Morgan Documaster Pro User manual

70-174 Issue 4 FEBRUARY 2013
Documaster Pro (CB/UL)
SERVICE MANUAL
Document Creasing & Automatic
Morgana Systems Limited United Kingdom www.morgana.co.uk Telephone: ( 01908 ) 608888 Facsimile: ( 01908 ) 692399
Booklet Making Machine

Page 2
INTRODUCTION
CREASING / BOOKLET MAKING
MORGANA DOCUMASTER 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
Documaster 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
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 consul facing)
Rear of machine (opposite to control consul)
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 or 115 60Hz 15 Amps.
Fit the delivery to the machines together as described later in this
manual.
Turn the rollers by hand to ensure they rotate freely.
Switch on the machine and check that all functions operate. Set up
the machine and check that the machine feeds correctly.
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.
DocuMaster Pro

Page 4 CREASING / BOOKLET MAKING
INDEX
Introduction
Section 1
Section 2
Section 3
Section 4
Section 5
Section 6
Section 7
Section 8
Section 9
Section 10
Section 11
………………………………………………………………….....……..PAGE
¡ Introduction ................................................................. 2
¡¡ Fasteners .................................................................... 2
¡¡¡ Identification ................................................................ 3
iv New Machine Preparation ............................................ 3
V Index............................................................................4/5
Vi Key to Creaser Unit........................................................6
…… Covers………….…....................................................................
Creaser Covers............................................................. 7
Gatherings Station Covers............................................ 8
…… Vacuum Drum…………………………………………………….
Belt Removal/Replacement........................................9/10
…….Butterfly Valve
Removal/Replacement.................................................12
……Main Mechanism - Creaser Unit................................................
Removal of Unit..........................................................14/15
Removal /Replacement Stepper Drive Belt / Pulleys......16
…….Infeed Roller Removal/Replacement - Creaser……………………...17
…….Drive Hub - Replace Rubber Torsion Bush (shock absorber)..........18
…….Drive Link Refurbishment…….…………………………………...........19
…….Width Drive Mechanism…….…………………………….......……......20
…….Gathering Station Removal/refitting.…………………….......……......21
…...Gathering Station Timing Belts Removal/refitting.…….......……......22
……Creaser Electrics…..………….…………………………….......……...
Removal/Refitting PCBs. ......................................................23
Removal/Replacement Controller PCB....................................24
Processor PCB Replacement .................................................25
Relay PCB Replacement ........................................................25
Removal of USB Flash Drive...................................................26
Removal/Replacement Stepper Drive PCB ............................27
Removal/Replacement Small Stepper Drive PCBs ................27
....

Page 5
SYSTEM
Section 12
Section 13
Section 14
Section 15
Section 16
Section 17
Section 18
Section 19
Section 20
Section 21
Section 22
…….Gathering Station Electrics….…………………………….......……PAGE
Removal/Refitting PCBs. .....................................................28
Replacement Interface PCB....................................................28
Removal/Replacement Stepper Drive PCB ............................28
Removal/Replacement Small Stepper Drive PCBs ................28
…..Optical Sensors…….…………………………………………................
Creaser - Cleaning and Setting....................................... 29
….Machine Installation............................................................................
Machine Installation....................................................31
Software upgrade Watkiss bookletmaker....................31
….Machine Set-up Prior to Calibration..................................................32
….Replacing Touch Screen Assembly…………………………..............33
…Calibration…….…………………………………………...............
Calibration of crease position ......................................34
Width Trim ...................................................................34
Calibration of Gathering Station paper guides............35
Switching from Watkiss to Nagel.................................36
Setting the Measurement System METRIC to INCH...36
Zero Total Count .........................................................36
….Trouble Shooting…………………………………………………
Error Messages.........................................................37
Camera and Double Detect.......................................37
Creasing Unit........................................................38/41
Machine Width Positioning.......................................41
Gathering Station..................................................47/48
…Creaser Circuit Diagrams………..………….……………….......…
UK - Wiring Diagram................................................49
Control PCB Connection Diagram............................50
…Gathering Station Circuit Diagrams………..………….…………
UK - Wiring Diagram...............................................51
Control PCB Connection Diagram...........................52
….Fuse Positions & Ratings ............…………………………..............53
…Image Recognition Camera………..……………….......…
Camera Replacement...........................................54/56
....
DocuMaster Pro

Page 6 CREASING / BOOKLET MAKING
THE CREASING UNIT
Key to photograph below
1 Roller tilt handle
2 Stacker assembly
3 Suction slot knob
4 The control panel 16 Gathering Station
5 Air distribution knob
7 Adjustable side lay 13 Vacuum Bleed Knob
8 Back stop 14 Touch Screen
9 Fixed side lay 15 Anti-Static Unit
10 Roller tilt knob
11 Paper Gate
6 Air separation knob 12 Exit Guard
DocuMaster Pro
8
7
4
1331016

