Morgana Digifold 5000P User manual

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

Page 2
INDEX
10
10
11
11
11
11
11
12
13
14
14
15
16
SET BY FOLD
19
SET BY POSITION
25
26
Adjusting the Papergate
Setting the Suction Slot
Setting the Vacuum Bleed
Setting the Adjustable Side Lay
Setting the Back-Stop
Setting the Air Distribution
Setting the Air Separation Pressure
Setting the Blade Tilt Mechanism
Setting the Roller Gaps (Gap 1, Gap 2 & Gap 3)
Gap Set Guide Table
Fold Type Table
Setting the Positions of the Drive Wheels and Hubs
Setting the Delivery Conveyor System
Setting the Paper Length
Setting the Process (
Setting the Crease Positions
Setting the Fold Positions
(
(
Crease & Fold, Crease Only, Fold Only
or No Crease or Fold).
Crease & Fold, Crease Only, Fold Only
or No Crease or Fold).
19
20
20
20
21
21
24
Setting the Fold Type
Setting the Batch Quantity
Storing the Program
Adjusting the Crease Positions
Adjusting the Fold Positions
Setting the Process (
Example of Set by Position
Feeding Sheets Manually
27
28
CREASING / FOLDING
INTRODUCTION & SPECIFICATION
PAGE 4
SAFETY Do’s & Don’ts 5
THE DIGIFOLD 5000P
7
THE CONTROL PANEL
8
9
The Morgana Digifold 5000P
Labeled Photograph
Detailed diagram and description
Features on the control panel
OPERATING THE DIGIFOLD 5000P

Page 3
SYSTEM
INDEX
THE BLADE ASSEMBLY
PAGE 29
30
REPLACING CREASING BLADE SETS
32
35
PERFORATING
36
37
REMOVING PAPER JAMS 39
‘Clip 1 wasnt Blocked’ 44
‘Check edge sensor’ 44
‘Blade error. Run stopped, Please check
Settings’ 44
‘Last crease is too close to the end of the
sheet’ 44
‘Double sheet detected’ 45
‘Overlap - Probable cause, double sheet’ 45
‘Blade Home Failure 2’ 45
‘45
‘NV checksum error 45
DISPATCH KIT 46
ACCESSORIES AND OPTIONS 47
RECOMMENDED SPARES 48 - 49
Adjusting the blade pressure
Adjusting the blade alignment
Installing new blade sets
Spare Blades
Equipment, Spares
Setting the machine
Display reads
Display reads
Display reads
Display reads
Display reads
Display reads
Display reads
Display reads
Display reads
TROUBLE SHOOTING
41
41
41
41
42
42
43
‘Clip 1 was not clear’ 44
‘Clip 2 was not clear’ 44
‘Clip 2 wasnt Blocked’ 44
‘Paper Jam’ ‘Inch Motor Drive’ 44
45
MACHINE CALIBRATION HISTORY SHEET 50
FUSE POSITIONS & RATINGS 51
PRODUCT RECYCLING AND DISPOSAL 52
Paper crease out of square
Paper fold out of square
Paper Jamming
Machine will not start
Paper not feeding
Cracking of the printed material along the crease
Using the Correct Blade Set
Display reads
Display reads
Display reads
Display reads
Recommended weekly operator maintenance
Crease Position Inaccuracy 41
Warning Blade pressure may be too high’
’
Digifold 5000P

