Morgana Documaster Pro, Operator'S Manual

Page 1: ...ATORS MANUAL Part 2 Booklet Making Unit 70 152 Morgana Systems Limited United Kingdom Website www morgana co uk Telephone 01908 608888 Facsimile 01908 692399 DOCUMENT CREASING AUTOMATIC BOOKLET MAKING MACHINE Documaster Pro ...

Page 2: ...ion 3 Booklet Making 10 Edge Corner Stapling 14 Edge Stapling Folding 16 The Staple Heads 18 Troubleshooting Chart 22 Maintenance 26 Appendices Index 44 Connecting the TMP 30 Staple Position Adjustment 32 Sharpening the TMP Blade 34 Conveyor Clamp Adjustment 40 ...

Page 3: ...o be used for the stapling folding and trimming of materials as specified Electrical Voltage 115V 60 Hz or 230V 50 Hz Single Phase earthed supply required Power 150VA exc TRIM 115V 500VA inc TRIM 20VA Stand by 230V 700VA inc TRIM 30VA Stand by Current 4 4A 115V or 3 0A 230V DocuMaster Pro ...

Page 4: ...y This equipment has been tested and found to comply with Emissions the limits for a Class A digital device pursuant to part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accord...

Page 5: ...er Pro have been designed to staple fold and trim booklets of up to 20 sheets in a wide range of paper sizes Their modular design means that they are equally at home being used offline or online with a Watkiss Collator For offline use a Motorised Infeed unit is recommended although a man ual Infeed Guide is also available The BookMaster Pro and TrimMaster Pro units are also compatible with other m...

Page 6: ...s machine must only be plugged into an electrical supply line of the correct voltage and with a proven earth Any damage caused by failure to do so will not be covered by the warranty The required machine voltage is shown on the label on the rear of the unit see Figure 5 Your BookMaster Pro and TrimMaster Pro units have been designed with safety as a key feature and incorporate safety covers which ...

Page 7: ... the correct voltage as indicated by the mains input see Figure 5 Also ensure the outfeed conveyor cable is connected to the socket on the BMP see Figure 6 If the TMP is installed ensure that this too is connected see p 30 MOTORISED INFEED An optional Motorised Infeed P N 041 571 is recommended This fits on to the BMP infeed and makes offline use easier A paper tray see Figure 7 is supplied with t...

Page 8: ...P N 041 571 FIGURE 7 Paper Tray Sidelay FIGURE 8 Fixing Clip Hand Screw An alternative is the BookMaster Infeed Guide P N 041 572 see Figure 4 Fitting the Motorised Infeed Loosen the two hand screws see Figure 8 on either side of the Motorised Infeed ...

Page 9: ...sed Infeed interface cable to the socket on the top of the BMP see Figure 9 Position the Motorised Infeed on the BMP so that the fixing clips see Figure 8 locate inside the BMP infeed Fit the rear hand screw see Figure 10 and then tighten the two side hand screws Fit the paper tray see Figure 7 if required DocuMaster Pro ...

Page 10: ...or lights on the BMP lid see Figure 6 show the status of the corresponding staple head Indicator Light Mode BMP Status Indicator Light Mode Staple Head Status Blinking once per second The unit is ready to run Constantly illuminated The unit is running Blinking rapidly There is a jam or other error Not illuminated BMP TMP lid is open paper is stuck in the paper path or the unit is not switched on B...

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Page 12: ...on the BMP see Figure 16 select centre staple operation lift up Select the Staple Heads Select the two centre staple heads using the button next to the lever see Figure 16 The staple head indicator lights show which heads are selected The position of the staple heads can also be adjusted For more details see page 19 Adjust the Fold Roller Gap The gap between the fold rollers is adjusted using a le...

Page 13: ...e together to produce a neat booklet If the fold rollers are set too close together the booklet covers may be pulled resulting in damage around the staples or the spine of the booklets may be scuffed Fine tune the position of the lever to produce the best booklets possible Adjust the Outfeed Conveyor Slide the large payout wheels see Figure 18 up or down their mounting rail so that they are just n...

Page 14: ...cale For example for an A5 5 x 8 book use the A5 marker Hook the trim offcut box see Figure 19 onto the TMP Starting the Job The BMP will automatically start when the first set of sheets is placed into the Motorised Infeed Tip There is a sensor on the TMP to detect when the offcut box is full Once this sensor is activated the BMP will beep after every second booklet produced If you stop feeding se...

