90-134_DocuFold Pro (CB) Operators Manual
Contents
1. confirm that you want to reset the count Batch count click to zero Click to start machine with settings currently A screen will appear to confirm that shown you will receive a notification if system switch is not on Press again to stop you want to reset the count Page 20 DocuFold Pro Operating the DocuFold Pro Run Job kel 297 0 Ind PY ia sf amp Click to run machine system Switch Not On warning u y Click to confirm System switch is on Switch Compressor switch on amp then click run button again Or click the icon to run three test sheets As Aa Xx The display will briefly show that the fold plates and delivery roller are moving to their set positions as shown below Page 21 Operating the DocuFold Pro morgana The machine running screen will appear Run count Jed 0 0 ad Batch Count Sheet Count Click to stop machine NOTES 1 The folds can be micro adjusted from the run screen if necessary while the job is still running 2 The speed can also be adjusted from the run screen while the job is still running Page 22 DocuFold Pro Operating the DocuFold Pro Store Pages To get to the Store setting page click the lower tab or i from the Status area New Jobs Having set up your job you can give the job a name and save it to a store You can also retrieve previously saved jobs mo2. Lead Edge Sensor Fault If the machine stops and error message 60 is displayed on the touch screen this indicates that the lead edge sensor is blocked Check that the paper path is clear This error message could also mean that the lead edge sensors are faulty or need cleaning Page 40 PAPER DocuFold Pro 9 95 12 UK DISPATCH KIT 9 95 13 USA PART NUMBER DESCRIPTION 134 10 11 12 13 OEP 17 18 90 018 650 040 650 041 650 016 617 004 620 620 620 620 620 620 620 624 0 1 99 1 99 6 99 007 020 004 006 025 027 032 18 35 41 05 71 083 01 401 02 050 008 WARNING DOCUFOLD PRO OPERATORS MANUAL ROLLER CLEANING KIT POWER CORD C19 3Pin UK POWER CORD C19 3Pin USA L6 15P Re Wirable Plug Used on USA Only GLASS BALL HEX BALL DRIVER 2mm HEX BALL DRIVER 2 5mm HEX BALL DRIVER 4 0mm ALLEN KEY 3mm BONDUS L WRENCH 2 5mm BONDUS L WRENCH 5 0mm COMBINATION SPANNER 13 A F DISPATCH BOX ANVIL SET PERFORATING SET 56T SLITTING SCORING SET TYPE A OUTRIGGER FOOT SCREW PAN POZI TAPTITE M5 X 8 LONG THE BLADES FOR ANVIL PERFORATING amp SCORING SETS ARE SUPPLIED AS MATCHED PAIRS AND SHOULD NEVER BE MIXED UP OR LEFT UN PROTECTED AS SERIOUS DAMAGE WILL RESULT FOLDER Page 41 ACCESSORIES amp OPTIONS morgana ITEM PART NUMBER DESCRIPTION 6 99 06 SCORING S
3. Turn the Air separation knob E to the high position Make sure that air distribution knob D is set correctly If the paper width varies you may need to trim the sheets to the same size If the paper is curling upwards the suction drum may not be able to pull the sheet downward to wrap around the drum for efficient feeding You may need to bend the sheets downward prior to loading DOUBLE SHEET FEEDING Make sure the gap under the paper gate B 1s not set too high Make sure the air distribution knob D and the air separation knob E are at the correct setting In extreme cases you may need to separate the sheets prior to loading Make sure you run on Pulse not Stream FOLD IS NOT SQUARE OR CONSISTENT Check the sheets are all exactly the same size and are square before folding as you can only fold accurately if the material is consistent Make sure you have no foreign bodies such as fragments of torn paper inside the fold plates or the fold rollers Check that the fold plates are locked and located securely and that the roller tilt mechanism 1s set to zero and locked FOLDER Page 35 PAPER WILL NOT STACK CONSISTENTLY Make sure the feed 1s consistent before attempting adjustments to the Delivery Roller Set the delivery roller position as described in the manual Sometimes a small repositioning of the roller will improve the stacking See Delivery Roller Page 19 If the paper 1s too curly when being delivered place the
4. Repeat procedure for each roller that you wish to adjust and then replace the roller assembly into the machine Reset the roller tilt knob R back to the zero central position and screw in the Clamping knobs Y Rotate Roller in this direction to increase Gap each graduation equals 0 1 mm of gap adjustment Centre Roller Fixed 3 Outer Rollers Adjustable section Through Roller Assembly FOLDER Page 33 SENSOR CLEANING The sensors to detect and count the sheets are located on the ends of the ball holder just next to the fold roller unit If the counter is failing the sensor can be accessed for cleaning by removing the roller assembly as described on page 32 Clean by using a soft brush or damp cloth FOLD PLATES MAINTENANCE The fold plates can be opened up for maintenance removing paper jams cleaning etc by removing the two bolts shown below The fold plate can then be hinged open Bolt Page 34 PAPER DocuFold Pro FOLDING TIPS AND TROUBLE SHOOTING SHEETS DIFFICULT TO FEED Check that you have not got too many sheets in the feeder Heavy coated stock will not feed as high a pile as for example 80 gsm copier paper Make sure the moving side lay is not pushed in too tightly against the paper Similarly if the moving side lay is set too far away from the paper stack this will allow the air to escape instead of blowing through the paper Make sure that the gap under the paper gate B 1s not set too low
