Morgana MB300 XL Pro User manual

MB300 XL Pro
rev.0.2ID03570
OPERATOR MANUAL
Translation of the original instructions

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REVISIONE DATA MOTIVO
0.0 23/03/2017 Prima edizione
0.1 20/04/2018 Aggiornamento foto
0.2 15/02/2019 Aggiornamento Dich. CE Integrazione Lista Fusibili
Aggiornamento capitolo Spec. Elett.

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CONTENTS
1. INTRODUCTION .................................................................................... 5
1.1 DECLARATION OF CONFORMITY...............................................................6
1.2 CAUTION LABELS.........................................................................................7
1.3 SAFE OPERATION.........................................................................................8
1.3.1 GENERAL................................................................................................................. 8
1.3.2 USER QUALIFICATION ......................................................................................... 8
1.3.3 MACHINE OPERATORS......................................................................................... 8
1.3.4 GUIDELINES FOR SAFE OPERATION................................................................ 9
1.3.5 PERSONAL PROTECTIVE EQUIPMENT.............................................................. 10
1.4 RESIDUAL RISKS...........................................................................................11
1.5 INTENDED USE ..............................................................................................12
2. TRANSPORT.......................................................................................... 13
3. DISPOSAL.............................................................................................. 14
4. STORAGE............................................................................................... 15
5. GENERAL DESCRIPTION ................................................................... 16
5.1 TECHNICAL SPECIFICATIONS....................................................................16
5.2 ELECTRICAL SPECIFICATIONS..................................................................17
5.3 PNEUMATIC SPECIFICATIONS....................................................................18
5.4 NAME OF THE MAIN PARTS ........................................................................19
5.4.1 VICE UNIT................................................................................................................. 19
5.4.2 MILLING UNIT.......................................................................................................... 20
5.4.3 GLUE UNIT............................................................................................................... 20
5.4.4 PRESS UNIT............................................................................................................. 21
5.4.5 GLUE TANK AND CLEANER ................................................................................. 21
5.4.6 SHAVINGS EXTRACTOR MACHINE..................................................................... 22
5.4.7 COMMAND DEVICES AND INDICATORS ............................................................ 22
5.4.8 ACCESSORIES SUPPLIED.................................................................................... 23
5.5 OPERATOR PANEL........................................................................................24
5.5.1 MAIN PAGE .............................................................................................................. 24
5.5.2 CART PARAMETERS PAGE (2)............................................................................. 25
5.5.3 GLUE UNIT PAGE (3).............................................................................................. 27
5.5.4 PRESS OPERATION PAGE (4)............................................................................... 28
5.5.5 ADVANCED SET-UP PAGE (7)............................................................................... 30
5.5.6 ALARMS PAGE (8)................................................................................................... 35
5.5.7 PROCESSING RECIPES PAGE (10)...................................................................... 36
5.5.8 BOOKS COUNTER PAGE (12)............................................................................... 37
5.5.9 PROCESSING TYPE PAGE (14)............................................................................. 38
5.6 SAFETY DEVICES..........................................................................................39

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6. INSTALLATION...................................................................................... 41
6.1 PHYSICAL CHARACTERISTICS OF THE POSITIONING AREA..............41
6.2 FLOOR .............................................................................................................41
6.3 LIGHTING ........................................................................................................41
6.4 ENVIRONMENTAL CONDITIONS.................................................................41
6.5 POSITIONING AND WORKSPACES ............................................................42
6.6 LAYOUT ...........................................................................................................43
6.7 POWER CONNECTION..................................................................................44
6.7.1 EARTH CONNECTION............................................................................................ 44
6.8 PNEUMATIC CONNECTION..........................................................................45
7. OPERATION AND USE ......................................................................... 46
7.1 PREPARATION OF THE MACHINE..............................................................46
7.1.1 GLUE TANK LOADING ........................................................................................... 46
7.1.2 LOAD THE CLEANER............................................................................................. 51
7.1.3 MEASURING THE BOOK........................................................................................ 53
7.2 START PROCESSING....................................................................................54
7.2.4 GLUE REACTIVATING PROCEDURE................................................................... 54
7.2.5 LAUNCH.................................................................................................................... 57
8. MACHINE CLEANING........................................................................... 59
8.1 END OF WORK CLEANING...........................................................................60
8.2 CLEANING PROCEDURE FOR SPINE GLUE EXTRUDER ......................62
8.3 SIDE GLUE EXTRUDERS CLEANING PROCEDURE................................64
8.4 DETAILS CLEANING......................................................................................66
8.5 GLUE SYSTEM DRAINAGE..........................................................................68
9. MAINTENANACE................................................................................... 71
9.1 PINS LUBRICATION.......................................................................................71
9.2 DEEP CLEANING OF GLUE UNIT CLAMP .................................................73
9.3 COATING HEAD DEEP CLEANING..............................................................75
9.4 LISTA FUSIBILI...............................................................................................78
10. PROBLEMS - SOLUTIONS................................................................... 79

