Morgana Digibook 300 User manual

Disclaimer
As part of our continued product improvement plan, specifications and information published here are subject to change without notice.
All specifications are dependent on application, type of stock, temperature, RH and print engine used.
Specifications quoted were measured on uncoated and unprinted stock.
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Technical Manual
Mechanical and Electronic Division
Vers. 01.02
Digibook 300

Technical Setting
Digibook 300
www.morgana.co.uk
2
Digibook 300 R2: Technical Manual Rev.01 12-05-2012
Table of contents
Tools necessary for set up .................................................................................... 3
Working principle .............................................................................................. 3
Preliminary Operations ........................................................................................ 3
Start-up conditions............................................................................................. 5
Check height of Zero (MZ) .................................................................................... 5
1) Setting the jogger plate.................................................................................... 6
2) Setting the spine preparation unit ....................................................................... 9
3) Setting the PUR Nozzle....................................................................................12
4) Setting the cover press....................................................................................14
5) Pressure adjustment.......................................................................................18
6) Setting of operating distance for sensors...............................................................18
7) Photosensors adjustment. ................................................................................18
8) Cylinders speed. ...........................................................................................18
9) Axes positioning. ...........................................................................................18
10) Machine parameters......................................................................................19

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Digibook 300
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Tools necessary for set up
Tools necessary for performing dimensional tests on the machine:
Depth gauge L = 200 mm
Carpenter’s square 50 x 80 mm
Thickness gauge
Gauge block for clamp BlockM cod. P0103036-00
Gauge block for press BlockV cod. P0108062-00
Machine Password: 1° level----0104 2° level----2468
Working principle
The clamp is the mechanical device that takes and carries the block to be bound along the
machine. The clamp moves lengthwise along the machine using a very precise system.
The clamp is the reference unit so all the measurements and various references relate to it.
Preliminary Operations
Before starting the machine, you must verify the correct wiring.
1. Verify that the machine's main switch is in
position 0 and that the plug is not connected.
2. Remove the protective cover as shown in Picture
0.1.
3. Insert the plug.
4. Pay attention to the cable light blue label N,
always refer to the neutral.
5. Verify the correct presence of voltage between
the terminals (Picture. 0.2 and 0.3) as
indicated:
a. L1-L2 (400Vac)
b. L2-L3 (400Vac)
c. L1-L3 (400Vac)
d. L1-N (230Vac)
e. L2-N (230Vac)
f. L3-N (230Vac)
6. If tensions are not as indicated verify the
correct position of neutral on the wall socket.
Fig.0.1
Fig.0.2

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Digibook 300
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7. If the voltages are as indicated, proceed with
checking of the correct rotation of the milling.
Fig.0.3
8. Enter password in the page display N ° 61,
Picture 0.4, press button and verify the
direction of the milling rotation (clockwise).
9. If the milling rotation is incorrect:
a. Turn the main switch to position 0
b. Disconnect the plug.
c. reverse the wires marked with the letter
L (for example L1 and L2)
d. Reconnect the plug.
e. Turn main switch to position 1
f. Repeat operations from Step 8.
10. If the milling rotation is correct:
a. Turn the main switch to position 0
b. Disconnect the plug .
c. Restore the protective cover as shown in
Picture 0.1
Fig.0.4

Technical Setting
Digibook 300
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Start-up conditions
Starting conditions for checking the machine set-up values:
1) Machine on and at correct temperature.
2) Jogger knob set to 0.
3) Milling cutter set to ON position.
4) Height-adjustment knob of gluing unit set to ‘0’.
5) Internal jaw-adjustment knob of gluing unit set to ‘1’.
6) Gluing pressure set to ‘0’.
7) Press pressure set to ‘0’.
8) Machine in reset condition.
9) Remove the clamp cover.
10)Remove the press cover.
Check height of Zero (MZ)
The machine is calibrated in the factory with a measure of Zero which can range from 96
to 97mm, this is not a sign of poor quality.
Any organ will follow this MZ (measure zero) with the appropriate tolerances.
How to understand what is the MZ, proceed with the measure of the jogger and do a
quick check with the other groups.

