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Morgan Documaster Pro Manual

Document creasing & automatic booklet making machine
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70-174
Issue 4
FEBRUARY 2013
Documaster Pro
(CB/UL)
SERVICE MANUAL
Document Creasing & Automatic
Booklet Making Machine
Morgana Systems Limited
United Kingdom
www.morgana.co.uk
Telephone: ( 01908 ) 608888
Facsimile: ( 01908 ) 692399

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Summary of Contents for Morgan Documaster Pro

  • Page 1 70-174 Issue 4 FEBRUARY 2013 Documaster Pro (CB/UL) SERVICE MANUAL Document Creasing & Automatic Booklet Making Machine Morgana Systems Limited United Kingdom www.morgana.co.uk Telephone: ( 01908 ) 608888 Facsimile: ( 01908 ) 692399...

  • Page 2: Introduction

    INTRODUCTION MORGANA DOCUMASTER PRO i ..Introduction The purpose of this manual is to explain the procedure for dis- mantling and re-assembly of the major assemblies on the Morgana Documaster PRO machine. All the engineering adjustments are shown at the end of each relevant section.

  • Page 3: Identification

    DocuMaster Pro Pan head and Cross-head countersunk screws all have metric Taptite threads and Pozi-drive recesses. Use No.2 point Pozidriv or Supadriv drivers for all screws M4 & above, and No.1 point drivers for M3 & below. WARNING WORK SHOULD BE CARRIED OUT BY A TRAINED AND COMPETENT ENGINEER AND ALL SAFETY PROCEDURES SHOULD BE ADHERED SWITCH OFF MAINS POWER BEFORE COMMENCING.

  • Page 4: Table Of Contents

    INDEX Introduction …………………………………………………………………..……..PAGE ¡ Introduction ..............2 ¡¡ Fasteners ..............2 ¡¡¡ Identification ..............3 New Machine Preparation ..........3 Index................4/5 Key to Creaser Unit............6 …… Covers………….…..............Section 1 Creaser Covers............. 7 Gatherings Station Covers..........8 Section 2 …… Vacuum Drum……………………………………………………. Belt Removal/Replacement........9/10 Section 3 …….Butterfly Valve...
  • Page 5 DocuMaster Pro Section 12 …….Gathering Station Electrics….……………………………..……PAGE Removal/Refitting PCBs............28 Replacement Interface PCB............28 Removal/Replacement Stepper Drive PCB ......28 Removal/Replacement Small Stepper Drive PCBs ....28 Section 13 …..Optical Sensors…….…………………………………………....Creaser - Cleaning and Setting........29 Section 14 ….Machine Installation................Machine Installation............31 Software upgrade Watkiss bookletmaker....31...

  • Page 6: Key To Creaser Unit

    DocuMaster Pro THE CREASING UNIT Key to photograph below Roller tilt handle Adjustable side lay Vacuum Bleed Knob Stacker assembly Back stop Touch Screen Suction slot knob Fixed side lay Anti-Static Unit The control panel Roller tilt knob Gathering Station...

  • Page 7: Creaser Covers

    DocuMaster Pro SECTION 1 Creaser Covers: The Front Cover The compressor cover which is situated below the control panel is secured by 16 off M4 taptite screws and is located by three tongues protruding into the main frame. Removal of this cover provides access to the compressor & the crease mechanism and fitted, the Camera cable termination.

  • Page 8: Gatherings Station Covers

    SECTION 1 Gathering Station Covers: The Side Covers The side covers of the gathering station are each fixed with 5 off M4 taptite screws (3 off on top). The Op. side covers the drive pulley and friction clutch. The Lay side covers the gathering station PCB and guide pulleys. To remove covers, remove all screws and lift clear of the machine.

