Digifold Operators Manual Issue 11

DOCUMENT
CREASING / FOLDING MACHINE

OPERATORS MANUAL
Morgana Systems Limited United Kingdom
Telephone: ( 01908 ) 608888 Facsimile: ( 01908 ) 692399
Website: www.morgana.co.uk
ISSUE 11 SEPTEMBER 2007

SERIAL No. 120681KCADC ONWARDS 120-101
INDEX
INTRODUCTION & SPECIFICATION

The Morgana Digifold PAGE 4
SAFETY Do’s & Don’ts 5
THE DIGIFOLD
Labeled Photograph 6
THE CONTROL PANEL
Detailed diagram and description 8
Features on the control panel 9
QUICK START GUIDE 10

OPERATING THE DIGIFOLD
Accessing Menus. 12
Accessing Menus Flow Chart 13
Set by Fold 14
Set by Position 16
Example of Set by Position 18
Adjusting the Papergate 19
Setting the Suction Slot 19
Setting the Adjustable Side Lay 19
Setting the Back-Stop 20
Setting the Air Distribution 20
Setting the Air Separation Pressure 20
Setting the Positions of Drive Wheels and Hubs 20
Setting the Extension Table 21
Setting the Delivery Conveyor System 22
Adjusting the Batch Count 23
Adjusting the Roller Gap 23
Storing Programs 24
Reading Stored Programs 24
Clearing Stored Program 24
Feeding Sheets Manually 25
THE DELIVERY UNIT
Setting the Delivery Conveyor System 26

THE BLADE ASSEMBLY
Adjusting the blade pressure 27
Adjusting the blade alignment 27
Page 2 CREASING / FOLDING

Digifold INDEX
REPLACING CREASING BLADE SETS
Installing new blade sets PAGE 29

Spare Blades 30
TROUBLE SHOOTING
Paper crease out of square 31
Paper fold out of square 31
Paper Jamming 31
Machine will not start 31
Paper not feeding 32
Machine not counting 32
Cracking of the printed material along the crease 32
Paper marking or scratching 33
No suction 33
Display reads ‘h’ 33
Display reads ‘Crunch’ 34
Fold Blade relocation. 34
Display reads ‘Clip P’ 34
Display reads ‘Clip 1’ 34
Display reads ‘Clip 2’ 34
Recommended weekly operator maintenance 35
DISPATCH KIT (120-95-01) 36

ACCESSORIES AND OPTIONS 37
RECOMMENDED SPARES 38 - 40
MACHINE CALIBRATION HISTORY SHEET 41
SYSTEM Page 3
INTRODUCTION
INTRODUCTION AND SPECIFICATION

DigiFold 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 90gsm,
upto and often above 300gsm. The DigiFold 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.
It is IMPORTANT to note that to prevent cracking, when using dry ink or toner based print
engines, the material must be fully acclimatised for at least 48 hours before putting an
image onto the paper.
IMPORTANT the operating environment should be controlled to a temperature between

16° C and 27° C Maximum.
Specification
Feeding System ................................................ Bottom suction feed
Max. Sheet Size ................................................630mm x 330mm
Min. Sheet Size .................................................140mm x 160mm (dependant on stiffness
of paper and type of fold).
Max. Paper Weight ........................................... 300gsm + (varies according to hardness,
type of fold, and substrate).
Min. Paper Weight ............................................ 120gsm
Max. No. Creases per Sheet ............................ 9
Max. No. Folds per Sheet.................................. 2
Max. No. Stored Programmes ...........................6
Min. Repeat Crease Distance ........................... 4mm (depending on paper weight)
Min. Repeat Fold Distance ................................70mm (depending on paper weight)
Min. Crease Distance from Leading Edge ........ 25mm
Min. Fold Distance from Leading Edge ............. 70mm (depending on paper weight)
Min. Crease Distance from Tail Edge ............... 25mm
Min. Fold Distance from Tail Edge .................... 70mm (depending on paper weight)
Max. Fold Length .............................................. 560mm
Min. Fold Length ............................................... 70mm
Speed per Hour (A4 Material) One Crease or One Fold..........1800 sheets
Speed per Hour (A4 Material) One Crease & One Fold ..........1800 sheets
Speed per Hour (A4 Material) Two Creases or Two Folds ......1400 sheets
Speed per Hour (A4 Material) Two Creases & Two Folds .......1400 sheets
Speed per Hour (A3 Material) One Crease or One Fold .........1440 sheets
Speed per Hour (A3 Material) One Crease & One Fold ..........1440 sheets
Speed per Hour (A3 Material) Two Creases or Two Folds ......1200 sheets
Speed per Hour (A3 Material) Two Creases & Two Folds ......1200 sheets
Note: The production speed varies according to the material size and
the number of creases or folds on the sheet.
Dimensions ....................................................... L: 1830mm H: 1185mm W: 555mm
Weight ............................................................... 180Kgs (+50Kgs packing)
Power Requirement .......................................... 1 phase 220 / 240v

Digifold 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 - 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 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.
SYSTEM Page 5
DOCUMENT CREASING / FOLDING MACHINE
Key to photograph below
6 Air distribution knob 11 Paper Gate
2 Delivery assembly 7 Adjustable side lay 12 Exit Guard
3 Suction slot knob 8 Back stop 13 High Level Display
4 Control panel 9 Fixed side lay 14 Extension table fixing
5 Air separation knob screws
2 12 11 8 6 13 9
14 7 5
3

Digifold
BLANK
PAGE
SYSTEM Page 7
The Control Panel
The Control Panel on the Digifold allows the operator to read, edit, create
and initiate numerous creasing / folding programs within the memory.
The top face of the control panel houses four pushbuttons as shown in the
diagram below. For the purposes of the instructions these buttons will be
described as Push Buttons 1, 2, 3, 4.
The front face of the control panel houses the Compressor switch,
System switch, Feed switch, Suction switch, Setting dial and Set-up switch.
Under the control panel is an industry standard Emergency Stop switch
which will stop all power going to the machine when activated.

