Morgana DocuMaster MFC User manual

Morgana Systems Limited ¤ United Kingdom ¤ www.morgana.co.uk ¤ Tel: [phone] ¤ Fax: [phone]
DocuMaster MFC
Service ManuaI
Multi-Feed & Crease Bookletmaking System
Part Number: 190-98
Issue 1a - April 2013

© Morgana Systems Ltd 2013
All Rights Reserved
Reproduction, adaptation, or translation without prior written permission is prohibited, except as
allowed under the copyright laws.
Morgana Systems Limited shall not be liable for errors contained herein or for incidental or
consequential damage in connection with the furnishing, performance or use of this material.

Morgana DocuMaster MFC - Service Manual i
CONTENTS
CONTENTS
SECTION 1 Introduction
1.1 Introduction ...................................................................................................................................2
1.2 Safety........................................................................................................................................3
1.3 Warnings ..................................................................................................................................4
1.4 Warning Labels ........................................................................................................................5
1.5 Orientation................................................................................................................................6
1.6 Machine Covers .......................................................................................................................7
1.7 Safety Interlocks ......................................................................................................................8
1.7.1 The Main Input Switch ......................................................................................................8
1.7.2 The Emergency Stop Switch .............................................................................................9
1.7.3 The Rear Guard ................................................................................................................9
1.8 Machine Overview....................................................................................................................10
1.9 Description of Operation .........................................................................................................13
1.9.1 The Test Set .....................................................................................................................13
1.9.2 The Paper Feed ................................................................................................................14
1.9.3 The Creaser ......................................................................................................................16
1.9.4 The Gathering Area ..........................................................................................................17
SECTION 2 Error Conditions
2.1 MFC Error Procedure....................................................................................................................20
2.1.1 General Problems .............................................................................................................20
2.1.2 Blower Motor Problems.....................................................................................................21
2.1.3 Vacuum Pump Problems ..................................................................................................22
2.1.4 GUI Panel Problems .........................................................................................................22
2.1.5 Suction Feeder Problems..................................................................................................23
2.1.6 Friction Feeder Problems..................................................................................................24
2.1.7 Creaser Module Problems ................................................................................................ 26
2.1.8 Gathering Area Problems..................................................................................................28
2.2 Paper Jams...............................................................................................................................29
2.3 Error Message List...................................................................................................................31
SECTION 3 Output Quality Problems
3.1 Crease Quality...............................................................................................................................36
SECTION 4 Service Procedures
4.1 Introduction ...................................................................................................................................40
4.1.1 Test Material .....................................................................................................................40
4.1.2 Calibration Stock...............................................................................................................40
4.1.3 Test Strips.........................................................................................................................40
4.2 Covers ......................................................................................................................................41
4.2.1 Remove the CAP Rear Panel............................................................................................ 41
4.2.2 Remove the CAP Top Cover and Front Panel .................................................................. 42
4.2.3 Open the Hinged Front Panel and the Hinged Top Panel .................................................42
4.2.4 Open the Hinged Rear Panel ............................................................................................43
4.2.5 Remove the RH Side Covers ............................................................................................44
4.2.6 Remove the LH Side Covers.............................................................................................44
4.2.7 Remove the Rear Guard ...................................................................................................45
4.2.8 Remove the Input Guide ...................................................................................................45
4.2.9 Remove the Motor Cover ..................................................................................................46
4.2.10 Remove the Motor Cover Base Plate ..............................................................................47
4.2.11 Remove the Gathering Area Centre Guard .....................................................................47