INTRODUCTION
It is to note that to prevent cracking, when using dry ink or toner based print
engines, the material be fully acclimatised for at least 48 hours before putting an
image onto the paper.
Feeding System ................................................ Bottom suction feed
Max. Sheet Size ................................................700mm x 385mm (27.5” x 15”) [900mm x
385mm (35.4” x 15”) with Optional
extension table].
Min. Sheet Size .................................................210mm x 140mm (8.3” x 5.5”) (dependant
on stiffness of paper and type of fold).
Max. Paper Thickness ................................... 0.4mm (varies according to hardness,
type of fold, and substrate).
Min. Paper Thickness ....................................... 0.11mm
Max. No. Creases per Sheet ............................ 9
Max. No. Folds per Sheet.................................. 2
Max. No. Stored Programmes ...........................9
Min. Repeat Crease Distance ........................... 40mm (1.6”)
Min. Repeat Fold Distance ................................70
Min. Crease Distance from Leading Edge ........ 50mm (1.96”)
Min. Fold Distance from Leading Edge .............50mm (1.96”) (depending on paper weight)
IMPORTANT
must
IMPORTANT
Note:
the operating environment should be controlled to a temperature between
16° C and 27° C Maximum.
(varies according to hardness,
type of fold, and substrate).
mm (2.75”) (depending on paper weight)
Min. Crease Distance from Tail Edge ............... 50mm (1.96”)
Min. Fold Distance from Tail Edge .................... 50mm (1.96”) (depending on paper weight)
Min. Fold Length ............................................... 70mm (2.75”)
Speed per Hour (A4 Material)............................ 5000 sheets
Dimensions ....................................................... L: 1980mm H: 1265mm W: 655mm
L: (78”) H: (49.8”) W: (25.8”)
Weight ...............................................................190Kgs (+50Kgs packing)
Power Requirement .......................................... 1 phase 220 / 240v
Specification
The production speed varies according to the material size and
the fold type.
Page 4 CREASING / FOLDING
Digifold 5000P
INTRODUCTION AND SPECIFICATION
DigiFold 5000P
DigiFold 5000P
is a registered trade mark of Morgana Systems Ltd. The unique patented
creasing and folding system, makes it possible to fold most delicate stocks from 100gsm,
up to 400gsm. The reduces the possibility of scratching, marking or
cracking appearing on the substrate, as is often associated with conventional folding
machine methods. A maximum paper weight cannot be specified, as this can be governed
by the hardness of the substrate or the type of fold required to be produced.

Page 5
SYSTEM
Safety Do’s & Don’ts
Safety Do’s & Don’ts
Do - read this operator manual fully before operating the machine.
Do - operate with the designated AC current only. Use an exclusive outlet, as
overloading may cause fire or an electric shock.
Do - install the power cord out of the way to avoid a tripping hazard.
Do - make sure that the mains inlet connector is always easily accessible.
Do not - install the machine in an unstable place such that it tilts or shakes.
Do not - unplug the plug or unplug the power cord from the outlet with a wet hand,
this can cause an electric shock.
Do not - unscrew and remove any covers from the machine, as it can cause an
electric shock or injury.
Do not - place receptacles containing liquids on any surface.
Do not - adjust any part of the machine whilst rollers are running
Do not - operate the machine with loose or trailing clothing or loose hair.
Do not - under any circumstances adjust the paper gate when the machine is
switched on.
REGLES DE SECURITE : « A FAIRE » ET « A NE PAS FAIRE »
Lire ce mode d'emploi avant d'utiliser la machine.
Respecter l'alimentation électrique indiquée. Brancher sur une prise séparée
car une surcharge peut entraîner un incendie ou un choc électrique.
Installer le cordon d'alimentation de manière à ne pas pouvoir
trébucher par dessus.
Ménager un accès libre à la prise de courant.
Ne pas installer la machine sur une surface non plane, afin d'éviter
qu'elle ne penche ou ne vibre.
Ne pas installer la machine sur une surface non plane, afin d'éviter
qu'elle ne penche ou ne vibre.
Ne démonter et enlever aucun carter de la machine, par crainte de décharge
électrique ou de blessure.
Ne pas placer de récipient contenant un liquide sur la machine.
N'effectuer aucun réglage pendant que les rouleaux fonctionnent.
Ne pas porter de vêtements flottants et rassembler les cheveux longs
lors de l'utilisation de la machine.
En aucune circonstance, régler le séparateur de papier lorsque la
machine est branchée.
Digifold 5000P

Page 6 CREASING / FOLDING
Warning Labels
Do - be aware of any finger traps and rotating parts when operating
the machine.
Do - read this operator manual fully before operating the machine.
Do not - operate the machine with loose or trailing clothing.
Do not - operate the machine with loose hair.
Do - be aware of any finger traps and rotating parts when operating
the machine.
Do - be aware of sharp points and blades.
Do - be aware of rotating rollers.
Do - be aware of low current anti-static shock.
Attention au risque de se coincer les doigts, et aux pièces en
mouvement lors du fonctionnement de la machine.
Ne pas porter de vêtements flottants lors de l'utilisation de la machine
Rassembler les cheveux longs lors de l'utilisation de la machine.
Attention au risque de se coincer les doigts, et aux pièces en
mouvement lors du fonctionnement de la machine.
Attention aux éléments tranchants et aux couteaux.
Attention aux rouleaux en fonctionnement
Attention aux faibles chocs d'électricité statique
Lire ce mode d’emploi avant d’utiliser la machine.

