Morgana DocuFold Pro Operator'S Manual Download

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90-134 Issue 3 FEBRUARY 2013

DocuFold Pro

(CB/UL)

OPERATORS MANUAL

Automatic Paper Folding Machine

Morgana Systems Limited United Kingdom www.morgana.co.uk Telephone: ( 01908 ) 608888 Facsimile: ( 01908 ) 692399

Summary of Contents for DocuFold Pro

Page 1: ...90 134 Issue 3 FEBRUARY 2013 DocuFold Pro CB UL OPERATORS MANUAL Automatic Paper Folding Machine Morgana Systems Limited United Kingdom www morgana co uk Telephone 01908 608888 Facsimile 01908 692399 ...

Page 2: ...Tilt 11 Delivery Roller 12 Emergency Stop Switch 12 Overlap 12 TOUCHSCREEN OPERATION Touchscreen Layout 13 Paper Settings Page 14 Batch Size selection 15 Speed Selection 15 Fold Settings Pages Pre defined fold types 16 Setting Fold Positions Manually Set by Position 17 Delivery Settings Pages 19 Status Screen 20 Run Job 21 Store Pages 23 Tools Menu 26 Touch Screen Calibration 27 PLUG IN PERFORATOR...

Page 3: ...ll Not Deflect When Using One Fold Or Perforating 36 Total Batch Counter Not Working 36 Overlap Error Keeps Appearing 36 Machine Will Not Reset 36 No Power To Machine 37 Mains Switch Cuts Out 37 Fold Roller Replacement 37 ERROR SCREENS 38 DISPATCH KIT 41 ACCESSORIES AND OPTIONS 42 RECOMMENDED SPARES 43 FUSE POSITIONS RATINGS 45 PRODUCT RECYCLING AND DISPOSAL 46 DocuFold Pro FOLDER ...

Page 4: ...MPORTANT 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 674mm x 365mm 26 5 x 14 4 Min Sheet Size in automatic mode 160mm x 140mm 6 3 x 5 5 Max Paper Weight 240gsm Max 0 24mm thick according to hardness type of fold grain direction and substrate Min Paper Weight 56gsm 0 08mm thick Max No F...

Page 5: ...specter l alimentation électrique indiquée Brancher sur une prise séparée car une surcharge peut entraîner un incendie ou un choc électrique Installer le cordon d alimentation de manière à ne pas pouvoir trébucher par dessus Ménager un accès libre à la prise de courant Do Fit the yellow outrigger feet supplied in the Dispatch Kit to the front and back of the machine as shown on Page 7 to comply wi...

Page 6: ...tating rollers Do be aware of low current anti static shock Attention au risque de se coincer les doigts et aux pièces en mouvement lors du fonctionnement de la machine Ne pas porter de vêtements flottants lors de l utilisation de la machine Rassembler les cheveux longs lors de l utilisation de la machine Attention au risque de se coincer les doigts et aux pièces en mouvement lors du fonctionnemen...

Page 7: ... S Emergency stop switch C Suction slot knob K Upper fold plate T Compressor switch D Air distribution knob L Vacuum bleed knob U Extension table E Air separation knob N Delivery roller V Fixed side lay F Back Stop P Lead screw X Fuses G Moving side lay Q Touch screen Y Roller assy release knob Z Outrigger Foot Docufold Pro J A Q B E F A V D U G K H S T N P L C Y R X Z ...

Page 8: ... optimum position and cannot be moved backwards and forwards horizontally SETTING THE SUCTION SLOT The suction slot inside the suction drum may be adjusted by releasing knob C and swinging the knob in the desired position Lighter stocks including bond will run best with the knob set to the left For heavier stocks and curled up stock move the knob C to the right until a satisfactory position is obt...

Page 9: ... be rotated to supply the air to the correct ports as follows Position 1 This is for short sheets A5 or 8 long with only port 1 open Position 2 This is for sheets A4 or 11 long with the front port and port 2 open Position 3 This is for the longest sheets A3 or 17 with the front port and port 3 open Position 0 In this position only port 2 is open and can be used on long sheets with the curl up wher...

Page 10: ...ng until the rear pins can be located into the short slots When fully in position pull down the fold plate to lock into position Connect the push in power connectors short lead to upper plate long lead to lower plate Settings The fold plate lengths are set automatically Fold plate Tilt See roller tilt IMPORTANT NOTE If any of the fold plates or the plug in perforator unit are removed from the mach...

