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Plockmatic DigiFold Ultra Operating Instructions Manual

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T10229_EN_A DigiFold Ultra
DigiFold Ultra
Doc no: T10229_EN_A
Date: 16 September 2024
Read this manual carefully before you use this product and keep it handy for future
reference.
For safety, please follow the instructions in this manual.
Operating Instruction

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Summary of Contents for Plockmatic DigiFold Ultra

  • Page 1 T10229_EN_A DigiFold Ultra DigiFold Ultra Operating Instruction Read this manual carefully before you use this product and keep it handy for future reference. For safety, please follow the instructions in this manual. Doc no: T10229_EN_A Date: 16 September 2024...
  • Page 2 T10229_EN_A DigiFold Ultra Scan the QR code to access translated versions of this manual in German, Italian, French, and Spanish. Visit https://plockmaticgroup.com/myfinisher/DigiFoldUltra/ to view the manual in your preferred language.

  • Page 3: How To Read This Manual

    T10229_EN_A DigiFold Ultra Introduction This manual contains instructions on the operation and maintenance of this machine. To get maximum versatility from this machine all operators should carefully read and follow the instructions in this manual. Keep this manual in a handy place near the machine.
  • Page 4 T10229_EN_A DigiFold Ultra Safety Information When using this machine, safety precautions should always be followed. General Safety WARNING • This equipment is not suitable for use in locations where children are likely to be present. • Only connect the machine to a mains power supply of the correct voltage with a good earth- connection;...

  • Page 5: Electromagnetic Compliance

    T10229_EN_A DigiFold Ultra Safety during operation, continued WARNING • Turn off the power and disconnect the power plug (by pulling the plug, not the cable) if any of the following conditions exists: • Objects are dropped into the equipment. •...
  • Page 6 T10229_EN_A DigiFold Ultra Safety Information, continued English Description of Safety/Warning labels in the product Crushing Hazard Cutting Hazard Entanglement Hazard Risk for crushing or Sharp objects inside machine. Risk for loose hanging hair, squeezing body parts. jewelry, or clothes to get caught.

  • Page 7: Table Of Contents

    T10229_EN_A DigiFold Ultra TABLE OF CONTENTS What You Can Do With This Machine ..........10 Guide To Components ..................... 11 DigiFold Ultra - Top Level Overview .................... 11 Feeder Overview ........................12 Folder, Creaser Section ......................13 Slitter, Cutter Section ........................14 User Interface ..........................
  • Page 8 Paper Size ..........................69 Pre-set Patterns .......................... 71 Manual Input ..........................74 Roller Gap Adjustment ........................ 76 DigiFold Ultra Quick Reference Sheet ..................77 Saving and Loading Jobs ......................78 Counters ............................. 79 The Tools Screen ......................80 Overview ............................. 80 Feeder Settings ..........................
  • Page 9 T10229_EN_A DigiFold Ultra Page intentionally blank.

  • Page 10: What You Can Do With This Machine

    It is robustly designed to comple- ment mid to high volume digital and offset production presses. The DigiFold Ultra builds on the capabilities of the DigiFold Pro XL by adding slitting and cutting functionality for full-bleed trim applications. It can produce everything that the Digi- Fold Pro XL can, but now with full bleed trim, in a single pass.

  • Page 11: Guide To Components

    T10229_EN_A DigiFold Ultra Guide To Components DigiFold Ultra - Top Level Overview 1. Folded Sheet Stacker 10. Storage shelves 2. Crease skew adjustment 11. Front door 3. Top cover 12. User interface (UI) 4. Registration area 13. Feeder skew adjustment wheel 5.

  • Page 12: Feeder Overview

    T10229_EN_A DigiFold Ultra Feeder Overview NOTE: Covers removed for clarity. 1. User interface (UI) 9. Maximum paper stack height for sheets 2. USB port for software updates longer than 700 mm (27.6”) 3. Front separation fan (underneath) 10. Paper stack height sensor Q4 4.

  • Page 13: Folder, Creaser Section

    T10229_EN_A DigiFold Ultra Folder, Creaser Section NOTE: Slitter Cutter section removed for clarity. 1. Crease skew adjustment 2. Rotary tool carrier 3. DynaCrease unit 4. DynaCrease pressure lock 5. DynaCrease pressure adjustment 6. Optional static creaser 7. Input rollers 8. Input sensor (Q40)

  • Page 14: Slitter, Cutter Section

    T10229_EN_A DigiFold Ultra Slitter, Cutter Section 1. Slitter Cassette 2. Cross cutter 3. Trim waste fan 4. Input sensor 5. Sheet counter 6. Input roller 7. Entry guard 8. Waste conveyor...

