MyBinding Morgana DigiBook 200 User manual

Morgana DigiBook 200

Automatic PUR Perfect

Binding Machine

Instruction Manual

Digibook 200

rev.0.1UL ID01460

OPERATOR MANUAL

Translation of the original instructions

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REVISIONE DATA MOTIVO

0.0 01/02/2017 Prima edizione

0.1 20/03/2017 Tab. fusibili, avvertenze, indirizzo

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CONTENTS

1. INTRODUCTION ...................................................................................... 5

1.1 DECLARATION OF CONFORMITY ................................................................. 6

1.2 CAUTION LABELS ...........................................................................................7

1.3 SAFE OPERATION ...........................................................................................8

1.3.1 GENERAL .................................................................................................................. 8

1.3.2 USER QUALIFICATION ............................................................................................ 8

1.3.3 MACHINE OPERATORS ........................................................................................... 8

1.3.4 GUIDELINES FOR SAFE OPERATION .................................................................... 9

1.3.5 PERSONAL PROTECTIVE EQUIPMENT ................................................................. 10

1.4 RESIDUAL RISKS ............................................................................................11

1.5 INTENDED USE ................................................................................................12

2. TRANSPORT ........................................................................................... 13

3. DISPOSAL ............................................................................................... 13

4. STORAGE ................................................................................................ 14

5. GENERAL DESCRIPTION ..................................................................... 15

5.1 TECHNICAL SPECIFICATIONS ....................................................................... 15

5.2 ELECTRICAL SPECIFICATIONS ..................................................................... 16

5.3 PNEUMATIC SPECIFICATIONS ......................................................................16

5.4 PARTS IDENTIFICATION ................................................................................. 17

5.4.1 CLAMP UNIT (3) ........................................................................................................ 18

5.4.2 MILLING UNIT (2) ...................................................................................................... 18

5.4.3 GLUE UNIT (7) ........................................................................................................... 18

5.4.4 PRESS UNIT (6) ........................................................................................................ 18

5.4.5 GLUE & CLEANER TANKS ...................................................................................... 19

5.4.6 WASTE VACUUM ...................................................................................................... 19

5.4.7 CONTROLS AND INDICATORS ................................................................................ 20

5.4.8 ACCESSORIES ......................................................................................................... 20

5.5 OPERATOR PANEL ..........................................................................................21

5.5.1 MAIN PAGE ............................................................................................................... 21

5.5.2 MACHINE PRE-SET ICON (1) ................................................................................ 22

5.5.3 CARRIAGE PARAMETERS (2) ................................................................................. 23

5.5.4 GLUE UNIT (3) ........................................................................................................... 24

5.5.5 STAND-BY FUNCTION .............................................................................................. 26

5.5.6 PRESS UNIT (4) ........................................................................................................ 27

5.5.7 JOB MEMORY (5) ...................................................................................................... 28

5.5.8 SETTINGS PAGE (6) ................................................................................................. 30

5.5.9 MACHINE SPEED CAUTION PAGE (9) .................................................................... 32

5.5.10 ALARMS SCREEN (10) ............................................................................................. 32

5.5.11 PROCESSING TYPE PAGE (13) ............................................................................... 33

5.5.12 BOOKS COUNTER PAGE (14) ................................................................................. 34

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6. INSTALLATION ........................................................................................ 35

6.1 PHYSICAL CHARACTERISTICS OF THE POSITIONING AREA ................... 35

6.2 FLOOR ..............................................................................................................35

6.3 LIGHTING .........................................................................................................35

6.4 ENVIRONMENTAL CONDITIONS .................................................................... 35

6.5 POSITIONING AND WORKSPACES ...............................................................36

6.6 LAYOUT ............................................................................................................ 37

6.7 POWER CONNECTION ....................................................................................38

6.7.1 EARTH CONNECTION .............................................................................................. 38

6.8 PNEUMATIC CONNECTION ...........................................................................39

7. OPERATION AND USE ........................................................................... 40

7.1 PREPARATION OF THE MACHINE .................................................................40

7.1.1 GLUE TANK LOADING ............................................................................................. 40

7.1.2 CLEANER LOADING ................................................................................................ 45

