Morgana Major User manual

ISSUE 8 March 2008
90-103
PAPER FOLDING MACHINE
Morgana Systems Limited United Kingdom
Telephone: ( 01908 ) 608888 Facsimile: ( 01908 ) 692399
OPERATORS MANUAL
MajorMajor
Website: www.morgana.co.uk
SERIAL No. 901376KKAF ONWARDS

Page 2 PAPER
INDEX
INTRODUCTION & SPECIFICATION
PAGE 4
SAFETY Do’s & Don’ts 5
THE ‘MAJOR’
6
The Morgana ‘Major’
Labeled Photograph
Side Lay
QUICK START CHART (METRIC) 8
QUICK START CHART (IMPERIAL) 9
QUICK START GUIDE 10
MORGANA ‘MAJOR’ OPERATOR INSTRUCTIONS
11
11
11
11
11
11
12
12
12
12
13
14
14
14
14
14
14
14
14
14
15
16/17
18
19
19
20
Paper Gate
Suction Opening
Setting the ‘Short Suck’ or ‘Long Suck’ mode of operation
Setting the Vacuum Bleed
Setting the Speed
Air Distribution Knob (D)
Air Separation Knob (E)
Back Stop (F)
Fold Plates
Roller Tilt
Deflect
Stacking Roller
Emergency Stop Switch (S)
Main Switch (T)
Feed Switch (U)
Batch Knob (V)
Reset Switch (W)
Overlap
Speed Control (R)
Plug-in Perforator
Fitting Perforator Blades
Setting Perforators
Scoring
Illustration of Plug-in Perforator
Folding Card

INDEX
Page 3
FOLDER
Major
MORGANA ‘MAJOR’ OPERATOR INSTRUCTIONS (CONTINUED)
21
22
22
FOLDING TIPS & TROUBLE SHOOTING
23
23
23
24
24
24
24
25
25
25
DISPATCH KIT 26
ACCESSORIES & OPTIONS 27
RECOMMENDED SPARES 28
Roller Adjustment
Sensor Cleaning
Folding Plates - Maintenance
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 and Batch Counter not Working
O-Lap Keeps appearing on Counter Board
No Power to Machine
Main Switch Cuts Out
Fold Roller Replacement
Sheets Difficult to Feed

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INTRODUCTION AND SPECIFICATION
Major is a registered trade mark of Morgana Systems Ltd. The Morgana Major is designed
to be used in today’s environment of document production, the Morgana Major can be
used by non skilled personnel by following this easy to use operators guide. There are very
few operator adjustments required on the machine and our section will get
you 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
section. Be sure to read this section calling a service
engineer to avoid unnecessary expense. 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.
Feeding System .......................................... Bottom suction feed
Max. Sheet Size .......................................... 674mm Long x 365mm Wide (26.5” x 14.37”)
Min. Sheet Size ........................................... 160mm Long x 140mm Wide (6.3” x 5.5”)
Max. Paper Weight ...................................... 240gsm Max. according to hardness, type
of fold, grain direction and substrate
Min. Paper Weight ....................................... 56gsm
Max. No. Folds per Sheet............................. 2
Speed per Hour (A4 Material) ...................... 27,500 sheets (Stream Feed)
QUICK START
TIPS &
TROUBLE SHOOTING before
IMPORTANT
Note:
the operating environment should be controlled to a temperature between
16° C and 27° C Maximum.
Max. Fold Length ......................................... 337mm (13.25”)
17,250 sheets (Pulsed Feed)
Speed per Hour (A3 Material) ...................... 18,000 sheets (Stream Feed)
13,250 sheets (Pulsed Feed)
Dimensions .................................................. L: 1168mm H: 990mm W: 493mm
Weight ..........................................................120Kgs (+11Kgs packing)
Power Requirement ......................................1 phase 220 / 240v
Specification
The production speed varies according to the material size.
Major

Major
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FOLDER
Safety Do’s & Don’ts
Safety Do’s & Don’ts
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 - beware of finger traps when replacing roller cassette and fold plates.
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 - read this operator manual fully before operating the machine.
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 remove the fold plates when the machine is
Do not - under any circumstances adjust the paper gate when the machine is
switched on.
switched on.

