Plockmatic Morgana VFL Feeder User manual

Morgana VFL Feeder
Operating Instruction
Read this manual carefully before you use this product and keep it handy for future
reference.
For safety, please follow the instructions in this manual.
Doc no: T10211B
Date: 2020-06-10

WARNING
This is a Class A product. In a domestic environment this product may cause radio
interference in which case the user may be required to take adequate measures. The
product (System) which is connected to this machine will be class A.
NOTE
The domestic environment is an environment where the use of broadcast radio and television
receivers may be expected within a distance of 10 m of the apparatus concerned.

Introduction
This manual contains instructions on the operation and maintenance of this machine. To get
the maximum versatility from this machine all operators should carefully read and follow the
instructions in this manual. Keep this manual in a handy place near the machine.
Please read the Safety Information before using this machine. It contains information related
to USER SAFETY and PREVENTING EQUIPMENT PROBLEMS.
How to Read This Manual
Notation Conventions
Whenever necessary, the following points for attention are indicated in this manual.
WARNING
Indicates a potentially hazardous situation which, if instructions are not followed, could
result in death or serious injury.
CAUTION
Indicates a potentiality hazardous situation which, if instructions are not followed, may result
in minor or moderate injury or damage to machine or property.
NOTE
This sign refers to:
•Remarks for making the operation much easier. You get practical hints or knowledge to
assist you in the machine operation such as:
•Preparations required before operating
•How to prevent papers from being misfed or damaged
•Precautions required or actions to take after misoperation
•Limitations like numerical limits, functions that cannot be used together or conditions
under which a particular function cannot be used or obtained.

Safety Information
When using this machine, the following safety precautions should always be followed.
Safety During Operation
WARNING
•To avoid hazardous situations such as electric shock or danger while exposed
to moving, rotating or cutting devices, do not remove any covers, guards or
screws other than those specified in this manual.
•Turn off the power and disconnect the power plug (by pulling the plug, not the
cable) if any of the following conditions exist:
•Before disassembling or assembling parts of the System and peripherals.
•You drop objects or spill something into the equipment.
•You suspect that your equipment needs service or repair.
•Machine covers have been damaged
•You notice unusual noises or odours when operating the equipment.
•If the power cable or plug becomes worn out or otherwise damaged.
•Before cleaning and care (unless otherwise specifically instructed).
•Electromagnetic compliance:
•This is a Class A product. In a domestic environment this product may
cause radio interference in which case the user may be required to take
adequate measures.
•The product (System) which is connected to this machine will be class A.
General Safety
WARNING
•Always connect the equipment to a properly grounded power source (wall
outlet). Wall outlet should be located near the system and easily accessible.
If in doubt, have the power source checked by a qualified electrician.
•Improper grounding of the equipment can result in electrical shock. Never
connect the machine to a power source that lacks a ground connection
terminal. This machine is destined for specific purpose only. Any use going
beyond this specific purpose is regarded as beyond the determination. The
manufacturer will not be liable for damages resulting from any use beyond the
determination, unallowed operation, respectively. The user alone bears the
risk.
•Do not make arbitrary changes or modifications to the machine. The
manufacturer will not be liable for modifications made at the machine on your
own and damages resulting thereof. EC declaration of conformity and the
mark CE will be invalidated if you make changes to the machine or to
individual components.
•Do not override or bypass electrical or mechanical interlock devices.
•The machine is to be used only by authorized and instructed persons. The
responsibilities on operating the machine have to be strictly laid down and
observed so that there are no unclear competences regarding safety aspects.
•Vent holes serve for air circulation to protect the machine from overheating.
Make sure that the holes are not covered.
•Do not expose fingers or other parts of the body to moving, rotating or cutting
devices, e.g. between upper and lower trimmer knives.
•Always locate the equipment on a solid support surface with adequate
strength tor the weight of the machine.

CAUTION:
•The machine and its peripherals must be installed and maintained by a customer service
representative who has completed the training course on those models.
•Always follow all warnings marked on, or supplied with, the equipment.
•When you disconnect the power plug from the wall outlet, always pull the plug (not the
cable).
•Disconnect the power cord before you move the machine. While moving the machine,
always exercise care and make sure that the power cord will not be damaged under the
machine.
•Always contact service if relocating the equipment.
•Do not move the machine while the machine is running.
•Do not open covers while the machine is running.
•Do not switch off the power while the machine is running. Make sure the machine cycle
has ended.
•Lay the power cord in a way that nobody will stumble over it. Do not place things on the
cord.
•Never attempt any maintenance function that is not specifically described in this
documentation.
•Always keep magnets and all devices with strong magnetic fields away from the machine.
•If the place of installation is air-conditioned or heated, do not place the machine where it
will be:
•Subject to sudden temperature changes.
•Directly exposed to cool air from an air-conditioner.
•Directly exposed to heat from a heater.
•If the machine is not used over an extended period of time it should be unplugged to
prevent damage in the case of overload.
NOTE:
•The operator manual always has to be available at the place of use of the machine.
•In the interest of technical development, the company reserves the right to make
alterations to specifications without prior notice.