7.1.3 MEASURING THE BOOK ......................................................................................... 48

7.2 START PROCESSING ......................................................................................49

7.2.4 GLUE REACTIVATING PROCEDURE ...................................................................... 49

7.2.5 COVER POSITIONING .............................................................................................. 52

7.2.6 LAUNCH .................................................................................................................... 54

8. MACHINE CLEANING ............................................................................. 57

8.1 END OF WORK CLEANING .............................................................................58

8.2 SPINE GLUE EXTRUDER CLEANING PROCEDURE .................................... 60

8.3 SIDE GLUE EXTRUDERS CLEANING PROCEDURE .................................... 62

8.4 CLEANING DETAILS ........................................................................................64

8.5 GLUE SYSTEM DRAINAGE ............................................................................66

9. MAINTENANCE ....................................................................................... 71

9.1 PINS LUBRICATION ........................................................................................71

9.2 DEEP CLEANING OF GLUE UNIT CLAMP .....................................................73

9.3 COATING HEAD DEEP CLEANING ................................................................ 75

9.4 FUSE LIST ........................................................................................................78

10. PROBLEMS - SOLUTIONS ..................................................................... 79

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1. INTRODUCTION

It is essential for operator safety and correct use of the machine reading this

manual of use and maintenance.

This manual describes how to use the machine, the conguration of the basic operations work. This

manual was written so as to be easily understandable even to those users who have never used

this type of machine. To ensure that the machine provides maximum performance read this manual

carefully before using it. After reading, keep this manual in a safe place and consult it as needed.

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1.1 DECLARATION OF CONFORMITY

DICHIARAZIONE DI CONFORMITÀ CE DIRETTIVA CE PER MACCHINE 2006/42/CE, E

SEGUENTI DIRETTIVE EUROPEE (ALLEGATO IIA)

CE CONFORMITY DECLARATION DIRECTIVE FOR MACHINES 2006/42/CE,

AND FOLLOWING EUROPEAN DIRECTIVES (ANNEX IIA)

• COSTRUTTORE - MANUFACTURER:

K.G.S.SRL Via della Tecnica,37 - 35035 - Mestrino (PD) Italy

• RESPONSABILE DELLA COSTRUZIONE DEL FASCICOLO TECNICO - RESPONSIBLE

FOR PREPARING THE TECHNICAL DOSSIER: RACCANELLO ROBERTO

CON LA PRESENTE DICHIARIAMO CHE LA FABBRICAZIONE DEL / WE HEREWITH DECLARE

THAT THE MANUFACTURE OF:

• MODELLO TIPO / MODEL TYPE : 200-B (DIGIBOOK)

• MATRICOLA / SERIAL : MB200-XXXX

• ANNO DI COSTRUZIONE / MANUFACTURED IN: 2017

CORRISPONDE ALLE SEGUENTI DISPOSIZIONI NELLA VERSIONE ATTUALMENTE VALIDA /

IS IN AC-CORDANCE WITH THE FOLLOWING DIRECTIVES AS IT IS :

• Direttiva CE per Macchine 2006/42/CE / Directive 2006/42/CE

• Direttiva EMC 2014/30/UE / EMC Directive 2014/30/UE

• Direttiva sulla Bassa tensione 2014/35/UE / Low Voltage Directive 2014/35/UE

NORME ARMONIZZATE APPLICATE , IN PARTICOLARE

HARMONIZED STARDARDS, IN DETAIL :

• EN 1010

• EN 60 204-1

• EN 61 000-6-2, EN 61 000-6-3, EN 61 000-6-4

• EN 60950

Mestrino, (PD) Italy

__/__/2017

Dott. Marco Alfredo Tumaini

K.G.S. s.r.l. con socio unico

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1.2 CAUTION LABELS

During the manual and applied to the machine uses the following symbols to alert of any danger to

persons and / or property damage.