  • Page 15: User Interface

    T10229_EN_A DigiFold Ultra User Interface The Morgana DigiFold Ultra has a User Interface (UI) which allows for setting up jobs and viewing / modifying machine settings and properties. Detailed descriptions of each menu and sub-menu are found in Section 2 of this Operator Manual.

  • Page 16: Tools And Accessories

    T10229_EN_A DigiFold Ultra Tools and Accessories The following tools and accessories are included with the DigiFold Ultra Part number Description 601-167 Digital thickness gauge 1-99-12 28T rotary perforation blade (7 TPI) 1-99-41 56T rotary perforation blade (14 TPI) 1-99-35 Rotary perforation anvil...

  • Page 17: Optional Parts

    6-99-08 Scorer Type D (Pre-Fold Pencil Score) The DigiFold Ultra is supplied with a single DynaCrease unit. A static creaser can be fitted to this machine. This enables up/down creasing in a single pass and (with the cross-perfo- ration kit) creasing and cross-perforation in a single pass.

  • Page 18: Options

    BST4000 Belt Stacker Module The BST4000 High Capacity Belt Stacker Module is an option available for the DigiFold Ultra. The stacker can be configured in a straight line after the DigiFold Ultra or at a 90 degree angle. Parts that are important for setup, adjustments, troubleshooting or maintenance are indi- cated below.
  • Page 19 T10229_EN_A DigiFold Ultra BST4000 Belt Stacker Module (continued) Element Description Operation Power switch (on/off) The power switch is also used to reset the unit after an overload situation. Belt speed selector The belt speed can be adjusted in order to opti- mise the stacking function for various materials.

  • Page 20: Trim Waste Conveyor

    T10229_EN_A DigiFold Ultra Trim Waste Conveyor The Trim Waste Conveyor attaches to the built in internal Waste Conveyor and transports waste upwards which enables the use of a larger waste bin. Parts that are important for setup, adjustments, troubleshooting or maintenance are high- lighted below.

  • Page 21: Basics

    T10229_EN_A DigiFold Ultra 1. Basics Paper Paper Guidelines Paper comes in many different makes, types and finishes. There are many ways to print on the paper and then protect that printed image. The grain direction, fibre structure, sub- strate thickness, porosity, coating type, bond strength of the coating, water content, relative humidity and many other things can affect how the paper will behave when you crease and fold it.

  • Page 22: Creasing

    T10229_EN_A DigiFold Ultra Creasing About the Crease A crease stops the paper and printed image of a document from cracking when it is folded. The crease is made when a sheet of paper is compressed between the two parts of a mechanism known as a blade set.

  • Page 23: Choose The Correct Dynacrease Blade Set

    T10229_EN_A DigiFold Ultra About the Crease (continued) DynaCrease The DynaCrease offers a speed advantage compared to the Static Creaser (only) when both creasing and folding functions are turned on; however, it is not as flexible as the Static Creaser since it does not offer the perforating option and can perform creases in one direction only.

  • Page 24: Replacing Dynacrease Blade Set

    T10229_EN_A DigiFold Ultra Replacing DynaCrease Blade Set This machine is supplied with a single Standard crease blade set. The blade set can be rotated to produce up or down facing creases without flipping the stack of paper. NOTE: Optional blade sets to produce narrower crease are available.
  • Page 25 T10229_EN_A DigiFold Ultra Replacing DynaCrease Blade Set (continued) 4. Loosen the locking knobs (in red) in the direction indicated by the arrows [A]. 5. Slide the Locking knobs (in red) to the centre [B] to release locking pins. 6. Pull the blade set upwards to remove it [C].
  • Page 26 T10229_EN_A DigiFold Ultra Replacing DynaCrease Blade Set (continued) 7. Push Blade Guide Block [D] to the side and remove Blade Link [E]. 8. Attach Blade Links and Bridge to new blade set and reinsert. NOTE: A label on the blade set indicates paper movement direction. Ensure the blade set is in- stalled in the correct direction.
  • Page 27 T10229_EN_A DigiFold Ultra Replacing DynaCrease Blade Set (continued) 9. Close the top cover. 10. From the touchscreen interface choose [Tools] -> [Change Crease Blades]. 11. Use this menu to choose the blade set that has just been installed and set its direction...