Page 7
SYSTEM
SECTION 1
1.1
1.2
1.3
1.4
Creaser Covers:
The Front Cover
The Service Panel (Rear Panel)
The Creaser Mechanism Covers
The Loading Table.
The compressor cover which is situated below the control panel is secured by 16 off M4
taptite screws and is located by three tongues protruding into the main frame.
Removal of this cover provides access to the compressor & the crease mechanism and
the Camera cable termination.
To remove this cover, remove all screws and twist forwards to clear emergency stop button
and mains socket, pull out to release the tongues.
The Service Panel is at the rear of the machine and is secured by seven screws, three on
the top.
Removal of this panel allows access to the suction pipework and the Electric Control
System assembly.
The creaser mechanism is situated in the middle of the machine and is covered by a fixed
and a hinged guard.
To remove these guards just remove the four screws (M4 x 8 long) beneath the entry
guard. Pull off the rubber handle from the tilt lever, the entry guard can now be lifted
upwards and removed.
Removal of the loading table is as follows:-
Remove all eleven countersunk screws from the feed bed. Loosen the sidelay screws and
bring the sidelay assembly towards the operator side of the machine. Then lift out the
loading table towards the rear of the machine, passing over the fixed lay of the feed bed.
if
fitted,
To remove this panel, first remove the Touchscreen, (access through two holes in the
cover) loosen all screws, lift up the panel and twist outward to unhook the keyhole
locations on the opposite side to the screw fittings.
The Loading table is the stainless steel top on which the work is loaded.
DocuMaster Pro

Page 8 CREASING / BOOKLET MAKING
SECTION 1
1.8
Gathering Station Covers:
The Side Covers
The Rear Door
The Rear Panel
1.5
1.6
1.7
The side covers of the gathering station are each fixed with 5 off M4 taptite screws (3 off on
top).
The Op. side covers the drive pulley and friction clutch.
The Lay side covers the gathering station PCB and guide pulleys.
To remove covers, remove all screws and lift clear of the machine. NOTE: The lay side cover
has a key hole slot that secures the machine interface cable. This can be released when
removing cover.
Reassembly is the reverse order ensuring that the interface cover grommet is secured back
into the key hole slot.
The rear door is secured by 3 off tatpite screws. Removal of these screws will allow the door to
pivot open for access to the Hamlin Switch, Pot assembly and the mains power terminals.
The rear panel is secured with 12 off taptite screws and provides access to the electrical panel
assembly.
To remove, first open the rear door by unscrewing the 3 off fixing screws then continue to
remove the remaining 9 off taptite screws. The panel can then be lowered from the gathering
station. Reassembly is the reverse.
switched on at
The Interface Cover Assembly
The Interface Cover is situated between the creaser unit and the stapling unit and covers the
Alignment Channel which connects the Stapling and Creasing parts of the machine.
To remove this cover , two securing screws can be removed from the top flange and the cover
can be lifted clear giving access to the fixing screw through the channel.
Reassembly is reverse to the above, ensure the mains is plugged in and the
stapling unit, and the interface cable is attached at the creaser end. Care should be taken not
to damage these cables.

Page 9
SYSTEM
SECTION 2
VACUUM DRUM TIMING BELT REMOVAL / REPLACEMENT.
2.1 Remove the Feed Bed, Moving Sidelay, Papergate Assembly, Ball Holder, Support
Bracket and Double Sheet Detector Mounting Bracket. (See Fig. 2.1 below).
2.2 Remove the two screws that secure the Butterfly Valve. (The Butterfly Valve is located
2.3 Remove the two screws that secure the Vacuum Drum Mounting Block. The Vacuum
Drum Mounting Block can now be slid towards the back of the machine, (to
disengage it from the Vacuum Drum), and it can now be removed.
2.4 Remove the Sensor, the Timing Belt can now be removed.
2.5 Replace in reverse order, making sure that the two ‘O’ rings are in the Vacuum Drum
Mounting Block.
on the underside of the feed bed, towards the back of the machine.
Vacuum Drum
Mounting Block
Papergate
Assembly
Ball
Holder
Support
Bracket
Sensor
Vacuum
Drum
Timing
Belt
FIG.2.1
DocuMaster Pro

Page 10 CREASING / BOOKLET MAKING
VACUUM DRUM FEED BELT REMOVAL / REPLACEMENT.
2.7 Remove the M5 Socket Screw. (See FIG.2.2 below).
2.8 Remove the 3 screws securing the Center Support Plate (Posi Head Screw
in the side of the feed frame and 2 Cap Head Screws, from under the feed frame.
DO NOT adjust or remove the red bolt, as this is factory set.
2.9 Carefully slide the Center Support Plate towards the front of the machine.
Be careful when doing this as two bearings and shims can fall out.
2.10 The Feed Belt can now be removed..
2.11 Replace in reverse order, again be careful of bearings and shims.
When fitting the Center Support Plate, make sure it is up against red bolt and washer.
2.6 Remove the Feed Bed and the Moving Sidelay.
FIG.2.2
M5 Socket
Screw
Bearings
and Shims
Center
Support
Plate
Feed Belt