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Digibook 300
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1) Setting the jogger plate
Jogger features:
1) perpendicular to the clamp
2) parallel to the clamp
movement ±0.1 mm.
3) MZ±0.1 mm from the Top
Plate of the cursor
4) holds the sheets
5) BlockM assembly
6) Reference height ‘X’
1) Perpendicular-alignment test of the
jogger.
Place a 50 x 80 mm square on its shorter side
onto the jogger plate (see Fig. 1.1) and
check for perpendicular alignment.
The positioning tolerance allows a thickness
of 0.05 mm to pass through but not a 0.1 mm
one (on the 80 mm side).
If it does not, adjust the 4 screws
underneath. This check must be done at both
ends of the jogger plate (see Figs. 1.2 and
1.3).
Fig. 1.1
Fig. 1.2
Fig. 1.3
Fig. 1.4

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Digibook 300
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2) Parallelism test of the jogger
Reset the clamp, then position it,
completely opened, on the left side of the
jogger and measure using the depth gauge as
shown in Fig. 1.4. Then move it to the right
side and measure with the depth gauge as
shown in Fig. 1.5.
Parallelism is reached when the two
measurements are either equal or the
difference between them is not bigger than
±0.1 mm.
If the difference between the values is
bigger than ±0.1 mm, adjust the 4 central
adjusting screws.
After reaching parallelism, check again for
perpendicular alignment as described above
in point 1, as it may have been put out of
calibration.
3) Height check from the Top Plate
Position the depth gauge as shown in Fig. 1.4
and measure the height.
It must be MZ ±0.1 mm.
If greater than 0.1 mm, adjust the ‘Fixing
ring’ and position it again so that the
restrainer is in contact when the distance
between clamp and jogger is MZ ±0.1 mm.
Fig. 1.5
Fig. 1.6

Technical Setting
Digibook 300
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4) Gap to hold the sheets.
The jogger has a gap that serves to hold the
sheets when inserted into the clamp.
This gap must be at about 2.5 ±0.5 mm (GAP)
distance from the edge of the fixed jaw of
the clamp, as shown in Fig. 1.7.
Fig. 1.7
5) Assembly of BlockM.
After testing and setting up the jogger’s
characteristics, mount the gauge block
defined as ‘BlockM’ in Fig. 1.8.
BlockM serves for testing the other
machine units therefore it becomes the
main reference unit.
6) Reference height X.
Measure the distance between the gauge
block and jogger. The resulting figure will be
taken as the reference height ‘X’ (Fig. 1.9).
This height will serve as a reference for the
other units.
Fig. 1.8
Fig. 1.9

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Digibook 300
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2) Setting the spine preparation unit
Milling disk features:
1) perpendicular to the clamp
2) The rear plate must be
parallel to the clamp and
at a distance of 0.4 ±0.2
mm inwards from the
clamp.
3) on the left of the milling
cutter disk, the distance
between 'BlockM’ and the
tooth milling disk must be
equal to X ±0.1 mm.
4) on the right side of the
tooth milling disk, the
distance between 'BlockM’
and the milling disk must
be equal to (X+0.3)±0.2
mm.
A. unit adjustment.
5) the striker plate must be
at 0.15 mm horizontally
and 1.0 mm vertically from
the milling cutter teeth.
1) Perpendicular-alignment test of
the spine preparation unit.
Place a 50 x 80 mm square on its shorter
side onto the milling cutter disk (see Fig.
2.2) and check for perpendicular
alignment.
Positioning tolerance allows sheets 0.05
mm thick to pass through but not 0.1 mm
ones (on the 80 mm side). If it does not
pass, turn the 4 adjustment screws, see
point 4A.
Fig. 2.1
Fig. 2.2
Fig. 2.3

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2) Parallelism test of the spine
preparation unit.
When placing the square as shown in Fig.
2.4 the gap between the fixed jaw and
the striker plate of the milling cutter
must be 0.4±0.2 mm. The check must be
done at both ends of the striker plate.
If the measurements do not correspond,
slightly loosen the fixing screws (Fig. 2.9)
and move the whole milling cutter unit,
then tighten the screws again.
Fig. 2.4
3) Check of the spine preparation
unit height on the left side.
Measure the distance from BlockM to the
milling disk using the depth gauge, as in
Fig. 2.5, making sure that you place the
depth gauge on the tooth as shown in Fig.
2.6.
On the left side of the milling disk, the
distance between BlockM plane and a
tooth of the milling cutter must be X ±0.1
mm. If it is not, adjust the 4 adjustment
screws; see point 4A.
Fig. 2.5
Fig. 2.6

