Morgana AutoFold Pro Manuale utente
184-019 Issue 4 FEBRUARY 2013
AutoFold Pro (CB/UL)
SERVICE MANUAL
Document Folding Machine
Morgana Systems Limited United Kingdom www.morgana.co.uk Telephone: ( 01908 ) 608888 Facsimile: ( 01908 ) 692399
Page 2
INTRODUCTION
FOLDING
MORGANA Autofold Pro
i ..........Introduction
ii .........Fasteners
The purpose of this manual is to explain the procedure for dis-
mantling and re-assembly of the major assemblies on the Morgana
Autofold Pro machine.
All the engineering adjustments are shown at the end of each
relevant section.
Operator's adjustments and routine maintenance are explained in
the appropriate operators manual which should always be used in
conjunction with this manual.
It is always a good idea to have a copy of the machines illustrated
parts manual available when servicing, as its illustrations provide an
invaluable reference to the construction of the individual assemblies
used to build the machine.
All threaded fasteners are isometric & all nuts are isometric hexagon.
All screws are hardened high tensile steel.
Cap head, Button head, Socket countersunk, Shoulder bolts and
Grubscrews have internal hexagon drives which require isometric
hexagon wrenches (allen keys). Ball drivers may be used, but care
should be taken particularly when releasing screws for dismantling
to avoid breaking the driver as they cannot cope with full tightening
torques.
NOTE.........Do not substitute fasteners with low grade alternatives
which may fail or become irremovable.
Page 3
SYSTEM
Pan head and Cross-head countersunk screws all have metric Taptite threads and
Pozi-drive recesses. Use No.2 point Pozidriv or Supadriv drivers for all screws M4 &
above, and No.1 point drivers for M3 & below.
Warning
This machine is heavy care should be taken
when handling
iii ........Identification
iv ........New Machine Preparation
For general identification of areas of the machines, the following
terms are used:-
Operator side (control panel facing)
Rear of machine (opposite to control panel)
Delivery end (to the left of the operator side)
Feeder end ( on your right )
Remove all packaging materials
All metal parts, including the folding rollers have a protective coating
And any excess should be removed.
Connect the power cable to the mains supply. The machine
requires 230V 50Hz 10 Amps.
Turn the fold rollers by hand to ensure they rotate freely.
Switch on the machine and check that all functions operate.
Set up the machine to fold paper and check that the machine feeds
and folds correctly.
WARNING
WORK SHOULD BE CARRIED OUT BY A TRAINED AND COMPETENT
ENGINEER AND ALL SAFETY PROCEDURES SHOULD BE ADHERED
TO.
SWITCH OFF MAINS POWER BEFORE COMMENCING.
DO NOT USE PHILLIPS DRIVERS - THESE WILL DAMAGE THE SCREWS
& MAY SLIP, CAUSING DAMAGE OR INJURY.
Autofold Pro
Page 4
INDEX
Introduction
Section A
Section B
Section C
Section D
Section E
Section F
………………………………………………………………………..... ...PAGE
¡ Introduction ...................................................................2
¡¡ Fasteners ......................................................................2
¡¡¡ Identification ..................................................................3
iv New Machine Preparation .............................................3
…… Covers………….…. ..................................................................
Operator and Lay edge Side Doors............................... 9
Rear Cover.................................................................... 9
Operator and Lay edge Columns ................................. 10
Top Cover Assembly .................................................... 10
Delivery Conveyor Removal......................................... 11
…….Feed Bed........................................................................
Accessing the Fans and Control Board........................12
Removal of Feed Bed...................................................13
…….Infeed Roller Removal/Replacement ...............………....………....14
…….Replacing the Touchscreen Assembly ........…….…………............16
…….Electrics………..………….…………………………….......……...
Removal/Refitting Control PCB and prog board...........18
Removal/Refitting USB Flash Drive .............................19
Removal/Replacement ITX Boards .............................22
Removal/Replacement ITX PSU .................................22
Removal/Replacement Stepper Drive PCB .................22
Removal/Replacement Large PSUs’............................22
Entering Engineers tools ..............................................23
Zero Total Count...........................................................23
Setting the Measurement System ................................23
…..Optical Sensors…….………………………………………….........
..................... ...................Cleaning Sensors ..........................................................24
..... ................ ...................Changing Sensors - Leading Edge................................25
..... ................ ...................Changing Sensors - Crunch..........................................25
.... ................. ...................Changing Sensors - Folder Unit Clip 1&2.....................26
FOLDING
Page 5
SYSTEM
PAGE
…...Removing / Replacing Fold Knife Assembly……………….
…….................... ..................Upper Fold Knife.........................................................27
..................... ........................Bottom Fold Knife.......................................................27
…..Main Fold Rollers Removal…………………………................
