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Morgana Digifold Pro CB, Service Manual

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Morgana Digifold Pro CB Service Manual Download Page 74

Page 74

Crease & Fold Setup Procedure

Having completed the Pre-powered and Powered setup the digifold needs to have the
crease and fold positions calibrated. This is primarily conducted using software
adjustments within the 'tools' menu, however, during this process you may need to re-
adjust the creasing matrix and Upper input roller in accordance with the descriptions stated
below.

To complete this calibration procedure you should follow the 'Calibration Procedure' flow
chart (See page 79).

To enable any form of setup to take place it is essential to perform an approximate setup of
the fold knives. This enables the sheet to be processed without becoming jammed in the
machine. You may need to re-adjust the fold trims later, but this is covered towards the end
of the flow chart.

This initial setup is also concerned with removing any sheet steer caused by the fold rollers.
If the sheet is not folding in half squarely, then the upper input roller will need to be adjusted
to compensate.

To adjust the upper input roller follow this procedure.

Loosen the two operator side housing screws (M5 set screws).

Adjust the layside housing using the shaft flats on the operator end.

Temporarily tighten ONE of the op. side housing set screws (the top one).

Re-check for sheet steer. (fold in half test)

Repeat 1 to 3 until no steering takes place.

Tighten both of the op. side housing screws (M5 set screws).

If the layside housing is adjusted, it may be necessary to lower or raise the entire upper
input roller so ensure the loosest side has sufficient 'grip' on a single 80gsm test strip. If
this is adjusted, it will be necessary to re-check for sheet steer.

Check fold roller parallelism (See page 54).

17.

Primary Fold Setup

17.1.

17.2.

17.3.

17.4.

17.5.

17.6.

CREASING / FOLDING

Summary of Contents for Digifold Pro CB

Page 1: ...SUE 2 APRIL 2012 174 037 DOCUMENT CREASING FOLDING MACHINE SERVICE MANUAL Morgana Systems Limited United Kingdom Website www morgana co uk Telephone 01908 608888 Facsimile 01908 692399 Digifold Pro CB UL ...

Page 2: ...es illustrated parts manual available when servicing as its illustrations provide an invaluable reference to the construction of the individual assemblies used to build the machine All threaded fasteners are isometric all nuts are isometric hexagon All screws are hardened high tensile steel Cap head Button head Socket countersunk Shoulder bolts and Grubscrews have internal hexagon drives which req...

Page 3: ... Left of Fold Rollers Feeder end Right of Fold Rollers Remove all packaging materials All metal parts including the folding rollers have a protective coating And any excess should be removed Connect the power cable to the mains supply The machine requires 230V 50Hz 10Amps Turn the fold rollers by hand to ensure they rotate freely Switch on the machine and check that all functions operate Set up th...

Page 4: ...l of Creaser Unit 14 Removal Replacement Drive Belt 16 Vacuum Drum Loading Table Removal Replacement 18 Suction Drum Belt Removal Replacement 19 Infeed Roller Removal Replacement 20 21 Replacing the Touchscreen Assembly 22 Electrics The PRO Control System 23 24 24 Removal Replacement ITX Boards 26 Removal Replacement ITX PSU 26 Removal Replacement Stepper Drive PCB 27 Removal Replacement Large PSU...

Page 5: ...ion 45 Creasing Blade Installation 48 Input Roller Gear Mesh 50 Upper Input Roller Setting the Paralllelism Pressure 51 Fold Rollers Setting the Parallelism Pressure 54 Perforator Assembly 56 Setting The Fold Knives 58 Adjusting The Top Cover Safety Switch 60 Powered Setup Procedure Flow Chart 61 Control System Setup 62 Fold Roller Gap Potentiometers 63 Dynacrease Tilt Potentiometer 64 Setting The...

Page 6: ...djustments 81 Follow Stretch 82 Test Run 82 Trouble Shooting General 83 Creasing Unit 83 Folding Unit 83 For Error Messages refer to Operator manual 86 Circuit Diagrams DigiFold Wiring Diagram 88 Control PCB Connection Diagram 89 91 Section 15 Section 16 Crease Fold Setup Procedure Section 17 Section 18 Section 19 Section 20 Calibration Section 21 Section 22 Section 23 Section 24 Section 25 Sectio...

