Full Text Searchable PDF User Manual
ISSUE 1
November
2005
70-072
DOCUMENT SQUARE BACK BOOKLET
OPERATING SYSTEM
Morgana Systems Limited
United Kingdom
Website: www.morgana.co.uk
Telephone: ( 01908 ) 608888 Facsimile: ( 01908 ) 692399
Square Back System
OPERATORS MANUAL
Page 2
SQUARE BACK
CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . .4
Installation
Safety Information
Getting Help
About your Automatic Square Back System 5
How the Square Back System Works
Adjustments and Settings
Stacker
Using your Automatic Square Back System 8
Online Operation
Hand Feeding
Error Conditions . . . . . . . . . . . . . . . . . . . . . .10
Booklet Jammed Inside SBS
Small Booklets Do Not Stack Well
Unevenly Formed Spine
Replacing Fuses
Seeking Assistance
Maintenance . . . . . . . . . . . . . . . . . . . . . . . .13
Service Interval
Operator Maintenance
Specifications . . . . . . . . . . . . . . . . . . . . . . .15
Declaration of Conformity . . . . . . . . . . . . . .17
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
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SYSTEM
Square Back System
CONVENTIONS
The following conventions are used in this manual:
Warning
Warning messages alert you to a specific procedure or
practice which, if not followed correctly, could cause
serious personal injury.
Caution
Caution messages alert you to a specific procedure or
practice which, if not followed correctly, could result in
damage to equipment.
INTRODUCTION
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SQUARE BACK
The Automatic Square Back System post-processes stitched or
stapled booklets to give them the professional flat appearance
of a perfect bound book, but with the security of a stitched spine.
The resulting Square Back booklets are flat, making them easy to
stack, handle and pack.
In these instructions the Automatic Square Back System is
referred to as the SBS.
INSTALLATION
Your SBS should be located on a level floor.
If your SBS is used online with other equipment, installation
requires specialist knowledge and should therefore only be
Carried out by a Morgana approved engineer.
Caution
This machine must only be plugged into an electrical
supply line of the correct voltage and with a proven earth.
Anydamage caused by failureto do sowillnotbecovered
by the guarantee. The requiredmachine voltage is shown
on the label on the rear of the unit.
SAFETY
INFORMATION
Your SBS has been designed with safety as a key feature.
However, to ensure it is used safely please observe the
following cautions and warnings:
Warnings
• As with all electrical equipment, disconnect the unit
from the mains electricity supply when replacing
fuses or when instructed to do so in this manual.
• The disconnect device is the appliance inlet.
• Do not attempt to put your hands or objects, other
than booklets, inside the SBS during operation.
• Do not remove machine covers. Only competent and
trained service engineers should service this equipment.
GETTING HELP
We are confident that your SBS will give many years of
trouble-free production. If you have any queries or prob-
lems, in the first instance please refer to the problem
solving section in this book . Should you require further
assistance, the Morgana Service Department will be
happy to help.
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SYSTEM
Square Back System
2 About your Automatic
Square Back System
HOW THE
SQUARE BACK SYSTEM
WORKS
The booklet is transported, spine first, into the SBS. The
SquareBack spine is formed and the booklet is then
delivered to the stacker on the top of the SBS.
Fig 1. The Automatic Square Back System
ADJUSTMENTS AND
SETTINGS
Mains ON/OFF
The Mains ON/OFF switch is on the front of the machine.
1 = ON, 0 = OFF.
Mains Input
The Mains Input is on the back of the machine. Alongside
the Mains Input is a label indicating the machine voltage
requirements.
Book Thickness Adjustment
The Book Thickness Adjustment (see Fig 2.) can be used
to obtain optimum resultswith different booklet thicknesses.
Turn the knob clockwise to increase the effect, and
anti-clockwise to decrease the effect. The type ofmaterial
will also influence the required setting.
Outfeed
SquareBack Booklets
Stacker Support
Stacker Release Lever
Book Thickness Adjust-
ment
Stacker Full Sensor
Operating Mode Adjust-
ment
Sidelay
Infeed (Hand Feed)
Fig 2. Book Thickness
Adjustment
Max.
Min.
2
4
5
8
6
7
9
3
1
1
2
4
5
6
9
8
7
3
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SQUARE BACK
Operating Mode Selection
(see Fig 3.)