Digifold The Control Panel
Features on the Control Panel

Push Button 1
Used for adjusting a crease / fold position in increments of 10mm when used with
the setting dial.
Also used for inching feed forward when in handle or crunch / Clip 1 or Clip 2
situation.
Push Button 2
Used for adjusting a crease / fold position in increments of 0.1mm when used with
the setting dial.
Also used for inching feed in reverse when in handle or crunch / Clip 1 or Clip 2
situation.
Push Button 3
Used for locating the bottom blade or anvil to its ‘Top Dead Center’ position in order
to set the blade pressure (whilst the system switch is on).
Also used to return the creaser blade to the ‘Home’ position after a ‘Crunch’ if
required.
Push Button 4
Allows the operator to save a created program. When also used with the setting
dial the operator can scroll through the stored memory addresses.
Also used for cycling the folder blade / feed forward.
Set-up switch
Allows the operator to enter and subsequently edit or read a stored program. Also
resets the batch quantity.
Setting dial
Allows the operator to scroll through stored memory addresses and programs,
increase or decrease the batch quantity and set a crease / fold position.
Suction switch
Allows the operator to vary the length of suction on the sheet of paper being fed.
Position I For very short sheets.

Position II For short non-standard sheets.
Position III For all standard size sheets, general purpose.
Feed switch
Allows the operator to start and stop feeding sheets.
System switch
When activated the system switch will operate the motors in order to begin the
creasing / folding sequence.
Compressor switch
Allows the operator to switch off the compressor unit in order to utilize the machine
to manually feed sheets.
SYSTEM Page 9
Quick Start Guide
Setting the machine to operate in automatic mode.

(i.e. ,Set by Fold’)
1. Set the gap between the paper gate and the vacuum roller to
approximately twice the thickness of the stock to be creased.
(See page 19)
2. Place the stock to be creased onto the loading table against the
fixed side lay. (See page 19)
3. Release the clamps on the adjustable side lay and slide up to the
paper stack allowing a gap of approximately 0.5mm (1/64 inch)
between the paper and the side lay. (See page 19)
4. Place the backstop on to the adjustable side lay and slide up to

the paper stack, also allowing a gap (as stated in the above step)
before clamping. (See page 21)
5. Now follow the step by step instructions shown on page 11.
To manually feed sheets see instructions on page 25.

To ‘Set by Position’ see instructions on page 16.

Digifold Quick Start Guide
OPERATION INSTRUCTIONS
Step 1
Turn the Emergency Stop button clockwise
to switch the power on.
Step 2
Set the Set Up switch to its Mid- position.
Mid-Posn.
Step 3 SET MACHINE TO ‘SET BY FOLD’ Turn the Setting Dial clockwise until the
(’SEt FoLd’ or ‘SEt Pos’)
display reads ‘SEt FoLd’ or ‘SEt Pos’, flick
the Set Up switch upwards to change from
one to the other.
Step 4 SET FOLD & CREASE Turn the Setting Dial anti-clockwise until the
(’on’ or ‘off’)
display reads ‘CrEES’ or ‘FoLd’, flick the Set
Up switch upwards to select ‘on’ or ‘oF’ for
each as required.
Step 5 SET FOLD TYPE Turn the Setting Dial anti- clockwise to
To Change Fold Type
Select TypIcal Typical select the Main display, flick the Set Up
Main Display Display
switch down, press the pushbutton and turn
LcF 10 tYPE L
the Setting Dial.
Step 6 SET PAPER LENGTH Turn the Setting Dial clockwise to select
To Change Paper Length
Typical ‘LEn’, press the pushbutton and turn the
Display
Setting Dial to set the paper length in 10mm
LEn 100.0
or 0.1mm increments.
Step 7
Flick the Set Up switch up to its Mid-
position
Step 8
Switch the System switch on.
Step 9
Switch the Compressor switch on.
Step 10
Switch the Feed switch on to begin feeding
sheets
SYSTEM Page 11
Operating the Digifold
Accessing Menus.
Main Menu.
1. The mains switch on the machine must be off.
2. Set the Set-up Switch to its mid position and then turn the mains switch on.
3. The Main Menu functions can then be accessed by turning the Setting Dial
clockwise or anti-clockwise as shown.
Clockwise Anti-clockwise
CrEES on / oF = crease on or off bAt = batch
FoLd on / oF = fold on or off rG .00 .00 = roller gap
dELrY on / oF = delivery on or off
SEt PoS / FoLd = set by position or set by fold
F_cLr on / oF = fold blade clear of paper to reduce the possibility of marking or
scratching sensitive paper, on or off
Sub-menus.
To access the sub-menus flick the Set-up switch to the down position and turn the
Setting Dial clockwise or anti-clockwise.
Sub-Menu in Set by FoLd mode (set by fold)

tYPE L = type of fold i.e. L = letter fold rPoS 150 = delivery roller position
Len 100 = paper length Shin 41 = shingle (amount delivery wheel turns)
PAPEr 3 = type of paper (0= light 3 = heavy)
Cr1 0.0 = crease 1 position
Cr2 0.0 = crease 2 position
F1 0.0 = fold 1 position
F2 0.0 = fold 2 position
Sub-Menu in Set by PoS mode (set by position).