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1. INTRODUCTION
It is essential for operator safety and correct use of the machine reading this
manual of use and maintenance.
This manual describes how to use the machine, the conguration of the basic operations work. This
manual was written so as to be easily understandable even to those users who have never used
this type of machine. To ensure that the machine provides maximum performance read this manual
carefully before using it. After reading, keep this manual in a safe place and consult it as needed.

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1.1 DECLARATION OF CONFORMITY
DICHIARAZIONE DI CONFORMITÀ CE DIRETTIVA CE PER MACCHINE 2006/42/CE, E
SEGUENTI DIRETTIVE EUROPEE (ALLEGATO IIA)
CE CONFORMITY DECLARATION DIRECTIVE FOR MACHINES 2006/42/CE,
AND FOLLOWING EUROPEAN DIRECTIVES (ANNEX IIA)
• COSTRUTTORE - MANUFACTURER: K.G.S.SRL
Via della Tecnica, 37 - 35035 - Mestrino (PD) Italy
• RESPONSABILE DELLA COSTRUZIONE DEL FASCICOLO TECNICO - RESPONSIBLE
FOR PREPARING THE TECHNICAL DOSSIER: RACCANELLO ROBERTO
CON LAPRESENTE DICHIARIAMO CHE LA FABBRICAZIONE DEL / WE HEREWITH DECLARE
THAT THE MANUFACTURE OF:
• MODELLO TIPO / MODEL TYPE : 300-B (DIGIBOOK)
• MATRICOLA / SERIAL : MB300-XXXX
• ANNO DI COSTRUZIONE / MANUFACTURED IN: 2019
CORRISPONDE ALLE SEGUENTI DISPOSIZIONI NELLA VERSIONEATTUALMENTE VALIDA /
IS IN AC-CORDANCE WITH THE FOLLOWING DIRECTIVES AS IT IS :
• Direttiva CE per Macchine 2006/42/CE / Directive 2006/42/CE
• Direttiva EMC 2014/30/UE / EMC Directive 2014/30/UE
• Direttiva sulla Bassa tensione 2014/35/UE / Low Voltage Directive 2014/35/UE
NORME ARMONIZZATE APPLICATE , IN PARTICOLARE
HARMONIZED STARDARDS, IN DETAIL:
• EN 1010
• EN 60 204-1
• EN 61 000-6-2, EN 61 000-6-3, EN 61 000-6-4
• EN 60 950
Mestrino, (PD) Italy
__/__/2019
Dott. Marco Alfredo Tumaini

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1.2 CAUTION LABELS
During the manual and applied to the machine uses the following symbols to alert of any danger to
persons and / or property damage.
In extreme cases of non-compliance can cause damage to persons or property.
CAUTION! You place before certain procedures. His failure to comply may result
in injury to the operator, maintainer, installer or the machine.
CAUTION! Sharp blades!
Cut Risk
CAUTION! Electrical voltage!
Risk of electric shock
CAUTION! Hot surfaces!
Risk of burns.
CAUTION! Risk from rotating parts! Risk of crushing.
CAUTION! Hazardous moving parts, do not attempt ngers and other body parts.
CAUTION! Risk from rotating parts! Risk of crushing
CAUTION! Hazardous moving parts, do not attempt ngers and other body parts.

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1.3 SAFE OPERATION
1.3.1 GENERAL
Themanufacturer guaranteesthat thecontents ofthis manualare inaccordance withthe procedures
required by the machine. The manufacturer shall not therefore be liable for any use of the machine
in a manner inconsistent with the information contained in this manual.
1.3.2 USER QUALIFICATION
This machine is intended to be used by a single operator!
The operator must be fully trained on how to act in the occurrence of possible faults, malfunctions or
hazards to themselves or others, and must meet the following requirements:
Immediately stop the machine in case of emergency by acting the emergency button (red button
installed on board of the same). Do not attempt to go beyond the tasks and technical knowledge.
Immediately inform their superior responsible in case of problems, and avoid taking personal
initiatives.
It is assumed that the operator has at least the following requirements:
▪General culture and specic enough to level, each for its expertise, to read and understand the
contents of the manual in the parts that concern him, including the correct interpretation of the
drawings and diagrams electrical, pneumatic and hydraulic systems;
▪Ability to correctly interpret the symbols and video messages;
▪overall knowledge of the machine and the plant in which it is inserted;
▪Experience in the use of binding technology;
▪Ability and knowledge to take action in case of an emergency and uses protective equipment.
1.3.3 MACHINE OPERATORS
OPERATOR: Standard use of the machine, with the possibility of parameter settings, load glue,
aspirator emptying and nal cleaning work.
TECHNICAL OPERATOR: glue emptying and machine cleaning.
TECHNICAL INSTALLATION: opening the electrical panel and interventions on electrical system

