120-102_Digifold service Manual.cdr
Contents
1. OG SYSTEM Digifold Aoroana Digifold DOCUMENT CREASING FOLDING MACHINE 1 Roller tilt handle 6 Air distribution knob 11 2 Delivery assembly 7 Adjustable side lay 12 3 Suction slot knob 8 Back stop 13 4 Control panel 9 Fixed side lay 14 5 1 Air separation knob O Roller tilt knob DO 3 Exit Guard High Level Display Extension table fixing screws Page 6 CREASING FOLDING Digifold SECTION 1 Creaser Covers 1 1 The Front Cover The compressor cover which is situated below the control panel Its secured by 16 off 4 taptite screws and is located by three tongues protruding into the main frame Removal of this cover provides access to the compressor the Black Box assy amp the crease mechanism To remove this cover remove all screws and twist forwards to clear emergency stop button and mains socket pull out to release the tongues 1 2 The Service Panel Rear Panel The Service Panelis atthe rear ofthe machine and is secured by four screws Removal of this panel allows access to the suction valves amp pipework To remove this panel loosen all screws lift up the panel and twist outward to unhook the keyhole locations on the opposite side to the screw fittings 1 3 The Creaser Mechanism Covers The creaser mechanism is situated in the middle of the machine and is covered by a fixed and a hinged guard To remove these guards just remove the four scr2. Digifold DOCUMENT CREASING FOLDING MACHINE SERVICE MANUAL ISSUE 4 SEPTEMBER 2003 INTRODUCTION MORGANA DIGIFOLD Introduction The purpose of this manual is to explain the procedure for dis mantling and re assembly of the major assemblies on the Morgana Digifold machine All the engineering adjustments are shown at the end of each relevant section Operator s adjustments and routine maintenance are explained in the appropriate operators manual which should always be used in conjunction with this manual It is always a good idea to have a copy of the machines 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 Fasteners All threaded fasteners are isometric amp 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 require isometric hexagon wrenches allen keys Ball drivers may be used but care should be takenparticularly when releasing screws for dismantlingto avoid breaking the driver as they cannot cope with full tightening torques Do not substitute fasteners with low grade alternatives which may fail or become irremovable Page 2 CREASING FOLDING Digifold Pan head and Cross head cou
3. lox HLONET m ios 8 9 YOSNIS 1 80 21 Lad 110 nsd eee 2 909 Ml 9010390 Nid Qquvno NOLLO3NNOO TES 62 NENNE MM TNT P 7102 HOLIMS W31SAS Z00 vZ 335 LIS mmm ASd ONY M3dd3ls 21 92 db ava a LINN o T OIL V LSLLNV 2 4344315 13394315 eme S 5 gt ANIOd 3 INSIS 801 54 QV313A IVA I 070 64 5 15 NOLLNAIYLSIG Qv314ndlno xnv I zuo 021 9 4731 100 HOLIMS W31SAS 911 64 QV31 LPdNI Add AS BL 01 9 Qv31H21IMS HOLIMS WALSAS ANIOd 31015 18 NI SNIVN 221 92 66 4015 LNANI HOLIMS W31SAS CREASER UK 50Hz WIRING DIAGRAM Page 45 SYSTEM A nd Digifold ection 14 c c 94 LINN H3SY382 YOLOW 3QY lg Nouons 5 135 NOLLNG f P 1962 92 HOLON 3av18 6S IS 2 94 HOLON FAG 85 200 2 VHOVIO 9NIMIM M3dd3lS 335 ZS 01 755 9 H38ADN
4. BUTTONS BUTTONS O FEED SET ADJ SUCTION 3 1 1 2 ENCODER 76 231 EDGE TX 76 230 EDGE RX JAM TX 176 2281 JAM RX 76 229 BUTTON 175 0941 BUTTON 2 75 095 FEED 75 098 SET 75 100 ADJ 175 101 SUCTION 75 099 BUTTON 3 75 096 BUTTON 4 75 097 PAPER THICKNESS PAPER LENGTH ENGINEERING 75 128 SERIAL CREASER CONTROL PCB CONNECTION DIAGRAM SYSTEM Page 47 Digifold Uergana Section 14 DISPLAY PCB PINS 1 amp 2 VCC PINS 13 amp 14 GND MAIN PCB DISPLAY PCB PL CONTROL PCB DISPLAY PCB CONNECTION DIAGRAM Page 48 CREASING FOLDING Digifold Section 14 0180 5241 41815 01 350 10 70 6521 60 01 6611 H3AHOJSNVU I 07319 10 01 5011 YINYOISNY 01 80 6211 4 311 60 80 5411 41815 OL 80 80 61 41815 01 2233 ro 92 20 80 61 41815 OL WHLASAN 2233 90780 Scl 3514 OL cdd To 60 80 60 31815 OL 3504 27 70 80 6061 HLYVANVS 97 m 0 80 5211 31815 OL 9311 97 60 80 60 31815 OL VALOJN Yalla 10 80 61 31815 01 766 911 YOLON 39919 621 92 1 3A HQ 17 91 67 QY31 WNOIS 3Q
5. 9r Teo O O CIO 0 EEE Returning Creaser Blade Home After Crunch 37 Sensor Calibration Alignment 38 Setting Blade Gear Drive 5 40 REE Blade Deflection Diagram 11 Section 13 Trouble Shooting ENN Folder Unit 43 44 Section 14 Circuit Diagrams Creaser UK Wiring 45 Creaser USA Wiring Diagram 46 EE Creaser Control PCB Connection Diagram 47 s ee ee Control PCB Display Connection Diagram 48 Stepper Box Wiring 49 EE Stepper Box Connection 50 DigiFold Wiring Diagram 51 Runtime PCB Connection Diagram 92 Digidriver Plate Connetion Diagram
6. Remove the PCB from the 4 off pillars using a 2 5 mm allen key BOARD REPLACEMENT STEPPERDRIVE PLATE ASSEMBLY owitch the mains power off Remove the rear cover base by unscrewing the 4 off M4 Posi pan head screws Unplug all plugs from the PCB Remove the terminals Remove the PCB using a removal tool to depress the four fixing positions Liftoutthe assembly of PCB and heat sinks Refitting is the reverse of above but care should be taken to ensure that the rotarary switch and the dip switches are correctly setforthe correct PCB see circuit diagram ZERO COUNTER Set total counter to zero To do this the diagnostic plug socket is situated on the feeder end beneath the manifold deflection knob Switch the machine off at the emergency stop button and insert the calibration plug into the socket owitch on and the display will show the total count in tens Set this to zero by removing the calibration plug and the feed to on down and the set up switch to zero up The display now shows zero Switch the m c off amp to return to normal operating mode switch the m c back on NOTE This also removes all stored programmes including Calibration Settings which must be reinstated Page 18 CREASING FOLDING Digifold SECTION 9 Cleaning Sensors Creaser With blades removed the optical sensors are accessible for cleaning on either side of the creaser unit use a soft brush or cloth to remove any dust that may of collected onto
