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Morgana DocuMaster MFC, Service Manual

Introducing the Morgana DocuMaster MFC, a cutting-edge document processing solution. Unlock the full potential of your machine with our comprehensive Service Manual. Download it for free from our manualshive.com to access step-by-step instructions, troubleshooting tips, and maintenance guidelines. Maximize productivity with the ultimate manual companion for your Morgana DocuMaster MFC.

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4. Service Procedures - Diagnostic Procedures

58 

Morgana DocuMaster MFC - Service Manual

If the yellow light will not turn on, the replacement sensor or the bin control PCB is 
defective. Replace the bin control PCB (see Section 4.8.7).

4.4.4

Test a Feed Bin Clutch Assembly

Drive Pin

Clutch Shaft

Figure 4.23 

Clutch Shaft And Drive Pin

If a feed bin clutch is defective it can cause feed errors to occur. 

•

If the clutch does not operate or the drive bin is broken, the sheets will not feed.

•

If the clutch drags when it is turned off, double, trailing or stream-feed errors can 
occur.

To do a manual check of an individual feed bin clutch and drive system use the 
procedure that follows.

Before you start:

•

Remove the RH side covers (See Section 4.2.5)

•

Select ‘cleaning mode’ (See Section 4.13.2).

 

Warning: 

Use extreme caution not to touch live circuits when the MFC is turned on.

Step

Action

Information

1

Press the red ON/OFF button on 
the feed bin control switch and 
then release it.

(See Figure 4.22).
When you press the red button the 
feed bin control PCB sends an output 
signal to the feed clutch. This will 
make the feed head or feed shaft 
turn. When you release the red 
button the feed bin control PCB stops 
the output signal and the feed head 
or feed shaft will stop.

•

If the feed head or feed shaft 
does not turn, go to Step 2.

•

If the feed head or feed shaft 
does not stop, or turns constantly 
when the conveyor operates, 
replace the feed clutch (see 
Section 4.8.3) or (see Section 
4.9.2).

2

Do a check that the feed head or 
feed shaft is installed on the clutch 
shaft correctly.

(See Section 4.8.2.3) Replace the 
suction feed head.
(See Section 4.9.1.1) Remove the 
feed shaft.

3

Do a check that the drive pin in the 
clutch shaft is not broken.

(See Figure 4.23).

•

Replace the drive pin if it is 
broken.

Summary of Contents for DocuMaster MFC

Page 1: ...rgana Systems Limited United Kingdom www morgana co uk Tel 44 0 1988 608888 Fax 44 0 1988 692399 DocuMaster MFC Service ManuaI Multi Feed Crease Bookletmaking System Part Number 190 98 Issue 1a April 2013 ...

Page 2: ...lation without prior written permission is prohibited except as allowed under the copyright laws Morgana Systems Limited shall not be liable for errors contained herein or for incidental or consequential damage in connection with the furnishing performance or use of this material ...

Page 3: ...ems 22 2 1 5 Suction Feeder Problems 23 2 1 6 Friction Feeder Problems 24 2 1 7 Creaser Module Problems 26 2 1 8 Gathering Area Problems 28 2 2 Paper Jams 29 2 3 Error Message List 31 SECTION 3 Output Quality Problems 3 1 Crease Quality 36 SECTION 4 Service Procedures 4 1 Introduction 40 4 1 1 Test Material 40 4 1 2 Calibration Stock 40 4 1 3 Test Strips 40 4 2 Covers 41 4 2 1 Remove the CAP Rear ...

Page 4: ... 5 15 Adjust the DynaTilt Motor Gear Play 77 4 5 16 Adjust the DynaTilt Home Switch 79 4 5 17 Adjust the Crease Pressure 82 4 5 18 Calibrate the Creaser Module 83 4 5 19 Adjust the Jam Detector 91 4 5 20 Adjust the Edge Sensor Set Sensitivity 92 4 5 21 Calibrate the GUI Panel 95 4 5 22 Adjust the GUI Screen Display 95 4 5 23 GUI Access Levels 96 4 5 24 Configure the MFC Machine Options 97 4 5 25 C...

Page 5: ...0 12 Replace the DynaTilt Home Switch 165 4 10 13 Replace the Creaser Blade Out Switch 166 4 11 Replace Components Gathering Area 167 4 11 1 Replace the Tamper Solenoid 167 4 11 2 Replace the Paper Stop Solenoid 168 4 11 3 Replace the Flow Sensor 168 4 11 4 Replace the Ioniser Bar 170 4 11 5 Replace the Base Control PCB 171 4 12 Replace Components Electrical Cabinet 173 4 12 1 Replace the Processo...

Page 6: ...6 7 6 The Review Save Setting Page 210 SECTION 7 Electrical and Control System 7 1 Fuses 214 7 1 1 MFC Fuses 214 7 2 Low Voltage Transformer Tappings 215 7 2 1 Low Voltage Transformer Input 215 7 2 2 Low Voltage Transformer Output 216 7 3 PCBs 217 7 3 1 Windjammer Control PCB 217 7 3 2 Interface PCB 217 7 3 3 Motor Drive PCB 218 7 3 4 Suction Feed Bin Control PCB 219 7 3 5 Friction Feed Bin Contro...

Page 7: ...Control Software 246 7 8 4 Update the Creaser Control Software Replace the Processor PCB 246 7 9 GUI CPU Error Beeps 247 7 10 PC Configuration Problems 248 7 10 1 Install Hyperterminal on a Vista or Windows 7 Operating System 248 7 10 2 Setting the Network Port Number Range Vista and Windows 7 248 SECTION 8 Installation Manual 8 1 Before Installation 252 8 2 Unpack the MFC 253 8 2 1 Unload the MFC...

Page 8: ...CONTENTS vi Morgana DocuMaster MFC Service Manual ...

Page 9: ...Morgana DocuMaster MFC Service Manual 1 1 SECTION 1 Introduction ...

Page 10: ...acking of substrates and printed images when they are stapled and folded The DynaTilt mechanism registers each sheet and automatically adjusts the creaser blade set so that it is perfectly square to the sheet An integral static elimination system neutralises any charge present in the fed sheets before they enter the gathering station in the base of the machine When a complete set book has been gat...

Page 11: ...C Service Manual 3 1 Introduction Safety 1 1 2 Safety Follow good Health and Safety procedures when you lift or move the equipment If the machine is operated when the covers are removed be careful to prevent personal injury ...

Page 12: ...ollow are used in this manual Warning a WARNING message tells you that a procedure or operation can be dangerous To prevent injury you must obey the instructions Caution a CAUTION message tells you that a procedure or operation can damage the machine to prevent damage you must obey the instruction ...

Page 13: ...n bar and white background Hinged rear panel above the rear guard Shows that mains input voltages are present Black figure on a yellow background Mains input and areas with high voltage supply Shows that high voltages are present Black text on yellow background High voltage Anti static transformer Shows high voltages behind cover Black figure on a yellow background Hinged top panel Shows protectiv...

Page 14: ...s refer to the right hand RH or left hand LH side of the machine see Figure 1 1 The RH or LH is as seen from the feed bins Front The GUI touch screen is at the left The conveyor is at the rear Rear RH Side LH Side Emergency Stop Switch BookletMaker GUI Touch Screen Front Figure 1 1 DocuMaster MFC Orientation ...

Page 15: ...s that must be removed when included in a service procedure Warning Be careful to avoid serious injury if you are working on the MFC when the fixed covers are removed The user access covers are the rear guard input guide The fixed covers are the hinged top panel hinged front panel hinged rear panel motor cover electrical cabinet cover LH side covers RH side covers CAP rear panel gathering area cen...

Page 16: ...Figure 1 2 MFC Main Input Switch The main input switch controls the supply of electrical power to the MFC The switch has two positions Position Status Information 0 OFF The switch stops the supply of electrical power to the MFC I ON The switch starts the supply of electrical power to the MFC Warning Always remove the main power cord from the MFC when you work on the CAP DRV and electrical cabinet ...

Page 17: ... drive system when the emergency stop switch is pushed in These systems do not operate when the emergency stop switch is pushed in the conveyor drive the creaser conveyor drive the creaser mechanism 1 7 3 The Rear Guard Figure 1 4 Rear Guard The rear guard interlock removes the drive signal when the rear guard is removed from the MFC These systems do not operate when the rear guard is removed the ...

Page 18: ... air cooling operated by a thermostat sensor The cooling fan will continue to operate after the MFC has stopped until the internal temperature is below 50 C 2 The DRV Drive Unit The DRV module includes the main drive motor and electronics necessary to control the MFC feed system It also includes the high voltage anti static transformer that operates the ioniser bar in the sheet gathering area The ...

Page 19: ...n Note The friction feed bin must always be positioned directly above the creaser module where it can be used to insert heavier weight cover stocks up to 300gsm An alternative configuration that is available upon request is 4 suction feed bins Note This configuration would normally be used if a customer s stocks were unsuitable for a Friction feed system and if he only used stocks up to 240gsm 5 T...

Page 20: ...athering area gives full setup and control of the booklet making system from the GUI and will stop the MFC if a bookletmaker error is sensed 7 The Electrical Cabinet The electrical cabinet is located at the rear of the gathering area base and it houses the electrical control system for the creaser module and MFC drive system Note The high voltage AC power supply to the electrical cabinet is from t...

Page 21: ...d and sends the master timing PWM Pulse Width Modulation signal to the CPU The CPU sends instructions through the Data bus communication line These are received and stored by each of the feed bin control pcbs The feed bin control pcbs are connected in parallel with their own unique address When the CPU sends a feed trigger each bin will feed at the correct time because they all use the PWM signal ...

Page 22: ...hen a Test Set is complete the MFC is ready to run 1 9 2 The Paper Feed The MFC conveyor is run from a DC stepper motor in the DRV module The primary drive train is located on the LH side of the MFC A toothed timing belt connects between the main drive motor and the drive shaft of the top feed bin A staggered sprocket and chain system transfers the drive from feed bin to feed bin down to the gathe...

Page 23: ... the conveyor The feed clutch engages drive to the feeder belt and stays on for the entire sheet length 30mm which stops pre feed of the sheet below it When the front edge of the sheet is calculated to have moved past the emitter sensor by 15 2mm the feed bin senses for a miss or double error If a miss or double error is sensed the feed bin control PCB will send an error signal to the MFC CPU The ...

Page 24: ...nveyor and the creaser drive rollers must stop when the paper is creased When a sheet of paper enters the creaser module it moves through an array of edge sensors that are positioned across the width of the conveyor The MFC will use only two pairs of sensors at a time Which sensors are used is set by the sheet width value entered by the user on the GUI panel Pressure Adjuster Input Rollers Output ...

Page 25: ...tic electric charge on the paper as it moves into the gathering area Sheets of paper with a static charge will stick together and will not stack or jog into a tidy book A high voltage transformer in the DRV module is connected to the static elimination bar by an insulated cable and is turned on when the MFC main input switch is in the ON I position Figure 1 9 The A4 Pinch Drive Control Levers Pape...

Page 26: ...ce cable from the bookletmaker is connected directly to the gathering area control PCB which gives communications between the MFC and bookletmaker Figure 1 10 Gathering Area Interface Sockets A reed switch sensor above the paper stop latch detects the paper in the gathering area If the sensor detects paper at the end of the release sequence the paper stop latch will remain open and the MFC will sh...

Page 27: ...Morgana DocuMaster MFC Service Manual 19 2 SECTION 2 Error Conditions ...

Page 28: ...e the main input switch The main input switch is illuminated but LED1 on low voltage transformer is not illuminated Fuse F6 is defective Replace the fuse see Section 7 1 1 The main input switch and LED1 on the low voltage transformer are illuminated but the GUI CPU does not start Fuse F1 is defective Replace the fuse see Section 7 1 1 The Interface PCB is defective Replace the interface PCB see Se...

Page 29: ...les for short circuits F2 Fuse fails when the MFC is turned on Interface PCB is defective Replace the interface PCB see Section 4 7 5 BIN reset error problems Bad earth connection Check all earth connections earth plates and module fixing screws Electrical noise from a defective static elimination system Check the static elimination system see Section 4 4 2 Electrical noise from defective electric...

Page 30: ...fective Replace the motor drive PCB see Section 4 7 6 The blower motor is defective Replace the blower motor see Section 4 6 2 The 20 way cable is defective Replace the 20 way cable The blower motor starts at full speed when the MFC is turned on The motor drive PCB is defective Replace the motor drive PCB see Section 4 7 6 Problem Cause Solution The GUI panel touch screen is difficult to use The G...

