70-143_Documaster Pro OperatorsManual Pt 1 Iss1

70-143_Documaster Pro OperatorsManual Pt 1 Iss1
Documaster Pro
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
ISSUE 1
MAY 2010
FROM SERIAL No. 740001MMAA ONWARDS.
70-143
INDEX
INTRODUCTION
The Morgana Documaster Pro
PAGE 4
SAFETY Do’s & Don’ts
6
THE CREASING UNIT
Labeled Photograph
8
THE CONTROL PANEL
Detailed diagram and description
Features on the control panel
9
9
SETTING THE MACHINE UP AS A CREASER
Adjusting the Paper Gate
Setting the Suction Slot
Setting the Adjustable Side Lay
Setting the Back Stop
Setting the Air Distribution
Setting the Air Seperation Pressure
Setting the Roller Tilt Mechanism
Setting the position of the Drive Wheels and Hubs
Setting the Stacker Assembly
Programming the machine for Creaser Operation
Smart screen display
Selecting machine Mode
Paper Settings Page
Crease Settings Page
Status Screen
Run Job
Storing the Job
Paper Jamming
Setting the Machine to Run in Manual Mode
10
10
10
11
11
11
12
12
13
15
15
16
17
18
20
21
22
24
24
SETTING THE MACHINE UP AS A BOOKLET MAKER
Adjusting the Paper Guides
Adjusting the Sliding Back Stop
Programming the machine for Booklet Maker Operation
Paper Settings Page
Crease Settings Page
Stitch Settings Page
Setting the Knock
Setting the Machine to Edge Stitch
Trim Settings Page
Pre Fold Delay
Status Screen
Run Job
Storing the Job
Tools Options Page
Paper Jamming
Using the Booklet Maker in Manual Mode (Hand Feed)
26
26
27
28
29
30
30
31
32
32
33
34
34
34
35
35
Page 2
CREASING / BOOKLET MAKING
DocuMaster Pro
INDEX
Standard Sheet Sizes (Quick Books)
Camera Settings Page
Using the Optional Camera Recognition System (Fixed Data)
Using the Optional Camera Recognition System (Variable Data)
36
37
37
39
PERFORATING
Equipment, spares
Setting the machine
41
42
THE BLADE ASSEMBLY
Setting the blade pressure
Setting the blade alignment
44
45
REPLACING CREASING BLADE SETS
Installing new blade sets
Spares
46
47
TROUBLE SHOOTING
48
ERROR MESSAGES
51
DISPATCH KIT
56
ACCESSORIES AND OPTIONS
57
RECOMMENDED SPARES
58
MACHINE CALIBRATION HISTORY
60
PRODUCT RECYCLING & DISPOSAL
61
SYSTEM
Page 3
INTRODUCTION
DocuMaster Pro
The Morgana Documaster Pro is a fully automatic, suction feeding, creasing
/ booklet making system; designed for use with both conventional litho and
digital printers.
The system comprises a creasing unit linked to a fully automatic booklet
making machine, the creasing unit and booklet maker can be used
separately to give optimum flexibility.
The feed system incorporates an ultrasonic detector system to ensure
complete booklet integrity.
The feed on the Documaster Pro can also be manually operated for use with
heavy stock, very small or very large sheets, embossed or even irregular
sheets.
IMPORTANT the operating environment should be controlled to a temperature
between 16°C and 27°C Maximum.
The crease is programmed from the leading edge of the sheet using the
controls on the front panel.
The blade and anvil are mechanically controlled over their entire length
and can be adjusted to accommodate various weights of media
CREASER UNIT SPECIFICATION.
Max. sheet size:-........................... 630mm x 330mm (24.8” x 13”)
Min. sheet size:-............................ 210mm x 140mm (8.27” x 5.5”)
Max. sheet Thickness:-..................0.4mm (varies according to hardness,
type of fold and substrate)
Max. No. of creases per sheet:-.....16
Min. distance between creases:-....0.1mm
Min. incremental adjustment:-....... 0.1mm
Max. No. Stored Programs:-......... Unlimited
Min. crease distance from leading edge:- 2.5mm
Min. crease distance from trailing edge:- 35mm
Production up to 5000 sheets / hour, (one crease on A4 sheet).
Dimensions ................................... L: 1245mm H: 1210mm W: 522mm
L: (49”)
H: (47.3”) W: (20.5”)
Weight ...............................................................
123Kgs (+50Kgs packing)
Power Requirement ..........................................
1 phase 220 / 240v AC
Page 4
CREASING / BOOKLET MAKING
DocuMaster Pro
SYSTEM
Page 5
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. Use an exclusive outlet, as
overloading may cause fire or an electric shock.
Respecter l'alimentation électrique indiquée. Brancher sur une prise séparée
car une surcharge peut entraîner un incendie ou un choc électrique.
Do - install the power cord out of the way to avoid a tripping hazard.
Installer le cordon d'alimentation de manière à ne pas pouvoir
trébucher par dessus.
Do - make sure that the mains inlet connector is always easily accessible.
Ménager un accès libre à la prise de courant.
Do not - install the machine in an unstable place such that it tilts or shakes.
Ne pas installer la machine sur une surface non plane, afin d'éviter
qu'elle ne penche ou ne vibre.
Do not - unplug the plug or unplug the power cord from the outlet with a wet hand,
this can cause an electric shock.
Ne pas installer la machine sur une surface non plane, afin d'éviter
qu'elle ne penche ou ne vibre.
Do not - unscrew and remove any covers from the machine, as it can cause an
electric shock or injury.
Ne démonter et enlever aucun carter de la machine, par crainte de décharge
électrique ou de blessure.
Do not - place receptacles containing liquids on any surface.
Ne pas placer de récipient contenant un liquide sur la machine.
Do not - adjust any part of the machine whilst rollers are running
N'effectuer aucun réglage pendant que les rouleaux fonctionnent.
Do not - operate the machine with loose or trailing clothing or loose hair.
Ne pas porter de vêtements flottants et rassembler les cheveux longs
lors de l'utilisation de la machine.
Do not - under any circumstances adjust the paper gate when the machine is
switched on.
En aucune circonstance, régler le séparateur de papier lorsque la
machine est branchée.
Page 6
CREASING / BOOKLET MAKING
DocuMaster Pro
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.
Do - read this operator manual fully before operating the machine.
Lire ce mode d’emploi avant d’utiliser la machine.
Do not - operate the machine with loose or trailing clothing.
Ne pas porter de vêtements flottants lors de l'utilisation de la machine
Do not - operate the machine with loose hair.
Rassembler les cheveux longs lors de l'utilisation de la machine.
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.
Do - be aware of sharp points and blades.
Attention aux éléments tranchants et aux couteaux.
Do - be aware of rotating rollers.
Attention aux rouleaux en fonctionnement
Do - be aware of low current anti-static shock.
Attention aux faibles chocs d'électricité statique
SYSTEM
Page 7
DocuMaster Pro
THE CREASING UNIT
Key to photograph below
1
2
3
4
5
Roller tilt handle
Stacker assembly
Suction slot knob
The control panel
Air distribution knob
6 Air separation knob
7 Adjustable side lay
8 Back stop
9 Fixed side lay
10 Roller tilt knob
2 1 15 12
11 6
11
12
13
14
15
Paper Gate
Exit Guard
Vacuum Bleed Knob
Touch Screen
Anti-Static Unit
14
9
5
8
7
4
10
3
13
Page 8
CREASING / BOOKLET MAKING
DocuMaster Pro
The Touch Screen 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 Compressor switch, System switch, and an
industry standard Emergency Stop switch which will stop all power going to
the machine when activated.
THE CONTROL PANEL
Compressor Switch
System Switch
Emergency Stop Switch
Features on the Control Panel
System switch
When activated the system switch will operate the motors in order to begin the
creasing sequence.