7. 191 64 7 35 NSd 4334315 I 3349315 3399315 Nis Menus uL JAWA HOLIMS 09 7 HOLIMS ONIGNOS 97495 dWoo u WA 801 87 0 31 68179 QV31 HOLIMS HOSS3HdWOO 8c 0 0 5 HOIIMS ayna t330V1S QV31 1NdLNO 0 1 9 Qv111nd 100 HOLIMS W31SAS 071 5 V3 1 HOLIMS YOSSSYdNOD 911 64 Qv31 LAdNI Add 015 BL 015 201 6 07 1 1 5 HO LIMS WALSAS 1 339 JINIS NI SNIVA 281 92 0731 LAdNI 4015 BEI GL 0731 HOLIMS W3LSAS k E HLI USA 60Hz WIRING DIAGRAM CREASER CREASING FOLDING Page 46 Digifold Section 14 VALVE DRIVE BLADE BLADE STEPPER STEPPER 1 STEPPER 2 GRN BL PSU RD BRN SYSTEM SWITCH BL COIL BL PIN 384 AUTO CREASER BRN GUARD PIN 4 amp 5 DIGIFOLD BL BRN GRN BL INE YLW PAPER LENGTH O RD GRN BL YLW PAPER LENGTH O gt RD He BL SHEILD VALVE 75 108 RD PSU OUTPUT LEAD 125 08 11 DRIVE STEPPER 75 145 BL BLADE STEPPER 75 146 BLADE STEPPER 2 YLW SYSTEM SWITCH COIL 75 102 GRN L GUARD 75 107 BLADE HOME 75 111 SHEILD 15 14 CRANK ROTATION 76 233
8. 335 30v 18 ey 621 97 Y3gWNN 335 JANG Bn 911 92 QV31933MOd H3dd31S ZEZ 9Z LINN 9NISY3HO OL SISYHO 6 21 511 40078 NO9 OL SISVHO 51 6 QV31 ANNI NSA LE ZZ 1 92 4015 AONIOHINI 1611 5 1 0 31 LNANI HOLIMS W31SAS IE 1021 9 LNd O HOLIMS WALSAS Og yZI SZ QY3190SS38dACO 521 511 HOLIMS dN02 82 921 84 TYYLNIN HOLIMS dNOD 0 0 5 1 HOLIMS 089 M3X2V1S 9 0 0 H38APN 13395 3002 800102 33S Sc OL 971 54 0731 1 5 18 621 94 952 91 JAYA MOSN3S GET 92 1005 mov 136 0334 son souna A xa Wn 82d AV 1dSIG 01 814 89d XL AVP 31875 AV 1dSIG 193130 671 64 0731 WNOIS INYA 3903 3903 79 HOSNIS NOLLISOd 3QV 18 11752 HOLIMS 3ACH 1780 521 0931114 110 5 WOH 30778 MAIN PCB PL9 TO RUNTIME PCB 4 55 22 071035 5 Nid M3SV38DIV 186 S IIV L3d NOLLO3NNOO 404 H38ACN 33S NSd ANY H3dd31S 6c SNIH33NION3 911 64 0 31 5 H3dd31S 109 5 W31SAS HOLMS
9. Remove the rear delivery assembly Open the Top Cover Remove the Rear Cover Op Side Cover amp Op Side Edge Cover Locate Upper Exit Roller amp loosen cap head screw that secures shaft to op side of folder unit with a 5 mm allen key Using a 10mm A F spanner turn the shaft to make contact between nitrile drive wheel and roller drive hub whilst rotating by hand Note check drive is adequate through a complete turn Tighten cap head when happy with result Dom gn To adjust nitrile drive wheel to blade drive hub on fold roller drive train located adjacent to the shaft is an adjustable allen screw which can be screwed in using a 2 5mm allen key until resistance is felt SYSTEM Page 29 Digifold SECTION 11 Main Fold Rollers Removal The folding unit has 3 main folding rollers that can be easily removed for replacement the Procedure for removing the rollers is as follows 1 2 iii v vi Remove all covers Looking at the lay side of the folding unit locate and remove the two torsion springs on end s of the 2nd and 3rd roller assembly s by releasing the spring hubs Making note of which spring goes where as they are handed Remove the gap set assembly from the operators side of the machine by releasing the 3 off button head screws Remove the 2 worm gears from the 2nd and 3rd roller assembly s one gear has a spacer behind it these should be kept together for re assembly Remove The 3r
10. 1 lugged blade drive gear until No 2 lugged blade drive gear is free of mesh Rotate No 2 gear around by one tooth pitch roll idler gear back into mesh and relocate pin No 2 blade drive gear The fixing hole will now be fully visible and the screw can be fed through from the inside loosely attach nut amp washer Ensure the idler is contacting equally into mesh with both lugged gears and nip the fixing nut Check for free movement by rotating both gears amp ensure there is no backlash once this has been achieved tighten the fixing nut 2 5 mm Hex Ball Driver 620 020 2 off No 1 blade drive gear No 2 blade drive gear _z Holes In Blade Drive Ring Holes In Blade Drive Ring Idler Gear Assy Page 40 CREASING FOLDING Digifold SYSTEM Page 41 Digifold Section 13 Trouble Shooting Creaser Fault Erratic register of the creaser Red L E D on P C B Permanently On Crunch displayed when m c is switched on Yellow L E D on P C B Permanently On Intermittent fault on crunch or paper edge sensor No display Continuing blowing of fuse Rollers not Rotating On start up Feeds O K amp Counts O K PL5 But Does Not Crease Note Suction pulse length Page 42 Reason Damaged roller surface Plug PL1 Faulty Top dual Sensor On Creaser Faulty P C B Check without paper Paper jammed Damaged wires Plug PL2 Faulty P C B Check without paper Loose terminals i
11. F cLr off Paper 0 paper thickness or weight or gloss ie stiffness Crease 1 50 Crease 2 370 place this in store 1 oet 5 crease positions 94 2 141 3 188 4 235 5 282 6 Place in store 2 Run machine using Store 2 at least 10 sheets shingle and lay leading edge against a straight edge and check repeatability of creases the results should be straight lines of creases If first crease is out of position then it indicates the lead edge sensor is faulty and needs replacing or resetting using the sensor setup jig If the lead crease is straight and the others vary up and down then there could be pitch errors in the drive train ie belt braids broken backlash in main drive gears Run machine using Store 1 with one sheet Measure lead edge to 1 Crease and lead edge to 2 Crease and adjust to correct positions SYSTEM Page 35 Digifold SECTION 12 Machine Calibration Set the 17 knife position this adjusts first edge sensor on digifold to 17 fold knife Fetch the equivalent to Etch on AutoCreaser to take up tolerances of roller dia Deft this is equivalent to detr on AutoCreaser adjusts leading edge to first fold In operator mode do the following Using 630mm long paper 80 gsm with printed setting marks if available Input the following settings Crease off Fold on DELry off Set display to set by posn F cLr off F1 100 2 999 9 place this in store 3 F1 500 2 999 9 place this in store
12. Sensor lens SYSTEM Page 19 Digifold Uergana SECTION 9 Changing Sensors on the Folder unit Leading Edge Sensor Top amp Bottom 1 2 Remove rear cover front cover amp both top covers Tilt the DigiFold assembly by removing the top rear fixing screw and the top front fixing screw Also remove the center tilt attachment screw and loosen the lower fixings Tilt the unit Top Sensor Assembly 1 2 3 4 Unplug from runtime P C B amp remove green plug feed cable through apertures Remove top input roller by unscrewing the 2 cap head screws at either end of shaft Unscrew the cap head screw from end of sensor unit amp remove feeding cable through hole in side plate Replace with new sensor assembly and re assemle in reverse order Bottom Sensor Assembly 1 3 Unplug from runtime P C B amp remove green plug feed cable through apertures Unscrew the cap head screw from end of sensor unit amp remove feeding cable through hole in side plate Note Top input roller need not be removed for fitment but will require removal for realignment of sensor Replace with new sensor assembly and re assemle in reverse order Electrical sensor alignment must be carried out see section 12 But for an approximate position the sensors can be aliligned by passing a 3mm diameter drill through the holes in the upper amp lower sensor bars Page 20 CREASING FOLDING Digifold organa SECTION
