Morgana DocuMaster Automatic SquareBack User manual

ISSUE 1
November
2005
70-072
DOCUMENTSQUAREBACKBOOKLET
OPERATINGSYSTEM
MorganaSystemsLimited UnitedKingdom
Website:www.morgana.co.uk
Telephone: [phone] Facsimile:[phone]
SquareBackSystem
OPERATORS MANUAL

Page2 SQUAREBACK
CONTENTS
Introduction..........................4
Installation
SafetyInformation
GettingHelp
AboutyourAutomaticSquareBackSystem5
HowtheSquareBackSystemWorks
AdjustmentsandSettings
Stacker
UsingyourAutomaticSquareBackSystem8
OnlineOperation
HandFeeding
ErrorConditions......................10
BookletJammedInsideSBS
SmallBookletsDoNotStackWell
UnevenlyFormedSpine
ReplacingFuses
SeekingAssistance
Maintenance........................13
ServiceInterval
OperatorMaintenance
Specifications.......................15
DeclarationofConformity..............17
Index...............................18

Page3
SYSTEM
SquareBackSystem
CONVENTIONS Thefollowingconventionsareusedinthismanual:
Warning Warningmessagesalertyoutoaspecificprocedureor
practicewhich,ifnotfollowedcorrectly,couldcause
seriouspersonalinjury.
Caution Cautionmessagesalertyoutoaspecificprocedureor
practicewhich,ifnotfollowedcorrectly,couldresultin
damagetoequipment.

INTRODUCTION
Page4 SQUAREBACK
TheAutomaticSquareBackSystempost-processesstitchedor
stapledbookletstogivethemtheprofessionalflatappearance
ofaperfectboundbook,butwiththesecurityofastitchedspine.
TheresultingSquareBackbookletsareflat,makingthemeasyto
stack,handleandpack.
IntheseinstructionstheAutomaticSquareBackSystemis
referredtoastheSBS.
INSTALLATION YourSBSshouldbelocatedonalevelfloor.
IfyourSBSisusedonlinewithotherequipment,installation
requiresspecialistknowledgeandshouldthereforeonlybe
CarriedoutbyaMorganaapprovedengineer.
Caution Thismachinemustonlybepluggedintoanelectrical
supplylineofthecorrectvoltageandwithaprovenearth.
Anydamagecausedbyfailuretodosowillnotbecovered
bytheguarantee.Therequiredmachinevoltageisshown
onthelabelontherearoftheunit.
SAFETY
INFORMATION YourSBShasbeendesignedwithsafetyasakeyfeature. However,toensureitisusedsafelypleaseobservethe
followingcautionsandwarnings:
Warnings •Aswithallelectricalequipment,disconnecttheunit
fromthemainselectricitysupplywhenreplacing
fusesorwheninstructedtodosointhismanual.
•Thedisconnectdeviceistheapplianceinlet.
•Donotattempttoputyourhandsorobjects,other
thanbooklets,insidetheSBSduringoperation.
•Donotremovemachinecovers.Onlycompetentand
trainedserviceengineersshouldservicethisequipment.
GETTINGHELP WeareconfidentthatyourSBSwillgivemanyyearsof
trouble-freeproduction.Ifyouhaveanyqueriesorprob-
lems,inthefirstinstancepleaserefertotheproblem
solvingsectioninthisbook .Shouldyourequirefurther
assistance,theMorganaServiceDepartmentwillbe
happytohelp.

