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DocuMaster MFC User Operating Instructions. Rev. 1.0

1. 2000 eee 46 Mode nmas ann Sata ied nok facta Gale vee era 47 Adjusting the Creasing Pressure 2 5 49 Reversing the Crease Matrix Set 50 5 Maint nance lt 2 sei 0 a ee os oe ete we ee ee es 55 Service Interval 0 0000000 eee 55 Operator Maintenance 2020000000 eee 55 Booklet Maker and Trimmer 20200005 58 6 Problem Solving 2s62 662 lt 2e er nies eee eteeees 69 Trouble Shooting Chart 1 ayaa end oes viewer Bee ses 69 Paper Jams ic orsu aea lee ad vanes ee ae ho a Sate ea 79 Replacing Fuses lt i 2evds4 Pe eeaies aoa ae bees 80 Error Messages i Meo i hth As a BR Wie Pa A See S 80 7 Safety Information 000 ees 85 8 Specifications Ys 0 os Gatti eseie cers sears ee 87 9 Declaration of Conformity 0 0 eee eee 89 INDEX 22 oft n a hee foe olla ihe eek Sets 91 DocuMaster MFC User Manual DocuMaster MFC User Manual cHapteRn1 Introduction to the DocuMaster MFC Thank you for choosing the DocuMaster MFC About Your Manual This manual explains how to operate the DocuMaster MFC correct and solve most error conditions and perform routine maintainence Operator training will be provided when the machine is installed however it is recommended that you also take time to read this manual Safety Information Safety information is included in Safety Information on page 85 You are advised to read
2. A4 A5 Sheet Length Adjustment Sheet Width Adjustment Insert a few sheets from the job in between the sidelays Turn the thumbwheel until the marker aligns with the correct point on the scale Firmly push the side 34 DocuMaster MFC User Manual 3 About the Machine lays inwards to check the tamper position they should just touch the paper Make further adjustment if necessary Static Elimination Bar Gathering Station Sheet Length Adjustment TL Air Blow Adjustment E Sidelay Sheet Width Adjustment E Bypass Gate Interface Sock ets Hidden Air Blow Adjustment An air jet is used to prevent sheets in the gathering station from curling forwards This can be adjusted using the air blow adjustment tap on the side of the gathering station Manual Bypass Gate When the gathering station releases the sheets they are delivered into the booklet maker To bypass the booklet maker pull out the manual bypass gate and the sheets will be delivered out of the front of the gathering station above the booklet maker This is useful to avoid wasting sheets during the test set Note The manual bypass gate only works when the DocuMaster MFC is already running Start the machine first and then pull it out DocuMaster MFC User Manual 35 3 About the Machine Booklet Maker amp Trimmer The booklet maker and trimmer staple fold and trim the printed sheets to form a
3. Problem Paper Jam Problems PAPER IS JAMMED IN THE BOOKLET MAKER Open the booklet maker lid this will dis connect the power for safety and remove any jammed sets Check carefully and correct any faulty adjustments that caused the jam to occur Cause Paper is badly curled Staples are stuck in the clinchers Edge stitch drive is engaged when booklet making Infeed sidelays are not adjusted correctly Fold roller gap is too wide Solution Paper curl can normally be avoided by observing correct paper handling and storage procedures If there are staples stuck in the clinchers remove with a pair of pliers Disengage the edge stitch drive see p 40 Adjust PAPER SIZE so that both the infeed sidelays barely touch the paper see p 18 Adjust the fold roller gap a small gap gives more drive to pull the booklet through see p 42 PAPER IS JAMMED IN THE TRIMMER Paper offcuts are obscur ing the sensor in the con veyor Open the metal conveyor cover and remove any trim offcuts aac Discon nect the machine from the mains electricity supply before working near the blade area DocuMaster MFC User Manual 75 6 Problem Solving Friction Feed Problems Problem Cause Solution DOUBLE FEEDS Too much tray pressure Too little separation pres sure Insufficient air separation Worn or missing separa tors Bad guillotine burr or blunt drilling Misc
4. Adjustment is via the knob on the right hand side of the suction feeder The indi cator line on the knob shows the degree of adjustment The knob is infinitely adjustable between the limits of its travel When the indicator line on the knob is 30 DocuMaster MFC User Manual 3 About the Machine in the fully up position there is no added sheet separation The fully down posi tion produces maximum separation In general the heavier the sheet the less added separation is required The mid position is suitable for most paper types and should be used as a starting point if in doubt for initial running Feeder Angle The angle between the feeder and the paper can be adjusted to allow the feeding of _ Sister Fosse particularly heavy and or curled stocks ee ceder eg as lt Adjustment is made using the knob on the left hand side of the suction feeder Turning the knob one stop in either direction has the effect of raising or lowering the outer edge of the feeder Continuing to turn the knob will alternate between the two positions The default position is down Tray Height The tray height is adjusted via the lever on the SlimVac bin controls Moving the lever 3 downwards progressively lowers the paper tray This 1s increases the distance between the top of the paper stack and suction feeder and also simultaneously m adjusts the flow angle of the air separation Tray my Height The default positi
5. DocuMaster MFC User Operating Instructions Rev 1 0 Digital Finishing for Digital Printers Limited 2011 All Rights Reserved Reproduction adaptation or translation without prior written permission is prohibited except as allowed under the copyright laws Warranty The information contained in this document is subject to change without notice Limited makes no warranty of any kind with regard to this material including but not limited to the implied warranties of merchantability and fitness for a particular purpose Morgana Systems Limited shall not be liable for errors contained herein or for incidental or con sequential damage in connection with the furnishing performance or use of this material CONTENTS 1 Introduction to the DocuMaster MFC 1 2 Using the DocuMaster MFC 222005 7 Collating Sequentially Printed Sets 7 Normal Collatingus t2 a nx02hayiniees ceed Saas Uae es 9 3 About the Machine 00 cee eee eee 11 Control Panels suie Pere dena cae Chala es hue bo Ears 11 Friction Feed Bins 2 000 c eee eee 24 SlimVAC Suction Feed Bins 2205 28 Gathering Station sy lt ek cho eee ON elie Sat AE aces 34 Booklet Maker amp Trimmer 2020000005 36 4 Greaser Modulle 2 50002 Oise dearest ous 45 Creasing Module oi cuties sss sential eae as Raw eee vate 46 Crease Options
6. PAPER SIZE Touch PAPER SIZE to alter the settings of the booklet maker and trimmer to suit the input paper size RE REF If you suspect the booklet maker or trimmer adjustment system is not calibrated correctly touch RE REF to re reference the adjustment axes The adjustment axes will return to the current settings once this is complete Periodically the DocuMaster MFC will automatically re reference the axes during the setup procedure PAGE DIRECTION Touching PAGE DIRECTION switches the orientation of the paper between landscape and portrait This is only possible if the sheet does not exceed the maximum width accepted by the booklet maker PRESETS Select from a choice of standard paper sizes by touching the PRE SET window STITCH AND FOLD The position of the stitch and fold can be offset relative to the centre of the paper STITCH AND FOLD allows this position to be adjusted up to 20mm in either direction in increments of 0 2mm 18 DocuMaster MFC User Manual 3 About the Machine STITCH The STITCH OFF option will produce booklets that are folded but not stitched STITCH POSITION The ON FOLD option produces booklets which are stitched on the fold line The ON EDGE option produces sets which are edge stitched and folded The Edge Centre Staple Selection Lever on the booklet maker must be in the centre staple position see p 39 TRIM Touch TRIM to set the finished book size after trimming When a preset pap
7. PSU voltage There is a voltage error Contact your supplier error Rear cover open Check the rear cover guard is fitted and is actuating the safety switch correctly Remote stop The DocuMaster MFC has stopped because there is a prob lem with ancillary equipment to which it is linked Clear the problem with this equipment before restarting the job Set size wrong The wrong number of bins are switched on for the job speci fied in Multiset The number of bins switched on must be a multiple of the number of sheets in a set SFT jam There is a paper jam in the booklet maker Open the booklet maker and remove the jam SFT stalled There is a paper jam in the booklet maker Open the booklet BMP TMP only maker and remove the jam Staple head err A fault has occurred in the booklet maker Turn the mains switch off and then on again If the problem persists contact your supplier Staple head error There has been a staple head error in the booklet maker The heads should self clear If they do not turn the booklet maker off and on again to free the head If this does not work con tact your supplier DocuMaster MFC User Manual 83 6 Problem Solving Error Message Meaning Staple heads offline The staple heads are not selected on the booklet maker To select the staple heads press the Staple Head Select button on the booklet maker The staple head indicator lights on the b
8. running A4 or 8 x 11 portrait it will be necessary to fit tray extenders to support the sheets One B3 14 x 2074 tray extender is supplied as standard with each SlimVAC bin An optional tray extender is available for running A4 portrait 87 x 11 Rubber Endlays Rubber endlays are used to control the paper stack in the tray Two different types are supplied with the machine It is important that the correct endlay is used in the correct orientation for the paper size in use Do not push the endlay hard up against the edge of the paper stack Incorrect usage may result in either misfeeds or double feeds 330 351 When the rubber endlay will sit on the tray extender position it so that A is underneath the paper stack 330 351 B Step e When the rubber endlay will sit on the bar across the front edge of the bin position it so that B is underneath the paper stack and the step is on the bar 330 446 When the rubber endlay will sit within the bin itself use the special endlay 330 446 Posi tion it so that C is underneath the paper stack DocuMaster MFC User Manual 29 3 About the Machine Loading the Bins Place a full stack of paper between the two sidelays in the base of the tray Max imum capacity is achieved when the paper is slightly below the top of the side lays Slide the sidelays inwards to centralise the pape
9. amp folding 41 edge stitch assistor 39 edge stitch drive engage the 40 emergency stop 5 end job 13 endlays rubber slimvac bins 29 error messages 80 84 F feed clutch 17 feed wheels friction bins 57 feed window 23 mixed feed 23 feeder angle slimvac bins 31 finishing window 18 paper size 18 page direction 18 presets 18 re ref 18 pre fold jogging 19 fold delay 19 side jog hold 19 pre stitch jogging 19 double jog 19 pre jog 19 stitch delay 19 stitch and fold 18 stitch on fold 19 trim 19 fold delay 19 fold rollers adjustable 42 friction bins 24 27 adjustments 25 air separation 26 bin controls 24 bin linking 27 loading the bins 25 maintenance 57 DocuMaster MFC User Manual 91 INDEX sensor overrange 27 separator pressure 25 sidelay taps 26 switching bins on amp off 25 tray extenders 25 tray pressure 26 fuses 80 G gathering station 34 35 H help 13 honing trimmer blade 68 l inch 13 38 indicator lights 38 bin 38 booklet maker status 38 staple head 38 inserts 22 installation 1 interface sockets 34 introduction 1 5 J job details 20 K key symbol see padlock symbol L landscape 38 load 20 load and save window 20 delete 21 job details 20 load 20 padlock symbol 21 save cancel 20 replace 20 save new 20 view of job list 21 a gt z 21 by use 21 loading friction bins 25 loading sequence normal collating 9 loading slimvac bins 30 loading offline 8 locking job
10. A gathering station that gathers complete sets of pages e A booklet maker that staples and folds the sheets into booklets A trimmer that trims the fore edge of the booklet An outfeed conveyor that connects to the trimmer e The SquareBack system that post processes booklets to give them the appearance of perfect binding with the security of a stapled spine This is an optional module and is documented in a separate operating manual GUI graphical user interface Feed bins Creaser module Gathering station SquareBack system Trimmer Booklet Maker DocuMaster MFC with SquareBack system 2 DocuMaster MFC User Manual 1 Introduction to the DocuMaster MFC DocuMaster MFC with outfeed conveyor GUI graphical user interface Feed bins Creaser module Gathering station Outfeed conveyor Trimmer Booklet Maker DocuMaster MFC User Manual 1 Introduction to the DocuMaster MFC Switching the DocuMaster MFC On and Off Mains Input There are two mains inputs one on the rear of the tower drive unit and one on the rear of the booklet maker Two fuses are fitted next to each of the mains inputs Mains Input Serial Number 1e DocuMaster MFC Mains Input Spe 03 oklet Maker Mains Input Bo Mains On Off Switch Mains On Off switches are locate