Compressor switch
Allows the operator to switch off the compressor unit in order to utilise the machine
to manually feed sheets.
SYSTEM
Page 9
Setting the Machine up as a Creaser
Adjusting the Paper Gate
Set the height of the Paper Gate to approximately two thicknesses of paper, by turning the
disc j. An excessive gap is a most likely cause of double sheet feeding.
This setting is only intended as a guide, for instance, sheets with an upward curl will
require this setting to be increased.
J
TWO THICKNESSES
OF PAPER
WARNING.
DO NOT ADJUST THE
PAPER GATE WHILE THE
MACHINE IS RUNNING OR
THE SUCTION DRUM MAY
BECOME DAMAGED.
Setting the Suction Slot
The suction slot is located inside the vacuum roller and can be adjusted by releasing and
moving the suction knob horizontally in either direction to the required position.
For light stocks set the knob to the left and for heavier stocks set the knob to the right.
Adjustable
Side Lay
Suction
Slot Knob
Setting the Adjustable Side Lay
Place the paper stack on to the loading table and slide up to the fixed side lay and paper
gate. Release the clamps located at each end of the side lay and slide up towards the
paper stack as demonstrated in the image above . Allow a gap of approximately 0.5mm
(1/64 inch) between the paper and the side lay.
Page 10
CREASING / BOOKLET MAKING
DocuMaster Pro
Setting the Machine up as a Creaser
NOTE.
When using heavy stocks or large paper stacks, the feeding of the sheets may be improved
by fitting the Clamp Plates to the Adjustable Side Lay, as shown in the image below; but
please be aware that they may cause double feeding when using light stocks.
Clamp Plates
Setting the Back Stop
Position the backstop and slide up towards the paper stack allowing a gap (as specified
in the above step).
Setting the Air Distribution
Depending on the length of the sheet to be creased, the air distribution knob can be
rotated to various positions in order to supply air to different ports. Position 2 is
recommended for most sheet sizes. However, a better result may be obtained by using
the settings below or by experimentation.
Position 0 - For sheets longer than A3 (17”) in order to supply air to the centre of the
stack, ports 2 and 3 open.
1 - For A5 sheets or 8 inches long, ports 1 and 2 open.
2 - For A4 sheets or 11 inches long, ports 1 and 3 open.
3 - For sheets longer than A3 (17”) in order to supply air evenly along the stack,
ports 1 and 4 open.
Port 1
Port 4
Air Distribution
Knob Shown
Set To Posn. 1
Setting the Air Separation Pressure
To control the amount of air supplied to the ports, the air separation knob can be rotated
clockwise to decrease the pressure or anti-clockwise to increase the pressure.
SYSTEM
Page 11
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. The mechanism will be set to zero
(square) when the machine is supplied.
To set the mechanism, unlock the roller tilt knob located below the roller tilting handle by
turning anti- clockwise. Move the roller tilt handle left or right in order to compensate for
any inaccuracy. When the position is set, ensure to lock the roller tilt knob before
operating the machine. Repeat the above procedure until the creasing position is square.
Setting the positions of drive wheels and hubs
It is important that the drive wheels and drive hubs on the roller shafts are arranged evenly
across the width of the media being creased. This is done to ensure that the media is
accurately driven and supported through the rollers.
The drive wheels and hubs are fixed to the rollers by means of a grub screw. To locate
this grub screw the rollers can be rotated by operating the motor manually.
DO NOT ROTATE THE DRIVE ROLLERS BY HAND.
To operate the motors manually, switch the machine ‘on’ at the Emergency Stop switch.
Select the Tools tab
that shown below.
Inch paper in direction
of arrow to clear jams
at the bottom of the touch screen, the display will change to
Inch paper in direction
of arrow to clear jams
Press the system switch down and then select the right or left arrows, to rotate the rollers in
short pulses.
Lift the exit guard to see if the grub screws in the drive wheels and hubs can be seen. If the
grub screws cannot be seen, lower the exit guard and rotate the rollers by selecting the
right or left arrows. Loosen the drive wheels and hubs with a 2mm allen key. Arrange the
drive wheels and hubs as shown in FIG 10.1. In order to avoid marking on some types of
media ensure a gap between the drive wheels and hubs.
This procedure should be repeated when installing perforating blades and anvils onto the
drive wheels and hubs.
Page 12
CREASING / BOOKLET MAKING
DocuMaster Pro
Setting the Machine up as a Creaser
FIG 10.1
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.
1. Assemble the stacker unit to the machine as shown in fig 11.1 below.
Important
Ensure that the stacker unit has been assembled to the machine properly. However,
if it has not, the connection on the magnetic switch will be broken and the machine
will not operate (see Trouble shooting pages for details).
There are two side guides on the stacker unit; a left handed guide and a right handed
guide. The guides will control the way in which the paper is collated by setting their
positions on the stacker bed.
2. Place a single sheet (from the stack to be creased / perforated) on to the stacker bed
against the ‘left hand’ guide.
3. Position the ‘right hand’ side guide on to the stacker bed leaving a minimum
clearance of approximately 1mm each side of the sheet.
SYSTEM
Page 13
Setting the Machine up as a Creaser
LEFT HAND
BACK STOP
LEFT HAND
SIDE GUIDE
RIGHT HAND
BACK STOP
RIGHT HAND
SIDE GUIDE
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 the figure below to adjust
the position of the paper stack.
TIPS
!
Page 14
The magnetic back stop supplied with the machine
can also be used as a tool holder as demonstrated
In the photograph (left).
CREASING / BOOKLET MAKING
DocuMaster Pro
Setting the Machine up as a Creaser
Programming the machine for Creaser operation
1.
Switch the power ‘on’ by turning the Emergency stop button clockwise to release the
safety latch. The display is now switched on and will be as shown below.
IMPORTANT.
If you have not been trained to operate this machine, we strongly advise that you select
the red cross icon.We recommend that you either seek training or ask a trained operator
to run the machine for you.
Select the green tick icon only if you have been trained to operate this machine.
If you have not been trained to operate this machine and you select the green tick icon,
Morgana Systems Ltd accept no responsibility for personal injury, damage to the
machine or damage to materials being processed by the machine.
Touch Screen Display
The touch screen has three areas that you can interact with to set up your job. these
areas are shown below.
Status of
Machine &
data entry
areas. Also
used for quick
links to
settings page
Settings
Page
Tabs to enable switching between
setting pages. Tabs will change
depending on the machine mode you
are working in.
SYSTEM
Page 15
Setting the Machine up as a Creaser
2. If the display appears in Booklet Maker mode (this is indicated by the mode button
shown below), change the mode into Autocreaser operation by selecting the mode button
at top of the status area.
Mode
Button
Booklet Maker
Mode Icon
Autocreaser
Mode Icon
When you select the Mode button the settings area will change to a confirmation screen
shown below.
Cancel - Select to cancel
the change and return to
the previous mode.
Accept - Select to
accept the change from
Booklet Maker Mode to
Autocreaser Mode.
Page 16
CREASING / BOOKLET MAKING
DocuMaster Pro
Setting the Machine up as a Creaser
A typical Autocreaser display menu is shown below.
NOTE: The different number of tabs when in Autocreaser Mode. This is also a quick
indication of which mode you are in.
Settings Pages.
Paper Settings Page.
3.
To set the Paper Settings select the “Paper Settings Tab”
on this page
you can set the paper size, batch count, feed type and typical crease positions.
Vacuum Suck There are two
selections available
- 1 short suck & 2
continuous for
stream feeding.
Highlighted number
is type currently
selected. The
status area also
shows currently
selected suck.
Batch Button Image is identical to
that shown in the
status area. On
selection the status
area is replaced
with a calculator fro
inputting new
values. Batches of
any numerical
value.