  • Page 28: Adjusting Crease Depth Dynacrease

    T10229_EN_A DigiFold Ultra Adjusting Crease Depth DynaCrease 1. Run a proof sheet and inspect the output. 2. If the crease is too shallow or too deep loosen the locking knobs. 3. Adjust pressure lever on the DynaCrease bridge as shown (A – shallower crease, B –...

  • Page 29: Choose The Correct Easyblade Set (Optional)

    T10229_EN_A DigiFold Ultra Choose the Correct EasyBlade Set (optional) The static creaser upgrade kit is supplied with a single standard crease blade set. Several optional blade sets are available. Refer to the table below to see which type of blade set is most suitable for your job.

  • Page 30: Replacing Easyblade Sets (Optional)

    T10229_EN_A DigiFold Ultra Replacing EasyBlade Sets (optional) This upgrade kit is supplied with a single Standard crease blade set. The blade set can be rotated to produce up or down facing creases without flipping the stack of paper. NOTE: Optional blade sets to produce narrower creases or to cross perforate are available (see the “Choose the Correct EasyBlade Set”...
  • Page 31 T10229_EN_A DigiFold Ultra Replacing EasyBlade Sets (optional) (continued) 4. Lift the Bridge Assembly up and remove it. 5. Pull the blade set upwards to remove it. 6. Insert the new blade set. NOTE: A label on the blade set indicates paper movement direction. Ensure the blade set is in- stalled in the correct direction.
  • Page 32 T10229_EN_A DigiFold Ultra Replacing EasyBlade Sets (optional) (continued) 9. From the touchscreen interface choose [Tools] -> [Change Crease Blades]. 10. Use this menu to choose the blade set that has just been installed and set its direction (crease up or crease down). Tap on the green tick mark to confirm.

  • Page 33: Adjusting Crease Depth Easyblade (Optional)

    T10229_EN_A DigiFold Ultra Adjusting Crease Depth EasyBlade (optional) 1. Run a proof sheet and inspect the output. 2. If the crease is too shallow or too deep, use the adjustment lever on the EasyBlade bridge as shown (deeper crease + [A], shallower crease - [B]).

  • Page 34: Setting Crease Tilt Knob

    T10229_EN_A DigiFold Ultra Setting Crease Tilt Knob 1. Run a proof sheet with a single crease and inspect the output. 2. If the crease is skewed, adjustment is necessary. NOTE: Wrong crease positions are marked in red, correct crease position is marked in green.
  • Page 35 T10229_EN_A DigiFold Ultra Setting Crease Tilt Knob (continued) 4. Move the knob slightly, either to the left or to the right depending on the direction of the crease skew. 5. Rotate the knob clockwise to secure it. 6. Run another proof sheet to check if the crease is now perpendicular to sheet edge.

  • Page 36: Perforation

    A perforation is a series of cuts in the paper that allows it to be easily and neatly separated into two or more pieces. Perforation can be used to create coupons, tickets, return slips and other products. The Morgana DigiFold Ultra can perforate sheets in two perpendicular directions: • In the process direction using rotary tools •...

  • Page 37: Rotary Perforation

    T10229_EN_A DigiFold Ultra Rotary Perforation Rotary Perforation The rotary perforation process uses circular blades mounted on the rotary tool carrier to perforate sheets in the process direction. NOTE: 1. Perforation and creasing can be carried out simultaneously. However, if any skew adjustment is made to the feeder in order to compensate for the perforation line being “out of square”, this may affect the accuracy of the crease. If this occurs adjust crease...
  • Page 38 T10229_EN_A DigiFold Ultra Rotary Perforation (continued) A - Top shaft D - Bottom shaft B - Drive wheel E - Drive hub C - Perforation blade F - Anvil NOTE: Up to 5 rotary blades can be mounted on the rotary tool carrier.
  • Page 39 T10229_EN_A DigiFold Ultra Rotary Perforation (continued) 6. Mount a matching pair of anvils [F] and secure them to the drive wheel using a 2.5 mm hex key 7. Position the perforation blade [C] using the ruler on the rotary tool carrier. Secure the drive wheel in place using a 2 mm hex key.
  • Page 40 T10229_EN_A DigiFold Ultra Rotary Perforation (continued) 14. Loosen locking knob [G] by rotating it counterclockwise. 15. Use the adjustment wheel [H] to set paper registration wall angle. If the sheet skews away from the operator (L1 > L2) turn the wheel down. If the sheet skews towards the op- erator (L1 <...
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  • Page 42: Cross Perforation

    T10229_EN_A DigiFold Ultra Cross Perforation Blade removal / replacement WARNING! All blades are very sharp: use extreme caution when handling the blades. 1. Locate the Allen tools supplied with the machine. 2. Place the cross perforation tool on a table in the orientation shown below.
  • Page 43 T10229_EN_A DigiFold Ultra Blade removal / replacement (continued) WARNING! All blades are very sharp: use extreme caution when handling the blades. 6. Lift out the Blade [D]. 7. Replace with required blade. 8. Insert the blade into the blade channel.
  • Page 44 T10229_EN_A DigiFold Ultra Blade removal / replacement (continued) WARNING! All blades are very sharp: use extreme caution when handling the blades. 9. Ensure the blade is fully inserted and does not exceed the notch [E]. 10. Tighten screws [C] (x14).

