Morgana DigiBook 150r1 Operator's Manual

Rev. 1.00-C
K.G.S. srl
DigiBook 150r1
Operators Manual
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Summary
1 INTRODUCTION ________________________________________________________ 4
1.1 CE MARK __________________________________________________________________________ 5
1.2 SAFETY SIMBOLS __________________________________________________________________ 6
1.3 SYMBOLS OF PROHIBITION AND OBLIGATORINESS ___________________________________ 7
1.4 THE SAFETY DURING THE USE OF THE MACHINE _____________________________________ 8
1.4.1 General ________________________________________________________________________ 8
1.4.2 Safety warnings ________________________________ __________________________________ 8
1.5 SAFETY CLOTHING_________________________________________________________________ 9
1.6 INSTALLATION OF ELECTRICAL CABLES AND HOUSES _______________________________ 10
1.7 SAFETY EQUIPMENTS IN THE MASTER BOOK ________________________________________ 10
1.7.1 Emergency button _______________________________________________________________ 10
1.7.2 Green button To start cycle ________________________________________________________ 11
1.7.3 Protection plate of the milling station ________________________________________________ 11
1.7.4 Main Switch ____________________________________________________________________ 12
1.8 RESIDUAL RISKS __________________________________________________________________ 13
1.9 PURPOSES ________________________________________________________________________ 14
1.9.1 Not provided uses, prohibited uses __________________________________________________ 14
2 TECHNICAL SHEET FOR MASTERBOOK 150 ____________________________ 15
2.1.1 Electrical ______________________________________________________________________ 16
2.1.2 Pneumatics _____________________________________________________________________ 16 Air quality provided to the Master Book _____________________________________________________ 17 DIN ISO 8573-1 – air quality class _________________________________________________________ 17
3 STANDARD ACCESSORIES ______________________________________________ 18 4 TRANSPORTATION ____________________________________________________ 19 5 STORAGE ______________________________________________________________ 20 6 LAYOUT _______________________________________________________________ 21 7 POSITIONING AND WORKSPACES ______________________________________ 22 8 INSTALLATION ________________________________________________________ 23
8.1 TECHNICAL STAFF FOR THE INSTALLATION _________________________________________ 23
8.2 PHYSICAL CHARACTERISTICS OF THE AREA OF PLACEMENT _________________________ 23
8.3 BOLSTER _________________________________________________________________________ 23
8.4 WEATHER PROTECTION ___________________________________________________________ 23
8.5 LIGHT ____________________________________________________________________________ 23
8.6 ENVIRONMENTAL CONDITIONS ____________________________________________________ 24
8.7 ELECTRICAL CONNECTION ________________________________________________________ 25
8.7.1 Ground connection _______________________________________________________________ 25
9 TRAINING OF THE OPERATOR _________________________________________ 26 10 POWER ON ____________________________________________________________ 27
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10.1 FUNDAMENTALS _________________________________________________________________ 28
10.2 ELECTRICAL CONNECTION _____________________________________________________________ 30
10.3 PNEUMATIC CONNECTION _____________________________________________________________ 30
10.4 GROUPS DESCRIPTION ________________________________________________________________ 31
10.5 CHIPS ASPIRATOR ____________________________________________________________________ 34
10.6 PUR TANK OPENING AND CLOSING. GLUE LOADING. __________________________________________ 35
10.6.1 Opening of the PUR tank __________________________________________________________ 35 WARNINGS ON THE OPENING OF PUR TANK ______________________________________________ 35
10.6.2 Preparation and loading of the pur glue ______________________________________________ 37
10.6.3 Cleaner loading _________________________________________________________________ 39
11 FUNCTIONS OF MASTER BOOK _________________________________________ 41 12 PREPARATION OF THE MACHINE TO PRODUCE A BOOK. ________________ 53
12.1 GLUE REFURBISHMENT PROCEDURE _______________________________________________ 53