Single Pass :
The SBS will process the booklet a single
time. This is the default setting, and is suitable for the vast
majority of booklets.
Double Pass :
The SBS will process the booklet twice.
This can be useful for thick, inflexible covers which are
more resistant to re-forming.
Fig 3. Operating Mode Selection
SquareBack Mode :
The bookletswillbeprocessed and
receive a squared spine (SquareBack).
Bypass Mode :
The booklets will bypass the Square-
backing process and will be delivered straight to the
stacker. In Bypass Mode, the stacker may require ad-
justment (See “Stacker” on page 7 .).
Error Indicator / Reset Button
This indicator/button performs several functions -
• A green light indicates an error. Correct the error
and then press the button to reset the SBS.
• The button can be used to start the machine if it is
not automatically started by hand-feeding or by
connected equipment.
• When hand-feeding, the green light flashes as each
book is processed. Another booklet can be inserted
when the light goes out.
Double
Pass
Single Pass
SquareBack Mode
Bypass Mode
Error
Indicator /
Reset
Button
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SYSTEM
Square Back System
STACKER
Booklets are stacked, spine uppermost, in the stacker.
The stacker support automatically recedes to accommo-
date the increasing stack. When the stacker is full, a
sensor will automatically stop the SBS and the green
Error/Reset light illuminates.
Unload the booklets, slide the stacker support back up
towards the outfeed and then restart the connected
equipment.
Fig 4.
The SBS Stacker
Note:
1. To move the stacker support, squeeze the stacker
release lever towards the stacker support.
2. If booklets are not processed (ie. in Bypass Mode),
they may stack better lying flat. Slide the stacker
support away from the outfeed, taking care not to
trigger the stacker full sensor.
3. If small booklets do not stack well, adjustment may
be required , see “Small booklets do not stack well”
on page 11.
Stacker Support
Stacker Release Lever
Stacker Full Sensor
Page 8
SQUARE BACK
3 Using your Automatic
Square Back System
ONLINE OPERATION
The SBS can be used online to a variety of bookletmaking
machines. It will automatically start and stop as required,
controlled by the connected equipment.
1. First select the required Operating Mode and Book
Thickness Adjustment (see Chapter 2, ’About your
Automatic Square Back System’).
2. Start the connected equipment and run a single
booklet through the SBS.
3. Inspect the formed booklet, and adjust the Book
Thickness Adjustment or the Operating Mode as
required.
Spine Formations
Correct: This is how a well formed
spine should look.
Incorrect: The spine has not been
formed sufficiently.
Increase the Book Thickness Ad-
justment and/or use Double Pass
Mode
Incorrect: The spine has been
over-formedresultingindamageor
creasing on the cover.
Decrease the Book Thickness Ad-
justment and/or use Single Pass
Mode.
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SYSTEM
Square Back System
4. Adjust the operating speed of the connected equip-
ment to approximately 1,000 booklets per hour.
(Note: some connected equipment will automatically
adjust to an appropriate speed for the SBS.)
5. Gradually increase the speed to about 1,400 book-
lets per hour (single pass mode). If the speed is set
too high, some booklets will not be processed. They
will be clearly identifiable in the stacker.
HAND FEEDING
Booklets can be hand-fed into the SBS either when the
unit is stand-alone, or when it is connected to a booklet
maker. It is not necessary to disconnect it from other
connected machinery.
1. Adjust the sidelays to suit the booklet size.
2. Insert a booklet, spine first, into the infeed.
3. The completed booklet is delivered into the stacker.
The green Error/Reset indicator flashes as each book is
processed. Another booklet can be inserted when the
light goes out.
If the booklets are inserted too quickly, some will not be
processed. They will be clearly identifiable in the stacker.
Caution
• Do not exceed the specified book thickness.
Minimum : 1mm (0.04”)
Maximum : 6.5mm (0.25”) This is approximately 30
sheets of 80gsm (20# bond) folded into a 120 page
booklet.
• Only process one booklet at a time, DO NOT try to
process several booklets at once.
WET INK
Avoid using the SBS on booklets where the ink has not
dried. This may result in ink transfer and will increase the
amount of cleaning required (see Chapter 5, ’Mainte-
nance’).