11. DETEC TOR POSITION window PAPER JAM Sheet is pre feeding Treat as a double feed Sheet is miss feeding Treat as a miss feed FRONT EDGE OF Too much sheet corruga Reduce the sheet corru SHEET DAMAGED tion gation see p 30 Paper Jams in the Booklet Maker and Trimmer Paper jams are most commonly caused by incorrect settings of PAPER SIZE by paper jammed in the trimmer infeed an over full trimmer offcut box the use of curly paper using PRE JOG with large sheet sizes Open the safety covers of the booklet maker this will disconnect the power for safety and remove any jammed sets Sets jammed in the trimmer can be removed from either the infeed or outfeed of the unit or by removing the trimmer offcut box Check carefully and correct any faulty adjustments that caused the jam to occur Paper Offcuts Obscuring the Sensor Paper jams can also be caused by offcuts obscuring the sensor in the trimmer conveyor AY Warning Disconnect the machine from the mains electricity supply before removing the trimmer cover assembly DocuMaster MFC User Manual 79 6 Problem Solving Replacing Fuses Your DocuMaster MFC is fitted with two fuses at each of the mains inputs If either of these fail the machine will not power up AN Caution The system uses double pole neutral fusing i e two fuses When removing any covers or changing fuses always first disconnect the machine from the mains electricity supply by switching off and
12. MIXED FEED special feed sequences can be pro grammed Each column represents a stage in the collating cycle Up to twelve stages can be programmed The tower will complete each stage in turn and then repeat the cycle Use the left right arrow keys to navigate to the required stage Use the up down arrow keys to navigate to the required feed bin Touch the enter arrow to switch on Use the and keys to enter the number of feeds in each stage Touch O to switch on Switch off after use DocuMaster MFC User Manual 23 3 About the Machine Friction Feed Bins The DocuMaster MFC has four bins 1 x Friction and 3 x SlimVAC suction feed bins For operation of SlimVAC bins please refer to SlimVAC Suction Feed Bins on page 28 Bin Controls and Indicators Feed bins are numbered from 1 upwards with the bottom bin being bin 1 Each bin has its own controls immediately alongside it Key Item Description Function 1 Red light Indicates a double feed slow flash indicates the bin sensor is overrange see p 27 2 Yellow light Indicates a miss feed 1 amp 2 Red and yellow lights Indicate a feed jam or trailing sheet 3 Red button Bin on off switch 4 Green light Indicates the bin is switched on Green flashing light Indicates the bin is switched on but needs load ing 5 Grey button Bin linking switch see p 27 6 Small lower green light Indicates the bin is linked to the one bel
13. are always listed first only the operator saved jobs can be reordered A gt Z To list jobs alphabetically touch A gt Z BY USE To list jobs in the order they were last used touch BY USE The job that was run most recently will appear at the top of the list The BATCH Window The BATCH window allows sets to be grouped into batches with an action at the end of each batch stop pause oscillate or insert sheets INSERTS PAUSE RESTART a SEPARATE BATCH pidi BATCH Window NUMBER OF SETS Touch NUMBER OF SETS to enter the number of sets in each batch Entering 0 on the keypad will turn the batch mode off DocuMaster MFC User Manual 21 3 About the Machine Note A set is a feed cycle When making booklets from sequentially printed i e electronically collated sheets a set will be a single sheet In this case enter the number of sheets in the document Counts the total number of sets produced Counts the number of sets per batch Counts the total number of batches produced Batch Counter INSERTS INSERTS allows sheets from the top bin and or bottom bin to be inserted at the beginning or end of each batch If the inserted sheet is not part of the job i e it is being used purely as a batch separator it can be fed from either the top or bottom bin TOP Select TOP to feed a sheet from the top bin with the first set of each batch The insert
14. blade fixing screws 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 Qe P BLADE FIXING SCREWS LOCATOR HOLES FOR HANDLING Check the Anvil Carefully check the anvil for any damage If it requires re grinding remove the five fixing screws and lift away Refitting the Blade and Anvil Slacken the anvil adjuster screws back two rev olutions 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 DocuMaster MFC User Manual 65 5 Maintenance or below it at point B Lightly tighten the centre screw sufficient to hold the blade in this position Remove the left hand trimmer side cover two x M5 button screws and wash ers Release the clutch by depressing the lever see below through the access hole in the side plate Manual Crank Drive Use a 19mm spanner to manually crank the unit until the blade is at top dead centre At point C the blade must
15. booklet maker and trimmer units apart Connecting the Booklet Maker and Trimmer Line up the trimmer docking plates with the booklet maker Re connect the power and communications cables to the sockets on the booklet maker Communications Cable Docking Plate Push the two units together so that the hooks on the trimmer docking plates align with the holes in the booklet maker side plates Close the booklet maker lid and turn the handle to the right to lock the trimmer in place Starting and Stopping the Booklet Maker The booklet maker and trimmer automatically start and stop when required After the tower stops there is a delay of approximately 10 seconds before the booklet maker stops For an immediate stop either press the Emergency Stop button or open the lid on either the booklet maker or trimmer DocuMaster MFC User Manual 37 3 About the Machine Tip f you need to start the booklet maker and trimmer without starting the tower touch INCH It will automatically shut down 10 seconds after its last action Status Indicator Light The yellow indicator light on the top left surface of the booklet maker shows the status of the unit Indicator Light Mode Booklet Maker Status Blinking once per second The unit is ready to run Constantly illuminated The unit is running Blinking rapidly There is a jam or other error Not illuminated Booklet Maker or trimmer lid is open paper is s
16. centre 2 hinge creases Detection Electronic detection for miss double jam and empty bin Dimensions Width Length Height 693mm 27 3 1960mm 78 with booklet maker trimmer and out feed 2120mm 84 Weight 399Kg 878Ib Electrical 105 127V 60Hz or 208 254V 50Hz single phase DocuMaster MFC User Manual 87 8 Specifications Radio Frequency This equipment has been tested and found to comply Emissions with 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 accordance with the instruc tion 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 As part of our continued product improvement plan the specifications and infor mation published in this manual are subject to change without notice All specifications are dependent on application type of stock temperature RH and print engine used Specifications quoted were measured on uncoated and unprinted stock E amp OE 88 DocuMaster MFC User Manual
17. cuaptera Declaration of Conformity Name of Manufacturer Address of Manufacturer Description of Product Model and Serial Number Year of Manufacture DECLARATION OF CONFORMITY 2006 42 EC Morgana Systems Limited Davy Avenue Knowlhill Milton Keynes Buckinghamshire MK5 8HJ United Kingdom Automatic Multi Feed Paper Creasing and Gathering Machine MORGANA DocuMaster MFC 2011 Conforms to the following Product Specifications Safety EMC Authorized Representative 73 23 EEC and 89 392 EEC Council Directive on the approxi mation of laws of Member States relating to machinery amended by 91 368 EEC BS EN 60950 1992 89 336 EEC Council Directive on the approximation of laws of Member States relating to electromagnetic compatibility EN55022 1995 Class A EN 50082 1 1992 IEC 801 2 1991 8kV AD IEC 801 3 1984 3V m IEC 801 4 1988 0 5kV SL 1kV PL po ome P Garratt Director DocuMaster MFC User Manual 89 9 Declaration of Conformity Address Davy Avenue Knowlhill Milton Keynes Buckinghamshire MK5 8HJ United Kingdom Declaration declare that as the authorised representative the above information in relation to the manufacture of this product is in conformity with the stated standards and with the provisions of the essential health and safety requirements of the stated direc tive Signature of Authorised Representative Mash eeecanieceddieder vernal thane isin
18. each sheet and affects all bins The default sheet off set is 0 this causes the sheets in a set to enter the gathering base module with their leading edges level If an offset is required it is usual for the bottom sheet of the set to lead select a positive offset A small offset can make jogging more effective DETECTOR POSITION The sheet detector measures 15 2mm 0 6 from the feed edge of the sheet and then takes a reading If the edge of a particularly dark or solid area of print is in this area it can cause detection problems The DETECTOR POSITION can be adjusted so that it looks at a different part of the sheet This affects all the bins in the DocuMaster MFC TOLERANCE Changing TOLERANCE to x2 COARSE allows for more variation in the detector readings This prevents false errors being reported when there are variations in the paper or ink density The default setting is x1 NOR MAL The DocuMaster MFC allows for some variation in the paper or ink density and constantly changes the range of values it will accept by working out an average value for previous sheets Increasing Tolerance to x2 COARSE will only be necessary where there are larger variations in stock DOUBLE DETECTION Under unusual circumstances e g there are large vari ations in stock it may be necessary to turn off DOUBLE DETECTION This affects all the bins in the DocuMaster MFC Miss feed detection is unaf fected Before switching off double detection
19. first try setting TOLERANCE to x2 COARSE FEED CLUTCH FEED CLUTCH adjusts the clutch feed length for all bins during the test set only Increasing the value will cause the feed wheels or belt to drive the paper for longer which can prevent sheets from slipping The value can be reduced to prevent excessive pre feeding of the next sheet in the bin Optimising the clutch feed length for non standard paper lengths will produce a more accurate test set which in turn should reduce errors during the job The default value is 186 2mm 7 35 during the test set thereafter the feed length is automatically set to suit the paper size AUTO Touch AUTO to set the clutch feed length to the default value of 186 2mm 7 35 SUCTION HOLD Increasing the SUCTION HOLD value causes the feeder to allow more time to pick up each sheet If you are using stock that tends to stick DocuMaster MFC User Manual 17 3 About the Machine together increasing the suction hold can improve paper pick up and in some instances separation It is possible to reduce the suction hold when using paper that is easy to feed this will increase the operating speed of the machine The default setting is 300mS The FINISHING Window The FINISHING window controls the settings for the booklet maker and trimmer gS E PAPER STITCH TRIM PRE STITCH PRE FOLD SIZE ANDFOLD a aj JOGGING JOGGING FINISHING FINISHING Window
20. i e for larger sets or heavier stock move the lever upwards Move the lever down to bring the fold rollers closer together When edge stapling the fold rollers should be fully open i e the lever should be fully upwards Outfeed Conveyor Adjustment Slide the large payout wheels 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 Tip Common sizes are highlighted on the scale For example for an A5 5 X 8 book use the A5 marker DocuMaster MFC User Manual 43 3 About the Machine Trimmer Offcut Box The trimmer offcuts are delivered into the trimmer offcut box This box hooks onto the trimmer Offcut Box Remember to empty the trimmer offcut box periodically There is a sensor on the trimmer to detect when the offcut box is full Once this sensor is activated the booklet maker will beep after every second booklet pro duced Trim Margin If you are inserting sheets from a Friction bin which have been printed offset litho we recommend that the job be printed with a 12mm trim margin on the feed edge and a smaller perhaps 3 5mm trim margin on the trailing edge In this way any marking that could possibly occur due to wet ink or ink rub will always be in the trim margin 44 DocuMaster MFC User Manual cHapteRn4 Creaser Module The DocuMaster MFC has a C
21. pass the anvil by 1mm 1 25 Make fine adjustments to 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 fingers at each end Maintain a light pressure on the back of the anvil whilst tightening the anvil fixing bolts starting 66 DocuMaster MFC User Manual 5 Maintenance from the centre and working out Lightly tension the anvil adjuster screws against the anvil Final Adjustment Release the clutch and manually crank slowly several rota tions 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 AN 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 Fit the side cover and secure DocuMaster MFC User Manual 67 5 Maintenance Trimmer Blade Grinding Specification BLADE Note 2 f
