Morgana Digifold 5000P Operator's Manual
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Morgana Digifold 5000P Operator's Manual

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Digifold 5000P
DOCUMENT
CREASING / FOLDING MACHINE
OPERATORS MANUAL
Morgana Systems Limited
United Kingdom
Telephone:
( 01908 ) 608888
Facsimile: ( 01908 ) 692399
Website: www.morgana.co.uk
JULY 2009
ISSUE 13
Serial Number: 170237 Onwards
174-011

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  • Page 1 Digifold 5000P DOCUMENT CREASING / FOLDING MACHINE OPERATORS MANUAL Morgana Systems Limited United Kingdom Telephone: ( 01908 ) 608888 Facsimile: ( 01908 ) 692399 Website: www.morgana.co.uk JULY 2009 ISSUE 13 Serial Number: 170237 Onwards 174-011...

  • Page 2: Table Of Contents

    INDEX INTRODUCTION & SPECIFICATION PAGE The Morgana Digifold 5000P SAFETY Do’s & Don’ts THE DIGIFOLD 5000P Labeled Photograph THE CONTROL PANEL Detailed diagram and description Features on the control panel OPERATING THE DIGIFOLD 5000P Adjusting the Papergate Setting the Suction Slot...

  • Page 3: Table Of Contents

    Digifold 5000P INDEX THE BLADE ASSEMBLY Adjusting the blade pressure PAGE 29 Adjusting the blade alignment REPLACING CREASING BLADE SETS Installing new blade sets Spare Blades PERFORATING Equipment, Spares Setting the machine REMOVING PAPER JAMS TROUBLE SHOOTING Paper crease out of square...
  • Page 4 INTRODUCTION Digifold 5000P INTRODUCTION AND SPECIFICATION DigiFold 5000P 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 100gsm, up to 400gsm. The DigiFold 5000P...

  • Page 5: Safety Do's & Don'ts

    Digifold 5000P 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.
  • Page 6 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.
  • Page 7 Digifold 5000P Digifold 5000P DOCUMENT CREASING / FOLDING MACHINE Key to photograph below Delivery assembly Air separation knob Paper Gate Vacuum bleed knob Adjustable side lay Top Cover Suction slot knob Back stop Display Control panel Fixed side lay Extension table fixing screws...
  • Page 8 The Control Panel The Display Unit and the Switches on the Control Panel allow the operator to read, edit, create and initiate numerous creasing and folding programs within the memory. The Control Panel houses the Selection Switch, Compressor switch, System switch, and an industry standard Emergency Stop switch which will stop all power going to the machine when activated.

  • Page 9: Features On The Control Panel

    Digifold 5000P The Control Panel Features on the Control Panel Selection Switch Allows the operator to scroll through stored addresses and programs, increase or decrease the batch quantity and set crease and fold positions. System switch When activated the system switch will operate the motors in order to begin the creasing sequence.

  • Page 10: Setting The Suction Slot

    Operating the Digifold Adjusting the Paper Gate Set the height of the Paper Gate to approximately two thicknesses of paper, by turning the knob K. An excessive gap is a most likely cause of double sheet feeding. TWO THICKNESSES OF PAPER IMPORTANT:- To avoid possible damage to the suction drum, when adjusting the paper gate height, ensure that...

  • Page 11: Setting The Vacuum Bleed

    Digifold 5000P Operating the Digifold 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.

  • Page 12: Setting The Blade Tilt Mechanism

    Operating the Digifold 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.

  • Page 13: Gap Set Guide Table

    Digifold 5000P Operating the Digifold Setting the Roller Gaps (Gap 1, Gap 2 & Gap 3) The roller gaps can be adjusted to suit the thickness of the material being creased or folded; and the type of fold being produced. The roller gaps may also require adjustment if cracking of the print is noticeable.
  • Page 14 Operating the Digifold The table below shows the recommended roller gap settings for the different types of folds. GAP SET GUIDE FOLD TYPE GAP 3 GAP 2 GAP 1 Half Fold on Knife 1 Half K1 Half Fold on Knife 2 Half K2 Letter Concertina...
  • Page 15 Digifold 5000P Operating the Digifold 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.

