DigiFold Pro DOCUMENT FOLDING MACHINE OPERATORS MANUAL Morgana Systems Limited United Kingdom Telephone: ( 01908 ) 608888 Facsimile: ( 01908 ) 692399 Website: www.morgana.co.
INDEX INTRODUCTION & SPECIFICATION The Morgana DigiFold Pro PAGE SAFETY Do’s & Don’ts 4 5 THE Digifold Pro Labeled Photograph 7 THE SWITCH PANEL Detailed diagram and description Features on the switch panel OPERATING THE DigiFold Pro Adjusting the Papergate Setting the Suction Slot Setting the Vacuum Bleed Setting the Adjustable Side Lay Setting the Back-Stop Setting the Air Distribution Setting the Air Separation Pressure Setting the Positions of the Drive Wheels and Hubs 8 9 10 10 11 11 11 11 11 12
DigiFold Pro INDEX REPLACING CREASING BLADE SETS Installing new blade sets Spare Blades PAGE 38 41 PERFORATING Equipment, Spares Setting the machine Recommended Position of the Drive Wheels and Hubs 42 43 44 REMOVING PAPER JAMS 45 TROUBLE SHOOTING Paper crease out of square Crease Position Inaccuracy Paper fold out of square Paper Jamming Machine will not start Paper not feeding Cracking of the printed material along the crease Using the Correct Blade Set 47 47 47 47 48 48 48 49 ERROR SCREENS 01 S
INTRODUCTION DigiFold Pro INTRODUCTION AND SPECIFICATION Digifold Pro is a registered trade mark of Morgana systems Ltd. The unique patented creasing and folding system, makes it possible to fold most delicate stocks from 0.11mm, up to 0.4mm thick. The DigiFold Pro reduces the possibility of scratching, marking or cracking appearing on the substrate, as is often associated with conventional folding machine methods.
DigiFold 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.
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.
DigiFold Pro DigiFold Pro DOCUMENT FOLDING MACHINE Key to photograph below 1 2 3 4 5 Delivery assembly Vacuum bleed knob Suction slot knob Switch panel Air distribution knob 1 6 7 8 9 10 Air Separation Knob Adjustable side lay Back stop Fixed side lay Fuses 12 11 6 11 12 13 14 13 Paper Gate Top cover Touchscreen Optional Extension Table 7 9 5 8 3 2 14 10 4 SYSTEM Page 7
The Switch Panel The Switch Panel houses the Compressor switch, System switch, and an industry standard Emergency Stop switch which will stop all power going to the machine when activated.
DigiFold Pro The Switch Panel Features on the Switch Panel System switch When activated the system switch will operate the motors in order to begin the creasing sequence. Compressor switch Allows the operator to switch off the compressor unit in order to utilise the machine to manually feed sheets.
Operating the DigiFold Pro Adjusting the Paper Gate Set the height of the Paper Gate to approximately two thicknesses of paper, by turning the disc j. An excessive gap is a most likely cause of double sheet feeding. This setting is only intended as a guide, for instance, sheets with an upward curl will require this setting to be increased. J TWO THICKNESSES OF PAPER WARNING. DO NOT ADJUST THE PAPER GATE WHILE THE MACHINE IS RUNNING OR THE SUCTION DRUM MAY BECOME DAMAGED.
DigiFold Pro Operating the DigiFold Pro Setting the Vacuum Bleed 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 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 the paper stack on to the loading table and slide up to the fixed side lay and paper Gate.
Operating the DigiFold Pro Setting the positions of drive wheels and hubs It is important that the drive wheels and drive hubs, on the roller shafts, are arranged across the width of the media being creased; this is done to ensure that the media is accurately driven and supported through the rollers. A suggested layout, when Folding, is shown below (see FIG 15.1). The suggested layout, when perfing, is different, and is shown on page 44 (see FIG 38.1).
DigiFold Pro Operating the DigiFold Pro BLANK PAGE SYSTEM Page 13
Operating the DigiFold 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.