5. the guard circuit is automatically broken for safety reasons to prevent the fold rollers from rotating Ensure that the tilt roller is at zero plug the upper plate connector into the lower plate To prevent damage to the unused upper plate when scoring or perforating store safely on the stowage hooks at the reverse side of the machine Press the start button the built in deflector on the fold plate will close automatically to the deflect position Note the Docufold Pro will automatically recognise that the lower plate is in the upper plate position and that the plug in perforator unit is in the lower plate position Press the start button again to run the job or the 3 button to run three test sheets Note Always run perforating or scoring jobs on pulse feed NOTE When perforating or scoring with folding the upper fold plate remains in position at the top FITTING PERFORATER BLADES The perforator blades are split into two matching halves and are fitted to the upper hubs as shown in the drawing using the four screws supplied Page 28 PAPER DocuFold Pro Operating the DocuFold Pro PLUG IN PERFORATOR IN POSITON PERFORATOR STRIPPER FIXED SIDE GUIDE SHEET SMOOTHER BACK STOP CATCH TRAY EXTENDED BACK STOP ADJUSTABLE SIDE GUIDE PLUG IN PERFORATOR UNIT FOLDER Page 29 Operating the DocuFold Pro SCALE PERFORATING BLADE PERFORATOR STRIPPER UPPER TYRE AND HUB ASSEMBLIES FRAME PAD y R
6. ama MAN HARARE pue Brightness Contrast Horizontal Vertical il Using a plastic pointer soft leaded pencil biro cap etc and with gentle pressure Touch the centre of the cross in each corner of the Touch Screen as prompted by the hand graphics This procedure will calibrate the Touch Screen Page 27 Operating the DocuFold Pro morgana PLUG IN PERFORATOR The plug in perforator unit is used for perforating scoring and when folding card cover stock and should be stored on the rear stowage hooks ALWAYS UNPLUG POWER CONNECTORS BEFORE REMOVING FOLD PLATES OR PLUG IN PERFORATOR Remove the top fold plate and fit the catch tray in position by hooking it over the opening for the top fold plate The plug in perforator unit then locates the same as the fold plate and again take care not to twist when fitting into position You may need to turn the hand wheel and push the perforator unit inwards to engage the drive gear Plug in the lower fold plate power connector into the perforator unit For all applications the unit is set on the bench using the scale to indicate the positions of the blades and hubs It is important to spread the hubs evenly across the width of the work to reduce the risk of paper jams NOTES 1 When perforating or scoring without folding the upper fold plate must be removed and replaced with the lower fold plate 2 If any of the fold plates or the plug in perforator unit are removed from the machine
7. catch tray and plug in perforating unit with blades disengaged into position and deliver out the back This applies to single fold applications only If two folds are required you may need to reduce the weight of stock to achieve the desired results PAPER WILL NOT DEFLECT WHEN USING ONE FOLD OR PERFORATING Check to make sure that the second plate is being used as the deflector Make sure that the plate is located securely and that the deflector bar is wound right to the end Set the tilt roller mechanism to zero Check that the material is not too heavy to deflect TOTAL AND BATCH COUNTER NOT WORKING Clean the sensors as described in the manual OVERLAP ERROR KEEPS APPEARING ON TOUCHSCREEN If the overlap keeps tripping in and cutting off the machine first check you are not feeding doubles and reset the feeder Overlap tripping can also mean that the machine is slowing slightly which may mean the material is too heavy Check that you have no foreign bodies or torn paper stuck inside the fold plates or machine MACHINE WILL NOT RESET Your Docufold Pro is a mini computer you must have a clean consistent power supply Switch off at power switch S wait 20 seconds and re power Page 36 PAPER DocuFold Pro NO POWER TO MACHINE If the touchscreen display fails to come on check that isolator switch S is not pressed in To release turn knob clockwise Check power supply to the machine MAIN SWITCH CUTS OUT The feede
8. for each type of paper IMPORTANT The operating environment should be controlled to a temperature between 16 C and 27 C Maximum Specification Feeding SYSI M nata Bottom suction feed Max Sheet SIZE en 674mm x 365mm 26 5 x 14 4 Min Sheet Size in automatic mode 160mm x 140mm 6 3 x 5 5 Max Paper Weight cccceccseeceeeseeeeeeseeees 240gsm Max 0 24mm thick according to hardness type of fold grain direction and substrate Min Paper NOIRE maen aan 56gsm 0 08mm thick Max No Folds per Sheet 2 Max Fold Length long plate o 328mm 12 91 Max Fold Length short plate 225mm 8 85 Max No Stored Programmes Unlimited Speed per Hour A4 Material 2 500 sheets Stream Feed 17250 sheets Pulsed Feed Speed per Hour A3 Material 18000 sheets Stream Feed 13250 sheets Pulsed Feed Note The production speed varies according to the material size Dimensions a anna L 1240mm H 1370mm W 555mm L 48 8 H 53 9 W 21 8 AG ENE 132Kgs 50Kgs packing Power Requirement oooWooW oo 1 phase 230v 50Hz 1 phase 220v 60Hz SP 96 0 decibels As part of our continued product improvement plan specifications and information published in this manual are subject to change without notice All specifications