Page5
SYSTEM
SquareBackSystem
2AboutyourAutomatic
SquareBackSystem
HOWTHE
SQUAREBACKSYSTEM
WORKS
Thebookletistransported,spinefirst,intotheSBS.The
SquareBackspineisformedandthebookletisthen
deliveredtothestackeronthetopoftheSBS.
Fig1.TheAutomaticSquareBackSystem
ADJUSTMENTSAND
SETTINGS MainsON/OFF
TheMainsON/OFFswitchisonthefrontofthemachine.
1=ON,0=OFF.
MainsInput
TheMainsInputisonthebackofthemachine.Alongside
theMainsInputisalabelindicatingthemachinevoltage
requirements.
BookThicknessAdjustment
TheBookThicknessAdjustment(seeFig2.)canbeused
toobtainoptimumresultswithdifferentbookletthicknesses.
Turntheknobclockwisetoincreasetheeffect,and
anti-clockwisetodecreasetheeffect.Thetypeofmaterial
willalsoinfluencethe requiredsetting.
Outfeed
SquareBackBooklets
StackerSupport
StackerReleaseLever
BookThicknessAdjust-
ment
StackerFullSensor
OperatingModeAdjust-
ment
Sidelay
Infeed(HandFeed)
Fig2.BookThickness
Adjustment
Max.
Min.
24
5
8
6
7
9
3
1
1
2
4
5
6
9
8
7
3

Page6 SQUAREBACK
OperatingModeSelection (seeFig3.)
SinglePass:TheSBSwillprocessthebookletasingle
time.Thisisthedefaultsetting, andissuitableforthevast
majorityofbooklets.
DoublePass:TheSBSwillprocessthebooklettwice.
Thiscanbeusefulforthick,inflexiblecoverswhichare
moreresistanttore-forming.
Fig3.OperatingModeSelection
SquareBackMode:Thebookletswillbeprocessedand
receiveasquaredspine(SquareBack).
BypassMode:ThebookletswillbypasstheSquare-
backingprocessand willbedeliveredstraighttothe
stacker.InBypassMode, thestackermayrequiread-
justment(See“Stacker”onpage7.).
ErrorIndicator/ResetButton
Thisindicator/buttonperformsseveralfunctions-
•Agreenlightindicatesanerror.Correcttheerror
andthenpressthebuttontoresettheSBS.
•Thebuttoncanbeusedtostartthemachineifitis
notautomaticallystartedbyhand-feedingorby
connectedequipment.
•Whenhand-feeding,thegreenlightflashesaseach
bookisprocessed.Anotherbookletcanbeinserted
whenthelightgoesout.
Double
Pass
SinglePass
SquareBackMode
BypassMode
Error
Indicator/
Reset
Button

Page7
SYSTEM
SquareBackSystem
STACKER Bookletsarestacked,spineuppermost,inthestacker.
Thestackersupportautomaticallyrecedestoaccommo-
datetheincreasingstack.Whenthestackerisfull,a
sensorwillautomaticallystoptheSBSandthegreen
Error/Resetlightilluminates.
Unloadthebooklets,slidethestackersupportbackup
towardstheoutfeedandthenrestarttheconnected
equipment.
Fig4. TheSBSStacker
Note:
1.Tomovethestackersupport,squeezethestacker
releaselevertowardsthestackersupport.
2.Ifbookletsarenotprocessed(ie.inBypassMode),
theymaystackbetterlyingflat.Slidethestacker
supportawayfromtheoutfeed,takingcarenotto
triggerthestackerfullsensor.
3.Ifsmallbookletsdonot stackwell,adjustmentmay
berequired,see“Smallbookletsdonotstackwell”
onpage11.
StackerSupport
StackerReleaseLever
StackerFullSensor

Page8 SQUAREBACK
3UsingyourAutomatic
SquareBackSystem
ONLINEOPERATION TheSBScanbeusedonlinetoavarietyofbookletmaking
machines.Itwillautomaticallystartandstopasrequired,
controlledbytheconnectedequipment.
1.FirstselecttherequiredOperatingModeandBook
ThicknessAdjustment(seeChapter2,’Aboutyour
AutomaticSquareBackSystem’).
2.Starttheconnectedequipmentandrunasingle
bookletthroughtheSBS.
3.Inspecttheformedbooklet,andadjusttheBook
ThicknessAdjustmentortheOperatingModeas
required.
SpineFormations
Correct:Thisishowawellformed
spineshouldlook.
Incorrect:Thespinehasnotbeen
formedsufficiently.
IncreasetheBookThicknessAd-
justmentand/oruseDoublePass
Mode
Incorrect:Thespinehasbeen
over-formedresultingindamageor
creasingonthecover.
DecreasetheBookThicknessAd-
justmentand/oruseSinglePass
Mode.

