Morgana DigiBook 450 User manual

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Technical Manual
DigiBook 450
vers. 01.00

TechnicalSetting
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iDigiBook 450 R2: Technical Manual rev.01.00 10-12-2013
Summary
Tools necessary for set up ..................................................................................................................................3
Working principle...............................................................................................................................................3
Preliminary Operations.......................................................................................................................................3
Start-up conditions..............................................................................................................................................5
Check height of Zero (MZ).................................................................................................................................5
1) Setting the jogger plate...................................................................................................................................6
2) Setting the spine preparation unit...................................................................................................................9
3) Setting the PUR Nozzle................................................................................................................................13
4)Setting the nipping station ........................................................................................................................15
7)To adjust the discharge manipulator.........................................................................................................19
7)Adjust the cover feeder.............................................................................................................................23
8)Adjustment of discharge belt. ...................................................................................................................24
9)Pressure adjustment ..................................................................................................................................27
10)Setting of operating distance for sensors..............................................................................................27
11)Photosensors adjustment.......................................................................................................................27
12)Cylinders speed.....................................................................................................................................27
13)Axes positioning. ..................................................................................................................................27
14)Machine parameters..............................................................................................................................28
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TechnicalSetting
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3
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Toolsnecessaryforsetup
Toolsnecessaryforperformingdimensionaltestsonthemachine:
DepthgaugeL=200mm
Carpenter’ssquare50x80mm
Thicknessgauge
Gaugeblockforclamp BlockMcod. P010303600
Gaugeblockfornippingstation BlockVcod. P010806200
MachinePassword: 1°level0104 2°level2468
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Workingprinciple
The clamp is the mechanical device that takes and carries the block to be bound along the machine. The
clamp moves lengthwise along the machine using a very precise system.
The clamp is the reference unit so all the measurements and various references relate to it.
PreliminaryOperations
Beforestartingthemachine,youmustverifythecorrectwiring.
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1. Verifythatthemachine'smainswitchisinposition0
andthattheplugisnotconnected.
2. RemovetheprotectivecoverasshowninPicture0.1.
3. Inserttheplug.
4. PayattentiontothecablelightbluelabelN,always
refertotheneutral.
5. Verifythecorrectpresenceofvoltagebetweenthe
terminals(Picture.0.2and0.3)asindicated:
a. L1L2(400Vac)
b. L2L3(400Vac)
c. L1L3(400Vac)
d. L1N (230Vac)
e. L2N (230Vac)
f. L3N (230Vac)
6. Iftensionsarenotasindicatedverifythecorrect
positionofneutralonthewallsocket.
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Fig.0.1
Fig.0.2
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TechnicalSetting
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4
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7. Ifthevoltagesareasindicated,proceedwith
checkingofthecorrectrotationofthemilling.
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Fig.0.3
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8. EnterpasswordinthepagedisplayN°61,Picture0.4,
pressbuttonandverifythedirectionofthemilling
rotation(clockwise).
9. Ifthemillingrotationisincorrect:
a. Turnthemainswitchtoposition0
b. Disconnecttheplug.
c. reversethewiresmarkedwiththeletterL
(forexampleL1andL2)
d. Reconnecttheplug.
e. Turnmainswitchtoposition1
f. RepeatoperationsfromStep8.
10. Ifthemillingrotationiscorrect:
a. Turnthemainswitchtoposition0
b. Disconnecttheplug.
c. Restoretheprotectivecoverasshownin
Picture0.1
Fig.0.4
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TechnicalSetting
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5
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Startupconditions
Startingconditionsforcheckingthemachinesetupvalues:
1) Machineonandatcorrecttemperature.
2) Joggerknobsetto0.
3) MillingcuttersettoONposition.
4) Heightadjustmentknobofgluingunitsetto‘0’.
5) Internaljawadjustmentknobofgluingunitsetto‘1’.
6) Gluingpressuresetto‘0’.
7) Heightadjustmentofnippingstationsetto‘0’.
8) Machineinresetcondition.
9) Removetheclampcover.
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CheckheightofZero(MZ)
ThemachineiscalibratedinthefactorywithameasureofZerowhichcanrangefrom96to97mm,
thisisnotasignofpoorquality.
AnyorganwillfollowthisMZ(measurezero)withtheappropriatetolerances.
HowtounderstandwhatistheMZ,proceedwiththemeasureofthejoggeranddoaquickcheck
withtheothergroups. 