Page 31: ...unprinted margin on the lead edge of the sheets and the printed image causes false errors Advise the customer to reprint the job The sensor position is not set to read in the unprinted margin on the lead edge of the sheet See MFC User Operating Instructions Manual Too many double feeds occur The feed head separation is not set correctly Increase the feed head sheet separation see MFC User Operatin...

Page 32: ... 4 The tray lift motor assembly is defective Replace the tray lift motor assembly see Section 4 8 4 The MFC shows a Tray Lift Error message The tray lift motor assembly is defective Replace the tray lift motor assembly see Section 4 8 4 The paper tray will not go down A lower paper guide is not clipped on to the tie bar which stops the paper tray Check the lower paper guides The paper tray shows e...

Page 33: ...y pressure is not set correctly Adjust the tray pressure see MFC User Operating Instructions Manual The feed clutch is defective causes clutch drag Replace the feed clutch see Section 4 9 2 There was bad Test Set Do a Test Set see MFC User Operating Instructions Manual Too many miss feeds occur The separator pressure is not set correctly Adjust the separator pressure see MFC User Operating Instruc...

Page 34: ...aded sensor see Section 4 9 5 The feed bin control PCB is defective Replace the feed bin control PCB see Section 4 9 3 Problem Cause Solution Problem Cause Solution The main drive motor does not start There is no power to the high power stepper PCB Check the power supply to the high power stepper PCB Replace a PSU see Section 4 12 6 or see Section 4 12 7 The high power stepper PCB is defective Rep...

Page 35: ...edge sensor is dirty Clean the edge sensor set see Section 4 13 4 The crease blade set cycles constantly There is no input from the creaser position sensor to the controller PCB Check the creaser position sensor cable connections Replace the creaser position sensor assembly see Section 4 10 7 The DynaTilt mechanism goes out of position The DynaTilt home switch is not set correctly Check the DynaTi...

Page 36: ...stop in the gathering area The paper stop does not close Check the paper stop solenoid mechanism see Section 4 11 2 The flow sensor is defective Replace the flow sensor see Section 4 11 3 The sidelays do not tamp the sheets The tamper solenoid is defective Replace the tamper solenoid see Section 4 11 1 The base control PCB is defective Replace the base control PCB see Section 4 11 5 ...

Page 37: ...wheels are defective Replace the outer conveyor wheels see Section 4 8 11 or see Section 4 9 6 The inner conveyor wheel is defective Replace the inner conveyor wheel see Section 4 8 12 CREASER MODULE A sheet has jammed in the input rollers The paper is curled Roll the paper to remove the curl Advise the customer to use better paper review the printing process The paper has hit the blade set The bl...

Page 38: ...the static elimination test see Section 4 4 2 The sheets do not exit the gathering area The Paper stop solenoid is defective Replace the paper stop solenoid see Section 4 11 2 The gathering area sidelays are set to tight Adjust the gathering area sidelays see MFC User Operating Instructions Manual The online bookletmaker sheet width is set incorrectly Adjust the sheet width see MFC User Operating ...

Page 39: ...eyor See MFC User Operating Instructions Manual BIN lift error The suction feed bin tray has failed to lift up to the feed position BIN miscal There has been a data error on the Test Set Do a test set BIN miss The feed bin did not feed a sheet See MFC User Operating Instructions Manual BIN overload The tray lift motor on the suction feed bin has stalled Press the emergency stop switch and allow 10...

Page 40: ...he START button Cannot start width axis changing The width axis in the online bookletmaker is moving Allow the axis to set its position then touch the START button Creaser Error 1 The sheet was shorter than expected Check the sheet length is correct Creaser Error 2 The sheet was longer than expected Check the sheet length is correct Creaser Error 3 Job data queue overflow There were too many sheet...

Page 41: ... zerox PCB has been removed or is defective Check the zerox PCB see Section 4 7 5 Power fail The mains supply has been interrupted Turn MFC off and then on again PSU voltage error There is a voltage error See Section 7 2 1 The Interface PCB is defective See Section 4 7 5 Rear cover open The rear guard has been removed See Section 4 2 7 The rear guard interlock switch is not set correctly See Secti...

Page 42: ... error A suction feed bin tray has not lifted If the tray is up Press the emergency stop switch and allow 10 seconds before you release it If the tray is fully down Check that the tray lift motor pinion is engaged with the tray lift quadrant See Section 4 8 4 Trim bin full The trimmer waste bin on the online bookletmaker is full Empty the trimmer waste bin on the online bookletmaker Trim guard ope...

Page 43: ...Morgana DocuMaster MFC Service Manual 35 3 SECTION 3 Output Quality Problems ...

Page 44: ...Clean the edge sensor set see Section 4 13 4 The DynaTilt mechanism is defective Check the DynaTilt home sequence see Section 4 5 16 Check the DynaTilt home switch input on the creaser controller PCB see Section 7 3 8 Check the DynaTilt drive signal connections see Section 7 3 8 The edge sensor set pair in use are not calibrated Calibrate the creaser module see Section 4 5 18 There is too much gea...

Page 45: ...e belt tension is not set correctly Adjust the creaser drive belt see Section 4 5 10 The creaser roller gap is not set correctly Adjust the creaser roller gap see Section 4 5 13 The creaser roller spring pressure is too weak Check the creaser roller spring pressure Crease Quality Problem Cause Action ...

Page 46: ...3 Output Quality Problems Crease Quality 38 Morgana DocuMaster MFC Service Manual ...

Page 47: ...Morgana DocuMaster MFC Service Manual 39 4 SECTION 4 Service Procedures ...

Page 48: ...brate the creaser module a supply of Calibration Sheets 170 004 01 must be available 4 1 3 Test Strips It is important that the gap between the creaser rollers is parallel and set correctly Sheets of paper known as test strips are used to set the gap between the rollers It is recommended that you make some test strips if you have to adjust the creaser roller gaps To make test strips 1 Put some she...

Page 49: ...er Cable Rear Panel Earth Cable Cooling Fan Power Cable Figure 4 2 Inside the CAP Module Warning Use extreme caution not to touch live circuits when the MFC is turned on Tools Allen Key 3mm Spanner 8mm Before you start Set the main input switch to OFF 0 Disconnect the main power cord from the MFC Disconnect the main power link cord from the MFC Step Action Information 1 Loosen the four screws that...

Page 50: ...gure 4 2 To remove the top cover 1 Remove the four screws that attach the top cover to the CAP 2 Lift the top cover up and remove it from the CAP To remove the front panel 1 Remove the two screws that attach the front panel to the top of the CAP 2 Loosen the two retained screws at the bottom of the front panel 3 Lift the front panel and pull it towards you 4 2 3 Open the Hinged Front Panel and the...

Page 51: ...rew from the corner of the top panel see Figure 4 4 4 Hold the LH side of the hinged front panel and pull it towards you 5 Lift the hinged top panel and put it against the CAP 4 2 4 Open the Hinged Rear Panel You must open the hinged rear panel to gain access to the static eliminator transformer and to remove the CAP from the DRV module CAP Module DRV Module Put Paper Here Hinged Rear Panel Figure...

Page 52: ...t on the CAP 7 Open the hinged rear panel and let the CAP rest on the top panel 4 2 5 Remove the RH Side Covers 3mm Allen Key Cover Screw Access Hole Figure 4 6 Hidden Screw Access Hole RH Side Cover Tools Allen Key 3mm 1 Set the main input switch to OFF 0 2 Loosen the two hidden screws turn the screws counterclockwise by three full rotations see Figure 4 6 3 Pull the RH side cover towards you 4 M...

Page 53: ...e plates 4 2 7 Remove the Rear Guard Support Bracket Rear Guard Handle Figure 4 8 The Rear Guard The rear guard is a user access cover that can be removed by the user to clear paper jams or for maintenance 1 Hold the handle and lift the rear guard off the gathering module 2 Disengage the guard from the support brackets 3 Pull the guard towards you 4 2 8 Remove the Input Guide The input guide is a ...

Page 54: ... location pins see Figure 4 9 2 Pull the input guide towards you see Figure 4 10 4 2 9 Remove the Motor Cover Screw Screw 4 Figure 4 11 The Motor Cover You must remove the motor cover to access the creaser mechanism creaser drive motor Tools Screwdriver Pozidriv No 2 1 Set the main input switch to OFF 0 2 Remove the five screws that attach the motor cover to the MFC see Figure 4 11 3 Lift and pull...

Page 55: ...tor cover See Section 4 2 9 1 Cut the two cable ties that attach the electrical cables to the motor base plate cover 2 Remove the five screws that attach the motor base plate cover to the creaser module see Figure 4 12 3 Remove the motor base plate cover 4 2 11 Remove the Gathering Area Centre Guard You must remove the gathering area centre guard to gain access to components in the paper stop mech...

Page 56: ... blow guide Loosen the two screws see Figure 4 13 These screws are attached by a plastic washer and stay with the blow guide 3 Remove the two screws that attach the centre guard to the MFC Pull open the sample deflector to show the screws see Figure 4 14 Put your Allen Key through the slots in the sample deflector to remove the screws 4 Disengage the centre guard from the gathering area and pull i...

Page 57: ...ed on Tools Allen Key 3mm 1 Set the main input switch to OFF 0 2 Disconnect the main power cord from the MFC 3 Loosen the screw that is attached to the top of the electrical cabinet cover and let the electrical cabinet cover to open towards you see Figure 4 15 4 Disconnect the earth wire from the inside of the electrical cabinet cover 5 Lift the electrical cabinet cover and disengage it from the s...

Page 58: ...s to rotate the creaser rollers until you can access the end of the sheet 2 Hold the end of the sheet and pull it towards you as you continue to turn the rollers 3 Repeat steps 4 thru 5 until all the sheets are removed 4 3 2 Clear Jams in the Creaser Blade If the creaser blade set is closed on a sheet of paper and will not open automatically you must open it manually Before you start Set the main ...

Page 59: ...r has jammed in the infeed of the online bookletmaker but has not left the gathering area the paper is detected by a sensor which stops the paper stop latch from closing This type of jam can be cleared if the online bookletmaker is removed from under the MFC and the INCH button is touched on the GUI panel Remove the A4 pinch drive to give access to severe paper jams in the gathering area or when r...

Page 60: ...ply to them before they are damaged The cut out switches will automatically reset after the motors have cooled for approximately half an hour If the motors in the CAP overheat and the cooling system is defective use the test procedure that follows to identify the fault Temperature Control Switch Figure 4 18 The CAP Temperature Control Switch Warning Use extreme caution not to touch live circuits w...

Page 61: ...ct the vacuum control cable from PL6 on the interface PCB see Section 7 3 2 This will make the vacuum pump motor operate at idle speed when the MFC is turned on The vacuum pump will operate at full speed when the AIR BLOW window is open 7 Turn on the MFC Select the SUPERVISOR ACCESS LEVEL Set the AIR BLOW to 80 Let the blower and vacuum motors operate for 20 minutes 8 Remove the CAP rear panel See...

Page 62: ... that follows identifies which part of the static elimination system is defective Warning Use extreme caution not to touch live circuits when the MFC is turned on Tools Allen Key 3mm Screwdriver Pozidriv No 1 Spanner 2 x 15mm Open end Electrical Multimeter High Voltage Probe 1000 1 if available Non contact Volt Sensor Before you start Open the hinged rear panel see Section 4 2 4 Step Action Inform...

Page 63: ...n 4 4 2 3 Additional Tests The transformer s high voltage output can be measured with a high voltage probe across the output post The voltage must measure 7 0kV The transformer s high voltage output can be checked using a screwdriver with an electrically insulated handle Warning Use extreme caution not to touch live circuits when the MFC is turned on 1 Put the shaft of the screwdriver against the ...

Page 64: ... the ioniser bar and the back panel of the gathering area If no output is shown replace the ioniser bar see Section 4 11 4 If a weak output is indicated 50mm or below replace the ioniser bar see Section 4 11 4 If the output shown is not equal stronger at one end than the other replace the ioniser bar see Section 4 11 4 4 Use a high voltage probe 1000 to 1 to measure the voltage across the pins of ...

Page 65: ...lights on the bin control switch If the yellow light is on the receiver is detecting light from the emitter The emitter sensor assembly is ok If the red light is on the emitter or the receiver is defective Replace the emitter sensor assembly see Section 4 8 8 or see Section 4 9 4 It is recommended that you test the replacement emitter sensor assembly before you start the replacement procedure 1 Co...