Page 11: ...Pro Roller Tilt Lever R should always be set in the 0 square position To adjust folding out of square you can move the roller assembly in the or direction by releasing knobs Y and moving lever R always re tighten Knobs Y DocuFold Pro ...

Page 12: ...topped by the delivery roller it lies flat on the delivery without lying on the sloping plate See Diagram below and without the green belts showing between the sloping plate and the folded sheet Overlap The machine has a built in system that will detect any sheet that overlaps another sheet by at least 20mm When this happens feeding will stop and the main switch will switch off preventing serious ...

Page 13: ... 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 If you have not been trained to operate this machine and you select the green tick icon Morgana Systems Ltd accept no responsibility for...

Page 14: ...e 1 short suck 2 long suck 3 continuous for stream feeding Highlighted number is type currently selected The status area also shows the currently selected suck Batch Button Image is identical to that shown in the status area On selection the status area is replaced with a calculator for inputting new values Batch sizes of 1 to 998 may be set Arrows may be selected to increase or decrease the page ...

Page 15: ...R Batch size Selection Speed Selection Pre set Batch sizes for quick insertion Operating the DocuFold Pro DocuFold Pro Feed Speed selection slider 20 positions to choose from Note Motor speed will not change until you select run ...

Page 16: ...e the recommended fold positions will be shown in parenthesis and can be micro adjusted as required Fold 1 micro adjust On selection the status area is replaced with a calculator for inputting new values Micro adjust range is 5 0 to 5 0 with increments of 0 1mm Folding can be micro adjusted for fine adjustment Micro adjust range is 5 0 to 5 0 with increments of 0 1mm Operating the DocuFold Pro ...

Page 17: ...from the paper settings page the fold positions can be set manually EXAMPLE 1 Set Fold 1 to 210 0 Set Fold 2 to 90 0 Paper Length 297 0mm Feed Direction Fold 1 Fold 2 Fold 1 210 0mm Fold 2 90mm All dimensions are from the leading edge of the paper Fold 1 210 0 Finished Document Leading Edge SETTINGS Leading Edge Fold 2 90 0 on delivery bed ...

Page 18: ...d on the sheet set Fold 1 and Fold 2 to the same values Paper Length 297 0mm Feed Direction Fold 2 Fold 1 Fold 1 90 0mm Fold 2 210mm All dimensions are from the leading edge of the paper Leading Edge SETTINGS Fold 1 90 0 Finished Document Leading Edge Fold 2 210 0 Morgana Logo on underside of this flap on delivery bed ...

Page 19: ...19 Operating the DocuFold Pro Delivery Settings Pages To get to the Delivery setting page click the lower tab Roller position may be Micro adjusted by clicking Here Roller adjustment calculator DocuFold Pro ...

Page 20: ...stop Job Green icon indicates settings are saved a red icon would show that settings have changed but the job has not been saved Currently selected fold type can be one of the following Speed selector On selection a speed adjustment screen will appear Currently selected Vacuum Suck setting for slow pulse for stream feed choose choose selection 2 selection 3 Select this button to produce 3 test she...

Page 21: ...ly show that the fold plates and delivery roller are moving to their set positions as shown below Click to run machine Operating the DocuFold Pro Click to confirm System switch is on Switch Compressor switch on then click run button again Or click the icon to run three test sheets ...

Page 22: ...ll appear NOTES 1 The folds can be micro adjusted from the run screen if necessary while the job is still running 2 The speed can also be adjusted from the run screen while the job is still running Run count Batch Count Sheet Count Click to stop machine Batch Count ...

Page 23: ...ously saved jobs modify them or delete jobs you no longer require Keyboard for entering job name Return to Store Menu click save icon to save job to store To create a new job name click in text area keyboard will open to input job name Load existing job from store Clicking to search currently stored jobs Clicking to delete currently stored jobs Clicking to save job shown Current Job Name Yellow Te...

Page 24: ...f job click here To change your mind return to the previous screen click here Type in job description or first few characters Press search icon to start search Jobs matching characters in text box will be shown in this area selecting job from this area will show job settings in the right hand status area Job selected will be shown in text box Press to load job shown in text box Toggle between sear...

Page 25: ...ere To cancel overwrite of Job press here To confirm overwrite of Job press here To confirm deletion of Job press here To cancel deletion of Job press here Loading job confirmation screen Loaded job may be modified and then re saved as the same job name Overwrite job confirmation screen Delete job confirmation screen ...

