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.

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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