Page 7
SYSTEM
DOCUMENT CREASING / FOLDING MACHINE
Key to photograph below
1 Delivery assembly 6 Air separation knob 11 Paper Gate
2 Vacuum bleed knob 7 Adjustable side lay 12 Top Cover
3 Suction slot knob 8 Back stop 13 Display
4 Control panel 9 Fixed side lay 14 Extension table fixing screws
5 Air distribution knob 10 Fuses
1
3
10
5
6
7
89
11
12 13
14
2
4
Digifold 5000P
Digifold 5000P

The Control Panel
Page 8 CREASING / FOLDING
THE CONTROL PANEL
System Switch
Compressor Switch
Emergency Stop Switch
Selection Switch
The Display Unit and the Switches on the Control Panel allow the
operator to read, edit, create and initiate numerous creasing and folding
programs within the memory.
The Control Panel houses the Selection Switch, Compressor switch,
System switch, and an industry standard Emergency Stop switch which
will stop all power going to the machine when activated.

The Control Panel
Page 9
SYSTEM
Features on the Control Panel
Selection Switch
System switch
Compressor switch
Allows the operator to scroll through stored addresses and programs, increase or
decrease the batch quantity and set crease and fold positions.
When activated the system switch will operate the motors in order to begin the
creasing sequence.
Allows the operator to switch off the compressor unit in order to utilise the machine
to manually feed sheets.
Digifold 5000P

Page 10 CREASING / FOLDING
Adjustable
Side Lay
K
TWO THICKNESSES
OF PAPER
Suction
Slot Knob
IMPORTANT:-
To avoid possible damage to the suction drum,
when adjusting the paper gate height, ensure that
drum and not over a slot in the drum.
the disc is located over a solid section of the suction
Do not adjust the paper gate while the machine is
running.
Vacuum
Bleed Knob
Blade Tilt
Knob
Roller Gap 1
Knob
Roller Gap 2
Knob
Roller Gap 3
Knob
FIG 10.1
Air Seperation
Knob
Adjusting the Paper Gate
Set the height of the Paper Gate to approximately two thicknesses of paper, by turning the
knob K. An excessive gap is a most likely cause of double sheet feeding.
Setting the Suction Slot
The suction slot is located inside the vacuum roller and can be adjusted by releasing and
moving the suction knob horizontally in either direction to the required position.
For light stocks set the knob to the left and for heavier stocks set the knob to the right.
Operating the Digifold

Page 11
SYSTEM
Port 1 Port 5
Knob Shown
Set To Posn. 1
FIG 10.1
Air Distribution
Setting the Vacuum Bleed
Setting the Adjustable Side Lay
Setting the Back Stop
Setting the Air Distribution
Setting the Air Separation Pressure
Place the paper stack on to the loading table and slide up to the fixed side lay and paper
Gate. Release the clamps located at each end of the side lay and slide up towards the
paper stack as demonstrated in fig 10.1. Allow a gap of approximately 0.5mm (1/64 inch)
between the paper and the side lay.
Position the backstop and slide up towards the paper stack allowing a gap (as specified
in the above step).
Depending on the length of the sheet to be creased, the air distribution knob can be
rotated to various positions in order to supply air to different ports. Position 2 is
recommended for most sheet sizes. However, a better result may be obtained by using
the settings below or by experimentation.
For sheets longer than A3 (17”) in order to supply air to the centre of the
stack, ports 2, 3 and 4 open.
For A5 sheets or 8 inches long, ports 1 and 2 open.
For A4 sheets or 11 inches long, ports 1 and 3 open.
For A3 sheets or 17 inches long, ports 1 and 4 open.
For sheets longer than A3 (17”) in order to supply air to the ends of the stack,
ports 1 and 5 open.
For sheets longer than A3 (17”) in order to supply air evenly along the stack,
ports 1, 3 and 5 open.
To control the amount of air supplied to the ports, the air separation knob can be rotated
clockwise to decrease the pressure or anti-clockwise to increase the pressure.
Position 1 -
2-
3-
4-
5-
0-
Situated on the front of the feed table, the Vacuum Bleed Knob is used to allow more
control of the suction on the vacuum drum.
When light weight paper is being fed through the machine turn the knob clockwise to
reduce the possibility of marking, or damage to the leading edge of the paper.
Digifold 5000P Operating the Digifold

Page 12 CREASING / FOLDING
Gap_3 Gap_2 Gap_1
Home
More
Gap Settings
0.6 0.2 0.2
Tilt -0.50
Blade Tilt
Setting the Blade Tilt Mechanism
The blade tilt mechanism has been designed to compensate for when the creasing
position on the sheet is not square. This could be due to an inaccuracy in the media or if
the blade tilt mechanism has been incorrectly set. The mechanism will be set to zero
(square) when the machine is supplied. The Blade Tilt Mechanism can be adjusted if
necessary as follows:-.
With the machine switched (see page 18), move the Selection Switch to the right to
select .
The blade tilt can then be adjusted by rotating the Blade Tilt Knob (see FIG10.1 on page 10).
ON
Setup
Operating the Digifold

