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Morgana DigiBook 150r1 Operator's Manual

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DigiBook 150r1
Operators Manual
MyBinding.com
5500 NE Moore Court
Hillsboro, OR 97124
Rev. 1.00-C
Toll Free: 1-800-944-4573
K.G.S. srl
Local: 503-640-5920

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  • Page 1 DigiBook 150r1 Operators Manual MyBinding.com 5500 NE Moore Court Hillsboro, OR 97124 Rev. 1.00-C Toll Free: 1-800-944-4573 K.G.S. srl Local: 503-640-5920...

  • Page 2: Table Of Contents

    Operator Manual DigiBook 150 Summary INTRODUCTION ________________________________________________________ 4 CE MARK __________________________________________________________________________ 5 SAFETY SIMBOLS __________________________________________________________________ 6 SYMBOLS OF PROHIBITION AND OBLIGATORINESS ___________________________________ 7 THE SAFETY DURING THE USE OF THE MACHINE _____________________________________ 8 1.4.1 General ________________________________________________________________________ 8 1.4.2 Safety warnings __________________________________________________________________ 8 SAFETY CLOTHING_________________________________________________________________ 9 INSTALLATION OF ELECTRICAL CABLES AND HOUSES _______________________________ 10 SAFETY EQUIPMENTS IN THE MASTER BOOK ________________________________________ 10...
  • Page 3 Operator Manual DigiBook 150 10.1 FUNDAMENTALS _________________________________________________________________ 28 10.2 _____________________________________________________________ 30 ELECTRICAL CONNECTION 10.3 P _____________________________________________________________ 30 NEUMATIC CONNECTION 10.4 G ________________________________________________________________ 31 ROUPS DESCRIPTION 10.5 ____________________________________________________________________ 34 CHIPS ASPIRATOR 10.6 . __________________________________________ 35 PUR TANK OPENING AND CLOSING GLUE LOADING 10.6.1 Opening of the PUR tank __________________________________________________________ 35 WARNINGS ON THE OPENING OF PUR TANK ______________________________________________ 35...

  • Page 4: Introduction

    Operator Manual DigiBook 150 1 INTRODUCTION THE READING OF THIS OPERATOR AND MAINTE- NANCE MANUAL IS FUNDAMENTAL FOR THE SAFETY OF THE USER AND FOR THE PROPER USE OF THE EQUIPMENT. We thank you to have bought our product. This machine has been designed specifically for your job and your applications with the help of a single worker, provides a high quality production and a wide range of functions.

  • Page 5: Ce Mark

    Operator Manual DigiBook 150 1.1 CE MARK DICHIARAZIONE DI CONFORMITÀ CE CE CONFORMITY DECLARATION DIRETTIVA CE PER MACCHINE 2006/42/CE, DIRECTIVE FOR MACHINES 2006/42/CE, E SEGUENTI DIRETTIVE EUROPEE (ALLEGATO IIA) AND FOLLOWING EUROPEAN DIRECTIVES (ANNEX IIA)  COSTRUTTORE, MANUFACTURER: K.G.S.SRL Via Donizetti 5 – 20090 Assago (Mi) Italy ...

  • Page 6: Safety Simbols

    Operator Manual DigiBook 150 1.2 SAFETY SIMBOLS In the manual some symbols are used to inform about dangerous situations for people and/or things. The following symbols mean dangerous situations for people and/or things. If you don’t follow carefully the appropriate procedures, damages can occur to people and/or things, and in extreme situations also fatal accidents.

  • Page 7: Symbols Of Prohibition And Obligatoriness

    Operator Manual DigiBook 150 1.3 SYMBOLS OF PROHIBITION AND OBLIGATORINESS  This symbol means a prohibition.  This symbol means an imperative. This symbol means that it is mandatory to read in this manual information re- garding specific topics (for ex. related to the specifications of the electric and pneumatic connection).

  • Page 8: The Safety During The Use Of The Machine

    Operator Manual DigiBook 150 1.4 THE SAFETY DURING THE USE OF THE MACHINE 1.4.1 G ENERAL The manufacturer guarantees that the contents of this manual are in specification with the proce- dures required by the machine. The manufacturer therefore will be not responsible if the machine will be used in a different way.