9. of the stock curling will be minimised Put the upper plate into the upper plate position and the plug in perforator unit into the lower plate position Plug in power connectors upper into upper fold plate and lower into perforator unit Set the backstop and the moving side lay to suit the work Set the paper length Press the start button the upper plate will automatically move to half the length of the stack of cover stock Fine adjustments may be necessary to the fold position as described on page 16 It is recommended that when folding card the machine be set to batch after twenty sheets which will allow easy off loading For longer runs an optional rear delivery belt stacker Assy No 9 09 01 1s recommended to be used In the event of a paper jam the sensor will cut out the main switch The main fold rollers are linked to a clutch which will prevent sheets continuing to feed PAPER JAMS If for some reason a piece of paper jams in the machine remove and check inside the fold plates If there is paper jammed around the fold rollers take hold of a roller and wind them by hand to remove the jam If it is impossible to wind the roller by hand remove the roller assembly as described below After clearing a paper jam always check inside the fold plate see Fold Plate Section to make sure no torn pieces of paper are jammed inside the plate ROLLER ASSEMBLY REMOVAL The complete roller assembly unit can be removed from the machi
10. operate the machine with loose or trailing clothing Ne pas porter de v tements flottants lors de l utilisation de la machine Do not operate the machine with loose hair Rassembler les cheveux longs lors de l utilisation de la machine Page 6 A Do be aware of any finger traps and rotating parts when operating the machine Attention au risque de se coincer les doigts et aux pi ces en mouvement lors du fonctionnement de la machine Do be aware of sharp points and blades Attention aux l ments tranchants et aux couteaux Do be aware of rotating rollers Attention aux rouleaux en fonctionnement Do be aware of low current anti static shock Attention aux faibles chocs d lectricit statique PAPER DocuFold Pro morgana Docufold Pro AUTOMATIC PAPER FOLDING MACHINE Key to drawing below A Moving side lay knob H System switch R Roller Tilt lever B Paper gate knob J Front pins S Emergency stop switch C Suction slot knob K Upper fold plate T Compressor switch D Air distribution knob L Vacuum bleed knob U Extension table E Air separation knob N Delivery roller V Fixed side lay F Back Stop P Lead screw X Fuses G Moving side lay Q Touch screen Y Roller assy release knob Z Outrigger Foot FOLDER Page Operating the DocuFold Pro morgana ADJUSTING THE PAPER GATE Adjust the height of the paper gate using knob B clockwis
11. 51 01 HOSE Vacuum 95 152 01 HOSE Sheet Separation 95 153 01 HOSE Valve 95 187 POT amp LEAD ASSEMBLY DELIVERY ROLLER 96 028 02 FOLD ROLLER ASSEMBLY Standard 96 031 DRIVE BELT Large Roller Drive 96 049 02 FOLD ROLLER ASSEMBLY Bottom 97 121 POT amp LEAD ASSEMBLY FOLD PLATE 97 076 STEPPER MOTOR amp LEAD ASSEMBLY 174 19 01 RS232 ADAPTOR PCB ASSY 601 021 MAGNETIC ACTUATOR 601 111 TAPERED FERRULE SR1520 97 9 x 913 x 23 LG 606 030 SCALLOP KNOB Black 607 022 TWIN GRIP TIMING BELT 607 025 TIMING BELT 607 026 TIMING BELT 607 027 TIMING BELT 607 160 TIMING BELT T2 5 317 5 x 6MM WIDE 609 011 O RING 609 012 O RING WHITE SILICON 950 X 4 609 013 O RING 75 530 01 TRANSFORMER ASSEMBLY 230V TO 110V FOLDER Page 43 RECOMMENDED SPARES morgana PART NUMBER DESCRIPTION 609 014 609 023 613 137 613 255 613 365 652 011 655 015 655 016 613 023 681 015 652 047 681 020 O RING O RING PLUNGER amp SPRING ASSY SOLENOID COIL EMERGENCY STOP SWITCH SWITCH LOW CURRENT COIL BLACK ROCKER POWER SUPPLY UNIT SWITCHED MODE 24V POWER SUPPLY UNIT SWITCHED MODE 48V FUSE 3 15A Fast Blow FUSE 4A Anti surge FUSE 15A Anti surge FUSE 500mA Anti surge The items listed above represent parts which are subject to wear loss or accidental damage and is included for your guidance only Replacement of most
12. 90 0 Leading Edge Finished Document a on delivery bed 210 0 NOTE When only one fold is required on the sheet set Fold 1 and Fold 2 to the same values Page 18 DocuFold Pro Operating the DocuFold Pro Delivery Settings Pages To get to the Delivery setting page click the lower tab Roller position may be Micro adjusted by clicking Here Page 19 Operating the DocuFold Pro morgana Status Screen Paper length input from the Fold Positions amp Trim paper setting screen settings Currently selected Vacuum Suck setting for slow pulse choose selection 2 for stream feed choose Currently selected fold type can be one of the following selection 3 you to the fold settings 1 0 page F a Clicking in this area will take M98 0 Batch quantity this is input from the batch Speed selector On selection a speed adjustment screen calculator on the paper will appear setting screen max 999 Clicking in this area will take you to the delivery setting page Clicking in this area will take you to the store page Green icon indicates settings are saved a red icon would Select this button to produce 3 test sheets with the settings currently shown show that settings have changed but the job has not been saved Sheet count click to zero A screen will appear to