22. sheet trailing double feed If the problem persists see the Problem Solving section of this manual Bin programming error The bins in the DocuMaster MFC have not initialised prop erly Switch the machine off and then on again If the problem persists contact your supplier Bin reset An error has occurred in the electronics of the bin detailed Any number over 16 relates to a module other than a bin Restart the machine If the problem persists contact your supplier Cannot start fold axis changing The fold axis size adjustment of the booklet maker is in the process of adjusting Wait for the booklet maker to finish before touching INCH Touch to continue the job when using the DocuMaster MFC offline Cannot start sheets axis changing The sheets axis book thickness adjustment of the booklet maker is in the process of adjusting Wait for the booklet maker to finish before touching INCH Touch to continue the job when using the DocuMaster MFC offline Cannot start tray down Suction feed bin only One of the trays has been lowered by the operator Press the grey button on the bin controls to raise the tray Press DocuMaster MFC User Manual 81 6 Problem Solving Error Message Meaning Cannot start tray empty One of the switched on bins was empty when was touched Fill the bin with paper and touch again Cannot start trim axis changing The
23. the machine is ready to run If either the TEST SET or END JOB button is touched another test set will need to be run before the job can be restarted the test set icon will be highlighted If you are having trouble running a job and false errors are being reported it may help to run another test set This can be done at any time to recalibrate the detector system HELP Touch HELP and then touch any area of the screen to display the help text Use the up and down arrows next to the text to scroll up or down the screen Some sections of help text have a right arrow next to them This indicates that there is more text available explaining a related function in more detail Touch the right arrow to view this text A left arrow will then also appear touch this to return to the previous text DocuMaster MFC User Manual 13 3 About the Machine When you are viewing text you can find out about any of the other tabs that remain on display by touching them To exit the help text touch HELP or OK MENU MENU gives access to settings that do not need to be changed ona day to day basis These settings include e Change the display language Toggle between metric and imperial measurements e Adjust the screen contrast e Adjust the pause duration There are several access levels some of the settings can only be changed by users with an appropriate access code MIMIC DIAGRAM The mimic diagram o
24. the side covers At all times keep your hands away from the blade area of the trimmer Booklet Maker To clean the rollers and belts on the booklet maker first remove the right hand side cover two x M5 button screws to give access to the manual cranking point Right Hand Side Cover 62 DocuMaster MFC User Manual 5 Maintenance Open the booklet maker lid to access the fold rollers Using a 10mm A F span ner wrench manually crank the booklet maker by turning the nut clockwise and clean the rollers and belts with a cloth dampened with soap and water or alcohol isopropanol Do NOT use blanket wash or other chemicals Manual Cranking Point Trimmer To clean the belts on the trimmer first remove the left hand side cover two x M5 button screws to give access to the manual cranking point Orange Hand Screw Trimmer Lid m eS e Left Hand Side E e Cover a j M5 Button Screw Open the trimmer lid and using a 19mm A F spanner wrench manually crank the trimmer by turning the nut clockwise whilst cleaning the belts with a cloth dampened with soap and water or alcohol isopropanol Do NOT use blanket wash or any other chemicals Manual Cranking Point DocuMaster MFC User Manual 63 5 Maintenance Sharpening the Trimmer blade Periodically all trimmer blades will require re grinding Poor grinding will result in poor life cracks and nicks i
25. this information before you start to use the DocuMaster MFC Installation The installation of your DocuMaster MFC requires specialist knowledge and should therefore only be carried out by a supplier approved engineer AN Caution The DocuMaster MFC must only be plugged into an electrical sup ply 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 DocuMaster MFC and the rear of the Booklet Maker Getting Help We are confident that your DocuMaster MFC will give many years of trouble free production If you have any queries or problems in the first instance please refer to the problem solving section in this book Should you require further assistance please contact your supplier DocuMaster MFC User Manual l 1 Introduction to the DocuMaster MFC About the DocuMaster MFC The DocuMaster MFC converts sets of printed pages into staple folded book lets It will also add a separate pre printed cover if required A creaser module can pre crease any pages in the set to allow for heavier stock or digital printing The DocuMaster MFC typically consists of the following components e A GUI Graphical User Interface colour touch screen that controls the oper ation of the DocuMaster MFC Feed bins that are used to add covers or inserts to booklets where required Acreaser module e
26. x Chlorinated solvents cleaners e g trichloroethylene perchloroeth ylene genclenes All of these chemicals will damage the separators feed wheels and conveyor wheels to a varying degree resulting in poor performance and premature failure Touch Screen The touch screen should only be cleaned with a clean dry cloth Abrasive mate rials and chemicals should never be used to clean the screen Light pressure with a suitable cloth should be sufficient to remove fingerprints Do not use excessive force Static Elimination Bar The static elimination bar is located in the gathering station AN Caution Disconnect the machine from the mains electricity supply before cleaning the static elimination bar The pin side of the bar should be cleaned regularly using a small brush such as a toothbrush This is vital to the effectiveness and life expectancy of the static elimination equipment Static Elimination Bar 56 DocuMaster MFC User Manual 5 Maintenance Friction Feed Bins Paper Separators There is one paper separator located in the centre of each friction feed bin It slots into the aluminium pick up manifold immediately beneath the central feed wheel They should be cleaned if dirty and replaced when worn The replacement interval will depend upon the usage level and the type of papers used Paper Separator Remove the feed wheel shaft by pushing it to the left against the spring pres sure
27. 8 33 adjustments 30 32 bin controls 28 bin linking 31 difficult papers 32 feeder angle 31 loading the bins 30 rubber endlays 29 sensor overrange 32 sheet corrugation 30 switching bins on amp off 30 tray extenders 29 tray height 31 specifications 87 sph 15 staple cartridges changing 58 staple head clincher 42 position 41 selecting 41 staple cartridges changing 58 staple head indicator lights 38 staple position adjustment 59 staples low 58 start stop 12 static elimination bar 56 status indicator light 38 stitch and fold 18 stitch delay 19 stitch on fold 19 suction hold 17 T test set 13 third staple head 39 tolerance 17 tray extenders 25 29 tray height slimvac bins 31 tray pressure friction bins 26 trim 19 trim offcut box 44 trimmer blade sharpening 64 68 honing 68 U unlocking jobs 21 V view of job list 21 Ww window system 12 DocuMaster MFC User Manual 93 INDEX 94 DocuMaster MFC User Manual Digital Finishing for Digital Printers Davy Avenue Knowlhill Milton Keynes MK5 8HJ United Kingdom Tel 44 0 1908 608888 Fax 44 0 1908 692399 www morgana co uk sales morgana co uk
28. Master MFC User Manual 47 4 Creaser Module Offset Skew Use this setting to affect the position of the creases It is possible to move the crease from the calculated middle of a sheet by 5mm One of the key features of the creasing module is the ability for the crease angle to be automatically adjusted as the sheets pass through The creaser can automatically detect the lead edge of the sheets and adjust itself to match each sheet This means that even if the sheet is not placed into the feed bin perfectly squarely as the sheet passes through the Creasing Mod ule it will self adjust to align with the sheet each and every time Occasionally it is possible that the sheets have been poorly cut and the lead edge of the sheet may not be parallel to the desired fold position If this is the case the Skew Offset setting is designed to overcome this and will alter the default position according to the diagram below Skew Adjustment Orientation 48 DocuMaster MFC User Manual 4 Creaser Module Adjusting the Creasing Pressure Some stocks require a more defined crease in order to prevent the substrate from cracking when folded This is a mechanical adjustment and should be car ried out once you have creased and checked a test sheet There is an adjust ment scale printed onto each adjuster cam the thicker the scale the deeper the crease 1 Ensure the machine is switched ON and the Emergency
29. NCH to clear any partial sets from the conveyor If the error persists see the Problem Solving section of this manual 80 DocuMaster MFC User Manual 6 Problem Solving Error Message Meaning Bin lift error Suction feed bin only Too much paper has been loaded into the bin note that the grey button will not raise or lower the tray Remove the stock and reload a smaller quantity Bin miscal A feed sensor error has occurred during the test set The bin will recalibrate automatically but check the very first set for errors Bin miss A miss feed error has occurred on the bin detailed This means that the bin did not feed a sheet in the last set Check and correct the faulty set and restart the machine If the error persists see the Problem Solving section of this manual Bin overload An obstruction in the bin is preventing it from lifting correctly Check and remove any obstructions It may be that the stock has not been pushed fully forward into the bin Bin part reset It is necessary to switch the machine off and then on again after 10 seconds before running another test set If this prob lem persists contact your supplier Bin trailing A trailing feed error has occurred on the bin detailed This can mean one of two things 1 The sheet from this bin was delivered late trailing single feed 2 An extra sheet was delivered from this bin slightly behind the first
30. Stop button has been turned clockwise to release the safety latch 2 Move the creasing matrix to the Top Dead Centre position by pressing the red emergency stop button and twisting it to release 3 Lift and pull the the creaser cover to remove the creaser cover and give access to the creaser mechanism 4 Using a 5mm Allen key unlock the 2 shoulder bolts positioned at each end of the creasing blade See the diagram below 5 Rotate the 2 adjustment cams by the same amount to adjust the blade pres sure Increasing the gradient on the scale will increase the blade pressure Adjustment cam Creasing blade Shoulder bolt Blade pressure adjuster Left hand end 6 Ensure that both shoulder bolts are locked after making the setting 7 Fit the creaser cover DocuMaster MFC User Manual 49 4 Creaser Module Reversing the Crease Matrix Set It is possible to change the creasing anvil and blade to reverse the crease pro file This is often used to change the look of the finished folded document and is selected by customer preference 1 Ensure the machine is switched ON and the Emergency Stop button has been turned clockwise to release the safety latch 2 Move the creasing matrix to the Top Dead Centre position by pressing the red emergency stop button and twisting it to release 3 Remove the creaser cover to provide access to the creaser mechanism 4 Using a 5mm Allen key loosen an
31. WER UP plugged in Faulty fuse Check the fuse at the mains input and replace if necessary see p 80 THE MACHINE WILL Several possible causes Correct any faults shown NOT START exact cause will be shown on the display on the display DocuMaster MFC User Manual 69 6 Problem Solving Gathering Station Problems Problem Cause Solution SHEETS NOT IN COR The unit has not been set Set the levers on the front RECT ORDER NOT to the correct paper size of the unit to the correct STACKING WELL paper size see p 34 Sheets are falling forwards Adjust the air blow see in the gathering station p 35 POOR FEEDING INTO The static elimination baris Clean the static elimina BOOKLET MAKER dirty reducing effective tion bars see p 56 ness and causing the back sheet s of the book to cling to the gathering sta tion as they are released 70 DocuMaster MFC User Manual 6 Problem Solving Booklet Maker and Trimmer Problems Problem Cause Solution If you suspect the booklet maker adjustment system is not calibrated correctly touch RE REF in the PAPER SIZE window to manually recalibrate the booklet maker adjustment axes After recalibration the booklet maker adjustment axes will return to the current settings If the DocuMaster MFC s software detects a possible axis positional fault the unit will automatically recalibrate the axes Operational Problems BOOKLET MAKER The booklet maker is not Pl
32. aces must be flat to within 0 03mm 8mm k I ii ANVIL Note 2 faces must be flat to within 0 01mm 12 7mm 28mm This edge must be straight to within 0 04mm 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 of the Grinding Wheel 20 26 V M S 65 85 V Ft S Table Speed 20 26 V M Min 65 85 V Ft Min 19 22 xn Important AN Grind In This Direction Only Honing 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 dd a Incorrect Correct 68 DocuMaster MFC User Manual cHapterns Problem Solving This chapter explains how to resolve any problems that may occur with your DocuMaster MFC System If a problem persists please contact your supplier Trouble Shooting Chart As far as possible the DocuMaster MFC has been designed to be self explana tory In most cases problems or errors will be identified on the control panel This trouble shooting chart provides a further guideline to help solve any prob lems General Problems Problem Cause Solution THE MACHINE WILL The machine is not Plug in and switch on NOT PO
