70-169_Documaster Pro (CB) Operators Manual Pt 2
Contents
1. is supplied with the Motorised Infeed Page 5 SYSTEM An alternative is the BookMaster Infeed Guide P N 041 572 see Figure 4 a TIN y Paper Tray A P N 041 571 FIGURE 7 Fitting the Motorised Infeed Loosen the two hand screws see Figure 8 on either side of the Motorised Infeed Fixing Clip 6 ge Hand Screw 90 7 gt aa a FIGURE 8 Page 6 CREASING BOOKLET MAKING DocuMaster Pro Connect the Motorised Infeed interface cable to the socket on the top of the BMP see Figure 9 Motorised Infeed Socket FIGURE 9 Position the Motorised Infeed on the BMP so that the fixing clips see Figure 8 locate inside the BMP infeed Fit the rear hand screw see Figure 10 and then tighten the two side hand screws Length Adjustment Hand Screw Rear Hand Screw FIGURE 10 Fit the paper tray see Figure 7 if required SYSTEM Page Page 8 The BMP will automatically start when a set of sheets is fed into the Motorised Infeed The BMP will automatically stop approximately 10 seconds after the last feed and return to the standby mode The Motorised Infeed will only feed the next set when the BMP Is ready Status Indicator Light The yellow indicator light on the BMP see Figure 6 shows the status of the unit Indicator Light Mode BMP Status Blinking once per second The unit is ready to run Constantly illuminated The unit is running Blinking2. of the book Flat Blade Screwdriver first ensure that the BMP is adjusted correctly and that delivery into the unit is good If the problem persists fine tuning of the staple position may be necessary Adjust ment is via the central screw on the fold plate mechanism located behind the perspex cover see Figure 35 Fold Position Fine Tuning FIGURE 35 If necessary adjust the fold position until the screws align with the holes in the perspex cover Using a flat blade crewdriver loosen the two locking screws see Figure 36 Turn Clockwise to Lower the Staples Locking Screw Fine Adjustment Screw Locking Screw Turn Anticlockwise to Raise the Staples FIGURE 36 Turn the fine adjustment screw see Figure 36 clockwise to lower the position of the staples as viewed when the book exits the unit and anticlockwise to raise the staples One quarter turn of the screw equates to approximately 2mm of travel Tighten the locking screws and produce a test booklet Repeat the procedure if necessary Page 32 CREASING BOOKLET MAKING DocuMaster Pro SYSTEM Page 33 SHARPENING THE TMP BLADE morgana The TMP blade and anvil are located behind the conveyor assembly see Figure 37 at the docking end of the unit Conveyor Cover Conveyor Assembly FIGURE 37 Periodically all TMP blades will require re grinding Poor grinding will result in poor life and can cause cracks and nicks in the
3. second New cartridges are available P N 810 022 To change a cartridge first open the BMP lid by turning the handle to the left and lifting see Figure 22 The lid is supported by a strut on the right side Indicator Light FIGURE 22 Grasp the cartridge at the top and pull directly away from the staple head as shown by the arrow in the photo see Figure 23 Staple Cartridge Staple Head FIGURE 23 Page 18 CREASING BOOKLET MAKING DocuMaster Pro Fit the new cartridge and check the machine operation by making a few test booklets ADJUSTING THE The staple heads have two positions Normally the heads should be in the outer position 138mm 5 4 between staple centres For small booklets the inner position can be used 115mm 4 5 between staple centres Move the lever see Figure 24 to the right to select the inner position POSITION OF THE STAPLE HEADS Staple Head Adjustment Lever Optional third staple head Clincher FIGURE 24 When adjusting the staple heads ensure the staple clinchers are moved to suit To adjust loosen the orange hand screw see Figure 25 and slide the clincher fully across In the required direction Tighten the hand screw Orange Hand Screw FIGURE 25 SYSTEM Page 19 Note You may have to increase the infeed sidelay gap to access the hand screws To do this increase the paper width on the Creaser unit Before placing your ha