Page 66: ...g Use extreme caution not to touch live circuits when the MFC is turned on Step Action Information 1 Press the red ON OFF button on the feed bin control switch and then release it See Figure 4 22 When you press the red button the feed bin control PCB sends an output signal to the feed clutch This will make the feed head or feed shaft turn When you release the red button the feed bin control PCB st...

Page 67: ...the feed clutch output LED is on when you press the red button on the Replace the feed bin control PCB if the clutch output LED is not on see Section 4 8 7 or see Section 4 9 3 6 Do a check that the feed clutch cable is connected to the feed bin control PCB correctly Connect the feed clutch cable if it is disconnected Replace the feed clutch if it still does not operate see Section 4 8 3 or see Se...

Page 68: ...is important that the main drive belt is tensioned correctly to prevent belt slip or overload of the drive motor There must be 10 20mm of deflection in the centre of the drive belt here Belt Tensioner Pulley Figure 4 24 Correct Main Drive Belt Tension Belt Tensioner Locking Nut and Adjustment Slot Figure 4 25 Main Drive Belt Tensioner Locking Nut The correct drive belt tension is 10mm 12mm of defl...

Page 69: ...age the transformer taps must be re set see Section 7 2 1 Transformer Taps Transformer Tap Position Information Fuses Mains Input Figure 4 26 Low Voltage Transformer Input PCB Tools Allen Key 3mm Step Action Information 1 Open the hinged front panel See Section 4 2 3 2 Remove a blue transformer tap Hold the tap and pull it towards you to disengage it from the PCB 3 Fit the tap in the correct posit...

Page 70: ...head separation adjuster is calibrated If the separation adjuster is not in the central position go to step 3 3 Tilt the LH end of the support shaft away from the feeder head to release the timing belt tension 4 Rotate the separation adjuster until the green indicator bar is in the central position Hold the adjuster pulley to prevent it from moving 5 Reset the support shaft and check that the sepa...

Page 71: ...he BIN ADDRESSING button and wait for it to display DONE 8 Return to the BASIC page and turn the MFC off and on Note If a bin or bins fail to address turn off the MFC and start the address procedure again 4 5 6 Initialise the Feed Bin Control PCBs Each of the feed bin control PCBs and the gathering area base control PCB have IC control chip that uses a basic operating f w to function When you init...

Page 72: ... Rivet Figure 4 30 Feed Bin Emitter Sensor Warning Be careful not to touch metal objects to live low voltage circuits when the MFC is turned on This can cause severe damage to the machine Tools Allen Key 3mm Screwdriver Small Flat Blade Bin Sensor Calibration Stock VAR370 052 or 40gsm Bond Paper Before you start Remove the top RH side cover See Section 4 2 5 Step Action Information 1 Turn on the B...

Page 73: ...ment The paper tray in the friction feed bin is pushed against the feed shaft by two tray lift arms below the tray The tray lift arms are fixed to a hexagonal shaft which is connected to a spring mechanism to apply variable feed pressure A roller that is attached to the end of each tray lift arm pushes against a plastic wedge on the bottom of the tray If the sheets are seen to skew to one side as ...

Page 74: ...an adjust the tension of the creaser drive belt 4 5 10 1 Test the Creaser Drive Belt Tension Creaser Drive Belt Figure 4 32 Creaser Drive Belt Creaser Drive Belt Reference Hole Pulley Figure 4 33 Test the Creaser Drive Belt Tension Before you start Remove the RH side covers See Section 4 2 5 1 Push the creaser drive belt away from the pulleys see Figure 4 33 2 Make sure that the belt stops at the ...

Page 75: ...he creaser drive belt Push the idler gear assembly forward to increase the tension on the creaser drive belt Push the idler gear assembly back to decrease the tension on the creaser drive belt 3 Tighten the idler gear nut 4 Do the creaser drive belt tension test See Section 4 5 10 1 4 5 11 Adjust the Creaser Drive Motor Gear Play It is important and necessary that the play between the creaser driv...

Page 76: ...be 0 1mm of gear play 4 5 11 2 Adjust the Creaser Drive Motor Gear Play The top LH screw that attaches the creaser drive motor to the RH side plate is installed through a clearance hole a circular hole that has a slightly larger diameter than the diameter of the screw This screw is known as the pivot screw Each of the three remaining screws that attach the creaser drive motor to the RH side plate ...

Page 77: ... Turn the creaser drive motor counterclockwise around the pivot screw to increase the amount of gear play Tighten the screws 2 Do the creaser drive motor gear play test See Section 4 5 11 1 4 5 12 Adjust the Crease Motor Belt It is important that the crease motor belt is adjusted to the correct tension If the crease motor belt is too tight The crease mechanism can stall The crease motor can ignore...

Page 78: ...ight measurements should be 5 0mm If the tension on the crease motor belt is not correct it must be adjusted see Section 4 5 12 2 4 5 12 2 Adjust the Crease Motor Belt Tension The top LH screw that attaches the crease motor to the RH side plate is installed through a clearance hole a circular hole that has a slightly larger diameter than the diameter of the screw This screw is known as the pivot s...

Page 79: ...kshaft pulley assembly Tighten the set screws 2 Adjust the crease motor position to increase or decrease the crease motor belt tension Loosen the four screws that attach the crease motor to the RH side plate Turn the crease motor counterclockwise around the pivot screw to increase the belt tension Turn the crease motor clockwise around the pivot screw to decrease the belt tension Tighten the screw...

Page 80: ...Sheets of paper known as test strips see Section 4 1 3 are used to calibrate the gap between the rollers 80gsm Test Strips Figure 4 40 Measure the Roller Gap Punch Screw Head Set Screw Figure 4 41 Roller Parallel Adjustment 10mm Allen Key Figure 4 42 Open the Input Rollers when you adjust the Output Rollers Tools Allen Key 2 5mm 4mm 10mm 6 Steel Rule Pin punch and hammer Test Strips See Section 4 ...

Page 81: ...ller gap adjustment screw until there is an 8mm gap between the roller stop rod and the support bracket Figure 4 43 Roller gap adjustment screw start position 2 Increase the roller gap at the RH end of the rollers Loosen the set screw that attaches the RH operating lever hub to the roller shaft see Figure 4 41 Figure 4 44 Hold the stop rod against the adjustment screw Figure 4 45 Turn the RH opera...

Page 82: ...action will make the operating lever turn clockwise which will decrease the roller gap at the RH end of the rollers Continue to adjust the gap until the crease rollers are parallel To increase the gap see Steps 2 thru 3 4 Tighten fully the set screw that attaches the operating lever assembly to the roller shaft 5 Adjust the gap between the crease rollers Measure the gap with two test strips see Fi...

Page 83: ...ed to the power links and the crease matrix connected to the blade adjustment cams 4 5 14 1 Test the Crease Blade Set Alignment Figure 4 46 Correct Creaser Blade and Creaser Matrix Alignment Figure 4 47 Edging Incorrect Creaser Blade and Creaser Matrix Alignment 1 Crease a sheet of paper in the MFC and remove it from the gathering area 2 Examine the crease at both sides of the sheet The crease mus...

Page 84: ... Holes Figure 4 50 Crease Blade Adjuster Access Holes RH Side Plate Access Holes Figure 4 51 Crease Blade Adjuster Access Holes LH Side Plate Tools Allen Key 3mm 4mm Paper Calibration Sheets 170 004 01 Before you start Remove the RH side covers See Section 4 2 5 Remove the bottom LH side cover See Section 4 2 6 Set the MFC main input switch to the ON I position and let the MFC boot up ...

Page 85: ... blade set and test the crease blade set alignment See Section 4 5 14 1 If the alignment is incorrect move to Step 5 5 Set the blade set to t d c See Step 1 6 Set the crease adjuster bolts on the crease matrix matrix Turn the adjuster bolt clockwise to move the matrix down Turn the adjuster bolt counterclockwise to move the matrix up 7 Repeat the alignment test and adjustment procedure until you h...

Page 86: ...ith no stiffness or free play 4 5 15 2 Adjust the DynaTilt Motor Gear Play Pivot Screw DynaTilt Drive Motor Figure 4 53 DynaTilt Drive Motor The top LH screw that attaches the DynaTilt drive motor to the LH side plate is installed through a clearance hole a circular hole that has a slightly larger diameter than the diameter of the screw This screw is known as the pivot screw see Figure 4 53 Each o...

Page 87: ...nd the pivot screw to decrease the amount of gear play Turn the DynaTilt drive motor counterclockwise around the pivot screw to increase the amount of gear play Tighten the screws 2 Do the DynaTilt motor gear play test See Section 4 5 15 1 4 5 16 Adjust the DynaTilt Home Switch The DynaTilt home switch has two functions Function Description Limit Switch Limits and sets the movement range of the Dy...

Page 88: ...e covers removed Step Action Information 1 Make the MFC do a DynaTilt reference check Set the main input switch to the ON I position the DynaTilt mechanism will do a reference check To repeat the reference check Push in the emergency stop button Wait for five seconds and then release the emergency stop button Note The DynaTilt mechanism will not do a reference check if the rear guard is off the MF...

Page 89: ...arning Use extreme caution not to touch any electrical or mechanical components when you operate the MFC with the side covers removed Step Action Information 1 Set the main input switch to the OFF O position 2 Disconnect the two wires from the DynaTilt home switch See Figure 4 55 3 Loosen the locking screw and move the mounting lever down fully See Figure 4 55 4 Set the creaser unit dowel pin 0 5m...

Page 90: ...2 Crease Blade at t d c Figure 4 57 Adjust the Crease Blade Pressure Blade adjustment cam cut out faces the blade set Centre Line Figure 4 58 Crease Blade Set at Minimum Pressure 6 Adjust the DynaTilt home switch Move the mounting lever up so that the switch actuator touches the creaser unit dowel pin Move the mounting lever up slowly until the Multimeter indicates that the DynaTilt home switch ha...

Page 91: ...ge of the sheet Note The lead edge of a sheet is used as the datum for all crease position calibration Electronic calibration of the creaser module is important and necessary to make sure that the DynaTilt and drive operations are synchronised to the input signal from the edge sensor set Electronic calibration is necessary to make allowance for the difference in electrical and mechanical manufactu...

Page 92: ...rned on 4 5 18 1 Adjust the Skew Offset The skew offset trim adjusts the angle of the crease from the lead edge of the sheet The skew offset trim should be adjusted so that the crease is parallel to the lead edge of the sheet The DynaTilt mechanism operates on a central pivot point so that when a sheet is seen in the gathering area the skew offset will affect the crease angle as shown see Figure 4...

Page 93: ...See Section 4 5 20 5 Feed a single sheet of test stock through the MFC Remove the sheet from the gathering area 6 Do a check to see if the crease is parallel to the lead edge of the sheet Put the sheet on a flat surface Fold the LH edge of the sheet on top so that the LH edge of the sheet is parallel with the RH edge of the sheet Do a check to see if the two ends of the crease are aligned see Figu...

Page 94: ...Information 9 Adjust the sensitivity of the middle pair of edge sensors See Section 4 5 20 10 Adjust the middle pair skew offset trim to make the crease parallel to the lead edge of the sheet Do Steps 5 thru 8 Figure 4 64 Outer Sensor Pair Skew Offset Adjustment Page Step Action Information 11 Adjust the sensitivity of the outer pair of edge sensors See Section 4 5 20 ...

Page 95: ...ease stretch A offset value will increase the crease stretch 12 Adjust the outer pair skew offset trim to make the crease parallel to the lead edge of the sheet Do Steps 5 thru 8 13 Do a check to see if the crease stretch trim is correct See Section 4 5 18 2 Step Action Information Step Action Information 1 Do a skew offset check if you did not do it before this See Section 4 5 18 1 2 Feed a singl...

Page 96: ...eps that is approximately equal to 0 5 x circumference of the input rollers The lead edge trim makes the crease position accurate on the sheet Figure 4 66 Measure the Crease Lead Edge Distance 5 Repeat Steps 2 thru 4 until the stretch crease measurement is correct Left Click NEXT when done Note The Machine Configuration wizard will show the next calibration page and write the trim values to the EE...

Page 97: ... check to see if the lead edge trim is correct Put the sheet on a flat surface Do a check to see if the distance between the crease and the lead edge of the sheet is 50mm see Figure 4 66 4 Adjust the inner pair lead edge trim to make the distance between the crease and the lead edge of the sheet measure 50mm Set a lead edge trim value in the setting box 5 Repeat Steps 2 thru 4 until the lead edge ...

