Morgana Digifold Pro CB User manual

ISSUE 2APRIL 2012
174-037
DOCUMENT
CREASING/FOLDINGMACHINE
SERVICE MANUAL
MorganaSystemsLimited UnitedKingdom
Website: www.morgana.co.uk
Telephone:[phone] Facsimile:[phone]
DigifoldPro (CB/UL)

Page2
INTRODUCTION
CREASING/FOLDING
MORGANADIGIFOLDPro
i..........Introduction
ii.........Fasteners
Thepurposeofthismanualistoexplaintheprocedurefordis-
mantlingandre-assemblyofthemajorassembliesontheMorgana
Digifoldmachine.
Alltheengineeringadjustmentsareshownattheendofeach
relevantsection.
Operator'sadjustmentsandroutinemaintenanceareexplainedin
theappropriateoperatorsmanualwhichshouldalwaysbeusedin
conjunctionwiththismanual.
Itisalwaysagoodideatohaveacopyofthemachinesillustrated
partsmanualavailablewhenservicing,asitsillustrationsprovidean
invaluablereferencetotheconstructionoftheindividualassemblies
usedtobuildthemachine.
Allthreadedfastenersareisometric&allnutsareisometrichexagon.
Allscrewsarehardenedhightensilesteel.
Caphead,Buttonhead,Socketcountersunk,Shoulderboltsand
Grubscrewshaveinternalhexagondriveswhichrequireisometric
hexagonwrenches(allenkeys).Balldriversmaybeused,butcare
shouldbetakenparticularlywhenreleasingscrewsfordismantling
toavoidbreakingthedriverastheycannotcopewithfulltightening
torques.
NOTE.........Donotsubstitutefastenerswithlowgradealternatives
whichmayfailorbecomeirremovable.

Page3SYSTEM
PanheadandCross-headcountersunkscrewsallhavemetricTaptitethreadsand
Pozi-driverecesses.UseNo.2pointPozidrivorSupadrivdriversforallscrewsM4&
above,andNo.1pointdriversforM3&below.
Warning
Thismachineisheavycareshouldbetaken
whenhandling
iii........Identification
iv........NewMachinePreparation
Forgeneralidentificationofareasofthemachines,thefollowing
termsareused:-
Operatorside(controlpanelfacing)
LaysideorRearofmachine(controlpanelside)
Deliveryend(totheleftoftheoperatorsideie.LeftofFoldRollers)
Feederend(RightofFoldRollers)
Removeallpackagingmaterials
Allmetalparts,includingthefoldingrollershaveaprotectivecoating
Andanyexcessshouldberemoved.
Connectthepowercabletothemainssupply.Themachine
requires230V50Hz10Amps.
Turnthefoldrollersbyhandtoensuretheyrotatefreely.
Switchonthemachineandcheckthatallfunctionsoperate.
Setupthemachinetofoldpaperandcheckthatthemachinefeeds
andfoldscorrectly.
WARNING
WORKSHOULDBECARRIEDOUTBYATRAINEDANDCOMPETENT
ENGINEERANDALLSAFETYPROCEDURESSHOULDBEADHERED
TO.
SWITCHOFFMAINSPOWERBEFORECOMMENCING.
DONOTUSEPHILLIPSDRIVERS-THESEWILLDAMAGETHESCREWS
&MAYSLIP,CAUSINGDAMAGEORINJURY.
DigifoldPro

Page4 CREASING/FOLDING
INDEX
Introduction
SectionA
SectionB
SectionC
SectionD
SectionE
SectionF
SectionG
………………………………………………………………………........PAGE
¡Introduction...................................................................2
¡¡Fasteners......................................................................2
¡¡¡Identification..................................................................3
ivNewMachinePreparation.............................................3
……Covers………….…...................................................................
OperatorandLayedgeSideDoors...............................9
RearCover....................................................................9
ControlCoverandTopCover......................................10
DeliveryConveyorRemoval.........................................11
……VacuumValve…………………………………………………….
ValveReplacement......................................................12
ValveAssemblyDrawing..............................................13
……MainMechanism-CreaserUnit...............................................
RemovalofCreaserUnit..............................................14
Removal/ReplacementDriveBelt..............................16
…….VacuumDrum........................................................................
LoadingTableRemoval/Replacement.........................18
SuctionDrumBeltRemoval/Replacement...................19
…….InfeedRollerRemoval/Replacement...............………....………...20/21
…….ReplacingtheTouchscreenAssembly........…….………….............22
…….Electrics…….................ThePROControlSystem..........……......23
......24
......24
Removal/ReplacementITXBoards.............................26
Removal/ReplacementITXPSU...................................26
Removal/ReplacementStepperDrivePCB.................27
Removal/ReplacementLargePSUs’............................27
EnteringEngineerstools..............................................28
ZeroTotalCount...........................................................28
SettingtheMeasurementSystem................................28
SettingtheVacuumDrumPosition.............................28
Removal/RefittingControlPCBandprogboard.....
Removal/RefittingUSBFlashDrive.......................