4. that the left and right conveyor clamps are set unevenly Booklets are trimmed too short If the conveyor clamps are set too tight the following problem may occur The cover of the booklets are pulled resulting in dam Tools required Procedure 4mm allen key On the BMP control panel set the paper size to A4 gt A5 2 off 150mm 6 rule regardless of the booklet size Once the BMP beeps to confirm it is ready disconnect it from the mains Page 40 CREASING BOOKLET MAKING DocuMaster Pro Open the TMP conveyor cover by lifting the orange handscrew see Figure 43 Conveyor cover FIGURE 43 There are two clamp roller shafts which are adjusted using a 4mm allen key see Figure 44 Adjustment screw Adjustment screw Clamp Roller Clamp Roller Shaft Shaft FIGURE 44 Adjusting the Conveyor Clamps To adjust the conveyor clamp Turn the adjustment screws clockwise to increase the gap reducing clamp pressure Turn the adjustment screws ant clockwise to reduce the gap increasing clamp pressure SYSTEM Page 41 Second Rule Clamp Roller Shaft Page 42 Checking the adjustments It is important that both clamp roller shafts are adjusted to the same height The factory default is 17mm between the top of each shaft and the top of the wire frame When making any adjustments you must re measure the height of both shafts to ensure they are set the same The easiest way t
5. 70 169 Issue 2 FEBRUARY 2013 Documaster Pro cau WA I Inu Bw an W A un nun Mang e EN a ao EN AN Kae N NI E BR ar 7 1B 4 ELL OPERATORS MANUAL Part 2 Booklet Making Unit Document Creasing amp Automatic Booklet Making Machine Morgana Systems Limited United Kingdom www morgana co uk Telephone 01908 608888 Facsimile 01908 692399 CONTENTS morgana Specifications oococoncococonnanoncarononnanono 1 Introduction oococococoncnconononononcarananonos 3 Booklet Making cccseeeeeeeeeees 10 Edge amp Corner Stapling 14 Edge Stapling amp Folding 16 The Staple Heads zuu2u2un000nnenn 18 Troubleshooting Chart 22 Maintenance z2s2u2u0000nononannnnnnn 26 Appendices Connecting the TMP uu eee 30 Staple Position Adjustment 32 Sharpening the TMP Blade 34 Conveyor Clamp Adjustment 40 Lo gt EEE ana nNa anae AA CREASING BOOKLET MAKING DocuMaster Pro SPECIFICATION Intended Use This product is intended to be used for the stapling folding and trimming of materials as specified Electrical Voltage 115V 60 Hz or 230V 50 Hz Single Phase earthed supply required Power 150VA exc TRIM 115V 500VA inc TRIM 20VA Stand by Power 200VA exc TRIM 230V 700VA inc TRIM 30VA S
6. GURE 17 The lever has 11 positions To move the fold rollers further apart i e for larger sets or thicker stock move the lever upwards Move the lever down to bring the fold rollers closer together The fold rollers should be set sufficently close together to produce a neat booklet If the fold rollers are set too close together the booklet covers may be pulled resulting in damage around the staples or the spine of the booklets may be scuffed Fine tune the position of the lever to produce the best booklets possible Adjust the Outfeed Conveyor Slide the large payout wheels see Figure 18 up or down their mounting rail so that they are just nipping the spine of the book when it is released from the rollers Use the scale on the outfeed as a guide Scale Payout Wheels FIGURE 18 SYSTEM Page 11 The contact point of the wheels should be aligned with the required dimension on the scale as shown by the dotted line in the photo see Figure 18 If required make any fine adjustments once the job is running Tip Common sizes are highlighted on the scale For example for an A5 5 x 81 2 book use the A5 marker Hook the trim offcut box see Figure 19 onto the TMP Payout Wheels Offcut Box FIGURE 19 Starting the Job The BMP will automatically start when the first set of sheets is placed into the Motorised Infeed Tip There is a sensor on the TMP to detect when the offcut box is f