33. air level into the side of the paper stack The tap has three positions The default position is 90 to the sidelay which provides 100 air Moving the lever one notch towards you provides 50 air Moving the lever towards you so that it is parallel with the sidelay shuts off the air Air Separation Adjustment Too much air into the side of the stack can cause the paper to skew as it feeds Any bins that are not being used should have the air tap shut off on the sidelay to preserve overall system air Remember to open the tap when the bin is next used 26 DocuMaster MFC User Manual 3 About the Machine Bin Linking If required two or more feed bins may be linked to operate as a single bin When one runs out of stock the next bin in the linked group will automatically take over This allows reloading without stopping the machine Bin linking can only be enabled when the bins are unlocked i e when the TEST SET icon is high lighted on the control panel Press the grey button on the upper bin to link it with the one below This will be indicated by the small green light The mimic dia gram on the control panel will show a broken line between bins that are linked By pressing the red bin on off button it is possible to select which bin in the linked group is active If the system is locked pressing the grey button on any bin will indicate which bins are in the same linked group Sensor Overrange Sensor overrange is indi
34. alibration during the test set Reduce by moving han dle in by one notch ata time see p 26 Increase by moving the lever down by one notch at a time see p 26 Increase the value of AIR BLOW in the BASIC win dow Check separators are present and replace if worn see p 57 Fan the stock by hand before loading ensure paper is cut well next time Run another test set by touching followed by TEST SET followed by MISS FEEDS Too little tray pressure Too much separation pressure Untidy loading Worn feed wheels Miscalibration during the test set Increase by pulling the handle out by one notch at a time see p 26 Reduce by moving the lever up by one notch at a time see p 26 Reload the bins tidily ensuring the paper stack is underneath the feed wheels and under the guides Check and replace the feed wheels if necessary see p 57 Run another test set by touching followed by TEST SET followed by W It may be necessary to increase the tray pres sure to obtain a better feed 76 DocuMaster MFC User Manual 6 Problem Solving Problem Cause Solution TRAILING FEED On a trailing sheet the machine stops imme diately You need to look carefully to iden tify which of the follow ing is the cause The faulty set can be inched through by touching and holding INCH Late feeding double sheet Slow feeding sheet Slow feeding during test set c
35. all the 2 locking shoulder bolts positioned at each end of the creasing blade Ensure the pressure is set loosely the narrow end of the scale before finally tightening the shoulder bolts 15 Fit the creaser cover 16 Proceed to adjust the creasing pressure DocuMaster MFC User Manual 53 4 Creaser Module 54 DocuMaster MFC User Manual chapters Maintenance Service Interval It is recommended that your DocuMaster MFC is serviced by an approved serv ice engineer every 1 000 operating hours Please contact your supplier This chapter covers all routine adjustment and maintenance procedures that can be carried out by an operator Some of these procedures require a degree of technical competence and you may prefer for these to be undertaken by your service engineer Operator Maintenance As with all machinery your DocuMaster MFC will benefit from periodic cleaning of general accumulations of paper dust ink etc DocuMaster MFC User Manual 55 5 Maintenance Cleaning Materials The DocuMaster MFC should only be cleaned with a cloth moistened with soap and water or with alcohol isopropanol Important Do not use any of the following chemicals to clean the separators feed wheels or conveyor wheels x Cleaners based on esters and ketones e g ethyl or butyl acetate esters or methyl ketone MEK x Aliphatic solvents e g petrol or SBP1 Aromatic solvents cleaners e g toluene xylene napthas
36. and lifting the right end clear Locate the separator and lift it out vertically Clean or replace the separator as required When cleaning the separator use only soap and water or alcohol isopropanol Refit the separator and ensure that it seats firmly in the correct position Refit the feed wheel shaft Feed Wheels The friction feed bins are fitted with three feed wheels B mounted on a shaft They should be cleaned if dirty and replaced when worn The replacement interval will depend upon the usage level and the type of papers used Remove the feed wheel shaft by pushing it to the left against the spring pres sure and lifting the right end clear Clean the wheels using only soap and water or alcohol isopropanol If the wheels need to be replaced grasp the shaft firmly and slide off each wheel this will be eased by wetting the shaft slightly Ensure the shaft is clean and slide on each new wheel ensuring that the wheels align with the correct marks on the shaft The standard position for the wheels is shown below DocuMaster MFC User Manual 57 5 Maintenance e Replace the shaft e Select CLEANING in the MENU USER SETTINGS window and press the red button on the bin controls to turn the feed wheel shaft Visually check that each wheel runs true To straighten a wheel gently hold a flat edge against the wheel whilst it turns Booklet Maker and Trimmer Changing the Staple Cartridge Wh
37. ausing incorrect cali bration Treat as double feed above Treat as miss feed above Run another test set by touching followed by TEST SET followed by It may be necessary to increase the tray pres sure to obtain a better feed PAPER JAM Sheet is jammed in the Locate the sheet and paper path either pull it out or INCH it through Sheet is only half feeding Treat as miss feed above Feeding A5 572 x 87 Select SHORT in the landscape without select ADVANCED FEED ing SHORT in the CLUTCH window and run ADVANCED FEED another test set by touch CLUTCH window ing followed by TEST SET followed by FRONT EDGE OF Too much separation Reduce by moving the SHEET DAMAGED pressure lever up by one notch ata time see p 25 DocuMaster MFC User Manual 77 6 Problem Solving SlimVAC Feed Problems Problem Cause Action DOUBLE FEEDS The tray is too high Not enough corrugation on suction feeder Mechanical paper prob lem guillotine burr sticky ink poor perforations high static charge etc Rubber endlay is incor rect type or position Lower the tray height see p 31 Increase sheet corruga tion see p 30 Fan stock by hand before loading and ensure these problems are avoided in future Use correct type and positioning see p 29 MISS FEEDS Not enough air separation Too much sheet corruga tion The tray is too low Heavy and or rigid sheets Paper has
38. ave function if it is not used for a period of time it automatically dims After an extended period it switches off In either case touch the screen to return it to normal Tip The touch screen takes two or three minutes to reach full brightness when it is switched on DocuMaster MFC User Manual 11 3 About the Machine The Window System The DocuMaster MFC is controlled by touching buttons on the control panel The buttons are divided into groups that perform related functions Each group of buttons has its own window which is selected by touching the relevant tab e Load amp Save e Basic e Advanced e Feed e Batch e Finishing Start Stop Test Set Inch Pause Help End Job Menu cs p3 p b R La SETS Control Buttons p Each window contains a group of related buttons 3 SETS PER AIR PRESET PRENUMBER HOUR a BLOW Touch the relevant tab _py Po ae to display each window Load amp Save Basic Advanced Finishing Main Window Tabs on the Control Panel Control Buttons There are six main control buttons listed across the top of the screen START STOP The button starts the machine When the machine is run ning this button changes to which stops the machine These are duplicated by the start stop buttons above the touch screen 12 DocuMaster MFC User Manual 3 About the Machine INCH Touch and hold INCH to turn the conv
39. booklet Finished booklets are delivered onto the outfeed conveyor The booklet maker fits underneath the DocuMaster MFC tower It is wheel mounted and can be pulled in and out when required Opening the Booklet Maker amp Trimmer Access to the inside of the booklet maker is necessary for changing the staple cartridge adjusting the staple heads and clearing paper jams Access to the inside of the trimmer may be necessary for clearing paper jams The booklet maker and trimmer lids incorporate safety switches which automat ically cut the power when the lid is opened The booklet maker lid can be opened by turning the handle to the left and lifting The lid is supported by a strut on the right side Support Strut To close the booklet maker lid lift it slightly push the support strut inwards and close the lid Turn the handle to the right to lock in place The trimmer lid can be opened by lifting the orange hand screw Orange Hand Screw for Opening the Trimmer Lid Connecting the Booklet Maker amp Trimmer The booklet maker and trimmer will be connected together when the DocuMas ter MFC is installed However it may be necessary to separate them when mov ing the units or when clearing paper jams 36 DocuMaster MFC User Manual 3 About the Machine Disconnecting the Booklet Maker and Trimmer Open the booklet maker lid Disconnect the communications and power cables and wheel the
40. cated after the test set by a slow flashing red light on the bin in question Particularly heavy or opaque stock may cause the bin sensor to go overrange This means that the sheet is too optically dense for the sensor to see through it Double feeds will not be detected but misses trailing sheets and jams will be detected as normal DocuMaster MFC User Manual 27 3 About the Machine SlimVAC Suction Feed Bins The DocuMaster MFC has four bins 1 x Friction and 3 x SlimVAC suction feed bins For operation of Friction bins please refer to Friction Feed Bins on page 24 Bin Controls and Indicators Feed bins are numbered from 1 upwards with the bottom bin being bin 1 Each bin has its own controls immediately alongside it Key Item Description Function 1 Red light Indicates a double feed slow flash indicates the bin sensor is overrange see p 32 2 Yellow light Indicates a miss feed 1 amp 2 Red and yellow lights Indicate a feed jam or trailing sheet 3 Red button Bin on off switch 4 Green light Indicates the bin is switched on Green flashing light Indicates the bin is switched on but needs load ing 5 Grey button Bin linking switch see p 31 6 Small lower green light Indicates the bin is linked to the one below 28 DocuMaster MFC User Manual 3 About the Machine Tray Extenders For large sheet sizes over A4 8 2 x 11 or when
41. curly edge Rubber endlay is too tight against the paper stack or is incorrect type Increase the value of AIR BLOW in the BASIC win dow Reduce the sheet corru gation see p 30 Raise the tray height see p 31 Raise the angle of the suction feeder see p 31 Refer to recommended settings see p 32 Position the endlay approx 1mm 1 16 clear of the edge of the stack Ensure it is the correct type for the paper size see p 29 TRAILING FEED On a trailing sheet the machine stops immedi ately You need to look carefully to identify which of the following is the cause The faulty set can be inched through by touching and holding INCH Trailing double feed Trailing single feed Treat as a double feed Treat as a miss feed TOP AND OR BOT TOM BIN ONLY FEEDS ON TEST SET Batch insert selected from batch menu Check that INSERTS in the BATCH window are set as required 78 DocuMaster MFC User Manual 6 Problem Solving Paper Jams Problem Cause Action DOUBLE FEEDS ARE _ The bin sensor is over N A NOT BEING range due to the feeding DETECTED of particularly heavy or opaque stock The red light on the bin controls will flash slowly when the sensor is overrange Detector Position toler Set TOLERANCE to x1 ance is set to x2 Coarse NORMAL in the ADVANCED DETEC TOR POSITION window Double Detection is not Set DOUBLE DETEC selected TION to on in the ADVANCED
42. d on the side of the tower next to the emergency stop button and alongside the booklet maker mains input The mains On Off switches should be used to turn the system on and off when required When the system is switched off it retains the control panel settings in memory Mains ON OFF Switch Emergency Stop 4 DocuMaster MFC User Manual 1 Introduction to the DocuMaster MFC Important To maintain the efficiency and prolong the service life of the static elimination equipment it is important to switch off the tower when it is not being used for a period of hours e g overnight Emergency Stop The emergency stop button should only be used when an immediate stop of the machine is required Under normal circumstances the machine should be stopped by touching the stop button on the control panel If the emergency stop button is used the system will not restart until the button has been released by turning it clockwise DocuMaster MFC User Manual 5 1 Introduction to the DocuMaster MFC 6 DocuMaster MFC User Manual charter Using the DocuMaster MFC This chapter provides details on how to use the DocuMaster MFC For details on the individual modules and how to adjust them please refer to Chapter 3 on page 11 Collating Sequentially Printed Sets The DocuMaster MFC system can be used to automatically gather sets from a sequentially printed stack of paper The sheets are held in the gath
