Morgana Documaster MK3 Operator's Manual
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Morgana Documaster MK3 Operator's Manual

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Documaster MK3
DOCUMENT CREASING & AUTOMATIC
BOOKLET MAKING MACHINE
OPERATORS MANUAL (Part 1)
(Creasing Unit)
Morgana Systems Limited
United Kingdom
Telephone: ( 01908 ) 608888 Facsimile: ( 01908 ) 692399
Website: www.morgana.co.uk
JULY 2009
ISSUE 8
FROM SERIAL No. 780156 ONWARDS.
70-111

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Summary of Contents for Morgana Documaster MK3

  • Page 1 Documaster MK3 DOCUMENT CREASING & AUTOMATIC BOOKLET MAKING MACHINE OPERATORS MANUAL (Part 1) (Creasing Unit) Morgana Systems Limited United Kingdom Telephone: ( 01908 ) 608888 Facsimile: ( 01908 ) 692399 Website: www.morgana.co.uk JULY 2009 ISSUE 8 FROM SERIAL No. 780156 ONWARDS.

  • Page 2: Table Of Contents

    INDEX INTRODUCTION The Morgana Documaster Mk3 PAGE 4 SAFETY Do’s & Don’ts THE CREASING UNIT Labelled Photograph THE CONTROL PANEL Detailed diagram and description Features on the control panel SETTING THE MACHINE UP AS A CREASER Adjusting the Paper Gate...
  • Page 3 DocuMaster MK3 INDEX Storing the Program Running the Machine Reading Stored Programs Clearing Booklet Sheets from the Booklet Maker Infeed Tray Using the Booklet Maker in Manual Mode (Hand Feed) Using the Optional Camera Recognition System (Fixed Data) Using the Optional Camera Recognition System (Variable Data)
  • Page 4 The feed system incorporates an ultrasonic detector system to ensure complete booklet integrity. The feed on the Documaster MK3 can also be manually operated for use with heavy stock, very small or very large sheets, embossed or even irregular sheets.
  • Page 5 DocuMaster MK3 BOOKLET MAKER UNIT SPECIFICATION Maximum sheet size:- 460mm x 320mm (18.1” x 12.6”) Minimum sheet size:- 210mm x 140mm (8.27” x 5.5”) Maximum staple pitch:- 138mm (5.4”) Minimum staple pitch:- 115mm (4.5”) Maximum number of sheets in book:- 20 sheets (80 gsm)

  • Page 6: Safety Do's & Don'ts

    Safety Do’s & Don’ts Safety Do’s & Don’ts REGLES DE SECURITE : « A FAIRE » ET « A NE PAS FAIRE » Do - read this operator manual fully before operating the machine. Lire ce mode d'emploi avant d'utiliser la machine. Do - operate with the designated AC current only.
  • Page 7 DocuMaster MK3 Safety Do’s & Don’ts Warning Labels Do - be aware of any finger traps and rotating parts when operating the machine. Attention au risque de se coincer les doigts, et aux pièces en mouvement lors du fonctionnement de la machine.
  • Page 8 BLANK PAGE Page 8 CREASING / BOOKLET MAKING...

  • Page 9: The Creasing Unit

    DocuMaster MK3 DocuMaster MK3 THE CREASING UNIT Key to photograph below Roller tilt handle Air separation knob Paper Gate Stacker assembly Adjustable side lay Exit Guard Suction slot knob Back stop Vacuum Bleed Knob The control panel Fixed side lay...

  • Page 10: The Control Panel

    THE CONTROLS The Display Unit and the Switches on the Control Panel allow the operator to read, edit, create and initiate numerous creasing programs within the memory. The Control Panel houses the Selection Switch, Compressor switch, System switch, and an industry standard Emergency Stop switch which will stop all power going to the machine when activated.
  • Page 11 DocuMaster MK3 THE CONTROLS Features on the Control Panel Selection Switch Allows the operator to scroll through stored addresses and programs, increase or decrease the batch quantity and set a crease position. System switch When activated the system switch will operate the motors in order to begin the creasing sequence.
  • Page 12 Setting the Machine up as a Creaser Adjusting the Paper Gate The standard setting for horizontal adjustment of the paper gate is 6.5mm (1/4") away from the mounting block. Turn disc J to make this adjustment. This setting is only intended as a guide, for instance, sheets with an upward curl will require this setting to be in- creased.