Page5SYSTEM
PAGE
…..OpticalSensors…….………………………………………….........
.............................................CleaningSensors-Creaser.......................................29
.............................................ChangingSensors-LeadingEdge............................30
.............................................ChangingSensors-Crunch.......................................30
.............................................ChangingSensors-FolderUnitClip1&2..................31
…...Removing/ReplacingFoldKnifeAssembly……………….……
.............................................UpperFoldKnife.........................................................32
.............................................BottomFoldKnife.......................................................32
…..MainFoldRollersRemoval…………………………................
.............................................RemovalThirdFoldRoller...........................................33
.............................................RemovalSecond/FirstFoldRoller...............................34
.............................................MainFoldRollers-Replacement...............................35
…..PerforatorUnit…….…………………………………………..........
.............................................ReplacingtheGasStrut.............................................36
----------------------------------------
Pre-PowerSetupProcedureFlowChart.............................38
.................LoadingTableAlignment.....................................................39/40
.................DynacreaseAlignment........................................................42/44
.................BeltTension........................................................................45
................CreasingBladeInstallation...................................................48
................InputRollerGearMesh.........................................................50
................UpperInputRoller-SettingtheParalllelism&Pressure......51
................FoldRollers-SettingtheParallelism&Pressure.................54
................PerforatorAssembly.............................................................56
................SettingTheFoldKnives........................................................58
..............AdjustingTheTopCoverSafetySwitch................................60
----------------------------------------
PoweredSetupProcedureFlowChart.................................61
..............ControlSystemSetup...........................................................62
…..........FoldRollerGapPotentiometers...………..............................63
…..........DynacreaseTiltPotentiometer..............................................64
……......SettingTheVacuumDrumandPapergate...………….......…64
SectionH
SectionJ
SectionK
SectionL
Pre-PowerSetupProcedure
Section1
Section2
Section3
Section4
Section5
Section6
Section7
Section8
Section9
Section10
PoweredSetupProcedure
Section11
Section12
Section13
Section14
ENGINEERINGSET-UP&CALIBRATIONTECHNIQUES
DigifoldPro

Page6 CREASING/FOLDING
INDEX
PAGE
……......SensorsandDetectors..........................................................65
……......DeliveryAssembly.................................................................67
----------------------------------------
Crease&FoldSetupProcedureFlowChart.................................73
.............PrimaryFoldSetup...............................................................74
.............CreaseSetup........................................................................75
.............Squareness...........................................................................77
.............CreaseBias..........................................................................78
----------------------------------------
CalibrationFlowChart.................................................................79
.............DeliveryRoller.....................................................................81
.............CreasePositions.................................................................80
.............FoldPositions......................................................................80
.............DeflectAdjustments............................................................81
.............FollowStretch.....................................................................82
............TestRun..............................................................................82
.............TroubleShooting...........................................................
..............................................General..................................................................83
.............................................CreasingUnit........................................................83
.............................................FoldingUnit...........................................................83
..............................................ForErrorMessagesrefertoOperatormanual......86
.............CircuitDiagrams...........................................................
..............................................DigiFoldWiringDiagram.......................................88
.............................................ControlPCBConnectionDiagram.........................89
...................................................................91
Section15
Section16
Crease&FoldSetupProcedure
Section17
Section18
Section19
Section20
Calibration
Section21
Section22
Section23
Section24
Section25
Section26
SectionM
SectionN
OptionalDoubleSheetDetectKit
..............................................FusePositions&Ratings............……....………....90