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TABLE OF CONTENTS
What You Can Do with This Machine...................................................................................8
Guide to Components.................................................................................................... 9
VFL Feeder ................................................................................................................. 9
Feed Area.................................................................................................................. 10
User Interface............................................................................................................ 11
Tools and Accessories................................................................................................. 12
1Basics............................................................................................................................13
Paper........................................................................................................................... 13
Paper Guidelines....................................................................................................... 13
2Setting Up a Job ...........................................................................................................14
Getting Started............................................................................................................. 14
Turning the Machine On and Off............................................................................... 14
Paper Stack Preparation ........................................................................................... 15
Loading Paper........................................................................................................... 17
Feeder Table Extension............................................................................................ 18
The Home Screen........................................................................................................ 19
Overview ................................................................................................................... 19
Paper Size................................................................................................................. 20
Saving and Loading Jobs.......................................................................................... 22
Counters.................................................................................................................... 23
The Tools Screen ........................................................................................................ 24
Overview ................................................................................................................... 24
Feeder Settings......................................................................................................... 25
Checking for Software Updates................................................................................. 26
3Troubleshooting ...........................................................................................................27
Misfeeds / Jams........................................................................................................... 27
General...................................................................................................................... 27
Misfeed / Jam in the Feeder...................................................................................... 27
Fault Codes ................................................................................................................. 28
General...................................................................................................................... 28
List of Fault Codes .................................................................................................... 29
Accuracy Checks......................................................................................................... 32
Separation Pad Check .............................................................................................. 32
How to Get Support..................................................................................................... 33
4Remarks.........................................................................................................................34
Do’s and Don’ts ........................................................................................................... 34
Where to Put Your Machine......................................................................................... 35
Machine Environment................................................................................................ 35
Power Connection..................................................................................................... 35
Access to Machine .................................................................................................... 36
Maintaining Your Machine........................................................................................... 37
Recommended Weekly Operator Maintenance ........................................................ 37
Limitations of the VFL Feeder...................................................................................... 38
5Specifications ...............................................................................................................39
Machine Specification.................................................................................................. 39
General...................................................................................................................... 39
Physical Characteristics ............................................................................................ 39
Paper handling.......................................................................................................... 39
EU DECLARATION OF CONFORMITY [1] .................................................................. 40

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8
What You Can Do with This Machine
The Morgana VFL Feeder is a state-of-the-art paper feeding system.
•The vacuum top feed mechanism uses air knives together with advanced sensing to
separate, feed and accurately register sheets ranging from 93 x 210 mm (3.67” x 8.27”)
all the way up to 385 x 1300 mm (15.16” x 51.2”).
•Up to 200 mm (7.9”) high stack of paper can be loaded on the table.
•A built-in ultrasonic double sheet detector ensures only correctly separated sheets exit
the feeder.
•An intuitive touchscreen interface is used to set all job parameters ensuring that
operators of all skill levels can quickly set up and run jobs.
•This machine can feed up to 10 000 A4 sheets per hour.

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9
Guide to Components
VFL Feeder
1. Registration area
2. Vacuum belts
3. Paper guide tongues
4. Paper wall
5. Power switch
6. Paper table
7. Paper table extension
8. Power inlet and fuse
9. Storage shelf
10. Magnetic paper guides
11. Feeder skew adjustment
12. User interface (UI)
2
1
3
4
5
7
8
9
10
11
12
6

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10
Feed Area
1. User interface (UI)
2. USB port for software updates
3. Front separation fan
4. Paper separation pads
5. Vacuum belts
6. Paper guide tongues
7. Side float fan
8. Maximum paper stack height for sheets
shorter than 700 mm (27.6”)
9. Maximum paper stack height for sheets
longer than 700 mm (27.6”)
10. Paper stack height sensor Q4
11. Separated paper (SP) sensor Q12
12. Feeder skew adjustment wheel
13. Feeder skew adjustment locking knob
14. Registration (alignment) belts
15. Ultrasonic double sheet detector
(US DSD) Q10
3
1
2
4
5
6
7
10
9
8
11
13
12
10
5
15
14
6

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11
User Interface
The Morgana VFL Feeder has a Graphical User Interface (GUI) which allows for setting up
jobs and viewing / modifying machine settings and properties. Detailed descriptions of each
menu and sub-menu are found in Section 2 of this Operator Manual.
NOTE:
Depending on modules and features installed, the screen may look different from what you
see here. Some functions may be greyed out of not visible at all and remaining buttons will
stretch to fit the screen. This manual will most often show a fully configured system.
The control panel is of touch screen type. Point at the screen and press the “button” to reach
the desired function or change the desired setting.
The Home screen displays paper and job parameters. The operator can start, edit, pause or
abort the job from this screen.
To get started:
1. Load paper in the feeder tray and choose the correct paper size by clicking the Media
button from the top menu.
2. Choose the desired line speed on the Home screen.
3. Press the Play button to start the machine cycle.