43. d remove the 2 shoulder bolts positioned at each end of the creasing matrix set Remove the shoulder bolts 5 Locate the removal tool over the tie bars Fit the removal tool 50 DocuMaster MFC User Manual 4 Creaser Module 6 Ensure the adjuster assembly is positioned horizontally so that the 2 tangs are able to locate fully into the adjuster as shown below Correct position of the removal tool 7 The creasing matrix set can then be unclipped from the machine by pulling the tool towards you Pull the removal tool toward you 8 Repeat on the opposite side to release both adjusters DocuMaster MFC User Manual 51 4 Creaser Module 9 Slide the creasing matrix horizontally out from the machine See below Put the creasing matrix on a flat surface Slide the creasing matrix from the machine 10 Remove the blade adjustment cam assemblies from the dowels located in the ends of the blades or anvils Remove the blade adjustment cams 11 To re install the creasing matrix fit the adjustment cams to each end of the creasing blade or the anvil depending on the application 12 Slide the creasing matrix into the slots of the creasing unit Fit the creasing matrix 52 DocuMaster MFC User Manual 4 Creaser Module 13 Push firmly into the unit until the matrix clips into the mechanism with a pos itive click 14 Re inst
44. e Centre Staple Selection Lever _ Staple Head Selection n Staple Head Indicator Light When edge or corner stapling the staples will be inserted into the feed edge of the sheet Note The maximum sheet width that can be edge or corner sta pled is 250mm 9 8 If the sheet width exceeds this the top jog is automatically switched off and may not give satisfactory results Third Staple Head Kit The booklet maker has two staple heads as standard A third head can be spec ified as an option to enable corner stapling Optional Third Staple Head for Corner Stapling Edge Stitch Assistor When edge or corner stapling only a few sheets it is possible for the thin sets to jam in the booklet maker In this case the Edge Stitch Assistor should be fitted DocuMaster MFC User Manual 39 3 About the Machine This is supplied as part of the optional third staple head kit or can be ordered as an accessory Tabs Locating Pins Fitting the edge stitch assistor To fit the edge stitch assistor open the book let maker lid Hold the assistor with the locating pins facing downwards and slide the tabs under the staple clinchers Make sure the assistor is positioned squarely and then press down until it clicks into place see below Clincher Edge Stitch Assistor in place Engage the Edge Stitch Drive Open the staple panel Unhook the oran
45. e job name is not changed before touching OK or CLOSE the job will be saved with the current name suffixed by an asterisk JOB DETAILS Touching JOB DETAILS shows the settings for each saved job Select the job that you wish to view from the job list and touch JOB DETAILS to see a summary of the job settings LOAD To load a job select it on the job list using the up and down arrows or by touching it Touch the LOAD button You must touch END JOB before loading a job 20 DocuMaster MFC User Manual 3 About the Machine PADLOCK SYMBOL The padlock symbol is used to lock and unlock saved jobs Each saved job has a small padlock symbol next to it to show whether it is locked or not To lock or unlock a job select it on the job list and touch the large padlock button Some padlock symbols may be greyed out This is because there are several access levels to the system which can be used to prevent jobs being altered DELETE To delete a particular job it must be unlocked Select the job from the job list using the up and down arrows or by touching it Touch and hold DELETE A red bar will appear filling from left to right Continue to hold until the red bar reaches the right hand side VIEW OF JOB LIST VIEW OF JOB LIST alters the order in which saved jobs are listed either alphabetically or most recent first There is a line between Factory Template jobs and other jobs saved by the operator The Factory Template jobs
46. ed sheet will be at the bottom of the batch pile as the back ing board for a pad for example BOTTOM Select BOTTOM to feed a sheet from the bottom bin with the last set of each batch The inserted sheet will be at the top of each batch pile athe cover sheet of a pad for example STOP STOP causes the machine to stop after each batch and the counter display will flash Touch the start button to run another batch If STOP is selected while the machine is part way through collating a batch it will stop once it has completed that batch This allows the operator to interrupt a job at a convenient point PAUSE SEPARATE PAUSE SEPARATE causes the machine to pause for approximately 5 seconds after each batch The pause icon on the control panel will flash between batches This function will also separate batches on a booklet maker outfeed conveyor The pause time can be altered on the Machine Options page touch MENU MACHINE OPTIONS 22 DocuMaster MFC User Manual 3 About the Machine RESTART BATCH Touching RESTART BATCH zeros the batch counter so that you can restart a batch Note that if the tower is running this button will interrupt a batch that is partly completed and a new batch will be started The FEED Window The FEED window contains the Mixed Feed option With this option the tower can be programmed to feed in selective or special sequences FEED Window MIXED FEED By using
47. en a staple cartridge runs out the corresponding red indicator light will blink once per second The message STAPLES LOW will also be shown on the Docu Master MFC control panel New cartridges are available from your supplier P N 810 022 To change a cartridge first open the booklet maker lid by turning the handle to the left and lifting The lid is supported by a strut on the right side Indicator Light gt aN k a ES i 58 DocuMaster MFC User Manual 5 Maintenance Grasp the cartridge at the top and pull directly away from the staple head as shown by the arrow in the photo Staple Cartridge Staple Head Fit the new cartridge and check machine operation by making a few test book lets Staple Position Adjustment If both staples are consistently off the spine of the book first ensure that the booklet maker is adjusted correctly and that delivery into the unit is good If the problem persists fine tuning of the staple position may be necessary Tools Required Flat Blade Screwdriver Adjustment is via the central screw on the fold plate mechanism located behind the perspex cover x ES y Fold Position Fine Tuning DocuMaster MFC User Manual 59 5 Maintenance In the FINISHING window set PRESETS to A3 or 11x17 regardless of booklet size The screws will now align with the holes in the perspex cover Using a flat blade scre
48. er size is selected this distance is automatically adjusted but can be fine tuned The trim function can also be switched off PRE STITCH JOGGING The PRE STITCH JOGGING window has options to alter the way sets are jogged prior to stitching This ensures the finished book lets are as neat as possible The maximum speed of the booklet maker will be reduced when any of the Pre Stitch Jogging options are selected PRE JOG This provides additional jogging to the bottom of the set when using heavy or large sheets The booklet is stopped by the edge stitch latch and jogged before it drops to the stitch latch DOUBLE JOG This provides additional jogging to the sides of the set when using heavy or large sheets The sidelays jog the set twice when it reaches the stitch latch STITCH DELAY Increasing the STITCH DELAY value will cause a delay between the set arriving on the stitch latch and it being stitched This allows more time for the sheets to settle The default delay is 1mS PRE FOLD JOGGING The PRE FOLD JOGGING window has options to alter the way sets are jogged prior to folding This ensures the finished booklets are as neat as possible SIDE JOG HOLD When SIDE JOG HOLD is selected the sidelays 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 FOLD DELAY This can be adjusted to alter the dela
49. ering station until the set is complete and it is then released into the booklet maker and trim mer Preparation e Press END JOB to end the previous job e Press INCH to check that there are no sheets remaining in the conveyor e Clear any remaining sheets from the DocuMaster MFC system Tip Load the Default Template to return the control panel to its default fac tory settings Touch END JOB Touch LOAD amp SAVE Select the Default Template from the list of jobs Touch LOAD If asked select YES to confirm that you wish to load the Default Template DocuMaster MFC User Manual 7 2 Using the DocuMaster MFC Loading the Bins with Paper Load the sheets so that the centre spread of the book is face up Centre Spread Face Up SS 3 COVER on en Finishing Sequentially Printed Sheets e Load the bins and switch on use bin linking if required e Adjust the feed bin settings to suit the paper type Inserting a Cover If you wish to insert a separate cover it should be loaded into the lowermost bin with the outside face down The other sheets are then loaded in the bin s directly above Adjust the Booklet Maker and Trimmer e Adjust the booklet maker and trimmer for the paper size using the GUI con trol panel e Adjust the outfeed conveyor wheel e Select edge or centre stapling e Select which staple heads should be used and adjust their position if neces sary e Adjust the fold
50. eyor The conveyor will stop when INCH is released This is used for clearing any sets remaining in the conveyor after a jam etc When the machine is running this button changes to PAUSE Touch PAUSE to pause the feed for approximately 5 seconds the conveyor continues to run The pause time can be altered on the Machine Options page END JOB Touch END JOB when you want to set the machine up for a new job or alter an existing job When a job is loaded some of the machine settings can not be changed to prevent accidental changes END JOB unlocks these set tings This only affects settings that change the integrity of the job e g the number of sheets in a set or the number of sets in a batch TEST SET When the test set icon is highlighted the DocuMaster MFC is ready to run a test set The DocuMaster MFC uses the test set to calibrate the system according to the stock in each bin The test set is not counted by the counter except when in prenumber mode Once the test set is completed and is accepted by starting the machine the bins and certain functions cannot be changed to prevent errors and accidental button pushes To run a test set e Load the DocuMaster MFC e Touch the button e The tower will feed a single sheet from each bin that is switched on and loaded e Ifan error occurred during the test set or the bin loading is changed at this stage touch to run another test set e When the test set icon is grey
51. f the DocuMaster MFC shown on screen is automatically created based on how many bins are fitted and what finishing equipment is connected Various areas on the outline will be high lighted in different colours according to the DocuMaster MFC s operational sta tus The feed bin colours mimic the bin indicator lights Mimic Diagram 74 Counter VA e Steady green This bin is selected and is loaded with paper e White This bin is not selected e Broken line between bins These bins are linked e Flashing green This bin is selected but it has run out of paper e Flashing red This bin has had a double feed which has caused the Docu Master MFC to stop The error will be explained in a pop up box e Flashing yellow This bin has had a miss which has caused the DocuMaster MFC to stop The error will be explained in a pop up box Booklet Maker and Trimmer e White The booklet maker and trimmer are ready for use 14 DocuMaster MFC User Manual 3 About the Machine e Red The booklet maker and trimmer are not ready This may be caused by an open guard or full trim bin Errors in other modules are indicated in red C Touching C resets the set counter to 0 SPH SPH shows the actual production speed of the DocuMaster MFC in sets per hour The production speed is affected by paper size online finishing equip ment and the job setup The BASIC Window The BASIC window contains settings that re
52. fety as a key feature and in accordance with international safety standards Please read and observe the following safety rules Warnings and Cautions Where warnings and cautions are given in the body of this manual they are identified by a warning triangle AN Warning Warning messages alert you to a specific procedure or practice which if not followed correctly could cause serious personal injury AN Caution Caution messages appear before procedures which if not observed could result in damage to the equipment Safety Rules e Do not carry out any maintenance procedures other than those documented in this manual Do not remove any screws fixings or covers other than when told to do so in this manual e Ifa procedure requires removing covers or changing fuses always first dis connect the machine from the mains electricity supply by switching off and unplugging the machine e Do not modify the machine in any way This may affect safe working and will invalidate your warranty e Do not do anything to interfere with the safety cut out switches fitted to some machine covers e Do not block air ventilation grilles on the machine Do not use the machine if it is making unusual noises Disconnect the machine from the mains electricity supply and call your service engineer DocuMaster MFC User Manual 85 7 Safety Information Installation e The installation of your DocuMaster MFC requires specialist knowledge and sho