Page 13
SYSTEM
Roller Gap 3
Roller Gap 1
INFEED
FIG 13.1
Roller Gap 2
Gap_3 Gap_2 Gap_1
Home
More
Gap Settings
0.6 0.2 0.2
Tilt -0.50
Gap Settings
Setting the Roller Gaps (Gap 1, Gap 2 & Gap 3)
PROCEDURE.
The roller gaps can be adjusted to suit the thickness of the material being creased or
folded; and the type of fold being produced. The roller gaps may also require adjustment
if cracking of the print is noticeable. (see Fig 13.1 below).
The roller gaps can be adjusted as follows:-
With the machine switched (see page 18), move the Selection Switch to the right to
select .
The gap settings (Gap_1, Gap_2 & Gap_3) can then be adjusted by rotating the Roller
Gap Set Knobs (see FIG 10.1 on page 10).
When setting roller gaps, you first adjust the gap to a value greater than that required
and then decrease the value to the required setting. (Do not set the gap, from a value lower
than that required).
(i) Measure the thickness of the sheet using a Digital Vernier Calliper.
(ii) Set roller GAP 1 to the vernier reading.
(iii) Set roller GAP 2 and roller GAP 3, (for the type of fold being produced), using the
GAP SET GUIDE table on the next page.
ON
Setup
IMPORTANT.
must
Digifold 5000P Operating the Digifold

Page 14 CREASING / FOLDING
Half Fold on Knife 1
Half Fold on Knife 2
Half K1
Half K2
Letter
Concertina
Gate
Closed Gate
Engineering
FOLD TYPE GAP 1GAP 2GAP 3
GAP SET GUIDE
X
X
X
X
X
X
X
2X
X
X
X
X
X
X
2X
2X
3X
3X
3X
3X
3X
Double X2X4X
HALF
LETTER
DOUBLE
CLOSED GATE ENGINEERING
GATE
CONCERTINA
FOLD TYPES
The table below shows the recommended roller gap settings for the different types of folds.
Example 1:- When producing a fold, if GAP 1 is 0.2 (X) then set GAP 2 to 0.4
(2 x X) and set GAP 3 to 0.4 (2 x X).
Example 2:- When producing a fold, if GAP 1 is 0.3 (X) then set GAP 2 to 0.3 (X)
and set GAP 3 to 0.9 (3 x X).
Half K1
Gate
.
Operating the Digifold

Page 15
SYSTEM
FIG 15.1
A5 Sheet (5.8”)
A4 Sheet (8.25”)
A3 Sheet (11.7”)
WHEEL & HUB ARRANGEMENT, (WHEN FOLDING)
Setting the positions of drive wheels and hubs
It is important that the drive wheels and drive hubs, on the roller shafts, are arranged across
the width of the media being creased; this is done to ensure that the media is accurately
driven and supported through the rollers. A suggested layout, , is shown
below (see FIG 15.1). The suggested layout, is different, and is shown on
page 38 (see FIG 38.1).
The drive wheels and hubs are fixed to the rollers by grub screws.
when Folding
when perfing,
Digifold 5000P Operating the Digifold

Page 16 CREASING / FOLDING
Setting the Delivery Conveyor System.
WARNINGS:-
1. The Machine will start if the delivery unit is not in its up position.
1. With the machine switched (see page 18), move the Selection Switch to the left
(one click at a time) until the display contains the words .
2. Move the Selection Switch down to or .
3. Move the Selection Switch to the right to toggle between or
.
When using the ‘Set by Position’ mode of operation; the Roller Position and Shingle Length
must be adjusted manually to suit the job, as described below.
1. With the machine switched (see page 18), move the Selection Switch to the left
(one click at a time) until the display contains the words , as shown below.
2. Move the Selection Switch down to or and then rotate the Selection
Switch to adjust its value.
3. When the optimum settings for the roller position and shingle length are achieved they
can be stored with the job (see on page 20).
not
Turning the delivery system ‘ON’ or ‘OFF’
Adjusting the Roller Position and Shingle Length. (See FIG 17.1)
.
If the delivery is turned off the roller will feed to the far end of the belt conveyor and park
there until turned on again.
If the delivery is turned on when using the ‘Set by Fold’ mode of operation; the Roller
Position and Shingle Length are automatically set, relative to the paper length and type of
fold selected.
ON
Select Tools
Delivery is ON Delivery is OFF
Delivery is ON Delivery
is OFF
ON
Set Delivery
Shingle Roller
Storing the Program
Shingle 26.0
Home
More
Set Delivery
Roller 61.9
Operating the Digifold