  • Page 13: Setting The Vacuum Bleed

    DocuMaster MK3 Setting the Machine up as a Creaser Setting the Vacuum Bleed Situated on the front of the feed table, the Vacuum Bleed Knob is used to allow more control of the suction on the vacuum drum. When light weight paper of 90gsm and lower is being fed through the machine turn the knob clockwise to reduce the possibility of marking, or damage to the leading edge of the paper.

  • Page 14: Setting The Roller Tilt Mechanism

    Setting the Machine up as a Creaser Setting the Roller Tilt Mechanism The roller tilt mechanism has been designed to compensate for when the creasing position on the sheet is not square. This could be due to an inaccuracy in the media or if the roller tilt mechanism has been incorrectly set.

  • Page 15: Setting The Stacker Assembly

    DocuMaster MK3 Setting the Machine up as a Creaser Setting the Stacker assembly The stacker unit on the machine is used to catch the sheets once they have been creased or perforated. NOTE:- This stacker unit is not fitted when the machine is being used as a Booklet maker.
  • Page 16 Setting the Machine up as a Creaser 4. Whilst the sheet is between the two guides on the stacker bed, set the distance . between the top of the sheet and the backstop flanges to approximately 5mm. 5. For shorter sheets, the back stop can be used (as shown in FIG 13.1 to adjust the position of the paper stack.

  • Page 17: Programming The Machine For Creaser Operation

    If you have not been trained to operate this machine and you select Morgana Systems Ltd accept no responsibility for personal injury, damage to the machine or damage to materials being processed by the machine.

  • Page 18: Setting The Batch Quantity

    Setting the Machine up as a Creaser Long Pulse for all standard size sheets, general purpose. Medium Pulse for short non-standard sheets. Short Pulse for very short sheets. Stream Feed for high throughput, see note below. NOTE. Do not use stream feed for creases less than 32mm from the leading edge of the paper. Setting the batch quantity 4.

  • Page 19: Storing The Crease Positions

    DocuMaster MK3 Setting the Machine up as a Creaser Set Creases Back Tens Decimals ( 1st Crease 297.0 ) 2nd Crease (iv) Move the selection switch to the left to select Tens, or to the right to select Decimals. (v) The Tens or Decimals (whichever has been selected) can then be adjusted by rotating the Selection Switch, (clockwise to increase or anti-clockwise to decrease).

  • Page 20: Running The Machine

    Setting the Machine up as a Creaser Running the machine 7. To run the job with the selected settings. (i) Press the Compressor Switch down. (ii) Press the System Switch down. (iii) Move the selection switch down to begin feeding the sheets. To stop feeding the media at anytime during the program, flick the selection switch up.
  • Page 21 DocuMaster MK3 BLANK PAGE SYSTEM Page 21...
  • Page 22 Setting the Machine up as a Booklet Maker Adjusting the Paper Guides Inse rt a sample sheet into t he infeed tray of the Booklet Maker. Adjust the width of the paper guides, by sliding the lever (on the underside of the infeed tray) forwards or backwards until the sample sheet slides freely in the guides.

