Morgana DigiBook 150r1 User manual

Rev. 1.00-C
K.G.S. srl
DigiBook 150r1
Operators Manual
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Operator Manual DigiBook 150
2
Rev. 1.00-C
Summary
1INTRODUCTION ________________________________________________________ 4
1.1 CE MARK__________________________________________________________________________ 5
1.2 SAFETY SIMBOLS __________________________________________________________________ 6
1.3 SYMBOLS OF PROHIBITION AND OBLIGATORINESS ___________________________________ 7
1.4 THE SAFETY DURING THE USE OF THE MACHINE _____________________________________ 8
1.4.1 General ________________________________________________________________________ 8
1.4.2 Safety warnings __________________________________________________________________ 8
1.5 SAFETY CLOTHING_________________________________________________________________ 9
1.6 INSTALLATION OF ELECTRICAL CABLES AND HOUSES _______________________________ 10
1.7 SAFETY EQUIPMENTS IN THE MASTER BOOK ________________________________________ 10
1.7.1 Emergency button _______________________________________________________________ 10
1.7.2 Green button To start cycle ________________________________________________________ 11
1.7.3 Protection plate of the milling station ________________________________________________ 11
1.7.4 Main Switch ____________________________________________________________________ 12
1.8 RESIDUAL RISKS__________________________________________________________________ 13
1.9 PURPOSES________________________________________________________________________ 14
1.9.1 Not provided uses, prohibited uses __________________________________________________ 14
2TECHNICAL SHEET FOR MASTERBOOK 150 ____________________________ 15
2.1.1 Electrical ______________________________________________________________________ 16
2.1.2 Pneumatics_____________________________________________________________________ 16
Air quality provided to the Master Book _____________________________________________________ 17
DIN ISO 8573-1 –air quality class _________________________________________________________ 17
3STANDARD ACCESSORIES______________________________________________ 18
4TRANSPORTATION ____________________________________________________ 19
5STORAGE______________________________________________________________ 20
6LAYOUT_______________________________________________________________ 21
7POSITIONING AND WORKSPACES ______________________________________ 22
8INSTALLATION ________________________________________________________ 23
8.1 TECHNICAL STAFF FOR THE INSTALLATION_________________________________________ 23
8.2 PHYSICAL CHARACTERISTICS OF THE AREA OF PLACEMENT _________________________ 23
8.3 BOLSTER_________________________________________________________________________ 23
8.4 WEATHER PROTECTION ___________________________________________________________ 23
8.5 LIGHT____________________________________________________________________________ 23
8.6 ENVIRONMENTAL CONDITIONS____________________________________________________ 24
8.7 ELECTRICAL CONNECTION ________________________________________________________ 25
8.7.1 Ground connection_______________________________________________________________ 25
9TRAINING OF THE OPERATOR _________________________________________ 26
10 POWER ON ____________________________________________________________ 27

Operator Manual DigiBook 150
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Rev. 1.00-C
10.1 FUNDAMENTALS _________________________________________________________________ 28
10.2 ELECTRICAL CONNECTION _____________________________________________________________ 30
10.3 PNEUMATIC CONNECTION _____________________________________________________________ 30
10.4 GROUPS DESCRIPTION ________________________________________________________________ 31
10.5 CHIPS ASPIRATOR ____________________________________________________________________ 34
10.6 PUR TANK OPENING AND CLOSING.GLUE LOADING. __________________________________________ 35
10.6.1 Opening of the PUR tank __________________________________________________________ 35
WARNINGS ON THE OPENING OF PUR TANK______________________________________________ 35
10.6.2 Preparation and loading of the pur glue ______________________________________________ 37
