Morgana Documaster Pro User manual

ISSUE1 MAY 2010
OPERATORSMANUAL(Part2)
(BookletMakingUnit)
70-152
MorganaSystemsLimited UnitedKingdom
Website: www.morgana.co.uk
Telephone:[phone] Facsimile:[phone]
DOCUMENTCREASING&AUTOMATIC
BOOKLETMAKINGMACHINE
DocumasterPro

CREASING/BOOKLETMAKING
CONTENTS
Specifications....................................1
Introduction.......................................3
BookletMaking................................10
Edge&CornerStapling..................14
EdgeStapling&Folding.................16
TheStapleHeads............................18
TroubleshootingChart....................22
Maintenance.....................................26
Appendices
Index..................................................44
ConnectingtheTMP.............................30
StaplePositionAdjustment..................32
SharpeningtheTMPBlade..................34
ConveyorClampAdjustment..............40

Page1SYSTEM
SPECIFICATION
IntendedUse
Power200VAexc.TRIM
Thisproductisintendedto
beusedforthestapling,
foldingandtrimmingof
materialsasspecified.
Electrical
Voltage115V,60Hzor
230V,50Hz
SinglePhase
(earthedsupplyrequired)
Power150VAexc.TRIM
(115V)500VAinc.TRIM
20VAStand-by
(230V)700VAinc.TRIM
30VAStand-by
Current4.4A(115V)or
3.0A(230V)
DocuMasterPro

Page2 CREASING/BOOKLETMAKING
WARNING!
Dimensions
BookMasterPro546,495,595mm,70kg
(W,D,H)21.5,19.5,23.4",154.3lb
BookMasterProwith546,830*,840mm**,79kg
MotorisedInfeed(W,D,H)21.5,32.7,33.1",174.2lb
TrimMasterPro546,650,595mm,85kg
(W,D,H)21.5,25.6,23.4",187.4lb
OutfeedConveyor404,1050,720mm,17kg
(W,D,H)15.9,41.3,28.4",37.5lb
*Depthwithoutpapertrayis710mm(28.0").
**Heightwithinfeedtrayinnormaloperatingposition.915mm(36")withTMP.
Noise74dB(A)
Productionmayvaryaccordingtooperatingconditions.
Inlinewithapolicyofcontinualproductimprovement,the
manufacturerreservestherighttoalterthematerialsor
specificationofthisproductatanytimewithoutnotice.
RadioFrequencyThisequipmenthasbeentestedandfoundtocomplywith
EmissionsthelimitsforaClassAdigitaldevice,pursuanttopart15
oftheFCCRules.Theselimitsaredesignedtoprovide
reasonableprotectionagainstharmfulinterferencewhen
theequipmentisoperatedinacommercialenvironment.
Thisequipmentgenerates,usesandcanradiateradio
frequencyenergyand,ifnotinstalledandusedinaccord-
ancewiththeinstructionmanual,maycauseharmful
interferencetoradiocommunications.Operationofthis
equipmentinaresidentialareaislikelytocauseharmful
interferenceinwhichcasetheuserwillberequiredto
correcttheinterferenceathisownexpense.
TheTrimMasterProunitcontainsamotorisedguillotine.
Itisthereforeessentialthatduecareistakenandthe
operatinginstructionsadheredtowhenusingtheunit.
Alsopayparticularattentiontoanyspecificwarnings
given.
†
†

Page3SYSTEM
FIGURE1
BMPwithOutfeedConveyor
FIGURE2
BMPwithMotorisedInfeedand
OutfeedConveyor
FIGURE3
BMP,TMPandOutfeed
Conveyor(MotorisedInfeed
canbefittedalso)
FIGURE4
BMPwithmanualInfeedGuide
INTRODUCTION
TheBookMasterProandTrimMasterProhave
beendesignedtostaple,foldandtrimbookletsofupto
20sheets,inawiderangeofpapersizes.Theirmodular
designmeansthattheyareequallyathomebeingused
offline,oronlinewithaWatkissCollator.Forofflineuse,a
MotorisedInfeedunitisrecommended,althoughaman-
ualInfeedGuideisalsoavailable.
TheBookMasterProandTrimMasterProunitsarealso
compatiblewithothermanufacturers'bench-topandta-
ble-topcollators.
DocuMasterPro

Page4 CREASING/BOOKLETMAKING
Important
Theinstructionsthatfollowincludetheset-upand
operatingprocedurefortheBookMasterPro,theTrim-
MasterProandtheMotorisedInfeedunits.Pleaseignore
thosepartsoftheinstructionsthatdonotapplytoyour
configuration.
IntheseinstructionstheBookMasterProisreferredtoas
theBMPandtheTrimMasterProisreferredtoastheTMP.
ItisrecommendedthatyourBookMasterProandTrim-
MasterProaresitedonalevelfloor.
Thismachinemustonlybepluggedintoanelectrical
supplylineofthecorrectvoltageandwithaproven
earth.Anydamagecausedbyfailuretodosowillnot
becoveredbythewarranty.Therequiredmachine
voltageisshownonthelabelontherearoftheunit
(seeFigure5).
YourBookMasterProandTrimMasterProunitshavebeen
designedwithsafetyasakeyfeatureandincorporate
safetycoverswhich,whenopened,willautomaticallycut
thepowertomovingparts.However,aswithallelectrical
equipment,whenchangingfusesorcarryingoutopera-
tionsotherthanthosedetailedinthisbook:
Alwaysfirstdisconnectthemachinefromthe
mainselectricitysupply.
INSTALLATION
SAFETYFIRST