7. NING The TrimMaster Pro unit contains a motorised guillotine It is therefore essential that due care is taken and the operating Instructions adhered to when using the unit Also pay particular attention to any specific warnings given Page 2 CREASING BOOKLET MAKING DocuMaster Pro INTRODUCTION The BookMaster Pro and TrimMaster Pro have been designed to staple fold and trim booklets of up to 20 sheets in a wide range of paper sizes Their modular design means that they are equally at home being used N offline or online with a Watkiss Collator For offline use a Motorised Infeed unit is recommended although a man ual Infeed Guide is also available The BookMaster Pro and TrimMaster Pro units are also compatible with other manufacturers bench top and ta ble top collators FIGURE 1 BMP with Outfeed Conveyor FIGURE 2 BMP with Motorised Infeed and Outfeed Conveyor FIGURE 3 BMP TMP and Outfeed Conveyor Motorised Infeed can be fitted also FIGURE 4 BMP with manual Infeed Guide SYSTEM Page 3 The instructions that follow include the set up and operating procedure for the BookMaster Pro the Trim Master Pro and the Motorised Infeed units Please ignore those parts of the instructions that do not apply to your configuration In these instructions the BookMaster Pro is referred to as the BMP and the TrimMaster Pro is referred to as the TMP INSTALLATION Itis recommended that your BookMaster Pr
8. blade We therefore offer the guidelines on page 39 which should accompany the blade and anvil when they are sent for regrinding Whenever the TMP blade is reground check the condition of the anvil also This will only require regrinding if it has become dam aged arning This procedure is potentially hazardous and should onl be conducted by suitably skilled personnel Disconnect the power before removing the conveyor assembly Handle the blade with extreme caution and keep hands clear of cutting edges at all times Parts Required if necessary Tools Required TMP 1189 onwards 3mm allen key 253 835 TrimMaster blade amp guide 4mm allen key TMP 1188 and earlier 6mm allen key 253 173 TrimMaster blade 10mm allen key 19mm spanner Page 34 CREASING BOOKLET MAKING DocuMaster Pro Procedure Separate the TMP from the BMP Open the TMP conveyor cover loosen the orange hand nut Remove the two orange hand screws that secure the conveyor assembly to the TMP unit see Figure 38 Orange Hand Screws FIGURE 38 Lift away the conveyor assembly to reveal the blade assembly see Figure 39 Anvil Blade Mark Along Here FIGURE 39 Note the angled position of the TMP blade and with a marker pen or similar mark along the bottom edge of the blade see Figure 39 This will act as a guide when refitting SYSTEM Page 35 Removing the TMP Blade Slightly loosen all five blade fixing screws see Fig
9. conveyor adjustment 11 P paper jams 24 payout wheels adjustment 11 power supply 1 R radio frequency emissions 2 S safety 4 setting up the bmp 10 12 centre staple selection 10 outfeed conveyor adjustment 11 trim offcut box 12 side stapling 14 15 specifications 1 staple cartridges changing 18 staple head indicator lights 8 staple heads 18 20 adjusting 19 clinchers 19 selecting 14 staple cartridges changing 18 staple position fine tuning 32 status indicator light 8 switching on 4 tmp blade sharpening 34 39 final adjustment 38 honing 39 refitting the blade and anvil 36 removing the blade 36 trim offcut box 12 troubleshooting 22 24 operational problems 22 paper jams 24 staple head problems 24 CREASING BOOKLET MAKING DocuMaster Pro SYSTEM Page 45