CONTENTS
ii Morgana DocuMaster MFC - Service Manual
4.2.12 Remove the Electrical Cabinet Cover ............................................................................. 49
4.3 Clear Paper Jams .................................................................................................................... 50
4.3.1 Clear Jams in the Creaser Rollers .................................................................................... 50
4.3.2 Clear Jams in the Creaser Blade ...................................................................................... 50
4.3.3 Clear Jams in the Paper Conveyor ................................................................................... 50
4.3.4 Clear Jams in the Gathering Area..................................................................................... 51
4.4 Diagnostic Procedures ........................................................................................................... 52
4.4.1 Test the CAP Temperature Control Switch ....................................................................... 52
4.4.2 Test the Static Elimination System ................................................................................... 53
4.4.3 Test a Feed Bin Emitter/Sensor Assembly ....................................................................... 56
4.4.4 Test a Feed Bin Clutch Assembly..................................................................................... 58
4.5 Machine Adjustments and Calibration................................................................................... 60
4.5.1 Adjust the Vacuum Pump Pressure .................................................................................. 60
4.5.2 Adjust the Main Drive Belt Tension................................................................................... 60
4.5.3 Adjust the Low Voltage Transformer Taps........................................................................ 61
4.5.4 Calibrate the Feed Head Separation Adjuster .................................................................. 61
4.5.5 Address the Feed Bins .....................................................................................................62
4.5.6 Initialise the Feed Bin Control PCBs................................................................................. 63
4.5.7 Adjust the Feed Bin Emitter/Sensor Low Range............................................................... 64
4.5.8 Adjust the Friction Feed Wheel Tracking .......................................................................... 65
4.5.9 Adjust the Friction Tray Alignment .................................................................................... 65
4.5.10 Adjust the Creaser Drive Belt ......................................................................................... 65
4.5.11 Adjust the Creaser Drive-Motor Gear Play...................................................................... 67
4.5.12 Adjust the Crease-Motor Belt.......................................................................................... 69
4.5.13 Adjust the Creaser Roller Gap ........................................................................................ 71
4.5.14 Adjust the Crease Blade-Set Alignment.......................................................................... 74
4.5.15 Adjust the DynaTilt Motor Gear Play............................................................................... 77
4.5.16 Adjust the DynaTilt Home Switch.................................................................................... 79
4.5.17 Adjust the Crease Pressure............................................................................................ 82
4.5.18 Calibrate the Creaser Module ......................................................................................... 83
4.5.19 Adjust the Jam Detector ................................................................................................. 91
4.5.20 Adjust the Edge-Sensor Set Sensitivity .......................................................................... 92
4.5.21 Calibrate the GUI Panel..................................................................................................95
4.5.22 Adjust the GUI Screen Display ....................................................................................... 95
4.5.23 GUI Access Levels ......................................................................................................... 96
4.5.24 Configure the MFC Machine Options.............................................................................. 97
4.5.25 Centre the Gathering Area Sidelays ............................................................................... 98
4.5.26 Adjust the Rear Guard Interlock Switch .......................................................................... 99
4.6 Replace Components - Cap Module....................................................................................... 102
4.6.1 Remove the CAP.............................................................................................................. 102
4.6.2 Replace the Blower Motor ................................................................................................ 103
4.6.3 Replace the Cooling Fan .................................................................................................. 104
4.6.4 Replace the TCS (Temperature Control Switch)............................................................... 105
4.6.5 Replace the Vacuum Pump .............................................................................................. 105
4.7 Replace Components - DRV Module ...................................................................................... 107
4.7.1 Remove the DRV Module ................................................................................................. 107
4.7.2 Replace the Drive Motor ................................................................................................... 112
4.7.3 Replace the GUI CPU....................................................................................................... 114
4.7.4 Replace the GUI Panel ..................................................................................................... 115
4.7.5 Replace the Interface PCB ............................................................................................... 115
4.7.6 Replace the Motor Drive PCB........................................................................................... 116
4.7.7 Replace the Blower Motor Air Filter .................................................................................. 117
4.7.8 Replace the High Voltage Anti-static Transformer ............................................................ 117
4.8 Replace Components - Suction Feed Bin.............................................................................. 119
4.8.1 Remove a Suction Feed Bin ............................................................................................. 119
4.8.2 Replace the Feed Band .................................................................................................... 121
4.8.3 Replace the Feed Clutch .................................................................................................. 123
4.8.4 Replace the Tray Lift Motor Assembly .............................................................................. 124
4.8.5 Replace the Air/Vacuum Solenoid Valve .......................................................................... 124
4.8.6 Replace the Paper Stop Fingers....................................................................................... 126
4.8.7 Replace the Feed Bin Control PCB .................................................................................. 127