  • Page 45: Anvil Strip Removal / Replacement

    T10229_EN_A DigiFold Ultra Anvil strip removal / replacement WARNING! All blades are very sharp: use extreme caution when handling the blades. NOTE: Before replacing anvil strip, decrease perforation depth to avoid causing excess strain on motor and reducing life span of anvil strip. Adjustment procedure can be found under 'perforation depth adjustment'.
  • Page 46 T10229_EN_A DigiFold Ultra Anvil strip removal / replacement (continued) WARNING! All blades are very sharp: use extreme caution when handling the blades. 5. Loosen screws [C] (x5). 6. Lift out the anvil strip [D]. 7. Rotate anvil strip 180° or replace with spare.

  • Page 47: Perforation Depth Adjustment Procedure

    T10229_EN_A DigiFold Ultra Perforation depth adjustment procedure WARNING! All blades are very sharp: use extreme caution when handling the blades. NOTE: Before adjusting depth of perforation ensure the anvil strip does not require replacement. 1. Locate the tools supplied with the machine.

  • Page 48: Adjusting The Ejector Height

    T10229_EN_A DigiFold Ultra Adjusting the Ejector height WARNING! All blades are very sharp: use extreme caution when handling the blades. 1. If the perforation does not go smoothly, adjust the height of the ejector [A] (2x). 2. Locate the tools supplied with the machine.

  • Page 49: Adjusting The Ejector Movement

    T10229_EN_A DigiFold Ultra Adjusting the Ejector movement WARNING! All blades are very sharp: use extreme caution when handling the blades. If a paper jam occurs during perforation, the Screws [A] (6x in total, 3x on each side) may be too tight. If perforation causes paper damage, the Screws [A] (6x in total, 3x on each side) may be too loose.

  • Page 50: Folding

    Roller Gap 1 Fixed Roller Roller Gap 3 1st Fold Knife (K1) This machine has many different fold configurations available. The fold configurations are shown in detail in the “DigiFold Ultra Quick Reference Sheet” in Section 2 of this manual.

  • Page 51: Deflects

    T10229_EN_A DigiFold Ultra Deflects About Deflects The Flying Knife folding system has a unique function that lets the machine pass flat sheets through the fold rollers. This operation is known as a deflect. When you choose to do an A fold or V fold on K1 or K2, the fold knife that is not used to fold the document be- comes a deflector.

  • Page 52: Cutting

    T10229_EN_A DigiFold Ultra Cutting About the Cross Cutter A cross-cut knife is available to cut the lead and trail edges of the sheet. Also, in general, it allows for cutting across the sheet, perpendicular to the feed direction. Cross cutter cut Feed direction The cross-cut knife can cut off between 3 and 20 mm.
  • Page 53 T10229_EN_A DigiFold Ultra WARNING! When the cross cutter cover is open, take care not to touch the blades. Cross cutter cover [A] can be opened to remove jammed sheets. 1. Turn off the main power and disconnect the power cord.

  • Page 54: Slitting

    T10229_EN_A DigiFold Ultra Slitting About the Slitting Cassette After a sheet is fed, two automatically positioned slitting blades trim off the top and bottom of the sheet (Paper is cut parallel to the feed direction). The top and bottom slitting blades can trim anywhere from 3 to 50 mm from the top and bottom edges of the sheet (max trim capability of 50 mm will be dependent on trim strip behavior / paper properties).

  • Page 55: Slitting Cassette Removal

    T10229_EN_A DigiFold Ultra Slitting Cassette Removal WARNING! When the slitting cassette is removed, take care not to touch the rotary blades. The Slitting Cassette [A] can be removed from the machine to help clear jams. 1. Turn off the main power and disconnect the power cord.
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  • Page 57: Setting Up A Job

    T10229_EN_A DigiFold Ultra 2. Setting Up a Job Getting Started Turning the Machine On/Off 1. Ensure the main power cord is plugged into the machine [A] and the wall socket. 2. Ensure the CAN termination plug [B] is plugged in.

