Morgana AutoCreaser Pro 385 User manual

Morgana AutoCreaser Pro 385
High Speed Creasing Machine
with Deep File Feeder
Instruction Manual

Read this manual carefully before you use this product and keep it handy for future
reference.
For safety, please follow the instructions in this manual.
Doc no: T10202A
Date: 02 Dec 2016
Operating Instruction
Morgana Pro 385
Feeder/Creaser/Folder
MyBinding.com
5500 NE Moore Court
Hillsboro, OR 97124
Toll Free: 1-800-944-4573
Local: 503-640-5920

WARNING:
This is a Class A product. In a domestic environment this product may cause radio
interference in which case the user may be required to take adequate measures.
The product (System) which is connected to this machine will be class A.
NOTE:
The domestic environment is an environment where the use of broadcast radio and
television receivers may be expected within a distance of 10m of the apparatus concerned.
MyBinding.com
5500 NE Moore Court
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Toll Free: 1-800-944-4573
Local: 503-640-5920

Introduction
This manual contains instructions on the operation and maintenance of this machine. To
get maximum versatility from this machine all operators should carefully read and follow
the instructions in this manual. Keep this manual in a handy place near the machine.
Please read the Safety Information before using this machine. It contains information
related to USER SAFETY and PREVENTING EQUIPMENT PROBLEMS.
How to Read This Manual
Notation Conventions
Whenever necessary, the following points for attention are indicated in this manual.
WARNING:
Indicates a potentially hazardous situation which, if instructions are not followed,
could result in death or serious injury.
CAUTION:
Indicates a potentiality hazardous situation which, if instructions are not followed, may
result in minor or moderate injury or damage to machine or property.
NOTE:
This sign refers to:
• Remarks for making the operation much easier. You get practical hints or knowledge to
assist you in the machine operation such as:
• Preparations required before operating
• How to prevent papers from being misfed or damaged
• Precautions required or actions to take after misoperation
• Limitations such as numerical limits, functions that cannot be used together, or condi-
tions under which a particular function cannot be used or obtained
• Information
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WARNING:
• To avoid hazardous situations like for instance electric shock or danger while exposed
to moving, rotating or cutting devices, do not remove any covers, guards or screws
other than those specied in this manual.
• Turn off the power and disconnect the power plug (by pulling the plug, not the cable) if
any of the following conditions exists:
• You drop objects or spill something into the equipment.
• You suspect that your equipment needs service or repair.
• Your equipment’s covers has been damaged.
• You notice unusual noises or odours when operating the equipment.
• If the power cable or plug becomes worn out or otherwise damaged.
•Before cleaning and care (unless otherwise specically instructed).
• Electromagnetic compliance:
•This is a Class A product. In a domestic environment this product may cause radio
interference in which case the user may be required to take adequate measures.
• The product (System) which is connected to this machine will be class A.
Safety Information
When using this machine, following safety precautions should always be followed.
Safety During Operation
General Safety
WARNING:
• Always connect the equipment to a properly grounded power source (wall outlet). If in
doubt, have the power source checked by a qualied electrician.
• Improper grounding of the equipment can result in electrical shock. Never connect the
machine to a power source that lacks a ground connection terminal. This machine is
destined for specic purpose only. Any use going beyond this specic purpose is re-
garded as beyond the determination. The manufacturer will not be liable for damages
resulting from any use beyond the determination, unallowed operation, respectively.
The user alone bears the risk.
•Do not make arbitrary changes or modications to the machine. The manufacturer will
not be liable for modications made at the machine on your own and damages result-
ing thereof. EC declaration of conformity and the mark CE will be invalidated, if you
make changes at the machine or at the individual components.
• Do not override or bypass electrical or mechanical interlock devices.
• The machine is to be used only by authorized and instructed persons. The responsibil-
ities on operating the machine have to be strictly laid down and observed so that there
are no unclear competences regarding safety aspects.
• Vent holes serve for air circulation to protect the machine from overheating. Make sure
that the holes are not covered.
•Do not expose ngers or other parts of the body to moving, rotating or cutting devices
such as for instance between upper and lower trimmer knives.
• Always locate the equipment on a solid support surface with adequate strength tor the
weight of the machine.
MyBinding.com
5500 NE Moore Court
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Toll Free: 1-800-944-4573
Local: 503-640-5920