13. 90 134 Issue 3 FEBRUARY 2013 DocuFold Pro CB UL DZ Automatic Paper Folding Machine Morgana Systems Limited United Kingdom www morgana co uk Telephone 01908 608888 Facsimile 01908 692399 INDEX morgana INTRODUCTION amp SPECIFICATION PAGE 4 SAFETY Do s amp Don ts THE DocuFold Pro Labelled Photograph 7 OPERATING THE DocuFold Pro Adjusting the Paper Gate 8 Setting the Suction Slot 8 Setting the Vacuum Bleed 9 Setting the Adjustable Side Lay 9 Setting the Back ha 9 Setting the Air Distribution Knob 9 Setting the Air Separation Knob 9 Fold Plates 10 Roller Tilt 11 Delivery Roller 12 Emergency Stop Switch 12 Overlap 12 TOUCHSCREEN OPERATION Touchscreen Layout 13 Paper Settings Page 14 Batch Size selection 15 Speed Selection 15 Fold Settings Pages Pre defined fold types 16 Setting Fold Positions Manually Set by Position 17 Delivery Settings Pages 19 Status Screen 20 Run Job 21 Store Pages 23 Tools Menu 26 Touch Screen Calibration 27 PLUG IN PERFORATOR 28 Setting Perforators 31 Scoring 31 Folding Card 32 ka Jams 32 Roller Assembly Removal 32 Roller Adjustment 33 Sensor Cleaning 34 Fold Plates Maintenance 34 Page 2 PAPER DocuFold Pro INDEX FOLDING TIPS AND TROUBLESHOOTING Sheets Difficult To Feed Double Sheet Feeding Fold Is Not Square Or Consistent Paper Will Not Stack Consistently Paper Will Not Deflect When Using One Fold Or Perforating Total Batch C
14. ET TYPE B 6 99 09 SCORING SET TYPE D 1 99 10 PERFORATING SET 20T SLITTING 1 99 11 PERFORATING SET 20T SLITTING HEAVY DUTY 1 99 12 PERFORATING SET 28T SLITTING 1 99 41 PERFORATING SET 56T SLITTING 1 99 13 SLITTING BLADE SET 1 99 35 ANVIL SET 98 018 02 PERFORATOR STRIPPER SET LONG 69 033 SHEET SMOOTHER STACKER LONG 6 99 36 PAPER PROFILE ROLLERS SET SPLIT ACCESSORIES OPTIONS May be obtained from your May also be obtained and fitted dealer and fitted to your machine using by your dealer You should not attempt the instructions supplied or by to fit options yourself as specialist tools consulting your operators manual and knowledge are required Technician Maintenance It is recommended that your machine is fully serviced at least once every six months by a factory trained Service Engineer Page 42 PAPER DocuFold Pro RECOMMENDED SPARES PART NUMBER DESCRIPTION 75 06 02 TOUCH SCREEN ASSY 7 NEW CONTROLLER 75 500 08 MINI ITX MOTHERBOARD DOCUFOLD PRO 76 272 PSU ASSEMBLY ATX12V 300W 90 06 02 CONTROL PCB ASSY CHIP DOCUFOLD PRO UL 90 08 01 PCB FOLD PLATE MOTOR DRIVE 92 010 TRANSPORT BELT Delivery 92 027 01 DRIVE BELT Delivery Flat 12mm 93 021 FEED BELT 93 022 DRIVE BELT Vacuum Roller 93 028 SMOOTHER Delivery 93 042 LOWER SENSOR ASSEMBLY 94 088 UPPER SENSOR ASSEMBLY 95 189 DC MOTOR PCB ASSY 95 150 01 HOSE Exhaust 95 1
15. are dependant on application type of stock temperature RH and print engine used Specifications quoted were measured on uncoated and unprinted stock E amp OE Page 4 DocuFold Pro Safety Do s amp Don ts Safety Do s amp 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 Do operate with the designated AC current only Use an exclusive outlet as overloading may cause fire or an electric shock Respecter l alimentation lectrique indiqu e Brancher sur une prise s par e car une surcharge peut entrainer un incendie ou un choc lectrique Do install the power cord out of the way to avoid a tripping hazard Installer le cordon d alimentation de mani re ne pas pouvoir tr bucher par dessus Do make sure that the mains inlet connector is always easily accessible M nager un acc s libre la prise de courant Do Fit the yellow outrigger feet supplied in the Dispatch Kit to the front and back of the machine as shown on Page 7 to comply with safety regulations Fixer les pieds stabilisateurs jaune fourni dans le kit d exp dition l avant et l arri re de la machine comme indiqu sur la page 7 pour se conformer aux r glements de s curit Do not install the machine in an unstable place such that it tilts or shakes Ne pas installer la machine sur une surface
16. art up procedure the touch screen will be displayed as shown below ag IMPORTANT If you have not been trained to operate this machine we strongly advise that you select the red cross icon We recommend that you either seek training or ask a trained operator to run the machine for you Select the green tick icon only if you have been trained to operate this machine If you have not been trained to operate this machine and you select the green tick icon Morgana Systems Ltd accept no responsibility for personal injury damage to the machine or damage to materials being processed by the machine WARNING Wait at least 10 seconds after making any selection on the Touchscreen panel before switching the machine OFF Failure to do so could result in the data storage being corrupted and the machine not operating The touch screen is laid out into 3 main areas as shown below Status of machine amp data entry area Also Setting page used for guick links to setting pages RS 297 0 B 3G a ao 0 2 Tabs to enable switching between setting pages choose either Paper Settings Fold Settings Delivery Setting Store or Tools Page 13 Operating the DocuFold Pro morgana Setting Pages Paper settings Page Vacuum suck There Fold Selection For guick setting of crease positions on standard size sheets are three selections available 1 sh
