Morgana AutoFold Pro Service Manual Download

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184-019

Issue 4

FEBRUARY 2013

AutoFold Pro

(CB/UL)

SERVICE MANUAL

Document Folding Machine

Morgana Systems Limited

United Kingdom

www.morgana.co.uk

Telephone: ( 01908 ) 608888

Facsimile: ( 01908 ) 692399

Summary of Contents for AutoFold Pro

Page 1: ...184 019 Issue 4 FEBRUARY 2013 AutoFold Pro CB UL SERVICE MANUAL Document Folding Machine Morgana Systems Limited United Kingdom www morgana co uk Telephone 01908 608888 Facsimile 01908 692399 ...

Page 2: ... 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 requi...

Page 3: ...erator side Feeder end on your right 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 the machine to fold ...

Page 4: ...oval of Feed Bed 13 Infeed Roller Removal Replacement 14 Replacing the Touchscreen Assembly 16 Electrics Removal Refitting Control PCB and prog board 18 Removal Refitting USB Flash Drive 19 Removal Replacement ITX Boards 22 Removal Replacement ITX PSU 22 Removal Replacement Stepper Drive PCB 22 Removal Replacement Large PSUs 22 Entering Engineers tools 23 Zero Total Count 23 Setting the Measuremen...

Page 5: ...38 Fold Rollers Setting the Parallelism Pressure 40 Setting The Fold Knives 42 Adjusting The Top Cover Safety Switch 44 Powered Setup Procedure Flow Chart 45 Control System Setup 46 Fold Roller Gap Potentiometers 47 Sensors and Detectors 48 Delivery Assembly 50 Fold Setup Procedure Flow Chart 55 Primary Fold Setup 56 Section G Section H Pre Power Setup Procedure Section 1 Section 2 Section 3 Secti...

Page 6: ...stments 59 Test Run 60 Trouble Shooting Folding Unit 61 For Error Messages refer to Operator manual 63 Circuit Diagrams AutoFold Pro Wiring Diagram 64 Control PCB Connection Diagram 65 Fuse Positions Ratings 66 Calibration Section 12 Section 13 Section 14 Section 15 Section M Section N FOLDING ...

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

Page 8: ...o photograph below 1 Delivery assembly 6 Fixed Sidelay 11 Top Cover 2 Vacuum Table 7 12 Input Guide 3 Touchscreen 8 13 Fuses 4 Switch panel 9 5 Gap Sets 10 Lay Side Door Op Side Door Column Lay Side Column Op Side 1 10 7 9 2 11 8 12 FOLDING 3 5 4 13 6 ...

Page 9: ...r Panel see below To open first unscrew the three 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 front and rear covers...

Page 10: ...access to the Main Rollers the Input Rollers and 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 adsorbent foam to allow access to the two posi pan head fixing screws which can be unscrewed from the pivot shaft 4 From the rear of the machine slide the guard pivot shaft out taking care not to...

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: ... guide to the end of the bed be carefull not to lose the spacer they secure 2 With the Guard removed Unscrew the Countersunk Screws in the Feed bed 3 Lift off the bed This provided access to the fans and board 4 To remove the fans Unscrew the four Cap head screws securing the fans to the center support FOLDING ...

Page 13: ...ator and lay doors This requires unscrewing the two pan head screws diagonally opposite each other as shown below Support the feed bed from underneath and remove the support shaft that holds the gas struts in place CAUTION removal of shaft will cause Feed Bed to pivot Ensure Bed is supported before removal of shaft 7 With the Shaft removed you can now slide the bed out of the location plates and l...

Page 14: ...from the slot in the frame 3 From the lay side of the machine remove the circlip from the shaft housing 4 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 the roller assembly t...

Page 15: ...Page 15 SYSTEM Layedge Side Operator Side Autofold Pro ...

Page 16: ...ain 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 to obtain the correct orientation required move to the next button to move the position to centralize horizontal 2 Select the tools menu tab and then sel...

Page 17: ...erating system and runs only one program which is the machine control program for the particular machine that it is installed on 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 115V...

Page 18: ...the switch must be set in the correct position For machines with Serial No 180209 or higher the switch must be set over to the left in the position these machines were fitted with as standard For machines with Serial numbers earlier than 180209 the switch must generally be set over to the right in the position unless the machine has been upgraded to include Earlier Machines that have been upgraded...