13 COVER POSITIONING __________________________________________________ 55 PREPARATION OF THE MACHINE TO MANUFACTURE A BOOK. _____________ 57
13.1 STARTING THE MACHINE __________________________________________________________ 58
14 BOOK SPINE PREPERATION ____________________________________________ 61
14.1 PREPERATION OF LARGER BOOKS ________________________________________________________ 62
14.2 CHANGING THE NOTCHING TOOL HEIGHT __________________________________________________ 63
15 CLEANING THE MACHINE _____________________________________________ 64
15.1 END OF JOB CLEANING ______________________________________________________________ 65
15.2 PROCEDURE TO CLEAN THE SPINE GLUE EXTRUDER. __________________________________________ 66
15.3 PROCEDURE TO CLEAN THE GLUE SIDE EXTRUDERS. _________________________________________ 69
15.4 DETAILS CLEANING _________________________________________________________________ 72
16 PROBLEMS - SOLUTIONS _______________________________________________ 75
16.1 CHIPS ASPIRATOR LESS VACUUM: _________________________________________________ 75
16.2 CLAMP IT DOESN’T START: ___________________________________________________________ 75
16.3 MILLING STATION IRREGULAR CUT AND NOTCHING: ____________________________________ 75
16.4 COVER PLATE MILLING STATION IT DOESN’T OPEN / CLOSE CORRECTLY: _________________ 75
16.5 HEAD - OUT OF TOO MUCH OR LITTLE GLUE: _________________________________________ 75
16.6 NIPPING STATION _________________________________________________________________ 75
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1 INTRODUCTION
THE READING OF THIS OPERATOR AND MAINTE­NANCE MANUAL IS FUNDAMENTAL FOR THE SAFETY OF THE USER AND FOR THE PROPER USE OF THE EQUIPMENT.
We thank you to have bought our product. This machine has been designed specifically for your job and your applications with the help of a single worker, provides a high quality production and a wide range of functions. This manual describes how to use the machine, starting from the configuration phase to the most important operations. This manual has been written in order to be easily understood also by user not trained about the use of this kind of machine. For the best use of the equipment, please read careful­ly this manual before to use the machine. After reading, we suggest you to save the manual in a safety place and don’t hesitate to read him when necessary.
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1.1 CE MARK
DICHIARAZIONE DI CONFORMITÀ CE
CE CONFORMITY DECLARATION
DIRETTIVA CE PER MACCHINE 2006/42/CE,
DIRECTIVE FOR MACHINES 2006/42/CE,
E SEGUENTI DIRETTIVE EUROPEE (ALLEGATO IIA)
AND FOLLOWING EUROPEAN DIRECTIVES (ANNEX IIA)
COSTRUTTORE, MANUFACTURER: K.G.S.SRL Via Donizetti 5 – 20090 Assago (Mi) 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 : PERFECTBINDER MASTERBOOK 150 MATRICOLA / SERIAL : MB150-XXXX ANNO DI COSTRUZIONE / MANUFACTURED IN 2013
CORRISPONDE ALLE SEGUENTI DISPOSIZIONI NELLA VERSIONE ATTUALMENTE VALIDA / IS IN AC­CORDANCE WITH THE FOLLOWING DIRECTIVES AS IT IS :
Direttiva CE per Macchine 2006/42/CE / Directive 2006/42/CE Direttiva EMC 2004/108/CE / EMC Directive 2004/108/CE Direttiva sulla Bassa tensione 2006/95/CE / Low Voltage Directive 2006/95/CE
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
Assago , (MI) Italy __/__/2013
Dott. Marco Alfredo Tumaini Amministratore unico
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1.2 SAFETY SIMBOLS
In the manual some symbols are used to inform about dangerous situations for people and/or things.
The following symbols mean dangerous situations for people and/or things.
If you don’t follow carefully the appropriate procedures, damages can occur to people and/or things,
and in extreme situations also fatal accidents. Together with the symbols it is written also what to do.
Attention – General danger!
Attention – Electrical voltage! Risk of electric shock.
Attention – Sharp blades! Risk of cut.
Attention – Hot surfaces! Risk of burn.
Attention – Risk of rolling parts! Risk of crushing.
Attention – Risk of moving chain! Risk of crushing.
In case of not warning of the symbols damages, also great, can happen to the machine and to the accessories.
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1.3 SYMBOLS OF PROHIBITION AND OBLIGATORINESS
This symbol means a prohibition.
This symbol means an imperative.
This symbol means that it is mandatory to read in this manual information re­garding specific topics (for ex. related to the specifications of the electric and pneumatic connection).