In extreme cases of non-compliance can cause damage to persons or property.

CAUTION! You place before certain procedures. His failure to comply may result

in injury to the operator, maintainer, installer or the machine.

CAUTION! Sharp blades!

Cut Risk

CAUTION! Electrical voltage!

Risk of electric shock

CAUTION! Hot surfaces!

Risk of burns.

CAUTION! Risk from rotating parts! Risk of crushing.

CAUTION! Hazardous moving parts, do not attempt ngers and other body parts.

CAUTION! Risk from rotating parts! Risk of crushing

CAUTION! Hazardous moving parts, do not attempt ngers and other body parts.

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1.3 SAFE OPERATION

1.3.1 GENERAL

The manufacturer guarantees that the contents of this manual are in accordance with the procedures

required by the machine. The manufacturer shall not therefore be liable for any use of the machine

in a manner inconsistent with the information contained in this manual.

1.3.2 USER QUALIFICATION

This machine is intended to be used by a single operator!

The operator must be fully trained on how to act in the occurrence of possible faults, malfunctions or

hazards to themselves or others, and must meet the following requirements:

Immediately stop the machine in case of emergency by acting the emergency button (red button

installed on board of the same). Do not attempt to go beyond the tasks and technical knowledge.

Immediately inform their superior responsible in case of problems, and avoid taking personal

initiatives.

It is assumed that the operator has at least the following requirements:

▪ General culture and specic enough to level, each for its expertise, to read and understand the

contents of the manual in the parts that concern him, including the correct interpretation of the

drawings and diagrams electrical, pneumatic and hydraulic systems;

▪ Ability to correctly interpret the symbols and video messages;

▪ overall knowledge of the machine and the plant in which it is inserted;

▪ Experience in the use of binding technology;

▪ Ability and knowledge to take action in case of an emergency and uses protective equipment.

1.3.3 MACHINE OPERATORS

OPERATOR: Standard use of the machine, with the possibility of parameter settings, load glue,

aspirator emptying and nal cleaning work.

TECHNICAL OPERATOR: glue emptying and machine cleaning.

TECHNICAL INSTALLATION: opening the electrical panel and interventions on electrical system

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1.3.4 GUIDELINES FOR SAFE OPERATION

The application of procedures other than those specically described in this manual may cause

operational errors. Carefully read the safety instructions in this manual.

The manufacturer is relieved from any liability arising from an arbitrary and improper use of the

machine, such as:

▪ Use of the machine by untrained personnel;

▪ Use contrary to the applicable law;

▪ Incorrect Installation;

▪ Defective power supply and / or pneumatic supply;

▪ Total or partial disregard of the instructions of use;

▪ Changes or other actions not authorized by the manufacturer;

It’s forbidden to remove or render inoperative the guards provided for the safety of persons, as well

as tampering with and / or modify, even partially, the safety devices installed on the machine. In case

of alarm due to the intervention of the safety, the operator must request the immediate intervention

of the qualied maintenance personnel.

It is forbidden to intervene on the screws marked with red or yellow tracer. The intervention

on these screws leads to a malfunction of the machine.

The manufacturer declines all responsibility in case of any damage to persons, animals or property,

caused by the tampering of the protections.

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1.3.5 PERSONAL PROTECTIVE EQUIPMENT

Safety clothing is not supplied with the machine and must be procured by the user.

In the various sections of the manual will be shown the symbols of personal protection equipment to

be in the different operations to be carried out.

Tight clothing, to avoid that they not remain hooked to protruding parts.

Long hair should be worn away from the moving machinery or in a net.

Do not wear watches or jewellery.

Eye protection against possible splashes of glue or PUR Cleaner high

temperature.

Protective Gloves

Respirator mask suitable for the use of removing used glue.

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1.4 RESIDUAL RISKS

These are the risks that cannot be completely eliminated either by protective devices or the design

of the machine.

Glue Head.

CAUTION!

Hot surfaces!

Risk of burns.

Use protective gloves.

Glue tank.

CAUTION!