13. 1 Creaser Folder 000 000000000000 9 Section 2 Vacuum Er Valve Plunger Replacement s 9 Valve OF 0 nennen nnne nennen nnn nnne 9 Section 3 EEE Belt 10 Section 4 Main Mechanism Creaser Unit Removal of Unilt nennen 11 12 Removal Replacement Stepper Drive Belt Pulleys 13 Section 5 Infeed Roller Removal Replacement 14 Section 6 Drive Hub Replace Rubber Torsion Bush shock absorber 15 Section 7 Drive Link 16 Section 8 EUS Removal Refitting Control 5 17 Removal Replacement Stepper Drive Box 17 Removal Replacement Runtime 18 Removal Replacement Stepper Drive Plate PCB 18 Zero Total 18 Section 9 Optical 5 8 Clea
14. 4 Run one sheet using store 3 catch the sheet at the top exit guide and remove then run the same sheet using store 4 ensure leading edge is same for each catch the sheet at top exit Measure lead edge to 1 fold and lead edge to 2 fold and adjust to correct positions Similar to Creaser Set gap between 1 and 2 fold knives GapF Distance between fold knives adjustable ie 10 1 0 Using 630mm long paper 80 gsm with printed setting marks if available Input the following settings Crease off Fold on DELry off Set display to set by posn F cLr off F1 100 2 500 place this in store 5 Run one sheet using store 5 and measure the 1 fold to 2 fold distance and adjust to correct positions Cen This adjusts the center position of the knife travel set with gauge 63 6 mm Hold PB4 set up switch down Adjust with knob to cen and adjust with PB1 knob EURO inch Metric Imperial settings Whilst in Engineering mode scroll to the last position you can now toggle using the rotary switch between mm and inches displayed Notes Setting of lengths round odd figures upwards ie 0 3 call 0 4 Paper type Oset to zeros Type 1 light Type 2 medium Type heavy weight Note all dimensions are relative to the leading edge Page 36 CREASING FOLDING Digifold Alorgana Returning Blade to Home Position after Crunch It will be evident that the Blade is stuck in the Top Dead Centre TDC if when yo
15. 4 11 Attach the beltto the drive shaft 4 12 Fitthe tilt lever to the inside front frame with the bottom button head and screw in tilt knob 4 13 Slide rear spacer bar down in position see below Fixthe bottom screw in and align the top screw and fit loosely Replace cable ties to mountings Align the roller set square with the fixed lay edge while the fronttilt lever is in the centre position Use the rear slots to adjust the square Tighten the screws and replace the top covers lii Page 12 CREASING FOLDING Digifold REMOVAL REPLACEMENT STEPPER DRIVE BELT PULLEYS 4 14 Loosen the adjuster nut from the inside unit and slide the belt off 4 15 Loosen the securing socket set screws the drive pulley on the roller for it to be remopved NOTE there is one screw located ina hole in the shaft SYSTEM Page 13 Digifold Uergana SECTION 5 REMOVAL REPLACEMENT OF INPUT ROLLER 5 1 With the unit on a bench 5 2 Remove the drive belt and pulley from the roller to be removed See SECTION 4 WORKING ON THE DRIVE BELT SIDE 5 3 Removethe three 4 posi head taptite screws from around the bearing hole in the side plate Drive belt side to allow easy access to the bearing retaining rings Remove rings 5 4 Slide the roller out and remove the bearing from the shaft drive belt side Theroller can be turned sideways to allow removal Note the position of the spring washers 5 9 Replace the roller in th
16. 9 Changing Sensors on the Folder unit Clip Sensors Remove front amp rear covers Note Unit does not have to be tilted to replace these sensors Clip 1 Sensor Assembly 1 2 To remove short sensor assembly unplug green plug from runtime board Unscrew cap head screw and remove from unit feeding cable through hole in side plate To remove long sensor assembly unplug green plug from runtime board Remove 2 off nuts amp washers securing curved roller guide and remove 2 off cap head screws at ends of bars Remove Sensor assembly from unit feeding cable through hole in side plate Electrical sensor alignment must be carried out see section 12 But for an approximate position the sensors can be aligned by passing a 3mm diameter drill through the holes in the upper amp lower sensor bars Clip 2 Sensor Assembly 1 2 To remove short sensor assembly unplug green plug from runtime board Unscrew cap head screw and remove from unit feeding cable through hole in side plate To remove long sensor assembly unplug green plug from runtime board Remove 2 off nuts amp washers securing curved roller guide and remove 2 off cap head screws at ends of bars Remove Sensor assembly from unit feeding cable through hole in side plate Electrical sensor alignment must be carried out see section 12 but for an approximate position the sensors can be aligned by passing a 3mm diameter drill through the holes in the
17. Shows F 0 Delivery Belt not driving Delivery Roller incorrect Position Delivery Roller not driving to position Stepper PCB red grn LED not on Page 44 Reason System Switch will not Hold in when Actuated Faulty transformer Check PCBs for burning Faulty RF Filter Plug CN1 Faulty Transformer Faulty PCB Plug CN2 Faulty PCB Lead Edge Sensor Wrongly adjusted Solution Check that all Guards are Closed Check Gaurd Microswitches operating Check magnetic reed switch functions ok Replace Transformer s Replace PCB Check the RF Filter Replace Check plug is connected on board Check for loose wires or termination Check Transformer Voltage 28 VAC Change stepper PCB Check plug is connected on board Check for loose wires or termination Check Transformer Voltage 56 VAC Change stepper PCB Check Slider Sw1 on Runtime board is set to Right Hand side Check potentiometers Rv1 amp Rv2 are correctly adjusted use Calibration Unit 70 043 Lead Edge Sensor Faulty Check using Calibration Unit 70 043 Plug CN4 Faulty PCB Plug Cn5 Stepper PCB red grn Faulty PCB Faulty Power Supply Faulty Wiring Faulty PCB Check plug is connected on board Check for loose wires or termination Check Transformer Voltage 28 VAC Change stepper PCB Check for loose wires or termination Adjust Check Potentiometer is OK Check plug is connected on board Check Transformer Voltage 28 VAC Change st