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PAPER FOLDING MACHINE
Major
Z
H
J
Y
N
K
L
M
I
AA
R
Q
T
U
V
W
S
P
A
B
C
E
F
G
A
FIXED
SIDELAY
D
BB

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FOLDER
Major
BLANK
PAGE

QUICK START CHART
(METRIC)
FOLD
LETTER
TYPE
PLATE
POSN
TOP
BOTTOM
PAPER SIZE
A5 A4 A3
70 98 139
70 99 139
RESET
SWITCH
PULSE
STREAM
or
HALF
TOP
BOTTOM
105 148 209
DDD
PULSE
STREAM
or
DOUBLE PARALLEL
TOP
BOTTOM
105 148 209
53 74 105
PULSE
STREAM
or
CONCERTINA
TOP
BOTTOM
140 198 280
70 99 139
PULSE
ONLY
ENGINEERING
TOP
BOTTOM
157 224 315
52 74 105
GATE
TOP
BOTTOM
53 74 105
104 149 210
PULSE
ONLY
PULSE
ONLY
Major
Fold Plate Setting Figures are for Guidance Only. Final Adjustment is
Likely to be Required, Dependant on Speed etc.
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Major
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FOLDER
QUICK START CHART
(IMPERIAL)
FOLD
LETTER
TYPE
PLATE
POSN
TOP
BOTTOM
PAPER SIZE
2.795 3.615 4.630
RESET
SWITCH
PULSE
STREAM
or
HALF
TOP
BOTTOM
PULSE
STREAM
or
DOUBLE PARALLEL
TOP
BOTTOM
PULSE
STREAM
or
CONCERTINA
TOP
BOTTOM
PULSE
ONLY
ENGINEERING
TOP
BOTTOM
GATE
TOP
BOTTOM
PULSE
ONLY
PULSE
ONLY
Major
Fold Plate Setting Figures are for Guidance Only. Final Adjustment is
Likely to be Required, Dependant on Speed etc.
5½x8½ 8½x11 8½x14 11x17
5.625
2.780 3.620 4.630 5.595
4.240 5.475 7.035 8.510
DDD D
4.240 5.455
7.000 8.495
2.055 2.680 3.470 4.210
5.645 7.310 9.395 11.360
2.780 3.610 4.600 5.580
6.355 8.255 10.575 12.795
2.055 2.630 3.470 4.190
2.100 2.750 3.505 4.260
4.205 5.475 7.000 8.495

QUICK START GUIDE:
1. Set the paper gate gap (knob B) to two thickness of the paper to be folded.
2. Place the paper to be folded onto the loading table against the fixed side lay.
3. Unclamp the moving side lay (knobs A) and slide up against the side of the paper but allow
approximately a 1/2 mm or 1/64 inch gap between the moving side lay and the paper.
4. Clamp the backstop (F) onto the moving side lay at the back of the paper stack.
(Note) Do not attempt to load too many sheets onto the loading table during set up as this
may affect the feeding operation.
5. Look at the diagram showing the various fold types and standard paper sizes. Select the
type of fold that you require to make.
6. Unlock the fold plate locking knob (H) on the fold plates and press button L on the 1
fold plate. This will display the fold plate setting position. Turn the dial J to the dimension
required as indicated on the fold type diagram. Lock knob H. Repeat this operation for the
2 fold plate.
.
7. Fold a sheet of paper by hand to the finished folded size and set the delivery stacking roller.
8. Set the Speed Dial (R) to the required position.
9. Make sure you have power to the machine and that knob (S) is turned onto the ON position.
Start the machine with switch (T) and by pressing the feed switch on and off quickly you
will feed a single sheet. Check the fold for correct length and adjust if necessary. If correct,
zero the counter by pressing switch W upwards. Select batch size if required by turning
knob (V). Press the feed switch and the machine will start the folding operation.
st
nd
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MORGANA ‘Major’ OPERATOR INSTRUCTIONS
SIDE LAY
PAPER GATE
SUCTION OPENING
SETTING THE 'SHORT SUCK' OR 'LONG SUCK' MODE OF OPERATION.
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
is about half a millimetre clearance or 1/64 inch
Tighten the clamp screws.
Adjust the height of the paper gate using knob (B) (clockwise 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.
On this machine, the paper gate is fixed in an optimum position and cannot be moved
backwards and forwards (horizontally).
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 is obtained.
The Morgana ‘Major’ can be set to a 'Short Suck' mode of operation, which improves the
feed of A4 sheets (in landscape orientation), and also improves the feed of sheets smaller
than A4. The 'Short Suck' mode of operation is particularly useful for perforating or scoring
applications.
Set the “Feed' switch (U) on the operator panel to the up position ('Off').
Set the “Reset Pulse' switch (W) on the operator panel to the down position ('Stream').
Turn the 'Batch' knob (V) on the operator panel to select “P1' or 'P2' in the Batch Counter
Display Window.
P1 = Short Suck mode of operation. P2 = Long Suck mode of operation.
Operation
SETTING THE VACUUM BLEED (BB).
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 possibility of marking, or damage to the leading edge of the paper.
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FOLDER