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1.4 THE SAFETY DURING THE USE OF THE MACHINE
1.4.1 GENERAL
The manufacturer guarantees that the contents of this manual are in specification with the proce­dures required by the machine. The manufacturer therefore will be not responsible if the machine will be used in a different way.
1.4.2 SAFETY WARNINGS
Before the use of the machine, please read carefully the manual. Save the manual for further needs.
By apply different procedures, and not the specific procedures described in the manual, can produce operational problems. Please, read carefully the following safety rules.
It is forbidden to use the machine when occurs one of the following situations: in explosive environment; in flammable atmosphere; in excessive dusty environments.
Danger! Failure to comply with some or all the instructions listed in this manual could cause damage to the machine and / or personal injury. The manufacturer is not re­sponsible for an arbitrary and improper use of the machine such as: Using the machine by untrained personnel; Use contrary to law; Incorrect installation; Defects in electrical power and / or pneumatic; Partial or total failure to comply with the instructions; Lack of maintenance and / or use of aftermarket parts; Changes or other actions not authorized by the manufacturer;
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1.5 SAFETY CLOTHING
Clothing to use during the cleaning and /or maintenance operations
Eye protection against any spray of PUR glue or high temperature cleaner
Respiratory mask suitable for the glue you are using
Protective gloves
Tight clothing, to avoid that they remain engaged with protruding parts. Long hair must be covered or otherwise collected by using e. g. a protective screen. Do not wear watches or jewelry.
Safety clothing
The safety clothing IS NOT INCLUDED in the machine and must be pro­cured by the machine user.
The operator should wear clothing appropriate to the situation and special­ly during the following operations:
-Maintenance
-Replacing of the PUR glue
-Cleaning of the PUR system
a) Eye protection against any spray of PUR glue or high temperature cleaner
b) Respiratory mask suitable for the glue you are using.
c) Protective gloves for high temperature
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1.6 INSTALLATION OF ELECTRICAL CABLES AND HOUSES
Cables and houses must be put inside of special cable channels to avoid the people to stumble and get hurt.
1.7 SAFETY EQUIPMENTS IN THE MASTER BOOK
DANGER! It is forbidden to remove or render ineffective the safety guards for the
safety of persons, and to tamper and / or modify, even partially, safety devices in­stalled on the machine. In case of alarm signals due to the intervention of the safe­ty, the operator must request the immediate intervention of technical people trained on the maintenance. The manufacturer is not responsible of any damage to persons or animals caused by tampering with the guards."
1.7.1 EMERGENCY BUTTON
It is located on the front, easily accessible from the operator's position.
In the diagrams the emergency button is identi­fied SB20.01
. ACTIVATION of emergency state: the push­button must be pressed
OFF state emergency stop: the button must be turned clockwise"
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1.7.2 GREEN BUTTON TO START CYCLE
The two front green buttons execute the com­mand to start cycle, it means that the clamp closes and moves to the right, the mill will run the cut, the glue will be applied, and if the press has been activated will crush the book; all this happens if I put the book block in the clamp and place a cover on the press.
1.7.3 PROTECTION PLATE OF THE MILLING STATION
The plate consists of a mobile plate that, except when the book block is moving, covers the cutter in all operating conditions, even at a standstill
A spring exerts a constant force on the plate a force that covers the mill disc. The motor of the cutter is equipped with a brake.
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1.7.4 MAIN SWITCH
It is located on the right side of the machine.
Position OFF
The switch is open. The machine is off.
Position ON The switch is closed. The machine is on.
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1.8 RESIDUAL RISKS
There are risks that cannot be completely eliminated by either protective or as designed by the ma­chine.
Area of the glue head.
Attention – Hot surfaces! Risk of burn. Use protective gloves.
Area of glue loading.
Attention – Hot surfaces! Risk of burn. Use protective gloves.
Area of the mill.
The disc contains several types of milling cutters. Use protec­tive gloves, in case of remov­ing the Notching Roughening or the brush.
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1.9 PURPOSES
The machine is used to bind books using the following materials:
a) Signatures, or sheet of paper (printed or not) for the block book
b) Cardboard as cover of the book
within the limits specified in the data sheet, included in this manual.