10. conveyor belts will eventually cause slippage or ink transfer Warning Access to the manual cranking points on the BMP and TMP requires the side covers to be removed For safety reasons this procedure should therefore only be con ducted by authorised personnel Disconnect the power before removing the side covers BMP To clean the rollers and belts on the BMP first remove the right hand side cover two x M5 button screws to give access to the manual cranking point see Figure 27 Right Hand Side Cover M5 Button Screw FIGURE 27 Open the BMP lid to access the fold rollers Using a 10mm A F spanner wrench manually crank the BMP by turning the nut see Figure 28 clockwise and clean the rollers Page 26 CREASING BOOKLET MAKING DocuMaster Pro and belts with a cloth dampened with soap and water or alcohol isopropanol Do NOT use blanket wash Manual Cranking Point TMP To clean the belts on the TMP first remove the left hand side cover two x M5 button screws to give access to the manual cranking point see Figure 29 is ja Da Orange Hand Screw 7 gt e a Sie Left Hand Side Cover M5 Button Screw FIGURE 29 SYSTEM Page 2 Open the TMP conveyor lid see Figure 29 by lifting the orange hand screw this doesn t need to be loosened just use it as a handle Manual Cranking Point FIGURE 30 Using a 19mm A F spanne
11. e head If this does not work con tact your local Watkiss service department Paper Jams Paper Jams are most commonly caused by incorrect settings of the Motorised Infeed sidelays by paper jammed in the TMP infeed or the conveyor Other causes include the use of curly paper and staples stuck in the clinchers Open the BMP lid this will disconnect the power for safety and remove any jammed sets Check carefully and correct any faulty adjustments that caused the jam to occur as detailed If there are staples stuck in the clinchers remove with a pair of pliers Paper jams in the TMP can be caused by offcuts obscuring the sensor in the conveyor The metal conveyor lid see Figure 29 on p 27 can be opened to remove any jammed sets and trim offcuts WARNING DISCONNECT THE MACHINE FROM THE MAINS ELECTRICITY SUPPLY BEFORE WORKING NEAR THE BLADE AREA Error Indication Certain errors are highlighted by the yellow indicator light or the red staple head indicator lights For more information see page 8 Page 24 CREASING BOOKLET MAKING DocuMaster Pro SYSTEM Page 25 MAINTENANCE morgana The BMP and TMP units require only a small amount of routine maintenance CLEANING Build up of set off powder ink or general dust will grad ually impair the performance of your BMP and TMP Optimum performance will be obtained by keeping the machine clean Fold Roller and Conveyors Build up of set off powder or ink on the fold rollers and
12. m HM DI 19 N x Important Grind In This Direction Only ANVIL Note 2 faces must beflattowithin 0 01mm 12 7mm 28mm 7 This edge must be straight to within 0 04mm SYSTEM Honing Note TrimMaster blade 253 835 is fitted with a guide leg This must be removed when the blade is reground and refitted afterwards Blade Material High Carbon High Chrome Aisi D2 D3 Grinding Angle See drawing alongside Grinding Wheel Cup or Cylinder Grinding Material Grit 46 60 Hardness G H Bond Vitrified Peripheral speed 20 26 V M S of the grinding wheel 65 85 V Ft S Table Speed 20 26 V M Min 65 85 V Ft Min Feed per pass 0 01 0 02mm 0 0004 0 0008 After re grinding the burr should be carefully removed by honing The quality of honing affects the useful life of the cutting edge Correct dd dd Incorrect Page 39 m lt CONVEYOR CLAMP ADJUSTMENT morgana The TMP conveyor clamps are set to a default position at the factory which gives a good trim over a wide variety of booklet thicknesses However when trimming unusually thick or thin booklets the conveyor clamps may need to be adjusted If the conveyor clamps are set too loose the booklet may not be delivered correctly to the trim stop or it may bounce against the trim stop This will result in the following problems booklets are trimmed out of square this may also indicate