  • Page 9: Vacuum Drum

    DocuMaster Pro SECTION 2 VACUUM DRUM TIMING BELT REMOVAL / REPLACEMENT. 2.1 Remove the Feed Bed, Moving Sidelay, Papergate Assembly, Ball Holder, Support Bracket and Double Sheet Detector Mounting Bracket. (See Fig. 2.1 below). 2.2 Remove the two screws that secure the Butterfly Valve. (The Butterfly Valve is located on the underside of the feed bed, towards the back of the machine.

  • Page 10: Removal/Replacement

    VACUUM DRUM FEED BELT REMOVAL / REPLACEMENT. 2.6 Remove the Feed Bed and the Moving Sidelay. 2.7 Remove the M5 Socket Screw. (See FIG.2.2 below). 2.8 Remove the 3 screws securing the Center Support Plate (Posi Head Screw in the side of the feed frame and 2 Cap Head Screws, from under the feed frame. DO NOT adjust or remove the red bolt, as this is factory set.
  • Page 11 DocuMaster Pro BLANK PAGE SYSTEM Page 11...
  • Page 12 SECTION 3 Removal of Butterfly Valve Assembly. The Butterfly Valve assembly is located on the underside of the feed bed, towards the back of the machine. 3.1 Remove the two pipe mounting clip plates (ITEM 5 on page 13) so that the hoses can be detached from the valve.
  • Page 13 DocuMaster Pro SYSTEM Page 13...

  • Page 14: Main Mechanism - Creaser Unit

    SECTION 4 MAIN CREASER MECHANISM REMOVAL OF UNIT: First access should be gained by removing the top input and output guards See Section 1 Remove guard micro switch by removing two screws taking care not to drop them. Remove the compressor cover and cut and remove cable ties from cable mountings, retaining wiring loom.
  • Page 15 DocuMaster Pro For working, place the unit on a solid and clear bench ensuring no wires are trapped beneath the metal side plates. Replacement is as follows. Assemble loosely around the pulley the green drive belt. 4.10 Replace the unit ensuring the wiring harness is threaded as it was removed 4.11 Attach the belt to the drive shaft.

  • Page 16: Removal/Replacement Stepper Drive Belt/Pulleys

    REMOVAL/REPLACEMENT STEPPER DRIVE BELT/PULLEYS 4.14 Loosen the adjuster nut from the inside unit and slide the belt off. 4.15 Loosen the securing socket set screws in the drive pulley on the roller. NOTE there is one screw located in a hole in the shaft) 4.16 Slide the pulley from the shaft and remove the belt.

  • Page 17: Infeed Roller Removal/Replacement - Creaser

    DocuMaster Pro SECTION 5 REMOVAL/REPLACEMENT OF INPUT ROLLER With the unit on a bench. 5.2 Remove the drive belt and pulley from the roller to be removed. (See SECTION 4) WORKING ON THE DRIVE BELT SIDE: 5.3 Remove the three M4 posi-head taptite screws from around the bearing hole in the side plate (Drive belt side) to allow easy access to the bearing retaining rings.

  • Page 18: Drive Hub - Replace Rubber Torsion Bush (Shock Absorber)

    SECTION 6 DRIVE HUB:- REPLACE RUBBER TORSION BUSH (SHOCK ABSORBER). 6.1 Loosen grub screws in one half of hub. 6.2 Slide hub outward & remove rubber. Replace in reverse order. Rubber Torsion Bush Page 18 CREASING / BOOKLET MAKING...

  • Page 19: Drive Link Refurbishment

    DocuMaster Pro SECTION 7 DRIVE LINK REFURBISHMENT 7.1 Remove the drip tray by removing the four securing screws fixed to the tie bars. 7.2 Remove both tie bars and drip tray. 7.3 Remove the micro switch assembly to gain access to the rear drive link.

  • Page 20: Width Drive Mechanism

    SECTION 8 WIDTH DRIVE MECHANISM The width drive mechanism is situated beneath the bottom plinth of the creasing unit. This mechanism drives the unit sideways via a rack and pinion to position the fixed sidelay of the creasing unit with the central guides of the gathering station. The position is controlled by a rack driving a potentiometer, with the electronic program calculating the final position.