..................... ........................Removal Third Fold Roller...........................................28
..................... ........................Removal Second/First Fold Roller...............................29
..................... ........................Main Fold Rollers - Replacement ...............................30
------------------ ----------------------
Pre-Power Setup Procedure Flow Chart .............................. 33
.................Vacuum Table Installation and Alignment............................. 34
.................Belt Tension ......................................................................... 37
................Upper Input Roller - Setting the Paralllelism & Pressure ...... 38
................Fold Rollers - Setting the Parallelism & Pressure ................. 40
................Setting The Fold Knives ........................................................ 42
................Adjusting The Top Cover Safety Switch ................................ 44
------------------ ----------------------
Powered Setup Procedure Flow Chart ................................. 45
................Control System Setup ........................................................... 46
…............Fold Roller Gap Potentiometers ...……….............................. 47
……........Sensors and Detectors .......................................................... 48
……......Delivery Assembly ................................................................. 50
--------------------------- ----------------------
Fold Setup Procedure Flow Chart ........................................ 55
.............Primary Fold Setup ............................................................... 56
Section G
Section H
Pre-Power Setup Procedure
Section 1
Section 2
Section 3
Section 4
Section 5
Section 6
Powered Setup Procedure
Section 7
Section 8
Section 9
Section 10
Fold Setup Procedure
Section 11
ENGINEERING SET-UP & CALIBRATION TECHNIQUES
Autofold Pro
Page 6
INDEX
PAGE
------------------ ----------------------
Calibration Flow Chart ................................................................. 57
.............Delivery Roller ..................................................................... 58
.............Fold Positions...................................................................... 58
.............Deflect Adjustments ............................................................ 59
............Test Run .............................................................................. 60
.............Trouble Shooting ...........................................................
.............................................Folding Unit...........................................................61
..............................................For Error Messages refer to Operator manual......63
.............Circuit Diagrams ...........................................................
.............................................. AutoFold Pro Wiring Diagram................................64
.............................................Control PCB Connection Diagram.........................65
..............................................Fuse Positions & Ratings.......................................66
Calibration
Section 12
Section 13
Section 14
Section 15
Section M
Section N
FOLDING
Page 7
SYSTEM
BLANK
PAGE
Autofold Pro
Page 8
DOCUMENT FOLDING MACHINE
Autofold Pro
Key to photograph below
1 Delivery assembly 6 Fixed Sidelay 11 Top Cover
2 Vacuum Table 7 12 Input Guide
3 Touchscreen 8 13 Fuses
4 Switch panel 9
5 Gap Sets 10
Lay Side Door
Op. Side Door
Column Lay Side
Column Op. Side
1
10
79
2
11
812
FOLDING
3
5
4
13
6
Page 9
SYSTEM
SECTION A
A.1
A.2
Covers:
The Operator Side Door.
The Lay Edge Side Door
The Operator Side Door cover which is situated adjacent to the operator, covers the Gap Set
mechanism and small stepper boards.
To remove this cover, first remove the two top fixing screws attaching the top plate, this must
be lifted upwards to clear the gap set adjuster Knobs.
Remove three screws from the right hand side and pivot the door forwards.
The Lay Side door is at the rear of the machine and is secured by three screws and a hinge,
similar to the Operator side door.
Removal of this panel allows access to the Fold Knife drive mechanism PCB and ITX Boards.
The top cover safety switch and the perforator gas strut is also inside this cover.
To remove this panel on its own remove all countersunk screws attached to the hinge and
lift away.
To replace is the reverse procedure.
Alternatively remove the front and rear covers along with the Rear Cover Panel, see below.
To open, first unscrew the three pan head screw adjacent to the touch screen and then the five
pan head screws below the feed bed which also fixes the Control Cover Door in place, hinge
backwards to open.
To remove this panel on its own, remove all countersunk screws attached to the hinge and lift
away.
To replace is the reverse procedure.
Alternatively remove the front and rear covers along with the Rear Cover Panel, see below.
The Rear Cover is situated at the output end of the machine below the delivery conveyor. This
cover is secured on each side by four posi pan head screws, fixing it to the main frame. Hinges
are attached each side of the cover to allow the side two doors to pivot from it.
To remove the rear cover including the operator side and lay edge side doors, remove the
eight posi pan head screws (4 each side) and the screws in the rear panel.
With the conveyor fully up and with one person each side, the assembly can be manouvered
out and under the rear delivery conveyor.
To replace is the reverse procedure care should be taken and two persons should carry this
out.
A.3 The Rear Cover Assembly
Autofold Pro
Page 10
SECTION A
A.4
A.5
The Operator and Lay side Columns
The Top Cover Assembly
The Operator and lay side column doors conceal the Gas struts for the Feed Bed.
To remove the doors open them up using the handles provided and remove the six screws
securing the hinge to the main frame.
To replace is the reverse procedure.
The Top Cover Assembly is hinged on top of the Machine and covers the Mechanism, this
hinges upwards to allow access to the Main Rollers, the Input Rollers and the Top Sensors.
This cover can be removed from the machine as follows.-
1. Open the Lay Side Door as previously described.
2. Open upwards.
3. Peel back the sound adsorbent foam to allow access to the two posi pan head fixing
screws which can be unscrewed from the pivot shaft.
4. From the rear of the machine slide the guard pivot shaft out taking care not to damage
the microswitch. the cover can now be removed. Take care not lose/drop the nylon washers at
each end of the pivot shaft.
To replace is the reverse procedure, ensure the micro switch is correctly set after this
procedure.
FOLDING
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