SYSTEM
Fold Selection - For quick setting of crease positions on
standard size sheets. Highlighted fold is type currently selected,
other folds may be selected. Currently selected fold is shown in
the status area.
Page Length - On
selection the status
area is replaced with
a calculator for
inputting new
values.
Min Length
= 190mm
Arrows may be
selected to increase
or decrease the
page size in 0.1mm
increments
Page 17
Setting the Machine up as a Creaser
Crease settings Pages.
4. To get to the crease setting page click the lower tab
area.
or
from the status
If you have selected a predefined standard crease type from the paper settings page the
crease positions will be set for you. These positions can be fine tuned
by ± 0.1 mm increments by pressing side arrow buttons
Number of creases - if
more than 6 creases
are added a scroll bar
will appear to enable
viewing of all creases
Arrows may be
selected to increase
or decrease the page
size in 0.1mm
increments
Crease ON/OFF
selector green is ON
& red is OFF. This is
also indicated in the
status area.
Crease Position - On
selection the status
area is replaced with a
calculator for inputting
new values.
for each crease.
Cross box for deletion of
crease. On deletion of
crease the following creases
will move up by one place.
You will be asked to confirm
deletion of crease.
Press to remove all
creases - you will
be asked to confirm
deletion.
Plus box for
inserting additional
creases. On
selection the status
area will become a
calculator for
inputting values.
Creases will be
displayed in
numerical order.
Additional Creases
added - scroll bar
appears for more
than six creases.
Page 18
CREASING / BOOKLET MAKING
DocuMaster Pro
Setting the Machine up as a Creaser
Individual deletion of crease confirmation screen
Select green tick icon to confirm deletion of crease.
Remove all creases confirmation screen.
Turn Crease on/off.
Creasing turned OFF
- Greyed out areas
are unselectable.
Status area will show
creasing is OFF with
a Red icon.
SYSTEM
Page 19
Setting the Machine up as a Creaser
Status Screen
Currently selected
Vacuum Suck setting - For
Pulse setting choose
selection 1 and for Stream
setting choose selection 2.
Mode Button
Paper Length - input
from the paper setting
screen.
Currently selected fold
type - can be one of the
following
Number of creases This may alter
automatically if a predefined fold is selected.
Adjustments may be
made in the crease
setting screen.
Creasing ON/OFF. A
green icon indicates
creasing is on and a red
Icon indicates creasing
is turned off
Green icon indicates
settings are saved - a
Red icon would show
that settings have been
changed but the job
has not been saved.
Batch quantity - this is
input from the batch
calculator on the paper
setting screen - MAX
999.
Current Job Count - click
to zero
A screen will appear to
confirm that you want to
reset the count.
Click to start the machine with settings
currently shown - you will receive a
notification if the system switch is not
on. Press again to stop the Job.
Selecting any of the buttons on the Status area will open the relevant settings page for
that button.
Page 20
CREASING / BOOKLET MAKING
DocuMaster Pro
Setting the Machine up as a Creaser
The Status Screen will on occasions be replaced with an Input Calculator Screen as shown
below.
Pre-set Paper sizes for quick
insertion - standard sizes for
country origin would be shown
Pre-set Batch sizes for
quick insertion
Paper size
input calculator
Batch size
input calculator
Crease position
input calculator
NOTE:
The green tick or the red cross must be selected on the Calculator Screen to make the left
hand side of the touchscreen active again.
Run Job
To Run a job using the current settings you must activate the compressor and system
switches on the side of the machine. Then select the Start Button
at any time. If you
have not activated the system switch you will be notified by the screen below.
If you see this screen select the green tick to acknowledge the warning, activate the
switch and then reselect the Start Button.
SYSTEM
Page 21
Setting the Machine up as a Creaser
Storing the Job
6.
The job that has been set can now be stored as follows.
(i) Select the lower tab
or
from the status area to get to the
Store Settings Page.
(ii) The job can be given a name and stored as described below. You can also retrieve
previously saved jobs, modify them or delete jobs that are no longer required.
To create a new job name click in text area &
a keyboard will open to input name.
Load existing job from
store
Click to search
currently stored jobs
Click to delete currently
stored job
Click to save job shown
(iii) On the Keyboard, enter the name you wish to save the job under and select
the save button. If you do not wish to save your job select the return arrow.
Return Arrow - On
selection the screen
will return to the
main store page.
Page 22
Save Button - On
selection a confirmation
screen will appear to
save your job.
CREASING / BOOKLET MAKING
DocuMaster Pro
Setting the Machine up as a Creaser
Save Confirmation Screen
Select to cancel saving
Save Icon
Select to Confirn save
The Icons for confirming Load, Delete and Re-Save are shown below.
Load Icon
Delete Icon
Re-Save Icon - This
Icon will appear to
confirm you are
overwriting an
existing Job.
Search for current jobs to load or modify.
You can search for jobs by clicking the search icon
keyboard for text input.
, this will bring up the search
Type job
description or first
few characters
Return Arrow - On
selection the screen
will return to the
main store page.
SYSTEM
Press search icon
to start search
Page 23
Setting the Machine up as a Creaser
Toggle between search
results and full list of
jobs.
Jobs matching
characters in text box
will be shown in this
area - selecting a job
from this area will
show the job settings
in the status area.
Job selected will be
shown in the text
box.
Press to load job
shown in text box.
Running the machine
Run the job as described on page 21. The machine will complete its creasing operation if a
sheet has already been fed through the paper gate.
Paper jamming
In the event of a paper jam occurring whilst the machine is operating, select the Tools
tab
at the bottom of the touch screen, the display will change to that shown
below. Press the system switch down and then select the right or left arrows, to inch the
paper forwards or backwards.
Inch paper
in direction
Right arrow
of arrow to clear jams
Inch paper in Left
direction
arrow
of arrow to clear jams
Setting the machine to operate in manual sheet feed mode
In order to feed heavy stock, very small or very large sheets, embossed or even irregular
shaped sheets, it may be necessary to feed the sheets manually. The machine can be
programmed and set up in exactly the same way as explained when operating the machine
automatically. However, the paper gate must be raised to its highest position for the sheets
to be fed freely. Operating the machine in manual sheet feed mode will also require the
suction length to be continuous in order to accommodate various types of stock. Therefore,
the feed should be set to Stream Feed (Vacuum Drum position 2) see page 17.
The machine can now be started by activating the System switch to ‘on’. Do not activate
the Compressor switch.
Select the
icon on the touch screen and begin to slide the sheets individually through
the paper gate until they are driven by the drive belts.
To stop feeding the sheets, select the
System Switch off.
Page 24
icon on the touch screen and switch the
CREASING / BOOKLET MAKING
DocuMaster Pro
BLANK
PAGE
SYSTEM
Page 25
Setting the Machine up as a Booklet Maker
Adjusting the Paper Guides
Insert a sample sheet into the 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.
Adjusting the Sliding Back Stop
With the sample sheet in its downward resting position, adjust the sliding back stop until it is
approximately 5mm to 10mm clear of the back edge of the sample sheet.
Rear Paper Guide
Sliding Back
Stop
Front Paper Guide
Infeed Tray
Paper Guide Adjustment Lever
(On Underside Of Infeed Tray)
Page 26
CREASING / BOOKLET MAKING
DocuMaster Pro
Programming the machine for Booklet Maker operation
1.
Switch the power ‘on’ by turning the Emergency stop button clockwise to release the
safety latch. The display is now switched on and will be as shown below.
IMPORTANT.
If you have not been trained to operate this machine, we strongly advise that you select
the red cross icon. We recommend that you either seek training or ask a trained operator
to run the machine for you.
Select the green tick icon only if you have been trained to operate this machine.