53. ge edge stitch tyres from their retaining position and place into the grooves on the top jog pulley control discs on either side of the belt Orange Edge Stitch Tyres in their retaining position 40 DocuMaster MFC User Manual 3 About the Machine Orange Edge Stitch Tyres in their grooves a rae Close the staple panel and place the edge stitch selector lever to the edge sta pling position Note When returning to booklet making the orange edge stitching tyres MUST be removed from the belt control discs and returned to their retaining position Leaving the tyres on the belt control discs during booklet making will result in jams in the booklet maker Edge Stapling amp Folding If required it is possible to edge staple the set and then fold it The only limita tion to this is that the distance from the stapled edge to the fold must be at least half the width of the paper e Set STITCH POSITION to ON EDGE from the STITCH AND FOLD window Lift the Edge Centre Staple Selection Lever up to select centre stapling NOT edge stapling Select the Staple Heads Use the Staple Head Selection Button to select which staple heads are active For bookletmaking the two centre staple heads should be used Corner stapling is only possible if the optional third staple head is fitted The staple head indica tor lights show which heads are selected Staple Head Position The staple heads have
54. gularly need to be altered when set ting up a new job PRESET PRENUMBER CREASER BASIC Window SETS PER HOUR SETS PER HOUR allows the production rate of the Docu Master MFC to be set AUTO Selecting AUTO allows the DocuMaster MFC to run at its maximum production speed according to paper size online finishing equipment and the job setup SINGLE SET Normally there will be more than one set in the conveyor at any one time Touch SINGLE SET to allow only one set in the conveyor at a time This minimises the correction required should an error occur The sets per hour will automatically adjust to achieve this AIR BLOW AIR BLOW alters the amount of air available for sheet separation in the feed bins As a general rule the heavier and larger the sheet the more air you need The default factory setting depends on the type of feed bins 25 for friction 40 for SlimVAC DocuMaster MFC User Manual 15 3 About the Machine If you are running mixed stocks on friction bins individual air taps on each bin allow the air to be independently controlled PRESET PRESET is used if an exact number of sets are required Touch PRE SET and enter the number of sets required on the number pad The counter in the main area of the screen will turn white When the machine is started the counter will automatically count down to zero and the DocuMaster MFC will then stop Touch to restart the machine The counter will
55. ich staple heads should be used and adjust their position if neces sary Adjust the fold roller gap Adjust the gathering station Adjust the Creaser Starting The Job Adjust the gathering station for sheet width Adjust for sheet length Adjust the air blow if necessary Adjust the creaser module as needed See Creasing Module on page 46 Touch to run a test set A test set must be run at the start of each job Remove the resulting booklet from the outfeed conveyor and check that the sheet sequence is correct Touch to run the job Once the machine is running adjustments may be necessary depending upon the stock in use The machine can be stopped at any time by touching 10 DocuMaster MFC User Manual cHapter3s About the Machine This chapter explains in detail about each of the different modules that make up your DocuMaster MFC and how to make adjustments to them For instructions on using the DocuMaster MFC for production jobs please refer to Chapter 2 on page 7 Control Panel Your DocuMaster MFC is fitted with a GUI Graphical User Interface control panel The control panel has an 8 2 colour touch screen which offers a user friendly interface for operators There are start and stop buttons mounted on the control panel s frame these buttons are also repeated on the touch screen Start Button Stop Button Touch screen GUI Control Panel The touch screen has a power s
56. l separator pressure will depend upon the stock in use Initially set the lever to its mid position To increase separation move the lever downwards one notch at a time and to decrease separation move the lever upwards one notch at a time Moving the lever to its highest position disengages the separator This position is used for the improved feeding of heavy cardstocks DocuMaster MFC User Manual 25 3 About the Machine Tray Pressure Increasing the tray pressure gives the feed wheels greater force on the paper too much will result in double feeds and increases the possi bility of scuffing the paper Tray Pressure tor Pres Separator Pres Adjustment sure Adjustment The ideal pressure will depend upon the stock in use Always use the least pressure possible The lever has five positions and is adjusted by gently push ing downwards whilst sliding the lever in or out The innermost position gives minimum pressure Initially set the pressure to minimum for small stock For large sheets i e if tray extenders are used initially position the lever one notch out Air Separation Air directed from the right hand sidelay is used to separate the top sheets of paper in the stack The overall air level is adjusted if required by altering the AIR BLOW value in the BASIC window see p 15 The air level is also adjustable on each individual bin via a tap on the right hand sidelay The tap on the sidelay controls the
57. n the blade We therefore offer the guidelines on p 68 which should accompany the blade and anvil when they are sent for re grinding Your service engineer will arrange regrinding for you if required Whenever the trimmer blade is re ground check the condition of the anvil also This will only require re grinding if it has become damaged Warning This procedure is potentially hazardous and should only be con ducted 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 Tools Required 3mm Allen Key 4mm Allen Key 6mm Allen Key 10mm Allen Key 19mm Spanner The trimmer blade and anvil are located behind the conveyor assembly at the docking end of the unit Vi Trimmer Lid E e wae Conveyor Assembly Separate the trimmer from the booklet maker Open the trimmer lid Remove the two M5 button screws and washers that secure the conveyor assembly to the trimmer unit M5 Button Screws 64 DocuMaster MFC User Manual 5 Maintenance Lift away the conveyor assembly to reveal the blade assembly Anvil Blade Mark Along Here Important Note the angled position of the trimmer blade and with a marker pen or similar mark along the bottom edge of the blade This will act as a guide when refitting Removing the Trimmer Blade Slightly loosen all five
58. next crease 10 Unknown Creaser error Creaser Jam There is a paper jam in the Creaser module Emergency stop The emergency stop button has been pressed Turn the emergency stop button clockwise to release it Fuse blown A fuse has blown on the Motor Drive PCB in the drive unit Contact your supplier 82 DocuMaster MFC User Manual 6 Problem Solving Error Message Meaning Fuses blown Fuses have blown on the Motor Drive PCB in the drive unit Contact your supplier Initialising bins The bins in the DocuMaster MFC are being checked If this message appears regularly contact your supplier Motor stalled There may be a bad jam causing the conveyor to lock Clear the jam Touch INCH to clear any partial sets from the con veyor If the DocuMaster MFCDocuMaster MFC does not restart a fault may have occurred in the drive unit Contact your supplier No power to stacker Check that the stacker is plugged into a suitable mains sup ply and is switched on No response The bins in the DocuMaster MFC have not initialised prop erly Switch the machine off and then on again If the problem persists Contact your supplier Output path The paper path has been altered on the tower s base Select deflector the correct paper path before restarting the job changed Power fail The mains supply has been interrupted Switch the Docu Master MFC off and on again
59. old position except hinges 46 DocuMaster MFC User Manual 4 Creaser Module Mode Cover Only Cover Centre All Sheets Off Hinges There are 4 creasing modes that are selectable depending on the type of job finish that is required SETS 003659 Crease modes SETSPER AIR PRESET PRENUMBER HOUR BLOW Be BASIC Crease Mode Settings The Cover Only mode is used to ensure it is ONLY the cover that is creased as it passes through the Creasing Module This mode will place a crease on the first sheet of a Set as well as the cover sheet As this sheet ends up in the middle of the finished book it is referred to as the Centre sheet All sheets that pass through the creaser one at a time will be creased All creasing is disabled Pressing the creaser button brings up several other settings these are addi tional functions that enable user adjustments to the pre set crease type and positions The cover sheet may require the use of hinge creases Creases are designed to facilitate the opening of the book and relieve some of the stress from the sta ples of the finished booklet Hinges are selectable by turning them ON or OFF using the toggle button Hinge Distance will default to 6mm This indicates that each of the 2 hinge creases will be positioned 6mm from the centre crease fold position The user is able to manually adjust the setting from 6mm up to a maximum of 12mm Docu
60. on for the lever is the mid position L Adjust which should be suitable for the majority of stock 2 ranges Note When lowering the tray height the change will only take effect the next time the tray raises i e after reloading or restart ing Bin Linking If required two or more feed bins may be linked to operate as a single bin When one runs out of stock the next bin in the linked group will automatically take over This allows reloading without stopping the machine Bin linking can only be enabled when the bins are unlocked i e when the TEST SET icon is high lighted on the control panel Press the grey button on the upper bin to link it with the one below This will be indicated by the small green light The DocuMaster MFC mimic diagram on the control panel will show a broken line between bins that are linked By pressing the red bin on off button it is possible to select which bin in the linked group is active If the system is locked pressing the grey button on any bin will indicate which bins are in the same linked group DocuMaster MFC User Manual 31 3 About the Machine Sensor Overrange Sensor overrange is indicated after the test set by a slow flashing red light on the bin in question Particularly heavy or opaque stock such as a straw board backing sheet may cause the bin sensor to go overrange This means that the sheet is too opti cally dense for
61. ooklet maker show which heads are selected Stapler Guard The top cover of the rear corner stapler is open Close the Open cover Stapler Jam A paper jam has occurred in the rear corner stapler Lift the top cover and clear the jam Staples low A staple cartridge in the booklet maker needs replacing Fit a new staple cartridge Stitch guard open The top cover of the booklet maker is open Close the cover Touch START to clear machine There may still be paper in the conveyor Touch to clear the machine before starting a new job Tray lift error Friction feed bin only There is a fault with the tray lowering mechanism Contact your supplier Tray lift error SlimVAC bin only One of the trays has not lifted Try unloading and reloading the bin If this does not work press the emergency stop switch and allow 10 seconds before releasing it If the problem persists contact your supplier Trim bin full The trimmer offcut bin is full Empty the offcut bin Trim Bin Open The Trimmer offcut bin is not fitted or is not contacting the safety switch Fit the offcut bin correctly Trim guard open The trimmer cover is open and should be closed 2xDivert Two successive diverts i e two errors have occurred from the same bin Check the bin is feeding correctly 84 DocuMaster MFC User Manual charter Safety Information Your DocuMaster MFC has been designed with sa
62. opped at any time by touching Alternatively to stop the machine when the current batch set is complete touch STOP in the BATCH window Normal Collating Preparation e Press END JOB to end the previous job e Press INCH to check that there are no sheets remaining in the conveyor e Clear any remaining sheets from the DocuMaster MFC system Tip Load the Default Template to return the control panel to its default fac tory settings Touch END JOB Touch LOAD amp SAVE Select the Default Template from the list of jobs Touch LOAD If asked select YES to confirm that you wish to load the Default Template Loading Sequence Load the centre spread of the book face up in the uppermost bin see below The other pages should be loaded progressively downwards using as many bins as are required The cover should be loaded into the lowermost bin with the outside face down DocuMaster MFC User Manual 9 2 Using the DocuMaster MFC Centre Spread 1 2 3 COVER Outside Face Down Finishing Batch Printed Sheets From the BATCH window set the NUMBER OF SETS to 1 This will feed one sheet from each active bin and then open the latch in the gathering station to allow the set to travel into the booklet maker Adjust the Booklet Maker and Trimmer Adjust the booklet maker and trimmer for the paper size using the GUI con trol panel Adjust the outfeed conveyor wheel Select edge or centre stapling Select wh