  • Page 16: Setting The Delivery Conveyor System

    Operating the Digifold Setting the Delivery Conveyor System. WARNINGS:- 1. The Machine will start if the delivery unit is not in its up position. Turning the delivery system ‘ON’ or ‘OFF’ 1. With the machine switched (see page 18), move the Selection Switch to the left Select Tools (one click at a time) until the display contains the words 2.
  • Page 17 Digifold 5000P Operating the Digifold FIG 17.1 SYSTEM Page 17...
  • Page 18 If you have not been trained to operate this machine and you select Morgana Systems Ltd accept no responsibility for personal injury, damage to the machine or damage to materials being processed by the machine.
  • Page 19 Digifold 5000P Operating the Digifold Setting the Paper Length Following the arrows on the display unit; move the Selection Switch to the right (one click at a time) until the display contains the words Set Paper More Set Paper Home Paper Length 190.0...

  • Page 20: Setting The Fold Type

    Operating the Digifold 7. Move the Selection Switch down to select Set Process, the required crease or fold option can now be set by moving the Selection Switch down to the required setting and then moving the Selection Switch to the right. The options are Crease/Fold, Crease Only, Fold Only Perf only...

  • Page 21: Adjusting The Crease Positions

    Digifold 5000P Operating the Digifold More Programs Home Save Settings Retrieve Program 13. The program can now be saved, if required, by moving the Selection Switch down to Save Settings . Rotate the Selection Switch to select the program number (1 - 9) and then move the Selection Switch to the right to store the program.

  • Page 22: Adjusting The Fold Positions

    Operating the Digifold Adjusting the Fold Positions. 16. The fold positions can also be adjusted as follows:- (i) From the start up menu move the Selection Switch to the left to select Adjust (ii) Move the Selection Switch to the left (one click at a time), selecting More, until the display contains the words...

  • Page 23: Set By Position

    If you have not been trained to operate this machine and you select Morgana Systems Ltd accept no responsibility for personal injury, damage to the machine or damage to materials being processed by the machine.
  • Page 24 Operating the Digifold If the display contains any of the following words the machine is in the Set By Fold mode of operation ( Letter, Concertina, Half on K1, Half on K2, Double, Engineer, Gate Closed Gate ). Change to the Set By Posn.
  • Page 25 Digifold 5000P Operating the Digifold Setting the Crease Positions. 4. Move the Selection Switch to the left (one click at a time) selecting Adjust until the display shows the words Set Creases. as shown below. More Set Creases Home 1st Crease 105.0...

  • Page 26: Setting The Fold Positions

    Operating the Digifold Setting the Fold Positions. 11. Move the Selection Switch to the left (one click at a time) selecting Adjust until the display shows the words Set Folds as shown below. More Set Folds Home 1st Fold 105.0 2nd Fold 210.0 12.

  • Page 27: Example Of Set By Position

    Digifold 5000P Operating the Digifold Example of Set by Position. Paper Length = 350mm (13.8”) Feed Direction Leading Edge Crease 1 Crease 2 Crease 3 SETTINGS Fold 1 Fold 2 Crease 1 = 97.0mm (3.8”) Crease 2 = 179.0mm (7”) Crease 3 = 260.0mm (10.2”)

  • Page 28: Feeding Sheets Manually

    Operating the Digifold Feeding Sheets Manually In order to feed heavy stock, very small or very large sheets, embossed or even irregular shaped sheets, it may be required to operate the machine manually. The machine can be programmed and set up in exactly the same way as explained when operating the machine automatically.

  • Page 29: Adjusting The Blade Pressure

    Digifold 5000P The Blade Assembly Adjusting the blade pressure (no paper required) With the machine switched (see page 18), move the Selection Switch to the left (one click at a time) until the display contains the words Select Tools as shown below.
  • Page 30 The Blade Assembly The diagram below demonstrates the adjustment of blade pressure. (5mm SOCKET ALLEN KEY) Page 30 CREASING / FOLDING...
  • Page 31 Digifold 5000P The Blade Assembly BLANK PAGE SYSTEM Page 31...
  • Page 32 Replacing Blade Sets 1. Before removing the blade assembly, ensure that the lower blade / anvil is at ‘Top Dead Centre’, see page 29. 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.
  • Page 33 Digifold 5000P 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...
  • Page 34 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 Blade Adjustment...
  • Page 35 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.
  • Page 36 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.