17. chine at the slow speed to check position Adjust the backstop and side guide to suit the work For work longer than the backstop will allow remove the backstop and use the extended backstop that is located underneath the catch tray There is a full range of perforator blades available as follows For fine perforation 56tooth Part Number 1 99 41 For Paper 28 tooth Part Number 1 99 12 For heavier Stock 20 tooth Part Number 1 99 10 For use with blades Anvil Part Number 1 99 35 Slitter set for cutting Part Number 1 99 13 SCORING It is possible to score work using the plug in perforator The scorers are split in two halves fitted to the upper shaft and set as shown in the drawing using the scale on the unit as a guide to position The lower hubs are moved up to but just clear of the scoring blade The actual gap is critical and may require some experimentation to obtain a satisfactory score line As with perforating the remaining hubs must be spread to support the sheet fully across its width Scorers available Type A Part Number 6 99 05 for most card Type B Part Number 6 99 06 for deep score Type D Part Number 6 99 09 for paper FOLDER Page 31 Operating the DocuFold Pro morgana FOLDING CARD For best results the card material should always be printed cross grain as this causes less resistance when folding Pre scoring of card stock is also recommended By using the plug in perforator unit to deliver card the problem
18. dify them or delete jobs you no longer require To create a new job name click in text area amp Load existing job from keyboard will open to input job name store A4 DOUBLE PARA a anes Clicking to search J J currently stored jobs A4 DOUBLE PARA A4 LETTER a I Clicking to delete currently stored jobs Current Job Name Yellow Text Denotes Saved Job Red Text Denotes Unsaved Job Clicking to save job shown Keyboard for entering job name Return to Store Menu amp click save icon to save job to store Page 23 Operating the DocuFold Pro morgana Save confirmation screen ma 74 3 0 10 0 Ej To confirm saving ac of job click here Search for current jobs to load or modify You can search for jobs by clicking the search icon 2 this will bring up the search keyboard for text input Type in job description or first few characters Press search icon to start search To change your mind amp return to the previous screen click here Toggle between search Jobs matching characters in text box will be shown in this TA results amp full list of jobs area selecting job from this area will show job settings in the right hand status area Job selected will Press to load job be shown in text box shown in text box Page 24 DocuFold Pro Operating the DocuFold Pro Loading job con
19. e UN Ne A 1 A i i A UPPER PERF SHAFT ANVIL LOWER PERF SHAFT LOWER HUBS SOLID EDGE OF SHEET DRIVE HUB RECOMMENDED PERFORATOR SET UP SCALE UPPER PERF SHAFT SCORER UPPER TYRE AND HUB ASSEMBLIES FRAME PAD 22 8 7 6 5 4 3 2 VA I 1 0 mm 3 64 LOWER PERF 1 0 mm 3 64 HOS 1 0 mm 1 0 mm 1 0 mm 3 64 3 64 3 64 SHAFT LOWER HUBS SOLID EDGE OF SHEET DRIVE HUB RECOMMENDED SCORER SET UP Page 30 PAPER DocuFold Pro Operating the DocuFold Pro SETTING PERFORATORS Upper and lower hubs can be positioned on the shaft by unscrewing the 2mm grub screw Slide the hub with the blade attached along the shaft into position to correspond to the work using the scale as a guide For example to perforate 20mm from the edge of an A4 sheet you would set the blade at 190mm 210 minus 20 When positioned re tighten the 2mm grub screw Important Do Not Over Tighten This Grub Screw Slide the hub with the anvil up to the perforator blade and the remaining upper and lower hubs set as the drawing remembering to spread them to support the sheet fully across its width Clip the perforator stripper adjacent to the upper hub as shown Plug the unit into position fit the sheet smoother into position to hold the sheets down and run the ma
20. e to lower anti clockwise to raise so that the clearance above the vacuum roller is two thicknesses of the paper to be folded Do not make this adjustment when the face of the paper gate is above a hole in the vacuum roller if it is rotate the vacuum roller by hand to bring the metal between holes below the paper gate RR TWO THICKNESSES OF PAPER a WARNING DO NOT ADJUST THE PAPER GATE WHILE THE MACHINE IS RUNNING OR THE SUCTION DRUM MAY BECOME DAMAGED On this machine the paper gate is fixed in an optimum position and cannot be moved backwards and forwards horizontally SETTING THE SUCTION SLOT The suction slot inside the suction drum may be adjusted by releasing knob C and swinging the knob in the desired position Lighter stocks including bond will run best with the knob set to the left For heavier stocks and curled up stock move the knob C to the right until a satisfactory position 1s obtained Paper Gate Air Seperation Knob Back Stop Vacuum Suction Adjustable Bleed Knob Slot Knob Side Lay Page 8 PAPER DocuFold Pro Operating the DocuFold Pro SETTING THE VACUUM BLEED L 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 of 90gsm and lower is being fed through the machine turn the knob clockwise to reduce the possibili