Hot surfaces!

Risk of burns.

Use protective gloves.

Milling Area.

CAUTION!

The disc cutter contains several

types of cutting tools.

Use protective gloves, in case you

want to remove the roughening.

Press Area

CAUTION! Danger of crushing

between the frame and the grip.

CAUTION! Danger of crushing

on the press.

CAUTION! Hazardous moving

parts, do not attempt ngers and

other body parts.

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1.5 INTENDED USE

The machine is designed to bind books using the following materials:

▪ Signatures or single sheets of paper (printed or not) for the book block

▪ Card as book cover

The machine must be used by one operator only to the extent and in the manner prescribed in this

user manual.

Any other use is forbidden, such as:

▪ Milling / notching of book spines already bound (e.g. bound with glue, staples, stitched, seal

point);

▪ Use of materials other than those specied in the previous paragraph

▪ Operations outside of the specications of the data Sheet.

The user is solely responsible for damage to persons or property that result from improper use,

outside of the intended use.

It is forbidden to use the machine in explosive atmosphere conditions, of ammable atmosphere and

where there is excessive dust.

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2. TRANSPORT

CAUTION! For no reason the staff is authorized to pass under a suspended load

during transport or in the vicinity of it.

CAUTION! The transport phase will have to be carried out by trained competent

and authorized personnel, equipped with the necessary personal safety

protections.

The binder must be moved by means of a forklift. It can only be lifted by forking the two long sides,

the front and rear side.

For the nal positioning or for small movements a trans-pallet can be used.

The machine can be only lifted with a trans-pallets in the 2 long sides, the front and rear side.

IMPORTANT

a) Tools for clamping and lifting are not provided.

b) The disposal of packaging materials is at the recipient’s care and must be performed in

accordance with the laws in the country where it will be carried out.

c) Remove dust and external dirt accumulated during the transport phases.

3. DISPOSAL

If you decide to stop using the machine, or some part of it, the disposal and decommissioning of the

same must be carried out.

The machine must be handed to designated wasted recycling centres and disposed of according to

the country’s current regulations. Electrical and electronic parts should be disposed of in accordance

with Directive 2012/19 / EU.

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4. STORAGE

The information contained in this section shall be observed during periods of temporary storage of

the machine that may occur, eg., In the following situations:

▪ Installation of the machine immediately after its delivery.

▪ Decommission of the machine.

▪ Machine in storage.

The machine must be used by a single operator within the limits and in the manner provided in this

manual.

Conditions for Storage

Temperature range -5/+55°C

Humidity range 30/90%

Lighting Natural and / or adequate articial lighting

Weathering Adequate protection

Space required Sufcient to perform the operations of lifting and safe

transport

Location The bearing surface must have a capacity greater

than the total mass of the machine

Unused for less than 30 days Never open the glue tank otherwise it accelerates

deterioration creating serious permanent damage to

the glue application. This failure to comply will void

the warranty of the group glue.

Unused for more than 30 days Empty the system of glue and insert inside the

protective cleaner. This failure to comply will void

the warranty of the group glue.

Protect against corrosion of the parts subject to wear

and work plans. See Maintenance section.

Note Do not stand or place any object on top of the machine.

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5. GENERAL DESCRIPTION

5.1 TECHNICAL SPECIFICATIONS

Features of the machine:

Hour cycles 200 cycles / mechanical

Length of processed spine from 120 to 380 mm

Height of processed book from 110 to 320 mm

Cover size Max 700x380 / 222x120 mm

Thickness of workable book from 2 to 50 mm

Cover weight Max from 120 to 400 g / m

2

Control panel

Touch-Screen Yes

Copy Count Yes

Glue change counter Yes

Work memory Yes

Diagnosis and controls Yes

Size setting, temperature control Yes

Speed Yes

Book Loading

Vise adjustment Auto according to parameters entered by the operator

Vise unlocking Automatic electric

Vice Closure Automatic electric

Spinw preparation

Milling disc Ø 120 mm

Roughening (roughening devices) for processing

the spine

1 (double)