Page 98: ...ormation 6 Adjust the middle pair lead edge trim to make the distance between the crease and the lead edge of the sheet measure 50mm Do Steps 2 thru 5 Figure 4 69 The Outer Sensor Pair Lead Edge Adjustment Page Step Action Information 7 Adjust the outer pair lead edge trim to make the distance between the crease and the lead edge of the sheet measure 50mm Do Steps 2 thru 5 ...

Page 99: ...ne Configuration Wizard and put back the original trim values 4 5 19 Adjust the Jam Detector The MFC uses the jam detector assembly to detect a paper jam in the creaser module The jam detector assembly indicates a jam when the emitter sensor beam is blocked The jam detector is normally blocked when a sheet of paper has jammed against the creaser blade set The VR7 potentiometer POT on the controlle...

Page 100: ...e sensors on the RH side of the edge sensor set are identified as Bank A The sensors on the LH side of the edge sensor set are identified as Bank B Figure 4 71 The Edge Sensor Set When the MFC operates a sensor pair is automatically set to operate The MFC makes the decision which sensor pair to use from the sheet width input on the GUI panel Sheet Width mm Sensor Pair Less than 208 Inner 208 1 302...

Page 101: ...abinet cover See Section 4 2 12 Clean the edge sensor set See Section 4 13 4 Step Action Information 1 Set the main input switch to the ON I position Make sure that the emergency stop button is not pushed in 2 Set a sheet width value of less than 208mm on the GUI panel See the DocuMaster MFC User Operating Instructions or use the MFC Test program 3 Do a check that the inner sensor pair is set to b...

Page 102: ...Set a sheet width value of more than 208 1mm on the GUI panel 6 Do a check that the middle sensor pair is set to be on Repeat the check in Step 3 Place test strips over the middle sensor pair 7 Adjust the middle sensor pair sensitivity Repeat the adjustment in Step 4 Turn the middle sensor pair adjustment potentiometers 8 Set a sheet width value of more than 302 1mm on the GUI panel 9 Do a check t...

Page 103: ...ion 2 Open the screen calibration page Touch the stop button above the screen on the screen bezel five times 3 Calibrate the GUI panel Touch the GUI screen with the point of a blunt object in the extreme top LH corner where prompted Touch the GUI screen with the point of a blunt object in the extreme bottom RH corner where prompted Touch the GUI screen in the centre to finish 4 5 22 Adjust the GUI...

Page 104: ...ACTORY Only available to manufacturer Function Operator Supervisor Service Distributor Factory Job Unlock Delete job level 1 3 4 5 any MENU USER SETTINGS ACCESS LEVEL CURRENT LANGUAGE LIGHTER DARKER FEEDER INFO CLEANING TOTAL SET LIMIT View only when limit reached View only add 100 sheets if at limit View only add 5000 sets if at limit MACHINE OPTIONS REMOTE OUTPUT n a View only View only REMOTE I...

Page 105: ...ess level See Section 4 5 23 1 2 Open the MACHINE OPTIONS setting page Touch the MACHINE OPTIONS tab on the MENU page 4 5 24 2 Select the Measurement Units The GUI panel can be configured to display measurement in either metric or imperial units Figure 4 73 Machine Options Measurement Units Step Action Information 1 Open the MACHINE OPTIONS setting page See Section 4 5 24 1 2 Select the type of me...

Page 106: ...t the side of the MORGANA text see Figure 4 74 3 Turn the MFC OFF ON 4 5 25 Centre the Gathering Area Sidelays To prevent paper jams it is important that the gathering area sidelays are correctly referenced to the centre of the MFC This procedure is necessary when the sidelay adjustment mechanism has been disconnected RH Sidelay Adjustment Shaft Gear Removed Hand Wheel LH Sidelay Adjustment Shaft ...

Page 107: ...4 76 Figure 4 76 3 Adjust the gap between the LH side plate and the top of the LH sidelay to be the same as the measurement taken on the RH side Use the hand wheel to adjust the LH sidelay position see Figure 4 75 4 Install the gear on the RH sidelay adjustment shaft 4 5 26 Adjust the Rear Guard Interlock Switch The rear guard interlock switch must stop the MFC before the rear conveyor is open eno...

Page 108: ... Put a steel rule against the pivot plate at the rear of the DRV module See Figure 4 77 4 Test the rear guard interlock switch Lift the rear guard Note The maximum permitted lift before the rear guard open error message is shown on the GUI panel is 2mm 5 If the rear guard interlock switch does not pass the test you must adjust the rear guard interlock switch See Section 4 5 26 2 4 5 26 2 Adjust th...

Page 109: ...tch test See Section 4 5 26 1 Step Action Information 1 Loosen the screws that attach the rear guard interlock switch to the mounting bracket Loosen the screws just enough so that you can move the interlock switch on the mounting bracket see Figure 4 79 2 Adjust the position of the rear guard interlock switch until the result of the rear guard interlock switch is a pass See Section 4 5 26 1 ...

Page 110: ...igure 4 81 Blower Motor Power Connector Warning The CAP module is heavy It is necessary for two people to lift the CAP module Always follow good health and safety procedures when you lift Tools Allen Key 3mm Before you start Open the hinged front panel See Section 4 2 3 Open the hinged rear panel See Section 4 2 4 Step Action Information 1 Disconnect the Windjammer and vacuum control cable Disconn...

Page 111: ...e four screws that attach the CAP to the hinged rear panel see Figure 4 82 Figure 4 82 CAP Screws 4 Close the hinged rear panel Pull the Windjammer and blower motor cables through the hinged rear cover as you close it 5 Lift the CAP and remove it from the MFC It is necessary for two people to lift the CAP Make sure that the area around the MFC is clear Stand on the two sides of the MFC Hold below ...

Page 112: ...r into the CAP and blows hot air out of the vents in the top cover If the cooling fan is defective the vacuum motor and blower motor will overheat and can cause damage Air Flow Direction Indicator Arrows Figure 4 84 The Cooling Fan Air Flow Direction Tools Allen Key 3mm Spanner 7mm Screwdriver Flat Blade Before you start Remove the CAP rear panel See Section 4 2 1 Step Action Information 1 Disconn...

Page 113: ... 2 1 1 Disconnect the wires from the TCS 2 Remove the screws and nuts that attach the TCS to the mounting bracket 3 Remove the TCS 4 Install the replacement TCS and do the CAP temperature control test see Section 4 4 1 4 6 5 Replace the Vacuum Pump The vacuum pump gives the suction feed bins a constant vacuum which they use to feed sheets of paper If the vacuum pump is defective it must be replace...

Page 114: ...l the connector away from the vacuum pump 3 Remove the tie bar Remove the two screws that attach the tie bar to the mounting bracket and the CAP 4 Remove the nuts from the compression bungs These nuts attach the mounting bracket to the rubber compression bungs 5 Remove the vacuum pump Lift the vacuum pump and pull it towards the front of the CAP to remove The 90 elbow pipe will pull off the straig...

Page 115: ... The Drive Module DRV must be removed from the MFC before you can remove a feed bin When you replace components inside the DRV you do not need to remove the DRV 4 7 1 1 Disconnect the Electrical Cables Link Power Bus Cable Data Bus Cable Figure 4 87 Power and Data Buses Creaser Module Power Supply Cable Cable Clamps Figure 4 88 Signal Interface Connections ...

Page 116: ... Key 3mm Spanner 10mm 14mm Pliers Side Cutters Before you start Remove the RH and LH side covers See Section 4 2 5 and See Section 4 2 6 Remove the rear guard See Section 4 2 7 Remove the CAP See Section 4 6 1 Step Action Information 1 Disconnect the Power Bus and Data bus cables from the interface PCB Pull the cables out through the RH side plate See Figure 4 87 2 Disconnect the feed signal cable...

Page 117: ...on the cable clamp to open the cable clamp 5 Disconnect the PWM cable from PL2 on the signal interface PCB Pull the cable out through the LH side plate See Figure 4 89 6 Disconnect the RS232 serial comms cable and the GUI interface cable from the GUI CPU Pull the cables out through the LH side plate The RS232 serial connector fixing screws are captured and remain with the connector Press both of t...

Page 118: ...DRV Module Drive Motor Pulley Drive Belt Belt Tensioner and Idler Pulley Figure 4 93 Main Drive Belt and Tensioner Tensioner Lock Nut and Washer Adjustment Slot Figure 4 94 Drive Belt Tensioner Lock Nut Lift the bin number label here Hidden screw behind the bin number label Figure 4 95 Remove the Bin Number Label ...

Page 119: ...e Figure 4 95 3 Loosen the screw on the bin control switch and disengage the switch from the DRV module The screw is attached and will remain with the switch Allow the switch to be supported by the electrical cable 4 Remove the remaining three screws that attach the DRV module to the feed bin Figure 4 96 Location of the LH rear fixing screw Figure 4 97 Location of the RH rear fixing screw Figure 4...

Page 120: ...ve Motor Pulley Drive Pulley Main Drive Belt Straight Edge 6 Rule Primary Drive Pulley Figure 4 100 Align the Drive Pulleys Tools Allen Key 2 5mm 4mm Spanner 8mm Pliers Side Cutters 6 Steel Rule Before you start Remove the LH side covers See Section 4 2 6 Open the hinged front panel and hinged top panel See Section 4 2 3 Open the hinged rear panel See Section 4 2 4 ...

Page 121: ...crews that attach the drive pulley to the drive motor shaft Pull the drive pulley off the shaft 5 Attach the drive pulley to the replacement drive motor Do not tighten the set screws 6 Install the replacement drive motor 7 Install the main drive belt Put the main drive belt onto the drive pulley Pre tension the main drive belt Put a straight edge against both faces of the drive pulley and the prim...

Page 122: ...sides of the connector to release the connector from the GUI CPU see Figure 4 103 2 Disconnect the 20 way ribbon cable from the GUI CPU Push apart the latches on the connector to release the cable from the CPU 3 Disconnect the RS232 creaser interface cable from the GUI CPU Loosen the two connector screws and detach the cable from the CPU 4 Remove the two screws that attach the GUI CPU to the hinge...

Page 123: ...I panel See Figure 4 103 2 Loosen the two hidden screws that attach the GUI panel to the MFC Turn the screws counterclockwise by three full turns 3 Remove the GUI panel from the MFC Pull the GUI panel towards you Move the GUI panel towards the rear of the MFC to disengage it from the side plates 4 Fit the replacement GUI panel 5 Calibrate the GUI panel touch screen See Section 4 5 21 4 7 5 Replace...

Page 124: ...ce PCB onto replacement interface PCB Find the Zerox PCB on the interface PCB see Figure 4 104 Gently pull the Zerox PCB away from the plug on the interface PCB Install the Zerox PCB in to the plug on the replacement interface PCB 5 Install the replacement interface PCB 4 7 6 Replace the Motor Drive PCB Tools Screwdriver Small Flat blade Anti static Wrist Band Before you start Open the front panel...

Page 125: ... Before you start Open the hinged rear panel See Section 4 2 4 1 Remove the air filter from the air filter housing 2 Clean the air filter housing 3 Install the replacement air filter blue face up 4 7 8 Replace the High Voltage Anti static Transformer Lid Screws 3 Ioniser Bar Cable Power Cable Screw 2 High Voltage Output Indicator Light ON OFF Switch Figure 4 107 High Voltage Anti Static Transforme...

Page 126: ...Remove the three screws that attach the transformer lid to the high voltage anti static transformer see Figure 4 107 3 Open the transformer lid 4 Disconnect the ioniser bar cable from the high voltage output post inside the high voltage anti static transformer see Figure 4 108 5 Remove the ioniser bar cable fixing nut and washer and remove the cable from the high voltage anti static transformer 6 ...

Page 127: ... creaser module remove the feed bins as a group see Section 4 10 1 1 The procedure that follows gives instructions on how to remove the top feed bin but the same procedure can also be used to remove any other feed bin Tray Lift Motor Screw Air Vacuum Valve Chain Tensioner Plate Knock Back Solenoid Link Cable Figure 4 109 Chain Tensioner Plate and Distributor PCB Connections Circlip Drive Sprocket ...

Page 128: ...re 4 111 Power and Data Connectors 2 Remove the electrical cabinet power cord from the RH side plates Cut the cable ties as required 3 Remove the air vacuum solenoid valve vacuum supply See Section 4 8 5 2 4 Remove all of the chain tensioner plates Remove the screw that attaches the tensioner plate to the LH side plate see Figure 4 109 Note There are two screws that attach the bottom chain tension...