Morgana DocuMaster MFC - Service Manual iii
CONTENTS
4.8.8 Replace the Emitter/Sensor Assembly ..............................................................................128
4.8.9 Replace the Tray Height Sensor .......................................................................................131
4.8.10 Replace the Tray Loaded Sensor....................................................................................132
4.8.11 Replace the Outer Conveyor Wheels..............................................................................133
4.8.12 Replace the Inner Conveyor Wheel ................................................................................ 135
4.8.13 Replace the Vacuum Filter..............................................................................................137
4.9 Replace Components - Friction Feed Bin ..............................................................................138
4.9.1 Replace the Feed Wheels.................................................................................................138
4.9.2 Replace the Feed Clutch...................................................................................................139
4.9.3 Replace the Feed Bin Control PCB...................................................................................140
4.9.4 Replace the Emitter/Sensor Assembly ..............................................................................140
4.9.5 Replace the Tray Loaded Sensor...................................................................................... 142
4.9.6 Replace the Outer Conveyor Wheels ................................................................................142
4.9.7 Replace the Inner Conveyor Wheels.................................................................................144
4.10 Replace Components - Creaser Module.................................................................................145
4.10.1 Remove the Creaser Module ..........................................................................................145
4.10.2 Remove the Creaser Unit................................................................................................ 149
4.10.3 Replace the Input Rollers................................................................................................152
4.10.4 Replace the Output Roller...............................................................................................153
4.10.5 Replace the Jam Detector Assembly ..............................................................................154
4.10.6 Replace the Edge Sensor Set .........................................................................................156
4.10.7 Replace the Creaser Position Sensor Assembly ............................................................. 157
4.10.8 Replace the DynaTilt Motor............................................................................................. 158
4.10.9 Replace the Crease Motor ..............................................................................................160
4.10.10 Replace the Creaser Drive Motor.................................................................................. 161
4.10.11 Replace the Anti-Static Brushes....................................................................................163
4.10.12 Replace the DynaTilt Home Switch ...............................................................................165
4.10.13 Replace the Creaser Blade Out Switch ......................................................................... 166
4.11 Replace Components - Gathering Area..................................................................................167
4.11.1 Replace the Tamper Solenoid.........................................................................................167
4.11.2 Replace the Paper Stop Solenoid ...................................................................................168
4.11.3 Replace the Flow Sensor ................................................................................................168
4.11.4 Replace the Ioniser Bar ..................................................................................................170
4.11.5 Replace the Base Control PCB .......................................................................................171
4.12 Replace Components - Electrical Cabinet .............................................................................173
4.12.1 Replace the Processor PCB ...........................................................................................173
4.12.2 Replace the Controller PCB Assembly............................................................................173
4.12.3 Replace the Dual Stepper Drive PCB .............................................................................174
4.12.4 Replace the High Power Stepper Drive PCB ..................................................................175
4.12.5 Replace the Low Power Stepper Drive PCB ................................................................... 175
4.12.6 Replace the 24V PSU .....................................................................................................177
4.12.7 Replace the 48V PSU .....................................................................................................178
4.12.8 Replace the 5V/24V PSU ................................................................................................ 179
4.13 Maintenance Procedures.........................................................................................................180
4.13.1 Clean the MFC................................................................................................................180
4.13.2 Select Cleaning Mode .....................................................................................................180
4.13.3 Clean the Feed Bin Emitter/Sensor................................................................................. 181
4.13.4 Clean the Edge-Sensor Set ............................................................................................181
4.13.5 Clean the Ioniser Bar ......................................................................................................182
4.14 The MFC Maintenance Schedule ............................................................................................183
4.14.1 General Information ........................................................................................................183
4.14.2 The CAP Module Maintenance Schedule........................................................................184
4.14.3 The DRV Module Maintenance Schedule .......................................................................184
4.14.4 The Suction Feed Bin Maintenance Schedule ................................................................184
4.14.5 The Friction Feed Bin Maintenance Schedule.................................................................185
4.14.6 The Creaser Module Maintenance Schedule .................................................................. 186
4.14.7 The Gathering Area Maintenance Schedule ...................................................................186
4.14.8 The Electrical Cabinet Maintenance Schedule................................................................187