18. correctly this can be achieved as follows 1 Lift the Top Cover locate the Input Rollers and place a strip of 80 gsm paper between the upper amp lower rollers and check to see that the grip pressure is constant along the roller length If the Rollers require adjustment do the following Remove conveyor assembly Remove covers to enable access to cap head screws securing input shafts The Input Rollers are secured to the main unit with the cap head screws by loosening off these screws it is possible to slightly move the input shafts since there is a small amount of clearance in the side plates around the screw threads By tapping the Input Roller Shafts in the right direction the required pressure can be achieved tap the rollers apart to decrease the roller pressure or tap the rollers towards one another to increase the grip pressure required 5 Once the grip along the length of the rollers is equal tighten up the cap head screws to secure the input shafts 6 Replace all covers 28 CREASING FOLDING Digifold SECTION 11 Adjusting The Exit Roller The Exit Drive Roller Assembly is adjustable The upper drive shaft can be moved to ensure that the correct drive pressure between the exit roller assembly drive hub and the nitrile drive hub is achieved The pressure between the blade drive ring and the nitrile hub can also be adjusted The procedure for making adjustment is as follows
19. the cable tie fixing itbeneath the bed Unplug the green plug on the PCB inside the bed Unscrew the four fixings attaching the unitto the main frame support the weight Lowerthe box and remove from the machine Unscrew the front fixings four off screws attaching the heat sinks and turn the unit over With the base uppermost remove the four pan head screws atthe sides fixing the base to the sides ofthe box and the six off screws in the base Gently lift the base plate off to allow access to the inside take note of the spade terminals on each board they are the same for each PCB Remove the terminals Liftoutthe assembly of PCB s and heat sinks REPLACEMENT OF PCB s Creaser First check and setthe switches as below Blade PCB slide switch to read 1 amp 2 Rotary switch set at 1 Drive PCB slide switch to read amp 2 on Rotary switch set at 1 Assemble as a pair with four attaching screws Assemble in the reverse order to the above Slide this assembly into the black box ensuring the cables are not trapped beneath the heat sinks the fan wires are black and difficult to See Attach spade terminals in the correct positions and refit base NOTE See STEPPERBOXWIRING DIAGRAM SYSTEM Page 1 Digifold SECTION 8 BOARD REPLACEMENT RUNTIME P C B Switch the mains power off Remove the rear cover base by unscrewing the 4 off M4 Posi pan head screws Unplug all plugs from the PCB
20. until L E D Marked knife is illuminated lock in position 9 Activate feed switch with system switch on Cycle a couple of times reinsert setting jig and ensure blade is gently touching jig measure 63 6 The blade is now correctly positioned Adjusting the drive motor over travel 1 Ensure the blade setting jig is removed and cycle the blade motor several times using the hAndLE mode of operation see operator manual page 18 until the travel stop screw is in the position shown in FIG A5 2 Adjust the over travel stop bracket down to within 0 5 mm of the travel stop screw as shown in FIG A5 and then tighten the fixing screws do this for both directions Shown below 3 Cycle the blade motor a few times and observe that the travel stop screw is just clear of both of the over travel stop brackets when cycling back and forth Over travel Stop Bracket Over travel Stop Bracket 0 5mm Typ Travel Stop Screw FIG A5 Page 26 CREASING FOLDING Digifold Aforgana Adjusting Top Door safety Switch 1 Remove conveyor assembly 2 Remove front cover 3 Holding top cover shaft fully into slot adjust until machine switches off when there is an approximate gap of 6 mm at front end 4 Re tighten screw replace covers and test SYSTEM Page 27 Digifold SECTION 11 Adjusting The Folder Input Rollers The Folder Upper amp Lower Input shafts must be parallel to one another to ensure media is fed
21. IFE on the Runtime Board is illuminated 4 Lightly tighten the travel stop screw and the small grub screw in the stop hub and remove the allen keys Note This gives an approximate start to setting the blade travel 5 Increase the gap between the exit Rollers by turning the Fold Gap 2 Adjusting Knob until the blade setting jig Part Number 120 014 can be pushed between the exit rollers as shown in fig A3 SYSTEM Page 23 Digifold SECTION 10 Slot Flag Blade Hub Travel Stop Screw Stop Hub Bracket Aperture See FIG A2b FIG A2a Bracket Aperture Allen Key FIG A2b Page 24 CREASING FOLDING Digifold SECTION 10 P Top Exit Roller Blade setting Jig 120 014 FIG A3 6 Adjust the two over travel stop brackets to their fully up position see FIG A4 Turn the flag blade hub clockwise until the top blade no 2 is felt to touch edge of the setting jig Note If the blade setting jig is not available a straight edge and rule may be used to measure the distance between the blade edge and th rear of the side plates when set correctly the blade should be 63 5 from the rear of the side plates Over travel Stop Bracket Over travel otop Bracket Flag Blade Hub Travel Stop Screw SYSTEM Page 25 Digifold SECTION 10 8 Holding the Flag blade Hub gently turn backwards counting 59 steps amp hold in this position loosen the socket set screw in flag 2 off and rotate
22. R BOX CONNECTION DIAGRAM Page 50 CREASING FOLDING Digifold Section 14 DOOR SWITCH x xs gt gt 02 ad cN LLI LU z z gt gt 92 SYNC 2 TX ANTI STATIC UNIT 120 106 GRN YEL GRN YEL CN6 CN7 CN10 CN12 CN8 CN9 CN11 A 1 RUNTIME PCB ASSY 125 05 01 2 IMPORTANT CABLE No 7 MUST BE IN POSITION SHOWN i e PINS 4 amp 5 INTERFACE LEAD EMERGENCY STOP SWITCH B SW1 1 OFF SW1 2 ON SW1 1 OFF SW1 2 OFF 124 01 35 124 01 36 SW2 SET TO POSITION 2 SW2 SET TO POSITION 1 DELIVERY DRIVE MOTOR 124 01 37 124 01 37 FAN ASSY FAN ASSY KNIFE MOTOR 22 DELIVERY DRIVE SW1 1 ON MOTOR SW1 2 ON SW1 1 OFF SW1 2 OFF SW2 SET TO POSITION 2 SW2 SET TO POSITION 1 DELIVERY POSITION DELIVERY POSITION MOTOR KNIFE MOTOR DRIVE MOTOR 1 TO 13 15 21 amp 26 SEE COLOUR CODE SHEET 124 03 22 DELIVERY DRIVE MOTOR 124 01 22 DIGIDRIVER PLATE ASSY 121 02 02 23 DELIVERY POSN MOTOR 124 01 28 SEE DRAWING 121 02 02 FOR WIRING DETAILS 25 MOTOR EARTH LEAD 124 01 32 DIGIFOLD WIRING DIAGRAM SYSTEM Page 51 Digifold Section 14 Edge Rx Edge Tx Sync 1 Sync 2 Stack