NOTE:
• The operator manual always has to be available at the place of use of the machine.
• In the interest of technical development the company reserves the right to make
alterations to specications without prior notice
CAUTION:
• The machine and its peripherals must be installed and maintained by a customer service
representative who has completed the training course on those models.
• Always follow all warnings marked on, or supplied with, the equipment.
• When you disconnect the power plug from the wall outlet, always pull the plug (not the cable).
• Disconnect the power cord before you move the machine. While moving the machine, always
exercise care and make sure that the power cord will not be damaged under the machine.
• Always contact service if relocating the equipment.
• Do not move the machine while the machine is running.
• Do not open covers while the machine is running.
• Do not switch off the power while the machine is running. Make sure the machine cycle has
ended.
• Lay the power cord in a way that nobody will stumble over it. Do not place things on the cord.
•Never attempt any maintenance function that is not specically described in this
documentation.
•Always keep magnets and all devices with strong magnetic elds away from the machine.
• If the place of installation is air-conditioned or heated, do not place the machine where it will be:
• Subject to sudden temperature changes.
• Directly exposed to cool air from an air-conditioner.
• Directly exposed to heat from a heater.
• If the machine is not used over an extended period of time it should be unplugged to prevent
damage in the case of overload.
General Safety (Continued)
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Page intentionally blank.
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Toll Free: 1-800-944-4573
Local: 503-640-5920

TABLE OF CONTENTS
What You Can Do With This Machine ............................................................................... 9
Guide To Components ..................................................................................................... 10
Pro 385 Feeder........................................................................................................................... 10
Pro 385 Creaser ......................................................................................................................... 11
Pro 385 Folder ............................................................................................................................ 12
User Interface ............................................................................................................................. 13
Optional parts ................................................................................................................... 14
Pro 385 AutoCreaser .................................................................................................................. 14
Pro 385 DigiFold ......................................................................................................................... 14
Tools and Accessories..................................................................................................... 15
Pro 385 AutoCreaser .................................................................................................................. 15
Pro 385 DigiFold ......................................................................................................................... 16
1. Basics............................................................................................... 17
Paper.................................................................................................................................. 17
Paper Guidelines ........................................................................................................................ 17
Creasing ............................................................................................................................ 18
About the Crease........................................................................................................................ 18
Choose the Correct Crease Blade Set ....................................................................................... 19
Replacing Blade Sets ................................................................................................................. 20
Setting the Crease Tilt Knobs ..................................................................................................... 23
Folding............................................................................................................................... 26
About the Fold ............................................................................................................................ 26
Deects.............................................................................................................................. 29
About Deects ............................................................................................................................ 29
Perforating ........................................................................................................................ 30
Using the perforation .................................................................................................................. 30
Turning On / Off the Power .............................................................................................. 32
Main Power Switch ..................................................................................................................... 32
Calibration......................................................................................................................... 33
Sensor Calibration ...................................................................................................................... 33
Stop Gate Distance Calibration .................................................................................................. 33
Folder Bypass Tray Installation ...................................................................................... 34
2. Setting Up a Job .............................................................................. 35
Quick Start ........................................................................................................................ 35
The Run Screen ................................................................................................................ 37
Modifying Settings ........................................................................................................... 38
Paper Size and Thickness .......................................................................................................... 38
Crease Settings .......................................................................................................................... 39
Pro 385 Quick Reference Sheet ................................................................................................. 41
Custom Crease........................................................................................................................... 42
Fold Conguration ...................................................................................................................... 43
Roller Gap Adjustment................................................................................................................ 44
Save a Job.................................................................................................................................. 45
Batch Jobs .................................................................................................................................. 45
Fans and Choke settings ............................................................................................................ 46
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Local: 503-640-5920