  • Page 9: Safety Clothing

    Operator Manual DigiBook 150 1.5 SAFETY CLOTHING Clothing to use during the cleaning and /or maintenance operations Eye protection against any spray of PUR glue or high temperature cleaner Respiratory mask suitable for the glue you are using Protective gloves Tight clothing, to avoid that they remain engaged with protruding parts.

  • Page 10: Installation Of Electrical Cables And Houses

    Operator Manual DigiBook 150 1.6 INSTALLATION OF ELECTRICAL CABLES AND HOUSES Cables and houses must be put inside of special cable channels to avoid the people to stumble and get hurt. 1.7 SAFETY EQUIPMENTS IN THE MASTER BOOK DANGER! It is forbidden to remove or render ineffective the safety guards for the safety of persons, and to tamper and / or modify, even partially, safety devices in- stalled on the machine.

  • Page 11: Green Button To Start Cycle

    Operator Manual DigiBook 150 1.7.2 G REEN BUTTON O START CYCLE The two front green buttons execute the com- mand to start cycle, it means that the clamp closes and moves to the right, the mill will run the cut, the glue will be applied, and if the press has been activated will crush the book;...

  • Page 12: Main Switch

    Operator Manual DigiBook 150 1.7.4 M WITCH It is located on the right side of the machine. Position OFF The switch is open. The machine is off. Position ON The switch is closed. The machine is on. MyBinding.com 5500 NE Moore Court Hillsboro, OR 97124 Toll Free: 1-800-944-4573 Local: 503-640-5920...

  • Page 13: Residual Risks

    Operator Manual DigiBook 150 1.8 RESIDUAL RISKS There are risks that cannot be completely eliminated by either protective or as designed by the ma- chine. Area of the glue head. Attention – Hot surfaces! Risk of burn. Use protective gloves. Area of glue loading.

  • Page 14: Purposes

    Operator Manual DigiBook 150 1.9 PURPOSES The machine is used to bind books using the following materials: a) Signatures, or sheet of paper (printed or not) for the block book b) Cardboard as cover of the book within the limits specified in the data sheet, included in this manual. 1.9.1 N OT PROVIDED USES PROHIBITED USES...

  • Page 15: Technical Sheet For Masterbook 150

    Operator Manual DigiBook 150 2 TECHNICAL SHEET for MasterBook 150 Machine features: Cycle/Hour 150 cycles Spine length from 120 to 380mm Workable height of the book from 110 to 320mm Max. Cover size 700x360/222x120 mm Workable thickness of the book from 2 to 50mm Max.

  • Page 16: Electrical

    Operator Manual DigiBook 150 2.1.1 E LECTRICAL Electrical power 220 V ±5%, 50/60 Hz Protection fuses on the power network are duties of Power of the machine the customer 16 A Distribution cabinet, customer side Differential protection class A 300mA 2.1.2 P NEUMATICS Supply pressure...

  • Page 17: Air Quality Provided To The Master Book

    Operator Manual DigiBook 150 Air quality provided to the Master Book CLASS 3, DIN ISO 8573-1 Durst: 5 micron - 5 mg/m Water: -20°C - 0,88 g/m Oil: 1 mg/m The compressed air system upstream of the machine must be equipped with a dryer. Periodically check the quality of the compressed air supplied to the machine and the operating values .

  • Page 18: Standard Accessories

    Operator Manual DigiBook 150 3 STANDARD ACCESSORIES The standard composition includes: – Cleaning Kit – Start- up Kit CLEANING KIT Polizene green spatula (to remove excess glue or cleaner) Steel Wire Ø0.4 (for cleaning the channels of leakage of the lateral glue) Lamella thickness of 0.4 (for cleaning the slit of leakage of the spine glue) Spare Headless screws for the closure of the...

  • Page 19: Transportation

    Operator Manual DigiBook 150 4 TRANSPORTATION The Master Book must be handled by a heaver. It can be got ONLY along the 2 long sides, front and rear side. For the final positioning or small movements can be used a trans-pallet. The machine can be raised by trans-pallet only in the 2 long sides, front and rear.

  • Page 20: Storage

    Operator Manual DigiBook 150 5 STORAGE The information contained in this section must be observed in case of temporary storage of the ma- chine that may occur in the following situations:  installation of the machine not immediately after its delivery. ...

  • Page 21: Layout

    Operator Manual DigiBook 150 6 LAYOUT Rev. 1.00-C...