DigiFold Pro Operating the DigiFold Pro Setting Pages. Paper settings Page Paper Type - As a guide choose as follows: 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 the status area. 0 - approx 0.1 thk 1 - approx 0.2 thk Page Thickness - On selection of status area is replaced with a calculator for inputting new values 2 - approx 0.3 thk 3 - approx 0.
Operating the DigiFold Pro Batch size Selection. Pre-set Batch sizes for quick insertion. Paper Thickness input Paper Thickness Selection. Pre-set Paper Thickness sizes for quick insertion.
DigiFold Pro Operating the DigiFold Pro Roller Gap Set & Tilt Mechanism Page. To get to the roller gap setting page click the lower tab Roller gaps may be in the range of 0.05mm to 1.5mm, with increments of 0.05mm Current gap setting Current gap setting for 2nd Fold Roller for 1st Fold Roller Current gap setting for 3rd Fold Roller Current set Tilt Angle Recommended gap values based on paper thickness.
Operating the DigiFold Pro The gap settings (Gap 1, Gap 2 & Gap 3) can then be adjusted by rotating the Roller Gap Set Knobs (see FIG 10.1 on page 10). IMPORTANT. When setting roller gaps, you must first adjust the gap to a value greater than that required and then decrease the value to the required setting. (Do not set the gap, from a value lower than that required). PROCEDURE. (i) Measure the thickness of the sheet using a Digital Vernier Calliper. (ii) Set roller GAP 1 to the vernier reading.
DigiFold Pro Operating the DigiFold Pro Setting the Blade Tilt Mechanism The blade tilt mechanism has been designed to compensate for when the creasing position on the sheet is not square. This could be due to an inaccuracy in the media or if the blade tilt mechanism has been incorrectly set. The mechanism will be set to zero (square) when the machine is supplied. The Blade Tilt Mechanism can be adjusted if necessary by rotating the Blade Tilt Knob (see FIG10.1 on page 10).
Operating the DigiFold Pro Crease Settings Pages. To get to the crease setting page click the lower tab status area. or from the If you have selected a predefined standard Fold Type from the paper settings page the crease positions will be set for you. These positions can be fine tuned by ± 0.1mm increments by pressing the arrow buttons for each crease. Creases in ‘Set By Fold’ mode. Crease trim - On selection the status area is replaced with a calculator for inputting new values.
DigiFold Pro Operating the DigiFold Pro Creases in ‘Set By Position’ mode. Arrows may be selected to increase or decrease The page size in 0.1mm increments Crease position - On selection the status area is replaced with a calculator for inputting new values, a maximum of 9 creases can be added. Number of creases - if more than 6 creases are added a scroll bar will appear for to enable viewing of all creases. Also shown in status area. Cross box for deletion of crease.
Operating the DigiFold Pro Turn crease on/off. Greyed out area indicates the trim is not selectable Status shows creasing off icon This button toggles creasing on & off. Individual deletion of crease confirmation screen. Crease 230 mm from lead edge will be deleted. Remove all creases confirmation screen. All creases - in this case 7 off will be deleted.
DigiFold Pro Operating the DigiFold Pro Fold Settings Pages. To get to the Fold setting page click the lower tab status area. or from the If you have selected a predefined standard Fold Type from the paper settings page the crease positions will be set for you. These positions can be fine tuned by ± 0.1mm increments by pressing the arrow buttons for each crease. Folds in ‘Set By Fold’ mode. K1 Fold trim - On selection the status area is replaced with a calculator for inputting new values.
Operating the DigiFold Pro Folds in ‘Set By Position’ mode. Fold distance from lead edge for knives (K1 & K2) increments of 0.1mm K1 deflect button K1 micro adjust selected K1 in deflect position. This can be micro adjusted. Clicking this icon switches deflect off &K1 returns to its original position. Trim range is -5.0 +5.0 with increments of 0.1mm K1 & K2 in deflect position. This can be micro adjusted. Trim range is -5.0 +5.0 with increments of 0.