10.6.3 Cleaner loading _________________________________________________________________ 39
11 FUNCTIONS OF MASTER BOOK_________________________________________ 41
12 PREPARATION OF THE MACHINE TO PRODUCE A BOOK.________________ 53
12.1 GLUE REFURBISHMENT PROCEDURE _______________________________________________ 53
13 COVER POSITIONING __________________________________________________ 55
PREPARATION OF THE MACHINE TO MANUFACTURE A BOOK. _____________ 57
13.1 STARTING THE MACHINE__________________________________________________________ 58
14 BOOK SPINE PREPERATION ____________________________________________ 61
14.1 PREPERATION OF LARGER BOOKS________________________________________________________ 62
14.2 CHANGING THE NOTCHING TOOL HEIGHT __________________________________________________ 63
15 CLEANING THE MACHINE _____________________________________________ 64
15.1 “END OF JOB”CLEANING ______________________________________________________________ 65
15.2 PROCEDURE TO CLEAN THE SPINE GLUE EXTRUDER.__________________________________________ 66
15.3 PROCEDURE TO CLEAN THE GLUE SIDE EXTRUDERS. _________________________________________ 69
15.4 DETAILS CLEANING_________________________________________________________________ 72
16 PROBLEMS - SOLUTIONS_______________________________________________ 75
16.1 CHIPS ASPIRATOR –LESS VACUUM: _________________________________________________ 75
16.2 CLAMP –IT DOESN’T START:___________________________________________________________ 75
16.3 MILLING STATION –IRREGULAR CUT AND NOTCHING:____________________________________ 75
16.4 COVER PLATE MILLING STATION –IT DOESN’T OPEN /CLOSE CORRECTLY: _________________ 75
16.5 HEAD -OUT OF TOO MUCH OR LITTLE GLUE: _________________________________________ 75
16.6 NIPPING STATION_________________________________________________________________ 75
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Operator Manual DigiBook 150
4
Rev. 1.00-C
1INTRODUCTION
THE READING OF THIS OPERATOR AND MAINTE-
NANCE MANUAL IS FUNDAMENTAL FOR THE
SAFETY OF THE USER AND FOR THE PROPER USE
OF THE EQUIPMENT.
We thank you to have bought our product. This machine has been designed specifically for your job
and your applications with the help of a single worker, provides a high quality production and a
wide range of functions.
This manual describes how to use the machine, starting from the configuration phase to the most
important operations. This manual has been written in order to be easily understood also by user not
trained about the use of this kind of machine. For the best use of the equipment, please read careful-
ly this manual before to use the machine. After reading, we suggest you to save the manual in a
safety place and don’t hesitate to read him when necessary.
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Operator Manual DigiBook 150
5
Rev. 1.00-C
1.1 CE MARK DICHIARAZIONE DI CONFORMITÀ CE
CE CONFORMITY DECLARATION
DIRETTIVA CE PER MACCHINE 2006/42/CE,
DIRECTIVE FOR MACHINES 2006/42/CE,
E SEGUENTI DIRETTIVE EUROPEE (ALLEGATO IIA)
AND FOLLOWING EUROPEAN DIRECTIVES (ANNEX IIA)
COSTRUTTORE, MANUFACTURER: K.G.S.SRL Via Donizetti 5 –20090 Assago (Mi) Italy
RESPONSABILE DELLA COSTRUZIONE DEL FASCICOLO TECNICO / RESPONSIBLE FOR PREPARING THE
TECHNICAL DOSSIER: RACCANELLO ROBERTO
CON LA PRESENTE DICHIARIAMO CHE LA FABBRICAZIONE DEL / WE HEREWITH DECLARE THAT THE
MANUFACTURE OF:
MODELLO TIPO / MODEL TYPE : PERFECTBINDER MASTERBOOK 150
MATRICOLA / SERIAL : MB150-XXXX
ANNO DI COSTRUZIONE / MANUFACTURED IN 2013
CORRISPONDE ALLE SEGUENTI DISPOSIZIONI NELLA VERSIONE ATTUALMENTE VALIDA / IS IN AC-
CORDANCE WITH THE FOLLOWING DIRECTIVES AS IT IS :
Direttiva CE per Macchine 2006/42/CE / Directive 2006/42/CE
Direttiva EMC 2004/108/CE / EMC Directive 2004/108/CE
Direttiva sulla Bassa tensione 2006/95/CE / Low Voltage Directive 2006/95/CE
NORME ARMONIZZATE APPLICATE , IN PARTICOLARE
HARMONIZED STARDARDS, IN DETAIL :
EN 1010
EN 60 204-1
EN 61 000-6-2, EN 61 000-6-3, EN 61 000-6-4
Assago , (MI) Italy
__/__/2013
Dott. Marco Alfredo Tumaini
Amministratore unico
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Operator Manual DigiBook 150
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Rev. 1.00-C
1.2 SAFETY SIMBOLS
In the manual some symbols are used to inform about dangerous situations for people and/or things.