21. ect run FOLDER Page 15 Operating the DocuFold Pro morgana Fold Settings Pages m To get to the Fold setting page click the lower tab herres Pre defined Standard Folds If you have selected a pre defined standard Fold Type from the paper settings page the recommended fold positions will be shown in parenthesis and can be micro adjusted as required Fold 1 micro adjust On selection the status area is replaced with a calculator for inputting new values Micro adjust range is 5 0 to 5 0 with increments of 0 1mm AC Folding can be micro adjusted for fine adjustment 198 0 Micro adjust range is 5 0 to 5 0 with increments of 0 1mm A Page 16 PAPER DocuFold Pro Operating the DocuFold Pro Setting Fold Positions Manually Set By Position If you have selected the Ruler Icon from the paper settings page the fold positions can be set manually EXAMPLE 1 Set Fold 1 to 210 0 Set Fold 2 to 90 0 Leading Edge Fold 2 Fold 1 SETTINGS Bt 5 na All dimensions are from the leading edge of the paper Leading Edge Fold 2 Finished Document 90 0 on delivery bed FOLDER Page 17 Operating the DocuFold Pro morgana EXAMPLE 2 Set Fold 1 to 90 0 Set Fold 2 to 210 0 Feed Direction ss Leading Edge Fold 1 Fold 2 SETTINGS Ine E seas All dimensions are from the leading edge of the paper Morgana Logo on underside of this flap
22. firmation screen To cancel loading of Job press here To confirm loading of Job press here Loaded job may be modified and then re saved as the same job name Overwrite job confirmation screen To cancel overwrite of Job press here To confirm overwrite of Job press here Delete job confirmation screen To cancel deletion of Job press here To confirm deletion of Job press here Page 25 Operating the DocuFold Pro morgana Tools Menu To get to the Tools page click the lower tab Touch Screen Calibration Change Machine measurement Clicking this icon will See Page 27 settings Imperial Metric show Machine program revision amp Touch Screen Touch screen software an 0 software revision revision IP 10 0 2 15 Page 26 DocuFold Pro Operating the DocuFold Pro Touch Screen Calibration 1 Switch the mains power on and wait for the main screen to appear before commencing to check the horizontal and vertical position of the display The position of the display within the surround is achieved by operating the button at the rear of the housing press this a number of times to obtain the correct orientation required move to the next button to move the position to centralize horizontal arent Ur 2 ma SM 2S gt Display Increase value ON OFF DOWN Decrease value AV Display Channel 4 sh bi F JE et ER a D vat hop
23. ithin EU Member States may return used electrical and electronic equipment to designated collection facilities free of charge Please contact your local disposal authority for information In some Member States when you purchase new equipment your local retailer may be required to take back your old equipment free of charge Please ask your retailer for information Other Countries Please contact your local waste authorities and request disposal information Page 46 DocuFold Pro REVISION HISTORY Rev Mod No Mod Description Date Mod By 3 EC0O2811 Page 45 Changes T15A Fuse was F15A 23 01 13 BAL Page 4
24. ne simply by unscrewing the knobs Y on each side and taking hold of the rear roller and lifting out the unit This 1s beneficial to clear paper jams to clean the roller and for maintenance With the roller assembly removed the safety circuit prevents the machine from running Replace the roller unit in the reverse sequence Clean the rollers with a stiff brush between the grooves using QD wash supplied by Morgana Page 32 PAPER DocuFold Pro Operating the DocuFold Pro ROLLER ADJUSTMENT The unique fold roller design of your Morgana Docufold Pro will fold most paper stocks without the need for adjustment If you have a requirement to fold very delicate or thicker stock or re feeding to produce a cross fold the fold roller gap can be easily adjusted as follows I Remove the roller assembly from the machine as described above 2 Loosen the Cap Head Screw on the operators side of the roller that you wish to adjust any of the 3 outer rollers using the 5 mm Bondus L wrench provided amp release the M8 lock nut on the non operators side with the 13 A F spanner provided Insert the 4 mm hex ball driver into the socket screw at the end of the roller shaft and rotate in the required direction to adjust the roller gap The graphics on the inside of the roller side plate show which way to turn the roller to adjust the gap relative to the centre roller Re tighten the half nuts amp cap head screws to lock the roller into position
25. non plane afin d viter qu elle ne penche ou ne vibre Do not unplug the plug or unplug the power cord from the outlet with a wet hand this can cause an electric shock Ne pas installer la machine sur une surface non plane afin d viter qu elle ne penche ou ne vibre Do not unscrew and remove any covers from the machine as it can cause an electric shock or injury Ne d monter et enlever aucun carter de la machine par crainte de d charge lectrique ou de blessure Do not place receptacles containing liquids on any surface Ne pas placer de r cipient contenant un liquide sur la machine Do not adjust any part of the machine whilst rollers are running N effectuer aucun r glage pendant que les rouleaux fonctionnent Do not operate the machine with loose or trailing clothing or loose hair Ne pas porter de v tements flottants et rassembler les cheveux longs lors de l utilisation de la machine Do not under any circumstances adjust the paper gate when the machine is switched on En aucune circonstance r gler le s parateur de papier lorsque la machine est branch e Page 5 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 pi ces 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 Do not