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SQUARE BACK
4 Error Conditions
BOOKLET JAMMED
INSIDE SBS
If a booklet jams in the SBS for any reason, switch the
SBS off at the mains input and then switch it back on
again. The machine will reset and the booklet should be
ejected onto the stacker. If the booklet is not ejected,
press the green Error / Reset button.
If the booklet still remains inside the SBS, it must be
removed.
• Switch the SBS OFF and unplug the mains input
lead.
• Push in the two securing latches and gently lower the
front cover downwards.
Fig 5. SBS, front cover and latches
Front Cover
Front Cover Latches
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SYSTEM
Square Back System
• Open the top lid by lifting it upwards.
Fig 6. The SBS with front cover and lid opened
• Retrieve the booklet from inside the machine. Take
care not to dislodge any of the conveyor belts.
Caution
If the booklet cannot be removed because it is jammed
in the clamp mechanism, do not attempt to force the
mechanism open. Contact your Morgana service
Department.
• Close the SBS lid by lifting it slightly, push the sup-
port strut and then lower the lid.
• Lift up the front cover and push it closed, ensuring
that the latches re-engage.
Warning
When releasing the SBS lid support strut, hold the lid
securely and take care not to drop it on your hand.
SMALL BOOKLETS
DO NOT STACK WELL
If small booklets do not stack tidily, the booklet control
springs should be used.
Open the front cover of the SBS, as explained above,
and release the two springs by pulling them out from
Front Cover
(open)
Lid (open)
Lid Support Strut
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SQUARE BACK
underneath the shaft. When the springs are not required,
they should be tucked back under the shaft.
Fig 7. Booklet Control Springs
UNEVENLY FORMED
SPINE
If the spine is well formed at only one end of the booklet,
Double Pass Mode should be used. Some stocks may
require Double Pass Mode to achieve an even result see
“Spine Formations” on page 8 ).
REPLACING FUSES
Your SBS is fitted with two fuses at the mains input. If
either of these fail, the SBS will not operate.
Warning
TheSBSusesdouble-pole/neutral fusing (i.e., two fuses),
so when changing fuses always first disconnect the ma-
chine from the mains electricity supply by switching OFF
and unplugging the machine.
• Switch the SBS OFF and unplug the mains input
lead. Open the flap on the fuse holder.
• Pull out each fuse casing in turn and check the fuse.
• Replace if necessary with a fuse of the correct spec-
ification, as detailed below.
Reference
230V machines:
730-016 Fuse, 1.25" (32mm) 5.0A HRC-Quick Acting F
115V machines:
730-020 Fuse, 1.25” (32mm) 10.0A HRC (Quick Acting, F)
SEEKING
ASSISTANCE
If you require assistance with your SBS, please contact
your local Morgana Service Department.
Spring
Shaft
Page 13
SYSTEM
Square Back System
5 Maintenance
SERVICE INTERVAL
It is recommended that your SBS is serviced by an
approved Morgana engineer at six to twelve month inter-
vals (depending on usage). Please contact Morgana
for further details.
OPERATOR
MAINTENANCE
As with all machinery, your SBS will benefit from regular
cleaning to prevent build up of dust and general dirt.
• Check that the air vents are not obstructed or
blocked. Obstructed air vents will cause the motor to
overheat.
• Once a week, or as required, clean the carriage
roller as explained below.
• Do not use the SBS on booklets where the ink is still
wet. This may result in ink transfer, and increase the
need for cleaning.
Cleaning the Carriage Roller
1. Set the operating mode to Double Pass, and the
Book Thickness Adjustment to maximum.
2. Take a maximum thickness (6.5mm) A4 size booklet,
and wrap a sheet of paper around the outside. Alter-
natively, take about 30 sheets of A3 80gsm paper
and fold into an A4 size booklet.
3. Apply a thin coating of a suitable cleaning product
(see below) to the spine of the booklet.
4. Hand feed the booklet into the SBS in the normal
way. Re-insert the booklet and reprocess about 5
times.
5. Remove the outer sheet, to give a fresh clean sur-
face, and repeat step 4.
Suitablecleaningproductsincludealcohol (isopropanol),
offset litho blanket wash or RS Solvent Cleaner Aerosol.
Always observe any health and safety information
supplied with cleaning products.