SETTING THE SPEED. (Speed setting dial ‘R’)
0 = Slow (Use for Delicate Paper and accuracy)
3 = Recommended Perforating Speed
10 = Fast (Use for Medium Weight Paper)
Use setting number 6 for normal use.
Note:-
AIR DISTRIBUTION KNOB (D)
AIR SEPARATION KNOB (E)
BACK STOP (F)
FOLD PLATES
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 1 - This is for short sheets A5 or 8" long with only port 1 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.
Position0-Inthis 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.
.
This knob controls the amount of air that is fed to the paper. The machine would normally run
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.
This is placed up to the end of the paper stack and clamped to the moving side lay (G).
Fit the fold plates into their respective positions (long fold plate upper and short plate lower), by
locating the front pins (I) 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.
Set the fold length by releasing the lock knob (H) and rotating the dial (J). The fold length may
be read on a manual plate directly off the scale (K) or for the digital fold plate by pressing the
'ON' button (L). More precise movements will be registered by pressing 'micro' button M which
will display increments (of one tenth of a millimetre, or for imperial machines one hundredth of
an inch). To preserve battery life, the display will switch off after 30 seconds.
If the fold needs to be tilted, this can be achieved by releasing knob (N) and turning the dial (J),
( ). Moving the dial to the + direction will increase the fold length
on the operator side.
(Note) Position 1 feeds most paper stocks and sizes, thus the air distribution knob can be
left in this position for most jobs.
Do not release lock knob (H)
Fitting
Settings
Fold plate Tilt
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Roller Tilt
Lever (AA) 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 (AA) always re-tighten Knobs (Y).
You can move knob (AA) on it's own or in conjunction with the fold plate tilt, + on the fold
plate tilt moves paper in the same direction as + on the roller tilt.
+-
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FOLDER