Page 19: ...ty Either one of these devices could be supplied as a replacement When fitting an Internal USB Flash Drive its orientation is important Note the position of the Lock Recess shown in FIG 2 below The lock must also be in the unlocked position Ensure that the device fits securely and is fully inserted If the Internal Flash Drive is fitted the wrong way round it will not be damaged it just won t work ...

Page 20: ... 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 mother b...

Page 21: ...Page 21 SYSTEM Autofold Pro BLANK PAGE ...

Page 22: ...itch the mains power off Remove the four posi pan head screws securing the flanges and withdraw slowly Unplug all plugs from the PSU flying leads and remove the Mains connector Replacement is the reverse procedure There are two Small Stepper Driver Boards which supply the drive motors with the correct power These are located behind the Operator Side door Switch the mains power off and disconnect f...

Page 23: ...ay and continue to select required tool To set the total counter to zero 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 this button this value denotes the Machine total To set the measurement system for Imperial Inch or Metric mm the following procedure Is necessary Turn the machine on Select Tools on the Disp...

Page 24: ... and the Clean Lead Edge Sensor Warning screens can be cleaned when required using a slim brush Clip 2 sensor is situated on the upper guides inside the top cover and can be cleaned when required using a slim brush 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 to dust but if re...

Page 25: ...ve 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 of the mac...

Page 26: ...lows 2 Unscrew 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 withou...

Page 27: ...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 blade is free...

Page 28: ...bly from 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...

Page 29: ...embly 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 Autofold Pro ...

Page 30: ... set 1 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 ...

Page 31: ...SYSTEM Page 31 BLANK PAGE Autofold Pro ...

Page 32: ...Top Cover and the Entry Guard are removed An adequate supply of 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 Autofold Pro FOLDING ...

Page 33: ...ING TABLE No Yes ADJUST ANY INCORRECTLY SET BELTS CHECK ALL BELT TENSIONS ARE ALL BELTS OK No Yes SET UPPER INPUT ROLLER PARALLELISM AND CORRECT PRESSURE SET FOLD ROLLERS PARALLEL AND TO CORRECT PRESSURE SET FOLD KNIFE POSITIONS USING JIG REPLACE TOP COVER ADJUST TOP COVER MICROSWITCH POWERED SETUP PROCEDURE Pre Power Set up Procedure 1 1 2 3 4 5 6 ...

Page 34: ...cating the Support Disk on either side of the Table into the Location plates See FIG 1 3 Below 1 4 With the Table at its highest point tighten the Support Stud to support the Table and then Tighten the Gas Strut Eyes in place ensuring the Gas Struts are fully extended 1 5 Now loosen the Support Stud and lower the Table so that the Gas struts are compressed and the Table is level Then tighten the S...

Page 35: ...ing the Locking Screw using a 4mm hexagon key to move it down towards the VacuumTable See FIG 1 6 below Place aTest Sheet on the Vacuum Table with its Lay Edge against the Fixed Side Lay slide it through the open Input Rollers until the lead edge just becomes visible Do not use damp bent buckled or damaged test sheets It should be possible to visually check the parallel alignment of the lead edge ...

Page 36: ... roller Ensure the location plate is located around the position of the support disk and tighten the four screws on the location plate Check the lead edge is still parallel and then secure the latch with the two remaining screws NOTE It s important to note that the lay edge of the test sheet must be kept in Location Plate Latch Support Disk FIG 1 9 NOTE The Main Frame is displayed transparent ...

Page 37: ...hen complete See FIG 2 1 2 2 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 all fixings when complete See FIG 2 1 2 4 Ensure the fold knife...

Page 38: ...lled On the Layside 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 3 1 FIG 3 1 A Op Side Housing M5 Cap Head Screw Radial Slot Upper Input Roller Layside Eccentric Housin...

Page 39: ...ew 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 3 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 roll...

Page 40: ...ips 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 pu...

Page 41: ...Page 41 SYSTEM Autofold Pro ...

Page 42: ...4 Cap 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 ...

Page 43: ...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 44: ...g The Top Cover safety Switch 6 1 Open layside door 6 2 Loosen the two fixings on the switch 6 3 Adjust the switch position until lifting the top cover switches the machine when lifted by 6mm 10mm Page 44 FOLDING ...