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1.3.4 GUIDELINES FOR SAFE OPERATION
The application of procedures other than those specically described in this manual may cause
operational errors. Carefully read the safety instructions in this manual.
The manufacturer is relieved from any liability arising from an arbitrary and improper use of the
machine, such as:
▪Use of the machine by untrained personnel;
▪Use contrary to the applicable law;
▪Incorrect Installation;
▪Defective power supply and / or pneumatic supply;
▪Total or partial disregard of the instructions of use;
▪Changes or other actions not authorized by the manufacturer;
It’s forbidden to remove or render inoperative the guards provided for the safety of persons, as well
as tampering with and / or modify, even partially, the safety devices installed on the machine. In case
of alarm due to the intervention of the safety, the operator must request the immediate intervention
of the qualied maintenance personnel.
It is forbidden to intervene on the screws marked with red or yellow tracer. The intervention
on these screws leads to a malfunction of the machine.
The manufacturer declines all responsibility in case of any damage to persons, animals or property,
caused by the tampering of the protections.

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1.3.5 PERSONAL PROTECTIVE EQUIPMENT
Safety clothing is not supplied with the machine and must be procured by the user.
In the various sections of the manual will be shown the symbols of personal protection equipment to
be in the di󰀨erent operations to be carried out.
Tight clothing, to avoid that they not remain hooked to protruding parts.
Long hair should be worn away from the moving machinery or in a net.
Do not wear watches or jewellery.
Eye protection against possible splashes of glue or PUR Cleaner high
temperature.
Protective Gloves
Respirator mask suitable for the use of removing used glue.

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1.4 RESIDUAL RISKS
These are the risks that cannot be completely eliminated either by protective devices or the design
of the machine.
Glue Head.
CAUTION!
Hot surfaces!
Risk of burns.
Use protective gloves.
Glue tank.
CAUTION!
Hot surfaces!
Risk of burns.
Use protective gloves.
Milling Area.
CAUTION!
The disc cutter contains several
types of cutting tools.
Use protective gloves, in case you
want to remove the roughening.

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1.5 INTENDED USE
The machine is designed to bind books using the following materials:
▪Signatures or single sheets of paper (printed or not) for the book block;
▪Card as book cover.
The machine must be used by one operator only to the extent and in the manner prescribed in this
user manual.
Any other use is forbidden, such as:
▪Milling / notching of book spines already bound (e.g. bound with glue, staples, stitched, seal
point);
▪Use of materials other than those specied in the previous paragraph;
▪Operations outside of the specications of the data Sheet.
The user is solely responsible for damage to persons or property that result from improper use,
outside of the intended use.
It is forbidden to use the machine in explosive atmosphere conditions, of ammable atmosphere and
where there is excessive dust.