  • Page 21: Gathering Station Removal/Refitting

    DocuMaster Pro SECTION 9 GATHERING STATION: REMOVAL/REFITTING ASSEMBLY The Gathering station is directly mounted onto the top of the booklet maker To remove the gathering station, disconnect the interface cable from the rear of the creaser unit. Then disconnect the power lead entering the rear door of the gathering station and the power lead going to the Booklet maker.

  • Page 22: Gathering Station Timing Belts Removal/Refitting

    SECTION 10 GATHERING STATION TIMING BELTS REMOVAL/REFITTING DRIVE BELT The timing belt for the fan module is situated inside the Op. side cover of the gathering station. It is driven by a size 34 stepper motor and drives the fan module through a friction clutch. To remove the belt loosen the M5 cap heads securing the motor to the side plate, this loosens the tension in the belt allowing it to be removed from the friction clutch pulley.

  • Page 23: Removal/Refitting Pcbs

    DocuMaster Pro SECTION 11 CREASER ELECTRICS: The PRO Control System. The Morgana PRO control system is essentially a computer system just like the PC you use at home. Unlike your Microsoft Windows PC, the PRO system uses a LINUX operating system and runs only one program, which is the machine control program for the particular machine that it is installed on.

  • Page 24: Creaser Electrics

    SECTION 11 CREASER ELECTRONICS REMOVAL/REFITTING PCB/POWER SUPPLY ASSEMBLY All the Electric controls and pcbs are located within the rear cover mounted on a common base plate. REPLACEMENT OF MAIN CONTROL P.C.B. This PCB controls all functions of the machine and houses the Main Program PCB. The use of an antistatic wrist band should be used during work on the main control PCB.

  • Page 25: Processor Pcb Replacement

    DocuMaster Pro REPLACEMENT OF PROCESSOR BOARD This Small PCB is plugged onto the face of the Main Control PCB and houses the Program Chip. The use of an antistatic wrist band should be used during work on this Processor PCB.

  • Page 26: Removal Of Usb Flash Drive

    REPLACEMENT OF USB FLASH DRIVE. The USB Flash Drive controls all functions of the graphics and touch screen operation. The External USB Flash Drive and the Internal USB Flash Drive devices (shown in FIG.2 below) have the same functionality. Either one of these devices could be supplied as a replacement.

  • Page 27: Removal/Replacement Stepper Drive Pcb

    DocuMaster Pro Jetway ATX Mother Board Asrock ATX Mother Board FIG.3 FIG.4 BOARD REPLACEMENT. STEPPER DRIVE PCB The Stepper Driver board supplies the power to both Blade motor and Main Drive motor and can be removed whilst located on the machine.

  • Page 28: Gathering Station Electrics

    SECTION 12 GATHERING STATION ELECTRONICS REMOVAL/REFITTING PCB/POWER SUPPLY ASSEMBLY All the power supplies and stepper control boards are located within the rear panel and mounted on a common base plate. The gathering station interface PCB is located with in the lay side cover. REPLACEMENT OF INTERFACE P.C.B.

  • Page 29: Creaser - Cleaning And Setting

    - use a soft brush or cloth to remove any dust that may have collected onto the sensor lens. See the Documaster Pro Operators Manual (70-168), Trouble Shooting section, for instructions of how to clean the Lead Edge Sensors; and the Clean Lead Edge Sensor Warning screens.
  • Page 30 SECTION 13 Crunch Sensor uses a beam projected across the machine just in front of the blade and above the paper path, when the beam is broken the machine will stop. The receiver is housed in the Side Plate of the machine and is on the Operator Side, whilst the transmitter is housed in the Side Plate of the machine on the Lay Side.