Page 7: ...Page 7 SYSTEM BLANK PAGE Digifold Pro ...

Page 8: ...ow 1 Delivery assembly 6 Air separation knob 11 Paper Gate 2 Vacuum bleed knob 7 Adjustable side lay 12 Top Cover 3 Suction slot knob 8 Back stop 13 Touchscreen 4 Switch panel 9 Fixed side lay 14 Loading Table Extension 5 Air distribution knob 10 Fuses Optional 1 3 10 5 6 7 8 9 11 12 13 2 4 14 ...

Page 9: ...ng with the Rear Cover Panel see below To open first unscrew the single pan head screw adjacent to the touch screen and then the five pan head screws below the feed bed which also fixes the Control Cover Door in place hinge backwards to open To remove this panel on its own remove all countersunk screws attached to the hinge and lift away To replace is the reverse procedure Alternatively remove the...

Page 10: ...e Top Cover Assembly is hinged on top of the Machine and covers the Mechanism this hinges upwards to allow access to the Main Rollers the Input Rollers the Creasing Assemblies the Top Sensors This cover can be removed from the machine as follows 1 Open the Lay Side Door as previously described 2 Open upwards 3 Peel back the sound absorbent foam to allow access to the two posi pan head fixing screw...

Page 11: ...se to lock the delivery strut into this position Shown in photo below Using the body of the gas strut unscrew from its clevis until released Unscrew the support blocks each side using a 5mm A F allen key at the top fixing and loosen the bottom screw Pivot both blocks forward note the operator side will have a resistance from the perf gas strut The assembly can now be lifted clear SECTION A Deliver...

Page 12: ...l board Remove the two pipe mounting clip plates ITEM 6 on next page so that the hoses can be detached from the valve Remove the two screws that secure the valve to the rear of the frame Refit in reverse order When refitting the valve ensure that the ends of the hoses are clear of nylon fibres and that the O ring is in place Do not over tighten aluminum parts and use grease to stop binding Note Pa...

Page 13: ...Page 13 SYSTEM Digifold Pro ...

Page 14: ...he hub By loosening the grub screws on the counterweight and rotating access can be gained to remove the fixing screws 7 Loosen the four M5 securing screws on the Dynacrease motor to enable removal of the drive belt the main frame with care See SectionA From the front of the machine remove the Tilt Mechanism assembly by unscrewing the two button socket screws Ensure that the mains is unplugged Cut...

Page 15: ...the upper and lower worms C the pins A on the upper and lower worm wheel assemblies D are in the same relative position as shown above This will ensure the throw of each eccentric is in the same position at the top and the bottom See Dynacrease Tilt Potentiometer in the Powered Setup Procedure on page 61 Digifold Pro ...

Page 16: ...de AnvilAssembly 3 Unscrew the two countersunk head screws from the input and output guides and remove them 4 Remove the four tie bar securing nuts at the drive end of the mechanism Pulley end 5 Using a 3 0 mmA F allen key remove the two shoulder bolts 6 Remove the top swinging block along with the M6 thin washer 7 Tap the side plate from the assembly and remove the belt The Belt must be tensioned...

Page 17: ...Page 17 SYSTEM BLANK PAGE Digifold Pro ...

Page 18: ... Remove the Valve assembly and the manifold PortAdaptor 9 Remove the M10 cap head screw to allow access to the Ball Holder screw 10 Remove the two fixing screws in the rear of the Ball HolderAssembly and remove 11 Loosen the Display fixing screws two off 12 Remove the four Manifold fixing screws and the one fixing the Sidelay 13 Slide the green feed belt from the pulleys 14 Remove the two M8 butto...

Page 19: ...lt 5 Leave the feed drum idler and feed drum roller You can now remove belt 6 Replace in reverse order be careful of bearings and shims Remove choke shaft by unscrewing the soc set screw from underneath using a 2 5mmA F allen key Remove the bearing center support plate by unscrewing the two cap head screws in position Digifold Pro ...