1 Cr = crease position 1 rPoS = delivery roller position
Shin = shingle (amount delivery wheel turns)
9 Cr = crease position 9
F1 = fold 1 position
F2 = fold 2 position
rESEt = reset

Digifold Operating the Digifold
SYSTEM Page 13
SET BY FOLD
Typical Set by Fold main display screen
LcF 0
fold type fold on count

L = letter
crease on
1. Turn the Emergency Stop button clockwise to switch the power on, and select the
main display screen.
2. Set the Set Up switch to its Mid-position.
3. Turn the Setting Dial clockwise until display reads ‘SEt FoLd’ or ‘SEt Pos’, flick the
Set Up switch upwards to change from one to the other. (select ‘SEt FoLd’)
4. Turn the Setting Dial anti-clockwise until the display reads ‘CrEES’ or ‘FoLd’, flick the
Set Up switch upwards to select ‘on’ or ‘oF’ for each as required.
5. Turn the Setting Dial anti-clockwise to select the main display, flick the Set Up
switch down, press and hold down the pushbutton PB1 and turn the Setting Dial to
select fold type i.e. h C G etc. Release pushbutton Pb1.
6. Turn the Setting Dial clockwise to select paper length ‘LEn’.
7. Hold down PB1 or PB2, and turn the Setting Dial clockwise to adjust the paper
length in 10.0mm or 0.1mm increments. Release PB1 or PB2.
8. Turn the Setting Dial clockwise to select paper type ‘PAPEr’, i.e. stiffness of paper,
not necessarily the paper thickness.
9. Hold down PB1 and turn the Setting Dial to adjust the paper type. Release PB1.
i.e. PAPEr 0 is for lightest stock
PAPEr 1 is for light stock of 120 gsm upwards
PAPEr 2 is for heavy stock of 180 gsm upwards
PAPEr 3 is for heaviest stock of 200 gsm upwards
NOTE: These paper types are a guide only, all four settings should be tried
before adjusting the crease or fold positions.
10. Set the Delivery Conveyor System as described on page 22.
11. Adjust the Batch Count as described on page 23, if required.
12. The program settings can now be stored, if required, as described on page 24.

13. Run the job by switching the System and Compressor switches on, then
switch the Feed switch on.
14. View the results, the ‘micro adjust’ function can be used to adjust positions.
15. To ‘micro adjust’ the crease position, turn the Setting Dial clockwise until Cr1 is
displayed. This will be the calculated length of the crease position.
Press and hold PB1 and the display shows 0.0
To ‘micro adjust’, hold down PB1 and turn the Setting Dial to adjust in either direction
ie +3.1mm to -3.1mm Max.
Release PB1.
16. To ‘micro adjust’ the fold position, turn the Setting Dial clockwise until F1 is displayed.
This will be the calculated length of the fold position.
Press and hold PB1 and the display shows 0.0
To adjust hold down PB1 and turn the Setting Dial to adjust in either direction
ie +3.1mm to -3.1mm Max.
Release PB1.
NOTES:-
If a crease position is ‘micro adjusted’, the fold will move with it.
If a fold position is ‘micro adjusted’, then only the fold will move.
‘Micro adjust’ a fold only if the fold appears to be giving an out of square result
or cracking appears.
The fold is probably too close to the center of the crease and will be trying to
fold from one side of the crease to the opposite side of the crease (see page 16
for explanation).
SYSTEM Page 15
SET BY POSITION
IMPORTANT NOTES.
1. If the fold is too near, or on the center line of the crease; the fold will try to fold
diagonally across the crease profile and pull the fold out of square to the paper.
The best fold squareness is achieved when the fold is not on the center line of the
crease, it should be to one side of the crease center line as shown below.
Thus for a crease setting of Cr1 = 100 for example, the fold should be set to a figure
slightly smaller or greater than 100.
ideal fold line ideal fold line

center line of crease
2. When using Set By Position, all dimensions are from the leading edge of the paper
as shown in the example on page 18.
Typical Set by Position main display screen
2cF 0
number of fold on count

creases
crease on
1. Turn the Emergency Stop button clockwise to switch the power on, and select the
main display screen.
3. Turn the Setting Dial clockwise until display reads ‘SEt FoLd’ or ‘SEt Pos’, flick the
Set Up switch upwards to change from one to the other. (select ‘SEt Pos’)
4. Turn the Setting Dial anti-clockwise until the display reads ‘CrEES’ or ‘FoLd’, flick the
Set Up switch upwards to select ‘on’ or ‘oF’ for each as required.
5. Turn the Setting Dial anti-clockwise until the main display screen is displayed and
switch down the Set-up switch

6. Turn the Setting Dial clockwise to select ‘1 cr’
7. Hold down PB1or PB2 and turn the Setting Dial to adjust the crease position in
10.0mm or 0.1 mm increments. Release PB1 or PB2.
(this can be done on all further crease positions)
8. Turn the Setting Dial clockwise to ‘2 cr’ etc. (there are 9 crease positions in total)
Note:- the crease positions must increase upwards. (i.e. ‘1 cr’ must be less than
‘2 cr’, ‘2 cr’ must be less than ‘3 cr’ etc)
If any of the nine available crease options (’1 cr’ to ‘9 cr’) are not required for
the job being set up, they must be set to ‘0’
9. Continue turning the Setting Dial clockwise to ‘F1’.
10. Hold down PB1 or PB2 and turn the Setting Dial to adjust the fold position in 10.0mm
or 0.1 mm increments. Release PB1 or PB2 and turn the Setting Dial clockwise.
‘F2’ is the last fold position.
Note:- the fold positions may be in any order. (i.e. ‘F1’ can be larger than ‘F2’)
If the fold option F2 is not required for the job being set up, it must be set to ‘0’
11. Set the Delivery Conveyor System as described on page 22.
12. Adjust the Batch Count as described on page 23, if required.
13. The program settings can now be stored, if required, as described on page 24.
14. Run the job by switching the System and Compressor switches on, then
switch the Feed switch on.
NOTES:-
Once the Set by Position has been selected, if returned to Set by Fold the default
length of 100 will be found and any previous settings will be lost unless stored.
Deflect knife position.

If “fold off” is selected then both knives will go to the double deflect settings which
are determined by the paper type setting.
If in “set by fold” and doing a Half fold then the 1st knife will be set to the deflect
position which is determined by the paper type setting.
When using Set by Position if only one fold is required, always set this on F2 and
set F1 at 0.0. If the leading edge of the sheet buckles up, adjust F1 to 0.5 for PAPEr
type 1, 1.0 for PAPEr type 2 and 1.5 for PAPEr type 3.
SYSTEM Page 17
Example of Set by Position.