Page9
SYSTEM
SquareBackSystem
4.Adjusttheoperatingspeedoftheconnectedequip-
menttoapproximately1,000bookletsperhour.
(Note:someconnectedequipmentwillautomatically
adjusttoanappropriatespeedfortheSBS.)
5.Graduallyincreasethespeedtoabout1,400book-
letsperhour(singlepassmode).Ifthespeedisset
toohigh,somebookletswill notbeprocessed.They
willbeclearlyidentifiableinthestacker.
HANDFEEDING Bookletscanbehand-fedintotheSBSeitherwhenthe
unitisstand-alone,orwhenitisconnectedtoabooklet
maker.Itisnotnecessarytodisconnectitfromother
connectedmachinery.
1.Adjustthesidelaysto suitthebookletsize.
2.Insertabooklet,spinefirst,intotheinfeed.
3.Thecompletedbookletisdeliveredintothestacker.
ThegreenError/Resetindicatorflashesaseachbookis
processed.Anotherbookletcanbeinsertedwhenthe
lightgoesout.
Ifthebookletsareinserted tooquickly,somewillnotbe
processed.Theywillbeclearlyidentifiableinthestacker.
Caution •Donotexceedthespecifiedbookthickness.
Minimum:1mm(0.04”)
Maximum:6.5mm(0.25”)Thisisapproximately30
sheetsof80gsm(20#bond)foldedintoa120page
booklet.
•Onlyprocessonebookletatatime,DONOTtryto
processseveralbookletsatonce.
WETINK AvoidusingtheSBSonbookletswheretheinkhasnot
dried.Thismayresultininktransferandwillincreasethe
amountofcleaningrequired(seeChapter5,’Mainte-
nance’).

Page10 SQUAREBACK
4ErrorConditions
BOOKLETJAMMED
INSIDESBS IfabookletjamsintheSBSforanyreason,switchthe SBSoffatthemainsinputandthenswitchitbackon
again.Themachinewillresetandthebookletshouldbe
ejectedontothestacker.Ifthebookletisnotejected,
pressthegreenError/Resetbutton.
IfthebookletstillremainsinsidetheSBS,itmustbe
removed.
•SwitchtheSBSOFFandunplugthemainsinput
lead.
•Pushinthetwosecuringlatchesandgentlylowerthe
frontcoverdownwards.
Fig5.SBS,frontcoverandlatches
FrontCover
FrontCoverLatches

Page11
SYSTEM
SquareBackSystem
•Openthetoplidbyliftingitupwards.
Fig6.TheSBSwithfrontcoverandlidopened
•Retrievethebookletfrominsidethemachine.Take
carenottodislodgeanyoftheconveyorbelts.
Caution Ifthebookletcannotberemovedbecauseitisjammed
intheclampmechanism,donotattempttoforcethe
mechanismopen.ContactyourMorganaservice
Department.
•ClosetheSBSlidbyliftingitslightly,pushthesup-
portstrutandthenlowerthelid.
•Liftupthefrontcoverandpushitclosed,ensuring
thatthelatchesre-engage.
Warning WhenreleasingtheSBSlidsupportstrut,holdthelid
securelyandtakecarenottodropitonyourhand.
SMALLBOOKLETS
DONOTSTACKWELL Ifsmallbookletsdonotstacktidily,thebookletcontrol springsshouldbeused.
OpenthefrontcoveroftheSBS,asexplainedabove,
andreleasethetwospringsbypullingthemoutfrom
FrontCover
(open)
Lid(open)
LidSupportStrut