63. ow 24 DocuMaster MFC User Manual 3 About the Machine Tray Extenders Adjustments For large sheet sizes over A4 8 x 11 or when running A4 or 8 x 11 portrait it will be necessary to fit tray extenders to support the sheets One B3 14 x 207 tray extender is supplied as standard with each Friction bin An optional tray extender is available for running A4 portrait 8 x 11 Loading the Bins Slide the stock into the bin between the sidelays Push in the sidelays to centralise the paper in the bin and so that they hold the paper securely Bin Sidelays Switching Bins On amp Off Before a test set is produced individual bins will automatically switch on and off as they are loaded and unloaded Bins can also be manually selected by pressing the red button alongside the bin In addition loading the Default Template will switch on all loaded bins Remember that bins cannot be switched on or off when the system is locked touch END JOB if nec essary Adjustments for paper type and or size include control over the amount of tray pressure and the amount of separator pressure Separator Pressure Increasing the separator pressure acts like a brake mak ing it more difficult for a second sheet of paper to pass the separator pad Too little separator pressure will result in double feeds too much will result in miss feeds or damage to the feed edge of the paper The idea
64. p see p 42 CANNOT CLOSE BOOKLET MAKER LID Support strut is in place Lift the booklet maker lid slightly push the support strut see p 36 and close the lid DocuMaster MFC User Manual 73 6 Problem Solving Problem Cause Solution BOOKLET IS Trimmer conveyor clamp See p 60 TRIMMED OUT OF requires adjustment SQUARE BOOKLETS ARE Trimmer conveyor clamp See p 60 TRIMMED TOO requires adjustment SHORT COVER IS DAM Trimmer conveyor clamp See p 60 AGED AROUND STA PLES requires adjustment Fold roller gap is too nar row Adjust the fold roller gap see p 42 Staple Head Problems ONE OR BOTH LEGS Incorrect clincher align Re align see p 41 TURN OUT ment STAPLE COMES OUT Staple jammed inthe car Inspect cartridge see IN PIECES tridge p 58 and remove any A staple head error has occurred jammed staple wire The heads should self clear If not turn the unit off and on again to free the head If this does not work contact your author ised distributor STAPLE HEAD INDI CATOR LIGHT BLINKS ONCE PER SECOND Staple cartridge empty Replace cartridge see p 58 STAPLE HEAD INDI CATOR LIGHT BLINKS RAPIDLY 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 contact your author ised distributor 74 DocuMaster MFC User Manual 6 Problem Solving
65. r Position the rubber endlays on each tray at the end of the paper stack The end lay should be underneath and just clear of the edge of the paper by about 1mm 1 16 Note When using the DocuMaster MFC to collate small sheet sizes make sure the tray loaded sensor is not covered by the rubber endlay The paper tray raises automatically when the system initially starts and thereaf ter when the tray is loaded It is therefore important to load a full stack of paper at a time The tray automatically lowers either when the tray is empty or when is pressed after the machine stops for any reason Switching Bins On amp Off Adjustments Before a test set is produced individual bins will automatically switch on and off as they are loaded and unloaded Bins can also be manually selected by pressing the red button alongside the bin In addition loading the Default Tem plate will switch on all loaded bins Remember that bins cannot be switched on or off when the system is locked touch END JOB if necessary There are three adjustments to the feed system which allow the feeding of a wide range of papers Suction Feeder Suction Feed Angle Adjustment Sheet Corrugation Adjustment Sheet Corrugation The profile of the suction feeder can be adjusted to provide varying amounts of corrugation in the sheet Greater corrugation AC gives greater separation less corrugation gives less separation
66. rease the space between the feeder and the sheets If necessary increase the feeder angle also Stock Curling Up The upward curl means the tray height detector will see the paper before it is close enough to the feeder e Raise the tray height to lift the paper stack closer to the feeder Lightweight Porous Papers K Suction Feeder e Increase sheet corrugation The feeder may suck through one e Lower the tray height to increase the dis sheet and onto the next resulting in tance between the feeder and the paper double feeds stack DocuMaster MFC User Manual 33 3 About the Machine Gathering Station The gathering station holds the sheets which have been delivered from the feed bins until the set is complete The set is then released into the booklet maker Interface Sockets The interface sockets are located on the right underside of the gathering station There are three sockets in all Two identical EEE ug sockets either one of which is used to connect the booklet A Not Online maker and one smaller socket that is currently not used Used Finishing Sheet Length Adjustment Select the correct paper size using the two levers on the front of the DocuMas ter MFC see below For non standard paper sizes use the setting for the next largest standard paper size
67. reasing module fitted This is designed to crease single sheets of any given set as they pass through it To enable creasing for a particular job please see Creasing Module on page 46 Creaser Overview The creasing section is always located immediately below the lowest feeder bin and directly above the Gathering Base module Blade Adjustment Cam Input Rollers Output Rollers Creasing Matrix Set Adjustment locking Screw Pivoter Creasing Mechanism The Creasing Module DocuMaster MFC User Manual 45 4 Creaser Module Creasing Module When the creasing module is installed a creasing menu button is available on the Basic Window The mimic shows the creasing module is installed The creasing module shown on the mimic BATCHES id Creasing menu button SETS PER AIR PRESET PRENUMBER HOUR BLOW 1Be BASIC Creaser Button and Mimic Crease Options Pressing the Creaser button on the basic window displays the available set tings oe aa yon Ki oe SETS 003659 07 8 CREASER HINGE DISTANCE HINGE 4 0 Da OFFSET Sheet Length 297 0 Fold Position 148 5 Nbr of Sheets 8 ETS PER AIR PRESET PRENUMBER HOUR BLOW Creaser Settings Window Crease positions are calculated from the information entered in the Finishing window The crease positions are always positioned in the centre of the sheets to be aligned with the f
68. revert to black and will count up to show how many overs are produced The Preset function is ideal for producing a one off batch If you wish to produce several identical batches it is easier to use the Batch function PRENUMBER PRENUMBER is intended for use when collating pre numbered carbonless sets Touching PRENUMBER selects Single Set mode and causes the test set to be counted by the counter It also prevents the operator from switch ing linked bins before one bin has emptied It is possible to switch off Single Set mode once Prenumber is selected This allows the machine to run faster when using stock that feeds easily CREASER See Creasing Module on page 46 The ADVANCED Window The ADVANCED window allows advanced machine settings to be altered These settings may be altered to optimise the quality and productivity of a job at 5 SHEET OFFSET DETECTOR POSITION FEED CLUTCH SUCTION aj HOLD Sao ADVANCED ADVANCED Window DRIVE SPEED DRIVE SPEED alters the drive speed of the conveyor rollers and therefore the speed at which the sheets exit the DocuMaster MFC This set ting is independent from the SETS PER HOUR setting 16 DocuMaster MFC User Manual 3 About the Machine SHEET OFFSET SHEET OFFSET shales the sheets as they exit the feed bins This can assist the neat stacking of thick sheets or large sets The range of off set is 20mm between
69. roller gap Adjust the Gathering Station Adjust the gathering station for sheet width e Adjust for sheet length e Adjust the air blow if necessary Adjust the Creaser e Adjust the creaser module as needed See Creasing Module on page 46 Starting the Job e Touch NUMBER OF SETS in the BATCH window and input the number of sheets required in each book To insert a cover in the BATCH window touch INSERTS and set BOTTOM to ON the NUMBER OF SETS in the BATCH window must be set to 1 or greater 8 DocuMaster MFC User Manual 2 Using the DocuMaster MFC In the BASIC window select PRENUMBER and set the SETS PER HOUR to AUTO Test Set A test set must be run at the start of each job Touch to run a test set If PRENUMBER is selected the test set is counted and the sheet should be left in the gathering station Tip To avoid wasting sheets during the test set the sheets can be diverted out of the front of the gathering station using the manual bypass gate Note f PRENUMBER is not selected the test set is not counted and the sheet should be removed from the gathering station and replaced in the feed bin Note f a cover is being inserted it is not fed during the test set The cali bration reading for the cover is automatically taken when the job is started Touch to run the job Once the machine is running adjustments may be necessary depending upon the stock in use The machine can be st
70. s e Turn the adjustment screws clockwise to increase the gap reducing clamp pressure e Turn the adjustment screws anti clockwise to reduce the gap increasing clamp pressure 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 Lay the first rule across the wire frame so that it is above the clamp roller shaft Using the second rule measure the height from the top of the shaft to the bot tom of the first rule DocuMaster MFC User Manual 61 5 Maintenance Adjust the shafts as necessary and re measure to ensure they are both set to the same height Wire Frame Second Rule First Rule Clamp Roller Shaft Restarting the Job Before restarting the job reset the paper size as neces sary Note t is important to return both clamp roller shafts to the factory default height of 17mm before booklets of a more typical thickness are produced Fold Roller and Conveyors Build up of dust or dirt on the fold rollers and conveyor belts will eventually cause slippage or ink transfer They should therefore be cleaned periodically AN Warning Access to the manual cranking points on the booklet maker and trimmer requires the side covers to be removed For safety reasons this pro cedure should therefore only be conducted by authorised personnel Discon nect the power before removing
71. s 21 M mains input 4 mains on off switch 4 maintenance 55 55 68 manual bypass gate 35 manual cranking point booklet maker 62 manual cranking point trimmer 63 menu 14 mimic diagram 14 mixed feed 23 N normal collating loading sequence 9 number of sets 21 Oo operator maintenance 55 55 68 outfeed conveyor adjustment 43 P padlock symbol 21 page direction 18 38 paper jam 75 paper separators friction bins 25 57 paper size 18 paper size adjusting 38 pause 13 pause separate 22 payout wheels 43 portrait 38 power save 11 pre fold jogging 19 pre jog 19 pre stitch jogging 19 prenumber 16 preset 16 presets 18 problem solving 69 84 booklet maker and trimmer problems 71 error messages 80 84 friction feed problems 76 gathering station problems 70 general problems 69 paper jam 75 slimvac feed problems 78 staple head problems 74 trouble shooting 69 R re ref 18 71 restart batch 23 rubber endlays slimvac bins 29 S safety 1 85 save 20 sensor overrange 27 32 service interval 55 sets per hour 15 setting up the booklet maker 36 44 connecting 36 opening 36 starting 37 setting up the bookletmaker outfeed conveyor adjustment 43 trim offcut box 44 sharpening trimmer blade 64 68 sheet corrugation slimvac bins 30 sheet length adjusment 34 sheet offset 17 sheet width adjustment 34 92 DocuMaster MFC User Manual INDEX side jog hold 19 single set 15 slimvac bins 2
72. ser Manual 6 Problem Solving Problem Cause Staple position is not adjusted correctly Solution Fine tune the position of the staples see p 59 UNTIDY BOOKLET Infeed sidelays are not adjusted correctly Set needs more time to settle before stapling Tower delivering an untidy set The booklet maker adjustment system is not calibrated correctly Adjust PAPER SIZE see p 18 Allow more time for the set to settle by increasing STITCH DELAY Improve tower delivery Touch RE REF in the PAPER SIZE window to manually recalibrate the booklet maker adjustment axes FINISHED BOOKLET IS TOO LOOSE Fold roller gap is too wide Adjust the fold roller gap see p 42 TOP JOG DAMAGE ON THE SET The sheet length has been set too short Fold roller gap is too nar row when edge stitch ing Tower delivering an untidy set Adjust PAPER SIZE see p 18 Adjust the fold roller gap see p 42 Improve tower delivery BOOKLETS WILL NOT STACK ON THE CONVEYOR Large payout wheels incorrectly positioned Electrical connection is unplugged Reposition see p 43 Plug in electrical connec tion between the booklet maker trimmer and the outfeed conveyor BOOKLET COVER IS MARKED Dirty fold rollers Fold roller gap is too nar row Clean them with a cloth dampened with soapy water or alcohol isopro panol Do NOT use blan ket wash see p 62 Adjust the fold roller ga