  • Page 58: Job Preparation

    T10229_EN_A DigiFold Ultra Job Preparation Paper stack preparation Before loading paper in this machine, it is recommended to fan the sheets as shown. 1. Hold the paper stack on a flat surface as shown 2. Bend the paper stack 3. Use your fingers and thumbs to pinch the paper stack 4.
  • Page 59 T10229_EN_A DigiFold Ultra Paper stack preparation (continued) 5. Flex the paper back and forth a couple of times to break surface tension and preseparate the sheets 6. Realign the sheets into a stack before putting them into the tray NOTE: If the sheets you are using are too stiff or too large format to carry out the above proce- dure, fan the front edge of the sheets when loading them in the machine.

  • Page 60: Measuring The Paper Curl

    T10229_EN_A DigiFold Ultra Measuring the paper curl Take a sample of the stack (about 15 mm / 0.59” high) and place it on a flat surface 1. Take the midpoint as reference and do all the measurements within the marked area of the picture (from the...

  • Page 61: Loading Paper

    T10229_EN_A DigiFold Ultra Loading Paper 1. Take a stack of printed paper and place it on the feeder table in the desired orientation. NOTE: If using sheets longer than 450 mm (17.7”), but shorter than 700 mm (27.6”) extend the built-in pull-out table. If using sheets longer than 700 mm (27.6”) see the optional “Feeder Table Extension”...
  • Page 62 T10229_EN_A DigiFold Ultra Loading Paper (continued) If stacking paper narrower than 256 mm / 10.07'' then use Front Paper Guide to support narrow sheets. This paper guide attaches to the separation frame magnetically. Separation Frame Magnetic Guide Front Paper Guide How to use the Front Paper Guide 1.
  • Page 63 T10229_EN_A DigiFold Ultra Loading Paper (continued) 3. Push up against the vacuum belts 4. Ensure that the guide is parallel to the paper pile.

  • Page 64: Feeder Table Extension (Optional)

    T10229_EN_A DigiFold Ultra Feeder Table Extension (optional) Install table extension if using sheets longer than 700 mm (27.6”): 1. Ensure the built-in pull-out table [A] is fully stowed. 2. Hook the table extension [B] into the lift [C] as shown.

  • Page 65: Stacker Settings

    T10229_EN_A DigiFold Ultra Stacker Settings Stacker Settings Menu The machine automatically adjusts the stacker settings when a job is selected, these set- tings will not always be appropriate for certain custom jobs or all paper types: see 'Paper Guidelines' section. If the job being run is not stacking correctly, follow the below section.

  • Page 66: Folding Stacker Settings

    T10229_EN_A DigiFold Ultra Folding Stacker Settings There are two ways to adjust the position of the delivery roller position: • Stacker settings menu [D] (see table above and previous page). • Manually by pressing the physical button [F]. 1. Follow steps 1 & 2 on Stacker Settings page to enter the Stacker Settings sub-menu.

  • Page 67: Fold-Off Stacker Settings

    T10229_EN_A DigiFold Ultra Fold-Off Stacker Settings Air Flow NOTE: When setting the magnetic paper guides make sure there is sufficient space around the stack. Otherwise there will be more frequent jams. 1. Take a single sheet from the stack and use it to set the magnetic stacker guides to the correct paper size. Use the lever [G] to raise the stacker guides from the surface to make them easier to move.

  • Page 68: The Home Screen

    T10229_EN_A DigiFold Ultra The Home Screen Overview Element Description Home button Returns to this screen. Tools button Access additional machine settings. Counter button Set batch counter mode. Crease switch Switch creasing on or off. Slit / Cut switch Switch Slitting / Cutting on or off.

  • Page 69: Paper Size

    T10229_EN_A DigiFold Ultra Paper Size To set paper size and type: Press [Media] in the Home screen. 1. Select one of the preset paper NOTE: Changing paper size or thick- ness will reset any fine adjust- ments that may have been entered on other screens.
  • Page 70 T10229_EN_A DigiFold Ultra Paper Size (continued) weight. 4. Paper properties: enter paper NOTE: Measure paper thickness using the included vernier calliper. surface finish and curl if neces- sary see 'Measuring the paper curl'. 5. Confirm the settings by tapping the green tick mark.