Page 26: ...achine main board software revision Touch screen software revision Operating the DocuFold Pro Clicking this icon will show Machine program revision Touch Screen software revision Touch Screen Calibration Change Machine measurement settings Imperial Metric See Page 27 ...

Page 27: ...mber of times to obtain the correct orientation required move to the next button to move the position to centralize horizontal 2 i Select the tools menu tab and then Select the Touch Screen calibration icon ii Using a plastic pointer soft leaded pencil biro cap etc and with gentle pressure Touch the centre of the cross in each corner of the Touch Screen as prompted by the hand graphics This proced...

Page 28: ...ed with the lower fold plate Ensure that the tilt roller is at zero plug the upper plate connector into the lower plate To prevent damage to the unused upper plate when scoring or perforating store safely on the stowage hooks at the reverse side of the machine Press the start button the built in deflector on the fold plate will close automatically to the deflect position Note the Docufold Pro will...

Page 29: ...Page 29 DocuFold Pro FOLDER Operating the DocuFold Pro ...

Page 30: ...ER SET UP SCALE 1 0 mm 3 64 1 0 mm 3 64 SCORER 15 22 21 20 19 18 17 16 4 3 2 1 0 5 6 7 8 9 10 11 12 13 14 DRIVE HUB SCALE RECOMMENDED PERFORATOR SET UP EDGE OF SHEET FRAME PAD UPPER PERF SHAFT LOWER HUBS SOLID LOWER PERF SHAFT ANVIL PERFORATING BLADE PERFORATOR STRIPPER UPPER TYRE AND HUB ASSEMBLIES 22 21 20 19 18 17 16 4 3 2 1 0 5 6 7 8 9 10 11 12 13 14 Operating the DocuFold Pro ...

Page 31: ...o suit the work For work longer than the backstop will allow remove the backstop and use the extended backstop that is located underneath the catch tray There is a full range of perforator blades available as follows For fine perforation 56 tooth Part Number 1 99 41 For Paper 28 tooth Part Number 1 99 12 For heavier Stock 20 tooth Part Number 1 99 10 For use with blades Anvil Part Number 1 99 35 S...

Page 32: ...ended to be used In the event of a paper jam the sensor will cut out the main switch The main fold rollers are linked to a clutch which will prevent sheets continuing to feed PAPER JAMS If for some reason a piece of paper jams in the machine remove and check inside the fold plates If there is paper jammed around the fold rollers take hold of a roller and wind them by hand to remove the jam If it i...

Page 33: ...the roller shaft and rotate in the required direction to adjust the roller gap 4 The graphics on the inside of the roller side plate show which way to turn the roller to adjust the gap relative to the centre roller 5 Re tighten the half nuts cap head screws to lock the roller into position 6 Repeat procedure for each roller that you wish to adjust and then replace the roller assembly into the mach...

Page 34: ... the counter is failing the sensor can be accessed for cleaning by removing the roller assembly as described on page 32 Clean by using a soft brush or damp cloth FOLD PLATES MAINTENANCE The fold plates can be opened up for maintenance removing paper jams cleaning etc by removing the two bolts shown below The fold plate can then be hinged open Bolt Bolt ...

Page 35: ...me size If the paper is curling upwards the suction drum may not be able to pull the sheet downward to wrap around the drum for efficient feeding You may need to bend the sheets downward prior to loading DOUBLE SHEET FEEDING Make sure the gap under the paper gate B is not set too high Make sure the air distribution knob D and the air separation knob E are at the correct setting In extreme cases yo...

Page 36: ...to make sure that the second plate is being used as the deflector Make sure that the plate is located securely and that the deflector bar is wound right to the end Set the tilt roller mechanism to zero Check that the material is not too heavy to deflect TOTALAND BATCH COUNTER NOT WORKING Clean the sensors as described in the manual OVERLAP ERROR KEEPS APPEARING ON TOUCHSCREEN If the overlap keeps ...

Page 37: ...ing You must have the machine plugged directly into a 30 amp ring main Do not attempt to run the machine with an extension lead The main switch will cut out if you have a paper jam or overlap is indicated FOLD ROLLER REPLACEMENT Your Morgana Docufold Pro has been designed to make fold roller replacement an easy and low cost operation Your local sales agent will be able to supply you with a complet...