Delivery....................................................................................................................................... 47
Lower Paper Tray ....................................................................................................................... 47
Running Test Sheets................................................................................................................... 48
Action Buttons............................................................................................................................. 48
Creating and Saving Jobs........................................................................................................... 48
Expert User Options ................................................................................................................... 49
Home .......................................................................................................................................... 49
Job completed ............................................................................................................................ 50
Check Paper Size ....................................................................................................................... 50
Job Preparation ................................................................................................................ 52
Loading Paper ............................................................................................................................ 52
Crease Pressure......................................................................................................................... 52
Setting Crease Pressure............................................................................................................. 53
3. Expert User Options........................................................................ 55
Accessing Expert User Options...................................................................................... 55
Expert User Main Menu .............................................................................................................. 55
DSD switch button ...................................................................................................................... 55
Conversion button....................................................................................................................... 56
Service menu.............................................................................................................................. 56
Plint............................................................................................................................................. 56
Settings in production ................................................................................................................. 57
Tools menu ................................................................................................................................. 57
4. Troubleshooting - General.............................................................. 59
Misfeeds/Jams.................................................................................................................. 59
Misfeed/Jam in Feeder Area....................................................................................................... 59
Jam between Units or Jam in Creaser/Folder ............................................................................ 60
Recommended Settings Adjustments............................................................................ 61
5. Troubleshooting - Fault Codes....................................................... 63
Pro 385 Fault codes.......................................................................................................... 63
General ....................................................................................................................................... 63
Pro 385 Jam Codes .................................................................................................................... 64
Pro 385 Error Codes .................................................................................................................. 69
6. Remarks ........................................................................................... 73
Do’s And Don’ts................................................................................................................ 73
Where to Put Your Machine ............................................................................................. 74
Machine Environment ................................................................................................................. 74
Power Connection ...................................................................................................................... 74
Access to Machine...................................................................................................................... 75
Maintaining Your Machines ............................................................................................. 76
Pro 385 Maintenance.................................................................................................................. 76
Limitations of the Pro 385................................................................................................ 77
7. Specications ................................................................................. 79
Machine Specications - Feeder Pro385 ................................................................................... 79
Machine Specications - Creaser Pro385 .................................................................................. 79
Machine Specications - Folder Pro385 ..................................................................................... 79
EU Declaration Of Conformity .................................................................................................... 82
MyBinding.com
5500 NE Moore Court
Hillsboro, OR 97124
Toll Free: 1-800-944-4573
Local: 503-640-5920

9
What You Can Do With This Machine
Creaser
AutoCreaser Pro 385 DigiFold Pro 385
Folder
Feeder
The Morgana PRO 385 is a state of the art feeding, creasing and folding system. There
are two primary intended congurations for the Pro 385 system. The rst conguration
is the Feeder in combination with the Creaser. The second conguration is the Feeder in
combination with the Folder. Both congurations utilize the top feeding, vacuum assisted
Feeder which is capable of feeding up to 10,000 A4 sheets per hour.
The Feeder/Creaser conguration allows for automatic sheet feeding and single or dual
static creasing accurate to within 0.1 mm. This conguration can crease and or perforate
sheets accurately at a rate of 8,500 A4 sheets per hour. After creasing, the nished
products are collected neatly on a stacking tray.
The Feeder/Folder conguration allows for automatic sheet feeding, dynamic creasing and
folding. The dynamic creaser in this system does not need the paper transport system to
stop when it makes a crease, which allows this system to process up to 6,500 A4 sheets
per hour.
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Toll Free: 1-800-944-4573
Local: 503-640-5920

10
Guide To Components
Pro 385 Feeder
1 Top Plate, Feeder
2 System Main Power Switch
3 Stack Support Assembly
4 Loading Table
5 Base Spine Assembly
6 Graphical User Interface
7 Blower Case / Vacuum Fan Assy
8 Paper Guides
9 Vacuum Drum / Drum Guard
10 Ultrasonic Double Sheet Detection
(USDSD) Sensor (Q10)
1
2
3
4
5
6
8
171615
141312
7
9
10
11
11 Exit Feed Sensor (Q7)
12 Paper Stop Gate
13 SP Sensor
14 Side Lay w/ Separation Fans
15 Latching handles
16 Paper Backstop
17 Paper Weight
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Toll Free: 1-800-944-4573
Local: 503-640-5920