1.9.1 NOT PROVIDED USES, PROHIBITED USES
Any other use such as,
- Milling / Roughening of book spines already bounded (adhesive binder, stitching book, sewing book, etc.)
- Use of materials other than those specified in a) and b)
- Operations beyond the technical specifications are not to be re­garded as intended use.
The user has the total responsibility of the damages to people or things due to an improper use, outside of their intended use.
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2 TECHNICAL SHEET for MasterBook 150
Machine features:
Cycle/Hour 150 cycles Spine length from 120 to 380mm Workable height of the book from 110 to 320mm Max. Cover size 700x360/222x120 mm Workable thickness of the book from 2 to 50mm Max. Cover Weight from 120 to 400 g/m2
Control Screen
Touch - Screen Yes Copy Counter Yes Diagnostic and Check Yes Setting size, temperature control Yes Speed Yes
Book Loading
Adjustment of the clamp Manual Clamp opening/closing Manual
Spine preparation
Milling disks Ø 110 mm (optional) Roughening for spine processing 2 Chips aspirator Included in the machine
Glue application system
Tank PUR/Hot-Melt glue 3 Kg sealed Extrusion system of PUR/Hot-melt integrated and sealed Extrusion head adjustment Manual Glue stops Adjustable by Touch-Screen Cleaning / sealing Yes
Press:
Press Electric (servo-controlled) Adjustment Pressing time
Mechanical Adjustment
Cover back bar adjustment Manual Cover loading Hand made by the operator
Dimensions / Weight
Length 1400 mm Width 880 mm Height 1270 mm Weight 210 Kg
Power consumption
Electrical power Max. 4Kw Power grid 220 V ±5%, 50/60 Hz
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2.1.1 ELECTRICAL
Electrical power 220 V ±5%, 50/60 Hz
Power of the machine
Protection fuses on the power network are duties of the customer
Distribution cabinet, customer side
16 A Differential protection class A 300mA
2.1.2 PNEUMATICS
Supply pressure
The pneumatic system of the user must ensure, in the inlet connection of the compressed air in the perfect binder, the following values: Min.: 7 bar air consumption: 160 Nl/min
air quality: Class 3
Pneumatic characteristics for the machine Compressed air consumption
100 Nl/min
Calibration of input gauge
6 bar
Min. working pressure
5.5 bar. If the pressure value falls below this value the machine enter in an “alarm” condition
Diameter of air inlet
6 mm The 6 mm diameter house for the connection to the compressor is not provided together with the machine.
It is suggested the use of a compressor equipped with the automatic condensate drain, to avoid verifying weekly if there is some water inside the compressor. It is suggested to use a silenced compressor, if the compressor is located inside the working plant.
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Air quality provided to the Master Book CLASS 3, DIN ISO 8573-1 Durst: 5 micron - 5 mg/m
3
Water: -20°C - 0,88 g/m
3
Oil: 1 mg/m
3
The compressed air system upstream of the machine must be equipped with a dryer.
Periodically check the quality of the compressed air supplied to the machine and the operating values .
AIR QUALITY PROVIDED TO THE MASTER BOOK
To make work the pneumatic devices in an affordable, efficient and safe way, the compressed air supplied to the pneumatic device must have the following quality features: Pressure, Quantity, Water content, Solids content, Oil content.
DIN ISO 8573-1 AIR QUALITY CLASS
The manufacturers of pneumatic components refer to the quality of compressed air to be used on their products, referring to the table below
The compressed air used in the industry contains water, oil, dust and other impurities. The interac­tion of these elements produces an aggressive mixture that can damage the compressed air devices and also the PUR glue contained in the PUR tank, the results will be a low quality production and increased maintenance costs.
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3 STANDARD ACCESSORIES
The standard composition includes:
Cleaning Kit Start- up Kit
CLEANING KIT
Polizene green spatula (to remove excess glue or cleaner) Steel Wire Ø0.4 (for cleaning the channels of leakage of the lateral glue) Lamella thickness of 0.4 (for cleaning the slit of leakage of the spine glue) Spare Headless screws for the closure of the ducts Protective gloves Set of allen keys Small arches for supporting the book block in the clamp
START-UP KIT
One pack of 2 kg of PUR Glue Henkel One pack of 2 litres of beans Cleaner-Blue Henkel
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4 TRANSPORTATION
The Master Book must be handled by a heaver. It can be got ONLY along the 2 long sides, front and rear side. For the final positioning or small movements can be used a trans-pallet. The machine can be raised by trans-pallet only in the 2 long sides, front and rear.