Brush for processing and cleaning the spine

Yes

Excludable cutter Mechanical with position control

Milling thickness Variable

Woodchip vacuum Inside the machine

Glue application system

PUR glue tank / Hot-Melt 3 Kg hermetically sealed

PUR extrusion plant/ Hot-melt Integrated and hermetic

Application head adjustment Automatic

Glue stop Touch-Screen settable

Cleaning / sealing Yes

Press

Press Electric power- assisted

Adjustment Pressing time

Mechanical adjustment

Back hit cover adjustment Auto according to parameters inserted on Touch-Screen

Cover positioning Operator manual

Dimensions weight

lenght x width x height 1770 x 910 x 1280 mm

Weight 250 Kg

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5.2 ELECTRICAL SPECIFICATIONS

Power Supply 220 ─ 230 V 50/60 Hz, 1 ~ + N + PE

Max Power Consumption 3,5 Kw

Fuse Protection By the customer, on the power supply line 16 A

Class differential protection A 300mA

5.3 PNEUMATIC SPECIFICATIONS

Ensure that the equipment and pneumatic circuits can operate reliably, efciently and safely, it is

necessary that the compressed air used to power the pneumatic system has the following quality

requirements in accordance with DIN ISO 8573-1:

▪ Quality of the supplied air CLASS 3

▪ Dust: 5 micron - 5 mg/m

3

▪ Water: -20°C - 0,88 g/m

3

▪ Oil: 1 mg/m3

The compression system air upstream of the binding machine must be of the type with dryer.

Periodically check the quality of the compressed air supplied to the machine and operating values.

Supply pressure

The pneumatic air supply of the user must ensure, to the inlet tting of the compressed air in

the binder, the following values:

▪ 7 bar;

▪ ensure a consumption of air equal to 160 Nl/min

▪ Air Quality: Class 3

Pneumatic features:

Air consumption 100 Nl/min

Gauge input 6 bar

Minimum pressure 5.5 bar

Input gauge 6 mm

The connecting pipe to the compressor diameter of 6 mm is not supplied with the machine.

We recommend a compressor with automatic condensate drain. To avoid the weekly check

of the presence of water inside the tank of the compressor.

If the compressor is placed within the company we recommend the purchase of a silent

compressor.

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5.4 PARTS IDENTIFICATION

6

7

1

2

3

4

5

8

9

10

12

13

14

11

1. Glue tank compartment access;

2. Milling unit;

3. Clamp unit;

4. Table of measurement;

5. Front left cover;

6. Press unit;

7. Glue unit;

8. Front right cover;

9. Cleaner tank compartment access;

10. Fixed empty glue cover;

11. Book holder;

12. Rear cover;

13. Serial plate;

14. Pneumatic unit.

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5.4.1 CLAMP UNIT (3)

3a. Rear book support

3b. Front book support

3c. Moveable clamp

3d. Stop glue sensor

5.4.2 MILLING UNIT (2)

2a. Milling guard

2b. Milling tool

2c. Notching & roughening

5.4.3 GLUE UNIT (7)

7a

7b

7a. Glue head

7b. Waste collector

6a

5.4.4 PRESS UNIT (6)

6a. Square Adjusters

3a

3b

3c

3d

2c

2a

2b

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5.4.5 GLUE & CLEANER TANKS

15

15a

15. Cleaner tank;

15a. Opening/Closing knob;

16a. Air valve tap (glue);

16a

16b

16

16c

16. Cleaner tank;

16b. Opening/Closing knob;

16c. Handgrip;

16d. Serial label.

5.4.6 WASTE VACUUM

The extractor is contained in the left side of

the binder and is electrically connected to it.

Upon delivery of the binder, the extractor is ready,

and connected both electrically and mechanically

(suction tube), turns on and off simultaneously

with the cutter.

CAUTION! Max power

absorbable by the socket

1,2 Kw.

16d

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MyBinding Morgana DigiBook 200 User manual

MyBinding Morgana DigiBook 200 User manual

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