Deflect
Stacking Roller
Emergency Stop Switch (S)
Main Switch (T)
Feed Switch (U)
Batch Knob (V)
The second (short) fold plate has the ability to be shut off into a deflect position to enable
single folds to be achieved without removing the fold plate from the machine. To set the plate
to deflect, first ensure that the tilt is set at zero, then after releasing the lock knob (H), keep
winding the dial (J) to minimum length until it stops, then tighten the lock (H). The digital
plate will show a series of dashes --- in the window.
The stacking roller must be set according to the length of the folded work. The roller is moved
by releasing knob (P) while sliding the block Q to the required position. You should adjust the
roller position so that when the work is stopped by the stacking roller, it lies flat on the delivery
without lying on the sloping plate (R) and without the green belts showing between the sloping
plate (R) and the folded sheet.
This switch also serves as the main isolator and when 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.
The main switch (T) will run the whole machine. This switch incorporates a circuit that
switches off every 100 seconds whilst the feed switch U is in the off position. The main switch
may disengage seemingly at random but this is a normal function and may be instantly re-
engaged.
Switches the feed on and off.
The batch knob is a rotary switch and turning the knob slightly so that it moves one position
will cause the display to show the set batch quantity. Moving the knob further will change the
batch quantity in multiples of 10 up to 990. Stopping the feed in the middle of a batch will not
affect the batch. When the machine batches, the feed will stop and the display will show the
batch quantity with a series of dashes. Feeding will resume after a short period. If batching is
not required, turn the batch knob (V) until it reads 0 in the display panel. When 0 is shown
after turning batch knob (V) the counter will only total count.
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FOLDER
Reset Switch (W)
Overlap
Speed Control (R)
This switch has two functions:
To set the type of feed, either pulse or stream
To zero the total and batch counts
The switch has three positions:
Operating the switch upwards will zero the total count and if part way through a batch, it
will reset the batch count.
After operating the switch upwards, it will spring back to its centre (default) position. In
this position the feeder pauses between each sheet fed, leaving a gap between sheets. This
is called pulse feed.
Operating the switch to its lowest position will change the feed to continuous with the
sheets following directly behind each other. This is called stream feed.
(Note) In the pulse position a gap of 160 mm will be set between each sheet as it is being fed
into the machine. This gap prevents sheets over lapping inside the fold plates, which lessens the
chance of static being generated and will decrease paper jams.
Zigzag / concertina, engineering and gate folds should only be run on pulse. By holding switch
(W) down, the feed mode will switch to stream feed which will feed paper with little or no gap
between the sheets. Stream feed will increase productivity but folding accuracy may be slightly
impaired. Only use stream on letter, half or double parallel folds.
The pulse feed will cope with all types of fold including perforating.
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 and the display will show 'O-LAP'. 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.
The machine has variable running speeds, which are selected using the knob (R). Turn the
knob clockwise to increase the speed and anti-clockwise to reduce the speed. The slow speed is
recommended when running work that is difficult to stack, for example when perforating or
folding an engineering type fold.
··
·
·
·

PLUG-IN PERFORATOR
FITTING PERFORATER BLADES
The plug in perforator unit is used for perforating scoring and when folding card cover stock.
Remove the second fold plate and fit the catch tray in position by hooking it over the opening
for the second 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.
For all applications, the unit is set on the bench using the scale to indicate 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.
When perforating or scoring without folding, the first fold plate must be removed and replaced
with the second fold plate. Ensure that the tilt is at zero and set the second fold plate to deflect.
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.
A hardened anvil is fitted to the lower hub as shown in the drawing also using the four screws
supplied. Again the anvils are made from matching halves. Note - Do not mix matching halves
of blades or anvils
Important - THE PERFORATOR BLADES ARE VERY SHARP AND GREAT CARE
MUST BE TAKEN WHILST HANDLING.
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1522 21 20 19 18 17 16 4 3 2 1 0567891011121314
22 21 20 19 18 17 16 4 3 2 1 0 567891011121314
RECOMMENDED PERFORATOR SET - UP
RECOMMENDED SCORER SET - UP
LOWER PERF SHAFT LOWER HUBS (SOLID)
1.0mm
(3/64”)
1.0mm
(3/64”)
1.0mm
(3/64”)
1.0mm
(3/64”)
1.0mm
(3/64”) EDGE OF SHEET DRIVE HUB
FRAME PAD
UPPER TYRE AND HUB ASSEMBLIES
SCORER
UPPER PERF SHAFTSCALE
EDGE OF SHEET DRIVE HUB LOWER HUBS (SOLID)
LOWER PERF SHAFT
UPPER PERF SHAFT
SCALE UPPER TYRE AND HUB ASSEMBLIES FRAME PAD
ANVIL
PERFORATOR BLADE PERFORATOR STRIPPER
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FOLDER

SETTING PERFORATORS
SCORING
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. -
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 machine
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 56 tooth - 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
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
Important Do Not Over Tighten This Grub Screw
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FOLDER

FOLDING CARD
PAPER JAMS
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 of the stock curling will be
minimised. Set the backstop and side guide to suit the work. It is recommended that when
folding card, the machine is set to batch after twenty sheets, which will allow easy off loading.
For longer runs a optional rear delivery belt stacker (Assy. No. 9-09-01) is 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.
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 machine simply by unscrewing the
knobs (Y) on each side and taking hold of the rear roller and lifting out the unit. This is
beneficial to clear paper jams, and to clean the roller for maintenance.
With the roller assembly removed, the safety circuit prevents the machine from running. Clean
the rollers with a stiff brush between the grooves using the QD wash supplied with the
machine. Replace the roller unit in the reverse sequence.
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