Page 38: ...chine stops and error message 13 is displayed on the touch screen this indicates that the Lead Edge Sensor has seen a sheet subsequent to the first one as being longer Again this could actually be a longer sheet OR it could be a sensor problem if it is a recurring problem Check that the paper gate has been set correctly Upper fold plate set out of range If the touchscreen shows the error screen sh...

Page 39: ...ng If the touchscreen shows the error screen shown below this indicates that the wrong fold plate is fitted When perforating or scoring without folding the short fold plate must be fitted in the upper slot position Incorrect fold plate fitted for perforating or scoring with folding If the touchscreen shows the error screen shown below this indicates that the wrong fold plate is fitted When perfora...

Page 40: ...ng unit has not been fitted System switch not on If the touchscreen shows the error screen shown below this indicates that the system switch must be switched to the ON position Lead Edge Sensor Fault If the machine stops and error message 60 is displayed on the touch screen this indicates that the lead edge sensor is blocked Check that the paper path is clear This error message could also mean tha...

Page 41: ...D PAIRS AND SHOULD NEVER BE MIXED UP OR LEFT UN PROTECTED AS SERIOUS DAMAGE WILL RESULT ITEM PART NUMBER QTY DESCRIPTION 1 1 2 1 3 4 1 5 8 9 10 1 11 1 1 14 1 6 7 1 1 15 1 1 5 1 620 020 HEX BALL DRIVER 2 5mm 1 620 027 BONDUS L WRENCH 5 0mm 1 620 032 COMBINATION SPANNER 13 A F 624 018 DISPATCH BOX 1 99 35 6 99 05 ANVIL SET SCORING SET TYPE A 9 95 13 USA 650 041 POWER CORD C19 3Pin USA 1 13 12 617 00...

Page 42: ...RIPTION 6 99 06 SCORING SET TYPE B 1 6 99 09 SCORING SET TYPE D 2 1 99 10 PERFORATING SET 20T SLITTING 3 1 99 11 PERFORATING SET 20T SLITTING HEAVY DUTY 4 1 99 12 PERFORATING SET 28T SLITTING 5 1 99 41 PERFORATING SET 56T SLITTING 6 1 99 13 SLITTING BLADE SET 7 1 99 35 ANVIL SET 8 98 018 02 PERFORATOR STRIPPER SET LONG 9 69 033 SHEET SMOOTHER STACKER LONG 10 6 99 36 PAPER PROFILE ROLLERS SET SPLIT...

Page 43: ...T BELT Delivery 93 021 FEED BELT 93 028 SMOOTHER Delivery 95 150 01 HOSE Exhaust 95 152 01 HOSE Sheet Separation 95 187 POT LEAD ASSEMBLY DELIVERY ROLLER 96 031 DRIVE BELT Large Roller Drive 97 121 POT LEAD ASSEMBLY FOLD PLATE 174 19 01 RS232 ADAPTOR PCB ASSY RECOMMENDED SPARES 94 088 UPPER SENSOR ASSEMBLY 93 042 LOWER SENSOR ASSEMBLY 601 111 TAPERED FERRULE SR1520 Ø7 9 x Ø13 x 23 LG 607 027 TIMIN...

Page 44: ...d therefore be entrusted to your dealer RECOMMENDED SPARES 609 014 O RING PART NUMBER DESCRIPTION 613 255 SOLENOID COIL 655 016 POWER SUPPLY UNIT SWITCHED MODE 48V 609 023 O RING 652 011 SWITCH LOW CURRENT COIL BLACK ROCKER 613 365 EMERGENCY STOP SWITCH 613 137 PLUNGER SPRING ASSY 655 015 POWER SUPPLY UNIT SWITCHED MODE 24V 613 023 FUSE 3 15A Fast Blow FUSE 15A Anti surge 652 047 FUSE 4A Anti surg...

Page 45: ... FUSE POSITIONS RATINGS POSITION ET CLASSIFICATION DES FUSIBLES T500mAH 250V 681 020 PSUs 24V 48V T4 0AH 250V 681 015 FUSIBLE PSUs 24 V 48 V TRANSFORMER ASSY T15AH 250V 652 047 MAINS IN F3 15AH 250V 613 023 DC MOTOR BOARD ...

Page 46: ...his 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 facil...

Page 47: ...Page 47 DocuFold Pro Mod No Rev Mod Description Date Mod By REVISION HISTORY 3 ECO2811 23 01 13 BAL Page 45 Changes T15A Fuse was F15A ...

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