11
Guide To Components (Continued)
Pro 385 Creaser
19
12
13
11
10
2
3
4
5
6
7
8
1 Top Cover, Creaser
2 Creaser Tilt Adjustment Knobs
3 Articulating Rigid Foot
4 Caster
5 Indexing Lever
6 Stacker Tray
7 Stacker Guides
8 Creaser Assembly Exit
9 Antistatic Kit (optional)
10 Static Creaser Assembly 2
11 Static Creaser Assembly 1
12 Entry Sensor (Q20)
13 Exit Sensor (Q25)
4x 4x
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5500 NE Moore Court
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Toll Free: 1-800-944-4573
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12
Guide To Components (Continued)
Pro 385 Folder
1
7
8
6
12
13
15
14
16
11109
3
4
5
1 Top Cover, Folder
2 Creaser Tilt Adjustment Knobs
3 Articulating Rigid Foot
4 Caster
5 Delivery Module Handle
6 Delivery Module
7 Stacker Guides
8 Folding Roller Assembly
9 Fold Knife K1 Sensor (Q45)
10 Exit Sensor (Q52)
2
4x
4x
11 Power/Signal Connector
12 Interlock
13 Antistatic Kit (optional)
14 Dynamic Creaser Assembly
15 Static Creaser Assembly
16 Entry Sensor (Q40)
MyBinding.com
5500 NE Moore Court
Hillsboro, OR 97124
Toll Free: 1-800-944-4573
Local: 503-640-5920

13
User Interface
Home Screen
From the Home Screen, the operator
can set up a job and view/modify
machine settings and properties.
The “Quick Start” button in the middle
of the screen launches the Quick
Start sequence, which walks the user
through the necessary steps to start
a simple job (Paper Format, Paper
Thickness and Fold Settings).
The control panel is of touch screen type. Point at the screen and press the “button” to
reach the desired function or change the desired setting.
The Morgana Pro 385 has a Graphical User Interface (GUI) / Control Panel which allows
for setting up jobs and viewing/modifying machine settings and properties. The Pro 385
GUI was designed to have minimal text for intuitive operation across multiple languages.
Detailed descriptions of each menu and sub-menu are found in this Operator Manual.
NOTE:
Depending on modules and features installed, the screen may look different from what you
see here. Some functions are greyed out or not visible at all and remaining buttons may
stretch to t the screen. This manual will most often show a fully congured system.
Control Panel
Intro Page
Turning on the Morgana Pro 385
brings up the introductory page. This
page is in place for operator safety.
The Main Menu will not come up
unless the operator acknowledges
he or she is trained to operate the
machine.
If jobs have been previously programmed, the operator can initiate or edit them by
pressing the “Folder” button.
The “Play” button takes the operator to the Run Screen, where jobs can be set up manually
and overall system status is displayed.
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14
The Run Screen
The Run Screen is where the
operator is taken after selecting
the “play” button on the Home
Screen. This screen displays paper
parameters, job status and system
status. The operator can start, edit,
pause or abort the job from this
screen.
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Toll Free: 1-800-944-4573
Local: 503-640-5920