CONTENTS
iv Morgana DocuMaster MFC - Service Manual
SECTION 5 Parts Lists
SECTION 6 General Procedures
6.1 MFC Specifications ...................................................................................................................... 192
6.2 MFC System Data Sheet.......................................................................................................... 193
6.3 MFC Test Program Overview.................................................................................................. 194
6.3.1 Get the MFC Test Program .............................................................................................. 194
6.4 MFC Test Program Description .............................................................................................. 195
6.4.1 The Title Bar..................................................................................................................... 195
6.4.2 The Menu Bar................................................................................................................... 195
6.4.3 The Tool Bar..................................................................................................................... 196
6.4.4 The Page Tabs ................................................................................................................. 197
6.4.5 The Control Bar ................................................................................................................ 197
6.5 Create the MFC Test Program Connection............................................................................ 198
6.5.1 Connect the MFC Test Program ....................................................................................... 198
6.6 The Diagnostic Tools Pages................................................................................................... 200
6.6.1 The ERROM Contents Page............................................................................................. 200
6.6.2 The Creaser Tools Page................................................................................................... 201
6.6.3 The Inputs Display Page................................................................................................... 202
6.6.4 The Terminal Page ........................................................................................................... 203
6.6.5 Diagnostic Port Commands .............................................................................................. 203
6.7 The MFC Machine Configuration Wizard Description........................................................... 207
6.7.1 The Calibration Page Title ................................................................................................ 207
6.7.2 The Procedure Instructions............................................................................................... 207
6.7.3 The Crease Position Information ...................................................................................... 208
6.7.4 The Command Buttons..................................................................................................... 208
6.7.5 The Control Bar ................................................................................................................ 208
6.7.6 The Review & Save Setting Page..................................................................................... 210
SECTION 7 Electrical and Control System
7.1 Fuses........................................................................................................................................ 214
7.1.1 MFC Fuses ....................................................................................................................... 214
7.2 Low Voltage Transformer Tappings....................................................................................... 215
7.2.1 Low Voltage Transformer Input ........................................................................................ 215
7.2.2 Low Voltage Transformer Output...................................................................................... 216
7.3 PCBs......................................................................................................................................... 217
7.3.1 Windjammer Control PCB................................................................................................. 217
7.3.2 Interface PCB ................................................................................................................... 217
7.3.3 Motor Drive PCB............................................................................................................... 218
7.3.4 Suction Feed Bin Control PCB ......................................................................................... 219
7.3.5 Friction Feed Bin Control PCB.......................................................................................... 220
7.3.6 Base Control PCB ............................................................................................................ 220
7.3.7 Creaser Processor PCB ................................................................................................... 221
7.3.8 Creaser Controller PCB Assembly.................................................................................... 221
7.3.9 Low Power Stepper Motor Drive PCB............................................................................... 223
7.3.10 High Power Stepper Motor Drive PCB ............................................................................ 224
7.3.11 Dual Stepper Motor Drive PCB ....................................................................................... 226
7.4 Software Overview .................................................................................................................. 227
7.4.1 Get the GUI CPU software ............................................................................................... 227
7.4.2 Get the Creaser Control Software..................................................................................... 227
7.5 Software System Description ................................................................................................. 229
7.5.1 GUI CPU Control Software ............................................................................................... 229
7.5.2 Creaser Control Software ................................................................................................. 230
7.6 GUI CPU Software Updates through an RS232 Connection................................................. 232
7.6.1 Install the GUI Software through an RS232 Connection ................................................... 233
7.6.2 Update the GUI Software through an RS232 Connection................................................. 235
7.7 GUI PCPU Software Updates through a Network Connection ............................................. 236

