtime PCB Assembly

Stepper Driver + Daughter Board

Fold Input Roller

Fold Roller - Standard

Access Unit - 1st Fold

Access Unit - 3rd Fold

Access Unit - 2nd Fold

Support Unit - 1st Fold

Support Unit - 2nd Fold

Support Unit - 3rd Fold

1st Blade Assembly

2nd Blade Assembly

Input Roller - Upper

Input Roller - Lower

SYSTEM

Page 39

RECOMMENDED SPARES

PART NO. QUANTITY DESCRIPTION

126-053

126-053-02

126-059

126-060-01

126-060-02

126-060-03

126-060-04

126-063-01

126-063-02

128-026-02

1

1

4

1

1

2

2

1

1

1

Blade Guide

Blade Guide - Long

Link - Paper Guide

Paper Sensor - Edge Detect RX

Paper Sensor - Edge Detect TX

Paper Sensor - Sync 2 RX

Paper Sensor - Sync 1 RX

Sensor Bar - Sync 2 TX

Sensor Bar - Sync 1 TX

Belt - Paper Transport

NOTE.....

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

Section and item numbers refer to the illustrations and tables in this manual.

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

Page 40

CREASING / FOLDING

Digifold

Date:-

Total Count:-

Etch dEtr

FECh dEtF gAPF cEn

MACHINE CALIBRATION HISTORY

Serial Number:-

Date:-

Total Count:-

Etch dEtr

FECh dEtF gAPF cEn

Date:-

Total Count:-

Etch dEtr

FECh dEtF gAPF cEn

SYSTEM

Page 41

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 confirmation that you should not dispose of the equipment in the normal household waste stream.

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

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

In some Member States when you purchase new equipment your local retailer may be required to take back your old equipment free of charge. Please ask your retailer for information.

Other Countries

Please contact your local waste authorities and request disposal information.

Page 42

CREASING / FOLDING

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