15
Pro 385 AutoCreaser
Component no Quantity Description
1-99-35 1 Anvil Set
1-99-12 1 28T Slitter Perforator blade
601-185 1 Sensor Cleaning Brush
601-118 1 Wooden Handled Brush
601-119 2Disposable Latex Glove-Size XL
90-031 1 Instruction Sht. Roller C.
T-302A 2Blade Removal Tools
Pro 385 DigiFold
Component no Quantity Description
1-99-35 1 Anvil Set
1-99-12 1 28T Slitter Perforator blade
601-185 1 Sensor Cleaning Brush
601-118 1 Wooden Handled Brush
601-119 2Disposable Latex Glove-Size XL
90-031 1 Instruction Sht. Roller C.
T-302A 2Blade Removal Tools
170-101-02 1Installation Setup-DigiFold
Tools and Accessories
Below are the lists of the tools and accessories included in the despatch kits both for the
AutoCreaser and for the DigiFold.
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16
Optional parts
Component no Description
1-99-10 20T Slitter Perf Set
1-99-13 Slitting Blade Set
1-99-41 56T Slitter Perf Set
1-99-42 96T Slitter Perf Set
336-03-02 Blade Set - Narrow - for Static Creaser
336-30-01 Cross Perf. Blade Set (up to 150mm) - for Static Creaser
Pro 385 AutoCreaser
Pro 385 DigiFold
Component no Description
1-99-10 20T Slitter Perf Set
1-99-13 Slitting Blade Set
1-99-41 56T Slitter Perf Set
1-99-42 96T Slitter Perf Set
336-03-02 Blade Set - Narrow - for Static Creaser
336-30-01 Cross Perf. Blade Set (up to 150mm) - for Static Creaser
176-213-01 Blade Set - Narrow - for DynaCrease
176-213-03 Blade Set - Ultra Narrow - for DynaCrease
Below are the lists of the optional parts that can be ordered by the user both for the
AutoCreaser and for the DigiFold.
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17
Paper comes in many different makes, types and nishes. There are many different
ways to print on the paper and then protect that printed image. The grain direciton, bre
structure, substrate thickness, porosity, coating type, bond strength of the coating, water
content, relative humidity and many other things can affect how the paper will behave
when you crease and fold it. We recommend that you learn to identify these differences.
Be prepared to make small adjustments to the machine to stop any problems that they
might cause.
Guidelines:
-Always make sure that the sheets of paper you use are cut square. This machine is
designed to fold the paper at right-angles. It cannot do this if the paper edges are not cut
at 90° angles to each other.
-Always make sure that all of the paper for a job is cut the same. This machine uses the
sheet length that you set to automatically set the crease and fold positions on a document.
The document will not be accurate if the paper length is not set correctly, or if the length of
the paper changes during a job.
1. Basics
Paper
Paper Guidelines
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18
1
A crease stops the paper and printed image of a document from cracking when it is folded.
The crease is made when a sheet of paper is compressed between the two parts of a
mechanism known as a blade set. The blade set uses an ANVIL and a BLADE to form
the crease. A powerful motor operates the blade set so that it can put a large amount of
pressure on the paper. This pressure compresses the substrate and printed image, which
makes the paper thin and weak along the edges of the crease. This allows the paper to
fold accurately along the crease.
NOTE:
When you crease and fold, the crease is the most important process. The paper will not
fold accurately if the crease is not made correctly, or if it is not made in the correct position.
Creasing
About the Crease
Paper Feed Direction
Blade
Anvil
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19
1
Two different types of blade set are supplied with your machine. Refer to the table below to
see which type of blade/set is most suitable for your job.
The Standard blade set is designed to give a good crease on thick paper and thin card.
To do this, it makes a wide crease. A wide crease is necessary because it gives sufcient
material at the spine of the fold.
The Narrow blade set is designed to give a good crease on medium and thin paper. To do
this it makes a narrower crease than the Standard blade set does. A narrower crease is
necessary because if there is too much material at the spine of the fold, the fold might not
be accurate or square.
An optional blade set, known as the Ultra-Narrow blade set, is also available for purchase.
The Ultra-Narrow blade set is designed to make a very narrow crease. One should use
an ultra-narrow blade set if folding very thin paper (paper thickness close to the minimum
specication for this machine).
Always make sure you have the correct blade set installed before starting a job. When
running into creasing or folding problems, try a different blade set. This can help solve
the problem, even if it is not the usual blade set that is recommended. For blade set
replacement instructions, see the “Replacing Blade Sets” section within this manual.
Choose the Correct Crease Blade Set
Sheet Thickness Blade Set Crease Width
≥ 0.25 mm (0.010”) Standard (supplied w/ machine) 1.3 mm (0.051”)
≤ 0.25 mm (0.010”) Narrow (supplied w/ machine) 1.0 mm (0.039”)
0.1 mm - 0.2 mm (0.004” - 0.008”) Ultra-Narrow (optional) 0.7 mm (0.027”)
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