13. mp Edge Staple FIGURE 21 Adjust the Staple Heads If required open the BMP lid and adjust the position of the staple heads via the lever see Figure 24 on p 26 Adjust the clinchers to suit Adjust the Fold Roller Gap The gap between the fold rollers is adjusted using a lever to the left of the front face of the BMP see Figure 17 on p 11 The Lever should be moved to its lowest position when edge or corner stitching Note With certain stocks it is possible that edge stitched booklets may occasionally jam in the BMP An edge stitch assistor plate P N 907 442 will prevent these Booklets from jamming The plate is supplied with the optional 3rd stapler head kit P N 914 414 and can Also be ordered separately SYSTEM Page 15 EDGE STAPLING amp FOLDING morgana If required it is also possible to edge staple the set and then fold it The only limitation to this is that the distance from the stapled edge to the fold must be at least half the width of the paper Adjustments Note The gap between the fold rollers must be set to suit the set size when edge stapling and folding see p 10 Note The maximum sheet width that can be stapled in this mode is 250mm 9 84 Page 16 CREASING BOOKLET MAKING DocuMaster Pro SYSTEM Page 17 THE STAPLE HEADS morgana CHANGING THE When a staple cartridge runs out the corresponding red STAPLE CARTRIDGES indicator light see Figure 22 will blink once per
14. nds inside the BMP you should disconnect the unit from the mains electricity supply To close the BMP lid lift it slightly push the support strut see Figure 26 and close the lid Turn the handle to the right to lock in place Support Strut FIGURE 26 Page 20 CREASING BOOKLET MAKING DocuMaster Pro SYSTEM Page 21 TROUBLESHOOTING CHART morgana The following is a guideline to help solve any problems or errors if they persist please call the Morgana Service Department or your Morgana Dealer PROBLEM CAUSE SOLUTION Operational Problems BMP WILL NOT START The BMP is not plugged in Plug into mains connection of the correct type and voltage Fuse has blown on the main input On 220 240V machines there are two 5 amp fuses in the mains input connector check and replace as necessary On 115V machines they are 10 amp fuses BMP TMP lid is open Close the lid BMP STATUS INDICATOR There is a jam or other error inthe Clear the jam see p 24 LIGHT IS BLINKING RAPIDLY unit BMP STATUS INDICATOR BMP TMP lid is open or unit is not Close the lid switch on the unit LIGHT IS NOT ILLUMINATED switched on BMP BEEPS CONTINUOUSLY Offcut Box is full Empty Offcut Box see p 12 ONE OR BOTH STAPLE HEADS _ Staple heads are not selected Select required staple heads see p ARE NOT ACTIVATED 10 A staple head error has occurred The heads should self clear If not turn the unit off and on again to free the head If this does not wo
15. o and Trim Master Pro are sited on a level floor Important This machine must only be plugged into an electrical supply line of the correct voltage and with a proven earth Any damage caused by failure to do so will not be covered by the warranty The required machine voltage is shown on the label on the rear of the unit see Figure 5 SAFETY FIRST Your BookMaster Pro and TrimMaster Pro units have been designed with safety as a key feature and incorporate safety covers which when opened will automatically cut the power to moving parts However as with all electrical equipment when changing fuses or carrying out opera tions other than those detailed in this book Always first disconnect the machine from the mains electricity supply Page 4 CREASING BOOKLET MAKING DocuMaster Pro SWITCHING ON Plug in the BMP unit to a single phase power supply of the correct voltage as indicated by the mains input see Figure 5 N Mains ON OFF Switch Voltage Indicator Label Mains Input FIGURE 5 Also ensure the outfeed conveyor cable is connected to the socket on the BMP see Figure 6 If the TMP is installed ensure that this too is connected see p 30 Status Indicator Light Yellow Staple Head Indicator Light Red Conveyor Socket FIGURE 6 MOTORISED INFEED An optional Motorised Infeed P N 041 571 is recommended This fits on to the BMP infeed and makes offline use easier A paper tray see Figure 7