Page 20: ...he frame 4 From the lay side of the machine remove the circlip from the shaft housing 5 Remove the Dynacrease tilt mechanism 6 The roller can now be removed through the hole in the operator sideplate 6 Remove the circlip from the shaft on the operator side 7 Remove the pulley from the opposite end and then loosen the layside hub securing set screw located in the aluminium side plate edge Withdraw ...

Page 21: ...Page 21 SYSTEM Layedge Side Operator Side Digifold Pro ...

Page 22: ...nit up and through the top cover aperture Replacement is the opposite procedure Calibration of the Touch Screen 1 Switch on the power and wait for the main screen to appear before commencing to check the horizontal and vertical position of the display The position of the display within the surround is achieved by operating the centre button at the rear of the housing press this a number of times t...

Page 23: ...one program which is the machine control program for the particular machine that it is installed on ELECTRICS The PRO Control System Block Diagram of the PRO Control System ITX Motherboard Controller PCB ATX PSU E Stop 240V AC 5V DC 12V DC 0V RED YELLOW BLACK Comms GUI USB Stick Flash Drive Hard Drive Touch Panel VGA Digital Analogue Interface PCB Machine Control Processor PCB Touchscreen Display ...

Page 24: ...ver located beneath the feed bed This Small PCB is plugged onto the face of the Main Control PCB and houses the Program Chip The use of an antistatic wrist band should be used during work on this Processor PCB Switch the mains power off and disconnect from the mains supply Access is from the hinged Control Cover located beneath the feed bed REPLACEMENT OF PROCESSOR BOARD Note REPLACEMENT OF USB FL...

Page 25: ...e like for like i e Green for Green and Red for Red 4 Power the machine up 5 To access the machine menu open the calculator and type 608888 then press X to exit the calculator screen 6 Choose the machine type from the list and perform a power cycle when prompted 7 Re enter the calibration settings NOTE FIG 1 and FIG 2 above show the Internal USB Flash Drive position for the current Gigabyte ATX mo...

Page 26: ...e to the above If using the existing USB stick the machine calibration will be as before but using a new stick will lose the settings and will mean recalibrating the machine This supplies power to the main control PCB and the graphic interface ITX control board and is located as above 5 volts DC is used as the control circuit and 12volts DC is utilised for the Safety circuit Switch the mains power...

Page 27: ...rminals in the correct positions and refit This controls the fold knives motor and the main roller drive motor and is located as above see section on covers for removal Switch the mains power off and disconnect from the mains supply Unplug all the green plugs from the PCB Using a posi drive screw driver unscrew the five fixing screws and carefully remove the PCB Replacement is the reverse procedur...

Page 28: ...wing procedure Is necessary Turn the machine on Select Tools on the Display and select METRIC or IMPERIAL by toggling the button white is ON To set the vacuum drum start position the following procedure Is necessary Turn the machine on Insert the Engineers Plug into the Socket located at the rear of the machine Select Tools on the Display and select Vac Drum Trim by toggling the button Input a val...

Page 29: ...en required using a slim brush With a slim brush the sensors can be cleaned when required Pass the brush under the ball holder and push through until it passes the infeed rollers as can be seen in the picture below Alternatively it The Jam Sensor is situated just after the edge sensor and is inline across the paper path with the receiver in the operator side sideplate This is not usualy sensitive ...

Page 30: ...oors 2 Remove the top infeed roller 3 Unscrew the two cap head allen screws and lift the sensor housing out 4 Replace the sensor with a new unit and retighten the screws Reassembly is the reverse procedure The crunch sensor is a beam projected across the machine just in front of the blade and above the paper path when the beam is broken the machine will stop The receiver is housed in the sideplate...

Page 31: ... the soc set dog point screw from the housing to allow the post to rotate Clip 1 2 Sensor Assembly 3 Unscrew the soc set screw from the post that retains the leg of the sensor 4 Rotate the post through 180 degrees to gain access to the other leg and unscrew this screw 5 Replace the sensor with a new unit and retighten the leg screws Note All sensors can be tested for operation without removing the...