The following symbols mean dangerous situations for people and/or things.
If you don’t follow carefully the appropriate procedures, damages can occur to people and/or things,
and in extreme situations also fatal accidents. Together with the symbols it is written also what to
do.
Attention –General danger!
Attention –Electrical voltage!
Risk of electric shock.
Attention –Sharp blades!
Risk of cut.
Attention –Hot surfaces!
Risk of burn.
Attention –Risk of rolling parts!
Risk of crushing.
Attention –Risk of moving chain!
Risk of crushing.
In case of not warning of the symbols damages, also great, can happen to the
machine and to the accessories.
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Operator Manual DigiBook 150
7
Rev. 1.00-C
1.3 SYMBOLS OF PROHIBITION AND OBLIGATORINESS
This symbol means a prohibition.
This symbol means an imperative.
This symbol means that it is mandatory to read in this manual information re-
garding specific topics (for ex. related to the specifications of the electric and
pneumatic connection).


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Operator Manual DigiBook 150
8
Rev. 1.00-C
1.4 THE SAFETY DURING THE USE OF THE MACHINE
1.4.1 GENERAL
The manufacturer guarantees that the contents of this manual are in specification with the proce-
dures required by the machine. The manufacturer therefore will be not responsible if the machine
will be used in a different way.
1.4.2 SAFETY WARNINGS
Before the use of the machine, please read carefully the manual.
Save the manual for further needs.
By apply different procedures, and not the specific procedures described in the manual, can produce
operational problems.
Please, read carefully the following safety rules.
It is forbidden to use the machine when occurs one of the following situations:
in explosive environment;
in flammable atmosphere;
in excessive dusty environments.
Danger!
Failure to comply with some or all the instructions listed in this manual could
cause damage to the machine and / or personal injury. The manufacturer is not re-
sponsible for an arbitrary and improper use of the machine such as:
Using the machine by untrained personnel;
Use contrary to law;
Incorrect installation;
Defects in electrical power and / or pneumatic;
Partial or total failure to comply with the instructions;
Lack of maintenance and / or use of aftermarket parts;
Changes or other actions not authorized by the manufacturer;

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Operator Manual DigiBook 150
9
Rev. 1.00-C
1.5 SAFETY CLOTHING
Clothing to use during the cleaning and /or maintenance operations
Eye protection against any spray of PUR glue or high temperature cleaner
Respiratory mask suitable for the glue you are using
Protective gloves
Tight clothing, to avoid that they remain engaged with protruding parts.
Long hair must be covered or otherwise collected by using e. g. a protective screen.
Do not wear watches or jewelry.
Safety clothing
The safety clothing IS NOT INCLUDED in the machine and must be pro-
cured by the machine user.
The operator should wear clothing appropriate to the situation and special-
ly during the following operations:
-Maintenance
-Replacing of the PUR glue
-Cleaning of the PUR system
a) Eye protection against any spray of PUR glue or high temperature
cleaner
b) Respiratory mask suitable for the glue you are using.
c) Protective gloves for high temperature
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Operator Manual DigiBook 150
10
Rev. 1.00-C
1.6 INSTALLATION OF ELECTRICAL CABLES AND HOUSES
Cables and houses must be put inside of special cable channels to avoid the people to stumble and
get hurt.
1.7 SAFETY EQUIPMENTS IN THE MASTER BOOK
DANGER! It is forbidden to remove or render ineffective the safety guards for the
safety of persons, and to tamper and / or modify, even partially, safety devices in-
stalled on the machine. In case of alarm signals due to the intervention of the safe-
ty, the operator must request the immediate intervention of technical people
trained on the maintenance. The manufacturer is not responsible of any damage to
persons or animals caused by tampering with the guards."
1.7.1 EMERGENCY BUTTON
It is located on the front, easily accessible from the operator's position.
In the diagrams the emergency button is identi-
fied SB20.01
.
ACTIVATION of emergency state: the push-
button must be pressed
OFF state emergency stop: the button must be
turned clockwise"
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Operator Manual DigiBook 150
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Rev. 1.00-C
1.7.2 GREEN BUTTON TO START CYCLE
The two front green buttons execute the com-
mand to start cycle, it means that the clamp
closes and moves to the right, the mill will run
the cut, the glue will be applied, and if the
press has been activated will crush the book;
all this happens if I put the book block in the
clamp and place a cover on the press.