If you have not been trained to operate this machine and you select the green tick icon,
Morgana Systems Ltd accept no responsibility for personal injury, damage to the
machine or damage to materials being processed by the machine.
2. If the machine has started in Autocreaser Mode
Select the Mode button as
explained on page 16. On Selection the display will show the following confirmation page
where you need to accept the change of mode by Selecting the green tick.
3. Adjust the Paper Gate, Adjustable Sidelay etc, as Described on Pages 10 to 11
(Setting the Machine up as a Creaser).
SYSTEM
Page 27
Setting the Machine up as a Booklet Maker
A typical Booklet Maker display menu is shown below.
The Booklet Maker display retains the three areas for interaction that the Autocreaser
display uses.
Status of
Machine &
data entry
areas. Also
used for quick
links to
settings page
Settings
Page
Tabs to enable switching between setting
pages. Tabs will change depending on
the machine mode you are working in.
Settings Pages.
Paper Settings Page.
3.
To set the Paper Settings select the “Paper Settings Tab”
on this page you
can set the paper size, feed type and the number of sheets in your book
+/- may be selected to increase or decrease
the numer of sheets incrementally
Vacuum Suck There are two
selections available
- 1 Short Suck & 2
Continuous for
Stream Feeding.
Highlighted number
is the type currently
selected. The
status area also
shows the currently
selected suck.
Number of Sheets in
the Book - On
Selection the status
area is replaced with
a calculator for
inputting values.
MAX No. 22
Variable Data. Set to
?
?
Sheet Length - On
Selection the status
area is replaced with
a calculator for
inputting values.
Page 28
Arrows may be
selected to
increase or
decrease the page
size in 0.1mm
increments.
Sheet Width - On
Selection the status
area is replaced with
a calculator for
inputting values.
CREASING / BOOKLET MAKING
DocuMaster Pro
Crease settings Pages.
4. To get to the crease setting page click the lower tab
or
from the status area.
Centre Crease
Position - The Centre
Crease will
automatically position
itself at the centre of
the sheet length that
you entered on the
Paper Settings Page
when a change is
made. On Selection
the status area is
replaced with a
calculator for inputting
values.
Arrows may be
selected to
increase or
decrease the page
size in 0.1mm
increments.
Hinge distance - On
Selection the status
area is replaced with
a calculator for
inputting values.
+/- may be selected
to increase or
decrease the hinge
distance in 0.1mm
increments.
Crease Style - There are three
selections for which sheets are
creased. Selected style will be
highlighted.
Cover
Only
Cover &
Centre
All
Creasing ON/OFF
Select to turn
Creasing ON or
OFF. When The
button is Green
Creasing is ON.
When Button is
Red Creasing is
OFF.
Hinges
ON/OFF
Select to turn
Hinges ON or
OFF. When The
button is Green
Hinges are ON.
When Button is
Red Hinges are
OFF.
When the Creasing or Hinges are turned OFF, the respective value entry box and image will appear
grey as shown below and no input will be possible until the Selection is turned back ON.
Here the Hinges have
been turned OFF
NOTE: When you Turn the Creasing OFF the Hinges will automatically turn OFF.
SYSTEM
Page 29
Setting the Machine up as a Booklet Maker
Stitch settings Pages.
5. To get to the Stitch setting page click the lower tab
from the status area.
Knock Type - There are four selections for
Knocking the sheets Selected Style Will Be
Highlighted.
Pre Stitch Delay On Selection the
status area is
replaced with a
calculator for
inputting values.
+/- may be selected
to increase or
decrease the time
in 10ms
increments.
Stitch Offset - On
Selection the status
area is replaced with
a calculator for
inputting values.
Arrows may be
selected to increase
or decrease the
page size in 0.1mm
increments.
NOTE.
Definitions of Set Knock types.
Short Knock:-
Causes the infeed sidelays to actuate prior to stapling.
This Knocks the sheets of a booklet together.
(Short Knock is the default setting for the machine).
Double Knock:- Causes the infeed sidelays to actuate twice prior to stapling.
This ensures that the booklet is Knocked into a uniform book.
Long Knock:-
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.
Double Knock
Short & Long:- Causes the infeed sidelays to actuate prior to stapling and
then hold the set during both stapling and folding without
releasing. This is useful for a high number of sheets that are
not being folded square. however it is essential that the sheet
width is set accurately.
Page 30
CREASING / BOOKLET MAKING
DocuMaster Pro
PreStitch Delay:- This adjusts the time delay between the side knock and stapling; this is
sometimes useful in ensuring a tidy set. The default setting is 200ms,
but the setting can be adjusted between 200ms and 900ms.
Setting the Machine to Edge Stitch.
(i) Set the Sheet Length to double the length of the finished document.
i.e. If the finished document is 210mm, (see FIG.2 below), set the sheet length to 420mm.
(See page 28 for setting the sheet length).
FIG. 2
210mm
(ii) Turn Creasing OFF. (See page 29 for setting the crease).
(iii) Set the lever on the Booklet Making Unit to the Edge Stapling position,
(Lever in down position).
Edge or Centre Staple Selection
Lever Up For Centre Stapling
Lever Down For Edge Stapling
SYSTEM
Page 31
Setting the Machine up as a Booklet Maker
Trim settings Pages.
6. To get to the Trim setting page click the lower tab
from the status area.
Pre Fold Delay On Selection the
status area is
replaced with a
calculator for
inputting values.
+/- may be selected
to increase or
decrease the time
in 100ms
increments.
Trim Length - On
Selection the status
area is replaced with
a calculator for
inputting values.
Arrows may be selected to
increase or decrease the
page size in 0.1mm
increments.
Trimming ON/OFF
Select to turn
Trimming ON or
OFF. When The
button is Green
Trimming is ON.
When Button is
Red Trimming is
OFF.
If the Trim is turned OFF, the value entry box and image will appear grey and no input will
be possible until the Selection is turned back ON.
Pre-Fold Delay:- This adjusts the time delay before folding. The default setting is 300ms,
but the setting can be adjusted between 300ms and 900ms. Reducing the
value will increase the book making speed
Page 32
CREASING / BOOKLET MAKING
DocuMaster Pro
Status Screen
The Status screens in Booklet maker Mode are divided into two pages and can be easily
switched using the “Next”
and “Previous”
Arrow Buttons.
Status Screen 1
Mode Button
Paper Width - input from
the paper setting screen
Currently selected
Vacuum Suck setting - For
Pulse setting choose
selection 1 and for Stream
setting choose selection 2.
Paper Length - input from
the paper setting screen
Creasing ON/OFF. A green
icon indicates creasing is
on and a red Icon indicates
creasing is turned off
Crease Position
Hinges ON/OFF. A green
icon indicates Hinges are
on and a red Icon
indicates Hinges are
turned off
Number of Sheets in a Book
Crease Style
Next Arrow- Select to
view Status Screen 2.
Green icon indicates
settings are saved - a
Red icon would show
that changes have been
made but the job has
not been saved.
Status Screen 2
Stitch. - Select to view
Stitch Settings Page
Trimming ON/OFF. A green
icon indicates Trimming is on
and a red Icon indicates
Trimming is turned off
Camera ON/OFF. A green icon
indicates the Camera is on and a
red Icon indicates the Camera is
turned off. For Camera setting
Information see page **
sheet count - This will keep track of
the number of sheets fed. On
selection a confirmation page will
appear to reset the count to zero.
Book count - This will keep track of
the number of books you have
created. On selection a confirmation
page will appear to reset the count
to zero.
SYSTEM
Stitch Offset.
Pre-Stitch Delay
Trim Length
Pre-Fold Delay
Sheet Image Capture
Camera Image Distance
Previous Arrow- Select
to view Status Screen 1.
Click to start machine with
settings currently shown - you
will receive a notification if the
system switch is not on. Press
again to stop the job.