TechnicalSetting
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6
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1)Settingthejoggerplate
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Joggerfeatures:
1) perpendiculartotheclamp
2) paralleltotheclampmovement
±0.1mm.
3) MZ±0.1mmfromtheTopPlate
ofthecursor
4) holdsthesheets
5) BlockMassembly
6) Referenceheight‘X’
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1)Perpendicularalignmenttestofthejogger.
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Place a 50 x 80 mmsquare on its shorter side
ontothejoggerplate(seeFig.1.1)andcheckfor
perpendicularalignment.
The positioning tolerance allows a thickness of
0.05 mm to pass through but not a 0.1 mm one
(onthe80mmside).
If it does not, adjust the 4 screws underneath.
This check must be done at both ends of the
joggerplate(seeFigs.1.2and1.3).
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N.B.Alwaysusethesametestpoints
ontheclamp.
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Fig.1.1
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Fig.1.2
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Fig.1.3
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TechnicalSetting
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2)Parallelismtestofthejogger
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Reset the clamp, then position it, completely
opened, on the left side of the jogger and
measure using the depth gauge as shown in Fig.
1.4. Then move it to the right side and measure
withthedepthgaugeasshowninFig.1.5.
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Parallelism is reached when the two
measurementsareeitherequal orthedifference
betweenthemisnotbiggerthan±0.1mm.
Ifthedifferencebetweenthevaluesisbiggerthan
±0.1mm,adjustthe4centraladjustingscrews.
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After reaching parallelism, check again for
perpendicular alignment as described above in
point 1, as it may have been put out of
calibration.
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3)HeightcheckfromtheTopPlate
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PositionthedepthgaugeasshowninFig.1.4and
measuretheheight.
ItmustbeMZ±0.1mm.
Ifgreaterthan0.1mm,adjustthe‘Fixingring’and
positionitagainsothattherestrainerisincontact
when the distance between clampand jogger is
MZ±0.1mm.
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Fig.1.4
Fig.1.5
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Fig.1.6
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TechnicalSetting
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4)Gaptoholdthesheets.
The jogger has a gapthat serves to holdthe
sheetswheninsertedintotheclamp.
This gap must be at about 2.5 ±0.5 mm (GAP)
distance from the edge of the fixed jaw of the
clamp,asshowninFig.1.7.
Fig.1.7
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5)AssemblyofBlockM.
After testing and setting up the jogger’s
characteristics,mountthegaugeblockdefinedas
‘BlockM’inFig.1.8.
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BlockM serves for testing the other machine
units therefore it becomes the main reference
unit.
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6)ReferenceheightX.
Measure the distance between the gauge block
and jogger. The resulting figure will be taken as
thereferenceheight‘X’(Fig.1.9).
Thisheightwillserveasareferencefortheother
units.
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Fig.1.8
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Fig.1.9
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TechnicalSetting
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9
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2)Settingthespinepreparationunit
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Millingdiskfeatures:
1) perpendiculartotheclamp
2) The rear platemust be
paralleltotheclampandata
distance of 0.4 ±0.2 mm
inwardsfromtheclamp.
3) on the left  of the milling
cutter disk, the distance
between 'BlockM’ and the
toothmilling disk must be
equaltoX±0.1mm.
4) ontherightsideofthetooth
milling disk, the distance
between 'BlockM’ and the
millingdiskmustbeequalto
(X+0.3)±0.2mm.
A. unitadjustment.
5) the striker plate must be at
0.15mmhorizontallyand1.0
mmvertically from the
millingcutterteeth.
6) Coverfrontfurnituremustbe
more internal than the
movable jaw of 1mm ±
0.5mm.
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1)Perpendicularalignmenttestofthe
spinepreparationunit.
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Placea50x80mmsquareonitsshorterside
ontothemillingcutterdisk(seeFig.2.2)and
checkforperpendicularalignment.
Positioningtoleranceallowssheets0.05mm
thicktopassthroughbutnot0.1mmones
(onthe80mmside).Ifitdoesnotpass,turn
the4adjustmentscrews,seepoint4A.
Fig.2.1
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Fig.2.2
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Fig.2.3
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TechnicalSetting
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10
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2)Parallelismtestofthespine
preparationunit.