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4) Check of the spine preparation
unit height on the right side.
On the right side of the milling disk, the
distance between BlockM plane and the
upper surface of cutting knives must be
(X+0.3) ±0.1 mm. If it is not, turn the 4
adjustment screws; see point 4.1.
Fig. 2.7
4A) To access the adjustment screws,
remove the mobile guard and the
Plexiglas® inspection panel (Fig. 2.8).
Slightly loosen the fixing screws and turn
the adjustment screws so as to move the
unit to the desired height. Measure again
using the depth gauge; then tighten the
side fixing screws. After fixing the unit,
return the Plexiglas® panel and mobile
guard to their positions.
Fig. 2.8
Fig. 2.9
5) Test of the back-cut unit block.
The distances of the back-cut unit block
(Fig. 2.10) must be:
A= 0.15 mm
B= 1.0 mm
Check the measurements using the
thickness gauge.
Fig. 2.10

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Digibook 300
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3) Setting the PUR Nozzle
Gluing unit features:
1) perpendicular to the
clamp.
2) the distance between
‘BlockM’ and the
extruder plane must be
(X+0.3) ±0.1 mm.
3) The distance from the
inner jaw must be 0.15
mm.
1) Perpendicular-alignment test of
the gluing unit.
Place a 50 x 80 mm square on its
shorter side onto the extruder plane
(see Fig. 3.1 and 3.2) and check for
perpendicular alignment.
Positioning tolerance allows a
thickness of 0.05 mm to pass through
but one of 0.1 mm (on the 80mm side).
If perpendicularity needs adjusting,
adjust the screws on the right side
underneath the pre-melter, accessing
it from the back of the machine; see
Fig.3.3
Fig. 3.1
Fig. 3.2
Fig. 3.3

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Digibook 300
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2) Check of the gluing unit height.
Measure the distance from BlockM to
the extruder plane as shown in Fig.
3.4, making sure you place the depth
gauge on the extrusion slit. The
resulting measurement must be
(X+0.3) ±0.1 mm. If it is not, adjust
the positioned restrainer.
Fig. 3.4
3) Distance between the internal
side plate and the clamp fixed jaw.
Leaning the square as shown in Fig.
3.5, the internal plate of the nozzle
must leave room for a thickness of
0.15 mm. If it does not, adjust the
positioning knob (Fig. 3.6), position
the screw retaining ring in contact
with the sheet, see Fig.3.7.
Fig. 3.6
Fig. 3.5
Fig. 3.7

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4) Setting the cover press
Press features:
1) Perpendicular to the
clamp.
2) Parallel to the clamp
movement.
3) The distance between
'BlockM’ and the spine
plate must be equal
to ( X ) ±0.1 mm.
4) The distance from the
fixed plate must be 0.3
±0.05 mm.
5) The distance between
the mobile plate and the
spine plate must be
equal to 0.1 mm.
N.B.
The press unit does not only need gauging but
also adjusting after the book has been
produced. This means that after adjusting the
machine, it is necessary to make a book and,
according to the quality of the resulting
product, it may prove necessary to adjust the
set-up.
Introduction:
To check the press is required to be
in the high position.
Previously set the height of the press
on the value 0 in page 23 of the
display Picture 4.2
Next you must to pick up the press in
manual mode (by pressing the button
indicated) in Picture 4.2 putting
BlockV the central section, this in
order to support the square on page
34 of the spine plate on the display,
Fig.4.3.
Fig. 4.1
Fig. 4.2
Fig. 4.3