Morgana DocuMaster MFC - Service Manual v
CONTENTS
7.7.1 Install the Software through an Ethernet Connection ........................................................ 237
7.7.2 Update the Software through the Ethernet Connection .....................................................238
7.7.3 Configure the Solarwinds TFTP Server.............................................................................238
7.7.4 How to find the IP Address................................................................................................239
7.7.5 Create the Ethernet Connection........................................................................................240
7.7.6 Update the MFC Software through an Ethernet Connection .............................................241
7.8 Crease Control Software Updates though a PICkit 2 Programmer ...................................... 242
7.8.1 Create the PICkit 2 Connection.........................................................................................243
7.8.2 Transfer the Creaser Control Software to the PICkit 2 Programmer .................................244
7.8.3 Update the Creaser Control Software ...............................................................................246
7.8.4 Update the Creaser Control Software - Replace the Processor PCB ................................246
7.9 GUI CPU Error Beeps ..............................................................................................................247
7.10 PC Configuration Problems ....................................................................................................248
7.10.1 Install Hyperterminal on a Vista or Windows 7 Operating System...................................248
7.10.2 Setting the Network Port Number Range (Vista and Windows 7)....................................248
SECTION 8 Installation Manual
8.1 Before Installation ...................................................................................................................252
8.2 Unpack the MFC.......................................................................................................................253
8.2.1 Unload the MFC................................................................................................................253
8.2.2 Install the Adjustable Feet.................................................................................................254
8.2.3 Remove the Transport Brackets........................................................................................ 254
8.3 Install the MFC .........................................................................................................................255
8.3.1 Install the CAP ..................................................................................................................255
8.3.2 Adjust the Voltage Settings ...............................................................................................255
8.3.3 Install the MFC..................................................................................................................255
8.3.4 Connect the Booklet-Maker System.................................................................................. 255
8.3.5 Turn on the Booklet-Maker System................................................................................... 256
8.3.6 Turn on the MFC...............................................................................................................256
8.3.7 Make Some Book Samples ...............................................................................................257
8.3.8 Check the Book Quality ....................................................................................................257

CONTENTS
vi Morgana DocuMaster MFC - Service Manual

Morgana DocuMaster MFC - Service Manual 1
1
SECTION 1 Introduction
.

1. Introduction - Introduction
2 Morgana DocuMaster MFC - Service Manual
1. Introduction
1.1 Introduction
The Morgana DocuMaster MFC (Multi-Feed Creaser) booklet making system
automatically gathers sheets of pre-collated, sequentially printed paper and transfers
them to an online bookletmaker to produce saddle stapled booklets with a
SquareBack™ finish. The MFC can be programmed to insert heavier cover-weight
stocks, and to crease individual sheets using the unique DynaTilt creasing mechanism,
which prevents the cracking of substrates and printed images when they are stapled
and folded. The DynaTilt mechanism registers each sheet and automatically adjusts
the creaser blade-set so that it is perfectly square to the sheet. An integral static
elimination system neutralises any charge present in the fed sheets before they enter
the gathering station in the base of the machine. When a complete set (book) has been
gathered it is automatically released into the online booklet making system where it is
stapled, folded, trimmed and given an optional SquareBack™ finish.
This service manual provides service information for the MFC machine. Service
information for the bookletmaker, trimmer and squareback is given in separate
manuals.

Morgana DocuMaster MFC - Service Manual 3
1. Introduction - Safety
1
1.2 Safety
Follow good Health and Safety procedures when you lift or move the equipment. If the
machine is operated when the covers are removed, be careful to prevent personal
injury.

1. Introduction - Warnings
4 Morgana DocuMaster MFC - Service Manual
1.3 Warnings
The warnings that follow are used in this manual.
Warning: a WARNING message tells you that a procedure or operation can be
dangerous. To prevent injury, you must obey the instructions.
Caution: a CAUTION message tells you that a procedure or operation can damage
the machine. to prevent damage, you must obey the instruction.