Warning
Cleaning solvents are flammable. DO NOT spray them
directly into the SBS.
USA Users:
6.5mm is ¼”
For A4, use 8½ x 11”
For A3, use 11 x 17”
80gsm is 20# bond
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SQUARE BACK
Caution
Do not attempt to use a cloth to clean the carriage roller.
This may leave loose fibres or debris inside the machine.
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SYSTEM
Square Back System
6 Specifications
Intended Use
This product is intended for the re-forming of booklet
spines, to flatten the booklet and give a square appear-
ance to the spine, within the specifications below.
Production
up to 1400 per hour single pass
Booklet Size
from 80 x 120mm to 250 x 350mm
(dependant on specification of connected equipment)
Booklet Thickness
minimum of 1mm, 0.04”
maximum of 6.5mm, 0.25”. This is approximately 30
sheets of 80gsm (20# bond) folded into a 120 page
booklet.
Dimensions
Width 707mm, 28”
Depth 745mm, 29.5”
Height 1242mm, 49”
Weight 132kg, 291lb
Electrical
230V, 50Hz, 3A or 115V, 60Hz, 5A
Single Phase, Earthed supply required
Noise
72 dB(A)
Operating Conditions
10-35°C at 35-85% relative humidity
Production and specifications are subject to operating
conditions. The specified paper thickness figures are
given for guidance only. The actual performance of the
machine will depend on the nature of the paper and
covers used. In line with a policy of continual improve-
ment, the manufacturer reserves the right to alter the
materials or specifications of this product at any time
without notice.
Radio Frequency
Emissions
This equipment has been tested and found to complywith
the limits for a Class A digital device, pursuant to part 15
of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when
the equipment is operated in a commercial environment.
This equipment generates, uses and can radiate radio
frequency energy and, if not installed and used in accord-
ance with the instruction manual, may cause harmful
Page 16
SQUARE BACK
interference to radio communications. Operation of this
equipment in a residential area is likely to cause harmful
interference in which case the user will be required to
correct the interference at his own expense.
Page 17
SYSTEM
Square Back System
7 Declaration of Conformity
Manufacturer's Name:
Morgana Systems Limited
Manufacturer's Address:
Grampian Gate
Snowdon Drive
Winterhill, Milton Keynes, Bucks.
Mk6 1AP
United Kingdom
Declares that the product
Product Name:
Morgana Square Back System
Product Number:
WA/ASM/0010 onwards
Conforms to the following Product Specifica-
tions:
Safety:
73/23/EEC & 98/37/EC Council Directive 'on the approx-
imation of laws of Member States relating to machinery'.
BS EN 60950 : 1992
EMC:
89/336/EEC Council Directive 'on the approximation of
laws of Member States relating to electromagnetic com-
patibility'.
EN55022:1998 Class A
EN55024:1998
EN61000-3-2:2000
EN61000-3-3:1995 + A1:2001
Page 18
SQUARE BACK
A
about your automatic Square Back System 5
adjustments 5
book thickness 5
operating mode 6
assistance 12
B
book thickness 5
book thickness adjustment 5
booklet control springs 12
booklet jam 10
bookletmaker, connection to 8
bypass mode 6
C
cleaning 13
conformity 17
D
declaration of conformity 17
double pass 6
E
error conditions 10
error indicator 6
F
front cover 11
fuses 12
H
hand feeding 9
help 4, 12
I
infeed (hand feed) 5
ink, wet 9
installation 4
introduction 4
J
jam, booklet 10
L
lid 11
M
mains input 5
mains on/off 5
maintenance 13
maintenance, operator 13
O
on/off switch 5
online operation 8
operating mode 6
bypass mode 6
double pass 6
single pass 6
squareback mode 4
operating mode adjustment 5
operator maintenance 13
outfeed 5
P
power, mains input 5
problem solving 10
R
reset button 6
S
safety 4
service interval 13
sidelay 5
single pass 6
small booklets 11
specifications 15
spine 8, 12
correct 8
incorrect 8
springs, booklet control 12
squareback mode 6
stacker 7
stacker full sensor 5
stacker release lever 5
stacker support 5
INDEX
Page 19
SYSTEM
Square Back System
U
using your automatic Square Back System 8
W
wet ink 9
INDEX