Page 45: ... IS DELIVERY BELT TENSION OK Yes No LOOSEN DELIVERY ROLLER DRIVE BELTS CHECK DELIVERY ROLLER DRIVE BELT TENSIONS 9 ARE THE DELIVERY ROLLER DRIVE BELT TENSIONS OK No Yes ADJUST DELIVERY ROLLER BELT TENSIONERS 9 CREASE FOLD SETUP PROCEDURE SET DELIVERY POTENTIOMETER 9 SET DELIVERY GAS STRUT DAMPING 9 DRG No 174 031 Iss A POWER UP AUTOFOLD 6 SCREEN POSITION OK No Yes CONTROL SYSTEM SETUP 6 ADJUST SCR...

Page 46: ...on to ensure it s the latest available for the machine build level check this by going to the tools menu and operating the information button There are two Stepper Drive Boards located on the operator side 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 See Autofold Wiring Diagr...

Page 47: ...ip Loosen 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 theTest Strip between the Paper Guide Upper Roller Shield It may be necessary to move the fold knives to gain access to the rollers 8 Turn the 2nd Gap SetAdjustment Knob 2nd from the...

Page 48: ...gher or earlier machines that have been upgraded Upgraded machines will have a main processor revision of F1 2x2 or higher and a touchscreen software revision of AF1 0x1 or higher 9 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 Slide the sheet up to the Input Rollers rotate the machine by hand to drive ...

Page 49: ...rt a piece of 80gsm paper Display should read and the yellow LED should come on a between the sensors Crunch Sensor Clip Sensors Clip 1 Clip 2 Clip 1 Clip 1 Clip 2 Clip 2 9 4 Ensure there is no paper in the machine before adjusting the sensitivity control pot on the Main Circuit Board fully anticlockwise 9 5 Ensure the appropriateYellow LED is off and feed a folded sheet of paper down between the ...

Page 50: ...e 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 10 1 10 1 1 10 1...

Page 51: ... screw clockwise will tighten the belt tension 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 t...

Page 52: ...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 10 1 2 On the delivery belt roller shaft there is a pulley on the layside Loosen the two M4 securing set screws and...

Page 53: ...tiometer Pulley Potentiometer Belt FIG 10 2 2 2 M4 Pan Head Screws Underside Cover 10 2 2 To position the roller correctly there is a potentiometer which provides the feedback to the processor In order to set this correctly you must follow this procedure 10 2 2 1 Raise the delivery until it is fully up 10 2 2 2 Remove the four M4 Pan Head screws from the Underside Cover remove this cover Delivery ...

Page 54: ...r 10 3 For the delivery to raise and lower correctly it is necessary to set the damping level of the supporting Gas strut that keeps it in position To adjust this gas strut use the following method 10 3 1 Raise the delivery to its operational position 10 3 2 Push the delivery down about 30 degrees and hold it 10 3 3 Using a 10mm spanner loosen the damping adjuster screw securing nut by 1 8th of a ...

Page 55: ...OLD AND NOTE SOFTWARE VERSION SET FOLD ONLY TO 100 250 10 RUN TEST SHEET POSITIONS OK No Yes ADJUST K1 K2 FOLD TRIMS 10 SET FOLD ONLY HALF FOLD ON K1 TURN K2 OFF 10 RUN TEST SHEET FOLDING SQUARE No Yes ADJUST UPPER INPUT ROLLER PARALLELISM AND PRESSURE 10 DRG No 174 029 Iss A Autofold Pro ...

Page 56: ... 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 tigh...

Page 57: ...H 12 RUN TEST SHEET IS THE FIRST FOLD AT 50 No ADJUST LEAD EDGE 12 DAMAGE TO LEAD EDGE No Yes ADJUST K2 DOUBLE DEFLECT TRIM 14 Yes SELECT CHECK DELIVERY SETUP RUN TEST SHEET LIVE TEST PROCEDURE RUN TEST SHEET ADJUST K1 DOUBLE DEFLECT TRIM 14 DAMAGE TO LEAD EDGE No Yes TURN K2 ON 14 RUN TEST SHEET TURN FOLDS OFF AND TURN K2 OFF 14 POSITIONS OK No Yes ADJUST K1 K2 FOLD TRIMS 13 RUN TEST SHEET SET FO...