Page 33
Setting the Machine up as a Booklet Maker
Run Job
To Run a job using the current settings you must activate the compressor and system
switches on the side of the machine. Then select the Start Button
at any time. If you
have not activated the system switch you will be notified by the screen below.
If you see this screen select the green tick to acknowledge the warning, activate the
switch and then reselect the Start Button.
Storing a Job
To Store the current job settings see “Storing the Job” section in Setting the machine as a
creaser on page 34
Tools Options Page
To view the Tools Options select the Tools Tabs
on the lower section of the screen.
BMP alignment - On
Selection the status
area is replaced with
a calculator for
inputting values to
adjust the alignment
of the BMP and
creaser unit.
Right/Left arrows Selection will inch
paper forward or
backwards to clear
jams.
Up arrow - Selection
will set Blade to Top
Dead Centre.
Info Button - On
selection the screen
will display the
software versions
and networking
information of your
machine.
Page 34
Arrows may be
selected to align the
machines in 1 unit
increments.
Re-Register BMP
- On selection the
Book Master pro
will register the
motor positions to
known start
positions
Hand Feed. ON/OFF.
Select ON to Manually
feed books into the
BMP. When icon is
Green hand feed is ON.
When icon is Red hand
feed is OFF.
Set Machine
Defaults - Select
to reset BMP to
Factory Default
Settings.
CREASING / BOOKLET MAKING
DocuMaster Pro
Paper jamming
In the event of a paper jam occurring whilst the machine is operating, select the Tools
tab
at the bottom of the touch screen, the display will change to that shown
below. Press the system switch down and then select the right or left arrows, to inch the
paper forwards or backwards.
Inch paper
inarrow
direction
Right
of arrow to clear jams
Inch paper in
direction
Left
arrow
of arrow to clear jams
Using the Booklet Maker in Manual Mode (Hand Feed).
Manual Mode allows you to drop the booklet sheets directly into the Booklet Maker in feed
tray so the sheets will automatically feed into the Booklet Maker and be stapled and folded.
To set the machine into Manual Mode. select the Tools Tab
at the bottom of the
screen.
Select the Red Hand Feed Button
(This indicates hand feeding is OFF). On Selection
the Button will turn Green Indicating that Manual Mode Is now ON. Select again to turn OFF
Manual Mode.
Single Sheet Booklet.
IMPORTANT.
1. If producing a single sheet booklet without stitch it will be necessary to set the
Creasing Style to All Sheets or Cover & Centre NOT Cover Only or None.
2. If the ‘Square Back System’ is installed with the Booklet Maker ensure that the switch
on the ‘Square Back System’ is set in the position shown below.
Set Switch in
this Position
SYSTEM
Page 35
Setting the Machine up as a Booklet Maker
Clearing Booklet sheets from the Booklet Maker Infeed Tray.
If for any reason the Feed switch is turned off, during booklet making operation, booklet
sheets may remain in the Booklet Maker infeed tray. To clear the sheets through
into the Booklet Maker, (to be folded and stapled), follow
“Using the Booklet Maker in Manual Mode (Hand Feed” on the previous page.
Standard Sheet Sizes (Quick Books).
A Quick setup for a standard size sheet can be set as follows:
For example A4/A5 - Settings will be sheet size 297 x 210, trim size is 145 and the number of
sheets in a book will be 1.
To setup a Quick Book select the Quick Book tab
at the bottom of the screen. This will
take you the following screen where you can select the Job you wish to use and accept the
settings.
Selected Jobs
Will become
highlighted.
Accept button - On
selection the
highlighted job will
be loaded.
If you do not accept to load the highlighted job, current machine settings will not change
when you navigate away from the Quick Books setting page.
Page 36
CREASING / BOOKLET MAKING
DocuMaster Pro
Camera settings Pages.
6. To get to the Camera setting page click the lower tab
Arrows may be
selected to increase
or decrease the
page size in 0.1mm
increments.
Range - This tells you the area
you can capture an image on
your current job setting.
Image Capture
Distance - On
Selection the status
area is replaced
with a calculator for
inputting values.
Sheet to be
captured. Select
the sheet in the
book that you want
to capture the
image from. Sheet
1 is the cover
+/- may be selected
to increase or
decrease the value.
from the status area.
Capture Image On selection the
machine will
automatically feed
the sheet and the
camera will capture
and store the
required image
Camera ON/OFF
Select to turn the
Camera ON or
OFF. When the
button is Green the
Camera is ON.
When Button is
Red the Camera is
OFF.
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)
4 Sheet Booklet
Cover (Sheet 1)
Sheet 2
Sheet 3
Sheet 4
4 Sheet Booklet
Cover (Sheet 1)
Sheet 2
Sheet 3
Sheet 4
4 Sheet Booklet
Cover (Sheet 1)
Sheet 2
Sheet 3
Sheet 4
Image To Be Captured Can Be On The
Underside Of Any Sheet Of The Book
SYSTEM
Feed Bed
Page 37
Setting the Machine up as a Booklet Maker
Operating the Camera Recognition System
1. Ensure the camera is turned on by selecting the Camera ON/OFF button
The Button should be Green.
2. Select the Page you wish to capture the image from. You can use the + and - buttons to
adjust the page as explained on the previous page.
3. Set the position of the image to be captured (from the leading edge of the sheet).
NOTE:Limitations of the position of the Image, to be captured, on the sheet.
The default position, (of the image capture position), from the leading edge of the sheet
is 90mm.
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. These limitations are displayed as the range as shown above the image
position entry box.
An Image template is provided with the camera recognition system kit to assist in showing
the possible area of the image that can be captured. The Template is shown below.
90 mm
3 mm
Image Area
Viewed From Underneath
Camera Recognition Assistant
Part No. 70-113
Fixed Rear Lay Edge
IMAGE TEMPLATE
Capture the Image
(i) Once the position has been set place the sheet that has the required image onto the feed
bed with the image face down.
(ii) Press the Compressor Switch down followed by the System Switch.
Page 38
CREASING / BOOKLET MAKING
DocuMaster Pro
(iii) Then select the capture image button
the image and store the image for recognition.
The machine will then feed the sheet, capture
(iv) With the Image now captured you can load the booklet stack onto the feed bed; and then
run the Job by selecting the Start Button.
Using The Optional Camera Recognition System (If Fitted), and the number
of sheets in each book are different. (i.e. Variable Data)
NOTE:Do not use ‘Stream Feed’ when running variable data jobs.
TYPICAL BOOKLET STACK (VARIABLE DATA)
5 Sheet Booklet
Cover (Sheet 1)
Sheet 2
Sheet 3
Sheet 4
Sheet 5
3 Sheet Booklet
Cover (Sheet 1)
Sheet 2
Sheet 3
4 Sheet Booklet
Cover (Sheet 1)
Sheet 2
Sheet 3
Sheet 4
Image To Be Captured Can Only Be On The
Underside Of The Cover (Sheet 1) or Sheet 2.
Feed Bed
1. Program the machine for Booklet Maker operation as described on page 27,setting the
Sheets in Book(on the Paper settings Page) to Variable Data as described on page 28.
2. Operate the Camera Recognition System as described on pages 37 to 39.
SYSTEM
Page 39
BLANK
PAGE
Page 40
CREASING / BOOKLET MAKING
DocuMaster Pro
Perforating
Once the machine is set-up, the Documaster Pro 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. If
this occurs creasing and perforating must be carried out as separate operations.
2. By adjusting the outfeed drive tyres relative to the drive hubs it is possible to stear
the sheet, (i.e. By placing the tyre on top of the hub one side of the paper will stear
faster on that side).
The components and tools required to install the perforator are contained in the despatch
kit supplied with the machine, they are listed below.
1 off Set of standard perforation ‘56 tooth’ blades.