Page 32: ... allen key and remove screws Once the blade is free it can be easily lifted from the machine Fold Knife Bottom Fold Knife Replacing Fold Knife Assemblies Remove the lower rear guide assembly by removing the four posi pan head screws 2 each end which fix the black delrin block to the side plates Unscrew the two countersunk head screws one each end using a 4mm allen key and remove screws Once the bl...

Page 33: ...m the operators side of the machine by removing the 3 button head screws 1 Remove 3 off screws on the access housing 2 Remove the collar from the shaft on the layside of the machine 3 The roller assembly can now be withdrawn from the operator side of the machine 4 To remove the worm from the roller assembly unscrew the grub screw To replace is the reverse procedure note the dog point on the large ...

Page 34: ...d Roller Assembly as follows 1 Remove the worm wheel from the shaft 2 Remove 3 off screws on access housing and 1 off on link plate 3 The roller assembly can now be withdrawn from the lay side of the machine 1 Remove 3 off screws on access housing 2 The roller assembly can now be withdrawn from the operator side of the machine ...

Page 35: ...Insert the roller assembly into the frame from the lay side of the machine 2 Replace screws to lock hub in position refit wormwheel ensure correct orientation 3 The parallelism can now be set 2 Replace screws to lock hub in position refit layside collar 3 The parallelism can now be set Replace The 1st Roller Assembly as follows Replace The 2nd Roller Assembly as follows 1 Insert the roller assembl...

Page 36: ...the socket set screw when required Loosen the soc set screw allowing the link to rotate about the shaft and locate the top shoulder bolt into the gas strut end and the link plate tighten using a 3mm allen key ref illustration below Using an adjustable or large spanner positioned as shown below compress the gas strut until the soc set screw aligns with the hole in the shaft and tighten the screw Re...

Page 37: ...SYSTEM Page 37 BLANK PAGE Digifold Pro ...

Page 38: ...f the Top Cover and the Entry Guard are removed An adequate supply of DigiFold Pro Test Sheets Part Number 170 004 01 should be made available for many of the set up procedures Ensure that test sheets are kept dry flat and undamaged Damp bent buckled and damaged test sheets must not be used TEST SHEETS Digifold Pro ...

Page 39: ...Page 39 SYSTEM Digifold Pro ...

Page 40: ...ly is controlled by the two M8 Button Head Screws which allow fore aft adjustment of the operator side of the Loading Table See FIG 1 5 Use the following procedure to check adjust the LoadingTable squareness Remove the Balls from the Sidelay Open the Input Roller gap fully by releasing the Locking Screw using a 4mm hexagon key to move it down towards the Loading Table See FIG 1 2 below Place a Tes...

Page 41: ...dingTable and move the operator side in a fore aft direction until the lead edge of the test sheet is parallel with the Upper Input Roller Tighten both screws when complete It s important to note that the lay edge of the test sheet must be kept in complete contact with the Fixed Side Lay Manifold during this process FIG 1 5 Side Lay Manifold Input Roller Paper Lead Edge of Test Sheet Fixed Upper F...

Page 42: ... to be centralized square to the Side Lay therefore parallel to the Input Rollers The squareness of the DynaCrease Unit is controlled by the Tilt Mechanism on the Operator side of the machine and by a pair of engineer adjustable Pivot Blocks on the Lay side Using the Operator Tilt Knob rotate the Spring Hubs on the eccentric Worm Wheels until the Spring Pins are vertical See FIG 2 1 below 2 1 FIG ...

Page 43: ...dge against the Fixed Side Lay slide it through the open Input Rollers until the lead edge just enters the DynaCrease Unit It should be possible to visually check the parallel alignment of the lead edge of the sheet with the UpperTie Bar of the DynaCrease Unit See FIG 2 5 Do not use damaged test sheets WARNING FIG 2 3 Side Lay Manifold Input Rollers Paper Dynacrease Fixed Tie Bar FIG 2 5 Leading E...

Page 44: ...appropriate direction until the lead edge of the test sheet is parallel with the Tie Bars Tighten all screws in the reverse order when complete Do not loosen the two inside or the two outside screws securing the bottom of the Blade Drive Stepper Motor Mounting Plate Do not tap the Upper Pivot Block or its fixing screws as this will twist the Dynacrease Unit the Upper Pivot Block will self align pr...