Page 129: ...late 4 Pull the suction feed head towards you and out of the feed bin 5 Remove the chain and sprockets between bin 2 and bin 3 Remove the circlips that hold the drive sprockets on the drive shaft Hold both of the drive sprockets and pull them off the drive shafts Note Be careful not to drop the sprocket drive pin found behind each drive sprocket Figure 4 113 Sprocket Drive Pin 6 Remove the chain a...

Page 130: ...s calibrated correctly See Section 4 5 4 5 Install the replacement feed band Make sure that the central rib is on the inside of the belt 6 Install the drive shaft Make sure that the feed band central rib is located the shaft grooves 7 Do a check that the separation adjuster is calibrated correctly See Section 4 5 4 4 8 2 3 Install the Suction Feed Head 1 Hold the suction feed head so that the vacu...

Page 131: ... from the MFC See Section 4 2 5 Step Action Information 1 Remove the air valve See Section 4 8 5 1 2 Disconnect the feed clutch power cable from PL4 on the feed bin control PCB See Section 7 3 4 3 Remove the clutch plate fixing screws Remove the washers and earth tab 4 Remove the clutch plate and support bush 5 Remove the stainless steel split pin Press the legs of the split pin together and pull ...

Page 132: ...ing plate screw 4 Remove the tray lift motor assembly 5 Install the replacement tray lift motor assembly Note To engage the tray lift motor drive pinion with the tray lift quadrant on the tray lift shaft lift the shaft with your hand 4 8 5 Replace the Air Vacuum Solenoid Valve A solenoid activated valve is used to switch on the vacuum and air supply to the suction feed bin The same valve type is u...

Page 133: ... the valve power cable from the feed bin control PCB 2 Hold the blow tube and pull it towards you 3 Disconnect the solenoid valve and blow tube from the air manifold connector 4 Remove the blow tube from the solenoid valve 5 Make sure that the arrow that shows the direction of the air flow on the base of the valve is pointing in the correct direction it must point towards the blow tube see Figure ...

Page 134: ... disconnect it from the valve body 3 Disconnect the solenoid valve from the vacuum manifold connector 4 Make sure that the arrow that shows the direction of the air flow on the base of the solenoid valve points in the correct direction it must point towards the vacuum manifold 5 Connect the solenoid valve to the vacuum manifold and lift the filter housing to connect it to the valve 6 Tidy the exce...

Page 135: ...p finger shaft and remove them from the shaft lubricate the shaft with water if necessary 3 Put the replacement stop fingers onto the stop finger shaft and set them in position 4 8 7 Replace the Feed Bin Control PCB Power Bus Cable Data Bus Cable Sensor Ribbon Sensor Ribbon Socket Retainer PCB Locking Support Post Figure 4 121 Suction Feed BIn Control PCB Tools Allen Key 3mm Screwdriver Small Flat...

Page 136: ... 5 5 8 Initialise the feed bins See Section 4 5 6 9 Do a check of the emitter sensor low range adjustment See Section 4 5 7 4 8 8 Replace the Emitter Sensor Assembly The feed bin emitter and sensor are mounted to the paper guides within the feed bin s conveyor To replace the emitter sensor assembly it is necessary to remove the DRV module and any feed bins above the one that you must work on Note ...

Page 137: ...ace Components Suction Feed Bin 4 Figure 4 122 Feed Bin RH Side Plate Blow Valve Removed Figure 4 123 Suction Feed Bin Emitter Sensor Cable Ties Emitter Sensor Sensor Housing Rivet Figure 4 124 Suction Feed BIn Emitter Sensor Rivet Sensor Housing Emitter Sensor Spacer Lower Paper Guide Figure 4 125 Emitter Sensor Detail Exploded View ...

Page 138: ... to the upper paper guide 7 Remove the emitter from the upper guide Lift out the emitter with a small screwdriver Pull it through the RH side plate 8 Disconnect the link cable from PL8 and the bin switch cable from PL3 on the bin control PCB 9 Remove the upper paper guide Remove the four screws that attach the upper paper guide to the side plates Pull the link and switch cables through the RH side...

Page 139: ... side of the ribbon cable faces the socket contacts away from the retainer on the bin control PCB 4 8 9 Replace the Tray Height Sensor Control Head Tray Height Sensor Head Figure 4 126 Suction Feed Bin Control Head RH Air Baffle Lift the Sensor Head out of the Control Head Lower Paper Guides Figure 4 127 Remove the Tray height Sensor Tools Allen Key 3mm Screwdriver Small Flat blade Pliers Side Cut...

Page 140: ... you have room to remove the sensor See Figure 4 127 7 Remove the sensor head from the control head Push the sensor head out of the control with the blade of a small electrical screwdriver see Figure 4 127 Note Do not damage the control head 8 Remove the protective foam strip from the lower paper guides 9 Pull the sensor ribbon through the lower paper guides and remove the sensor 10 Install the re...

Page 141: ...at secures the sensor cable to the RH side plate 3 Lift off the lower plate with a small electrical screwdriver See Figure 4 128 4 Remove the sensor from the housing 5 Peel off the ribbon cable and remove it from the tray Record the ribbon cable route 6 Install the replacement sensor Make sure that the ribbon cable is secured to the paper tray with the double sided tape provided Make sure that the...

Page 142: ... assembly See Section 4 8 3 2 Remove the drive gears from the RH side plate See Figure 4 130 Remove the circlip Pull the gear towards you Be careful not to drop the drive pins from the shaft behind the gear 3 Turn the earth tab on the LH side plate away from the outer conveyor shaft 4 Remove the two circlips from both ends of the outer conveyor shaft 5 Remove the two flanged bushes from both ends ...

Page 143: ... Conveyor Wheel Outer Conveyor Wheel Figure 4 132 Access to the Inner Conveyor Wheel Tools Screwdriver Pozidriv No 2 Pliers Long Nose Scalpel or Sharp Knife Before you start Turn off the MFC Remove the rear guard See Section 4 2 7 8 Install the replacement conveyor wheels 9 Do a check that the conveyor wheels are aligned and turn straight When the machine has been reassembled turn on CLEANING mode...

Page 144: ...ew on the split conveyor wheel and open the wheel at the hinge see Figure 4 131 Figure 4 133 Open the Split Conveyor Wheel 2 Lift the outer conveyor shaft and pass the split conveyor wheel underneath it and over the top of the drive shaft see Figure 4 133 Figure 4 134 Install the Split Conveyor Wheel 3 Turn the split conveyor wheel around the drive shaft 4 Close the split conveyor wheel and loosel...

Page 145: ...ection 4 2 6 Remove the GUI panel See Section 4 7 4 Step Action Information 1 Remove the vacuum filter housing Hold the air vacuum valve and push down on the filter housing to disconnect it from the valve Pull the filter housing assembly away from the LH side plate 2 Remove the filter pad Be careful to twist the elbow connector and separate it from the filter housing 3 Remove the filter pad from t...

Page 146: ... 136 Friction Feed Shaft 4 9 1 1 Remove the Feed Shaft 1 Turn off the MFC 2 Hold the feed shaft on its RH end 3 Push the feed shaft towards the LH side plate and compress the retaining spring 4 Disengage the feed shaft from the clutch shaft on the RH side plate 5 Pull the feed shaft towards you and out of the feed bin 4 9 1 2 Install the Feed Wheels Caution A blue or orange feed wheel must never b...

Page 147: ...ed clutch power cable from PL4 on the feed bin control PCB 3 Remove the clutch plate and support bush Remove the two screws that attach the clutch plate to the feed bin Remove the washers and earth tab 4 Remove the stainless steel split pin Press the legs of the split pin together and then pull it out of the shaft with a pair of side cutters 5 Remove the clutch from the clutch shaft 6 Install the ...

Page 148: ...o remove the DRV module and any feed bins above the one that you must work on Note It is recommended that you connect the replacement emitter sensor assembly to the bin control PCB and tested it before you dismantle the MFC see Section 4 4 3 Feed Clutch Double Drive Gear Figure 4 138 Friction Feed Bin Secondary Drive Gears Emitter Sensor Rivet Sensor Ribbon Cable Cable Tie Figure 4 139 Friction Fe...

Page 149: ...5 Cut the three cable ties that secure the emitter sensor ribbon to the RH side plate 6 Remove the cable clips that secure the emitter sensor ribbon and PCB link cable to the upper paper guides Figure 4 141 Cable Clip 7 Remove the emitter from the upper guide Push out the emitter with a small screwdriver and pull it through the RH side plate 8 Disconnect the switch cable from PL3 on the bin contro...

Page 150: ... 10 4 9 6 Replace the Outer Conveyor Wheels Drive Shaft Inner Conveyor Wheel Outer Conveyor Wheel Figure 4 142 The Outer Conveyor Wheels 11 Release the sensor from the sensor housing The sensor housing is secured to the lower guide by two plastic rivets Push the rivets out of the guide and remove the housing and spacer see Figure 4 140 12 Cut the cable ties that secure the sensor ribbon cable to t...

Page 151: ...e shaft behind the gear 3 Turn the earth tab on the LH side plate away from the outer conveyor shaft 4 Remove the two circlips from both ends of the outer conveyor shaft 5 Remove the two flanged bushes from both ends of the outer conveyor shaft Note Each flanged bush is under cut behind the flange on one side The under cut must be below the bush when it is installed 6 Remove the outer conveyor sha...

Page 152: ...4 Service Procedures Replace Components Friction Feed Bin 144 Morgana DocuMaster MFC Service Manual 4 9 7 Replace the Inner Conveyor Wheels See Section 4 8 12 ...

Page 153: ... Output Rollers 4 10 6 Replace the Edge Sensor Set 4 10 7 Replace the Creaser Position Sensor Assembly If it is necessary to remove the creaser module from the MFC you must first remove the modules that are above the creaser module Remove the feed bin modules as a group so that you can complete the procedure more quickly 4 10 1 1 Remove the Feed Bins Chain Tensioner The Creaser Module The Transfer...

Page 154: ...ople lift the feed bins Step Action Information 1 Remove the DRV module See Section 4 7 1 2 Cut the cable ties and remove the power cable that is for the electrical cabinet Power Cord Cable Tie Figure 4 146 Creaser Power Cord 3 Disconnect the power bus cable and the data bus cable from all of the feed bin control PCBs 4 Remove the transfer chain Transfer Chain Master Link Figure 4 147 Master Link ...

Page 155: ...e feed bins See Section 4 10 1 1 5 Remove the four screws that attach the bottom feed bin to the creaser module 6 Remove the feed bins as a group It is necessary for two people to lift the feed bins Make sure that the area around the MFC is clear Make sure that a flat surface is available to put the feed bins Stand on the two sides of the MFC Hold below the bottom feed bin at the front and the bac...

Page 156: ... cables from the LH side plate Push in the latches on the two sides of the cable connector and pull the cable away from the side plate See Figure 4 148 2 Disconnect the cable from the DynaTilt home switch Cut the cable tie 3 Disconnect the power cables from the RH side plate Push in the latches on the two sides of the cable connector and pull the cable away from the side plate See Figure 4 149 4 D...

Page 157: ...o the RH rear and LH rear screws see Section 4 3 4 1 Screw Figure 4 151 Remove the screw from below the creaser module 6 Remove the creaser module It is necessary for two people to lift the feed bins Make sure that the area around the MFC is clear and that a flat surface is available to put the feed bins Stand on the two sides of the MFC Hold below the creaser module at the front and the back Lift...

Page 158: ...Plate Set screw behind the operating lever Operating Lever Assembly Roller Pressure Spring Figure 4 152 RH Creaser Side Plate The operating lever assembly is removed from the input roller Figure 4 153 RH Side Plate Screws Figure 4 154 LH Side Plate Screws Tools Allen Key 2 5mm 3mm 4mm 6mm Screwdriver Pozidriv No 2 Gear Puller ...

Page 159: ...he roller drive belt off the idler gear 3 Remove the roller drive pulleys Loosen the two set screws that attach each pulley Pull each pulley off the roller shaft 4 Remove the operating lever assemblies from the RH end of the roller shafts Loosen the set screw that attaches each operating lever assembly to the roller shaft Pull each operating lever assembly out of the roller bearing and off the rol...

Page 160: ...the operating lever and roller stop rod from the two rollers Remove the two screws that attach the operating lever to the operating lever hub Pull the operating lever and roller stop rod out of the control bracket 5 Remove the four screws that attach the LH side plate to the creaser unit See Figure 4 154 6 Remove the LH side plate assembly Pull the LH side plate assembly away from the creaser unit...