  • Page 37: Setting The Machine

    Digifold 5000P 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.
  • Page 38 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.

  • Page 39: Removing Paper Jams

    Digifold 5000P 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.
  • Page 40 Releasing The Drive Gear The fold rollers can be rotated in the opposite direction, to that described on page 39, by releasing the drive gear. To release the drive gear unscrew the release knob and then slide it to the left as far as it will go to dis-engage the gears (see FIG 40.1 below). If the release knob cannot be moved freely to the left, rotate the top fold roller with one hand whilst moving the release knob to the left with the other hand.

  • Page 41: Crease Position Inaccuracy

    Digifold 5000P 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.

  • Page 42: Machine Will Not Start

    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).

  • Page 43: Using The Correct Blade Set

    Digifold 5000P 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.
  • Page 44 Trouble Shooting Error Messages (Display Window Reads) ’Clip 1 was not clear’ (Back Sensor) Clip 1 was not clear If the machine stops and the display window reads this indicates that the sensor is or was blocked when it should have been clear. i.e.

  • Page 45: Recommended Weekly Operator Maintenance

    Digifold 5000P Trouble Shooting Error Messages (Continued) ‘Last crease is too close to the end of the sheet’ This indicates that the sheet has ended too close to the last crease position. This can be caused by the sheet being too short (mistakenly), the sensor 'seeing' through the sheet towards the end of the sheet (damaged sheet) or some sort of sensor error (Calibration too close).

  • Page 46: Dispatch Kit

    170-95-01 DISPATCH KIT ITEM PART NUMBER DESCRIPTION OPERATORS MANUAL - 174-011 DIGIFOLD 5000P 90-018 ROLLER CLEANING KIT 650-040 POWER CORD C19 UK 16A 2.5m SCREW - SOCKET CAP HEAD - M3 x 6 LG 403-01-030-006 409-01-040-004 SCREW - SKT. SET FLAT PT. - M4 x 4 LG...

  • Page 47: Accessories And Options

    Digifold 5000P ACCESSORIES AND OPTIONS ITEM PART NUMBER DESCRIPTION 172-022-01 LOADING TABLE EXTENSION 1-99-10 PERFORATING BLADE SET 20T (Card) 1-99-12 PERFORATING BLADE SET 28T (Single Sheets) 1-99-41 PERFORATING BLADE SET 56T (Fine Perforations) 1-99-35 ANVIL SET USED WITH ABOVE BLADE SETS...

  • Page 48: Recommended Spares

    RECOMMENDED SPARES PART NO. DESCRIPTION 173-62-01 Vacuum Drum Motor Assembly 125-21-02 Dual Stepper Driver Board 174-06-01 Small Stepper Driver PCB Assembly 126-059-02 Link - Paper Guide 128-026-03 Delivery Belt 144-04-01 Joystick - Multifunction 144-143 Lead - Delivery Roller Position 144-141 Lead - Blade Position Sensor 145-093-02 Knife Driver Pin - M8...
  • Page 49 Digifold 5000P RECOMMENDED SPARES PART NO. DESCRIPTION 175-125-01 Connecting Link Assembly - Drive 175-125-02 Connecting Link Assembly - Knife Hubs 175-13-01 Paper Guide Asssembly 175-20-01 Paper Gate Assembly 175-21-01 Vacuum Roller 176-02-01 Blade Adjuster Assembly 176-081-01 Worm Wheel - Gap Set...
  • Page 50 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...

  • Page 51: Fuse Positions & Ratings

    Digifold 5000P FUSE POSITIONS & RATINGS (POSITION ET CLASSIFICATION DES FUSIBLES) PSUs (24V & 48V) PSU (5V / 24V) (FUSIBLE PSUs (24 V & 48 V) (FUSIBLE PSU (5V/24 V) T6.3AH 250 (681-019) F3.15AH 250 (613-023) SPARE FUSE ANTI-STATIC UNIT...
  • Page 52 PRODUCT RECYCLING & DISPOSAL European Union Disposal Information for Commercial Users Disposal Information for Domestic Users Other Countries Page 52 CREASING / FOLDING...
  • Page 53 Digifold 5000P SYSTEM Page 53...

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