Paper Length = 350mm
Feed Direction
Leading Edge
Cr1 Cr2 Cr3

SETTINGS F1 F2
Cr1 = 97.0mm
Cr2 = 179.0mm
Cr3 = 260.0mm All dimensions are from the leading edge of the paper
F1 = 179.0mm
F2 = 260mm
Cr2 = 179.0
F1
Cr3
= 260.0
F2
9mm
Leading Edge Leading Edge
First Fold Second Fold
9mm
Leading Edge
9mm
Finished Document

Adjusting the Paper Gate

The standard setting for horizontal adjustment of the paper gate is 6.5mm (1/4") away
from the mounting block. Turn disc J to make this adjustment. This setting is only intended
as a guide, for instance, sheets with an upward curl will require this setting to be
increased. Set the height of the Paper Gate to approximately two thicknesses of paper, by
turning knob K. An excessive gap is a most likely cause of double sheet feeding.
6.5mm (1/4")
K J
T W O T H ICK NE S S E S
OF P AP E R
IMPORTANT:-
To avoid possible damage to the suction drum,
when adjusting the paper gate height, ensure that
the disc is located over a solid section of the
suction drum and not over a slot in the drum.
Do not adjust the paper gate while the machine is
running.
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.
Setting the Adjustable Side Lay

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 shown in FIG 16.1. Allow a gap of approximately 0.5mm (1/64 inch) between
the paper and the side lay.
Adjustable
Side Lay
SYSTEM Page 19
Setting the Back-Stop

Place the back-stop on to the adjustable side lay and slide up towards the paper stack
allowing a gap (as specified in the above step) before clamping. When the extension table
is used for feeding longer sheets, remove clamp type back stop and use the magnetic
type back stop as shown in fig. 18.2.
Setting the Air Distribution

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 1 is
recommended for most sheet sizes. However, a better result may be obtained by using
the below settings or by experimentation.
Position 1 - For A5 sheets or 8 inches long, front port and port 1 open.
2 - For A4 sheets or 11 inches long, front port and port 2 open.
3 - For A3 sheets or 17 inches long, front port and port 3 open.
0 - For longer sheets in order to supply air to the centre of the stack, port
1 and port 2 open.
Setting the Air Separation Pressure

To control the amount of air supplied to the ports, the air separation knob can be adjusted
By first rotating the knob to unlock its position, then push the knob down to the required
Position and rotate the knob to re-lock its position.
Setting the positions of drive wheels and hubs

It is important that the drive wheels and drive hubs on the roller shafts are arranged evenly
across the width of the media being creased. This is done to ensure that the media is
accurately driven and supported through the rollers.
The drive wheels and hubs are fixed to the rollers by means of a grub screw. To locate this
grub screw the rollers can be rotated by operating the motor manually.
DO NOT ROTATE THE DRIVE ROLLERS BY HAND.

To operate the motors manually, switch the machine ‘on’ at the Emergency Stop switch.
Whilst holding down Push Button 1, flick the Set-up switch to ‘set up’.
The display will now read ‘hAndLE’. Press the System switch to ‘on’ and use Push Button
1 (forward) and Push Button 2 (reverse) to manually rotate the rollers in short pulses.
Rotate the rollers until the grub screw is located. Lift the exit guard and the machine will
switch ‘off’ automatically. Loosen the drive wheels and hubs by using a 2mm allen key.
Arrange the drive wheels and hubs as shown in FIG 18.1. In order to avoid marking on
some types of media ensure a gap between the drive wheels and drive hubs.
Setting the extension table

The extension table can be fixed to the machine in order to feed through longer sheets.
The table can be supported by the two fixing screws as shown on page 6.
The back stop can be used to support the paper stack as shown in FIG 18.2 below.
The other back stop supplied with the machine can be used as a tool holder as shown in
FIG 18.3 below.
SYSTEM Page 21
Setting the Delivery Conveyor System.

WARNING:-
The Digifold will not start if the delivery unit is not fitted onto the machine.
Turning the delivery system ‘on’ or ‘off’
1. Set the Set Up switch to its mid-position.
2. Turn the Setting Dial until the display reads ‘dELrY’ on or off.
3. Flick the Set Up switch upwards to toggle between ‘on’ and ‘off’.
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 (rPoS) and Shingle Length (Shin) are automatically set, relative to the paper
length and type of fold selected.
When using the ‘Set by Position’ mode of operation; the Roller Position (rPoS) and Shingle
Length (Shin) must be adjusted manually to suit the job, as described below.
Adjusting the Roller Position and Shingle Length. (See FIG 19.1)
1. Flick the Set Up switch down.

2. Turn the Setting Dial anti-clockwise to ‘rPoS’ (roller position), or
‘Shin’ (shingle length) as required.
3. Press and hold pushbutton PB1 and turn the Setting Dial, the numbers
displayed are pre selected lengths in millimeters (to reduce setting times).
4. When the optimum settings for ‘rPoS’ and ‘Shin’ are achieved they can be
stored with the job (see Storing Programs on page 24).
FIG 19.1
‘Shin’
(Shingle Length)
‘rPoS’
(Roller Position)

Adjusting the Batch Count

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.
The batch count is set as follows:-

2. Turn the Setting Dial until the display reads ‘bAt’.
3. Press and hold pushbutton PB1, and turn the Setting Dial to set the batch
quantity required. (the batch quantity changes in multiples of 10)
NOTE. Beware, if pushbutton PB1 is not held down, the display will register the
adjustment to the batch quantity but will not change within the program.
4. The Batch Count can be stored with the job if required (see Storing Programs
on page 24)
Adjusting the Roller Gap

The Roller Gap adjusts the gap between the large fold rollers, (see FIG 20.1).
The Roller Gap may require adjustment if thick paper is being folded, or if cracking of the
print is noticeable.
The Roller Gap is adjusted as follows:-

2. Turn the Setting Dial until the display reads ‘rG 00 00’.
3. The Roller Gaps are adjusted by turning the ‘Fold Gap 1’ or ‘Fold Gap 2’ knobs
on top of the folder unit. (the Roller Gap changes in increments of 0.05mm)
Roller Gap 2
FIG 20.1
INFEED
Roller Gap 1
SYSTEM Page 23
Storing Programs
A maximum of 6 programs, of crease / fold settings, can be stored in the machine.
When the crease / fold settings have been correctly entered, the program can be
stored as follows:-
1. Flick the Set Up switch down and then back up to its mid-position, the display
reads ‘StorE 1’
2. Turn the Setting Dial in either direction to cycle through the 6 memory addresses
available.
3. To store a program to the displayed address, press the pushbutton PB4.