WhenplacingthesquareasshowninFig.2.4
thegapbetweenthefixedjawandthestriker
plate of the milling cutter must be 0.4±0.2
mm.Thecheckmustbedoneatbothendsof
thestrikerplate.
If the measurements do not correspond,
slightlyloosenthefixingscrews(Fig.2.9)and
move the whole milling cutter unit, then
tightenthescrewsagain.

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
Fig.2.4
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3)Checkofthespinepreparationunit
heightontheleftside.

MeasurethedistancefromBlockMtothe
millingdiskusingthedepthgauge,asinFig.
2.5,makingsurethatyouplacethedepth
gaugeonthetoothasshowninFig.2.6.

On the left side of themilling disk, the
distance between BlockM plane and a tooth
ofthemillingcuttermustbeX±0.1mm.Ifit
is not, adjust the 4 adjustment screws; see
point4A.
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Fig.2.5
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Fig.2.6
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TechnicalSetting
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11
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4)Checkofthespinepreparationunit
heightontherightside.

On the right side of the milling disk, the
distance between BlockM plane and the
upper surface of cutting knivesmust be
(X+0.3) ±0.1 mm. If it is not, turn the 4
adjustmentscrews;seepoint4.1.
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Fig.2.7
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4A)Toaccesstheadjustmentscrews;remove
themobileguardandthePlexiglas®
inspectionpanel(Fig.2.8).



Slightlyloosenthefixingscrews,removethe
lockinggrubscrewsandturntheadjustment
screwssoastomovetheunittothedesired
height.Measureagainusingthedepthgauge;
thentightenthesidefixingscrews.After
fixingtheunit,returnthePlexiglas®panel
andmobileguardtotheirpositions.
Fig.2.8

Fig.2.9
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5)Testofthebackcutunitblock.

Thedistancesofthebackcutunitblock(Fig.
2.10)mustbe:
A=0.15mm
B=1.0mm

Checkthemeasurementsusingthethickness
gauge.
Fig.2.10


TechnicalSetting



12


6) Checkthemovablefrontcoverof
cutter
The movablefrontcovermust
protrude1mm±0.5mm.SeeFigure
2.10
Fig.2.11


 

TechnicalSetting



13

3)SettingthePURNozzle

Gluingunitfeatures:
1) perpendiculartotheclamp.
2) the distance between
‘BlockM’ and the extruder
plane must be (X+0.3) ±0.1
mm.
3) Thedistancefrom theinner
jawmustbe0.15mm.
1)Perpendicularalignmenttestofthe
gluingunit.
Place a 50 x 80 mmsquare on its shorter
side onto the extruder plane (see Fig. 3.1
and 3.2) and check for perpendicular
alignment.
Positioning tolerance allows a thickness of
0.05mmtopassthroughbutoneof0.1mm
(onthe80mmside).

If perpendicularity needs adjusting, adjust
thescrewsontherightsideunderneaththe
premelter,accessingitfromthebackofthe
machine;seeFig.3.3


















Fig.3.1

Fig.3.2

Fig.3.3










TechnicalSetting



14

2)Checkofthegluingunitheight.

Measure the distance from BlockMto the
extruderplaneasshowninFig.3.4,making
sure you place the depth gauge on the
extrusion slit. The resulting measurement
mustbe(X+0.3)±0.1mm.Ifitisnot,adjust
thepositionedrestrainer.



Fig.3.4


3)Distancebetweentheinternalside
plateandtheclampfixedjaw.
LeaningthesquareasshowninFig.3.5,the
internalplateofthenozzlemustleaveroom
for a thickness of 0.15 mm. If it does not,
adjust the positioning knob (Fig. 3.6),
positionthe screw retaining ring in contact
withthesheet,Fig.3.7.



Fig.3.6

Fig.3.5

Fig.3.7

 

TechnicalSetting



15

4) Settingthenippingstation
Nippingstationfeatures:
1) Perpendiculartotheclamp.
2) Parallel to the clamp
movement.
3) The distance between
'BlockM’ and the spine plate
mustbeequal
4) to(X)±0.1mm.
5) The distance from the fixed
platemustbe0.3±0.05mm.
6) The distance between the
mobile plate and the spine
plate must be equal to 0.1
mm.
N.B.
Thenippingstationunitdoesnotonlyneedgaugingbut
alsoadjustingafterthebookhasbeenproduced.This
meansthatafteradjustingthemachine,itisnecessary
tomakeabookand,accordingtothequalityofthe
resultingproduct,itmayprovenecessarytoadjustthe
setup.
Introduction:

Tocheckthenippingstationisrequired
tobeinthehighposition.