1 off Set of standard hardened anvils.
1 off Perforator stripper.
1 off Scoring wheel
1 off 3mm bondhus wrench / allen key
1 off 2mm bondhus wrench / allen key
The perforator blades are split into two matching halves and
are fitted to the drive wheels as shown in the photograph
using the four screws supplied.
A hardened anvil is fitted to the drive hub as shown in the
photograph also using the four screws supplied. Again the
anvils are made from matching halves.
Important: The perforator blades are very sharp and
care must be taken whilst handling.
Do not mix the matching pairs of blades or anvils.
Perforating ‘Spares’ kits
For perforating and other types of paper, various spares kits are available which can be
assembled to the machine in the same fashion. They are listed below along with a range
of scoring wheels,
Perforating blades
Anvils
SYSTEM
56 teeth
Part Number 1-99-41 - Standard stock /
fine perforations.
28 teeth
Part Number 1-99-12 - Medium stock /
Medium perforations.
20 teeth
Part Number 1-99-10 - Heavy stock /
coarse perforations.
Standard Part Number 1-99-35 - For all blade types
Page 41
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. Turn the mains supply to the machine ‘off’.
2. Remove the stacker unit and open the exit guard.
3. Locate and remove the blades / anvils from the despatch kit supplied with the
machine.
4. Using the 2mm allen key (supplied), loosen the drive wheel that is to accommodate
the blades.
5. Slide the drive wheel away from any obstructing drive wheels or hubs in order to
mount the blades.
FIG 16.1
6. Using the 2.5mm allen key (supplied), take one
half of the matching pair of blades and mount on
to the drive wheel. Do not secure the blade.
7. Mount the other half of the blade to the drive
wheel as shown (fig 35.1). Secure the blades to
the wheel ensuring not to over tighten grub screw.
8. Mark on a single sheet the desired perforating
position. Feed the sheet through the machine
manually until the mark can be seen. Use this
mark to assist in fixing the position of the
perforating drive wheel to the roller drive shaft.
9. Using the 2mm allen key, loosen the drive hub
nearest the perforating drive. Slide the drive hub
away from any obstructing drive wheels or hubs
in order to mount the anvils.
10. Using the 2,5mm allen key, take one half of the
matching pair of anvils and mount to the drive
hub. Do not secure the anvil.
FIG 16.2
Page 42
CREASING / BOOKLET MAKING
DocuMaster Pro
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.
13. To prevent damage to the blades or the anvils, do not force the drive wheel against
the hub.
14. Fix the perforator stripper adjacent to the drive wheel and blade as shown.
15. Operate the machine and test the perforations for form.
It is important that the drive hubs are arranged evenly across the width of the paper
in order to reduce the risk of jamming.
For multiple perforations repeat the above procedure.
2
1
3
5
4
FIG 17.1
Fig 17.1 Demonstrates a typical set-up for perforating sheets.
1 - Perforating drive wheel with mounted blades
2 - Perforator stripper
3 - Standard drive wheel
4 - Drive hub with mounted anvils
5 - Standard drive hub
Always remove blades and anvils once the perforating operation has been
completed to avoid marking on digital or delicate media.
SYSTEM
Page 43
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.
(ii) Once you have accepted you are trained to operate the machine select the
Tools Tab
at the bottom of the screen.
Up Arrow - Selcet to
set the blade to Top
Dead Centre
(iii) On the Tools Setting Page select the Up Arrow, the machine will activate and the
blade will move to top dead center.
2. Raise the exit guard
3. Using a 6mm allen key, unlock the shoulder bolts (labeled with scale transfer)
positioned at each end of the creasing blade.
4. Turn the adjustment cam to adjust the blade pressure. Increasing the gradient on the
scale will increase the blade pressure.
5. Ensure that the shoulder bolts are locked after setting.
The diagram below demonstrates the adjustment of the blade pressure
Page 44
CREASING / BOOKLET MAKING
DocuMaster Pro
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.
If the blade set is misaligned, the media being driven will be subject to scoring or even
tearing at any point along the crease line. Please note that to avoid damage to the
blade set, adjustment should only be made in small increments. The below sketch
demonstrates how the blade alignment can be carried out.
Adjustment can be made at either of the blade or anvil. The two clearance holes positioned above the roller tilt mechanism are the front alignment (one for blade, one for anvil).
The two holes are repeated on the back of the machine for the back alignment.
1. Remove the stacker unit from the machine.
2. Unlock and centralise the roller tilt mechanism in order to locate the heads of the
front alignment screws.
3. Using a 3mm allen key, loosen the cap head type locking screws located on the
front face at both ends of the blade /anvil as shown below.
4. Using a 4mm allen key, locate the two front or back alignment screws in the side
frame in order to adjust the blade / anvil.
5. The upper screw of the two, will adjust the upper blade / anvil whereas the
lower screw will adjust the lower blade / anvil both in very small increments.
6. In order to obtain the required position, adjust either the blade or the anvil by a
small amount and then operate the machine to test the form of the crease.
Repeat the exercise until centralisation is located.
7. Using a 3mm allen key, lock the cap head type screws (as per step 3) on both the
upper and lower blade / anvil.
SYSTEM
Page 45
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. Remove the screws and
the blade adjustment cams.
4. Insert the blade extractor tools (70-055-01 &
70-055-02) into the holes in the adjustment
links, as shown. Push downwards on the
handles of the blade extractor tools to
release the blade assembly from the power
links.
5. Slide the blade assembly out of the creasing
unit and lay it on a flat surface.
6. Slide the adjustment links away from the
dowels located in the ends of the blades /
anvils as shown in the photograph (left)
7. Place the new blade set into position.
Check that the eccentric shoulder bolts on
the link plates have been positioned as
shown in fig 20.1.
8. (Upper blade / anvil only)
Slide the adjustment links onto the dowels.
FIG 20.1
9. Slide the new blade set into the slots of the
creasing unit as shown in fig. 21.1.
Locate the blade extractor tools into the holes in
the adjustment links as shown. Pull the handles
of the blade extractor tools upwards to engage
the blade assembly back into the power links.
10. Set the cam graphics for both ends of the blade /
anvil to their lowest point on the scale (ie. When
the mark on the scale reaches the mark on cam
holder) Fasten the socket head screws on the
adjustment cams until they are tight.
Page 46
CREASING / BOOKLET MAKING
DocuMaster Pro
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 44 - 45 to adjust the creasing line.
‘Spares’ kits
In the event of any damaged or lost components within the blade assembly, spares kits
are available on request. However, components within the blade set can not be ordered
separately ie single blade or anvil.
Standard Blade set
Part number 76-213-01
Consisting of a standard blade and anvil, blade brushes, blade links and alignment bolts.
Extra Narrow Blade set
Part number 76-213-03
Consisting of a narrow blade and anvil, blade brushes, blade links and alignment bolts.
SYSTEM
Page 47
Trouble Shooting
Paper crease out of square
l
Check that the sheets are all square and exactly the same size before loading the
stack on to the table.
l
Check that the roller tilt mechanism is correctly set and locked in position.
l
Check that the adjustable side lay has been correctly positioned ie. No further than
0.5mm from the paper stack.
Paper jamming
l
Check that the leading edge of the paper is not being damaged by the paper gate. If
this is occurring, check that the suction slot and the paper gate have been correctly
set.
l
Check that the first crease position is not too close to the leading edge of the paper.
A minimum distance of 32mm is recommended.
Machine will not start
l
Check the power supply to the machine.
l
Check that the emergency stop button has been released.
l
Check that the exit guard is down.
l
Check that the stacker unit is located correctly and has not been disconnected from
the magnetic switch.
l
Check that the lower blade / anvil is connecting to the home switch (mounted below
the lower blade / anvil).