  • Page 22: Positioning And Workspaces

    Operator Manual DigiBook 150 7 POSITIONING AND WORKSPACES Positioning The Master Book must be positioned so as to have a clear space around of at least 80 cm, and around the work area at least 150 cm. The room where the machine is installed must be properly ventilated with air change according to law Workspaces Glue loading area...

  • Page 23: Installation

    Operator Manual DigiBook 150 8 INSTALLATION 8.1 TECHNICAL STAFF FOR THE INSTALLATION The machine must be installed by people specifically trained and authorized by K.G.S. . 8.2 PHYSICAL CHARACTERISTICS AREA PLACEMENT In addition to the overall dimensions of the machine given in the previous chapter, you must also meet the following conditions: Near the area of placement of the machine should be arranged the sources of electric power and pneumatic following what is written in this manual.

  • Page 24: Environmental Conditions

    Operator Manual DigiBook 150 8.6 ENVIRONMENTAL CONDITIONS The values of temperature and humidity should be within the values in the table below. In case of use of the system in corrosive environments it is important to intervene in the mainte- nance of the machine with adequate time to avoid excessive wear of components.

  • Page 25: Electrical Connection

    Operator Manual DigiBook 150 8.7 ELECTRICAL CONNECTION Electrical cable The end of the cable is prepared according to the destination of the Master Book. a) With the European standard plug with pro- tective earth (PE) mounted on a 3 meters length cable b) Cable length of 3 meters with sectioned end, with the earth conductor (PE)

  • Page 26: Training Of The Operator

    Operator Manual DigiBook 150 9 TRAINING OF THE OPERATOR DANGER! The operator must be trained about the operations to perform during the oc- currence of possible faults, malfunctions or conditions of danger to themselves or others, and any- way he must perform the following procedures: Stop the machine quickly by pressing the emergency button (red button installed aboard of the ma- chine herself);...

  • Page 27: Power On

    Operator Manual DigiBook 150 10 POWER ON 1) Be sure that the machine is pneumatically fed in the proper way 2) Turn on the machine turning the main switch 3) Open the valve you have on the premelter 4) Close the inspection panel on the top side On display you will have: ...

  • Page 28: Fundamentals

    Operator Manual DigiBook 150 10.1 FUNDAMENTALS Pay Attention during the glue loading because of the high tem- perature, as indicated by the la- bel, and use protective systems such as gloves. When you operate with PUR glue or with glue that is harmful to health, you have to adopt all the safety systems to handle these kind of substances, espe-...
  • Page 29 Operator Manual DigiBook 150  The machine cannot be without Without air compressed inside the ma- air compressed when the glue chine, the valve that handles the glue station is still hot. spilling in the head could open damaging itself. ...

  • Page 30: Electrical Connection

    Operator Manual DigiBook 150 10.2 ELECTRICAL CONNECTION Make sure that the cable of the Master Book is connected to electricity network with the specified features. Turn on the main switch located on the right side of the machine, turn right to achieve the position 1 = (ON). 10.3 PNEUMATIC CONNECTION Connect the pneumatic power source following the procedure: Connect the house (6mm diameter) to the quick of the...

  • Page 31: Groups Description

    Operator Manual DigiBook 150 10.4 GROUPS DESCRIPTION Position OFF Main switch open. The machine is off. Position ON Main switch closed. The machine is CLAMP MILLING STATION GLUE STATION PRESS 1) CLAMP A. Tag for book thickness B. Knob to adjust the slot C.
  • Page 32 Operator Manual DigiBook 150 2) MILLING STATION A. Milling disc protection 3) GLUE STATION A. Adjustment for glue pressure It allows adjusting the glue quantity spilling out from the extruder. B. Manometer for glue pressure Indicative values Pressure = 0 NO GLUE (do not use the machine) Pressure = from 1.2 to 1.8 bar for books un- til 5 mm thickness...
  • Page 33 Operator Manual DigiBook 150 4) PRESSA Adjustment of beat for the cover Adjustment for square cover Beat for the cover On the back and over the machine Access to glue tank Access to cleaner tank The machine does movements only when the panels are closed.