Page 45: ...tor until the correct tension is achieved tighten all fixings when complete See FIG3 1A 3 3 Ensure the fold knives are set correctly using the jig before setting the drive belt tension Loosen the four M5 fixings securing the Drive Motor to the Frame Plate Raise or lower the Motor until the correct Tension is achieved this should not be too tight approx one quarter twist on the free length tighten ...

Page 46: ...r to the Stepper Mounting Plate Access to these fixings is via the large clearance hole around the motor Raise or lower the Motor until the correct tension is achieved tighten all fixings when complete See FIG 3 1 FIG 3 2 Blade Drive Belt Blade Drive Belt Blade Drive Motor Blade Drive Motor Fixings FIG 3 2 CREASING FOLDING ...

Page 47: ...Drive Motor to the Vacuum Stepper Plate Rotate the Motor about its top left hand fixing until the correct tension is achieved tighten all fixings Vacuum Drive Belt FIG 3 4A FIG 3 4B FIG 3 4C Vacuum Roller Vacuum Drive Belt Vacuum Motor Fixings Vacuum Stepper Plate Adjust Tension Digifold Pro SYSTEM ...

Page 48: ...new Blade Set and check that the BladeAlignment Bolts are correctly positioned the high point of the Blade eccentrics should be facing the high point of theAnvil eccentrics at both ends If not loosen the M4 locking screws slightly adjust the bolts accordingly re tighten the locking screws See FIG 4 2 Assemble the BladeAdjustmentAssemblies onto the Blade orAnvil Pins install the Blade Set into the ...

Page 49: ...the DynaCrease Crankshaft one complete turn by hand using the Counterweight some effort should be required as the Blade Anvil come together to form the crease 4 7 Slide the Test Sheet back through the Input Rollers and examine the Crease it should be a similar depth each end reasonably central but does not have to be perfect at this stage Make adjustments if required following the procedure descri...

Page 50: ...ss Housing which is eccentric to adjust the gear mesh theAccess Housing is provided with a hardened screw in its end face to facilitate its rotation Whilst adjusting the gear mesh continually rotate the rollers using the Main Drive Pulley on the end of the Lower Input Roller to check the gear mesh is correct all the way round and there is no eccentricity in the gears Finally tighten theAccess Hous...

Page 51: ...yside end of this roller there is an eccentric housing which enables adjustment The housing is secured to the shaft using two M5 flat tip set screws Loosen the two Operator side Housing screws M5 set screws insert two 80gsm test strips one each end into the nip of the Input Rollers 6 1 FIG 6 1 A Op Side Housing M5 Cap Head Screw Radial Slot Upper Input Roller Layside Eccentric Housing Layside Hous...

Page 52: ...rew in the radial slot in the edge of the Operator Side Plate Check the feel on a complete rotation of the roller to ensure the roller is concentric repeat from 6 2 until both strips have the same very light feel on the test strips Finally tighten both of the opside housing screws M5 set screws Now using the operator side securing screw the M5 cap head screw in the radial Slot adjust the whole rol...

Page 53: ...Page 53 BLANK PAGE Digifold Pro SYSTEM ...

Page 54: ...one each end into the nip of the first Fold Roller by feeding the Test Strips between the Lower Roller Shield the Lower Guide It may be necessary to move the fold knives to gain access to the rollers Adjust the Layside Housing until an even pressure is felt on the two strips temporarily tighten the layside housing set screw Now turn the appropriate gap set adjuster knob to give a very light pull o...

Page 55: ...Page 55 Digifold Pro SYSTEM ...

Page 56: ...n of the Perforator Drive Wheels Hubs Lower the Delivery Unit swing the PerforatorAssembly down to its lowest position Using a 2mmA F Hexagon Key loosen the M4 Grub Screw in each of the Wheels Hubs and arrange them as shown below The recommended positions of the Wheels and Hubs are different when Folding or Perfing Perforating drive wheel with mounted blades Drive hub with mounted anvils Perforato...