23. V 18 y 91 6 1 41 IVNDIS O as 11 80 6411 Qv114nd4no NSd NO ZIMS I NOLLISOd 01 135 NS TYNDIS SAIC dod 10 1 05 YOLOW JP 5073 1 TWNOIS 8 HOLON 40 5117130 NOLLO3NOO 8043 LASHS 335 OO O O O O O OO YOLOW NH9 M A 18 8 0704 335 320 18 AWNIASLL ING HO LON 3QV 18 00 OO SQV31 TYNDIS YOLOW 40 5117130 NOLLO3NOO 404 c 13395 335 934 HO LON SCV 18 5 30 18 NO Z IMS 440 VIMS I NOILISOd OL LAS CMS NSd 404 m 26339 133005 23l Squvog 1349315 403 3L 13 114905 23l 18 218 5 STEPPER BOX WIRING DIAGRAM Page 49 SYSTEM Digifold Section 14 2 5AMP IEC INLET F STEPPER C OUTPUT SUPPLY 5 COLD CONDITION E YELLOW RED WHITE RED YELLOW WHITE ORANGE BLACK WHITE BLACK ORANGE WHITE 3 DRIVE SIGNAL LEAD 75 145 4 BLADE SIGNAL LEAD 75 146 gt 41 DRIVE MOTOR 76 129 6 42 BLADE MOTOR 76 234 gt IEC INLET CEE22 PSU SUPPLY HOT CONDITION BLACK ORANGE WHITE ORANGE BLACK WHITE RED YELLOW WHITE YELLOW RED WHITE STEPPE
24. d Roller Assembly as follows Remove 4 off screws 2 off on access housing and 2 off on support housing The roller assembly can now be withdrawn from the lay side of the machine Remove The 2nd Roller Assembly as follows Remove 4 off screws 2 off on access housing and 2 off on support housing Undo M5 Nut amp remove Blade Idler Assembly from each side of machine see diagram below for location Remove Exit Drive Roller Assembly this is secured by a M8 cap head screw on th lay side of the folder unit See diagram on page 29 Rotate the main roller so that the gear is clear of the exit roller drive ring the roller assembly can now be withdrawn from the Op side of the machine Remove The 1st Roller Assembly as follows Remove 4 off screws 2 off on access hosing and 2 off on support housing Release tension on the Blade Drive Belt by loosening the 4 off screws on the Blade Drive Assy Motor plate Remove the pulley from the Blade Drive Shaft assembly Remove the 3 off screws nuts and washers used to capture the blade drive shaft bearing on the op Side of the folder unit The Blade Drive shaft Assembly can now be removed from the op Side of the folder unit The roller assembly can now be withdrawn from the lay side of the machine Page 30 CREASING FOLDING Digifold Alorgana SECTION 11 Main Fold Rollers Replacement The main rollers should be fitted into the folding unit in the reverse order of removal Procedure fo
25. e 34 CREASING FOLDING Digifold SECTION 12 Calibration Mode To switch the machine into calibration mode do the following 1 With the machine on insert the calibration plug into the DIN socket located at the rear of the feed bed 2 Hold push button 4 down and press the set up switch to its down position the display will show tabrO 3 By turning the rotary switch you can now scroll through the menu of available machine settings that can be changed the order is as follows Tabr 0 Etch 17 These figures dEtr 105 are typical values FECh 35 and can be used DEtF 90 as an approximate gAPF 97 start position if no cEn 0 0 previous figures are available EURO inch 4 It is possible to toggle between the operator mode and the calibration mode by holding push button 4 and moving the setup switch between it s mid position and its down position Prior to calibration the machine must have some pre defined crease amp fold position input into the program software do this as follows Note Refer to the operator manual for explanation of accessing software menu s Set the crease positions Etch Adjusts the position of the last crease position relative to the sensor Detr Adjusts 1 crease position relative to the sensor In operator mode do the following Use 420mm A3 long paper 120 gsm wth printed setting marks if available Input the following settings Crease on Fold off DELry off Set display to set by
26. e Ring Holes In Blade Drive Ring Idler Gear Assy Page 22 CREASING FOLDING Digifold SECTION 10 Setting Blade Central Position Cen This adjusts the center position of the knife travel set with gauge 63 6 mm Ensure the Blade setting in Calibration Mode is set to 0 0 as a start position Using the 2 5mm allen keys provided in the Dispatch Kit locate one of the allen keys into the alignment bracket see FIG A1 and rotate the Flag Blade Hub see FIG until the allen key is located in the 1 hole the Blade Drive Ring see FIG A1 The lug on the Blade Drive Ring is now in a central position Allen key Alignment bracket lst hole 2nd hole FIG A1 2 Loosen the two screws that lock the stop hub onto the blade drive motor shaft i e the travel stop screw and the small grub screw see FIG A2a The stop hub can now be rotated freely on the shaft Rotate the stop hub until the travel stop screw is in line with the bracket aperture The stop hub can now be held in the correct position on the shaft by inserting an allen key through the bracket aperture and into the socket of the travel stop screw See FIG A2a and FIG A2b Ensure the travel stop screw is positioned 90 degrees to the slot in end of hub 3 With the mains power switched on Hold the stop hub in the correct position as described above with the allen key and rotate the flag blade hub slowly until the LED marked KN
27. e reverse manner Page 14 CREASING FOLDING Digifold SECTION 6 DRIVE HUB REPLACE RUBBER TORSION BUSH SHOCK ABSORBER 6 1 Loosen grub screws in one half of hub 6 2 Slide hub outward amp remove rubber 6 3 Replace in reverse order Rubber Torsion Bush SYSTEM Page 15 Digifold Aforgana SECTION 7 DRIVE LINK REFURBISHMENT 7 1 Remove the drip tray by removing the four securing screws fixed to the tie bars 7 2 Remove both tie bars and drip tray 7 3 Remove the micro switch assembly to gain access to the rear drive link 7 4 Using a short dumpy posi drive screwdriver unscrew the three screws from the side of the link plate Slide the side off O Rings should be maintained in position The plastic drive link can be removed by sliding it forward 7 5 Replace the drive link and outer plate 7 6 Re assemble in reverse order Link Plate Micro Switch Assembly Page 16 CREASING FOLDING Digifold SECTION 8 ELECTRICS REMOVAL REFITTING PCB s BOARD REPLACEMENT CONTROL P C B Switch the mains power off Remove the feed bed as in paragraph 1 4 Disconnect the mains Unplug all plugs from PCB remove the PCB using a removal tool to depress the five fixing positions BOARD REPLACEMENT STEPPERDRIVE BOX owitch the mains power off and remove the front cover and top feed bed Cut cable ties and unplug the four green plugs Remove the two mains plugs Follow the power supply lead up and cut through