Page 161: ...on 4 10 2 1 Step Action Information 1 Remove the front input roller Pull the front input roller away from the LH side plate and release it from the bearing housing 2 Remove the rear input roller Remove the two screws that attach the operating lever to the operating lever hub see Figure 4 156 Pull the rear input roller away from the LH side plate and release it from the bearing housing 4 10 4 Repla...

Page 162: ...H side plate and release it from the bearing housing 2 Remove the rear output roller Remove the two screws that attach the operating lever to the operating lever hub see Figure 4 157 Pull the rear output roller away from the LH side plate and release it from the bearing housing 4 10 5 Replace the Jam Detector Assembly Connector Bracket Jam Detector Housing Jam Detector Assembly Connector Cable Tie...

Page 163: ...tor cover base plate 2 Disconnect the jam detector cable from the jam detector assembly connector Push in the latches on the two sides of the cable connector and pull the cable away from the jam detector assembly connector see Figure 4 159 3 Disconnect the jam detector assembly connector from the connector bracket 4 Remove the jam detector housing from each side plate Push in the retainer clips an...

Page 164: ... four screws that attach the edge sensor set to the creaser unit See Figure 4 161 3 Lift the edge sensor set away from the creaser unit 4 Install the replacement edge sensor set Make sure that the edge sensor set is installed so that the bevelled surface is up see Figure 4 161 Tighten the four screws that attach the edge sensor set to the creaser unit 5 Secure the edge sensor set cables to the tie...

Page 165: ...ensor Connector Housing Before you start Remove the creaser module See Section 4 10 1 Tools Screwdriver Pozidriv No 2 Pliers Side Cutters Step Action Information 1 Cut the ties that attach the creaser position sensor cable to the tie bar See Figure 4 163 2 Disconnect the creaser position sensor cable connector from the LH side plate 3 Remove the four screws that attach the mounting channel to the ...

Page 166: ...sition sensor Cut the creaser position sensor cable below the sensor Remove the two parts from the creaser module Note Do not discard the part with the connector attached to it 7 Put the replacement creaser position sensor through the mounting channel 8 Attach the sensor to the mounting channel 9 Assembly the creaser position sensor connector Make sure that the sensor wires are in the correct posi...

Page 167: ... connector and pull the cable away from the side plate 5 Remove the DynaTilt Motor Remove the four screws that attach the DynaTilt motor to the LH side plate Note The screws are attached to the motor retention plate 6 Attach the replacement DynaTilt motor Install the four screws that attach the DynaTilt motor to the LH side plate but do not tighten them fully 7 Attach the DynaTilt motor gear to th...

Page 168: ...lates Tools Allen Key 2 5mm 4mm Pliers Side Cutters Before you start Remove the RH side covers See Section 4 2 5 Remove the motor cover See Section 4 2 9 Step Action Information 1 Cut the cable ties that attach the crease motor cable to creaser drive motor cable 2 Disconnect the crease motor cable from the RH side plate Latch Figure 4 169 Connector Push in the latches on the two sides of the cable...

Page 169: ...etention plate Be careful that the motor retention plate does not fall into the MFC when the screws are removed see Figure 4 168 Remove the crease motor belt from the pulley Lift the crease motor and move it away from the RH side plate 4 Loosen the set screws that attach the pulley to the crease motor shaft and remove the pulley 5 Install the pulley onto the shaft of the replacement crease motor D...

Page 170: ...Gear Assembly Figure 4 172 Creaser Drive Motor Attachment Tools Allen Key 2 5mm 4mm Screwdriver Pozidriv No 2 Pliers Side Cutters 6 Steel Rule Before you start Remove the motor cover See Section 4 2 9 Step Action Information 1 Cut the cable tie that attaches the creaser drive motor cable to the crease motor cable 2 Disconnect creaser drive motor cable connector from the RH side plate 3 Remove the ...

Page 171: ...e the drive gear from the creaser drive motor Loosen the two set screws that attach the drive gear to the creaser drive motor shaft Pull the drive gear away from the creaser drive motor shaft 6 Attach the drive gear to the replacement creaser drive motor Put the drive gear onto the creaser drive motor shaft Align one of the set screws with the flat surface on the creaser drive motor shaft Position...

Page 172: ...tic brush 2mm from the edge of creaser blade Figure 4 175 Install The Anti Static Brushes Tools Allen Key 5mm 6 Steel Rule Solvent Cleaner Lint Free Cloth Before you start Remove the creaser blade set See the MFC User Operating Instructions Manual Step Action Information 1 Remove the blade adjustment cams 2 Put the blade set on a flat surface so that the anti static brushes are at the top ...

Page 173: ...ner to remove the glue Clean the surface with a dry cloth to remove all the glue and the solvent 5 Attach the anti static brushes to the crease blade Pull off approximately 25mm of backing tape from the adhesive strip at one end of the anti static brush Align the end of the anti static brush with the end of the crease blade see Figure 4 174 Position the anti static brush onto the crease blade so t...

Page 174: ...minals on the DynaTilt Home Switch 3 Remove the DynaTilt home switch Remove the two screws that attach the DynaTilt home switch to the mounting lever Lift the DynaTilt home switch off the mounting lever 4 Attach the replacement DynaTilt home switch 5 Do a check of the DynaTilt home switch limit position and adjust as necessary See Section 4 5 16 1 4 10 13 Replace the Creaser Blade Out Switch The M...

Page 175: ...formation 1 Disconnect the power cables from the tamper solenoid See Figure 4 177 2 Remove the solenoid link Remove the screw and nut that attach the solenoid link to the tamper solenoid see Figure 4 177 3 Remove the tamper solenoid Remove the four screw that attach the tamper solenoid to the mounting bracket Note Before you fit the replacement solenoid you must set the solenoid travel see below T...

Page 176: ...wer the paper stop assembly away from the catch plate brackets and pull it towards you 3 Remove the paper stop solenoid from the paper stop Remove the four screws that attach the paper stop solenoid to the paper stop record the position of these screws for reassembly Slide the solenoid out of the plastic paper stop guides 4 Do a check of the solenoid travel adjustment on the replacement solenoid b...

Page 177: ...he Flow Sensor Tools Allen Key 3mm Screwdriver Small Flat Blade Pliers Small Long Nose Before you start Remove the gathering area centre guard See Section 4 2 11 1 Press the latch down on the flow sensor cable connector and pull the connector away from the flow switch 2 Press the latches of the sensor mounting clip together and pull the sensor away from the mounting bracket 3 Push the replacement ...

Page 178: ...Bar Cable Cable Tie Figure 4 182 The Ioniser Bar Power Cable LH Mounting Bracket RH Mounting Bracket Ioniser Bar A4 Pinch Drive Figure 4 183 The Ioniser Bar Mounting Bolt and Nut Bracket screws Figure 4 184 LH Ioniser Bar Mounting Bracket Tools Allen Key 3mm Screwdriver Right angle Pozidriv No 1 Spanner 7mm 2 x 15mm Pliers Side Cutters ...

Page 179: ...ut the cable through the gathering area side plate 4 Push off the end cap from the RH non cable end of the ioniser bar 5 Remove the ioniser bar mounting bolts from the ioniser bar Move the bolt along the channel in the ioniser bar 6 Push off the end cap from the replacement ioniser bar 7 Install the mounting bolts and replace the end cap 8 Install the ioniser bar Tidy the excess cable into neat co...

Page 180: ...erface cable See the MFC User Operating Instructions Manual Step Action Information 1 Disconnect the Data bus cable from PL1 See Figure 4 185 2 Disconnect the Power bus cable from PL2 See Figure 4 185 3 Disconnect all other cables 4 Remove the bin control PCB Push in the locking tab on each PCB support post and pull gently on the PCB to release it 5 Fit the replacement base control PCB and connect...

Page 181: ...on Step Action Information 1 Connect the anti static wrist band and lead to the earth post below the 5V 24 PSU 2 Remove the processor PCB Hold both sides of the processor PCB Pull the processor PCB away from the control PCB a small mount at the LH side Pull the processor PCB away from the control PCB a small amount at RH side Repeat these steps until the PCB is disengaged from the sockets on the c...

Page 182: ...l the replacement controller PCB Attach the cable connectors to the controller PCB See Section 7 3 8 5 Calibrate the creaser unit See Section 4 5 18 4 12 3 Replace the Dual Stepper Drive PCB The dual stepper PCB has two sets of mode configuration switches The switches must be set specifically for the type of function that the stepper motor is used for Caution Always make a check that the position ...

Page 183: ...C power supply wires from the high power stepper PCB 3 Remove the four screws that attach the high power stepper PCB to the electrical cabinet 4 Lift the high power stepper PCB away from the electrical cabinet 5 Install the replacement high power stepper PCB Attach the cable connectors to the dual stepper PCB see Section 7 3 10 Do a check of the mode configuration switches and adjust them as neces...

Page 184: ...trical cabinet cover See Section 4 2 12 Step Action Information 1 Disconnect the cable connectors from the low power stepper PCB 2 Disconnect the AC power supply wires from the low power stepper PCB 3 Remove the four screws that attach the low power stepper PCB to the electrical cabinet 4 Lift the low power stepper PCB away from the electrical cabinet 5 Install the replacement low power stepper PC...

Page 185: ...on 1 Loosen the two screws that attach the 24V PSU to the electrical cabinet The screws pass through a key hole in the electrical cabinet The screws are found below the gathering area see Figure 4 187 2 Remove the long trunking cover from below the 24V PSU 3 Disengage the 24V PSU from the electrical cabinet Lift the PSU and move it away from the electrical cabinet Pull the wires out of the trunkin...

Page 186: ...n 1 Loosen the two screws that attach the 48V PSU to the electrical cabinet The screws pass through a key hole in the electrical cabinet The screws are found below the gathering area see Figure 4 188 2 Remove the long trunking cover from below the 48V PSU 3 Disengage the 48V PSU from the electrical cabinet Lift the PSU and move it away from the electrical cabinet Pull the wires out of the trunking...

Page 187: ...Pozidriv No 2 Before you start Remove the electrical cabinet cover See Section 4 2 12 Step Action Information 1 Disconnect the cable con connectors from the 5V 24V PSU 2 Disconnect the earth wire from the from the 5V 24V PSU 3 Remove the four screws that attach the 5V 24V PSU to the electrical cabinet 4 Lift the 5V 24V PSU from the electrical cabinet ...

Page 188: ...ction Separator Friction Feed Wheels Conveyor Wheels Suction Feed Band 4 13 2 Select Cleaning Mode You can operate the MFC conveyor at a slow speed if you select cleaning mode Cleaning mode must be selected when you need to do maintenance where it is necessary for the conveyor to operate Cleaning mode can also be used to diagnose problems in the drive system Warning NEVER try to clean the MFC conv...

Page 189: ...e friction fed shaft see Section 4 9 1 1 1 Gently brush clean the emitter and the sensor Or carefully blow the dust away from the emitter and sensor with compressed air 2 Do a check that the feed bin emitter sensor low range is set correctly see Section 4 5 7 3 Replace the suction feed head and friction feed shaft 4 13 4 Clean the Edge Sensor Set Dust and paper debris can collect around the emitte...

Page 190: ...ee Section 4 5 20 4 13 5 Clean the Ioniser Bar Dust can carbonise around the pins on the ioniser bar The effect of these deposits can decrease the performance of the ioniser bar which will cause paper jams in the gathering area We recommend that you regularly brush clean the ioniser bar Caution You must never use water or liquid cleaner on the ioniser bar If a liquid is used damage to the ioniser ...

Page 191: ...rtant to make sure that a breakdown does not occur Use the table that follows to choose the correct recommended maintenance plan for your MFC customer Recommended MFC Maintenance Plan Weekly Operation hrs Between Inspections months 30 6 30 4 Caution Only a Morgana factory trained service technician should do an MFC maintenance inspection A service technician that is not trained could cause damage ...

Page 192: ...is set correctly See Section 4 5 26 4 Do a check that the emergency stop switch operates correctly See Section 1 7 2 5 Do a check that the high voltage anti static transformer operates correctly See Section 4 4 2 6 Clean replace the blower motor air filter See Section 4 7 7 7 Do a check that all screws are tight 8 Clean the DRV module See Section 4 13 1 Use the list that follows to do a maintenanc...

Page 193: ...ires and connectors are not damaged or lose 2 Do a check that the drive chains sprockets and tensioner bushes are not worn replace both the drive chain and sprockets if the sprockets are worn See Section 4 8 1 3 Select Cleaning Mode and lubricate all of the drive chains and sprockets Molykote MKLn chain grease is recommended See Section 4 13 2 4 Do a check that all the nylon gears are in a satisfa...