Previouslysettheheightofthepresson
thevalue0inpage23ofthedisplay
Picture4.2andpressgreenbutton.


Nextyoumusttopickupthepressin
manualmodepicture4.2(bypressingin
sequencethebuttonsindicated
Fig.4.3AB)puttingBlockVthecentral
section,thisinordertosupportthe
squareofthespineplate.

Fig.4.1
 
Fig.4.2


Fig.4.3AFig.4.3B



TechnicalSetting



16

1)Perpendicularalignmenttestof
thenippingstation.
Placea50x80mmsquareonitsshorter
side onto the spine plate (see Fig. 4.4
and 4.5) and check for perpendicular
alignment.
Positioning tolerance allows a 0.05 mm
thickness to pass through but not a 0.1
mmone(onthe80mmside).

Fig.4.4


Fig.4.5

2)Testoftheparallelalignmentof
thenippingstationtotheclamp
movement.

Measure the distance between BlockM
and the spine plateon the left side as
showninFigs.4.6and4.7.
















Fig.4.6


Fig.4.7



TechnicalSetting



17



Measure the distance, as shown in Fig.
4.8,aftermovingthe clamp to the right
endofthespineplate.
Thedifferencebetweenthetwo
measurementsmustnotbe±0.1mm.
Fig.4.8


3)Testofthenippingstationheight.

Measure the distance between BlockM
and the spine plate on the left side as
showninFig.4.9.
Itmustbe=X±0.1mm.

Fig.4.9

4)Testofthefixedplategap.

Placea50x80mmsquareonitsshorter
sideontothespineplate(seeFig.4.10).
Thesidefixedplatemustbeparallelto
thefixedjawoftheclampbutata
distanceof0.3mminwards.
Theresultinggapmustallowthe
insertionofathicknessof0.3±0.05mm.

Thetestmustbeperformedontheleft
andrightendsofthenippingstation
fixedplate(seeFig.4.11and4.12).






Fig.4.10


Fig.4.11

Fig.4.12

4)Testofthefixedsideplategap.
Fig.4.13

TechnicalSetting



18


Themobileplateoftheclampmustbe
adjustedinsuchawaythatitdoesnot
scrapeagainstthespineplate.(Figs.
4.134.14).
Usethethicknessgaugetomeasurethe
correctdistance.A0.05mmthickness
shouldbeabletopassthroughwhilethe
0.15mmshouldnot.Adjustthe
adjustmentscrewstosetitupcorrectly.
Werecommendthatthedistance
betweentheplatesiscloseto0.05mm
ratherthan0.15mm.






Thesameprocedureshouldbe
performedforthebackplate(Figs.4.15
4.16).

Fig.4.14

Fig.4.15

Fig.4.16

 

TechnicalSetting



19

7) Toadjustthedischargemanipulator
Featuresofthemanipulator
discharge:
1)Perpendiculartothevise.
2) Distance to plan manipulator
grip3mm±1mm
3) The gap from the fixed plate
mustbe1±0.5mm.

Introduction:

Tosearchthemanipulatorexhaustis
necessarythatthenippingstationisinthe
lowpositionandwiththeplateofthe
backintheretractedposition.








Inthetechnicalsetup,underpassword,
mustpickupthemanipulator,throughthe
manualmovements(Fig.4.24.21a),in
grippingpositionbypressthearrow
indicatedbythenumber1tolightthe
indicatorofposition2,turnthe
manipulatorbypressingthearrow
indicatedbythenumber2.Fig.4.21B

Fig.4.20




Fig.4.21AFig.4.21B


















TechnicalSetting



20

1) Checkthesquarenessofthe
manipulator.

Place a square 50x80 with the side to 50
on the floor of the manipulator (see Fig.
4.22)andtestteam.
Thetoleranceonthepositioningallowsto
passthethicknessfrom0.10butnotthat
from0.20mm(onthesideof80mm).








Fortheperpendicularityadjustmentis
necessary,loosenthenutunderthe
directionofthearrowmanipulatorof4.23
andscrew,unscrewthecylinderrod..




Fig.4.22





Fig.4.23



