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12
Tools and Accessories
The following tools and accessories are included with the VFL Feeder.
Component no
Qty
Description
601-167
1
Digital thickness gauge
142-115551
2
Multi-purpose wrench
201-111686
1
Screwdriver torx T20
201-111685
1
Hex wrench kit
960-108861
1
USB memory stick for performing machine software updates
601-185
1
Sensor cleaning brush
601-118
1
Roller cleaning brush
399-014-01
1
Calibration strip for ultrasonic double sheet detector
95177
1
Interlock cheater
125-113540
1
DFA (“Document Finishing Architecture”) kit for
communication with 3rd party machines

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13
1
1 Basics
Paper
Paper Guidelines
Paper comes in many different makes, types and finishes. There are many ways to print on
the paper and then protect that printed image. The grain direction, fibre structure, substrate
thickness, porosity, coating type, bond strength of the coating, water content, relative humidity
and many other things can affect how the paper will behave when it is separated and fed. We
recommend that you learn to identify these differences. Be prepared to make small
adjustments to the machine to stop any problems that they might cause.
Guidelines:
•Always make sure that the sheets of paper you use are cut square.
•Always make sure that all of the paper for a job is cut the same.

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14
2
2 Setting Up a Job
Getting Started
Turning the Machine On and Off
1. Ensure the main power cord is plugged in the machine [A] and the wall socket.
2. Toggle the main power switch [B] to turn the machine on.
3. To turn the machine off again toggle the main power switch [B] again.
A
B

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15
2
Paper Stack Preparation
Before loading paper in this machine, it is recommended to fan the sheets as shown.
1. Hold the paper stack on a flat surface.
2. Bend the paper stack.
3. Use your fingers and thumbs to pinch
the paper stack.
4. With the paper pinched between your
fingers, straighten out the paper stack.

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16
2
5. Flex the paper back and forth a couple
of times to break surface tension and
pre-separate the sheets.
6. Realign the sheets into a stack before
putting them in the machine.
NOTE:
If the sheets you are using are too stiff or too large format to carry out the above procedure,
fan the front edge of the sheets when loading them in the machine.

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17
2
Loading Paper
1. Take a stack of printed paper and place it on the feeder table in the desired orientation.
NOTE:
If using sheets longer than 450 mm (17.7”), but shorter than 700 mm (27.6”) extend the built-
in pull-out table. If using sheets longer than 700 mm (27.6”) see the “Feeder Table Extension”
section within this manual.
2. Ensure the paper is pushed into the corner and is aligned to both the
registration wall [A] and the front wall [B].
3. Align the magnetic paper guides [C] with the edges of the paper stack. Ensure the
guides are not too tight and the sheets can move freely.
NOTE:
To make sure the magnetic paper guides are not too tight put a single sheet of paper between
the stack and the guide when setting the guide.
A
C
C
B

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18
2
Feeder Table Extension
Install table extension if using sheets longer than 700 mm (27.6”):
1. Ensure the built-in pull-out table [A] is fully stowed.
2. Hook the table extension [B] into the lift [C] as shown.
NOTE:
The feeder table extension has a built-in pull out part that can be used to feed sheets up to
1300 mm (51”).
A
C
B

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19
2
The Home Screen
Overview
Element
Description
A
Home button
Returns to this screen
B
Media button
Set paper size and thickness for this job
C
Jobs button
Save / load job
D
Tools button
Access additional machine settings
E
Counter button
Set batch counter behavior
F
Line speed
Set the desired paper output speed
G
Gap between sheets
Set the desired distance between consecutive sheets
H
Total counter
Displays the number of sheets processed since it was last
cleared. “Clear” button resets it back to zero.
I
Batch counter
Displays the number of sheets processed in this batch and the
batch size. “Clear” button resets it back to zero.
J
Job name
Displays current job name. Asterisk (*) indicates that job
parameters have changed since the job was last saved.
K
Media type
Displays currently selected paper size and thickness
L
Feeder settings
Displays feeder operation mode –AUTO or Custom
M
Stop button
Stops the machine cycle
N
Proof / Pause button
Processes a single proof sheet with the current settings. If the
machine is running, pauses the cycle.
O
Play button
Starts the machine cycle with the current settings.
A
B
C
D
E
F
G
J
K
L
M
N
O
H
I

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20
2
Paper Size
To set paper size and type:
1. Choose Media from the
top menu in the Home
screen
NOTE:
Changing paper size or
thickness will reset any fine
adjustments that may have
been entered on other
screens.
2. Select one of the pre-
defined paper sizes. To
enter a custom size click
Edit
2.1. Click on Length and
Width to enter the
desired custom size.
Click the green tick mark
to confirm.