DigiFold Pro Operating the DigiFold Pro 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.
Operating the DigiFold Pro Example of Set by Position. Paper Length = 350mm (13.8”) Feed Direction Leading Edge Crease 1 SETTINGS Crease 1 = 97.0mm (3.8”) Crease 2 = 179.0mm (7”) Crease 3 = 260.0mm (10.2”) Fold 1 = 179.0mm (7”) Fold 2 = 260mm (10.2”) Crease 2 Fold 1 Crease 3 Fold 2 All dimensions are from the leading edge of the paper Crease 2 = 179.0 Fold 1 (7”) Crease 3 = 260.0 Fold 2 (10.2”) 9mm (0.35”) Leading Edge Leading Edge First Fold Second Fold 9mm (0.35”) Leading Edge 9mm (0.
DigiFold Pro Operating the DigiFold Pro Delivery Settings Page. To get to the Delivery setting page click the lower Roller position may be micro adjusted by clicking here. Shingle may be micro adjusted by clicking here. Roller adjustment calculator. Shingle adjustment calculator. The Delivery can be toggled On or Off by clicking here. SYSTEM Delivery on/off status red is off green is on.
Operating the DigiFold Pro Setting the Delivery Conveyor System. WARNINGS:1. The Machine will not start if the delivery unit is not in its up position. 2. 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. 3. If the delivery is turned on when using the ‘Set by Fold’ mode of operation; the Roller Position and Shingle Length are automatically set, relative to the paper length and type of fold selected. 4.
DigiFold Pro Operating the DigiFold Pro Status Screen. 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 store page Clicking in this area will take you to the paper setting page. Currently selected fold type - can be one of the following. Paper length & Paper Type - input from the paper setting screen. Number of creases - this may alter automatically if a pre-defined fold is selected.
Operating the DigiFold Pro Run Job. Click to run machine. System Switch Not On. Click to confirm System switch is on & then click run button again The machine running screen will appear. Run count Batch Count Job Count Click to stop machine.
DigiFold Pro Operating the DigiFold Pro Setting the machine to operate in manual sheet feed mode In order to feed heavy stock, very small or very large sheets, embossed or even irregular shaped sheets, it may be necessary to feed the sheets manually. The machine can be programmed and set up in exactly the same way as explained when operating the machine automatically. However, the paper gate must be raised to its highest position for the sheets to be fed freely.
Operating the DigiFold Pro Store Pages. To get to the Store setting page click the lower tab status area. or from the New Jobs. 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.
DigiFold Pro Operating the DigiFold Pro Save confirmation screen. 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.
Operating the DigiFold 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.
DigiFold Pro Operating the DigiFold Pro Tools Menu. To get to the Tools page click the lower tab Inch paper in direction of arrow to clear jams Clicking this icon will show Machine programme revision & Touch Screen software revision.
Operating the DigiFold Pro BLANK PAGE Page 36 FOLDING
DigiFold Pro The Blade Assembly Adjusting the blade pressure (no paper required) 1. (i) Switch the power ‘on’ by turning the Emergency stop button clockwise to release the safety latch. (ii) Select the Tools tab at the bottom of the touch screen, the display will change to that shown below. (iii) Select the up arrow to move the blade to the Top Dead Centre position. Click on Up Arrow to put Anvil into Top Dead Centre position (TDC) 2. Raise the exit guard 3.
Replacing Blade Sets 1. Before removing the blade assembly, ensure that the lower blade / anvil is at ‘Top Dead Centre’, see page 37. 2. Lift the top cover. 3. Using a 5mm allen key, remove the two socket head screws, one each end of the Blade Set, as shown in FIG 32.1 below. FIG 32.1 4. Remove the Sheet Guide Assembly, by pulling upwards on the two flanges, one each end, as shown in FIG 32.2 and FIG 32.3 below. Sheet Guide Assembly Flange FIG 32.2 FIG 32.3 5.