Page5SYSTEM
MainsInput
MainsON/OFFSwitch
VoltageIndicatorLabel
FIGURE5
FIGURE6
Conveyor
Socket
StatusIndicatorLight
(Yellow)
StapleHeadIndicatorLight
(Red)
SWITCHINGONPlugintheBMPunittoasinglephasepowersupplyof
thecorrectvoltageasindicatedbythemainsinput(see
Figure5).
Alsoensuretheoutfeedconveyorcableisconnectedto
thesocketontheBMP(seeFigure6).IftheTMPis
installed,ensurethatthistooisconnected(seep.30).
MOTORISEDINFEEDAnoptionalMotorisedInfeed(P/N041-571)is
recommended.ThisfitsontotheBMPinfeedandmakes
offlineuseeasier.Apapertray(seeFigure7)issupplied
withtheMotorisedInfeed.
DocuMasterPro

Page6 CREASING/BOOKLETMAKING
MotorisedInfeed
P/N041-571
FIGURE7
PaperTray
Sidelay
FIGURE8
FixingClip
HandScrew
AnalternativeistheBookMasterInfeedGuide,
P/N041-572(seeFigure4)
FittingtheMotorisedInfeed
Loosenthetwohandscrews(seeFigure8)oneitherside
oftheMotorisedInfeed.

Page7SYSTEM
MotorisedInfeedSocket
FIGURE9
FIGURE10
Length
Adjustment
HandScrew
RearHandScrew
ConnecttheMotorisedInfeedinterfacecabletothe
socketonthetopoftheBMP(seeFigure9).
PositiontheMotorisedInfeedontheBMP,sothatthe
fixingclips(seeFigure8)locateinsidetheBMPinfeed.
Fittherearhandscrew(seeFigure10)andthentighten
thetwosidehandscrews.
Fitthepapertray(seeFigure7)ifrequired.
DocuMasterPro

Page8 CREASING/BOOKLETMAKING
TheBMPwillautomaticallystartwhenasetofsheetsis
fedintotheMotorisedInfeed.TheBMPwillautomatically
stopapproximately10secondsafterthelastfeed,and
returntothestandbymode.
TheMotorisedInfeedwillonlyfeedthenextsetwhenthe
BMPisready.
StatusIndicatorLight
TheyellowindicatorlightontheBMP(seeFigure6)shows
thestatusoftheunit.
StapleHeadIndicatorLights
TheredindicatorlightsontheBMPlid(seeFigure6)show
thestatusofthecorrespondingstaplehead.
IndicatorLightModeBMPStatus
IndicatorLightModeStapleHeadStatus
BlinkingoncepersecondTheunitisreadytorun
ConstantlyilluminatedTheunitisrunning
BlinkingrapidlyThereisajamorothererror
NotilluminatedBMP/TMPlidisopen,
paperisstuckinthepaper
pathortheunitisnot
switchedon
BlinkingoncepersecondThestaplecartridgeis
abouttoorhasrunout
ConstantlyilluminatedThestapleheadisselected
andreadytorun
BlinkingrapidlyThereisastapleheadjam
orothererror
NotilluminatedThestapleheadisnot
selected

Page9SYSTEM
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DocuMasterPro

Page10 CREASING/BOOKLETMAKING
FIGURE16
StapleHeadSelection
EdgeorCentreStapleSelection
Staple
Head
Selection
Indicator
Light
Centre
Staple
Edge
Staple
Staple
Head
Select
BOOKLETMAKING
SETTINGUPTHESelectCentreStapling
BMP&TMPUsingtheleverontheBMP(seeFigure16),selectcentre
stapleoperation(liftup).
SelecttheStapleHeads
Selectthetwocentrestapleheadsusingthebuttonnext
tothelever(seeFigure16).Thestapleheadindicator
lightsshowwhichheadsareselected.
Thepositionofthestapleheadscanalsobeadjusted.
Formoredetails,seepage19.
AdjusttheFoldRollerGap*
Thegapbetweenthefoldrollersisadjustedusingalever
totheleftofthefrontfaceoftheBMP(seeFigure17).