  • Page 71: Pre-Set Patterns

    T10229_EN_A DigiFold Ultra Pre-set Patterns To set up one of the pre-defined creasing/slitting and cutting patterns: 1. Press [Pattern] on the Home screen. NOTE: Choosing a new pre-set pattern will reset any fine adjustments that may have been entered on other screens. 2. Select from one of the suggested standard Trim patterns or select [custom pattern].
  • Page 72 T10229_EN_A DigiFold Ultra Pre-set Patterns (continued) NOTE: You can also choose Custom Pattern to set up your own pattern. See “Custom Pattern” section of this manual for details. 4. Select one of the pre-defined crease/ fold patterns. The left column con- tains patterns for typical folded jobs.
  • Page 73 T10229_EN_A DigiFold Ultra Pre-set Patterns (continued) 5. Tap on the Proof button to run a single sheet. Inspect the output: • If the job is as desired, tap the green tick mark to confirm the job and return to the Home screen.

  • Page 74: Manual Input

    T10229_EN_A DigiFold Ultra Manual Input To fully customize the number and position of creases, slits and cuts on the sheet set up a custom job: 1. Press [Manual Input] on the Home screen. Jobs Jobs Tools Tools Counter Counter Home...
  • Page 75 T10229_EN_A DigiFold Ultra Manual Input (continued) • Use [Add] button to add more lines to the list. • Use [Edit] button to adjust existing lines. • Tap the green tick mark. • Use the [+] / [-] buttons to adjust position.

  • Page 76: Roller Gap Adjustment

    T10229_EN_A DigiFold Ultra Roller Gap Adjustment This sub-menu allows the user to adjust the distance between the rollers manually: 1. Press [Tools] on the Home screen NOTE: This feature should only be used if the default settings are not working properly.

  • Page 77: Digifold Ultra Quick Reference Sheet

    T10229_EN_A DigiFold Ultra DigiFold Ultra Quick Reference Sheet DigiFold Pro 385 Quick Reference Sheet Fold 2 Half Fold K1 K2 Fold 1 Deflect Fold 2 Double Parallel Fold Fold 1 Fold 2 Engineering Fold Fold 1 Gate Fold 2 Fold...

  • Page 78: Saving And Loading Jobs

    T10229_EN_A DigiFold Ultra Saving and Loading Jobs To store a customized job or to load a previously saved job: 1. Press [Job] from the main menu on the Home screen NOTE: The current job name is displayed in the box on the right. Asterisk (*)

  • Page 79: Counters

    T10229_EN_A DigiFold Ultra Counters Once the machine cycle is started by default this machine will continue processing sheets until there is no more paper on the table. Alternatively, the machine can be configured to run in batch mode: • Stop mode – the machine will stop after the specified number of sheets has been processed.

  • Page 80: The Tools Screen

    T10229_EN_A DigiFold Ultra The Tools Screen Overview The Tools screen allows the operator to adjust advanced machine settings. To access the Tools screen: 1. Press [Tools] from the top menu on the Home screen 2. Select the desired function. Element...

  • Page 81: Feeder Settings

    T10229_EN_A DigiFold Ultra Feeder Settings Element Description Registration fan Adjusts the force with which the sheet is registered against the pa- per wall. Increase this if the sheets exit the feeder in an inconsist- ent orientation. Thinner sheets can be damaged (over-registered) if this value is set too high.

  • Page 82: Feeder Settings - Advanced

    T10229_EN_A DigiFold Ultra Feeder Settings - advanced Element Description Ultrasonic dou- On by default. Can be switched off if the double sheet detector is ble sheet detec- giving incorrect readings, for example, on laminated stock. tion ON/OFF Repeat cycle On by default. In case the feeder fails to pick up a sheet it will try on misfeed ON/ again.

  • Page 83: Clear Jams

    T10229_EN_A DigiFold Ultra Clear Jams Use this screen to jog rollers and tools to help with removing paper jams in the machine. Move fold knives Element Description Cycle fold knives in Move knives in the process direction in short bursts.

  • Page 84: Machine Speed

    T10229_EN_A DigiFold Ultra Machine Speed Adjust machine operations speed for processing especially sensitive or difficult stocks. Auto Mode [A] is always turned on by default and it will allow the machine to perform cor- rectly for the majority of jobs.

  • Page 85: Change Crease Blades

    T10229_EN_A DigiFold Ultra Change Crease Blades When replacing creasing blades choose the currently installed creasing blades on this screen. Element Description Creaser 1 EasyBlade Static Creaser Optional NOTE: The perforation blade option can be chosen. Creaser 2 DynaCrease Blade Set NOTE: Not compatible with perforation.

  • Page 86: Export Files To Usb

    T10229_EN_A DigiFold Ultra Export files to USB This function allows the user to copy logs and custom job parameters from the machine to a USB drive. Sending logs to tech support might help with troubleshooting a jam or error condition.