28. epper PCB Check 240 v supply Check and replace if required Change stepper PCB CREASING FOLDING Digifold Section 14 c c 94 Qv31HlNv3 LINN M3SV3HO 6 Nouons 15 13S 0333 NOLLNE N c NOLLNG NOLLNAE 960792 0731 YO LON 19 6S S c 92 0731 YOLOW 8S 000 721 H3dddlS 335 ZG OL EV v c 97 335 16 cv ava 61 92 H38ACIN 335 YOLOW JAYA Iv 911 92 QV3183MOd u3dd31S OV 9 LINN 5 489 OL SISVHO 6 161 6 512018 OL SISVHO 8 SII S87 31 LAdNI 758 LE 661 821 QV31 1fndNI 4015 AON39H3A3 611792 QV31 HOLIMS W31SAS 041 9 1 0 HOLIMS WALSAS 06 701 871 0731 0553 09 521 63 HOLIMS dWOO 901792 TYYLNIN HOLIMS 16 070 92 HOLIMS 049 333915 9c 6001 43E8WANN 13395 3009 310709 33S OL 971 51 0731 IVNSIS 3Qv T8 621 9 952 91 YOLOW 986 94 Gez A xu WP 82d AV 1dSIG 01814 624 3 18VO JNT AV 19510 52 0731 JAYA Xu 3903 XL 3903 SS3N DIHL 1
29. er Rotation Knife Posn CN7 Roller Posn 9 N12 RUNTIME PCB ASSY 125 05 01 Motor KNIFE MOTOR SIGNAL LEAD 124 01 07 DRIVE MOTOR SIGNAL LEAD 124 01 06 DELIVERY POSN MOTOR SIGNAL LEAD 124 01 20 DELIVERY DRIVE MOTOR SIGNAL LEAD 124 01 21 EDGE DETECT RX LEADII26 060 0I EDGE DETECT TX LEADII26 060 02 SYNC RX LEADII26 060 041 SYNC I TX LEADII26 063 02 SYNC 2 RX LEADII26 060 03 IO SYNC 2 TX LEAD I26 063 01 1 DELIVERY POSN LEAD 124 01 26 I2 GAP SET I POT LEADII24 01 OI GAP SET 2 POT LEAD 124 01 08 2 3 4 5 6 7 8 9 15 KNIFE POSITION SENSOR LEAD 124 01 02 I6 SAFETY CIRCUIT LEAD 124 01 10 I7 INTERFACE CABLE 124 01 09 RUNTIME PCB CONNECTION DIAGRAM Page 52 CREASING FOLDING Digifold Section 14 L 0 OR BLK YLW RD DELIVERY DELIVERY POSITION 18 DELIVERY DRIVE MOTOR LEAD 1124 01 24 9 KNIFE MOTOR 124 01 05 I 20 DELIVERY MOTOR LEAD 124 01 25 1 2 DRIVE MOTOR 124 01 04 26 DIGIDRIVER MAINS LEAD 124 01 30 DIGIDRIVER PLATE CONNECTION DIAGRAM SYSTEM Page 53
30. er Unit from the operator side of the machine slide on the two gears and locate the bearings Align the balde drive gears by passing a 2mm allen key through the alignment brackets both sides and into the holes in the blade drive gears see diagram Fig A1 below Lock the gears onto the blade drive shaft the gear on the op side is located by a dog point allen screw into a hole in the shaft Allen key Alignment bracket lst hole 2nd hole FIG A1 lv Rotate the Flag Blade Hub and pass a 2 5mm allen key up through bracket aperture and into allen key hole in grub screw Fit the belt between blade drive shaft and the motor drive gear see diagrams below Slot Flag Blade Allen Key Hub Travel Stop Screw Stop Hub Bracket Aperture See FIG A2b SYSTEM Page 33 Digifold SECTION 12 Machine setup prior to Calibration Ensure feed system is set up correctly Papergate gap Balls amp Side Lay etc Set the creaser input rollers square to the rear fixed fence Set the top blade square to the rear fixed fence and parallel to the input rollers ensuring there is no excess play in the slideways see sketch below Side Lay Paper Input Rollers i d 0 05mm Top Blade 8 Set the bottom blade relative to top blade to give a good form to the crease profile see sketch below Set the digifold rollers parallel to the creaser rollers Set the Gap setting of the rollers both to 0 0 0 0 Pag
31. ews M4 x 8 long beneath the entry guard Pull off the rubber handle from the tilt lever the entry guard can now be lifted upwards and removed 1 4 TheLoading Table The Loading table doubles up as a cover for the Control amp Display P C B s Removal of the loading table is as follows Remove all eleven countersunk screws from the feed bed Loosen the side layscrews and bring the side lay assembly towards the operator side of the machine Then lift out the loading table towards the rear of the machine passing over the fixed lay of the feed bed SYSTEM Page Digifold Alorgana SECTION 1 Folder Covers 1 5 The Top Cover Assembly The Top Cover Assembly is on top of the Fold Roller Mechanism and hinges upwards to allow access to the Main Rollers the Input Roller the Blade Assembles amp the Sensors This cover can be removed from the machine once the Rear Cover assembly has been removed 1 6 The Rear Cover Assembly The Rear Cover Assembly is situated at the output end of the machine The cover is secured by two spring clips by simply pulling on the top of the cover the whole assembly hinges downwards Note The Conveyor must be removed to enable opening or removal of the Rear Panel Assembly 1 7 The Edge Covers Lay Side amp Op Side The Edge Covers are a structural part of the machine covers amp are secured with pan head posidrive taptite screws These covers must be in place to allow fitting of the side cover
32. g CN12 on P C B Permanently Off Red L E D Knife Plug CN12 on P C B Permanently On Clip P displayed Paper jammed Sensor Alignment fault Faulty Sensor Damaged wires Clip 1 displayed Paper jammed Sensor Alignment fault Faulty Sensor Damaged wires Clip 2 displayed Paper jammed Sensor Alignment fault Faulty Sensor Damaged wires SYSTEM Check circuit diagrams Check plug is connected on board Check for loose wires or termination Change Slot Detector Sensor Check plug is connected on board Check for loose wires or termination Change Slot Detector Sensor Check Flag Screws are secure Press Push Button2 and remove paper from Infeed Use Calibration unit pt 70 043 to check sensor alignment Adj VR on PCB anti clock increase beam intensity Replace Sensor Press Push Button1 and remove paper from Delivery Use Calibration unit pt 70 043 to check sensor alignment Adj VR on PCB anti clock increase beam intensity Replace Sensor Press Push Button1 or 2 and remove paper from top shute Use Calibration unit pt 70 043 to check sensor alignment Adj VR on PCB anti clock increase beam intensity Replace Sensor Page 43 Digifold Section 13 Trouble Shooting Folder Fault Display On but No Drive to Rollers Continual blowing of fuse on stepper plate Knife Motor not running Rollers not Rotating On start up Rollers Rotating slow On start up and Display