Morgana DocuMaster MFC - Service Manual 5
1. Introduction - Warning Labels
1
1.4 Warning Labels
The warning labels that follow are used in the DocuMaster MFC.
Warning Labels Description Location
Shows an entanglement hazard.
Black illustration on yellow
triangle.
Black text on orange caution bar
and white background.
Hinged rear
panel above the
rear guard.
Shows that mains input voltages
are present.
Black figure on a yellow
background.
Mains input and
areas with high
voltage supply.
Shows that high voltages are
present.
Black text on yellow background.
High-voltage
Anti-static
transformer.
Shows high voltages behind cover.
Black figure on a yellow
background.
Hinged top
panel.
Shows protective earth bonding.
White figure on a green
background.
DRV module at
earth bonding
points.

1. Introduction - Orientation
6 Morgana DocuMaster MFC - Service Manual
1.5 Orientation
Procedures or descriptions refer to the right hand (RH) or left hand (LH) side of the
machine (see Figure 1.1).
•The RH or LH is as seen from the feed bins (Front).
•The GUI touch screen is at the left
•The conveyor is at the rear.
Rear
RH Side
LH Side
Emergency Stop Switch
BookletMaker
GUI Touch Screen
Front
Figure 1.1 DocuMaster MFC Orientation

Morgana DocuMaster MFC - Service Manual 7
1. Introduction - Machine Covers
1
1.6 Machine Covers
The MFC has 2 types of covers:
•User access covers that are opened to clear a paper jam or for maintenance.
•Fixed covers that must be removed when included in a service procedure.
Warning: Be careful to avoid serious injury if you are working on the MFC when the
fixed covers are removed.
The user access covers are the:
•rear guard
•input guide.
The fixed covers are the:
•hinged top panel
•hinged front panel
•hinged rear panel
•motor cover
•electrical cabinet cover
•LH side covers
•RH side covers
•CAP rear panel
•gathering area centre guard.

1. Introduction - Safety Interlocks
8 Morgana DocuMaster MFC - Service Manual
1.7 Safety Interlocks
The DocuMaster MFC has safety interlocks that:
•Protect the operator when the machine is open for maintenance or to clear a jam.
•Protect a service technician when the machine is open for service procedures.
1.7.1 The Main Input Switch
Main Input Switch
Figure 1.2 MFC Main Input Switch
The main input switch controls the supply of electrical power to the MFC. The switch
has two positions.
Position Status Information
0OFF The switch stops the supply of electrical power to the MFC
ION The switch starts the supply of electrical power to the MFC
Warning: Always remove the main power cord from the MFC when you work on the
CAP, DRV and electrical-cabinet modules. High-voltage electricity can cause serious
injury and death.
Note: The mains input switch is illuminated when it is set in the
ON (I) position.

Morgana DocuMaster MFC - Service Manual 9
1. Introduction - Safety Interlocks
1
1.7.2 The Emergency Stop Switch
Drive Module (LH side)
Emergency Stop Switch
Figure 1.3 Emergency Stop Switch
The emergency stop interlock removes mains power from the drive system when the
emergency stop switch is pushed in.
These systems do not operate when the emergency stop switch is pushed in:
•the conveyor drive
•the creaser conveyor drive
•the creaser mechanism.
1.7.3 The Rear Guard
Figure 1.4 Rear Guard
The rear guard interlock removes the drive signal when the rear guard is removed from
the MFC.
These systems do not operate when the rear guard is removed:
•the conveyor drive
•the creaser conveyor drive.

1. Introduction - Machine Overview
10 Morgana DocuMaster MFC - Service Manual
1.8 Machine Overview
The MFC has a modular construction that makes it easy to disassemble for servicing
and maintenance.
1.
2.
7.
3. GUI Panel
4. Feed Bin
5. Creaser Module
6. Gathering Area
SquareBack
Trimmer
BookletMaker
Figure 1.5 DocuMaster MFC with Online Booklet Maker and SquareBack System
1. The CAP (Combined Air Pump): The CAP module includes the blower and the vacuum
motors in an enclosed acoustically-insulated box. The internal temperature of the CAP is
controlled by forced-air cooling operated by a thermostat sensor. The cooling fan will continue
to operate after the MFC has stopped until the internal temperature is below 50°C.
2. The DRV (Drive Unit): The DRV module includes the main drive motor and
electronics necessary to control the MFC feed system. It also includes the high voltage
anti-static transformer that operates the ioniser bar in the sheet gathering area.
The components in the DRV are the:
•main drive motor
•feeder and touchscreen CPU
•blower motor control PCB
•interface PCB
•low-voltage transformer
•high-voltage anti-static transformer
•mains inlet plug
•mains input ON/OFF switch
•emergency stop switch
•air filter.
The DRV module has three access doors that can be opened by an engineer for
service and maintenance.