Page 57: ...ess The gear mesh can be adjusted by rotating the Layside eccentricAdjuster Cam after releasing its M4 locking screw Check the gear mesh through 2 full rotations of the Perforator Shafts to ensure no eccentricity and lock the Cam into position Rotate the Operator side Cam to adjust the parallelism of the entire assembly finally Lock the Cams into position with their Grub Screws FIG 8 4 Perf Drive ...

Page 58: ...p Heads Loosen the front and rear fixing cap head screws on each side of the Delrin Cam eccentric shaft and position the flat on the shaft vertically as shown above From the Layside of the DigiFold rotate the Knife Drive Hubs fully counter clockwise fit the Setting Jig Part No T 045 Rev C as shown in the diagram below using the three shoulder Bolts supplied This locks the knives in one of the two ...

Page 59: ...ate the Jig and the Knife Drive Hub to which it is fixed and the drive motor pulley fully Clockwise and insert the Shoulder Bolt through the previously unused hole in the Jig and into the Left Hand Knife Drive Hub This locks the knives in the other of the two correct stop positions Re Check the positions of the Setting Jig Repeat above procedure if the shoulder screws do not slide into the jig smo...

Page 60: ...Top Cover safety Switch 10 1 Open layside door 10 2 Loosen the two fixings on the switch 10 3 Adjust the switch position until lifting the top cover switches the machine when lifted by 6mm 10mm Page 60 CREASING FOLDING ...

Page 61: ...Page 61 Digifold Pro SYSTEM ...

Page 62: ...ble for the machine build level check this by going to the tools menu and operating the information button There is one Dual Stepper Drive Board and three single Stepper Drive Boards located on the lower section of the Electronics Panel These boards are fitted with and These switches must be set in accordance with the correct Circuit Diagram issue for the Serial Number of the machine being set up ...

Page 63: ...oosen the right hand potentiometer coupling screw Rotate the pot until the display for Gap 1 reads 0 1 Finally tighten the coupling screw Insert an 80gsmTest Strip into the nip of the second Fold Roller by feeding the Test Strip between the Paper Guide Upper Roller Shield It may be necessary to move the fold knives to gain access to the rollers Turn the 2nd Gap SetAdjustment Knob 2nd from the left...

Page 64: ...he DynaCrease Unit Loosen the lower far left hand potentiometer coupling screw rotate the pot until the display forTilt reads 0 00 then tighten the coupling screw The Vacuum Drum which is part of the Feed System is driven by a Stepper Motor which is programmed to start after the sheet to be fed has been secured to the drum by the Vacuum Due to the specialised nature of the drum slot profile the po...

Page 65: ...k the operation of each Sensor or Detector in turn by entering theTools Menu operate Operate each sensor manually The registers the lead edge of the sheet to within 0 1mm Its correct setting is extremely critical to the performance of the machine and 15 2 Ensure the Red LED3 on the Main Control Board is Off Place an 80gsm sheet on the Loading Table with its Lay Edge against the Fixed Side Lay Slid...

Page 66: ... are no adjustments The position of the Creasing Blades in the Unit is detected by reading off a Slotted Disc on the DynaCrease Crankshaft 15 9 To test the rotate the DynaCrease Crankshaft by hand and the display will toggle between and the appropriate LED should be illuminated There are no adjustments Crunch Sensor Clip Sensors Clip 1 Clip 2 Vacuum Drum Slot Detector Vacuum Drum Slot Detector Dyn...

Page 67: ...the 2 Roller Drive Belts are first loosened to prevent excessive loads to the drive roller bearings Lower the delivery until the unit is vertical Remove the 4 fixing screws from the Upper End Panel and remove this panel Using a 5mm L SeriesAllen key and suitable lever a spanner is fine loosen the 2 button head screws that are used to secure each eccentric idler tensioner 1 each side 16 1 16 1 1 16...

Page 68: ...on If the belt starts to run off to one side it will be necessary to adjust the belt tension using the following rules The belt will always track to the loosest side If the Belt is already tight on both sides you should loosen the side you wish to track the Belt to If the Belt tension feels OK on both sides it is acceptable to tighten the side to which the belt has traversed a little Once the Deli...