73. t work contact your author ised distributor STAPLES LOW MES SAGE ON DISPLAY Staple cartridge empty Replace cartridge see p 58 STAPLE HEAD ERROR MESSAGE ON DISPLAY 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 contact your author ised distributor FOLD IS NOT ACTI VATED Unit is in edge staple mode Move lever into centre sta ple position see p 39 BOOK IS NOT TRIMMED Trim not selected Trim position is set off the edge of the sheet Edge stapling is selected or STITCH POSITION is set to ON EDGE Make sure TRIM is switched on see p 19 Reset trim position Not available in these modes EDGE STAPLE FUNC TION NOT WORKING Edge staple not selected Move lever to correct posi tion and select staple head see p 39 STAPLE IS NOT ON THE FOLD Set is bouncing before stapling Set is bouncing before folding Loose paper or staples in the fold plate area SIDE JOG HOLD is selected whilst the infeed sidelays are set too tight STITCH POSITION is set to ON EDGE Allow the set more time to settle by increasing STITCH DELAY Allow the set more time to settle by increasing FOLD DELAY Locate and remove see p 75 Adjust PAPER SIZE so that both the infeed side lays barely touch the paper see p 18 Set STITCH POSITION to ON FOLD 72 DocuMaster MFC U
74. tenement 190 95 02 Issue A 90 DocuMaster MFC User Manual INDEX INDEX A action buttons end job 13 help 13 inch 13 menu 14 start stop 12 test set 13 adjustable fold rollers 42 adjusting the paper size 38 adjustment axes re referencing 71 advanced window 16 detector position double detection 17 tolerance 17 drive speed 16 feed clutch 17 auto 17 sheet offset 17 suction hold 17 air blow 15 air blow adjustment 35 air separation adjustment 26 anvil sharpening 64 auto 15 17 axes calibration 71 B basic window 15 air blow 15 prenumber 16 preset 16 sets per hour auto 15 single set 15 batch window 21 inserts 22 bottom 22 top 22 number of sets 21 pause separate 22 restart batch 23 stop 22 bin controls 24 28 bin linking 27 31 blade sharpening 64 booklet making setting up the booklet maker 36 44 Cc calibration see re ref centre stapling 39 clamp roller shafts 61 62 cleaning see maintenance cleaning the touch screen 56 conformity declaration of 89 control panel 11 23 basic operation 11 12 error messages 80 84 conveyor clamp adjustment 60 corner stapling 39 cover inserting 8 creaser 45 adjusting the creaser pressure 49 crease options 46 mode 47 overview 45 reversing the crease matrix set 50 D delete 21 detector position 17 difficult papers slimvac 32 docking plates trimmer 37 double detection 17 double jog 19 drive speed 16 E edge stapling 39 edge stapling
75. the sensor to see through it Double feeds will not be detected but misses trailing sheets and jams will be detected as normal Difficult Papers Whenever feed difficulties are encountered we recommend that you follow two basic guidelines e Switch off all the bins except one This allows you to concentrate fully on the feed of a single bin e Ensure that only one remedy is tried at a time This will make it much easier to identify the solution The following suggested settings are a recommendation only Paper character istics vary and therefore any particular stock may require settings different to those shown Paper Condition Recommended Settings e Suction Feeder angled down es 4 Suction Fee e Tray height in mid position Se Coton see oo e Sheet corrugation in mid position o ofu Standard Settings Heavy or Rigid Stock Heavy or rigid stock or board may be f Suctio unable to bend sufficiently to meet sa a Feeder ae a oO oO the suction feeder in its lower posi tion e Raising the angle of the suction feeder reduces the feed angle e Raise the tray height 32 DocuMaster MFC User Manual 3 About the Machine Paper Condition Recommended Settings Stock Curling Down The stock is too close to the feeder for air to get in between the sheets Lowering the tray height will inc
76. trim axis size adjustment of the trimmer is in the proc ess of adjusting Wait for the trimmer to finish before touching Cannot start The width axis size adjustment of the DocuMaster MFC is width axis in the process of adjusting Wait for the booklet maker to fin changing ish before touching Change feed The tower s base is not set up correctly for the current job output to front Change the paper path to feed to the front of the tower Change feed output to rear The tower s base is not set up correctly for the current job Change the paper path to feed to the rear of the tower Change feed The tower s base is not set up correctly for the current job path down Change the paper path to feed down Check fuse A fuse may have blown in the drive unit Contact your sup plier Conveyor jam A paper jam has occurred in the bottom of the conveyor Clear the jam Touch INCH to clear any partial sets from the conveyor Creaser Error There is an Error in the Creaser module 1 Sheet was shorter than expected 2 Sheet was longer than expected possible jam 3 Job data queue overflow Too many sheets stored 4 Creaser blade initialisation failed or the blade did not cycle Blade clip out error Job data queue under flowed Invalid job data arrived back from the Vario or time out Only one of the skew sensors was covered Oo ON OO The machine is running too fast to stop for the
77. tuck in the paper path or the unit is not switched on Staple Head Indicator Lights The red indicator lights on the booklet maker lid show the status of the corre sponding 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 selected and ready to run Blinking rapidly There is a staple head jam or other error Not illuminated The staple head is not selected Refer to Changing the Staple Cartridge on page 58 for details on changing the staple cartridge Adjustment for Paper Size Adjustment for paper size is made on the GUI Graphical User Interface e Touch FINISHING to display and adjust the booklet maker settings e Touch PAPER SIZE PRESETS and select a standard sheet size A3 A4 or A5 11x17 8 5x11 or 5 5x8 5 e Choose PORTRAIT or LANDSCAPE in the PAPER SIZE PAGE DIRECTION win dow e For non standard paper sizes touch PAPER SIZE and then use the and keys to set the size Note PORTRAIT is the normal setting for booklet making Tip Remember that you can recall the settings from previously stored jobs in the LOAD amp SAVE window 38 DocuMaster MFC User Manual 3 About the Machine Select Edge or Centre Stapling Use the Edge Centre Staple Selection Lever to select centre staple operation lift up or side corner staple operation push down Edg
78. 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 DocuMaster MFC User Manual 41 3 About the Machine To adjust move the staple head adjustment lever to the right to select the inner position Staple Head Adjustment Lever Clincher Adjust the clinchers to suit by loosening the orange hand screw and sliding the clincher fully across in the required direction Tighten the hand screw Orange Hand Screw Clincher Note You may need to increase the infeed sidelay gap in order to access the hand screws Do this by touching FINISHING PAPER SIZE and then increasing the sheet width AN Caution Before placing your hands inside the booklet maker you should disconnect the unit from the mains electricity supply Fold Roller Gap Adjustment The fold rollers should be set sufficiently close together to produce a neat book let 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 42 DocuMaster MFC User Manual 3 About the Machine The gap between the fold rollers is adjusted using a lever to the left of the front face of the booklet maker Fold Roller Adjustment Lever The lever has 11 positions To move the fold rollers further apart
79. ug into mains connec WILL NOT START plugged in tion of the correct type and voltage Interface between book Plug in let maker and tower is not plugged in Fuse has blown on the On 220 240V machines main input there are two 5 amp fuses in the mains input connec tor check and replace as necessary On 115V machines they are 10 amp fuses Booklet maker or trimmer Close the lid lid is open BOOKLET MAKER There is a jam or other Clear the jam see p 75 STATUS INDICATOR LIGHT IS BLINKING RAPIDLY error in the unit BOOKLET MAKER STATUS INDICATOR LIGHT IS NOT ILLU MINATED Booklet maker or trimmer lid is open or unit is not switched on Close the lid switch on the unit BOOKLET MAKER DOES NOT STOP ON TOUCHING Note There is a 10s delay after touching For an immediate stop use the DocuMaster MFC emergency stop button or open the booklet maker lid Booklet maker has lost communication with the tower Check that the interface is plugged in it may have become disconnected when moving the booklet maker in and out ONE OR BOTH STA PLE HEADS ARE NOT ACTIVATED Staple heads are not selected Make sure STITCH is set to ON in the STITCH AND FOLD window see p 18 DocuMaster MFC User Manual 71 6 Problem Solving Problem Cause A staple head error has occurred Solution The heads should self clear If not turn the unit off and on again to free the head If this does no
80. uld therefore only be carried out by a supplier approved engineer e The DocuMaster MFC 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 guarantee The required machine voltage is shown on the label on the rear of the DocuMaster MFC and the rear of the booklet maker e Allow sufficient working space around the machine e Take care when moving machinery and observe safe lifting practices Trimmer Guillotine e The trimmer 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 86 DocuMaster MFC User Manual CHAPTER 8 Specifications Intended Use The DocuMaster MFC is intended for feeding sta pling folding and trimming materials as specified below Operating Conditions 10 35 C at 35 85 relative humidity Up to 2000m above mean sea level Configuration 1 x friction feed and 3 x SlimVAC feed stations with online booklet maker and trimmer Production Dependent on operating mode and finishing option Stock Sizes Min 140 x 210mm 5 5 x 8 3 Max 320 x 450mm 12 6 x 17 75 Stock Range 80 300gsm 80 240 SlimVAC Coated paper 90gsm minimum Max Book Thickness 22 sheets 80gsm Max No Creases Sheet 3
81. unplugging the machine e Unplug the mains input lead and open the flap on the fuse holder e Pull out each fuse casing in turn and check the fuse e Replace if necessary with a fuse of the correct specification as detailed below Machine Part No Description Unit 240V DocuMaster MFC Drive 730 018 Fuse 1 25 32mm 7 0A HRC Quick Acting F Unit 115V DocuMaster MFC Drive 730 020 Fuse 1 25 32mm 10 0A HRC Quick Acting F Booklet Maker 240V 730 016 Fuse 1 25 32mm 5 0A HRC Quick Acting F Booklet Maker 115V 730 103 Fuse 1 25 32mm 10 0A HRC Anti Surge T TABLE 1 Error Messages Under certain error conditions a message will be displayed on the control panel Some of the error messages will refer to an individual bin or module address In this case the relevant module number will appear where is shown below Error Message Meaning Bin double A double feed error has occurred on the bin detailed This means that the bin has fed two sheets of paper instead of one Check and correct the faulty set and restart the machine If the error persists see the Problem Solving sec tion of this manual Bin empty The paper tray of the bin detailed is empty Reload the bin and touch INCH to continue the job Touch to continue the job when using the DocuMaster MFC offline Bin jam A paper jam has occurred in the bin detailed Touch I
82. wdriver loosen the two locking screws Turn clockwise to lower the staples Locking Screw Fine Adjustment Screw Locking Screw Turn anticlockwise to raise the staples Turn the fine adjustment screw 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 Conveyor Clamp Adjustment The trimmer 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 This will be necessary if the following problems arise Booklets are trimmed out of square e Booklets are trimmed too short e The cover of the booklets are pulled resulting in damage around the staples Tools Required 4mm Allen Key 2 off 150mm 6 Rule Select A4 or 8 5x11 in the FINISHING PAPER SIZE window regardless of the booklet size Once the booklet maker beeps to confirm it is ready disconnect it from the mains electricity supply 60 DocuMaster MFC User Manual 5 Maintenance Open the trimmer lid by lifting the orange hand screw Adjustment Screw Clamp Roller Shaft Adjusting the Conveyor Clamp
83. y between the set arriving on the fold latch and being folded This is useful if the booklet is not being folded square and allows more time for the sheets to settle The default delay is 180mS The maximum production speed of the booklet maker will be reduced if the delay is increased DocuMaster MFC User Manual 19 3 About the Machine The LOAD amp SAVE Window The LOAD amp SAVE window allows job settings to be saved and reloaded at the touch of a button Each job is given a name and the jobs are listed on the screen To select a job highlight it by either touching it or by using the up and down arrows Rie LOAI VIEW OF DETAILS JOB LIST LOAD amp SAVE Window SAVE Touch SAVE to save the current settings of the DocuMaster MFC When the on screen keyboard appears enter the job name and then touch OK or CLOSE The new job will appear in the list of saved jobs This allows the settings to be recalled in the future which saves set up time REPLACE If an existing job has been loaded and modified touching REPLACE will replace the old job with the modified version CANCEL Touch CANCEL if you do not wish to save a job that you have modi fied SAVE NEW If an existing job has been loaded and modified touching SAVE NEW will save the modified version as a new job When the on screen key board appears enter the new job name and then touch OK or CLOSE The original job is unchanged If th

DocuMaster MFC User Operating Instructions. Rev. 1.0

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