16. o do this is e Lay the first rule across the wire frame so that it is above the clamp roller shaft see Figure 45 e Using the second rule measure the height from the top of the shaft to the bottom of the first rule e Adjust the shafts as necessary to ensure they are both set to the same height Wire Frame First Rule FIGURE 45 Restarting the job Before restarting the job don t forget to reset the paper size as necessary It is important to return both clamp roller shafts to the actory default height of 17mm before booklets of a more ypical thickness are produced CREASING BOOKLET MAKING DocuMaster Pro SYSTEM Page 43 Page 44 INDEX A adjustable fold rollers 10 adjustment of conveyor clamp 40 42 B blade sharpening tmp 28 booklet making 10 12 setting up the bmp 10 12 C centre staple selection 10 clamp roller shafts 41 42 connecting the tmp 30 31 conveyor clamp adjustment 40 42 corner amp edge stapling 14 15 D dimensions 2 docking plates tmp 30 E edge amp corner stapling 14 15 edge stapling amp folding 16 errors see troubleshooting F Fold rollers adjustable 10 I infeed see motorised infeed installation 4 introduction 3 8 J jams 24 M maintenance 26 28 cleaning the units 26 manual cranking point bmp 26 manual cranking point tmp 27 motorised infeed fitting the motorised infeed 6 using the motorised infeed 14 O offcut box 12 outfeed
17. o the position if necessary Tighten all the blade fixing screws starting from the centre and working out Push the anvil firmly forwards against the blade pushing from behind with your fin gers at each end Main tain a light pressure on the back of the anvil whilst tightening the anvil fixing bolts starting from the centre and working out Lightly tension the anvil adjuster screws against the anvil FIGURE 42 SYSTEM Page 3 Final adjustment Release the clutch and manually crank slowly several rotations to check that the blade passes the anvil smoothly without obstruction Place a single sheet of paper large sheet size between the blade and the anvil and manually crank to produce a test cut Warning Ensure that hands are kept clear at all times Check that a clean cut is obtained across the full width of the blade If necessary loosen the anvil fixing screws at the point where adjustment is needed apply additional pressure to the anvil adjusting screws 1 6th turn at a time and re tighten the anvil fixing screws Perform another test cut and make further adjustments if necessary Hook the conveyor assembly onto the support posts and push into position Secure with two M5 button screws and washers see Figure 38 Fit the side cover and secure Page 38 CREASING BOOKLET MAKING DocuMaster Pro TrimMaster Blade Grinding Instructions BLADE Note 2 faces must be flat to within 0 03mm 8m
18. r wrench manually crank the TMP by turning the nut see Figure 30 clockwise and clean the belts with a cloth dampened with soap and water or alcohol isopropanol Do NOT use blanket wash Warning Ensure that hands are kept clear of the TMP blade area at all times TMP BLADE The TMP blade and anvil should be sharpened when SHARPENING required see Appendix 3 Page 28 CREASING BOOKLET MAKING DocuMaster Pro SYSTEM Page 29 CONNECTING THE TMP morgana Procedure Open the BMP lid by turning the handle to the left and lifting see Figure 31 The lid is supported by a strut on the right side FIGURE 31 Line up the TMP docking plates see Figure 32 with the BMP Connect the power and communications cables to the sockets on the BMP Communications Cable Power Cable Docking Plate FIGURE 32 Page 30 CREASING BOOKLET MAKING DocuMaster Pro Push the two units together so that the hooks on the TMP docking plates align with the holes in the BMP side plates see Figure 33 FIGURE 33 Lift the BMP lid slightly push the support strut see Figure 34 and close the lid Turn the handle to the right to lock the TMP in place Support Strut FIGURE 34 Hook the Outfeed Conveyor onto the support posts on the TMP and connect the interface cable SYSTEM Page 31 A2 STAPLE POSITION ADJUSTMENT morgana Tools required If both staples are consistently off the spine