Page 69: ...g the sliding bracket positions to the slots on the side panels of the delivery If they are not equal the lay side must be adjusted using the following method Lower the delivery until the unit is vertical Remove the 4 fixing screws from the Upper End Panel and Remove this panel See FIG 16 1 2 On the delivery belt roller shaft there is a pulley on the layside Loosen the two M4 securing set screws a...

Page 70: ...ly up 16 2 2 2 Remove the four M4 Pan Head screws from the Underside Cover remove this cover Delivery Potentiometer FIG 16 2 2 4 M5 Cap Head Screws Potentiometer Pulley Potentiometer Belt FIG 16 2 2 2 M4 Pan Head Screws Underside Cover CREASING FOLDING 16 2 2 3 Slide the Delivery Roller to the mid point of the delivery belt 16 2 2 4 Loosen the two M5 cap head screws securing the potentiometer brac...

Page 71: ... to hold the belt away from the pulley and rotate the potentiometer pulley in the opposite direction for a full 5 turns use a mark for reference if required 16 2 2 7 Re engage the belt with this pulley and re tension the belt 16 2 2 8 Tighten the two M5 Cap head screws to secure the potentiometer bracket 16 2 2 9 Re fit the underside cover Digifold Pro SYSTEM ...

Page 72: ...16 3 2 Push the delivery down about 30 degrees and hold it 16 3 3 Using a 10mm spanner loosen the damping adjuster screw securing nut by 1 8th of a turn 16 3 4 Release the delivery to its operating position 16 3 5 Using a 3mmAllen key adjust the damping adjuster screw Turning the screw will some of the damping and vice versa 16 3 6 Adjust until the desired damping effect is achieved i e the delive...

Page 73: ...Page 73 Digifold Pro SYSTEM ...

Page 74: ... chart This initial setup is also concerned with removing any sheet steer caused by the fold rollers If the sheet is not folding in half squarely then the upper input roller will need to be adjusted to compensate To adjust the upper input roller follow this procedure Loosen the two operator side housing screws M5 set screws Adjust the layside housing using the shaft flats on the operator end Tempo...

Page 75: ...eases are not parallel then the upper input roller should be adjusted to compensate See FIG 18 1 Fold Line Pressures Correct Pressures Too Heavy Pressures Too Light Feed Direction Crease 1 Crease 2 Crease 3 FIG 18 1 SHEET STEER Layside Input Roller Crease 1 Crease 2 Crease 3 Fold Line Crease 1 Crease 2 Crease 3 Fold Line Layside Input Roller Layside Input Roller Digifold Pro SYSTEM ...

Page 76: ...ses test Repeat 1 to 3 until no steering takes place Tighten both of the operator side housing screws M5 set screws If the layside housing is adjusted it may be necessary to lower or raise the entire upper input roller so ensure the loosest side has sufficient grip on a single 80gsm test strip If this is adjusted it will be necessary to re check for sheet steer Once creases are parallel it is then...

Page 77: ...Layside adjustment To move the creasing matrix towards the delivery the upper blade bolt should be rotated clockwise and the lower blade bolt should be rotated anti clockwise by an equal amount To move the creasing matrix towards the loading table the upper blade bolt should be rotated anti clockwise and the lower blade bolt should be rotate clockwise by an equal amount Operator side adjustment To...

Page 78: ...alf on the crease by lifting the tail edge and folding to meet the lead edge At this point you need to analyse the sheet to see if the Bias is correct see FIG 20 below If an adjustment required please ensure both the operator and the Lay side blade bolts are adjusted by the same amount It is only necessary to adjust the blade portion of the creasing matrix Whilst checking the crease bias see if th...

Page 79: ...Page 79 Digifold Pro SYSTEM ...

Page 80: ...ivery Roller Trim until the upper stopping position is within 3mm of the perforator cover Using the test stock setup Crease Only at 50 and 370 Check the crease positions and using the Stretch and Lead Edge settings in the Tools menu adjust the crease positions until they are correct Always Set the Stretch first i e 320mm between creases 23 1 Using the test stock setup fold only ie turn off creasin...