Page7SYSTEM
BLANK
PAGE
DigifoldPro

Page8 CREASING/FOLDING
DOCUMENTCREASING/FOLDINGMACHINE
DigifoldPro
Keytophotographbelow
1Deliveryassembly6Airseparationknob11PaperGate
2Vacuumbleedknob7Adjustablesidelay12TopCover
3Suctionslotknob8Backstop13Touchscreen
4Switchpanel9Fixedsidelay14LoadingTable-Extension
5Airdistributionknob10Fuses(Optional)
1
3
10
5
6
7
8
9
11
12 13
2
4
14

Page9SYSTEM
SECTIONA
A.1
A.2
Covers:
TheOperatorSideDoor.
TheLayEdgeSideDoor
TheOperatorSideDoorcoverwhichissituatedadjacenttotheoperator,coverstheGapSet
mechanismandMainDrivePulleywithitsBelt.
Toremovethiscover,firstremovethetwotopfixingscrewsattachingthetopplate,thismust
beliftedupwardstoclearthegapsetadjusterKnobs.
Removefourscrewsfromtherighthandsideandpivotthedoorforwards.
TheLaySidedoorisattherearofthemachineandissecuredbyfivecountersunkhead
screws.
Removalofthispanelallowsaccesstothesuctionvalve&pipeworkandtheswitchedmode
powersupplies,alsotheFoldKnifedrivemechanismishousedinside.Thetopcoversafety
switchandtheperforatorgasstrutisalsoinsidethiscover.
Toremovethispanelonitsownremoveallcountersunkscrewsattachedtothehingeand
liftaway.
Toreplaceisthereverseprocedure.
AlternativelyremovethefrontandrearcoversalongwiththeRearCoverPanel,seebelow.
Toopen,firstunscrewthesinglepanheadscrewadjacenttothetouchscreenandthenthe
fivepanheadscrewsbelowthefeedbedwhichalsofixestheControlCoverDoorinplace,
hingebackwardstoopen.
Toremovethispanelonitsown,removeallcountersunkscrewsattachedtothehingeandlift
away.
Toreplaceisthereverseprocedure.
AlternativelyremovethefrontandrearcoversalongwiththeRearCoverPanel,seebelow.
TheRearCoverissituatedattheoutputendofthemachinebelowthedeliveryconveyor.This
coverissecuredoneachsidebyfourposipanheadscrews,fixingittothemainframe.Hinges
areattachedeachsideofthecovertoallowthesidetwodoorstopivotfromit.
Toremovetherearcoverincludingtheoperatorsideandlayedgesidedoors,removethe
eightposipanheadscrews(4eachside)andthefivescrewsintherearpanel.
Withtheconveyorfullyupandwithonepersoneachside,theassemblycanbemanouvered
outandunderthereardeliveryconveyor.
Toreplaceisthereverseprocedurecareshouldbetakenandtwopersonsshouldcarrythis
out.
A.3TheRearCoverAssembly
DigifoldPro

Page10 CREASING/FOLDING
SECTIONA
A.4
A.5
TheControlCover
TheTopCoverAssembly
TheControlCoverfixestothefrontofthemachineandsupportsthecontrolcoverdoorhinge,
withthedoorattached.
Toremovecompletelywiilgiveverylittleaccesstoanything,howeveropeningthedoor
beneaththefeedtablegivesaccesstothemainelectriccontrols.
Toopenthisdoorremovethesixposipanheadscrewsandpivotforwards.
Tocloseisthereverseprocedure.
Note.ensurethisissecurelyclosedwhenfinishedasmainselectricityispresentinside.
TheTopCoverAssemblyishingedontopoftheMachineandcoverstheMechanism,this
hingesupwardstoallowaccesstotheMainRollers,theInputRollers,theCreasing
Assemblies&theTopSensors.
Thiscovercanberemovedfromthemachineasfollows.-
1.OpentheLaySideDooraspreviouslydescribed.
2.Openupwards.
3.Peelbackthesoundabsorbentfoamtoallowaccesstothetwoposipanheadfixing
screwswhichcanbeunscrewedfromthepivotshaft.
4.Fromtherearofthemachineslidetheguardpivotshaftouttakingcarenottodamage
themicroswitch.thecovercannowberemoved.Takecarenottolose/dropthenylonwashers
ateachendofthepivotshaft.
Toreplaceisthereverseprocedure,ensurethemicroswitchiscorrectlysetafterthis
procedure.