DigiFold Pro Replacing Blade Sets 6. Insert the Blade Extractor Tools, one at each end of the Blade Set, as shown in FIG 33.1 below. Note The Position of The Blade Extractor Tool Under The Lip of The Blade Adjuster Assembly FIG 33.1 7. Lever the Blade Assembly in the direction shown in FIG 33.2 to unclip and release the Blade Set. FIG 33.
Replacing Blade Sets 8. Slide the blade assembly out of the creasing unit and lay it on a flat surface. 9. Slide the blade adjustment cams and the blade adjustment assemblies away from the dowels located in the ends of the blades / anvils as shown in FIG 34.1 below. Blade Adjustment Assembly Socket Head Screw Blade Adjustment Cam FIG 34.1 10. Slide the blade adjustment assemblies and the blade adjustment cams onto the dowels of the new blade set. 11.
DigiFold Pro Replacing Blade Sets 13. Refit the Sheet Guide Assembly 14. Close the top cover 15. Switch the machine on and test the crease for form. The following Blade sets are supplied with the Digifold 5000P as standard. Standard Blade set Part number 176-213-02 Consisting of a standard blade and anvil, pre-set for your machine. Narrow Blade set Part number 176-213-01 Consisting of a standard blade and a narrow anvil, pre-set for your machine. NOTE.
Perforating Once the machine is set-up, the Machine can be used to perforate or crease. Notes 1. Perforating and creasing can be carried out simultaneously. However, if any adjustment is made to the roller tilt mechanism in order to compensate for the perforation line being ’out of square’, this may effect the accuracy of the crease. If this occurs creasing and perforating must be carried out as separate operations. 2.
DigiFold Pro Perforating All of the blades and anvils are supplied with fixings. *Perforator stripper Standard Part Number 177-05-01 *It is recommended that for multiple perforations, a separate perforator stripper is used for every perforating blade set fitted in the creasing unit. Setting the machine 1. Turn the mains supply to the machine ‘off’. 2. Open the perforator assembly to get access to the drive wheels and hubs. 3.
Perforating 12. Slide the drive hub towards the perforating drive wheel until there is a clearance of 0.5mm (0.020”). 13. To prevent damage to the blades or the anvils, do not force the drive wheel against the hub. 14. Fix the perforator stripper adjacent to the drive wheel and blade as shown. 15. Operate the machine and test the perforations for form. It is important that the drive hubs are arranged evenly across the width of the paper in order to reduce the risk of jamming.
DigiFold Pro Removing Paper Jams Removing Paper Jams In the event of a paper jam occurring, whilst running the machine, follow the steps described below to allow access to remove the jammed paper. 1. Unlock and lower the delivery unit, open the top cover and the perforator unit; see FIG 39.1 below. 2. If the paper is jammed in the fold rollers; try to rotate the top fold roller, using both hands. Position the thumbs under the tie bar and spread the fingers out above the tie bar.
BLANK PAGE Page 46 FOLDING
DigiFold Pro 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 (0.020”) from the paper stack. Check that the blade tilt mechanism is correctly set. Crease Position Inaccuracy Check that the crease profile has not been set too deep. Check that the correct Blade Set is fitted.
Trouble Shooting Machine will not start Check the power supply to the machine. Check that the emergency stop button has been released. Check that the top cover is down. Check that the perforator assembly is in its closed position. Check that the delivery unit is in the up position, and located correctly, (the machine will not start if the delivery unit is not in its up position). Check that the Gearbox Release Knob is fully to the right against the Operator side frame.
DigiFold Pro Trouble Shooting Using the Correct Blade Set. Two Blade sets are supplied with the machine. The Standard Blade set is suitable for material thicknesses of 0.25mm (0.010”) and greater. The Narrow Blade set is suitable for material thicknesses of 0.25mm (0.010”) and smaller. If the Standard Blade Set is used to crease and fold materials less than 0.25mm (0.010”) inaccurate results can be produced. If the Narrow Blade Set is used to crease and fold materials greater than 0.25mm (0.