The display reads ‘StorEd’
Reading Stored Programs

Hold down pushbutton PB4 and turn the Setting dial in either direction to cycle through
the memory addresses. When any one of the 6 addresses are displayed release PB4 to
view the stored program at that memory address.
A typical program will show 3cF 100 see page 16 for explanation.
To view or edit any of the creases or folds within the program, refer to steps 4. to 9. on
the ‘Set By Position’ instructions on pages 16 and 17.
Clearing Stored Programs

Whilst viewing any of the stored programs, set the Set Up switch down and turn the
Setting Dial clockwise until the display reads ‘rESEt’.
Press pushbutton PB4 to clear the stored program.

Feeding Sheets Manually

In order to feed heavy stock, very small or very large sheets, embossed or even
irregular shaped sheets, it may be required to operate the machine manually.
The machine can be programmed and set up in exactly the same way as explained
when operating the machine automatically. However, when setting up the machine the
paper gate must be raised to its highest position for the sheets to be fed freely.
Operating the machine manually will also require the suction length to be continuous in
order to accommodate various types of stock. Therefore, the suction length switch
must be positioned at ‘III’.
The machine can now be started by activating the System switch to ‘on’. Do not
activate the Compressor switch. Flick the Feed switch to ‘on’ and begin to slide the
sheets individually through the paper gate until they are driven by the drive belts.
To stop feeding the sheets, flick the Feed switch to ‘off’ and then the System switch to
‘Off’.
SYSTEM Page 25
The Delivery Unit
The delivery unit on the Digifold is used to catch the sheets once they have been
creased, or folded.
WARNING:-
The Digifold will not start if the delivery unit is not fitted onto the machine.
Assemble the delivery unit as shown in FIG 23.1.
1. Hook the delivery unit onto the shaft in the positions shown below, being careful to
align the mating connectors.
2. Locate the Support Hoop into the channel on the underside of the delivery unit.
Hooks to be Located onto shaft

in these positions
Location Hooks
Delivery Unit
Connector
Support Hoop
FIG 23.1

Digifold The Blade Assembly
Adjusting the blade pressure (no paper required)

1. Turn the Emergency Stop button clockwise to switch the machine ‘on’.
2. Activate the system switch and the motors will begin to operate.
3. Flick the ‘Feed’ switch to ‘on’ and then back to ‘off’ to ensure that the lower blade /
anvil is at its bottom position.
4. Press Push Button 3, the machine will automatically switch off and the lower blade /
anvil is set to its top position where the pressure can be adjusted. Raise the exit guard.
5. Using a 6mm allen key, unlock the shoulder bolts (labelled with scale transfer)
positioned at each end of the creasing blade.
6. Turn the adjustment cam to adjust the blade pressure. Increasing the gradient on the
scale will increase the blade pressure.
7. Ensure that the shoulder bolts are locked after setting.
The diagram below demonstrates the adjustment of blade pressure
Adjusting the blade alignment

It is extremely important that the blade and anvil assembly within the creasing unit is
correctly aligned. Misalignment of the blade or anvil can lead to damaged profiles and
subsequently poor quality creasing so it must, therefore, be corrected immediately.
SYSTEM Page 27
The Blade Assembly
If the blade set is misaligned, the media being driven will be subject to scoring or even
tearing at any point along the crease line. Please note that to avoid damage to the
blade set, adjustment should only be made in small increments. The sketch below
demonstrates how the blade alignment can be carried out.
Adjustment can be made at either of the blade or anvil. The two clearance holes
positioned above the roller tilt mechanism are the front alignment (one for blade, one for
anvil). The two holes are repeated on the back of the machine for the back alignment.
1. Remove the stacker unit from the Digifold.
2. Using a 3mm allen key, loosen the cap head type locking screws located on the
front face at both ends of the blade /anvil as shown below.
3. Using a 4mm allen key, locate the two front or back alignment screws in the side
frame in order to adjust the blade / anvil.
4. The upper screw of the two, will adjust the upper blade / anvil whereas the
lower screw will adjust the lower blade / anvil both in very small increments.
5. In order to obtain the required position, adjust either the blade or the anvil by a
small amount and then operate the machine to test the form of the crease.
Repeat the exercise until centralisation is located.
6. Using a 3mm allen key, lock the cap head type screws (as per step 3) on both the
upper and lower blade / anvil.

Digifold Replacing Blade Sets
1. Before removing the blade assembly, ensure that the lower blade / anvil is NOT
at ‘top dead centre’, ie. Push Button 3 has not been pressed. Switch the machine off.
2. Remove the delivery unit and lift the top guard.
3. Using a 6mm allen key, loosen the socket

Blade Extractor Tools head screws located inside the blade
adjustment cams. Remove the screws and
the blade adjustment cams.
4. Insert the blade extractor tools (70-055-01 &

70-055-02) into the holes in the adjustment
links, as shown. Push downwards on the
handles of the blade extractor tools to
release the blade assembly from the power
links.
5. Slide the blade assembly out of the creasing

unit and lay it on a flat surface.
6. Slide the adjustment links away from the

dowels located in the ends of the blades /
anvils as shown in the photograph (left).
7. Place the new blade set into position.