SYSTEM Page11
A.6DeliveryConveyor
ToRemovetheDeliveryConveyortherearcovershouldberemovedforaccess.
Pivotthedeliverydownat45degreesusingthehandleontheendandturnthe‘delivery
lockingscrew’anti-clockwisetolockthedeliverystrutintothisposition.Showninphoto
below.
Usingthebodyofthegasstrutunscrewfromitsclevisuntilreleased.
Unscrewthesupportblockseachsideusinga5mmA/Fallenkeyatthetopfixingand
loosenthebottomscrew.
Pivotbothblocksforward(notetheoperatorsidewillhavearesistancefromtheperfgas
strut)
Theassemblycannowbeliftedclear.
SECTIONA
DeliveryLockingScrew
DigifoldPro

SECTIONB
B.1ValveSetting.
RemovalofButterflyValveAssembly.
TheButterflyValveassemblyislocatedinsidetherearcoveratthebackofthemachine.
ToremovethevalveAssemblyfirstunplugthecablefromitscontrolboard.
Removethetwopipemountingclipplates(ITEM6onnextpage)sothatthehosescan
bedetachedfromthevalve.
Removethetwoscrewsthatsecurethevalvetotherearoftheframe.
Refitinreverseorder.
Whenrefittingthevalveensurethattheendsofthehosesareclearofnylonfibresandthat
the‘O’ringisinplace.
Donotovertightenaluminumpartsandusegreasetostopbinding.
Note:-
Page12 CREASING/FOLDING

Page13SYSTEM
DigifoldPro

SECTIONC
REMOVALOFCREASINGUNIT:
ThecreasingmechanismAssemblyislocatedinthemiddleofthemachineandcan
Beaccessedbyopeningthetopcover.
1.First,accessshouldbegainedbyremovingthe‘RearCoverAssembly’and‘TopCover
Assembly’.()
2.Removebothtopsecuringblocksbyremovingthetwofixingscrewsfromeachofthem.
3.
4.Removethetopandbottompiniongearswiththecollarsbyusinga10mmspannerto
unscreweachofthepiniongearpostscompletely.
5.Fromunderneaththemachine(disconnectthe
homesensorfromthetiebar,onesocheadallenscrew.
6.Removetheflagfromthehub.Byloosening
thegrubscrewsonthecounterweightandrotating,accesscanbegainedtoremove
thefixingscrews.
7.LoosenthefourM5securingscrewsonthe‘Dynacrease’motortoenableremoval
ofthedrivebelt.
themainframewithcare.
SeeSectionA
Fromthefrontofthemachine,removetheTiltMechanismassemblybyunscrewingthe
twobuttonsocketscrews
Ensurethatthemainsisunplugged)
Cutandremovecableties
fromcablemountingbutleavetheassemblyhanginginside.
(Onlyiftheflagisscrewedontothepulley)
8.Theunitcanbeliftedverticallyoutof
9.Refittingisthereverseprocedure.
Notes.Bladeflag,flatstobeverticalwhen
TDCisselected.Alsothecounterbalance
weightshouldbedownwhenatTDC.
TheBeltmustbetightonfinalassembly.
Page14 CREASING/FOLDING

Page15SYSTEM
10.Whenre-assemblingtheTiltControlMechanism,itisimportanttomakesurethat
whenyoure-engagetheupperandlowerworms(C),thepins(A)ontheupperand
lowerwormwheelassemblies(D)areinthesamerelativepositionasshownabove.
Thiswillensurethethrowofeacheccentricisinthesamepositionatthetopandthe
bottom.
(See‘DynacreaseTiltPotentiometer’inthePoweredSetupProcedureonpage61)
DigifoldPro