Paper not feeding
l
Check that the paper stack is not too high or too heavy for the feeder. The height of
the paper stack should be defined by the weight and the size of the stock being
creased.
l
Ensure that the adjustable side lay is not pressed against the paper stack. However,
if the clearance between the adjustable side lay and the paper stack is too great, the
air supply will escape instead of blowing through the paper thus making it difficult to
feed.
l
Check that the clearance between the paper gate and the suction roller is not set too
low.
l
On digital media, the feeding performance may be improved if the leading edge of
the stack is trimmed before loading onto the machine.
Page 48
CREASING / BOOKLET MAKING
DocuMaster Pro
Trouble Shooting
l
Check that the air distribution has been correctly set.
l
Check that the air separation has been set high enough to feed the sheets.
l
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.
Machine not counting
Open the exit and remove the blade set
(see pages 46-47) to access the dual
sensor post located in between the drive
rollers. Using a soft brush, clean the
visible sensor on the end of the post.
Use the brush to clean the sensors
between the post and the bottom paper
guide which are not visible.
Photograph (left) shows the dual sensor
post containing the sensors.
No suction
l
If the suction drum is not rotating, check all of the drive belts for cleanliness and
splits (including the bottom in-feed roller drive belt).
.
To Re-register the Booklet Maker Unit.
1. Select the Tools Tab
at the bottom of the screen.
2. Select the Re-Register BMP button
the Booklet Maker to known positions.
The machine will register the moving parts of
To Reset The Booklet Maker Unit Back To Factory Default Settings.
1. Select the Tools Tab
at the bottom of the screen.
2. Select the Machine Defaults button
factory settings.
SYSTEM
This will set the Booklet Maker back to
Page 49
Trouble Shooting
To Adjust Misalignment Between Creaser Unit and Booklet Maker Unit.
Minor sideways misalignment, caused by uneven floor or machine build tolerances, can be
adjusted as follows:
1. Select the Tools Tab
at the bottom of the screen.
2. Use the BMP alignment area (shown below) to adjust the position of the creaser unit
NOTE:- Values of less than 3 may not be enough to adjust the position.
BMP alignment - On
selection the status area
will become a calculator
for inputting values.
Arrows may be
selected to align the
machines in 1 unit
increments.
Recommended weekly operator maintenance
• Clean all sensors
• Clean in feed rollers and output drive hubs using the cleaning kit supplied.
(Cleaning kit part number 90-018)
• Remove and clean the blade assembly
• With the blade assembly removed, clean the slots and surrounding area
within the creasing unit.
Technician Maintenance
It is recommended that your machine is fully serviced at least once every six months
by a factory trained Service Engineer.
Page 50
CREASING / BOOKLET MAKING
DocuMaster Pro
Error Messages
Error Screens
Sheet did not arrive.
If the machine stops and error message 01 is displayed on the touch screen, this
indicates that the paper did not arrive at the end of the suck process; so the machine
timed out. Press the green tick button and then press the start button.
Paper Crunch
If the machine stops and error message 02 is displayed on the touch screen, this
indicates that a paper jam has been detected.
Press the system switch down and then select the right or left arrows, to inch the
paper forwards or backwards. See page 31 that describes how to remove paper jams.
Press the green tick button and then press the start button.
Double Sheet Feed
If the machine stops and error message 03 is displayed on the touch screen, this
indicates that a double sheet feed has been detected. Check that the paper gate has
been set correctly. Press the green tick button and then press the start button.
Blade Not Home
If the machine stops and error message 04 is displayed on the touch screen, this
indicates that the lower blade / anvil has not made contact with the HOME switch.
i.e. blade still in top position. Switch the machine off and remove the blade set and
ensure that the area is free from obstructions. Return the blade set to the creasing unit
and switch the machine on. Operate the machine in the normal sequence, if the
display continues to read error message 04 it is advised to contact a Service Engineer
immediately.
SYSTEM
Page 51
Error Messages
Error Screens (Continued)
Overlap
If the machine stops and error message 13 is displayed on the touch screen, this
indicates that the ‘Lead Edge Sensor’ has seen a sheet subsequent to the first
one as being longer. Again this could actually be a longer sheet, OR it could be a
sensor problem (if it is a recurring problem). Check that the paper gate has been set
correctly.
BMP Error
If the machine stops and an image of the Booklet Maker is displayed. The error is
denoted by the Error Number. These are as follows:
Error:
14. Motor Error - Ensure All doors are closed and there are no sheets jammed in the machine.
Restart the job.
15. Setup failure - Re-register the BMP as explained on pages 34 and 49. Restart the job.
21. Staple Failure - Ensure the Staple heads are fitted correctly and the door to the BMP is
closed correctly.
28. Axis Moving - Restart the job once the machine has come to rest. If error reoccurs
re-register the BMP as Explained on Pages 34 and 49. Restart the job.
31. Motor Error - Ensure All doors are closed and there are no sheets jammed in the machine.
Restart the job.
34. Stitch Heads - Ensure the Staple heads are fitted correctly and the door to the BMP is
closed correctly.
35. Staples Low - Replace Staple Cartridges.
36. Stitch Motor. Ensure All doors are closed and there are no sheets jammed in the machine.
Restart the job.
41. Pre-start - Re-register the BMP as explained on pages 34 and 49. Restart the job
Slide Abandoned
This error (error 17) indicates that the user has stopped the machine aligning by
selection the stop button.
Page 52
CREASING / BOOKLET MAKING
DocuMaster Pro
Error Messages
Image NOT Found
If the machine stops and displays error message 19. This indicates that the camera has
not identified the stored image on the programmed page.
Image out of Sequence
If the machine stops and displays error message 20. This indicates that the camera has
identified the stored image and it is not in the order it should be.
Paper in Crease Mechanism
If the machine stops and displays error message 22. This indicates that there is paper in
the mechanism. Clear the paper by inching the rollers as explained on pages 34-35.
Count Inconsistent
If the machine stops and displays error message 23. This indicates that the machine
has detected too many or too few sheets in the book. Reset the stack and restart the
job.
Hardware error
If the machine stops and displays error message 24. This indicates that the machine
has detected a hard ware error. Ensure all cables are connected correctly and reset all
power switches.
SYSTEM
Page 53
Error Messages
Error Screens (Continued)
Sheets not in infeed
If the machine stops and error message 25 is displayed on the touch screen, this
indicates that the machine has not detected sheets on the infeed tray as expected.
Sheets not cleared infeed
If the machine stops and error message 26 is displayed on the touch screen, this
indicates that the sheets have not completely cleared the infeed tray. Loosen the
guides to prevent the guides trapping the sheet and restart the job.
Bad status
If the machine stops and error message 27 is displayed on the touch screen, this
indicates a bad status response from the BMP. See Booklet maker operators manual
70-114 for details.
Stitch Guard open
If the machine stops and error message 29 is displayed on the touch screen, Ensure
the stitch guard door is securely closed.
Trim Guard open
If the machine stops and error message 30 is displayed on the touch screen, Ensure
the trim guard door is securely closed.
Page 54
CREASING / BOOKLET MAKING
DocuMaster Pro
Error Messages
BPM Jam Detected
If the machine stops and error message 32 is displayed on the touch screen, Ensure
there are no sheet trapped within the Booklet Maker and restart job.
Trim Bin Full
If the machine stops and error message 33 is displayed on the touch screen, Empty
the Trim Bin and restart job.