Check that the eccentric shoulder bolts on
the link plates have been positioned as
shown in fig 26.1.
8. (Upper blade / anvil only)

Slide the adjustment links onto the dowels.
9. Slide the new blade set into the slots of the

FIG 26.1 creasing unit as shown in fig. 27.1.
Locate the blade extractor tools into the holes in

the adjustment links as shown. Pull the handles
of the blade extractor tools upwards to engage
the blade assembly back into the power links.
10. Set the cam graphics for both ends of the blade /
anvil to their lowest point on the scale (ie. When
the mark on the scale reaches the mark on cam
holder) Fasten the socket head screws on the
adjustment cams until they are tight.
SYSTEM Page 29
Replacing Blade Sets
11. Push the exit guard down and replace the delivery assembly before operating the
machine.
12. Switch the machine on and test the crease for form.
If the pressure and the alignment of the crease is not to a satisfactory level,
see pages 27 and 28 to adjust the creasing line.
‘Spares’ kits
In the event of any damaged or lost components within the blade assembly, spares kits
are available on request. However, components within the blade set can not be ordered
separately i.e. single blade or anvil.
Standard Blade set (fitted to Digifold as standard) Part number 76-213-01

Consisting of a standard blade and anvil, blade brushes, blade links and alignment bolts.
Extra Narrow Blade set (optional) Part number 76-213-03

Consisting of a special extra narrow anvil, a standard blade, blade brushes, blade links
and alignment bolts.

Digifold Trouble Shooting
Paper crease out of square

! Check that the sheets are all square and exactly the same size before loading the
stack on to the table.
! Check that the adjustable side lay has been correctly positioned ie. No further than
0.5mm from the paper stack.
! Check that the blade is a slide fit in the side plate slots, adjust if necessary, see
adjusting blade alignment.
Paper fold out of square

Note:- the best fold squareness is achieved when the fold is not on the center of the
crease, but to one side or the other.
! Check that the fold is to one side of the crease center line.
! Check that the roller gap is not too tight and squashing the crease.
! Check that the roller gap is not too large and allowing the paper to slide (especially
so on glossy paper).
! Check that the rollers are not worn on one end.
Paper jamming
! Check that the leading edge of the paper is not being damaged by the paper gate. If
this is occurring, check that the suction slot and the paper gate have been correctly
set.
! Check that the first crease / fold position is not too close to the leading edge of the
paper. A minimum distance of 40mm is recommended.
! If jamming is occurring in the out feed rollers, open up the roller gap. (See page 23)
Machine will not start

! Check the power supply to the machine.
! Check that the emergency stop button has been released.
! Check that the two top guards are down.
! Check that the delivery unit is fitted, and located correctly, (the machine will not start
if the delivery unit is not fitted).
! Check that the lower blade / anvil is connecting to the home switch (mounted below
the lower blade / anvil).
SYSTEM Page 31
Trouble Shooting
Paper not feeding

! Check that the paper stack is not too high or too heavy for the feeder. The height of
the paper stack should be defined by the weight and the size of the stock being
creased.
! Ensure that the adjustable side lay is not pressed against the paper stack. However,
if the clearance between the adjustable side lay and the paper stack is too great, the
air supply will escape instead of blowing through the paper thus making it difficult to
feed.
! Check that the clearance between the paper gate and the suction roller is not set too
low.
! On digital media, the feeding performance may be improved if the leading edge of
the stack is trimmed before loading onto the Digifold.
! Check that the air distribution has been correctly set.
! Check that the air separation has been set high enough to feed the sheets.
! For heavy stocks, very small or very large sheets, embossed or even irregular stock,
it may be necessary to feed the sheets manually - see page 25
Machine not counting

! Open the top and remove the blade set
(see pages 29-30) to access the dual
sensor post located in between the drive
rollers. Using a soft brush, clean the
visible sensor on the end of the post.
Use the brush to clean the sensors
between the post and the bottom paper
guide which are not visible.
Photograph (left) shows the dual sensor
post containing the sensors.
Cracking of the Printed Material along the Crease.

Cracking of the material along the crease may be caused by the following:-
! Pressure too heavy on the top blade - reduce pressure.
! Crease too narrow for heavy stock - change the blade to the standard blade set (part
number 76-213-01).
! Cracking on one edge caused by misalignment of the anvil and blade - realign blades
using cams at sides (see FIG 26.1 on page 29).

Cracking of the Printed Material along the Crease. (continued)

! When using dry ink or toner based print engines, the material must be fully
acclimatised for at least 48 hours before putting an image onto the paper.
Paper marking or scratching.

! If the paper is marking or scratching set ‘F_cLr’ to ‘on’, as described below.
This function is used to withdraw the top fold blade from the nip position, when paper
is in the fold roller. This reduces the possibility of marking or scratching sensitive
paper. On certain folds, gate types for instance, ‘F_cLr’ should be set to ‘off’ because
the trailing edge of the paper will catch on the withdrawn blade.
IMPORTANT NOTE.
If F_cLr’ has been set to ‘on’, any subsequent change to the programme settings will
automatically return ‘F_cLr’ back to its default setting of ‘off’; and it must therefore be
set back to ‘on’ again.
Setting ‘F_cLr’ to the ‘on’ position.

1. Select the main display screen (see pages 11 and 13 to identify main display).
3. Turn the Setting Dial clockwise until the display reads ‘F_cLr’.
4. Flick the Set Up switch upwards to select ‘on’.
! If the rollers are marking the media, open the roller gap (see page 23).
No suction
! If the suction drum is not rotating, check all of the drive belts for cleanliness and splits
(including the bottom in-feed roller drive belt).
Display Window Reads
! ‘h’
If at any time during the creasing / folding process the display window reads ‘h’, it is
indicating that the lower blade / anvil has not made contact with the HOME switch.
i.e. Blade still in top position. Switch the machine off and remove the blade set,
ensure that the area is free from obstructions. Return the blade set to the creasing
unit and switch the machine on. Operate the machine in the normal sequence, if the
letter ’h’ continues to appear it is advised to contact a Service Engineer immediately.
SYSTEM Page 33
Trouble Shooting
! ’Crunch’ (Paper Jamming)