26. of the parts fitted to your machine requires specialist knowledge and should therefore be entrusted to your dealer Page 44 DocuFold Pro FUSE POSITIONS amp RATINGS POSITION ET CLASSIFICATION DES FUSIBLES TRANSFORMER ASSY I T500mAH 250V 681 020 PSUs 24V amp 48V FUSIBLE PSUs 24 V amp 48 V T4 0AH 250V 681 015 ET MAINS IN T15AH 250V 652 047 DC MOTOR BOARD all F3 15AH 250V 613 023 Page 45 PRODUCT RECYCLING amp DISPOSAL European Union Disposal Information for Commercial Users Application of this symbol on your equipment is confirmation that you must dispose of this equipment in compliance with agreed national Procedures In accordance with European legislation end of life electrical and electronic equipment subject to disposal must be managed within agreed procedures Prior to disposal please contact your local dealer or representative for end of life take back information Disposal Information for Domestic Users Application of this symbol on your equipment is confirmation that you should not dispose of the equipment in the normal household waste stream In accordance with European legislation end of life electrical and electronic equipment subject to disposal must be segregated from household waste Private households w
27. ort Highlighted fold is type currently selected other folds may be selected suck 2 long suck amp 3 Currently selected fold is shown in status area Select the Ruler icon to set the fold positions manually Perforating scoring with fold button continuous for stream feeding Highlighted number is type currently selected The status area also shows the currently selected suck Speed Selector On selection a speed adjustment screen will appear Batch Button Image is identical to that shown in the status KS 2070 EE area On selection the Perforating scoring button status area is replaced with a calculator for x Arrows may be inputting new values Batch sizes of 1 to selected to increase or decrease the page 998 may be set size in 0 1mm increments Toggle between Delay between batches Page Length On selection the status area is replaced with a calculator for inputting new values Length range 190mm 900mm Pre set Paper sizes for quick insertion Standard sizes for country origin would be shown Paper length input Page 14 PAPER DocuFold Pro Operating the DocuFold Pro Batch size Selection Pre set Batch sizes for quick insertion Speed Selection Feed Speed selection slider 20 positions to choose from Note Motor speed will not change until you sel
28. ounter Not Working Overlap Error Keeps Appearing Machine Will Not Reset No Power To Machine Mains Switch Cuts Out Fold Roller Replacement ERROR SCREENS DISPATCH KIT ACCESSORIES AND OPTIONS RECOMMENDED SPARES FUSE POSITIONS amp RATINGS PRODUCT RECYCLING AND DISPOSAL FOLDER 35 35 35 35 36 36 36 36 36 37 37 38 41 42 43 45 46 Page 3 INTRODUCTION morgana morgana Docufold Pro The Morgana Docufold Pro is a brand new concept automatic paper folding machine designed to be used in today s environment of document production The Morgana DocuFold Pro can be used by non skilled personnel by following this easy to use operator s guide There are very few operator adjustments required and in conjunction with our new Smart screen you will get started very quickly but we do recommend that you take a little time to read this manual to ensure that you fully understand the machine We have also included a TIPS amp TROUBLE SHOOTING section Be sure to read this section before calling a service engineer to avoid any unnecessary expense On the DocuFold Pro The fold plates and delivery roller will move automatically according to the type of fold selected Please be aware that different weights humidity temperature or the grain direction of the paper may make the paper fold in a different position according to the material Some manual adjustment may sometimes be necessary to obtain the exact fold plate position
29. r will adjust automatically according to the paper length and the fold type selected Manual or fine adjustment for the position of the delivery roller can be made as shown on Page 19 You should adjust the roller position so that when the work is stopped by the delivery roller it lies flat on the delivery without Iying on the sloping plate See Diagram below and without the green belts showing between the sloping plate and the folded sheet Sloping plate Emergency Stop Switch S This switch also serves as the main isolator It is important that the machine is switched off at the end of the days running press this switch to isolate the machine To switch back on rotate the switch head clockwise Overlap The machine has a built in system that will detect any sheet that overlaps another sheet by at least 20mm When this happens feeding will stop and the main switch will switch off preventing serious jams The error screen shown below will be displayed on the touchscreen Note that this is not a double detector and will not detect all double sheet feeds However the overlap system is an indication of a tendency to double sheet feed and therefore the paper gate should be lowered slightly and the paper stack should be fanned out more thoroughly Page 12 DocuFold Pro Operating the DocuFold Pro TOUCHSCREEN OPERATION 1 Turn the Emergency Stop button clockwise to switch the power on After the system st