1.7.3 PROTECTION PLATE OF THE MILLING STATION
The plate consists of a mobile plate that, except
when the book block is moving, covers the cutter in
all operating conditions, even at a standstill
A spring exerts a constant force on the plate a
force that covers the mill disc. The motor of
the cutter is equipped with a brake.
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Operator Manual DigiBook 150
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Rev. 1.00-C
1.7.4 MAIN SWITCH
It is located on the right side of the machine.
Position OFF
The switch is open.
The machine is off.
Position ON
The switch is closed.
The machine is on.
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Operator Manual DigiBook 150
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Rev. 1.00-C
1.8 RESIDUAL RISKS
There are risks that cannot be completely eliminated by either protective or as designed by the ma-
chine.
Area of the glue head.
Attention –Hot surfaces!
Risk of burn.
Use protective gloves.
Area of glue loading.
Attention –Hot surfaces!
Risk of burn.
Use protective gloves.
Area of the mill.
The disc contains several types
of milling cutters. Use protec-
tive gloves, in case of remov-
ing the Notching Roughening
or the brush.
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Operator Manual DigiBook 150
14
Rev. 1.00-C
1.9 PURPOSES
The machine is used to bind books using the following materials:
a) Signatures, or sheet of paper (printed or not) for the block book
b) Cardboard as cover of the book
within the limits specified in the data sheet, included in this manual.
1.9.1 NOT PROVIDED USES,PROHIBITED USES
Any other use such as,
- Milling / Roughening of book spines already bounded (adhesive
binder, stitching book, sewing book, etc.)
- Use of materials other than those specified in a) and b)
- Operations beyond the technical specifications are not to be re-
garded as intended use.
The user has the total responsibility of the damages to people or things due to an improper
use, outside of their intended use.


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Operator Manual DigiBook 150
15
Rev. 1.00-C
2TECHNICAL SHEET for MasterBook 150
Machine features:
Cycle/Hour 150 cycles
Spine length from 120 to 380mm
Workable height of the book from 110 to 320mm
Max. Cover size 700x360/222x120 mm
Workable thickness of the book from 2 to 50mm
Max. Cover Weight from 120 to 400 g/m2
Control Screen
Touch - Screen Yes
Copy Counter Yes
Diagnostic and Check Yes
Setting size, temperature control Yes
Speed Yes
Book Loading
Adjustment of the clamp Manual
Clamp opening/closing Manual
Spine preparation
Milling disks Ø 110 mm (optional)
Roughening for spine processing 2
Chips aspirator Included in the machine
Glue application system
Tank PUR/Hot-Melt glue 3 Kg sealed
Extrusion system of PUR/Hot-melt integrated and sealed
Extrusion head adjustment Manual
Glue stops Adjustable by Touch-Screen
Cleaning / sealing Yes
Press:
Press Electric (servo-controlled)
Adjustment Pressing time
Mechanical Adjustment
Cover back bar adjustment Manual
Cover loading Hand made by the operator
Dimensions / Weight
Length 1400 mm
Width 880 mm
Height 1270 mm
Weight 210 Kg
Power consumption
Electrical power Max. 4Kw
Power grid 220 V ±5%, 50/60 Hz

Operator Manual DigiBook 150
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Rev. 1.00-C
2.1.1 ELECTRICAL
Electrical power 220 V ±5%, 50/60 Hz
Power of the machine
Protection fuses on the power network are duties of
the customer
Distribution cabinet, customer side
16 A
Differential protection class A 300mA
2.1.2 PNEUMATICS
Supply pressure
The pneumatic system of the user must ensure, in the inlet connection of the compressed air in the perfect
binder, the following values:
Min.: 7 bar
air consumption: 160 Nl/min
air quality: Class 3
Pneumatic characteristics for the machine
Compressed air consumption
100 Nl/min
Calibration of input gauge
6 bar
Min. working pressure
5.5 bar. If the pressure value falls below this value the machine enter in an “alarm” condition
Diameter of air inlet
6 mm
The 6 mm diameter house for the connection to the compressor is not provided together with the machine.
It is suggested the use of a compressor equipped with the automatic condensate drain, to avoid verifying
weekly if there is some water inside the compressor.