Page16 CREASING/FOLDING
SECTIONC
REMOVAL/REPLACEMENTCREASINGDRIVEBELT
1.Withthecreasingmechanismoutofthemachineyoucanworkonthebenchto
disassembletheunit.
8.TheBeltcannowbereplaced.
Reassemblyisthereverseprocedurebewarethat
whentighteningthetopswingingblockshoulder
screw,thisshouldbeheldparalleltothepowerlink.
Thiscanbeachievedbypassinga4mmallen
keythroughthesideplateslotandthepowerlinkslot.
2.RemovetheBlade/AnvilAssembly
3.Unscrewthetwocountersunkheadscrewsfromtheinputandoutputguidesand
removethem.
4.Removethefourtiebarsecuringnutsatthe
driveendofthemechanism(Pulleyend).
5.Usinga3.0mmA/Fallenkeyremovethetwo
shoulderbolts.
6.Removethetopswingingblockalongwith
theM6thinwasher.
7.Tapthesideplatefromtheassembly
andremovethebelt.
TheBeltmustbetensionedsothatittakes0.5Kg
topushthebeltuntilitjusttouchesthetiebar.
Thisiscarriedoutbyadjustingthemotordownwards
andispossibletodofromtheoutsideoftheframeby
looseningthefourM5
BeltTightness
Boltsthatlocatethemotor
withinadjustmentslots.

Page17SYSTEM
BLANK
PAGE
DigifoldPro

Page18 CREASING/FOLDING
SECTIOND
LOADINGTABLE
RemovaloftheLoadingTable
1.RemovetheSideLaywiththetwolockingKnobs.
2.RemovetheChokeBleedValveknobandtheChokeLockingKnob.
3.RemovetheChokeBleedValvecentershaftbyunscrewingthesoc.setscrew
beneaththeloadingtable.
4.RemovetheEntryGuard.
5.RemovetheFrontFeedBed.
6.UnscrewthefrontLoadingTablecountersunkscrew.
7.FromtherearofthemachineremovethePaperGateAssembly.
8.RemovetheValveassemblyandthemanifoldPortAdaptor.
9.RemovetheM10capheadscrewtoallowaccesstotheBallHolderscrew.
10.RemovethetwofixingscrewsintherearoftheBallHolderAssemblyandremove.
11.LoosentheDisplayfixingscrews(twooff).
12.RemovethefourManifoldfixingscrewsandtheonefixingtheSidelay.
13.Slidethegreenfeedbeltfromthepulleys.
14.RemovethetwoM8buttonheadscrewsfromthefrontoftheLoadingtableandslide
theassemblyfromthemachine.
ReplacingtheLoadingTable.
ReassemblyoftheLoadingTableistheReverseprocedure.
Howevercareshouldbetakenwhensettingthissquaretothemachine.(See‘LoadingTable

Page19SYSTEM
SECTIOND
SUCTIONDRUMANDBELTREMOVAL\REPLACEMENT
1.Removefeedbedandsideguide.
2.
3.
4.Removesuctiondrumandbelt.
5.LeavethefeeddrumidlerandfeeddrumrollerYoucannowremovebelt.
6.Replaceinreverseorder,becarefulofbearingsandshims.
Removechokeshaftbyunscrewingthesocsetscrewfromunderneath,usinga
2.5mmA/Fallenkey.
Removethebearingcentersupportplatebyunscrewingthetwocapheadscrews.
inposition.
DigifoldPro

Page20 CREASING/FOLDING
SECTIONE
REMOVAL/REPLACEMENTOFINPUTROLLERS
Allsidecoversandthetopcovershouldberemovedtoeaseaccesstotheinfeedrollers.
1.Removethemaincreasingmechanismandtiltmechanism.
2.Removetheleadedgesensorhousingbyunscrewingthetwofixingscrewsfromthe
rearofthemachineandleavelooseinsitu.
3.Unscrewandremovetheinputrollergaplockingscrewfromtheslotintheframe.
4.Fromthelaysideofthemachineremovethecirclipfromtheshafthousing.
5.RemovetheDynacreasetiltmechanism.
6.Therollercannowberemovedthroughtheholeintheoperatorsideplate.
6.Removethecirclipfromtheshaftontheoperatorside.
7.Removethepulleyfromtheoppositeendandthenloosenthelaysidehubsecuringset
screwlocatedinthealuminiumsideplateedge.Withdrawtherollerassemblythrough
the
8.Replacetherollerinthereversemanner,butcareshouldbetakentosetthe
Rollergapsandgearmesh.(Seepages50&52).
TOPINPUTROLLER
BOTTOMINPUTROLLER
holeinthelaysidesideplate.