Page 58: ...ust the Delivery Roller Trim until the upper stopping position is within 3mm of the perforator cover Ensure K1 K2 are set to zero before setting Adjusting lead edge and stretch Using the test stock setup folds to 50 and 370 Check the fold positions and using the Stretch and Lead Edge settings in the Tools menu adjust the fold positions until they are correct Always Set the Stretch first i e 320mm ...

Page 59: ...old 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 14 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 deflect tr...

Page 60: ... 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 Calibration Techniques section of this Service Manual Please read the notes at the beginning of this guide before attempting any adjustments FOLDING ...

Page 61: ...e GREEN and BLACK wires of the connector as shown in FIG 1 below iii With the ATX power supply switched on use a multi meter to measure the voltage across the RED and BLACK wires of one of the 4 way connectors The measured voltage should be between 4 75V to 5 25V Anything below 4 7V should be regarded as suspect and the power supply should be replaced iv With the ATX power supply switched on use a...

Page 62: ...d screwdriver The fan on the board will start spinning wait for 30 seconds and the machine will restart and boot up as normal When the power to the machine is turned off and back on again the procedure of linking pins 3 4 must be repeated to restart the machine This is therefore only a short term fix to get the customer up and running if a replacement ITX mother board is not readily available The ...

Page 63: ...Identify reason for no power to ATX PSU Check the top fuse See Page 66 If this fuse has blown it must be replaced with a T500mA fuse Morgana part number 681 020 230V 50Hz Machines only T1A fuse Morgana part number 681 021 110V 60Hz Machines only Is there a V DC output from the ATX PSU See page 61 Replace the ATX PSU Does the cooling fan run on the mini ITX motherboard See page 61 Replace the mini ...

Page 64: ...F SW4 3 OFF SW4 4 OFF SW3 1 ON SW3 2 ON SW4 1 OFF SW4 2 ON SW4 3 OFF SW4 4 OFF SW4 1 ON SW4 2 OFF SW4 3 OFF SW4 4 OFF SW4 1 ON SW4 2 ON SW4 3 ON SW4 4 OFF SW4 1 ON SW4 2 ON SW4 3 ON SW4 4 OFF SENSOR BU BRN BU BRN N V L E V GRN YEL BL RD YEL GRN BK WHI BL GRN RD YEL YEL RD GRN BL RD GRN BL BK WHI YEL GRN BL RD BRN 76 317 51 EARTH BONDING POINT GRN YEL 61 76 277 62 63 62 63 33 33 45 45 45 45 76 278 ...

Page 65: ...4 30 FOLD KNIVES SENSOR 76 304 62 SIGNAL LEAD 76 293 63 SIGNAL LEAD 76 294 77 DELIVERY INPUT CONNECTOR LEAD 76 302 86 INTERFACE LEAD 76 271 21 WHI WHI BLK RD YEL BRN BRN DISPLAY JOYSTICK ENGINEERING BELT BLADE DRIVE DOUBLE GUARD POWER AIR KNIFE BOARD WHEE L GAP 3 GAP 2 GAP 1 DELIVERY TILT VAC SLOT HOME SLOT 1 SLOT A CLIP 2 CLIP 1 CREASE CRUNCH CREASE EDGE 3 2 16 5 9 10 11 77 62 CONTROLLER PCB YEL ...

Page 66: ...047 MAINS IN FUSE MAINS INPUT T500mAH 250V 681 020 PSUs 24V 48V T6 3AH 250V 681 019 T315mAH 250V 681 011 ANTI STATIC UNIT FUSIBLE PSUs 24 V 48 V FUSIBLE ANTI STATIQUE TRANSFORMER ASSY 230V 50Hz MACHINES T1AH 250V 681 021 TRANSFORMER ASSY 110V 60Hz MACHINES ...

Page 67: ...e bottom of Page 18 added reference the position of switch SW1 when fitting a new Main Control PCB Page 24 see Autofold Operators Manual 184 018 for Lead Edge Sensor cleaning instructions statement added Page 48 re written reference Optical Sensors Setting 4 ECO2811 23 01 13 BAL Pages 64 66 Changes T15A Fuse was F15A ...

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