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Page 16: ...e feed the set spine first into the unit Note The maximum sheet width that can be edge stapled is 250mm 9 84 Select Edge Stapling Using the lever on the BMP see Figure 21 select edge staple operation push down Note This will automatically switch off the fold and trim actions Select the Staple Heads Select the required staple heads using the staple head selection button next to the lever see Figure...

Page 17: ... Adjust the Fold Roller Gap The gap between the fold rollers is adjusted using a lever to the left of the front face of the BMP see Figure 17 on p 11 The Lever should be moved to its lowest position when edge or corner stitching With certain stocks it is possible that edge stitched booklets may occasionally jam in the BMP An edge stitch assistor plate P N 907 442 will prevent these Booklets from j...

Page 18: ... The only limitation to this is that the distance from the stapled edge to the fold must be at least half the width of the paper Adjustments Note The gap between the fold rollers must be set to suit the set size when edge stapling and folding see p 10 Note The maximum sheet width that can be stapled in this mode is 250mm 9 84 ...

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Page 20: ...E CARTRIDGES indicator light see Figure 22 will blink once per second New cartridges are available P N 810 022 To change a cartridge first open the BMP lid by turning the handle to the left and lifting see Figure 22 The lid is supported by a strut on the right side Grasp the cartridge at the top and pull directly away from the staple head as shown by the arrow in the photo see Figure 23 ...

Page 21: ...ITION OF THE should be in the outer position 138mm 5 4 between STAPLE HEADS staple centres For small booklets the inner position can be used 115mm 4 5 between staple centres Move the lever see Figure 24 to the right to select the inner position When adjusting the staple heads ensure the staple clinchers are moved to suit To adjust loosen the orange hand screw see Figure 25 and slide the clincher f...

Page 22: ...s the hand screws To do this increase the paper width on the Creaser unit Before placing your hands inside the BMP you should disconnect the unit from the mains electricity supply To close the BMP lid lift it slightly push the support strut see Figure 26 and close the lid Turn the handle to the right to lock in place ...

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Page 24: ...S Staple heads are not selected Select required stapleheads seep ARE NOT ACTIVATED 10 A staple head error has occurred The heads should self clear If not turn the unit off and on again to free the head If this does not work contact your local Service Department FOLD IS NOT ACTIVATED Unit is in edge staple mode Move lever into centre staple position see FIGURE 21 on p 15 BOOK IS NOT TRIMMED Trim no...

Page 25: ... WILL NOT STACK Large payout wheels incorrectly Reposition see p 11 ON THE CONVEYOR positioned Electrical connection is unplugged Plug in electrical connection between the BMP TMP and the outfeed conveyor BOOKLET COVER IS MARKED Dirty fold rollers Clean them with a cloth dampened with soapy water or alcohol isopro panol Do NOT use blanket wash see p 33 Fold roller gap is too narrow Adjust the fold...

Page 26: ...curred The heads should self clear If not LIGHT BLINKS RAPIDLY turn the unit off and on again to free the head If this does not work con tact your local Watkiss service department Paper Jams are most commonly caused by incorrect settings of the Motorised Infeed sidelays by paper jammed in the TMP infeed or the conveyor Other causes include the use of curly paper and staples stuck in the clinchers ...

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Page 28: ...yor belts will eventually cause slippage or ink transfer Warning Access to the manual cranking points on the BMP and TMP requires the side covers to be removed For safety reasons this procedure should therefore only be con ducted by authorised personnel Disconnect the power before removing the side covers BMP To clean the rollers and belts on the BMP first remove the right hand side cover two x M5...

Page 29: ...ton Screw Orange Hand Screw and belts with a cloth dampened with soap and water or alcohol isopropanol Do NOT use blanket wash TMP To clean the belts on the TMP first remove the left hand side cover two x M5 button screws to give access to the manual cranking point see Figure 29 DocuMaster Pro ...

Page 30: ... a handle Using a 19mm A F spanner wrench manually crank the TMP by turning the nut see Figure 30 clockwise and clean the belts with a cloth dampened with soap and water or alcohol isopropanol Do NOT use blanket wash Warning Ensure that hands are kept clear of the TMP blade area at all times TMP BLADE The TMP blade and anvil should be sharpened when SHARPENING required see Appendix 3 ...

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Page 32: ...ng Plate CONNECTING THE TMP Procedure Open the BMP lid by turning the handle to the left and lifting see Figure 31 The lid is supported by a strut on the right side Line up the TMP docking plates see Figure 32 with the BMP Connect the power and communications cables to the sockets on the BMP ...