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Digibook 300
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1) Perpendicular-alignment test
of the press.
Place a 50 x 80 mm square on its
shorter side onto the spine plate
(see Fig. 4.4 and 4.5) and check for
perpendicular alignment.
Positioning tolerance allows a 0.05
mm thickness to pass through but
not a 0.1 mm one (on the 80 mm
side).
Fig. 4.4
Fig. 4.5
2) Test of the parallel alignment
of the press to the clamp
movement.
Measure the distance between
BlockM and the spine plate on the
left side as shown in Figs. 4.6 and
4.7.
Fig. 4.6
Fig. 4.7

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Digibook 300
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Measure the distance, as shown in
Fig. 4.8, after moving the clamp to
the right end of the spine plate.
The difference between the two
measurements must not be ±0.1 mm.
Fig. 4.8
3) Test of the press height.
Measure the distance between
BlockM and the spine plate on the
left side as shown in Figs. 4.6 and
4.7.
It must be = X ±0.1 mm.
Fig.4.9
4) Test of the fixed plate gap.
Place a 50 x 80 mm square on its
shorter side onto the spine plate
(see Fig. 4.10). The side fixed plate
must be parallel to the fixed jaw of
the clamp but at a distance of 0.3
mm inwards.
The resulting gap must allow the
insertion of a thickness of 0.3 ±0.05
mm.
The test must be performed on the
left and right ends of the press fixed
plate (see Fig. 4.11 and 4.12).
Fig. 4.10
Fig. 4.11
Fig. 4.12

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Digibook 300
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4) Test of the fixed side plate
gap.
The mobile plate of the clamp must
be adjusted in such a way that it
does not scrape against the spine
plate. Use the thickness gauge to
measure the correct distance. A 0.05
mm thickness should be able to pass
through while the 0.15 mm should
not. Adjust the adjustment screws to
set it up correctly. We recommend
that the distance between the plates
is close to 0.05 mm rather than 0.15
mm.
Fig. 4.13
Fig. 4.14

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Digibook 300
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5) Pressure adjustment
Machine system pressure:
7 bar
Press minimum pressure:
2 bar
Pressure value that triggers the
pressure switch
5.5 bar
6) Setting of operating distance for sensors
Inductive sensor “carriage zero”
0.70 mm
Inductive sensor “miller up”
0.70 mm
Inductive sensor “miller down"
0.70 mm
Inductive sensor “gluing head
zero”
0.70 mm
Inductive sensor “press zero”
0.70 mm
Inductive sensor “cover zero”
0.70 mm
Inductive sensor “jogger zero”
0.50 mm
Inductive sensor “milling cutter
guard closed”
0.50 mm
Read sensor “press-pistons stop”
6/7 mm stroke
Linear encoder “measurement
bench”
0.80 mm
7) Photosensors adjustment.
Light intensity 90%
Adjustment of the book-presence photosensor (jogger plate set to 0): 2.5-3 mm from the lower
clamp edge.
Adjustment of the photosensor for gluing starting/stopping (jogger plate on 0), reader in the
centre.
8) Cylinders speed.
Clamp opening-closing cylinder:
speed of the cylinder during closure 90%.
speed of the cylinder during opening 70%.
9) Axes positioning.
Clamp
Open 7 mm more than the set book (if BOOK
THICKNESS=10 MM, then CLAMP
THICKNESS=17 MM).
Glue Head.
Open 0.30 mm more than the set book (if
BOOK THICKNESS=10 MM, then HEAD =10.3
MM).

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Machine parameters.
Access to page manual movements
Reset axis
Movement of the group in the direction
indicated by the arrow, green arrow the size
increases.
Movement of the group in the direction
indicated by the arrow, red arrow decreases
the size.
The values written in blue character are user-
modifiable.
The values written in green character indicate
the current position of the axis.
To access the technical parameters
Password 1°Level----0104
Password 2°Level----2468
To exit the technical parameters

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NOTE: it is necessary that all of the preset values, are measured in the reset point the axis.
Here you set the aperture value measured with the
caliper of the clamp.
Opening and closing the clamp.
1° measure given by the factory
2° measure given by the factory
3° Measuring position of the carriage on the pressing
station.
4° Measuring position of the carriage on the pressing
station, book with gauze.
Here you set the aperture value measured with the
caliper of the nozzle.
Button to bring the pre-melting unit under
pressure.
Cycle button nozzle valve.
Value rear stop cover.
Value high press
Cycle button pressing station.