Page 17
SYSTEM
Shingle Length
Roller Position
FIG 17.1
Digifold 5000P Operating the Digifold

Page 18 CREASING / FOLDING
Operate This Machine
No
Yes
Are You Trained To
Letter Prog 1
Tota l 20
Reset
Setup
Adjust Run
Batch Off
Letter Prog 1
Tota l 20
Reset
Setup
Adjust Run
Batch Off
Crease/Fold
Set By Posn. Prog 1
Tota l 20
Reset
Setup
Adjust Run
Batch Off
Crease/Fold
Prog 1
Tota l 20
Reset
Setup
Adjust Run
Batch Off
Cr
SET BY FOLD
1. Switch the power ‘on’ by turning the Emergency stop button clockwise to release the
safety latch. The display is now switched on and will be as shown below.
If you have not been trained to operate this machine, we strongly advise that you move the
Selection Switch to the right to select . We recommend that you either seek training or
ask a trained operator to run the machine for you.
Move the Selection Switch to the left to select only if you have been trained to operate
this machine. If you have not been trained to operate this machine and you select ,
Morgana Systems Ltd accept no responsibility for personal injury, damage to the
machine or damage to materials being processed by the machine.
If the display contains the words as shown below, change to as
follows.
(i) Move the Selection Switch up to select and hold momentarily.
(ii) Move the Selection Switch down, one click at a time, to select .
(iii) Move the Selection Switch to the right.
IMPORTANT.
No
Yes
Yes
Set By Posn, Set By Fold
Reset,
Set by Fold
A typical, (SET BY FOLD), display menu is shown below.
Operating the Digifold

Page 19
SYSTEM
Paper Type 2
Paper Type 3
Back
Tens Decimals
Set Paper
Paper Length 210.3
Paper Type 2
Paper Length 190.0
Home
More
Set Paper
Back
Tens Decimals
Set Paper
Paper Length 210.3
(Crease/Fold) Home
More
Set Process
Crease Only
Setting the Paper Length
Setting the Process (
2. Following the arrows on the display unit; move the Selection Switch to the right
(one click at a time) until the display contains the words .
3. Move the Selection Switch down to select .
4. The paper length can now be set by moving the Selection Switch to the left to select
or to the right to select . The or (whichever has been
selected) can then be adjusted by rotating the Selection Switch, (clockwise to
increase or anti-clockwise to decrease).
5. Move the Selection Switch down to select .
Move the Selection Switch to the right to select .
or
Set Paper
Paper Length
Tens Decimals Tens Decimals
Paper Type
More
Crease & Fold, Crease Only, Fold Only No Crease or Fold).
6. The Paper Type can now be set to 0, 1, 2 or 3 by rotating the Selection Switch.
7. Move the Selection Switch up two clicks to the top level display menu.
8.
Digifold 5000P Operating the Digifold

Page 20 CREASING / FOLDING
(Engineering) Home
More
Set Type
Concertina
Batch Quantity 20
Home
More
Set Batching
Set Process,
Crease/Fold, Crease
Only, Fold Only Perf only
More
.
Set Type
Letter
Concertina, Half on K1, Half on K2, Double, Engineer, Gate Closed Gate
.
More
Batch Quantity
Back
More
7. Move the Selection Switch down to select the required crease or fold
option can now be set by moving the Selection Switch down to the required setting and
then moving the Selection Switch to the right. The options are
or
Move the Selection Switch to the right to select .
The can now be set by moving the Selection Switch down to the required
type and then moving the Selection Switch to the right. The fold options are ,
or ).
10. Move the Selection Switch to the right to select .
The batch quantity can now be set by moving the Selection Switch down and then
rotating the Selection Switch clockwise or anti-clockwise to adjust the
The Batch Counter controls the feed of the machine.
If for example the Batch Count is set to 10; the machine will feed 10 sheets of paper, pause
for approximately 5 seconds, the conveyor belt will feed the 10 sheets forward (to allow the
removal of the sheets from the conveyor) and then feed the next 10 sheets of paper.
11. Move the Selection Switch up to select .
12. Move the Selection Switch to the right to select .
Setting the Fold Type
Setting the Batch Quantity
NOTE.
).
8.
9.
Storing the Program.
Operating the Digifold