In the event of a paper jam occurring whilst the machine is operating the display
window will read ‘crunch”.
In order to remove the paper causing the jam:-
Push Button 1 and Push Button 2 can be used to manually operate the motor.
Push Button 1 will drive paper forward, in short pulses.
Push Button 2 will drive paper in reverse, in short pulses.
Push Button 4 will cycle the fold knives and drive the roller forward.
When pressed, the push button will activate the rollers for a short movement. For
continuous movement, press and release the push button repeatedly.
If the sheet remains jammed, check that the lower blade / anvil is not clamping the
sheet. If so, press Push Button 3 to lower the blade / anvil to release the jammed
sheet. When the paper jam has been removed, make sure the feed switch is off and
then press the Set Up switch up to clear ‘crunch’ from the display window.
Note .- As a safety device to overloading, the fold knives will be ejected from their drive /
location lugs.
To replace fold knives.- using two red handled allen keys (2.5mm as supplied)
align the holes in the blade drive gears (black lugged gears) with the brackets
attached to the mechanism side plates, each side. The gears may be turned by
hand. Insert the allen key through the slots in the top cover to lock the mechanism
and align the blade drive pins both sides with the lugs on the gears, with a small
amount of pressure on the rear face of the blade it will clip into position.
! ‘cLiP P’
If the Feed switch is turned off while a piece of paper is still feeding (but has not
reached the first fold roller), the machine will stop and the display window will read
‘cLiP P’. Use Push Buttons 1, 2, and 4 to remove the paper causing the jam; as
described above under the heading ‘crunch’. When the paper jam has been
removed, make sure that the Feed switch is off and then press the Set Up switch up
to clear ‘cLiP P’ from the display window.
! ’cLiP 1’
If the machine stops and the display window reads ‘cLiP 1’ this indicates that paper
has jammed in the rollers. Use Push Buttons 1, 2, and 4 to remove the paper
causing the jam; as described above under the heading ‘crunch’. If the jammed
paper can only be removed by inching the paper forward, the jammed paper will be
found on the underside of the delivery unit. When the paper jam has been removed
make sure that the Feed switch is off and then press the Set Up switch up to clear
‘cLiP 1’ from the display window.
! ’cLiP 2
If the machine stops and the display window reads ‘cLiP 2’ this indicates that paper
has jammed in the rollers. Use Push Buttons 1, 2, and 4 to remove the paper
causing the jam; as described above under the heading ‘crunch’. When the paper
jam has been removed, make sure that the Feed switch is off and then press the Set
Up switch up to clear ‘cLiP 2’ from the display window.

Recommended weekly operator maintenance

! Clean all sensors
! Clean in feed rollers and output drive hubs using the Morgana cleaning kit
(Morgana cleaning kit part number 90-018)
! Remove and clean the blade assembly
! With the blade assembly removed, clean the slots and surrounding area within the
creasing unit; add a small amount of grease to the slide ways.
Technician Maintenance
It is recommended that your Morgana Digifold is fully serviced at least once every six
months by a factory trained Service Engineer.
SYSTEM Page 35
120-95-01 DISPATCH KIT
ITEM PART NUMBER QTY DESCRIPTION

1 120-101 1 OPERATORS MANUAL - DIGIFOLD
2 90-018 1 ROLLER CLEANING KIT
3 121-006 1 TILT LEVER
4 613-316 1 POWER CORD CE UK 3Pin
5 617-004 4 GLASS BALL - Ø20
6 403-01-030-006 12 SCREW - SOCKET CAP HEAD - M3 x 6 LG

7 409-01-040-004 1 SCREW - SKT. SET FLAT PT. - M4 x 4 LG
8 620-007 1 HEXAGON BALL DRIVER 2mm

9 620-020 2 HEXAGON BALL DRIVER 2.5mm
10 620-004 1 ALLEN KEY 4mm
11 620-026 1 BONDUS L WRENCH 4mm

14 624-018 1 DISPATCH BOX
15 70-055-01 1 BLADE EXTRACTION TOOL - OP SIDE
16 70-055-02 1 BLADE EXTRACTION TOOL - LAY SIDE

Digifold ACCESSORIES AND OPTIONS
ITEM PART NUMBER DESCRIPTION

1 76-213-03 BLADE SET - 320 Wide - Extra Narrow
ACCESSORIES.... OPTIONS....
....May be obtained from ....May also be obtained and
your dealer and fitted to your fitted by your dealer. You should
machine using the instructions not attempt to fit options as
supplied, or by reading your specialist tools and knowledge are
operators manual. required.
SYSTEM Page 37
RECOMMENDED SPARES
PART NO. QUANTITY DESCRIPTION

606-028 1 Foot - Black
606-035 1 Knob - Roller Tilt
607-038 1 Twin Grip Timing Belt - 200DXL
607-040 1 Torque Disk - White
607-041 2 Timing Belt - 110XL 037
607-042 1 Timing Belt 160XL
607-045 1 Multi Beam Coupler Size 13
607-046 2 Timing Belt - 540XL 037
607-047 2 Timing Belt - 564XL 037
607-146 1 Timing Belt - 132XL 037
608-019 1 Shoulder Bolt - Adjustment Cams
609-011 1 ‘O’ Ring Ø20
609-013 1 ‘O’ Ring Ø25
609-014 1 ‘O’ Ring Ø15
609-022 1 ‘O’ Ring Ø32
613-137 1 Plunger and Spring
613-191 1 Micro Switch - Home Circuit
613-237 1 Cap - Ø15
613-255 1 Solenoid Coil
613-351 1 Micro Switch - Guard Circuit
613-365 1 Emergency Stop Switch
613-385 1 Knob Ø15
652-011 1 System Switch
681-007 1 Fuse - 3.15A - Time-Delay - (20 x 5mm)
75-040 1 Stacker Switch Assembly
75-077 1 Control PCB Assembly - Digifold
75-082 1 Display PCB Assembly
75-098 1 Switch Assembly - Feed
75-100 1 Switch Assembly - Set-up
75-101 1 Switch Assembly - Rotary Setting Dial
76-042 1 Drive Belt - Feed Bed - Ø4 Polycord
76-058 1 Anti-Static Brush - Autocreaser
76-082 1 Perforator - Drive Hub Assembly
76-083 1 Perforator - Drive Wheel
76-109 1 Power Link Bearing