Page11SYSTEM
FIGURE17
FoldRollerAdjustmentLever
FIGURE18
Payout
Wheels
Scale
Theleverhas11positions.Tomovethefoldrollersfurther
apart(i.e.forlargersetsorthickerstock)movethelever
upwards.Movetheleverdowntobringthefoldrollers
closertogether.
Thefoldrollersshouldbesetsufficentlyclosetogetherto
produceaneatbooklet.Ifthefoldrollersaresettooclose
together,thebookletcoversmaybepulled(resultingin
damagearoundthestaples)orthespineofthebooklets
maybescuffed.Fine-tunethepositionoftheleverto
producethebestbookletspossible.
AdjusttheOutfeedConveyor
Slidethelargepayoutwheels(seeFigure18)upordown
theirmountingrailsothattheyarejustnippingthespine
ofthebookwhenitisreleasedfromtherollers.Usethe
scaleontheoutfeedasaguide.
DocuMasterPro

Page12 CREASING/BOOKLETMAKING
FIGURE19
Payout
Wheels
OffcutBox
Thecontactpointofthewheelsshouldbealignedwith
therequireddimensiononthescale,asshownbythe
dottedlineinthephoto(seeFigure18).Ifrequired,make
anyfineadjustmentsoncethejobisrunning.
Tip:Commonsizesarehighlightedonthescale.For
exampleforanA5(5½x8½")book,usetheA5
marker.
Hookthetrimoffcutbox(seeFigure19)ontotheTMP.
StartingtheJob
TheBMPwillautomaticallystartwhenthefirstsetofsheets
isplacedintotheMotorisedInfeed.
Tip:ThereisasensorontheTMPtodetectwhenthe
offcutboxisfull.Oncethissensorisactivated,the
BMPwillbeepaftereverysecondbooklet
produced.Ifyoustopfeedingsetsintotheinfeed,
theBMPwillreturntostandbyandbeepcontinous-
ly,untiltheoffcutboxisemptied(seeFigure19).

Page13SYSTEM
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DocuMasterPro

Page14 CREASING/BOOKLETMAKING
EDGE&CORNERSTAPLING
FIGURE20
OptionalThirdStapleHeadfor
CornerStapling
Note:
Cornerstaplingisonlypossibleifanoptionalthirdstaple
headisfitted(seeFigure20).
ORGANISINGTHELoadingtheMotorisedInfeed
JOBThestapleswillbeinsertedintothefeededgeoftheset.
Thesheetsshouldthereforebeloadedaccordingly,i.e
feedthesetspine-firstintotheunit.
Note:Themaximumsheetwidththatcanbe
edgestapledis250mm,9.84".
SelectEdgeStapling
UsingtheleverontheBMP(seeFigure21),selectedge
stapleoperation(pushdown).
Note:Thiswillautomaticallyswitchoffthefoldandtrim
actions.
SelecttheStapleHeads
Selecttherequiredstapleheadsusingthestaplehead
selectionbuttonnexttothelever(seeFigure21).The
stapleheadindicatorlightsshowwhichheadsare
selected.
Foredgestapling,selectthetwocentrestapleheads.
Forcornerstapling,selectthethirdheadonly.

Page15SYSTEM
FIGURE21
StapleHeadSelection
EdgeorCentreStapleSelection
Staple
Head
Selection
Indicator
Light
Centre
Staple
Edge
Staple
Staple
Head
Select
Note:
AdjusttheStapleHeads
Ifrequired,opentheBMPlidandadjustthepositionof
thestapleheadsviathelever(seeFigure24onp.26).
Adjusttheclincherstosuit.
AdjusttheFoldRollerGap
Thegapbetweenthefoldrollersisadjustedusingalever
totheleftofthefrontfaceoftheBMP(seeFigure17on
p.11).
TheLevershouldbemovedtoitslowestpositionwhen
edgeorcornerstitching.
Withcertainstocks,itispossiblethatedge-stitched
bookletsmayoccasionallyjamintheBMP.Anedge
stitchassistorplate(P/N907-442)willpreventthese
Bookletsfromjamming.Theplateissuppliedwith
theoptional3rdstaplerheadkit(P/N914-414)andcan
Alsobeorderedseparately.
DocuMasterPro

Page16 CREASING/BOOKLETMAKING
EDGESTAPLING&FOLDING
Ifrequired,itisalsopossibletoedgestaplethesetand
thenfoldit.Theonlylimitationtothisisthatthedistance
fromthestaplededgetothefoldmustbeatleasthalfthe
widthofthepaper.
Adjustments
Note:Thegapbetweenthefoldrollersmustbesettosuit
thesetsizewhenedgestaplingandfolding(see
p.10).
Note:Themaximumsheetwidththatcanbe
stapledinthismodeis250mm,9.84".

Page17SYSTEM
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DocuMasterPro

Page18 CREASING/BOOKLETMAKING
THESTAPLEHEADS
FIGURE22
IndicatorLight
StapleHead
FIGURE23
StapleCartridge
CHANGINGTHEWhenastaplecartridgerunsout,thecorrespondingred
STAPLECARTRIDGESindicatorlight(seeFigure22)willblinkoncepersecond.
Newcartridgesareavailable(P/N810-022).
Tochangeacartridge,firstopentheBMPlidbyturning
thehandletotheleftandlifting(seeFigure22).Thelidis
supportedbyastrutontherightside.
Graspthecartridgeatthetopandpulldirectlyawayfrom
thestaplehead,asshownbythearrowinthephoto(see
Figure23).