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2. TRANSPORT
CAUTION! For no reason the sta󰀨 is authorized to pass under a suspended load
during transport or in the vicinity of it.
CAUTION! The transport phase will have to be carried out by trained competent
and authorized personnel, equipped with the necessary personal safety
protections.
The binder must be moved by means of a forklift. It can only be lifted by forking the two long sides,
front and rear side.
The front of the frame includes channels to insert the forks. (see bottom image).
The machine can only be moved having removed the output belt.
For the nal positioning or for small movements a trans-pallet can be used.
IMPORTANT
a) Tools for clamping and lifting are not provided.
b) The disposal of packaging materials is at the recipient’s care and must be performed in
accordance with the laws in the country where it will be carried out.
c) Remove dust and external dirt accumulated during the transport phases.
988 for fork lift
164 164
654 for trans pallet
6
D
C
B
A
E
F
G
H
E
A
B
C
D
5 4 3 2 1 7 8 9 10 11 12
1 2 3 4 5 6 7
A
Materiale di partenza:
QUOTE LINEARI E ANGOLARI
SECONDO ISO 2768 mK
4/4
ASS
A0100001-10
Raccanello -
14-11-2016
Massariolo
14-11-2016
Massariolo
Dimensione:
1:7.5
-
-
DIGIBOOK 300 REL.10
--
IL PRESENTE DISEGNO E' DI PROPRIETA' DELLA "K.G.S." NON PUO' ESSERE RIPRODOTTO NE' TRASMESSO A TERZI SENZA APPROVAZIONE SCRITTA
THIS DRAWING MUST NOT BE REPRODUCED WITHOUT OUR WRITEN CONSENT
Peso:
MATERIALE : -
K.G.S.
Srl
±2
±1.2
±0.8
±0.5
±0.3
±0.2
oltre 2000 a 4000
oltre 1000 a 2000
oltre 400 a 1000
oltre 120 a 400
oltre 30 a 120
oltre 6 a 30
METRIC
Foglio
Nr / di
Revisione
SolidWorks
Sistema CAD:
Trattamento:
Designazione materiale:
±0.1
PROGETTISTA
DISEGNATORE
Tolleranza
Mestrino
Sito
File: A0100001-10_300 REL.03
VERIFICATORE
TOLLERANZE GENERALI
Spigoli vivi secondo ISO 13715
Superfici : ISO 1302
Getti secondo ISO 8062-CT11
Saldature secondo ISO 13920-BF
Piegature secondo DIN 6935
Stampaggio secondo DIN 6930-m
Filettature secondo ISO 965-2 media
Codice materiale:
Dimensioni
oltre 0,5 a 6
Codice:
Descrizione:
Scala:
A2
Data Nome
Macchina:
- Kg
Sostituisce il: Sostituito da:
Verniciato Grigio RAL-9007 Bucciato
8

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3. DISPOSAL
If you decide to stop using the machine, or some part of it, the disposal and decommissioning of the
same must be carried out.
The machine must be handed to designated wasted recycling centres and disposed of according to
the country’s current regulations. Electrical and electronic parts should be disposed of in accordance
with Directive 2012/19 / EU.

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4. STORAGE
The information contained in this section shall be observed during periods of temporary storage of
the machine that may occur, eg., In the following situations:
▪Installation of the machine immediately after its delivery.
▪Decommission of the machine.
▪Machine in storage.
The machine must be used by a single operator within the limits and in the manner provided in this
manual.
Conditions for Storage
Temperature range -5/+55°C
Humidity range 30/90%
Lighting Natural and / or adequate articial lighting
Weathering Adequate protection
Space required Su󰀩cient to perform the operations of lifting and safe
transport
Location The bearing surface must have a capacity greater
than the total mass of the machine
Unused for less than 30 days Never open the glue tank otherwise it accelerates
deterioration creating serious permanent damage to
the glue application. This failure to comply will void
the warranty of the group glue.
Unused for more than 30 days Empty the system of glue and insert inside the
protective cleaner. This failure to comply will void
the warranty of the group glue.
Protect against corrosion of the parts subject to wear
and work plans. See Maintenance section.
Note Donotstandorplaceanyobjectontopofthemachine.

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5. GENERAL DESCRIPTION
5.1 TECHNICAL SPECIFICATIONS
Features of the machine:
Hour cycles 300 cycles / mechanical
Length of processed spine from 100 to 450 mm
Height of processed book from 120 to 450 mm
Cover size Max 1000x450/240x110 mm
Thickness of workable book from 2 to 50 mm
Cover weight Max from 120 to 400 g/m2
Control panel
Touch-Screen Yes
Copy Count Yes
Work memory Yes
Diagnosis and controls Yes
Size setting, temperature control Yes
Speed Yes
Book Loading
Vice adjustment Automatic according to parameters entered by the
operator
Vice unlocking Automatic electric
Vice Closure Adjustable pneumatics
Spine preparation
Milling disc Ø 160 mm
Perfect binders 4 (optional)
Roughening (roughening devices)
for processing the spine 4
Brush for processing and cleaning the spine 1
Excludable cutter Mechanical with position control
Milling thickness Variable from 0 to 2.3 mm
Woodchip vacuum Inside the machine
Glue application system
PUR glue tank / Hot-Melt 3 Kg hermetically sealed
PUR extrusion plant/ Hot-melt integrated and hermetic
Application head adjustment Automatic
Side adjustment (for hard binding, marking or sewing) Mechanics
Glue stop Touch-Screen settable
Cleaning / sealing Yes
Press
Press Electro-pneumatic servo assisted
Adjustment Force/pressure, pressing time
Mechanical adjustment Automatic/mechanical height adjustment