  • Page 34: Chips Aspirator

    Operator Manual DigiBook 150 10.5 CHIPS ASPIRATOR The chips aspirator is located inside the cabinet of the Master Book and is electrically connected to the Master Book itself. When the Perfect Binder is delivered, the chips aspirator is ready, mechanically (aspiration tube) and electrically connected, he switches on and off together with the Milling Station.

  • Page 35: Pur Tank Opening And Closing Glue Loading

    Operator Manual DigiBook 150 10.6 PUR TANK OPENING AND CLOSING. GLUE LOADING. 10.6.1 O PENING OF THE TANK To access the glue tank it is necessary to open the sliding door provided with handle. The opening of this protection put the machine in a state of emergency and reduces the pressure of the glue tank while the Cleaner tank remains at a pressure approximately of 2 Bar.
  • Page 36 Operator Manual DigiBook 150 Please follow scrupulously the sequence below. Open the sliding door in the back of the machine, provided with a handle. The machine goes into a state of emergency and takes away the pressure to the glue tank, while the cleaner tank remains under pressure of 2 bar about.

  • Page 37: Preparation And Loading Of The Pur Glue

    Operator Manual DigiBook 150 10.6.2 P REPARATION AND LOADING OF THE PUR GLUE Take a package of glue, verify the integrity of the aluminium colour pack, and check the expiration date printed package Please read the SAFETY cards of the used glue, and follow all the instructions of the manufacturer.
  • Page 38 Operator Manual DigiBook 150 Close the cap Remove the knob, paying attention to high temperature components. Turn the knob clockwise vigorous- ly to tighten the tank. Close the sliding panel in the back of the machine, provided with a handle. MyBinding.com 5500 NE Moore Court Hillsboro, OR 97124...

  • Page 39: Cleaner Loading

    Operator Manual DigiBook 150 10.6.3 C LEANER LOADING Open the sliding door in the back of the machine, provided with an handler. Attention! High temperature! Use protective gloves. Read carefully the SAFETY cards of the used cleaner, and fol- low all the instructions of the manufacturer. By loosening the knob of the cleaner tank you will notice an air leak, this is normal as...
  • Page 40 Operator Manual DigiBook 150 Tighten the knob until the noise of escaping air disap- pears. Close the sliding door in the back of the machine, provid- ed with a handle. MyBinding.com 5500 NE Moore Court Hillsboro, OR 97124 Toll Free: 1-800-944-4573 Local: 503-640-5920 Rev.

  • Page 41: Functions Of Master Book

    Operator Manual DigiBook 150 11 FUNCTIONS OF MASTER BOOK MB150 Start-up page for the operator Preliminary Operations: Turn on the machine using the main switch. While you are doing this, on display you will see the set up page from which it will be possible to access to the main features of the Master Book, see image below.
  • Page 42 Operator Manual DigiBook 150 Basic principles: 1. It is necessary to stay in the start-up page to be able to produce books (see previous image) 2. Put the book into the clamp 3. Close the clamp using the specific handle. If the clamp is not closed a dedicated sensor does not allow the machine to start the cycle and leave the machine in alarm.
  • Page 43 Operator Manual DigiBook 150 Icons, texts and meanings: Icon (button) indicating that it is necessary to do a preset of the machine. Icon (button) to access carriage parameters. Icon (button) to access milling station parameters. Icon (button) to access glue station features. Icon (button) to access to nipping functions.
  • Page 44 Operator Manual DigiBook 150 Icon (button) you can set up the frontal and rear stop gluing, and book length selecting the dimensions. If you press on sketch you have the possibility to change working function. The number above the clamp indicates the possible shift between book and cover (value not modifiable).
  • Page 45 Operator Manual DigiBook 150 2. Icon button for carriage parameters. Once the icon is pressed, the window below will appear The value in the red box can be modified from -10mm to +10mm. This moves forward (pos- itive sign) or backward (negative sign) the carriage (and consequently the book on the cov- er) during the cycle.
  • Page 46 Operator Manual DigiBook 150 4. Icon, glue station button. When the icon is pressed, the window below will appear. The number in the yellow box is the desired value of temperature, that one in the green box is the current value of the temperature. The indicators with “ * ” will be if the tempera- ture is out of threshold of tolerance, green...
  • Page 47 Operator Manual DigiBook 150 The standby decreases the temperatures of 30°C to avoid unnecessary continuous heating for the glue. After 30 minutes from the last book produced, the machine goes automatically in standby status. To exit the standby status, press any point on display. You have to wait for the glue to reach the predetermined temperature.
  • Page 48 Operator Manual DigiBook 150 When the nipping station is off, on the main window the selection is indicated by a red icon (see the image below). The book icon changes when the nipping station is off. In this status you have the possibility to make book block. 6.
  • Page 49 Operator Manual DigiBook 150 Here you have the active alarms, press ALARM RESET to reset the resettable alarms. With this icon you access the window for alarms record. Description N° Warnings Air pressure insufficient Air pressure fault to the machine. Verify that the manometer at the entry is at 6 bar or that the compressor is suitable Emergency activated...
  • Page 50 Operator Manual DigiBook 150 A18 Cover not present CRITICAL TEMPERATURE You do cycle cleaner and switch off the machine. Call technical support. 9. Described before. 10. Described before. 11. Icon, copies counter button, value not modifiable. When the icon is pressed, the window be- low will appear.
  • Page 51 Operator Manual DigiBook 150 Selecting the left icon you will produce book with cover, selecting the right icon you will produce book block. In this case too the icon on the main window will change to indicate the typology of work you are doing. When you select the right icon, you make the nipping station off.
  • Page 52 Operator Manual DigiBook 150 17. Previously described. MyBinding.com 5500 NE Moore Court Hillsboro, OR 97124 Toll Free: 1-800-944-4573 Local: 503-640-5920 Rev. 1.00-C...