  • Page 87: Import Jobs From Usb

    T10229_EN_A DigiFold Ultra Import jobs from USB The operator can use this function to copy jobs from one machine to another in order to match customized job settings across multiple systems. 1. Firstly, Export data to USB from machine with preferred job settings (See section "Export files to USB").
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  • Page 89: Troubleshooting

    T10229_EN_A DigiFold Ultra 3. Troubleshooting General Misfeeds / Jams If a misfeed or a jam condition should occur, it is indicated on the machine display. A mes- sage with the jam description, error code and approximate jam location is displayed.

  • Page 90: Fault Codes

    T10229_EN_A DigiFold Ultra Fault Codes List of Fault Codes To address fault codes other than those specified below, remove any paper in the paper path and power the system off and on again. If the fault code persists, contact a certified service technician.
  • Page 91 T10229_EN_A DigiFold Ultra FE-101 - Misfeed This code is displayed if the ultrasonic double sheet detector (US DSD) Q10 was not ac- tivated in time after the start of the feed cycle. This means that the sheet has failed to exit the feeder table area.
  • Page 92 T10229_EN_A DigiFold Ultra FE-103 - Sheet too long When a sheet exits the feeder the ultrasonic double sheet detector (US DSD) Q10 meas- ures its length to ensure the sheet matches machine settings. Error code FE-103 is dis- played if the sensor Q10 is covered longer than expected. This can be either because the sheet is too long or because there is insufficient grip on the registration belts and the sheet cannot be fed forward.
  • Page 93 T10229_EN_A DigiFold Ultra FE-108 - Paper table overload In order to stop paper table movement in case it is overloaded paper stack height sensor Q4 measures the amount of paper on the table when feed cycle starts. If the media used is longer than 700 mm (27.6”) the permitted paper stack height is limited to 100 mm (3.9”).
  • Page 94 T10229_EN_A DigiFold Ultra FE-120 / FE-121 - Waste Conveyor full/ blocked Actions: • Check waste conveyor drive belt tension and waste transport belt tension. • Check for trim waste build-up on conveyor. MS-401 - Sheet late to exit feeder This error occurs when the sheet triggers the input sensor (Q60) later than what expected.
  • Page 95 T10229_EN_A DigiFold Ultra MS-405 - Output sensor Q80 blocked Actions: • Remove the jammed sheet. If the sheet is damaged, discard it. • Check the paper path for any obstructions or debris. • Restart cycle. MS-410 - Cutter lost position Actions: •...
  • Page 96 T10229_EN_A DigiFold Ultra FO-309 - Static creaser lost position Actions: • Check that creaser tool moves freely in the machine. • Restart cycle. FO-310 - Dynacrease lost position Actions: • Check that creaser tool moves freely in the machine. •...
  • Page 97 T10229_EN_A DigiFold Ultra FO-315 - Creased sheet late to exit folder (Q45) Actions: • Remove the jammed sheet. If the sheet is damaged, discard it. • Check that stacker is in place and that nothing is obstructing the exit paper path.

  • Page 98: Accuracy Checks

    T10229_EN_A DigiFold Ultra Accuracy Checks Alignment Calibration Check To check that the machine has not lost its factory set alignment calibration during shipping and/or handling carry out the following procedure: 1. With the machine powered off, open the top cover.
  • Page 99 T10229_EN_A DigiFold Ultra Alignment Calibration Check (continued) 7. Run a proof sheet with a single crease and inspect the output. 8. If the crease is skewed, adjustment is necessary. NOTE: Wrong crease positions are marked in red, correct crease position is marked in green.

  • Page 100: Separation Pad Check

    T10229_EN_A DigiFold Ultra Separation Pad Check Rubber separation pads are used in the feeder to prevent several sheets from exiting the feeder table area at the same time. Separation pad position is set at the factory. If frequent misfeeds or double sheets occur the separation pad position may need to be adjusted by the following procedure: 1.

  • Page 101: Creaser Calibration Check

    T10229_EN_A DigiFold Ultra Creaser Calibration Check To check that the machine has not lost its factory set crease calibration during shipping and/or handling carry out the following procedure: 1. Disable Fold and Slit / Cut functions, run a proof sheet with a half fold pattern.

  • Page 102: Fold Calibration Check

    T10229_EN_A DigiFold Ultra Fold Calibration Check To check that the machine has not lost its factory set fold calibration during shipping and/or handling carry out the following procedure: NOTE: Paper should be at least A3/SRA3, 200-300 gsm. 1. Disable Crease and Slit / Cut functions, run a proof sheet with a half fold pattern.