It is suggested to use a silenced compressor, if the compressor is located inside the working plant.
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Operator Manual DigiBook 150
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Rev. 1.00-C
Air quality provided to the Master Book
CLASS 3, DIN ISO 8573-1
Durst: 5 micron - 5 mg/m3
Water: -20°C - 0,88 g/m3
Oil: 1 mg/m3
The compressed air system upstream of the machine must be equipped with a dryer.
Periodically check the quality of the compressed air supplied to the machine and the
operating values .
AIR QUALITY PROVIDED TO THE MASTER BOOK
To make work the pneumatic devices in an affordable, efficient and safe way, the compressed air
supplied to the pneumatic device must have the following quality features:
Pressure, Quantity, Water content, Solids content, Oil content.
DIN ISO8573-1 –AIR QUALITY CLASS
The manufacturers of pneumatic components refer to the quality of compressed air to be used on
their products, referring to the table below
The compressed air used in the industry contains water, oil, dust and other impurities. The interac-
tion of these elements produces an aggressive mixture that can damage the compressed air devices
and also the PUR glue contained in the PUR tank, the results will be a low quality production and
increased maintenance costs.
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Operator Manual DigiBook 150
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Rev. 1.00-C
3STANDARD ACCESSORIES
The standard composition includes:
–Cleaning Kit
–Start- up Kit
CLEANING KIT
Polizene green spatula (to remove excess glue
or cleaner)
Steel Wire Ø0.4 (for cleaning the channels of
leakage of the lateral glue)
Lamella thickness of 0.4 (for cleaning the slit
of leakage of the spine glue)
Spare Headless screws for the closure of the
ducts
Protective gloves
Set of allen keys
Small arches for supporting the book block in
the clamp
START-UP KIT
One pack of 2 kg of PUR Glue Henkel
One pack of 2 litres of beans Cleaner-Blue
Henkel
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Operator Manual DigiBook 150
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Rev. 1.00-C
4TRANSPORTATION
The Master Book must be handled by a heaver.
It can be got ONLY along the 2 long sides, front
and rear side.
For the final positioning or small movements
can be used a trans-pallet.
The machine can be raised by trans-pallet only
in the 2 long sides, front and rear.
DANGER! For no reason the staff is authorized to pass under a suspended load
during transport or in the proximity of. The producer is not responsible for what
happens during this operation, to be carried out by qualified and authorized per-
sonnel, with the necessary individual safety protections (suit, shoes, gloves, hel-
met and glasses).
Attention! The machine is balanced. In any case keep the forks low.
In case of unbalance use weights. It is forbidden to hold by the hands the project-
ing parts. The machine and its parts must be protected from the weather outside. In
particular, water, dust and moisture can oxidize certain elements of the machine,
damaging them irreversibly. Follow the usual precautions to avoid falls and
bumps.
IMPORTANT
a) We do not provide tools for docking and lifting.
b) The disposal of packaging materials will be provided by the recipient and must be conducted in
accordance with the local regulations.
c) Remove dust and dirt accumulated during the transportation.
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Operator Manual DigiBook 150
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Rev. 1.00-C
5STORAGE
The information contained in this section must be observed in case of temporary storage of the ma-
chine that may occur in the following situations:
installation of the machine not immediately after its delivery.
uninstalling the machine.
storage awaiting a new location.
The machine must be stored and transported under conditions of SAFETY as shown in the table be-
low.
Conditions of transportation and storage
Temperature average
-5/+55°C
Humidity average
30/90%
Lighting
Adequate natural and / or artificial
Weather
Adequate weather protection
Space required
Adequate to allow the operations of lifting
and carrying in SAFETY.
Horizontal bolster
Horizontal bolster must have a capacity in
excess of the total mass of the machine.
In the case of removal or unused for long peri-
ods (over 30 days), it is necessary to drain the
glue system and to put inside the protection
cleaner.
The damage caused by this failure will
void the warranty of the glue device.
During periods of downtime you should not
open the tank containing the glue, otherwise it
accelerates the deterioration creating serious
permanent damage to the glue device.
The damage caused by this failure will
void the warranty of the glue device.
Protect with anti-corrosive products the parts sub-
ject to wear and work plans. Ref. to the section
“maintenance”.
Do not climb or place any objects on top of the
machine
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