  • Page 31: Machine Installation

    DocuMaster Pro SECTION 14 Machine installation Tools and equipement required:- 3 mm Allen key 4 mm Allen key 5 mm Allen Key No.2 Posidrive screwdriver 9mm open ended spanner 10mm open ended spanner 1. Locate the area for the installation to be carried out ensuring the floor is level and sound.

  • Page 32: Machine Setup Prior To Calibration

    SECTION 15 Machine setup prior to Calibration Ensure feed system is set up correctly (Papergate gap, Balls & Side Lay etc.) Set the creaser input rollers square to the rear fixed fence. Set the top blade square to the rear fixed fence and parallel to the input rollers, ensuring there is no excess play in the slideways - see sketch below:- Side Lay Paper...

  • Page 33: Replacing Touch Screen Assembly

    DocuMaster Pro SECTION 16 Replacing the Touch Screen Assembly Replacing the Touch Screen Assembly. Ensure the mains power is turned off but with the plug in the socket, this maintains an earth to reduce static damage. 1. Open the hinged Service Panel (rear cover) to expose the mounting.

  • Page 34: Calibration Of Crease Position

    SECTION 17 Machine Calibration. Calibration of creasing position The length between the leading edge of the sheet and the 1st crease position can be calibrated in the event of the machine creasing out of position. Also the last crease closest to the back of the sheet can be adjusted relative to the front edge of the sheet to compensate for the inaccuracy of manufacture of the input roller diameters.

  • Page 35: Calibration Of Gathering Station Paper Guides

    DocuMaster Pro Calibration of Gathering station paper guides The paper guides on the gathering station are positioned by a pot connected to a rear shaft on the size 23 stepper. To calibrate the position of the guides follow the steps below: 1.

  • Page 36: Switching From Watkiss To Nagel

    All programme chips will default to Bookmaster type Documaster and will need to be reset to run as a Nagel type, below is the relevant procedure. The programme will be loaded into the PCB and will remain in the PCB as that type. Therefore if a chip or board is changed then the following should be carried out as a matter of course.

  • Page 37: Trouble Shooting

    DocuMaster Pro SECTION 18 Trouble Shooting In Bookletmaker mode. Error 27 Bookmaster Error Bookmaster power failure. Check switch is ON. Bad status Response Check fuse. Display- Bookmaster Error Length setting 0.0 Reset to acceptable length. Length out of range Error 16 Slide Error Width Motor Drive.

  • Page 38: Creasing Unit

    Section 18 Trouble Shooting - Creaser Page 38 CREASING / BOOKLET MAKING...
  • Page 39 DocuMaster Pro Section 18 Trouble Shooting - Creaser Page 39 SYSTEM...
  • Page 40 Section 18 Trouble Shooting - Creaser Page 40 CREASING / BOOKLET MAKING...

  • Page 41: Machine Width Positioning

    DocuMaster Pro Section 18 Trouble Shooting - Creaser SYSTEM Page 41...
  • Page 42 FAULT:- ‘NO SYNC’ appears on touchscreen. (Machine will not boot up). 1. CHECK THE ATX POWER SUPPLY AS FOLLOWS:- (i) Disconnect the 20/24 way ATX power supply connector from the ITX Motherboard. (ii) Using a piece of tinned copper wire, short out the GREEN and BLACK wires of the connector as shown in FIG.1 below FIG.1 TINNED COPPER WIRE LINK...
  • Page 43 DocuMaster Pro PINS 3 & 4 FIG.2 IMPORTANT RECYCLING NOTE:- The ITX mother board has a lithium battery fitted, the board together with its battery must be recycled in compliance with agreed national Procedures Please contact your local disposal authority for information CAUTION.
  • Page 44 FAULT:- No Touchscreen Display, (Machine will not boot up). When you release the E-stop switch, the control system should receive power and begin to boot-up. After a short period of time you will see the touchscreen become active and display the boot-up sequence.
  • Page 45 DocuMaster Pro FAULT:- Pump will not operate when the Compressor switch is switched on. Check the fuse on the PCB, in the Pump Overload assembly. The Pump Overload assembly is located on the inside of the yellow leg, below the baffle plate.
  • Page 46 BLANK PAGE Page 46 CREASING / BOOKLET MAKING...