  • Page 103: Slit/Cut Calibration Check

    T10229_EN_A DigiFold Ultra Slit/Cut Calibration Check To check that the machine has not lost its factory set slit/cut calibration during shipping and/or handling carry out the following procedure: 1. Disable Crease and Fold functions. 2. Press [Pattern] - [One-up size Trim].

  • Page 104: How To Get Support

    T10229_EN_A DigiFold Ultra How to get support CAUTION: Never attempt any maintenance that is not specifically described in this docu- mentation. Please contact your Dealer for authorized servicing. If you encounter problems running this machine and you cannot solve them by following the advice given in the Troubleshooting section of this manual, please contact your author- ised Dealer for further support.

  • Page 105: Remarks

    T10229_EN_A DigiFold Ultra 4. Remarks Do's and Don'ts • Always follow all warnings marked on, or supplied with, the equipment. • Always exercise care in moving or relocating the equipment. CAUTION: Unplug the power cord from the wall outlet and the machine before you move or relocate the equipment.

  • Page 106: Where To Put Your Machine

    T10229_EN_A DigiFold Ultra Where to Put Your Machine Machine Environment • Always locate the equipment on a solid support surface with adequate strength for the weight of the machine. • Always keep magnets and all devices with strong magnetic fields away from the ma- chine.

  • Page 107: Access To Machine

    56.4 • The optional high capacity Belt Stacker BST4000 (not shown) can be placed either in- line or angled to the DigiFold Ultra. • The BST4000 measures 1793 x 498 x 1000 mm / 70.6 x 19.6 x 39.4". •...

  • Page 108: Recommended Weekly Operator Maintenance

    T10229_EN_A DigiFold Ultra Recommended Weekly Operator Maintenance CAUTION: Never attempt any maintenance that is not specifically described in this docu- mentation. Please contact your Dealer for authorized servicing. Recommended Weekly Operator Maintenance To maintain the accuracy and reliability of this machine it is recommended to carry out the following maintenance on a weekly basis: 1.
  • Page 109 T10229_EN_A DigiFold Ultra Recommended Weekly Operator Maintenance (continued) Continued on next page...
  • Page 110 T10229_EN_A DigiFold Ultra Recommended Weekly Operator Maintenance (continued)

  • Page 111: Limitations Of The Digifold Ultra

    T10229_EN_A DigiFold Ultra Limitations of the DigiFold Ultra • The intended average monthly sheet volume for the DigiFold Ultra is 450k. • Maximum creasing and folding hourly productivity of this machine is 6000 sheets. This is measured using 200 gsm A4 paper short edge feed with a single crease and fold in the middle of the sheet.
  • Page 112 T10229_EN_A DigiFold Ultra Page intentionally blank.

  • Page 113: Specifications

    Operating temperature 10-30°C (50-86°F) Humidity 30-80% RH Sound emissions 80 dB Physical characteristics Product Length Width Height Weight DigiFold Ultra (with Static 2193 mm 1432 mm 398 kg Creaser) (86.4”) (28.6”) (56.4”) (877.4 lb) Packaged 1600 mm 900 mm 1460 mm 453 kg (62.3”)

  • Page 114: Paper Handling

    T10229_EN_A DigiFold Ultra Paper handling Feeder Section Max stack: 200 mm (100 mm for sheet lengths above 700 mm) 7.9” (3.9” for sheet lengths above 27.6”) Max paper size W x L: 385 x 700 mm (385 x 1300 mm with table extension) 15.2”...
  • Page 115 T10229_EN_A DigiFold Ultra Paper handling (continued) Conditions: • Paper size is assumed to be perfect • Sheets are assumed to be perfectly 90° • Tolerances are referring to deviations within one job Letter Ledger ± 0.25 mm ± 0.25 mm Cut / crease / fold* position variation: ±...
  • Page 116 T10229_EN_A DigiFold Ultra Paper handling (continued) Quality definitions Measurements refer to any crease position. Feed direction Crease position variation Measurement (L1+L2) / 2 from sheet to sheet Crease skew Measurement L1 - L2...
  • Page 117 T10229_EN_A DigiFold Ultra EU & UK DECLARATION OF CONFORMITY ......N0007378 (A.5) Manufacturer ..Plockmatic International AB, Telefonvägen 30, S-126 26 Hägersten, Sweden This Declaration of Conformity is issued under the sole responsibility of the manufacturer Object of the Declaration Model/Type...

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