Page 81: ...the Fold knife being too late and so minus some K1 Deflect trim General scuffing of the sheet underside are caused by the fold knife being too early add some K1 deflect trim 24 2 K2 Double Deflect Trim Ensure K2 is turned on using the Tools menu If marking occurs when K2 is turned on then follow these general rules Roller marks are caused by the Fold knife being too late and so minus some K2 defle...

Page 82: ...late reduce the Follow Stretch setting If the last crease is early increase the Follow Stretch setting i From the Home screen on the Display select a FoldType ii Select Crease Fold On iii Following the procedure laid out in the Operators Manual set up and run each of the folds listed in the SetType screen and examine the results iv If adjustment is required refer to the Engineering Set Up and Cali...

Page 83: ...se roller parallelism stock adjust as required Note if the crease continues to be out of square this parallelism may be needed to be out of parallel First set of fold rollers Check as note above applies parallelism Folding out of square Folding too close to crease Move fold further away with crease Crease blade too wide for Change creasing blade set for stock thickness narrow blade set Fold roller...

Page 84: ...age should be between 11 75V to 12 25V Anything below 11 7V should be regarded as suspect and the power supply should be replaced i Remove the 3V lithium disc battery from the ITX mother board and check the voltage using a multi meter If the voltage is less than 1 5V replace the ITX mother board If the voltage is more than 1 5V refit the battery to the board 1 RISK OF EXPLOSION IF BATTERY IS REPLA...

Page 85: ...r board has a lithium battery fitted the board together with its battery must be recycled DISPOSE OF BATTERIES ACCORDING TO THE MANUFACTURERS INSTRUCTIONS in compliance with agreed national Procedures Please contact your local disposal authority for information PINS 3 4 FIG 2 ...

Page 86: ...ere is V AC across the ATX PSU power cord Identify reason for no power to ATX PSU Check 500mA fuse below the Mains Input connector See Page 90 If this fuse has blown replace it must be replaced with a T500mA fuse Morgana part number 681 020 Is there a V DC output from the ATX PSU See page 84 Replace the ATX PSU Does the cooling fan run on the mini ITX motherboard See page 84 Replace the mini ITX m...

Page 87: ...ump Overload assembly The Pump Overload assembly is located on the inside of the frame next to the Anti static Transformer If this fuse has blown it must be replaced with a T315mA fuse Morgana part number 681 011 For Error messages see Operators Manual WHITE ORANGE RED YELLOW Morgana Systems Ltd PUMP OVERLOAD BOARD WHITE FUSE T315mA ...

Page 88: ...Page 88 CREASING FOLDING Section N BL YEL ...

Page 89: ...MITTER LEAD 175 072 01 18 PAPER JAM DETECTOR LEAD 175 072 02 20 SENSOR BAR ASSY 175 11 02 21 ENGINEERING LEAD 144 116 25 SENSOR BAR ASSY 175 11 03 26 SENSOR BAR ASSY 175 11 01 27 HOME SLOT SENSOR LEAD 173 57 01 28 VACUUM SLOT SENSOR LEAD 173 58 01 30 FOLD KNIVES SENSOR 76 266 77 ELIVERY INPUT CONNECTOR LEAD 76 261 78 VALVE SIGNAL LEAD 76 270 86 INTERFACE LEAD 76 271 WHI WHI BRN BRN DISPLAY JOYSTIC...

Page 90: ...age 90 CREASING FOLDING FUSE POSITIONS RATINGS T500mAH 250V 681 020 PSUs 24V 48V T6 3AH 250V 681 019 T315mAH 250V 681 011 ANTI STATIC UNIT SPARE FUSE POSITION TRANSFORMER ASSY F15AH 250V 652 047 MAINS IN ...

Page 91: ...ction sheet The double sheet detect feature can be 172 03 02 170 012 02 turned ON or OFF as follows 1 Insert the engineer s calibration plug into its socket 2 Select the Tools menu tab 3 Select the icon 4 The double sheet detect can then be switched ON or OFF by selecting the icon ON OFF 5 Return to the home screen and remove the engineer s calibration plug X ...

Page 92: ...Page 92 CREASING FOLDING Mod No Rev Mod Description Date Mod By REVISION HISTORY ...

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