19. rapidly There is a jam or other error Not illuminated BMP TMP lid is open paper is stuck in the paper path or the unit is not switched on Staple Head Indicator Lights The red indicator lights on the BMP lid see Figure 6 show the status of the corresponding staple head Indicator Light Mode Staple Head Status Blinking once per second The staple cartridge is about to or has run out Constantly illuminated The staple head is selecte and ready to run Blinking rapidly There is a staple head jam or other error Not illuminated The staple head is not selected CREASING BOOKLET MAKING DocuMaster Pro SYSTEM Page 9 BOOKLET MAKING morgana SETTING UP THE Select Centre Stapling BMP amp TMP Using the lever on the BMP see Figure 16 select centre Staple operation lift up Edge or Centre Staple Selection Staple Head Selection Staple Head n Selection Indicator Select Light FIGURE 16 Select the Staple Heads Select the two centre staple heads using the button next to the lever see Figure 16 The staple head indicator lights show which heads are selected The position of the staple heads can also be adjusted For more details see page 19 Adjust the Fold Roller Gap The gap between the fold rollers is adjusted using a lever to the left of the front face of the BMP see Figure 17 Page 10 CREASING BOOKLET MAKING DocuMaster Pro Fold Roller Adjustment Lever FI
20. rk contact your local Service Department FOLD IS NOT ACTIVATED Unit is in edge staple mode Move lever into centre staple position see FIGURE 21 on p 15 BOOK IS NOT TRIMMED Trim not selected Select Trim On on creaser unit Trim position is set off the edge of Reset trim position on creaser unit the sheet EDGE STAPLE FUNCTION Edge staple not selected Move lever to correct position and NOT WORKING select staple head see p 10 EDGE STAPLED BOOKLETS Leading edge of booklet is catching Fit edge stitch assistor plate see p ARE JAMMING IN THE BMP the edge stitch deflector shaft 15 Page 22 CREASING BOOKLET MAKING DocuMaster Pro PROBLEM CAUSE SOLUTION STAPLE IS NOT ON THE FOLD Loose paper or staples in the fold Locate and remove see p 24 plate area The infeed sidelays are set too tight Adjust so that the infeed sidelays barely touch the paper Staple position is not adjusted Fine tune the position of the staples correctly see p 32 FINISHED BOOKLET IS TOO Fold roller gap is too wide Adjust the fold roller gap see p 10 LOOSE TOP JOG DAMAGE ON THE The sheet length has been set too Adjust the paper input size setting SEI short on the creasing unit Fold roller gap is too narrow when Adjust the fold roller gap see p 10 edge stitching BOOKLETS WILL NOT STACK Large payout wheels incorrectly Reposition see p 11 ON THE CONVEYOR positioned Electrical connection is unplugged Plug in electrical connection be
21. tand by Current 4 4A 115V or 3 0A 230V SYSTEM Page 1 Dimensions BookMaster Pro 546 495 595mm 70kg W D H 21 5 19 5 23 4 154 3lb BookMaster Pro with 546 830 840mm 79kg Motorised Infeed W D H 21 5 32 7 33 1 174 2lb TrimMaster Pro 546 650 595mm 85kg W D H 21 5 25 6 23 4 187 4lb Outfeed Conveyor 404 1050 720mm 17kg W D H 15 9 41 3 28 4 37 5lb Depth without paper tray is 710mm 28 07 Height with infeed tray in normal operating position 915mm 36 with TMP Noise 74dB A Production may vary according to operating conditions In line with a policy of continual product improvement the manufacturer reserves the right to alter the materials or specification of this product at any time without notice Radio Frequency This equipment has been tested and found to comply with Emissions 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 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 WAR