Page12 SQUAREBACK
underneaththeshaft.Whenthespringsarenotrequired,
theyshouldbetuckedbackundertheshaft.
Fig7.BookletControlSprings
UNEVENLYFORMED
SPINE Ifthespineiswellformedatonlyoneendofthebooklet, DoublePassModeshouldbeused.Somestocksmay
requireDoublePassModetoachieveanevenresultsee
“SpineFormations”onpage8).
REPLACINGFUSES YourSBSisfittedwithtwofusesatthemainsinput.If
eitherofthesefail,theSBSwillnotoperate.
Warning TheSBSusesdouble-pole/neutralfusing(i.e.,twofuses),
sowhenchangingfusesalwaysfirstdisconnectthema-
chinefromthemainselectricitysupplybyswitchingOFF
andunpluggingthemachine.
•SwitchtheSBSOFFandunplugthemainsinput
lead.Opentheflaponthefuseholder.
•Pullouteachfusecasinginturnandcheckthefuse.
•Replaceifnecessarywithafuseofthecorrectspec-
ification,asdetailedbelow.
Reference
230Vmachines:
730-016Fuse,1.25"(32mm)5.0AHRC-QuickActingF
115Vmachines:
730-020Fuse,1.25”(32mm)10.0AHRC(QuickActing,F)
SEEKING
ASSISTANCE IfyourequireassistancewithyourSBS,pleasecontact yourlocalMorganaServiceDepartment.
Spring
Shaft

Page13
SYSTEM
SquareBackSystem
5Maintenance
SERVICEINTERVAL ItisrecommendedthatyourSBSisservicedbyan
approvedMorganaengineeratsixtotwelvemonthinter-
vals(dependingonusage).PleasecontactMorgana
forfurtherdetails.
OPERATOR
MAINTENANCE Aswithallmachinery,yourSBSwillbenefitfromregular cleaningtopreventbuildupofdustandgeneraldirt.
•Checkthattheairventsarenotobstructedor
blocked.Obstructedairventswillcausethemotorto
overheat.
•Onceaweek,orasrequired,cleanthecarriage
rollerasexplainedbelow.
•DonotusetheSBSonbookletswheretheinkisstill
wet.Thismayresultininktransfer,andincreasethe
needforcleaning.
CleaningtheCarriageRoller
1.SettheoperatingmodetoDoublePass,andthe
BookThicknessAdjustmenttomaximum.
2.Takeamaximumthickness(6.5mm)A4sizebooklet,
andwrapasheetofpaperaroundtheoutside.Alter-
natively,takeabout30sheetsofA380gsmpaper
andfoldintoanA4sizebooklet.
3.Applyathincoatingofasuitablecleaningproduct
(seebelow)tothespineofthebooklet.
4.HandfeedthebookletintotheSBSinthenormal
way.Re-insertthebookletandreprocessabout5
times.
5.Removetheoutersheet,togiveafreshcleansur-
face,andrepeatstep4.
Suitablecleaningproductsincludealcohol(isopropanol),
offsetlithoblanketwashorRSSolventCleanerAerosol.
Alwaysobserveanyhealthandsafetyinformation
suppliedwithcleaningproducts.
Warning Cleaningsolventsareflammable.DONOTspraythem
directlyintotheSBS.
USAUsers:
6.5mmis¼”
ForA4,use8½x11”
ForA3,use11x17”
80gsmis20#bond

Page14 SQUAREBACK
Caution Donotattempttouseaclothtocleanthecarriageroller.
Thismayleaveloosefibresor debrisinside themachine.