33. gainst red bolt Page 10 CREASING FOLDING Digifold SECTION 4 MAIN CREASER MECHANISM REMOVAL OF UNIT 4 7 4 2 4 3 4 4 4 5 4 6 Tilt the DigiFold assembly by removing the top rear fixing screw and the top front fixing screw Also remove the center tilt attachment screw and loosen the lower fixings Tilt the unit First access should be gained by removing the top input and output guards See Section 1 Remove guard micro switch by two screws taking care to drop them Cut and remove cable ties from cable mounting retaining wiring loom Ensure that the mains is unplugged From the rear of the machine remove two button socket screws with their washers Remove the unlock knob from the front of the machine and unscrew the button head socket screw located just below this portion The tilt handle can be removed by sliding the main mechanism to the rear of the machine Remove the polycord drive from the suction drum The unit can be lifted by two people vertically out of the main frame with care One person should be guiding the wiring and plugs to ensure they donot get trapped during the lifting SYSTEM Page 11 Digifold Aforgana 4 8 Place the unit on a solid and clear bench ensuring no wires are trapped beneath the metal side plates 4 9 Assemble loosely around the green drive to the pulley 4 10 Replace the unit ensuring the wiring harness is threaded as it was removed
34. mbled on its backplate but not fitted to the machine adjust both knobs to one end of the total travel Turn back counting five full turns of the potentiometer This sets the potentiometer in approximately a central position Ensure the roller gap to be set starting with roller gap 1 the horizontal pair of large fold rollers 1s adjusted with 80 gsm paper to give a slide fit between the rollers and that the gap is parallel both ends Check that the eccentricity of the rollers maintains a constant grip on the paper throughout its full rotation Lock the shafts using jigs see below Position the gap set mechanism assembly onto the 3 off hexagonal pillars adjusting the knobs 1f required to ensure an easy alignment of holes Fit the screws and tighten Connect the green plugs to the runtime PCB With the machine switched on and the display showing the roller gap setting 1e RG 1 RG 2 loosen the soc set screw in the torsion coupling to allow the potentiometer shaft to rotate Adjust the pot until the display reads 10 carry this procedure out for both pots locking the screw to the shaft very gently as this can easily be over tightened Replace The Roller Spring Assemblies as follows Remove the jigs from the roller shaft ends and assemble the springs with the legs pretensioned to a parallel position as shown Page 32 CREASING FOLDING Digifold SECTION 11 Blade Drive Gears Insert theBlade drive shaft assembly into the Fold
35. n plugs Loose or damaged wires in sensor housing Faulty Top dual Sensor Check the fuse on main Check PCB for burning 7 PL5 Uforpuna Solution Replace rubber rollers Check plug is connected on board Check for loose wires or termination Check Sensor Diagnostics see opposite Vdc 0 5 at 9 5 0V board side R9 1 2V Plug side neg probe pin3 plug 1 IC8 pin8 5 0V IC8 pin1 3 4V Press Push Button 3 to Ensure Blade is in Home Position amp remove paper Also clean lens Check continuity of cable Check plug is connected on board Check for loose wires or termination Vdc 0 5 at R15 5 0V board side R15 1 2V Plug side neg probe pin3 plug 2 IC8 pin8 5 0V pin7 3 7V Re crimp or solder terminations Replace with new unit Check Sensor Diagnostics see opposite Replace fuse Check for damage to board Replace PCB Check plug is connected on board Check for loose wires or termination Check plug is connected on board Check for loose wires or termination CREASING FOLDING Digifold section 13 Trouble Shooting Folder Fault Reason Erratic register of Fold in Wrong Position the fold relative to Roller Gap too wide the crease Damaged roller surface Solution Micro Adjust F1 or F2 Adjust Check Potentiometers is OK Replace rubber rollers Blade Drive Mech Sticking Blades tight in delrin guides otepper PCB switch setting wrong Red L E D Knife Plu
36. ning Sensors 19 Changing Sensors Folder Unit Leading Edge 20 EE Changing Sensors Folder Unit Clip 17 21 EEE Changing Sensors Folder Unit Clip 2 21 Page 4 CREASING FOLDING Digifold 5 TOD sls 19 19141914 TO TERT Setting Blade 23 26 Adjusting Blade Drive Motor Overtravel 26 Adjusting Top Door Safety Switch 277 Section 11 Fold 8 2 2 2 2 6 Adjusting the Folder Input Rollers 28 Adjusting the Folder Exit Rollers 29 PEE Main Fold Rollers 30 nus Main Fold Rollers Replacement 31 C Main Fold Rollers Roller Gap Setting 32 Ge Blade Drive Shaft 33 Section 12 Calibration ___ _ _ Machine Set up Prior to Calibration 94
37. ntersunk screws all have metric Taptite threads and Pozi drive recesses Use No 2 point Pozidriv or Supadriv drivers for all screws M4 amp above and No 1 point drivers for M3 amp below WARNING WORK SHOULD BE CARRIED OUT BY A TRAINED AND COMPETENT ENGINEER AND ALL SAFETY PROCEDURES SHOULD BE ADHERED TO SWITH OFF MAINS POWER BEFORE COMMENCING DO NOT USE PHILLIPS DRIVERS THESE WILL DAMAGE THE SCREWS amp MAY SLIP CAUSING DAMAGE OR Warning This machine is heavy care should be taken when handling Hil Identification For general identification of areas of the machines the following terms are used Operator side control consul facing Rear of machine opposite to control consul Delivery end to the left of the operator side Feeder end on your right iV New Machine Preparation 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 10 Amps or 115 60Hz 15 Amps Fitthe delivery to the machine supporting it with the hoop 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 paper and check that the machine feeds and folds correctly SYSTEM Page 3 INDEX NIANG PAGE Introduction ij Fasteners iii Identification iv New Machine Preparation Section