  • Page 23: Programming The Machine For Booklet Maker Operation

    If you have not been trained to operate this machine and you select Morgana Systems Ltd accept no responsibility for personal injury, damage to the machine or damage to materials being processed by the machine.
  • Page 24 Setting the Machine up as a Booklet Maker Set Feed 4. The length of suction on the sheet of paper being fed can be adjusted by setting the feed type as follows:- (i) Move the selection switch to the right to select Setup (ii) Move the selection switch down to select the required feed type ( Long Pulse...
  • Page 25 DocuMaster MK3 (iii) The Sheet Length can now be set as follows:- Move the Selection Switch to the left to select Tens or to the right to select Decimals . The Tens Decimals (whichever has been selected) can then be adjusted by rotating the Selection Switch, (clockwise to increase or anti-clockwise to decrease).
  • Page 26 Setting the Machine up as a Booklet Maker Set Booklet Set Booklet Back Back Sheets in Book Sheets in Book (Including Cover) (Including Cover) (ix) The number of Sheets in Book (Including Cover) can now be set by rotating the Selection Switch, (clockwise to increase or anti-clockwise to decrease).
  • Page 27 DocuMaster MK3 More Crease Style Home (Cover Only) Cover & Centre (iii) Move the selection switch down to select the Crease Style Cover Only Cover & Centre All Sheets None (iv) Move the selection switch to the right to select Select.
  • Page 28 Setting the Machine up as a Booklet Maker Setting the Stitch Position. 8. From the Booklet Maker start up menu, the Stitch Position can be set as follows:-. (i) Move the selection switch to the right to select Setup (ii) Move the selection switch to the right, one click at a time, (selecting More until the display contains the words Stitch Pos...
  • Page 29 DocuMaster MK3 (ii) Set the Crease Style None . (See page 26 for setting the crease style). (iii) Set the lever on the Booklet Making Unit to the Edge Stapling position, (Lever in down position). Edge or Centre Staple Selection...
  • Page 30 Setting the Machine up as a Booklet Maker NOTE. Definitions of Set Knock types. Long Knock:- Selects long side-knock which causes the infeed sidelays to hold the set during both stapling and folding without releasing. This is useful if the booklet is not being folded square, however it is essential that the sheet width is set accurately.
  • Page 31 DocuMaster MK3 (v) If the Trimmer has been set to On, Move the Selection Switch down to set the Trim Length Back Set Trimmer Trimmer is On Trim Length: 7.285 (vi) Move the Selection Switch down to select Set Trimmer...
  • Page 32 Setting the Machine up as a Booklet Maker (iii) Move the selection switch to the right, one click at a time, (selecting More until the display contains the word Programs (iv) Move the selection switch down to select Save Settings. (v) Rotate the Selection Switch to select the Program number (1 to 9).
  • Page 33 DocuMaster MK3 Using the Booklet Maker in Manual Mode (Hand Feed). (i) From the Booklet Maker start up menu, move the selection switch to the left to select Tools Feed Setup Tools Documaster Reset Prog 3 3 Sheet Book Books 9...
  • Page 34 Setting the Machine up as a Booklet Maker Using The Optional Camera Recognition System (If Fitted), and the number of sheets in each book are the same. (i.e. Fixed Data) TYPICAL BOOKLET STACK (FIXED DATA) Cover (Sheet 1) Sheet 2 4 Sheet Booklet Sheet 3 Sheet 4...
  • Page 35 DocuMaster MK3 (iii) Move the selection switch down, (selecting Recognition ). If the display reads Recognition Off , move the selection switch to the right to change it to Recognition On Recognition More Home Recognition On Location: (Cover) - (iv) Move the selection switch down.
  • Page 36 Setting the Machine up as a Booklet Maker If there is no image on the sheet, at 90mm from the leading edge of the sheet, then another position greater than 90mm must be set. Limitations to the positions of the captured image are pre set in the software and cannot be exceeded.
  • Page 37 DocuMaster MK3 (xii) Move the selection switch to the right to select Capture Image Now The sheet will be automatically fed into the machine and the camera will be activated to capture and store the required image. (xiii) The display will show that the image has been captured, as shown below.
  • Page 38 1. Programme the machine for Booklet Maker operation as described on pages 22 to 32, setting the Sheets in Book Variable Data as described on page 25. 2. Operate the Camera Recognition System as described on pages 34 to 36. NOTE:- Limitations of the position of the Image, to be captured, on the sheet.
  • Page 39 DocuMaster MK3 Perforating Once the machine is set-up, the Documaster Mk3 can be used to perforate or crease. Notes 1. Perforating and creasing can be carried out simultaneously. However, if any adjustment is made to the roller tilt mechanism in order to compensate for the perforation line being ’out of square’, this may effect the accuracy of the crease.