Page15
SYSTEM
SquareBackSystem
6Specifications
IntendedUse Thisproductisintendedforthere-formingofbooklet
spines,toflattenthebookletandgiveasquareappear-
ancetothespine,withinthespecificationsbelow.
Production upto1400perhoursinglepass
BookletSize from80x120mmto250x350mm
(dependantonspecificationofconnectedequipment)
BookletThickness minimumof1mm,0.04”
maximumof6.5mm,0.25”.Thisisapproximately30
sheetsof80gsm(20#bond)foldedintoa120page
booklet.
Dimensions
Width707mm,28”
Depth745mm,29.5”
Height1242mm,49”
Weight132kg,291lb
Electrical 230V,50Hz,3Aor115V,60Hz,5A
SinglePhase,Earthedsupplyrequired
Noise 72dB(A)
OperatingConditions 10-35°Cat35-85%relativehumidity
Productionandspecificationsaresubjecttooperating
conditions.Thespecifiedpaperthicknessfiguresare
givenforguidanceonly.Theactualperformanceofthe
machinewilldependonthe natureofthepaperand
coversused.Inlinewithapolicyofcontinualimprove-
ment,themanufacturerreservestherighttoalterthe
materialsorspecificationsofthisproductatanytime
withoutnotice.
RadioFrequency
Emissions Thisequipmenthasbeentestedandfoundtocomplywith
thelimitsforaClassAdigitaldevice,pursuanttopart15
oftheFCCRules.Theselimitsaredesignedtoprovide
reasonableprotectionagainstharmfulinterferencewhen
theequipmentisoperatedinacommercialenvironment.
Thisequipmentgenerates,usesandcanradiateradio
frequencyenergyand,ifnotinstalledandusedinaccord-
ancewiththeinstructionmanual,maycauseharmful

Page16 SQUAREBACK
interferencetoradiocommunications.Operationofthis
equipmentinaresidentialareaislikelytocauseharmful
interferenceinwhichcasetheuserwillberequiredto
correcttheinterferenceathisownexpense.

Page17
SYSTEM
SquareBackSystem
7DeclarationofConformity
Manufacturer'sName: MorganaSystemsLimited
Manufacturer'sAddress: GrampianGate
SnowdonDrive
Winterhill,MiltonKeynes,Bucks.
Mk61AP
UnitedKingdom
Declaresthattheproduct
ProductName: MorganaSquareBackSystem
ProductNumber: WA/ASM/0010onwards
ConformstothefollowingProductSpecifica-
tions:
Safety: 73/23/EEC&98/37/ECCouncilDirective'ontheapprox-
imationoflawsofMemberStatesrelatingtomachinery'.
BSEN60950:1992
EMC: 89/336/EECCouncilDirective'ontheapproximationof
lawsofMemberStatesrelatingtoelectromagneticcom-
patibility'.
EN55022:1998ClassA
EN55024:1998
EN61000-3-2:2000
EN61000-3-3:1995+A1:2001

Page18 SQUAREBACK
A
aboutyourautomaticSquareBackSystem5
adjustments5
bookthickness5
operatingmode6
assistance12
B
bookthickness5
bookthicknessadjustment5
bookletcontrolsprings12
bookletjam10
bookletmaker,connectionto8
bypassmode6
C
cleaning13
conformity17
D
declarationofconformity17
doublepass6
E
errorconditions10
errorindicator6
F
frontcover11
fuses12
H
handfeeding9
help4,12
I
infeed(handfeed)5
ink,wet9
installation4
introduction4
J
jam,booklet10
L
lid11
M
mainsinput5
mainson/off5
maintenance13
maintenance,operator13
O
on/offswitch5
onlineoperation8
operatingmode6
bypassmode6
doublepass6
singlepass6
squarebackmode4
operatingmodeadjustment5
operatormaintenance13
outfeed5
P
power,mainsinput5
problemsolving10
R
resetbutton6
S
safety4
serviceinterval13
sidelay5
singlepass6
smallbooklets11
specifications15
spine8,12
correct8
incorrect8
springs,bookletcontrol12
squarebackmode6
stacker7
stackerfullsensor5
stackerreleaselever5
stackersupport5
INDEX

Page19
SYSTEM
SquareBackSystem
U
usingyourautomaticSquareBackSystem8
W
wetink9
INDEX