Digifold RECOMMENDED SPARES

76-203-01 1 Input Roller Assy - Upper
76-203-02 1 Input Roller Assy - Lower
76-204 1 Output Shaft Assembly
76-213-01 1 Blade Set - 320 Wide - Standard
76-228 1 Upper Sensor Assembly
76-229 1 Paper Jam Sensor Assembly
76-230 1 Paper Guide Assembly - Bottom Sensor
93-021 1 Feed Belt
93-022 1 Drive Belt - Vacuum Roller
94-028 1 Lock Pin Assembly - Side Lay
79-040-01 1 Hose - Air Seperation
79-041-01 1 Hose - Vacuum
95-020 1 Lens - Display
79-042-01 1 Hose - Excess Air Bleed
79-043-01 1 Hose - Vacuum Blow
124-01-01 1 Pot & Lead Assy - Gap Set 1
124-01-02 1 Knife Position Sensor
124-01-08 1 Pot & Lead Assy - Gap Set 2
124-01-16 1 Toroidal Transformer Assembly
124-01-17 1 Toroidal Transformer Assembly
124-01-27 1 Roller Pot Lead
125-01-08 1 Black Box - Stepper Driver + Daughter Board
125-05-01 1 Runtime PCB Assembly
125-12-02 1 Stepper Driver + Daughter Board
126-02-01 1 Fold Input Roller
126-03-01 3 Fold Roller - Standard
126-06-01 1 Access Unit - 1st Fold
126-06-03 1 Access Unit - 3rd Fold
126-06-04 1 Access Unit - 2nd Fold
126-07-01 1 Support Unit - 1st Fold
126-07-02 1 Support Unit - 2nd Fold
126-07-03 1 Support Unit - 3rd Fold
126-12-01 1 1st Blade Assembly
126-12-02 1 2nd Blade Assembly
126-17-01 1 Input Roller - Upper
126-17-04 1 Input Roller - Lower
SYSTEM Page 39
RECOMMENDED SPARES

126-053 2 Blade Guide
126-053-02 2 Blade Guide - Long
126-059 4 Link - Paper Guide
126-060-01 1 Paper Sensor - Edge Detect RX
126-060-02 1 Paper Sensor - Edge Detect TX
126-060-03 1 Paper Sensor - Sync 2 RX
126-060-04 1 Paper Sensor - Sync 1 RX
126-063-01 1 Sensor Bar - Sync 2 TX
126-063-02 1 Sensor Bar - Sync 1 TX
128-026-02 1 Belt - Paper Transport
NOTE.....
The items listed above represent parts which are subject to wear, loss, or accidental
damage, and is included for your guidance only.
Section and item numbers refer to the illustrations and tables in this manual.
Replacement of parts fitted to your machine require specialist knowledge and should
therefore be entrusted to your dealer.

Digifold
MACHINE CALIBRATION HISTORY
Serial Number:-
Date:-
Total Count:-
Etch
dEtr
FECh
dEtF
gAPF
cEn
Date:-
Total Count:-
Etch
dEtr
FECh
dEtF
gAPF
cEn
Date:-
Total Count:-
Etch
dEtr
FECh
dEtF
gAPF
cEn
SYSTEM Page 41
PRODUCT RECYCLING & 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 within 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.

Digifold Operators Manual Issue 11

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DOCUMENT

CREASING / FOLDING MACHINE

ISSUE 11 SEPTEMBER 2007

INTRODUCTION & SPECIFICATION

QUICK START GUIDE 10

THE DELIVERY UNIT

Setting the Delivery Conveyor System 26

Page 2 CREASING / FOLDING

REPLACING CREASING BLADE SETS

Installing new blade sets PAGE 29

DISPATCH KIT (120-95-01) 36

INTRODUCTION AND SPECIFICATION

IMPORTANT the operating environment should be controlled to a temperature between

Page 4 CREASING / FOLDING

Safety Do’s & Don’ts

Do - read this operator manual fully before operating the machine.

Page 6 CREASING / FOLDING

Page 8 CREASING / FOLDING

Features on the Control Panel

Position I For very short sheets.

Setting the machine to operate in automatic mode.

4. Place the backstop on to the adjustable side lay and slide up to

5. Now follow the step by step instructions shown on page 11.

To manually feed sheets see instructions on page 25.

Page 10 CREASING / FOLDING

Sub-Menu in Set by FoLd mode (set by fold)

Sub-Menu in Set by PoS mode (set by position).

Page 12 CREASING / FOLDING

fold type fold on count

2. Set the Set Up switch to its Mid-position.

6. Turn the Setting Dial clockwise to select paper length ‘LEn’.

10. Set the Delivery Conveyor System as described on page 22.

11. Adjust the Batch Count as described on page 23, if required.

Page 14 CREASING / FOLDING

Press and hold PB1 and the display shows 0.0

Press and hold PB1 and the display shows 0.0

ideal fold line ideal fold line

Typical Set by Position main display screen

number of fold on count

2. Set the Set Up switch to its Mid-position.

Page 16 CREASING / FOLDING

6. Turn the Setting Dial clockwise to select ‘1 cr’

9. Continue turning the Setting Dial clockwise to ‘F1’.

11. Set the Delivery Conveyor System as described on page 22.

12. Adjust the Batch Count as described on page 23, if required.

Deflect knife position.

Example of Set by Position.

Cr1 Cr2 Cr3

First Fold Second Fold

Page 18 CREASING / FOLDING

Adjusting the Paper Gate

Setting the Adjustable Side Lay

Setting the Back-Stop

Setting the Air Distribution

Setting the Air Separation Pressure

Setting the positions of drive wheels and hubs

DO NOT ROTATE THE DRIVE ROLLERS BY HAND.

Page 20 CREASING / FOLDING

Setting the extension table

Setting the Delivery Conveyor System.

1. Flick the Set Up switch down.

Page 22 CREASING / FOLDING

Adjusting the Batch Count

The batch count is set as follows:-