  • Page 53: Preparation Of The Machine To Produce Abook

    Operator Manual DigiBook 150 12 PREPARATION OF THE MACHINE TO PRODUCE A BOOK. 12.1 GLUE REFURBISHMENT PROCEDURE The glue refurbishment procedure must be done every time the machine is switched off with the procedure END OF JOB. In case the machine has been switched off with the END OF JOB procedure, it will be possible to start working only doing a glue refurbishment.
  • Page 54 Operator Manual DigiBook 150 Remove the grub screws using the allen key you have (pay attention to the temperature). Press the key “OK” Press the button until the traces of Blue cleaner disappears. Help the glue to exit from the bin by using the green spatula. Help themselves with the fin calibrated in this operation.

  • Page 55: Cover Positioning

    Operator Manual DigiBook 150 13 COVER POSITIONING The indicator “A” marks the position of the cover register “B”. The value “A” indicated in- dicates is the same as the X dimension. Position the cover manually as shown by the arrows, against the eccentrics indi- cated on the side and against the cover register...
  • Page 56 Operator Manual DigiBook 150 The standard calibration requires that the angle between the sides of the cover is 90 ° The standard calibration requires that the angle be- tween the sides of the cover is 90 °. If the cover has some problems caused by im- proper trimming, you can adjust the placement by...

  • Page 57: Preparation Of The Machine To Manufacture A Book

    Operator Manual DigiBook 150 Preparation of the machine to manufacture a book. CONTROLS TO PERFORM BEFORE STARTING THE JOB Before to use the Perfect Binder perform the following controls: The operator must have read and understood this manual, including the important information concerning the SAFETY.

  • Page 58: Starting The Machine

    Operator Manual DigiBook 150 13.1 STARTING THE MACHINE Machine ignition using the main switch. Take the switch in ON position. Verify if the pressure indicated in the entry manometer is correct. MIN 6 BAR Open the valve on the premelter. The valve with the lever in vertical position means that is open.
  • Page 59 Operator Manual DigiBook 150 Do a general reset Adjust the glue pressure Put the cover onto the press leaning it against the left fix datum and that one adjustable at the end of the press. Adjust the thickness of the book loosing the knob B, then move the front jaw until the measure of the book thick- ness you read on tag A.
  • Page 60 Operator Manual DigiBook 150 Press together the two keys on the front side of the ma- chine. The machine will start working on the book; the clamp will move passing onto the milling disc and onto the glue station, when it will reach the position, the press will put the cover.

  • Page 61: Book Spine Preperation

    Operator Manual DigiBook 150 14 BOOK SPINE PREPERATION 14.1 PREPERATION OF LARGER BOOKS When making books larger than 30mm in width its not reccomended to use both cutting tools. The use of protective gloves is recommended during this procedure. Use a 5mm L-Wrench turn turn the milling disc clockwise into the required position.
  • Page 62 Operator Manual DigiBook 150 Reverse the procedure when using books smaller than 31mm. MyBinding.com 5500 NE Moore Court Hillsboro, OR 97124 Toll Free: 1-800-944-4573 Local: 503-640-5920 Rev. 1.00-C...