  • Page 47: Gathering Station

    DocuMaster Pro Section 18 Trouble Shooting - Gathering Station SYSTEM Page 47...
  • Page 48 Section 18 Trouble Shooting - Gathering Station Page 48 CREASING / FOLDING...

  • Page 49: Wiring Diagram

    DocuMaster Pro Section 19 CREASER WIRING DIAGRAM VACUUM DRUM VALVE MOTOR VACUUM DRUM MOTOR & SENSOR INTERFACE CABLE SENSOR 79-189 (TO GATHERING STATION SEE 79-206) 55 TRANSFORME R MAINS SUPPLY LEAD (76-325) 2 TO 24, SEE COLOUR CODE SHEET DRAWING...

  • Page 50: Control Pcb Connection Diagram

    Section 19 CONTROL PCB CONNECTION DIAGRAM PSU OUTPUT LEAD (75-190) DRIVE SIGNAL LEAD( 75-436 ) BLADE SIGNAL LEAD ( 75-437 ) DOUBLE SHEET DETECTION LEAD ( 75-354 ) SYSTEM SWITCH COIL LEAD ( 75-364) STACKER GUARD SWITCH LEAD ( 75-401 ) HOME SWITCH LEAD ( 75-231 ) BLADE POSITION SENSOR LEAD ( 76-156 ) EDGE DETECT LEAD (76-230-03 )

  • Page 51: Wiring Diagram

    DocuMaster Pro Section 20 GATHERING STATION WIRING DIAGRAM YEL/GRN YEL/GRN SYSTEM Page 51...

  • Page 52: Control Pcb Connection Diagram

    Section 20 GATHERING STATION PCB CONNECTION DIAGRAM 90 INTERFACE CABLE 79-189 91 LEAD DRIVE MOTOR 79-187 92 LEAD SIDE GUIDE MOTOR 79-199 93 LEAD PCB POWER 79-190 94 LEAD INTERFACE TO BMP 79-198 95 POT AND LEAD ASSEMBLY 79-07-01 109 LEAD FAN MODULE 79-204 Control PCB 75-493-01 Page 52...

  • Page 53: Fuse Positions & Ratings

    DocuMaster Pro Section 21 FUSE POSITIONS & RATINGS TRANSFORMER ASSY. ANTI-STATIC UNIT T500mAH 250V (681-020) T315mAH 250V (681-011) PSUs (24V & 48V) MAINS IN T4.0AH 250V (681-015) T15AH 250V (652-047) SYSTEM Page 53...

  • Page 54: Image Recognition Camera

    SECTION 22 Image Recognition Camera The Camera is not a serviceable item and must be replaced with a new camera assembly. REPLACEMENT 1. Remove the front cover and rear covers. 2. Remove the ball carrier and stainless steel feed bed. Service Cable Socket 3.
  • Page 55 DocuMaster Pro The default IP address of the camera is 192.168.100.100/24 with Subnet mask = 255.255.255.0. To establish a direct connection, the computer must be set to a corresponding, fixed IP address as follows:- 1. Click on Start Control Panel Network Connection Local Area Connection Properties the window "Local Area Connection Properties"...
  • Page 56 Factory set up. Setting the shutter delay, illumination, trigger mode, Focal distance etc. This should be set using the Sensopart Software installed on a computer and connected to the camera via the ‘Service Cable Kit- Fa45 Camera’ part no. 79-053-01 see below for setting parameters.
  • Page 57 DocuMaster Pro REVISION HISTORY Rev. Mod No. Mod Description Date Mod By Note at the bottom of Page 24 added, reference the position of switch SW1 when fitting a new Main Control PCB. ECO2809 02/01/13 Page 29 re-written, reference Optical Sensors - Cleaning and Setting.

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