Morgana DocuMaster MFC - Service Manual 11
1. Introduction - Machine Overview
1
3. The GUI (Graphical User Interface): The GUI control panel has an 8.2" colour
touch screen that the operator uses to control the MFC and online bookletmaker
system.
Note: the touchscreen has a power save function. If it is not
used for a period of time it automatically dims. After an
extended period it is turned off. Touch the screen to turn it on.
The GUI is attached to the LH side of the MFC in the same way as the side covers and is
controlled by the CPU inside the DRV module. A touch sensitive START button and a touch
sensitive STOP button on the bezel above the screen are used to operate the MFC.
4. The Feed Bins: The feed bins are loaded with paper in centre-referenced trays.
Multiple bins can be electronically linked together for continuous running and the
bottom two bins can be set to insert cover stock. The feed bin takes an individual sheet
from the top of the paper stack and moves it through the built-in SMART detection
system, which senses miss, double, trailing and jam errors. A separation air supply is
connected to all bins and simple controls on each feed bin let the operator adjust the
feeder to give an accurate sheet feed.
The standard MFC feeder configuration is:
•3 suction feed bins
•1 friction feed bin.
Note: The friction feed bin must always be positioned directly
above the creaser module where it can be used to insert
heavier weight cover-stocks up to 300gsm.
An alternative configuration that is available upon request is:
•4 suction feed bins.
Note: This configuration would normally be used if a
customer's stocks were unsuitable for a Friction feed system
and if he only used stocks up to 240gsm.
5. The Creaser Module: The creaser module is installed below the feed bins and can
be programmed from the GUI to crease covers, centre spreads or even all of the
sheets in a booklet.
To compensate for sheet skew during the feed process, the creaser control system
uses an array of sensors to register the lead-edge of each sheet as it enters the
creaser module. The creaser control system automatically sets the creaser blade-set
to be the same as the skew of the sheet, which makes a perfectly square crease every
time. This mechanism is known as the DynaTilt.
The crease pressure is infinitely adjustable and uses two simple mechanical
adjustment cams to produce up to 6 metric tonnes of pressure between the crease
blade and the crease matrix.
6. The Gathering Area: The gathering area is part of the MFC's base. Paper is put into
the gathering area through a neutralising ion field that is generated by an integral static
elimination bar. The sheets are controlled with a combination of conveyor guides and a
variable pressure air knife to make sure that they gather neatly and remain in the
correct order.

1. Introduction - Machine Overview
12 Morgana DocuMaster MFC - Service Manual
When the complete set (booklet) has been gathered, adjustable sidelays knock the
sheets up and an electronically controlled latch releases them into the online
bookletmaker that is positioned below the MFC. A flow sensor above the latch senses
when the sheets have gone into the bookletmaker so that the latch can reset for the
next sheets.
An electrical interface between the online bookletmaker and the gathering area gives
full setup and control of the booklet making system from the GUI, and will stop the
MFC if a bookletmaker error is sensed.
7. The Electrical Cabinet: The electrical cabinet is located at the rear of the gathering
area base and it houses the electrical control system for the creaser module and MFC
drive system.
Note: The high voltage AC power supply to the electrical
cabinet is from the MFC's emergency stop switch. When the
emergency stop switch is pushed in, the high voltage AC power
supply is removed.
The components in the electrical cabinet are the:
•creaser controller PCB
•stepper-motor control PCBs
•DC PSUs (Power Supply Units)
•fuses
•diagnostic interface plug.