Page 33: ...king plates align with the holes in the BMP side plates see Figure 33 Lift the BMP lid slightly push the support strut see Figure 34 and close the lid Turn the handle to the right to lock the TMP in place Hook the Outfeed Conveyor onto the support posts on the TMP and connect the interface cable DocuMaster Pro ...

Page 34: ...g of the staple position may be necessary Adjust ment is via the central screw on the fold plate mechanism located behind the perspex cover see Figure 35 If necessary adjust the fold position until the screws align with the holes in the perspex cover Using a flat blade crewdriver loosen the two locking screws see Figure 36 Turn the fine adjustment screw see Figure 36 clockwise to lower the positio...

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Page 36: ...vil when they are sent for regrinding Whenever the TMP blade is reground check the condition of the anvil also This will only require regrinding if it has become dam aged Warning This procedure is potentially hazardous and should only be conducted by suitably skilled personnel Disconnect the power before removing the conveyor assembly Handle the blade with extreme caution and keep hands clear of c...

Page 37: ...d nut Remove the two orange hand screws that secure the conveyor assembly to the TMP unit see Figure 38 Lift away the conveyor assembly to reveal the blade assembly see Figure 39 Important Note the angled position of the TMP blade and with a marker pen or similar mark along the bottom edge of the blade see Figure 39 This will act as a guide when refitting DocuMaster Pro ...

Page 38: ... If it requires regrinding remove the five fixing screws and lift away Refitting the TMP blade and anvil Slacken the anvil adjuster screws back two revolutions Position the anvil fully back towards the conveyor and lightly tighten the anvil fixing screws Affix the blade using the five blade fixing screws but do not tighten Using the mark made when the blade was removed adjust the angle of the blad...

Page 39: ...op dead centre At point C see Figure 42 the blade must pass the anvil by 1mm 1 25 Make fine adjustments to the position if necessary Tighten all the blade fixing screws starting from the centre and working out Push the anvil firmly forwards against the blade pushing from behind with your fin gers at each end Main tain a light pressure on the back of the anvil whilst tightening the anvil fixing bol...

Page 40: ...s are kept clear at all times Check that a clean cut is obtained across the full width of the blade If necessary loosen the anvil fixing screws at the point where adjustment is needed apply additional pressure to the anvil adjusting screws 1 6th turn at a time and re tighten the anvil fixing screws Perform another test cut and make further adjustments if necessary Hook the conveyor assembly onto t...

Page 41: ... blade is reground and refitted afterwards Blade Material High Carbon High Chrome Aisi D2 D3 Grinding Angle See drawing alongside Grinding Wheel Cup or Cylinder Grinding Material Grit 46 60 Hardness G H Bond Vitrified Peripheral speed 20 26 V M S of the grinding wheel 65 85 V Ft S Table Speed 20 26 V M Min 65 85 V Ft Min Feed per pass 0 01 0 02mm 0 0004 0 0008 Honing After re grinding the burr sho...

Page 42: ...op or it may bounce against the trim stop This will result in the following problems booklets are trimmed out of square this may also indicate that the left and right conveyor clamps are set unevenly Booklets are trimmed too short If the conveyor clamps are set too tight the following problem may occur The cover of the booklets are pulled resulting in dam age around the staples Tools required Proc...

Page 43: ...the orange handscrew see Figure 43 There are two clamp roller shafts which are adjusted using a 4mm allen key see Figure 44 Adjusting the Conveyor Clamps To adjust the conveyor clamp Turn the adjustment screws clockwise to increase the gap reducing clamp pressure Turn the adjustment screws ant clockwise to reduce the gap increasing clamp pressure DocuMaster Pro ...

Page 44: ...they are set the same The easiest way to do this is Lay the first rule across the wire frame so that it is above the clamp roller shaft see Figure 45 Using the second rule measure the height from the top of the shaft to the bottom of the first rule Adjust the shafts as necessary to ensure they are both set to the same height Restarting the job Before restarting the job don t forget to reset the pa...

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Page 46: ...tor lights 8 docking plates tmp 30 staple heads 18 20 adjusting 19 E clinchers 19 edge corner stapling 14 15 selecting 14 edge stapling folding 16 staple cartridges changing 18 errors see troubleshooting staple position fine tuning 32 status indicator light 8 F switching on 4 Fold rollers adjustable 10 T I tmp blade sharpening 34 39 infeed see motorised infeed final adjustment 38 installation 4 ho...

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