30. r will cut out automatically after 100 seconds if the main switch 1s left on without the feed switch being activated The compressor inside the machine requires up to 28 amps to start running You must have the machine plugged directly into a 30 amp ring main Do not attempt to run the machine with an extension lead The main switch will cut out 1f you have a paper jam or overlap is indicated FOLD ROLLER REPLACEMENT Your Morgana Docufold Pro has been designed to make fold roller replacement an easy and low cost operation Your local sales agent will be able to supply you with a complete replacement roller assembly which allows you to change the roller assembly yourself as described in the roller assembly removal section of this manual You will need to send back to your agent the existing roller assembly FOLDER Page 37 Error Screens Sheet did not arrive If the machine stops and error message 01 is displayed on the touch screen this indicates that the paper did not arrive at the end of the suck process so the machine timed out Press the green tick button and then press the start button Overlap If the machine stops and error message 13 is displayed on the touch screen this indicates that the Lead Edge Sensor has seen a sheet subsequent to the first one as being longer Again this could actually be a longer sheet OR it could be a sensor problem if it is a recurring problem Check that the paper gate has been set co
31. rrectly Upper fold plate set out of range If the touchscreen shows the error screen shown below this indicates that the fold that has been set for the upper fold plate is out of range Page 38 DocuFold Pro Error Screens continued Lower fold plate set out of range If the touchscreen shows the error screen shown below this indicates that the fold that has been set for the lower fold plate is out of range Incorrect fold plate fitted for perforating or scoring without folding If the touchscreen shows the error screen shown below this indicates that the wrong fold plate is fitted When perforating or scoring without folding the short fold plate must be fitted in the upper slot position Incorrect fold plate fitted for perforating or scoring with folding If the touchscreen shows the error screen shown below this indicates that the wrong fold plate is fitted When perforating or scoring with folding the long fold plate must be fitted in the upper slot position Page 39 Error Screens continued Perforating Scoring unit not fitted If the touchscreen shows the error screen shown below this indicates that the machine has been set for perforating or scoring with or without folding and the perforating scoring unit has not been fitted System switch not on If the touchscreen shows the error screen shown below this indicates that the system switch must be switched to the ON position
32. ty of marking or damage to the leading edge of the paper SETTING THE ADJUSTABLE SIDE LAY Place a single sheet of the job onto the loading table Release the side lay clamp screws A and slide the side lay just up to the sheet so that there 1s about half a millimetre clearance or 1 64 inch Tighten the clamp screws SETTING THE BACK STOP F This is placed up to the end of the paper stack and clamped to the moving side lay G SETTING THE AIR DISTRIBUTION KNOB D Depending on the length of the sheet the air distribution knob D should be rotated to supply the air to the correct ports as follows Position This is for short sheets A5 or 8 long with only port I open Position 2 This is for sheets A4 or 11 long with the front port and port 2 open Position 3 This is for the longest sheets A3 or 17 with the front port and port 3 open Position 0 In this position only port 2 is open and can be used on long sheets with the curl up where you need to blow air into the centre of the stack These setting positions are only a guide and some experimentation may obtain a better result with non standard settings Note Position 1 feeds most paper stocks and sizes thus the air distribution knob can be left in this position for most jobs Port 1 Port 3 LL Air Distribution Knob SETTING THE AIR SEPARATION KNOB E This knob controls the amount of air that 1s fed to the paper The machine would normally run
33. with this knob set at the High position If the machine is run with less than approximately 20 sheets on the loading table or running the job to the last sheet this knob should be set to the low position FOLDER Page 9 Operating the DocuFold Pro morgana FOLD PLATES ALWAYS UNPLUG POWER CONNECTIONS BEFORE REMOVING FOLD PLATES Fitting Fit the fold plates into their respective positions long fold plate upper and short plate lower by locating the front pins J into the long slots and carefully sliding forwards without twisting until the rear pins can be located into the short slots When fully in position pull down the fold plate to lock into position Connect the push in power connectors short lead to upper plate amp long lead to lower plate Settings The fold plate lengths are set automatically Fold plate Tilt See roller tilt IMPORTANT NOTE If any of the fold plates or the plug in perforator unit are removed from the machine the guard circuit is automatically broken for safety reasons to prevent the fold rollers from rotating Page 10 DocuFold Pro Operating the DocuFold Pro Roller Tilt Lever R should always be set in the 0 square position To adjust folding out of square you can move the roller assembly in the or direction by releasing knobs Y and moving lever R always re tighten Knobs Y Page 11 Operating the DocuFold Pro morgana Delivery Roller The delivery rolle
Download Pdf Manuals
Related Search