  • Page 40 Perforating All of the blades and anvils are supplied with fixings. *Perforator stripper Standard Part Number 78-013 *It is recommended that for multiple perforations, a separate perforator stripper is used for every perforating blade set fitted in the creasing unit. Setting the machine 1.
  • Page 41 DocuMaster MK3 Perforating 11. Mount the other anvil ensuring that they have matched on the drive hub. Secure the anvil to the hub ensuring not to over tighten grub screw as shown in fig 16.2. 12. Slide the drive hub towards the perforating drive wheel until there is a clearance of 0.5mm.
  • Page 42 The Blade Assembly Adjusting the blade pressure (no paper required) 1. (i) Switch the power ‘on’ by turning the Emergency stop button clockwise to release the safety latch. The display is now switched on and will show the start up menu as shown below.
  • Page 43 DocuMaster MK3 The Blade Assembly Adjusting the blade alignment It is extremely important that the blade and anvil assembly within the creasing unit is correctly aligned. Misalignment of the blade or anvil can lead to damaged profiles and subsequently poor quality creasing so it must, therefore, be corrected immediately.
  • Page 44 Replacing Blade Set 1. Before removing the blade assembly, ensure that the lower blade / anvil is NOT at ‘top dead centre’, Switch the machine off. 2. Remove the stacker unit and lift the exit guard. Blade Extractor Tools 3. Using a 6mm allen key, loosen the socket head screws located inside the blade adjustment cams.
  • Page 45 DocuMaster MK3 Replacing Blade Set FIG 21.1 11. Push the exit guard down and replace the stacker assembly before operating the machine. 12. Switch the machine on and test the crease for form. If the pressure and the alignment of the crease is not to a satisfactory level, see pages 42 - 43 to adjust the creasing line.
  • Page 46 Trouble Shooting Paper crease out of square Check that the sheets are all square and exactly the same size before loading the stack on to the table. Check that the roller tilt mechanism is correctly set and locked in position. Check that the adjustable side lay has been correctly positioned ie.
  • Page 47 DocuMaster MK3 Trouble Shooting Check that the air distribution has been correctly set. Check that the air separation has been set high enough to feed the sheets. For heavy stocks, very small or very large sheets, embossed or even irregular stock, it may be required to feed the sheets manually - see page 20 for instructions.
  • Page 48 Trouble Shooting Re-register the Booklet Maker Unit. The Booklet Maker Unit can be re-registered as follows:- 1. From the Booklet Maker start up menu, move the Selection Switch to the left to select Tools 2. Move the Selection Switch down to select Re-register BMP 3.
  • Page 49 DocuMaster MK3 Error Messages ‘Warning Sheets not cleared from Bookmaster infeed’ Remove sheets from the infeed tray of the Booklet Maker. ‘BookMaster Error’ Check all Doors and Access Panels are shut correctly Check Mains Power is Switched on and also Communication Cable is Plugged in.
  • Page 50 7-95-13 DISPATCH KIT ITEM PART NUMBER DESCRIPTION 70-111 OPERATORS MANUAL(Part 1) (Creasing Unit) OPERATORS MANUAL (Part 2) (Booklet Making Unit) 70-114 90-018 ROLLER CLEANING KIT 7-99-01 ANVIL SET - Perforator 1-99-12 PERFORATOR BLADE SET - 28T POWER CORD C19 - 3Pin - UK 650-040 650-041 POWER...
  • Page 51 DocuMaster MK3 ACCESSORIES AND OPTIONS ITEM PART NUMBER DESCRIPTION 1-99-10 PERFORATING BLADE SET 20T (Card) 1-99-12 PERFORATING BLADE SET 28T (Single sheets) 1-99-41 PERFORATING BLADE SET 56T (Fine perforations) 1-99-35 ANVIL SET USED WITH ABOVE BLADE SETS 76-213-03 BLADE SET - EXTRA NARROW...
  • Page 52 RECOMMENDED SPARES PART NUMBER DESCRIPTION 93-021 FEED BELT 93-022 DRIVE BELT - Vacuum Roller 609-011 ‘O’ RING Ø20 609-014 ‘O’ RING Ø15 94-028 LOCK PIN ASSEMBLY - Side Lay 75-365 HOSE - Vacuum 75-366 HOSE - Vacuum Blow 75-367 HOSE - Separation Air 613-137 PLUNGER AND SPRING 613-255...
  • Page 53 DocuMaster MK3 RECOMMENDED SPARES PART NUMBER DESCRIPTION 76-175-01 INPUT ROLLER - Lower 76-177-01 INPUT ROLLER - Upper 76-250-01 UPPER OUTPUT SHAFT ASSY 78-251-01 LOWER OUTPUT SHAFT ASSY 613-351 MICRO SWITCH - Guard Circuit 613-191 MICRO SWITCH - Home Circuit 78-071-01 ACTUATOR ASSY.
  • Page 54 MACHINE CALIBRATION HISTORY Serial Number:- Date:- Total Count:- Stretch Lead Edge Trim Width Trim Camera Fitted Page 54 CREASING / BOOKLET MAKING...
  • Page 55 DocuMaster MK3 PRODUCT RECYCLING & DISPOSAL European Union Disposal Information for Commercial Users Disposal Information for Domestic Users Other Countries SYSTEM Page 55...

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