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

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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.