  • Page 63: Changing The Notching Tool Height

    Operator Manual DigiBook 150 14.2 CHANGING THE NOTCHING TOOL HEIGHT. The height of the notching tools can be decreased by removing a spacer situated underneath each tool. To do this follow the steps below. The use of protective gloves is recommended during this procedure. Use a 5mm L-Wrench turn turn the milling disc clockwise into the required position.

  • Page 64: Cleaning The Machine

    Operator Manual DigiBook 150 15 CLEANING THE MACHINE When the machine work using PUR glue, it is imperative and essential an accurate cleaning of the glue. The dried glue is no more refundable. Residue of glue during the drying process can cause blockages or a uneven extrusion of the glue. The glue group must be kept clean with the deposits of glue, PUR glue residues harden over time and cause damages to the equipment.

  • Page 65: End Of Job" Cleaning

    Operator Manual DigiBook 150 15.1 “END OF JOB” CLEANING To switch off the machine at the end of the day you must eject the remaining glue inside of the extruder. To do it you must activate the automatic procedure that al- lows executing a safety off.

  • Page 66: Procedure To Clean The Spine Glue Extruder

    Operator Manual DigiBook 150 15.2 PROCEDURE TO CLEAN THE SPINE GLUE EXTRUDER. Press the key that corresponds to the glue station. Press the key for manual movements. Open the glue head until dimension Use the small wheel indicated with “A”, see below. Rev.
  • Page 67 Operator Manual DigiBook 150 Insert the calibrated blade into the slot extrusion to touch the bottom and move it along the slot to re- move or release any possible ob- structions. Adjust the value of the glue ex- trusion pressure to 1bar using the regulator “A”.
  • Page 68 Operator Manual DigiBook 150 Hold the key spill glue as indicat- ed by the arrow for few seconds until you do not see the glue spill- ing. Verify that the glue extrusion is uniform and continous; other- wise, insert the calibrated blade and repeat the cleaning operation.

  • Page 69: Procedure To Clean The Glue Side Extruders

    Operator Manual DigiBook 150 15.3 PROCEDURE TO CLEAN THE GLUE SIDE EXTRUDERS. Press the key corresponding to glue station Press the key for manual movements. Open the buttering head until quote 52. Use the Handwheel indicated by “A” see below. MyBinding.com 5500 NE Moore Court Hillsboro, OR 97124...
  • Page 70 Operator Manual DigiBook 150 The glue smeared on the side of the book is extruded through 3 small channels located on the plates contain- ing the book. To get a correct extrusion of the side glue you must remove the headless screw and insert in the holes the in- cluded wire.
  • Page 71 Operator Manual DigiBook 150 Pass the thread also in the main con- duit until you enter into the below slot. Be careful. When you replace the headless screws, they cannot pro- trude otherwise you cause a collision with the nipping station. Attention! Headless screws max.

  • Page 72: Details Cleaning

    Operator Manual DigiBook 150 15.4 DETAILS CLEANING Press the key corresponding to glue station Press the key for manual move- ments. Open the buttering head until quote 52. Use the Handwheel indicated by “A” see below. Rev. 1.00-C...
  • Page 73 Operator Manual DigiBook 150 Use the included blade to re- move all the visible glue trac- If necessary you can use liq- uid solvents to get a better cleaning of the surface. During the use of liquid sol- vents refer to the safety in- structions provided by the solvent manufacturer.
  • Page 74 Operator Manual DigiBook 150 Clean carefully all the tools used, otherwise they become unusable later. Clean periodically the glue tank. Please pay attention to HOT TEMPERATURE, use rags that do not leave any remain. Use scraping off tools that do not damage the internal surface of the premelter.

  • Page 75: Problems - Solutions

    Operator Manual DigiBook 150 16 Problems - Solutions 16.1 CHIPS ASPIRATOR – LESS VACUUM:  Verify that the Plexiglas inspection, located on the Milling Station, is free.  Verify that the chips aspirator tank is empty.  Verify that the chips aspirator tube is not full of chips. ...

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