DANGER! For no reason the staff is authorized to pass under a suspended load during transport or in the proximity of. The producer is not responsible for what happens during this operation, to be carried out by qualified and authorized per­sonnel, with the necessary individual safety protections (suit, shoes, gloves, hel­met and glasses).
Attention! The machine is balanced. In any case keep the forks low. In case of unbalance use weights. It is forbidden to hold by the hands the project­ing parts. The machine and its parts must be protected from the weather outside. In particular, water, dust and moisture can oxidize certain elements of the machine, damaging them irreversibly. Follow the usual precautions to avoid falls and bumps.
IMPORTANT
a) We do not provide tools for docking and lifting.
b) The disposal of packaging materials will be provided by the recipient and must be conducted in accordance with the local regulations.
c) Remove dust and dirt accumulated during the transportation.
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5 STORAGE
The information contained in this section must be observed in case of temporary storage of the ma­chine that may occur in the following situations:
installation of the machine not immediately after its delivery.uninstalling the machine.storage awaiting a new location.
The machine must be stored and transported under conditions of SAFETY as shown in the table be­low.
Conditions of transportation and storage
Temperature average
-5/+55°C
Humidity average
30/90%
Lighting
Adequate natural and / or artificial
Weather
Adequate weather protection
Space required
Adequate to allow the operations of lifting and carrying in SAFETY.
Horizontal bolster
Horizontal bolster must have a capacity in excess of the total mass of the machine.
In the case of removal or unused for long peri­ods (over 30 days), it is necessary to drain the glue system and to put inside the protection cleaner.
The damage caused by this failure will void the warranty of the glue device.
During periods of downtime you should not open the tank containing the glue, otherwise it accelerates the deterioration creating serious permanent damage to the glue device.
The damage caused by this failure will void the warranty of the glue device.
Protect with anti-corrosive products the parts sub­ject to wear and work plans. Ref. to the section “maintenance”.
Do not climb or place any objects on top of the machine
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6 LAYOUT
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7 POSITIONING AND WORKSPACES
Positioning The Master Book must be positioned so as to have a clear space around of at least 80 cm, and around the work area at least 150 cm. The room where the machine is installed must be properly ventilated with air change according to law
Workspaces
Glue loading area
Glue loading area, the operator enter in this area to load the glue in the machine. Access area for the maintenance, for access to the electrical and pneumatic panel.
Transit area
Used to transit from the work area to the glue loading area.
Operator’s work area
Operator’s work area during the normal use of the machine.
Right side of the machine
It is not necessary to leave an available space
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8 INSTALLATION
8.1 TECHNICAL STAFF FOR THE INSTALLATION
The machine must be installed by people specifically trained and authorized by K.G.S. .
8.2 PHYSICAL CHARACTERISTICS OF THE AREA OF
PLACEMENT
In addition to the overall dimensions of the machine given in the previous chapter, you must also meet the following conditions:
Near the area of placement of the machine should be arranged the sources of electric power and pneumatic following what is written in this manual. Provide sufficient space for normal use, maintenance of machinery, for any command and for addi­tional equipments to connect. Refer to the draft in the chapter of the positioning.
The chosen site should not be close to deposits of flammable materials, or to operational sites that may create flammable or explosive atmospheres. For the installation you must choose an operational area depending on the size of the machine parts and lifting equipment selected and pay attention to the presence of any obstacles on the road (equipments, walls, etc.).
8.3 BOLSTER
The machine requires no special foundations. It must be ensured the availability of an industrial floor. The producer has no responsibility about construction of foundations (resistance calculation, thick reinforced concrete, etc.), which are under responsibility of the customer or company performing the design and construction of the foundations themselves. The Master Book rests on four feet of 100 mm diameter.
8.4 WEATHER PROTECTION
The machine must be placed indoor, protected from direct contact with atmospheric agents.
8.5 LIGHT
To use and maintain in a safety way the machine a good light is needed. The room lighting should have a value that should allow normal operations without causing risks to the shadows.
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