Trouble Shooting 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. Paper Crunch If the machine stops and error message 02 is displayed on the touch screen, this indicates that a paper jam has been detected.
DigiFold Pro Trouble Shooting Error Screens (Continued) Blade Busy If the machine stops and error message 05 is displayed on the touch screen, this indicates that the blade is busy. Try to operate the machine again, If this fails it is advised to contact a Service Engineer.
Trouble Shooting Error Screens (Continued) Flying Home Failure If the machine stops and error message 08 is displayed on the touch screen, this indicates that the home signal was missed during creasing. Check that the blade pressure is not too high. Clip 1 NOT clear (Back Sensor) If the machine stops and error message 09 is displayed on the touch screen, this indicates that the sensor is or was blocked when it should have been clear. i.e.
DigiFold Pro Trouble Shooting Error Screens (Continued) Clip 2 NOT Blocked (Top Sensor) If the machine stops and error message 12 is displayed on the touch screen, this indicates that the sensor did not see the paper at the correct time. i.e. A jam in the paper path. To correct - Check if paper has jammed in the machine prior to the sensor. See page 39 that describes how to remove paper jams.
170-95-02 ITEM PART NUMBER DISPATCH KIT QTY DESCRIPTION 1 174-025 1 OPERATORS MANUAL - DigiFold Pro 2 90-018 1 ROLLER CLEANING KIT 3 650-040 1 POWER CORD C19 UK 16A 2.5m 4 170-009-01 2 BLADE REMOVAL TOOL 5 601-167 1 DIGITAL THICKNESS GAUGE 6 403-01-030-006 12 SCREW - SOCKET CAP HEAD - M3 x 6 LG 7 409-01-040-004 1 SCREW - SKT. SET FLAT PT. - M4 x 4 LG 8 620-007 1 HEXAGON BALL DRIVER 2mm 9 620-020 1 HEXAGON BALL DRIVER 2.
DigiFold Pro ITEM 1 2 3 4 5 6 7 8 ACCESSORIES AND OPTIONS PART NUMBER 172-022-01 1-99-10 1-99-12 1-99-41 1-99-35 172-03-01 172-04-01 173-169-01 DESCRIPTION LOADING TABLE EXTENSION PERFORATING BLADE SET 20T (Card) PERFORATING BLADE SET 28T (Single Sheets) PERFORATING BLADE SET 56T (Fine Perforations) ANVIL SET USED WITH ABOVE BLADE SETS DOUBLE SHEET DETECTOR KIT NARROW SHEET KIT ETHERNET KIT ACCESSORIES.... ....
RECOMMENDED SPARES PART NO.
DigiFold Pro PART NO.
MACHINE CALIBRATION HISTORY Serial Number:Date:Total Count:Vac Suck Trim Vac Park Trim Stretch Lead Edge Trim Follow Stretch Del. Roller Trim Knife 1 Trim Knife 2 Trim K1 Deflect Trim K2 Deflect Trim K1 Travel K2 Travel Date:Total Count:Vac Suck Trim Vac Park Trim Stretch Lead Edge Trim Follow Stretch Del. Roller Trim Knife 1 Trim Knife 2 Trim K1 Deflect Trim K2 Deflect Trim K1 Travel K2 Travel Date:Total Count:Vac Suck Trim Vac Park Trim Stretch Lead Edge Trim Follow Stretch Del.
DigiFold Pro FUSE POSITIONS & RATINGS (POSITION ET CLASSIFICATION DES FUSIBLES) PSU (5V / 24V) (FUSIBLE PSU (5V/24 V) F3.15AH 250 (613-023) SPARE FUSE POSITION (POSITION PORTE FUSIBLE) PSUs (24V & 48V) (FUSIBLE PSUs (24 V & 48 V) T6.
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.
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