22. tween the BMP TMP and the outfeed conveyor BOOKLET COVER IS MARKED Dirty fold rollers Clean them with a cloth dampened with soapy water or alcohol isopro panol Do NOT use blanket wash see p 33 Fold roller gap is too narrow Adjust the fold roller gap see p 10 CANNOT CLOSE BMP LID Support strut is in place Lift the BMP lid slightly push the support strut see Figure 34 on p 31 and close the lid BOOKLET IS TRIMMED OUT TMP conveyor clamp requires See Appendix 4 OF SQUARE adjustment SYSTEM Page 23 PROBLEM CAUSE SOLUTION BOOKLETS ARE TRIMMED TMP conveyor clamp requires See Appendix 4 TOO SHORT adjustment COVER IS DAMAGED TMP conveyor clamp requires See Appendix 4 AROUND STAPLES adjustment Fold roller gap is too narrow Adjust the fold roller gap see p 10 Staple Head Problems ONE OR BOTH LEGS TURN Incorrect clincher alignment Re align see p 19 OUT STAPLE COMES OUT IN Staple jammed in the cartridge Inspect cartridge see p 18 and PIECES remove any jammed staple wire A staple head error has occurred The heads should self clear If not turn the unit off and on again to free the head If this does not work con tact your local Watkiss service department STAPLE HEAD INDICATOR Staple cartridge empty Replace cartridge see p 18 LIGHT BLINKS ONCE PER SECOND STAPLE HEAD INDICATOR A staple head error has occurred The heads should self clear If not LIGHT BLINKS RAPIDLY turn the unit off and on again to free th
23. ull Once this sensor is activated the BMP will beep after every second booklet produced If you stop feeding sets into the infeed the BMP will return to standby and beep continous ly until the offcut box is emptied see Figure 19 CREASING BOOKLET MAKING DocuMaster Pro SYSTEM Page 13 EDGE amp CORNER STAPLING morgana Corner stapling is only possible if an optional third staple head is fitted see Figure 20 Optional Third Staple Head for Corner Stapling FIGURE 20 ORGANISING THE Loading the Motorised Infeed JOB The staples will be inserted into the feed edge of the set The sheets should therefore be loaded accordingly i e feed the set spine first into the unit Note The maximum sheet width that can be edge stapled is 250mm 9 84 __ Select Edge Stapling Using the lever on the BMP see Figure 21 select edge Staple operation push down Note This will automatically switch off the fold and trim actions Select the Staple Heads Select the required staple heads using the staple head selection button next to the lever see Figure 21 The staple head indicator lights show which heads are selected Note For edge stapling select the two centre staple heads For corner stapling select the third head only Page 14 CREASING BOOKLET MAKING DocuMaster Pro Edge or Centre Staple Selection Staple Head Selection Staple Head Selection Indicator Light a
24. ure 40 Remove the outer two screws and screw them into the locator holes These will now act as handles Remove the remaining screws and carefully lift the blade away Immediately put the blade away safely ANVIL FIXING BOLTS ANVIL ADJUSTER SCREWS Qo BLADE FIXING SCREWS LOCATOR HOLES FOR HANDLING FIGURE 40 Check the anvil Carefully check the anvil for any damage If it requires regrinding remove the five fixing screws and lift away Refitting the TMP blade and anvil Slacken the anvil adjuster screws back two revolutions Position the anvil fully back towards the conveyor and lightly tighten the anvil fixing screws Affix the blade using the five blade fixing screws but do not tighten Using the mark made when the blade was removed adjust the angle of the blade Ensure that it does not protrude above the clamp at point A or below it at point B see Figure 42 Lightly tighten the centre screw sufficient to hold the blade in this position Page 36 CREASING BOOKLET MAKING DocuMaster Pro Manual Crank Drive Access Hole Remove the left hand TMP side cover two x M5 but ton screws and washers Release the clutch by de pressing the lever see ar ow through the access hole in the side plate see Figure 41 Use a 19mm spanner to manually crank the unit until the blade is at top dead centre At point C see Figure 42 the blade must pass the anvil by 1mm 1 25 Make fine adjustments t
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