Page 194: ...essary See Section 4 10 11 13 Clean the crease blade set and check that the blade is in a satisfactory condition 14 Do a check that the crease blade set is aligned correctly See Section 4 5 14 15 Do a check that the creaser module is calibrated correctly See Section 4 5 18 16 Do a check that all screws are tight 17 Clean the suction feed bin Use the list that follows to do a maintenance inspection...

Page 195: ...r See Section 4 13 5 9 Do a check that the anti static system operates correctly See Section 4 4 2 10 Do a check that the sidelays can be adjusted from maximum to minimum width See User Manual 11 Do a check that the sidelay tamper solenoid and tamper mechanism operates correctly 12 Do a check that the A4 pinch drive operates correctly See User Manual 13 Clean the A4 pinch drive conveyor belts See ...

Page 196: ...4 Service Procedures The MFC Maintenance Schedule 188 Morgana DocuMaster MFC Service Manual ...

Page 197: ...Morgana DocuMaster MFC Service Manual 189 5 SECTION 5 Parts Lists ...

Page 198: ...5 Parts Lists 190 Morgana DocuMaster MFC Service Manual 5 Parts Lists The parts lists for the MFC are in separate documents ...

Page 199: ...Morgana DocuMaster MFC Service Manual 191 6 SECTION 6 General Procedures ...

Page 200: ... Speed Up to 7200 sph sheets per hour Capacity 40mm Stock range 0 11mm 0 35mm 80gsm 300gsm Suction Feed Bin Speed Up to 5000 sph sheets per hour Capacity 45mm Stock range 0 11mm 0 24mm 80gsm 240gsm Creaser Module Number of creases 1 centre of book 2 x optical hinge creases Hinge Range 4mm 12mm from the book centre cover only System Information Dimensions L1760mm x W720mm x H2125mm Weight 450Kg Pow...

Page 201: ...0Hz 50Hz Current 8 0A 3 5A 3 0A Protection Fuse CAP 10 0A MFC 2 x 7 0A 5 0A 5 0A Power Consumption Operation Standby 1400VA 50VA 700VA 30VA 700VA 30VA Mains Connection removable cable and plug removable cable and plug removable cable and plug Electrical 115V MFC CAP BMP TMP ASM Voltage 115V 105 127V 115V 105 127V 115V 105 127V Frequency 60Hz 60Hz 60Hz Current 8 5A 4 7A 10 0A 4 8A Protection Fuse 2...

Page 202: ...to calibrate the creaser module The MFC Test program has been designed to run on MS Windows XP preferable and MS Windows 7 operating systems 6 3 1 Get the MFC Test Program The MFC Test program is supplied as a self extracting zip file Get the MFC Test program from Morgana on USB Storage Disc or download the program from the internet at http www morgana co uk The dealer portal area of the Morgana w...

Page 203: ...n port information when the program is connected to the MFC The title bar also contains the window maximise minimise and close buttons 6 4 2 The Menu Bar The Menu Bar shows the available menus that are used to manage the MFC Test program The File Menu Click on to open the File Menu The File drop down menu lists three options 1 Save Terminal Screen Saves the current terminal session 2 Save Terminal...

Page 204: ...out DocuMaster MFC Test Dialogue Box Click on to open the Help Menu The Help drop down menu lists one option 1 About MFC Test Shows the MFC Test Program version and copyright information 6 4 3 The Tool Bar The tool bar shows the program control buttons The program control buttons set important program functions Button Information The Save button opens the Save As dialogue box in the information ar...

Page 205: ...Disconnect button will disconnect the communications connection between the computer and the MFC This will not exit the MFC Test program The Connect button will open the communications connection between the computer and the MFC This will open the MFC Test program when you start The MCW button will open the Machine Configuration Wizard in a new window The MCW lets you do the creaser module electro...

Page 206: ...al port is not available a USB RS232 adapter will be necessary These adapters are available from most computer supply companies Figure 6 5 Connect The MFC Test Program The MFC Test program is automatically configured to transfer data between the computer and the MFC The configuration settings are shown below Baud rate bits per second 19200 Data bits 8 Parity none Stop bits 1 Note The MFC Test prog...

Page 207: ...e 6 5 3 Release the emergency stop switch 4 Open the MFC Test program on the computer The Not Connected window is shown in the information area 5 Click Edit on the MFC Test Program Menu Bar and then click Communication Parameters The Select Com Port dialogue box is shown in the information area see Figure 6 6 6 Set the port on the computer that the diagnostic lead is connected to Click the OK butt...

Page 208: ... to update the EEROM values unless advised otherwise by Morgana Systems Ltd Command Button Information The Apply button updates the controller PCB memory chip The stored ERROM values are not changed The Revert button updates the controller PCB memory chip with the stored values from the EEROM The Read ERROM button shows the stored EEROM values and updates the controller PCB memory chip with these ...

Page 209: ...ase blade mechanism or the DynaTilt mechanism The Crease Blade Tools Command Button Information The Home button makes the crease blade mechanism move to its home position The home position is when the blades set is open The Blade TDC button makes the crease blade mechanism move to its TDC position The TDC position is when the blade set is at the top of its stroke The Cycle button makes the crease ...

Page 210: ...entral position The Move button makes the DynaTilt drive motor move the amount of steps that have been set in the move setting field Note 1 motor step 0 9424mm 6 6 3 The Inputs Display Page Figure 6 10 The Inputs Display Page The Inputs Display Page shows the input status of the senors and switches inside the creaser module You can check the status and operation of a mechanism and its sensors from...

Page 211: ... Diagnostic Terminal Page The Terminal page is a command line interface which can be used to show and record the MFC control software command strings as text when the machine operates You can also use the computer keyboard to enter commands that will directly control the MFC see Section 6 6 5 6 6 5 Diagnostic Port Commands Reboot the MFC Report Status Information Shows Status information Returned ...

Page 212: ...enths of a millimeter There may be a maximum of three creases and the crease distances must be specified in ascending order If less than three creases are required omit n3 or n2 and n3 Example Crease the next sheet at 50mm and 250mm C500 2500 E Clear or Set Current Error Clear the current error when in MANUAL mode or generate an error E Clear the current error The errors are cleared when the motor...

Page 213: ...rol The creaser bar will not be tilted to line up with the lead edge of the sheet This is always cancelled on a power reset KE Enable the tilt control The creaser bar will be tilted to line up with the lead edge of the sheet KPn Select the skew mode skew sensor pair to used Valid values are n 0 Auto mode Use the width returned from the GUI CPU to select a pair n 1 Use the inner sensor pair n 2 Use...

Page 214: ...10 Data string returned by GUI CPU was malformed 11 Check sum on data string bad 20 Invalid code for MODE M field 21 Invalid length L field 22 Invalid fold distance F field 23 Invalid Offset O field 24 Invalid Skew S field 25 Invalid Hinge on off H field 26 Invalid Hinge distance D field 27 Invalid SIZE 28 Invalid INSERT 29 INFO 30 WIDTH 31 NSHEETS Y Manually Set the Solenoid Outputs Not used Yn n...

Page 215: ...amage to the processor PCB Calibration Page Title Procedure Instructions Crease Position Information Calibration Setting Field Command Buttons Control Bar Figure 6 12 Parts Of A Machine Configuration Wizard Calibration Page The parts of the MCW calibration page are 6 7 1 The Calibration Page Title The calibration page title is shown at the top of the page The page title describes the calibration p...

Page 216: ...ction 4 5 18 If you do not obey this instruction the crease position will not be accurate 6 7 4 The Command Buttons The command buttons control navigation through the MCW Command Button Information When you have completed a calibration procedure Click Next to move to the next calibration page If you need to return to a calibration page Click Back to move to the previous calibration page If you nee...

Page 217: ...eed Note You must immediately put a sheet of paper into the creaser module input rollers when you click the Feed button or a time out error can occur Click the Stop button to stop the creaser drive motor Machine Control Mode Figure 6 14 The Control Bar Machine Control Mode The primary function of Machine Control Mode is to let a field service engineer test and calibrate the creaser module in an MF...

Page 218: ...ed off the run memory chip is erased When you do the creaser module calibration procedure the adjustments that you make are automatically stored in the run memory chip The MFC will use these values when it operates but they will be erased unless they are written to the EEROM The Review Save Settings page lets you store the calibration values to the EEROM The parts of the Review Save Settings page ...

Page 219: ...e The Stretch Trim Setting The stretch trim setting is shown above the calibration trims table because it is calibrated to only the inner pair of lead edge sensors The Command Buttons The command buttons control navigation through the MCW and make the trim calibration settings write to the EEROM Command Button Information When you have completed a calibration procedure Click Finish to write the ca...

Page 220: ...6 General Procedures The MFC Machine Configuration Wizard Description 212 Morgana DocuMaster MFC Service Manual ...

Page 221: ...Morgana DocuMaster MFC Service Manual 213 7 SECTION 7 Electrical and Control System ...

Page 222: ...tion Rating CAP Module Mains Input Main line fuse x 1 10 0A HRC Quick acting F DRV Module Main Input Main line fuse x 2 240V 7 0A HRC Quick acting F 115V 10A HRC Quick acting F Interface PCB F1 9V rail for data 3 15A Glass Anti surge T F2 28V rail for clutches solenoids etc 6 3A Glass Anti surge T F3 not used 2 0A Glass Anti surge T Motor Drive PCB F4 not used 240V 2 0A HRC Quick acting F 115V 4 0...

Page 223: ...05V 127V 200V 187V 220V 230V 210V 254V Example the transformer taps are set to the 230V positions on a machine installed in the UK 228V Input 210V 254V range 230V Tap The measured input voltage 228V The local input voltage range 210V 254V Use transformer tap position 230V If the local voltage is measured to be in the stated tap range the machine will function correctly When a local voltage is unst...

Page 224: ...V The usual local input voltage 210V 254V Use transformer tap position 200V 7 2 2 Low Voltage Transformer Output The low voltage AC output cable from the low voltage transformer connects to PL1 on the interface PCB in the DRV module The table that follows shows the nominal output voltages of the transformer Low Voltage Output Wire Pair Voltage VAC White 9 0V Orange 21 0V ...

Page 225: ...L1 Data input from GUI CPU PL2 Data output to vacuum pump 7 3 2 Interface PCB Figure 7 3 Interface PCB Description LED LED Function LED ON PL1 Input from transformer PL2 Power bus to feed bins PL3 Input from GUI CPU PL4 Connection to motor drive PCB PL5 Not used LED1 N A PL6 Vacuum control output LED3 Control signal to vacuum pump PL7 Data bus to feed bins LED4 Trigger signal to feed bins ...

Page 226: ...ED ON PL12 Connection to interface PCB PL13 Not used SK1 Power to blower motor SK2 Mains power input F4 Fuse F4 LED1 F4 Fuse blown when OFF F5 Fuse F5 LED2 F5 Fuse blown when OFF PL8 Not used LED2 N A PL9 Not used PL10 Zerox PCB PL11 Rear guard switch LED5 Rear guard is closed N A Emergency stop switch LED6 E stop switch not in Description LED LED Function LED ON ...

Page 227: ...in Control Distributor PCB Description LED LED Function LED ON PL1 Power bus input PL2 Data bus I O PL3 Feed bin control switch PL4 Feed clutch output LED2 Feed clutch signal output PL5 Blow valve output LED5 Blow valve signal output PL6 Not used PL7 Not used PL8 Connection to PL10 on LH side of the MFC PL9 Not used SK1 Emitter sensor Check in Bin Test mode SK2 Tray loaded sensor Shown on bin cont...

Page 228: ...ol PCB Description LED LED Function LED ON PL1 Power bus input PL2 Data Bus PL3 Bin controls PL4 Feed clutch LED1 Feed clutch signal output PL5 PL6 PL7 SK1 Emitter sensor SK2 Tray loaded sensor LED2 Spare not used 7 3 6 Base Control PCB Figure 7 8 Base Control PCB Description LED LED Function LED ON PL1 Power bus input PL2 Data bus I O PL3 Not used ...

Page 229: ...ller PCB Assembly The creaser controller PCB assembly is used as an interface between the processor PCB and the MFC An EEROM chip on the controller PCB is used to store all the creaser skew lead edge and stretch calibration values These values will be lost when the control PCB is replaced PL4 Tamper solenoid paper stop solenoid LED1 Output to tamper solenoid LED6 Output to paper stop solenoid PL6 ...