Spine Master Error
If have the optional Spine Master fittedyou may see the following errors:
Errors:
37. Guard Open - Ensure all doors and guards are securely closed.
38. Stacker full - Empty stacker and continue job.
39. infeed Jam - Remove books/sheets that are stuck in the infeed and continue
40. Clamp Jam - Remove books/sheets that are stuck in the clamp and continue
Camera Error
If have the optional camerar fitted you may see the following errors:
Errors:
42. Camera Fail - Camera failed to operate, re-capture image and restart job
43. User cancelled - user has cancelled image capture.
SYSTEM
Page 55
7-95-22
ITEM
PART NUMBER
DISPATCH KIT
QTY
DESCRIPTION
1
70-143
1
OPERATORS MANUAL(Part 1) (Creasing Unit)
2
70-152
1
OPERATORS MANUAL (Part 2) (Booklet Making Unit)
3
90-018
1
ROLLER CLEANING KIT
4
7-99-01
1
ANVIL SET - Perforator
5
1-99-12
1
PERFORATOR BLADE SET - 28T
650-040
1
650-041
1
POWER CORD C19 - 3Pin - UK
POWER CORD C19 - 3Pin - USA
7
650-016
1
L6 - 15P Re-Wirable Plug (Used on USA Only)
8
617-004
4
GLASS BALL - Ø20
9
620-007
1
HEXAGON BALL DRIVER 2mm
10
620-020
1
HEXAGON BALL DRIVER 2.5mm
11
620-026
1
BONDUS L WRENCH 4mm
12
620-028
1
BONDUS L WRENCH 3mm
13
620-033
1
BONDUS L WRENCH 6mm
14
70-055-01
1
BLADE EXTRACTION TOOL - OP SIDE
15
70-055-02
1
BLADE EXTRACTION TOOL - LAY SIDE
16
624-018
1
DISPATCH BOX
17
94-087-01
1
CLAMP PLATE - SIDELAY
18
94-087-02
2
CLAMP PLATE WIDE - SIDELAY
6
WARNING......
THE BLADES FOR ANVIL AND PERFORATING SETS ARE SUPPLIED AS
MATCHING PAIRS AND SHOULD NOT BE MIXED OR LEFT
UNPROTECTED OR SERIOUS DAMAGE MAY RESULT.
Page 56
CREASING / BOOKLET MAKING
DocuMaster Pro
ITEM
ACCESSORIES AND OPTIONS
PART NUMBER
DESCRIPTION
1
2
3
4
5
1-99-10
1-99-12
1-99-41
1-99-35
76-213-03
PERFORATING BLADE SET 20T (Card)
PERFORATING BLADE SET 28T (Single sheets)
PERFORATING BLADE SET 56T (Fine perforations)
ANVIL SET USED WITH ABOVE BLADE SETS
BLADE SET - EXTRA NARROW
6
7
79-052-01
75-407
FA45 OBJECT CAMERA KIT
ETHERNET KIT
ACCESSORIES....
....May be obtained from
your dealer and fitted to your
machine using the instructions
supplied, or by reading your
operators manual.
SYSTEM
OPTIONS....
....May also be obtained and
fitted by your dealer. You should
not attempt to fit options as
specialist tools and knowledge are
required.
Page 57
RECOMMENDED SPARES
PART NUMBER
DESCRIPTION
93-021
FEED BELT
609-011
‘O’ RING Ø20
94-028
LOCK PIN ASSEMBLY - Side Lay
613-365
EMERGENCY STOP SWITCH
652-011
SWITCH - LOW CURRENT COIL - BLACK ROCKER
652-043
SWITCH - 240 VOLT COIL - 20A - BLACK ROCKER
75-472-01
MINI ITX MOTHERBOARD (CONFIGURED)
75-457-01
CONTROL PCB ASSEMBLY
174-06-01
SMALL STEPPER DRIVER - LOW POWER - PCB ASSY
174-19-01
RS232 ADAPTOR PCB ASSY
125-21-02
DUAL STEPPER DRIVE PCB ASSEMBLY
75-06-01
TOUCH SCREEN ASSEMBLY - 7”
76-272
PSU ASSEMBLY - ATX12V - 300W
655-011
PSU UNIT 5V/24V
655-015
PSU UNIT - SWITCH MODE - 24V
655-016
PSU UNIT - SWITCH MODE - 48V
76-156
BLADE POSITION SENSOR
76-168
PAPER GUIDE ASSEMBLY - Bottom Sensor
76-166
PAPER JAM SENSOR ASSEMBLY
76-154
UPPER SENSOR ASSEMBLY
76-169
BLADE POSITION SENSOR-LEAD
76-255
LEAD - FOLD COMPENSATION SENSOR
98-013
ANTI-STATIC BRUSH
609-022
‘O’ RING Ø32
606-035
KNOB - Roller Tilt
76-109
POWER LINK BEARING
76-213-01
BLADE SET - Standard
76-042
DRIVE BELT - FEED BED
607-041
TIMING BELT - 110XL 037
607-042
TIMING BELT 160XL
607-048
608-019
TIMING BELT TWIN GRIP - 200 DXL 050
SHOULDER BOLT
76-082
PERFORATOR - DRIVE HUB ASSEMBLY
175-28-01
76-240
BUTTERFLY VALVE - STEPPER
STEPPER DRIVE MOTOR ASSEMBLY
76-241
STEPPER BLADE MOTOR ASSEMBLY
Page 58
CREASING / BOOKLET MAKING
DocuMaster Pro
RECOMMENDED SPARES
PART NUMBER
DESCRIPTION
75-425
LEAD VACUUM DRUM MOTOR
76-083
PERFORATOR - DRIVE WHEEL
76-175-01
INPUT ROLLER - Lower
76-177-01
INPUT ROLLER - Upper
76-019-03
OUTPUT SHAFT
78-013
PERFORATOR STRIPPER ASSEMBLY
613-351
MICRO SWITCH - Guard Circuit
613-191
MICRO SWITCH - Home Circuit
78-071-01
ACTUATOR ASSY. - STACKER
610-029
DOGA MOTOR
75-352
POT & LEAD ASSEMBLY
76-250-01
UPPER OUTPUT SHAFT ASSY
78-251-01
LOWER OUTPUT SHAFT ASSY
613-023
FUSE 3.15A - Fast Blow
681-011
FUSE 315ma - Anti-surge
681-015
FUSE 4A - Anti-surge
175-082-01
RELAY PCB Assy
75-388
INTERFACE CABLE
75-040
STACKER SWITCH Assy
654-014
ULTRASONIC RECEIVER
654-015
ULTRASONIC TRANSMITTER
626-004
STATIC ELIMINATOR BAR
75-258
ANTISTATIC TRANSFORMER
NOTE.....
The items listed above represent parts which are subject to wear, loss, or accidental
damage, and is included for your guidance only.
Replacement of parts fitted to your machine require specialist knowledge and should
therefore be entrusted to your dealer.
SYSTEM
Page 59
MACHINE CALIBRATION HISTORY
Serial Number:Date:Total Count:Stretch
Lead Edge Trim
Width Trim
Camera Fitted
Page 60
CREASING / BOOKLET MAKING
DocuMaster Pro
PRODUCT RECYCLING & DISPOSAL
European Union
Disposal Information for Commercial Users
Application of this symbol on your equipment is confirmation that you
must dispose of this equipment in compliance with agreed national
Procedures.
In accordance with European legislation end of life electrical and
electronic equipment subject to disposal must be managed within
agreed procedures.
Prior to disposal please contact your local dealer or representative for
end of life take back information.
Disposal Information for Domestic Users
Application of this symbol on your equipment is confirmation that
you should not dispose of the equipment in the normal household
waste stream.
In accordance with European legislation, end of life electrical and
electronic equipment subject to disposal must be segregated
from household waste.
Private households within EU Member States may return used
electrical and electronic equipment to designated collection
facilities free of charge. Please contact your local disposal
authority for information.
In some Member States when you purchase new equipment your
local retailer may be required to take back your old equipment
free of charge. Please ask your retailer for information.
Other Countries
Please contact your local waste authorities and request disposal information.
SYSTEM
Page 61
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