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Cover
Back hit cover adjustment Auto according to parameters inserted on Touch-
Screen
Cover position Manual
Check presence of missing covers Yes
Dimensions weight
Length 2200 mm
Width 1200 mm
Height 1400 mm
Weight 525 Kg
5.2 ELECTRICAL SPECIFICATIONS
Power Supply 220-230 V ± 5% 50/60 Hz, 1 ph + N + PE
Max Power Consumption 6,5 Kw
Current absorbed max. 31A
Fuse Protection By the customer, on the power supply line 32A
Class di󰀨erential protection A 300mA
“This equipment complies with IEC 61000-3-12, provided that the short-circuit power Ssc is greater
than or equal to that with minimum Rsce of 250, at the interface point between the power supply
unit of the user and the mains. It is the responsibility of the installer or the user of the equipment to
ensure, upon agreement with the distribution network operator, if necessary, that the equipment is
connected only to a power supply unit with a suitable Ssc short circuit power”.

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5.3 PNEUMATIC SPECIFICATIONS
Provided the devices and pneumatic circuits can work reliably, e󰀩ciently and safely, you need
the compressed air used for pneumatic system supply to have the following quality requirements
according to DIN ISO 8573-1:
▪Air quality provided to the binder CLASS 3,
▪Dust: 5 micron - 5 mg/m3
▪Water: -20°C - 0.88 g/m3
▪Oil: 1 mg/m3
The air compression system upstream of the machine book binder machine must have a dryer.
Periodically check quality of the compressed air supplied to the machine and the operating values.
Operating pressure
The user’s pneumatic system must guarantee the following values at the compressed air input
joint of the binder:
▪7 bar;
▪guarantee air consumption equal to 200 l/min
▪air quality: Class 3
Pneumatic features of the machine:
Compressed air consumption 150 l/min
Input gauge calibration 6 bar
Minimum working pressure 5.5 bar (if pressure goes below this pressure, the machine goes to
alarm status)
Air input coupling diameter 10 mm
The compressor connection tube diameter 10 mm is not supplied with the machine.
A compressor is recommended with an automatic condensate drain. This avoids checking
for water inside the compressor tank each week.
If the compressor is placed inside the company, you are advised to purchase a silent
compressor.
Standards DIN ISO 8573-1 - Air quality classes
The manufacturers of the pneumatic parts refer to the quality of the compressed air to use for
their products, taking into consideration the table below.
The compressed air used in an industrial environment contains water, oil, dust and other
impurities. The interaction of these elements produces an aggressive mix that causes
deterioration of compressed air-operated equipment and also the PUR glue contained in the
PUR tank, resulting in poor working quality and an increase in maintenance costs.

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5.4 NAME OF THE MAIN PARTS
5.4.1 VICE UNIT
1a. Mobile jaw;
1b. Press pressure regulator with gauge.
Regulator 1b enables regulation of the side press
force on the book.
Pressure = 0 - 3 bar minimum pressure
Pressure = 4 bar medium force
Pressure = 6 bar maximum force
1c. Machine status lights.
1b
1a
1c
Red light xed Machine in emergency mode with auxiliaries o󰀨
Red light ashing alarm present
Red light o󰀨 Machine not in emergency mode and without alarms
present
Orange light xed Machine with auxiliaries powered
Orange light ashing Auxiliaries on or o󰀨
Orange light o󰀨 Auxiliaries o󰀨
Green light xed Machine in cycle
Green light ashing Machine not in cycle
Green light o󰀨 Machine not ready

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5.4.2 MILLING UNIT
2a. Cutter mobile protection;
2b. Milling height regulator
Enables regulation of milling millimetres.
position 0 = notching only
position 0.5 to 1 = ideal milling and notching
position 2.3 = max. milling and notching
2c. Milling unit bypass lever.
Lever ON = working
Lever OFF = o󰀨 and lowered
2a
2b
2c
5.4.3 GLUE UNIT
3a
3b
3a. Coating head;
3b. Collection tank;
3c. Internal side gluing rear guide adjustment
Positioned on 1 = For book blocks composed of
single sheets.
Positioned >1 = For sewn book blocks.
3d. Glue unit - book block distance adjustment.
Positioned on 1 = minimum distance (little glue)
Positioned on 6 = max. distance (lots of glue)
Recommended position from 4 to 4.5.
3e. Glue pressure gauge.
3c
3e
3d