Page 230: ...er sensor in Bank B blocked LH CN6 Creaser Feeder interface LED6 Feed trigger from feeder LED7 PWM output to feeder LED9 Guard not used CN7 Creaser jam sensor LED3 Creaser jam emitter sensor blocked CN8 Edge sensor receivers CN9 DynaTilt drive signal CN10 Main drive signal CN11 Creaser drive signal CN12 Crease blade drive signal CN13 Home slot 1 blade out LED8 Blade home CN14 Home slot 2 crease fl...

Page 231: ...ust be set specifically for the type of function that the stepper motor is used for see Table below Figure 7 11 Mode Configuration Switches Low Power Stepper PCB MFC Mode Configuration Switch Positions 1 2 3 4 SW4 ON OFF OFF OFF SW5 OFF OFF OFF OFF CN17 Solenoid 1 Not used CN18 Engineering CN19 Solenoid 2 Not used VR1 VR6 Edge sensor emitter sensor power adjustment VR7 Creaser jam sensor emitter s...

Page 232: ... drive control signal CN5 Sensor input not used LED2 Sensor covered LED1 Power ON 7 3 10 High Power Stepper Motor Drive PCB The high power stepper motor drive PCB operates the main drive motor The low power stepper PCB has two mode configuration switches The switches must be set specifically for the type of function that the stepper motor is used for see Table below Figure 7 13 Mode Configuration ...

Page 233: ...3 4 SW3 ON ON SW4 ON OFF OFF OFF Morgana DocuMaster MFC Service Manual 225 7 Electrical and Control System PCBs 7 Figure 7 14 High Power Stepper Motor Drive PCB Description LED LED Function LED ON CN3 Main drive stepper motor CN4 Main drive control signal LED1 Power ON ...

Page 234: ...iguration Switches Dual Stepper PCB MFC Mode Configuration Switch Positions Rotor 1 2 SW1 2 SW2 ON ON SW3 ON ON SW4 2 Figure 7 16 Dual Stepper Motor Drive PCB Description LED LED Function LED ON CN1 Crease blade drive control signal CN2 Crease blade drive stepper motor CN3 Creaser drive stepper motor CN4 Crease drive control signal LED1 ...

Page 235: ...ternet at http www morgana co uk Copy the file to your computer and double click the icon to run the file Shows which version of MFC software is contained in the file Figure 7 17 GUI Software Self Extracting File A folder with the name GUI is created on the C drive of your computer The GUI folder contains the software file Varioapp lzw plus other related files Note When the software files are extr...

Page 236: ...s which version of creaser control software is contained in the file 7 Electrical and Control System Software Overview 228 Morgana DocuMaster MFC Service Manual Figure 7 18 Creaser Control Software hex file ...

Page 237: ...stall the application software The boot firmware also loads the application software from the flash memory when you turn on the machine Normally software updates only affect the application software because software updates have a direct effect on the operation of the machine There are several methods to program the software into the GUI CPU Figure 7 19 How top Update the Software in the GUI CPU T...

Page 238: ...o the RS232 connector on the GUI CPU Control information is transmitted between the two control systems to operate the MFC There are two PCBs in the control PCB assembly The large control PCB works as an interface for the small controller PCB The control PCB stores the crease calibration settings for the creaser sensors There are two parts to the software in the Controller PCB The application soft...

Page 239: ...rvice Manual 231 7 Electrical and Control System Software System Description 7 software When the application software has been imported from the computer onto the programmer the programmer can update the software controller PCB ...

Page 240: ...at does not have an Ethernet connection This method only requires a serial cable The GUI CPU can be connected directly to the serial port of a computer with a 9 pin RS232 cable If a serial port is not available a USB RS232 adapter will be required These cables are available from most computer supply companies Access the GUI boot firmware with a software program known as a terminal emulator You can...

Page 241: ...l and Control System GUI CPU Software Updates through an RS232 Connection 7 7 6 1 Install the GUI Software through an RS232 Connection Figure 7 22 RS232 Connection Figure 7 23 Hyperterminal Connection Description Figure 7 24 Hyperterminal Connection Type ...

Page 242: ... 3 Connect the RS232 cable from the computer to the RS232 port on the GUI CPU See Figure 7 22 4 Open Hyperterminal on your computer The Connection Description window is shown see Figure 7 23 5 Type in a name for the connection and select an icon for the connection Click the OK button The Connect to window is shown 6 Drag down on the Connect Using menu and select the serial port to which the RS232 ...

Page 243: ...p bits 1 Flow Control none Use the drag down menus The connection settings are shown on the cover of the GUI CPU see Figure 7 22 Click the OK button A blank dialogue window is shown 8 Turn on the MFC During the start up beeps Press the space bar on the keyboard of the computer to put the MFC into boot mode 9 Type h in the Hyperterminal window and press the Return to show the boot firmware help men...

Page 244: ...re 7 28 6 Click the Send button The software transfers to the download cache of the GUI CPU A window shows the progress of the transfer and the time left You do not need to click any buttons to start the transfer When the transfer is complete this window closes 7 Type Y at the prompt in the Hyperterminal dialogue box The next message appears Serial Xmodem success This message shows that the softwa...

Page 245: ...ted to a network can be configured remotely Service engineers or distributors can update the application software remotely The application software can be downloaded with greater speed To update the software by this method see Section 7 7 1 7 7 1 Install the Software through an Ethernet Connection The Ethernet connection on the GUI CPU lets the MFC connect directly to a computer network or a stand...

Page 246: ...nected correctly to the MFC before you start this procedure Make sure the TFTP server is configured to transmit and receive Some versions of TFTP server software only receive files as a default Change this setting in the configurations for the program Configure the TFTP Server to look for the MFC software in the correct folder on the computer You can download the Solarwinds TFTP server from http w...

Page 247: ...ee Figure 7 33 9 Click the OK button 7 7 4 How to find the IP Address You must know the IP address and Subnet Mask of the computer from where you download the application software The TFTP Server shows this IP address in the lower right corner of the configuration window The Subnet Mask is possibly set to 255 255 255 0 If your computer uses Microsoft Windows you can use these methods to find the I...

Page 248: ...tion Information 1 Turn off and turn on the MFC 2 Push in the Emergency Stop button during the start up beeps This action puts the MFC into boot mode When the beeps have stopped release the emergency stop button 3 On the computer open the guisearch exe file Double click the icon to open the file The GUI Search window will open 4 Click Network Search The window shows a list of all MFC s connected t...

Page 249: ... or later open the Run window from the Start menu 6 Type telnet xxx xxx xxx xxx where you replace the x characters with the MFC IP address 7 Press Return Windows 2000 When the Telnet window goes blank press Return again Windows 95 or 98 Press Return again when the Telnet window is shown Step Action Information Step Action Information 1 Create an Ethernet connection See Section 7 7 5 2 Type D in th...

Page 250: ...ct com 3 Type the IP address of the computer that has the TFTP server software installed This computer is the computer from where you download the application software Press Return This prompt is shown Enter filename to load varioapp lzw See Figure 7 36 4 Press Return to confirm that the file name for the MFC software is varioapp lzw If the name for the software update is different from varioapp l...

Page 251: ...ce the creaser processor PCB to update the creaser control software see Section 4 12 1 7 8 1 Create the PICkit 2 Connection The white indicator arrow on the programmer must align with the white dot on the controller PCB Figure 7 39 Connect The Pickit 2 Programmer To The Creaser Controller PCB Figure 7 40 PIckit 2 Programmer Application Window And Status Dialogue Box Step Action Information 1 Remov...

Page 252: ...re The Pickit 2 Device Figure 7 44 File Drop Down List 3 Connect the PICkit 2 programmer to the creaser processor PCB Push the programmer onto the 6 pin plug You must connect the programmer so that the white arrow points to the white dot on the controller PCB see Figure 7 39 4 Click on the PICkit 2 icon to open the PICkit 2 programmer application Figure 7 41 PICkit 2 Application Icon 5 Make sure t...

Page 253: ... 7 42 3 Click on PIC24 in the drop down list The PIC24 device will recognised as PIC24HJ256GP610 4 Click on File in the PICkit 2 programmer window See Figure 7 44 5 Click on Import Hex in the drop down list This action will open a browser window 6 Set the Source File Path to the creaser software hex file location on the computer Click on Open to import the software to the programmer Make sure that...

Page 254: ...e status message box The PICkit 2 programmer will show that it is busy while the software is updated Caution Do not turn off the MFC or remove the programmer when it is busy 3 Make sure that Programming Successful is shown in the status message box See Figure 7 46 4 Turn off the MFC 5 Disconnect the PICkit 2 programmer from the MFC 6 Write the creaser control software version on the processor PCB ...

Page 255: ...should more than one error occur Key short beep long beep pause Error Codes Normal start up countdown Flash memory successfully programmed The program in the flash memory is not recognised The decompression of the software has failed There is a problem with the machine setting files which store information about network settings etc or the device that stores them There is a problem with the job me...

Page 256: ... Windows XP copy the Hyperterminal files hypertrm exe hypertrm dll hypertrm chm Windows XP file locations C Program Files windows NT C WINDOWS System32 C WINDOWS HELP 3 Paste the Hyperterminal files into the new Hyperterminal folder on your computer Alternative terminal emulator programs are available Many of these are open source and can be freely downloaded from the internet 7 10 2 Setting the N...

Page 257: ...n as Administrator 5 Type the text below Do not type line breaks netsh int ipv4 set dynamicport udp start 31000 num 1000 6 Press Enter 7 Close the Command Prompt window To check the current settings the following command can be used at the command prompt netsh int ipv4 show dynamicport udp If you want to reset the port numbers then use the following command Do not type line breaks netsh int ipv4 s...

Page 258: ...7 Electrical and Control System PC Configuration Problems 250 Morgana DocuMaster MFC Service Manual ...

Page 259: ...Morgana DocuMaster MFC Service Manual 251 8 SECTION 8 Installation Manual ...

Page 260: ...nnected to dedicated power outlet sockets Never use a multi gang extension that has a long lead 3 Check that the low voltage transformer taps are correctly set See Section 4 5 3 4 Check that the environmental conditions are correct for the MFC Ambient temperature 10 35 C 50 95 F Relative humidity 35 85 5 Check the floor surface and covering Install the MFC system on a flat hard floor A floor that ...

Page 261: ...e shipping bolts 8 2 1 Unload the MFC Warning The MFC is heavy It is necessary for three people to unpack the MFC Always follow good health and safety procedures when you lift Step Action Information 1 Stand on the two sides of the MFC These persons will need to lift the MFC 2 Stand in front of the gathering area base of the MFC This person will need to guide the MFC off the pallet when it is lift...

Page 262: ...adjustment nut on each adjustable foot 2 Put the MFC at an angle to give access to the foot mounting bracket 3 Install the adjustable foot on the foot mounting bracket Turn the adjustable foot fully into the foot bracket 4 Do Steps 2 thru 3 to install the second adjustable foot 8 2 3 Remove the Transport Brackets The transport brackets are necessary to hold the MFC to the MFC shipping pallet You m...

Page 263: ... Spanner 12mm Step Action Information 1 Push the MFC to its final position See Section SECTION 8 2 Turn each of the four adjustable foot bots until the MFC base wheels are clear of the floor Turn each adjustable foot bolt clockwise Note The two front adjustable foot bolts are located below the base An access hole is cut on the inside of the base 3 Connect the MFC to the mains input 8 3 4 Connect t...

Page 264: ... BMP is stopped by the gathering area 8 3 6 Turn on the MFC Step Action Information 1 Connect the MFC to the mains power supply 230V connect the mains lead to the input plug on the CAP 115V connect the mains leads to the input plug on the CAP and the input plug on the DRV 2 Set the MFC main input switch to the ON I position Make sure that the E stop switch is not pushed in The GUI panel will show ...

Page 265: ...aults 2 Load feed bins 1 2 with A4 80gsm paper Portrait orientation 3 Set the MFC to feed 5 INNER SHEETS and 1 BOTTOM INSERT and to crease COVER ONLY 4 Make some books 5 Set the MFC to feed 11 INNER SHEETS and 1 BOTTOM INSERT and to crease COVER ONLY 6 Make some books 8 3 8 Check the Book Quality Step Action Information 1 Check the sample books for quality of the crease staple fold trim and spine ...

Page 266: ...8 Installation Manual Install the MFC 258 Morgana DocuMaster MFC Service Manual ...

Page 267: ......

Page 268: ...Morgana Systems Limited Davy Avenue Knowlhill Milton Keynes Buckinghamshire MK5 8HJ United Kingdom Tel 44 0 1908 608888 Fax 44 0 1908 692399 Email info morgana co uk Web www morgana co uk ...

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