38. r replacing the rollers is as follows Note Radial Position of Holes amp Approx Posn of Shaft Flats Replace The 1st Roller Assembly as follows Insert the roller assembly into the Folder Unit from the lay side of the machine Set gear mesh by rotating the op side hub there should be no backlash in the gear train but the feel when fully rotated should not be lumpy Replace screws to lock hub in position See diagram below for an approximate radial position as a starting point Note Fold Roller 3 Note Fold Roller 2 Note Fold Roller 1 Replace The 2nd Roller Assembly as follows Insert the roller assembly into the Folder Unit from the lay side of the machine Set gear mesh by rotating the op side hub there should be no backlash in the gear train but the feel when fully rotated should not be lumpy Replace screws to lock hub in position See diagram for an approximate radial position as a starting point Replace The 3rd Roller Assembly as follows Insert the roller assembly into the Folder Unit from the lay side of the machine Set gear mesh by rotating the op side hub there should be no backlash in the gear train but the feel when fully rotated should not be lumpy Replace screws to lock hub in position See diagram for an approximate radial position as a starting point SYSTEM Page 31 Digifold SECTION 11 Main Fold Roller Replacement con t Roller Gap Setting With the roller gap setting mechanism asse
39. s 1 8 The Side Cover Op Side Removal of the Side Cover on the operational side of the folder allows access to the drive motor the blade motor the gap set mechanism and timing belts These covers must also be removed to allow for setting up of the main rollers The cover is secured with pan head posi drive taptite screws 1 9 The Side Cover Lay Side Removal of the Side Cover on the Lay side of the folder allows access for setting up of the main rollers amp alignment of the sensors The cover is secured with pan head posi drive taptite screws 1 9 The Base Cover Rear The Base Cover is situated at the output end of the machine and is a structural part of the machine base unit This cover also supports the delivery assembly when fitted Removal of the Base Cover from the folder allows access to the electrics of the folder unit The coveris secured with four pan head posi drive taptite screws Page 8 CREASING FOLDING Digifold SECTION 2 2 1 Valve Plunger Replacement Remove coil cable e Remove 2 cap head screws holding body of valve to machine with 4 mm Allen key Ge Remove valve be careful not to loosen 0 ring seal which has a light coating of grease to ensure a good seal Ge Remove bottom of valve to release plunger and spring Check the rubber valve seating washer is secure and not split and the metal washer under the nut should be ftted 5 Set spool dimension to 44 2 mm See fig below Note The sea
40. ting washer is available as a spare Morgana Part No 04 070 amp the metal washer is also available as a spare Morgana Part No 481 125 A damaged washer or incorrect setting of these parts can cause loss of feed similar to a faulty electrical component 6 reverse order Note Do not over tighten aluminum parts and use grease to stop binding 44 2 Set Dim 2 Valve Coil Resistance readings on the coil should be 10 ohms To read the volts to the coil have the coil connected to the system and read the volts across the coil connections with the feed on This should be 12 volts SYSTEM Page 9 Digifold 3 SUCTION DRUM AND BELT REMOVAL REPLACEMENT 3 1 Remove feed bed and side guide 3 2 Remove valve assembly as in last paragraph 3 3 Remove 0 ring seal remove long Allen screw 408 01 050 030 3 4 Remove choke shaft from none operator side 3 5 Remove 4 screws securing the bearing center support plate posi head from front of feed frame amp 2 cap head from under the feed frame DO NOT adjust or remove red bolt as this is factory set 3 6 Remove bearing center support plate 93 010 Be careful when removing this as two bearings and shims can fall out 3 7 Remove suction drum and belt leave in feed drum idler and feed drum roller You can now remove belts 3 8 Replace reverse order again be careful of bearings and shims When fitting bearing support make sure it is up a
41. u press the PB1 or PB2 Buttons to drive the paper forward or backwards the paper remains stationary the Display will also show Crunch The procedure for returning the Blade to it s Home position is as follows G Power set to amp System Switch On Suction and Feed switches in there Up Position Off G Press Blade Push Button PB 3 the blade will return to it s home position Ge Remove the paper jam using the PB 1 PB2 buttons to drive the paper out e Clear the Display of Crunch by moving the set up switch to the Zero position SYSTEM Page 37 Digifold SECTION 12 Sensor Calibration and Alignment An electronic kit see picture below has been developed to assist the operation of calibrating and aligning the sensors This kit can be purchased from Morgana Systems Ltd by ordering part number 70 043 1 off SENSITIVITY m DIGIFOLD Sensor Calibration and Alignment Kit 70 043 Page 38 CREASING FOLDING Digifold SYSTEM Page 39 Digifold Urna Setting Idler Gear Blade Gear Drive Lugs With 2 mm allen key s passing through location brackets and into the holes in the blade drive ring gears see diagram slide idler gear between meshing teeth Look through the viewing hole in the side plate note if only half a hole is visible for the fixing screw to enter remove the pin on the exit blade drive gear No 2 pin roll idler gear around teeth of No
42. upper amp lower sensor bars SYSTEM Page 21 Digifold SECTION 10 REMOVING FITTING OF FOLD BLADE ASSEMBLIES Top Blade The top blade needs to be in the correct position to enable removal this is achieved by passing a 2mm allen key through the top alignment bracket and into the hole in the hub of the blade drive gear See diagram below Once the blade is correctly aligned it can be levered out using a screwdriver Bottom Blade The bottom blade needs to be in the correct position to enable removal this is achieved by passing a 2mm allen key through the bottom alignment bracket and into the hole in the hub of the blade drive gear See diagram below Once the blade is correctly aligned it can be levered out using a screwdriver Replacing Fold Blade Assemblies Replacement is the reverse procedure to the above the end drive pins in the blade must be positioned squarely over the lugs in the gears both sides before any pressure is exerted on the blade to clip it into place Using two red handled allen keys 2mm align the holes in the blade drive gears black lugged gears with the brackets attached to the mechanism side plates each side The gears may be turned by hand Insert the allen keys to lock the mechanism and align the blade drive pins both sides with the lugs on the gears with a small amount of pressure on the rear face of the blade it will clip into position 2 5 mm Hex Ball Driver 620 020 2 off z Holes In Blade Driv
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