Related Manuals for Morgana AutoCreaser Pro 385
Summary of Contents for Morgana AutoCreaser Pro 385
- Page 1 Morgana AutoCreaser Pro 385 High Speed Creasing Machine with Deep File Feeder Instruction Manual...
- Page 2 Morgana Pro 385 Feeder/Creaser/Folder Operating Instruction 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 MyBinding.com Date: 02 Dec 2016 5500 NE Moore Court...
- Page 3 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.
- Page 4 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.
- Page 5 Safety Information When using this machine, following safety precautions should always be followed. Safety During Operation 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 specified in this manual.
- Page 6 General Safety (Continued) 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. •...
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Page 8: Table Of Contents
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 ........................ - Page 9 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 ........................
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Page 10: What You Can Do With This Machine
AutoCreaser Pro 385 DigiFold Pro 385 The Morgana PRO 385 is a state of the art feeding, creasing and folding system. There are two primary intended configurations for the Pro 385 system. The first configuration is the Feeder in combination with the Creaser. The second configuration is the Feeder in combination with the Folder. -
Page 11: Guide To Components
Guide To Components Pro 385 Feeder Top Plate, Feeder Exit Feed Sensor (Q7) System Main Power Switch Paper Stop Gate Stack Support Assembly SP Sensor Loading Table Side Lay w/ Separation Fans Base Spine Assembly Latching handles Graphical User Interface Paper Backstop Blower Case / Vacuum Fan Assy Paper Weight... -
Page 12: Pro 385 Creaser
Guide To Components (Continued) Pro 385 Creaser Top Cover, Creaser Antistatic Kit (optional) Creaser Tilt Adjustment Knobs Static Creaser Assembly 2 Articulating Rigid Foot Static Creaser Assembly 1 Caster Entry Sensor (Q20) Indexing Lever Exit Sensor (Q25) Stacker Tray Stacker Guides Creaser Assembly Exit MyBinding.com 5500 NE Moore Court... -
Page 13: Pro 385 Folder
Guide To Components (Continued) Pro 385 Folder Top Cover, Folder Power/Signal Connector Creaser Tilt Adjustment Knobs Interlock Articulating Rigid Foot Antistatic Kit (optional) Caster Dynamic Creaser Assembly Delivery Module Handle Static Creaser Assembly Delivery Module Entry Sensor (Q40) Stacker Guides Folding Roller Assembly Fold Knife K1 Sensor (Q45) MyBinding.com... -
Page 14: User Interface
User Interface 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. -
Page 15: Optional Parts
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. -
Page 16: Pro 385 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. Pro 385 AutoCreaser Component no Quantity Description 1-99-35 Anvil Set 1-99-12 28T Slitter Perforator blade 601-185 Sensor Cleaning Brush 601-118... -
Page 17: Pro 385 Digifold
Optional parts Below are the lists of the optional parts that can be ordered by the user both for the AutoCreaser and for the DigiFold. Pro 385 AutoCreaser 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... -
Page 18: Basics
1. Basics Paper Paper Guidelines Paper comes in many different makes, types and finishes. There are many different ways to print on the paper and then protect that printed image. The grain direciton, fibre 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. -
Page 19: Creasing
Creasing About the Crease 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. -
Page 20: Choose The Correct Crease Blade Set
Choose the Correct Crease Blade Set 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. Sheet Thickness Blade Set Crease Width ≥... -
Page 21: Replacing Blade Sets
Replacing Blade Sets Before removing the blade assembly, ensure that the lower blade / anvil is at “Top Dead Centre”- See the “setting crease” section of this manual Switch the machine off Lift the top cover Using a 5mm allen key, remove the two socket head screws, one at each end of the Blade Set [A] Remove the Sheet Guide Assembly, by... - Page 22 Replacing Blade Sets (continued) Insert the Blade Extractor Tools, one at each end of the Blade Set, as shown Note The Position of The Blade Extractor Tool Under The Lip of The Blade Adjuster Assembly Pull the Blade Assembly in the direction shown to unclip and release the Blade Set Slide the blade assembly out of the creasing unit and lay it on a flat surface Slide the blade adjustment cams and the blade adjustment assemblies away from the dowels located in the ends of the blades / anvils as shown in the figure below...
- Page 23 Replacing Blade Sets (continued) Slide the blade adjustment assemblies and the blade adjustment cams onto the dowels of the new blade set Slide the new blade set into the slots of the creasing unit as shown NOTE: The blade can be fitted with the ANVIL at the bottom or with the ANVIL at the top.
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Page 24: Setting The Crease Tilt Knobs
Crease Tilt Knobs allow the user to get a perfectly perpendicular crease on the paper. User adjustment might be needed if crease positions are not perpendicular. AutoCreaser Pro 385 Knob Adjustment Procedure - Blades 1 and 2 From the GUI, select a two-crease... - Page 25 Setting the Crease Tilt Knob (continued) DigiFold Pro 385 Knob Adjustment Procedure - Blade 2 From the GUI, select a one-crease custom fold (see section 2) and load paper. From the fold configuration sub-menu, change both the folding offset values to 0 (see section 2).
- Page 26 Setting the Crease Tilt Knob (continued) DigiFold Pro 385 Knob Adjustment Procedure - Blade 1 From the GUI, select a one-crease custom fold (see section 2) and load paper. Turn the folding option off (see section 2). Run a test sheet (see section 2). If the crease is not in the correct position (see figure 3), adjustment is needed.
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Page 27: Folding
Folding About the Fold A fold is made when a sheet of paper is pushed through a pair of fold rollers by a fold-knife. This is known as a right-angle fold because the fold is made 90° to the direction of sheet travel. - Page 28 While setting up a job, the roller gaps are set to specified distances automatically. If results are unsatisfactory (i.e. cracking of the print is noticeable), these gaps may need to be adjusted manually to improve results. The table below details the default values for the roller gaps, per fold setting.
- Page 29 X represents the thickness of the sheet. Measure the sheet thickness accurately using a digital Vernier Caliper to determine what X is. Example: When producing a Half K1 fold with a 0.10 mm thick sheet of A4 paper, X is equal to 0.10 mm and the Roller Gaps are automatically set to the following values: Gap 1 = X = 0.10 mm Gap 2 = 2X = 0.20 mm...
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Page 30: Deflects
Deflects About Deflects The FlyingKnife folding system has a unique function that lets the machine pass flat sheets through the fold rollers. This operation is known as a deflect. When you choose to do a half fold on K1 or K2, the fold knife that is not used to fold the document becomes a deflector. -
Page 31: Perforating
Perforating Using the perforation Once the Machine is set-up, it can be used to perforate or crease. NOTE: 1. Perforating and creasing can be carried out simultaneously. However, if any adjustment is made to the roller tilt mechanism in order to compensate for the perforation line being “out of square”, this may effect the accuracy of the crease. - Page 32 Using a 2mm allen key, loosen the drive hub nearest the perforating drive. Slide the drive hub away from any obstructing drive wheels or hubs in order to mount the anvils. Using a 2.5mm allen key, take one half of the matching pair of anvils and mount to the drive hub.
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Page 33: Turning On / Off The Power
Turning On / Off the Power Main Power Switch Ensure that the main power cord is plugged into the wall and to the power socket [A] of the Pro 385 Check that terminator plug [B] is plugged in the Creaser / Folder Toggle on/off the Main Power Switch [C]... -
Page 34: Calibration
Calibration Sensor Calibration The Pro 385 has an Ultrasonic Double Sheet Detection (DSD) sensor [A]. If feed errors begin occuring more frequently, this sensor may need to be calibrated. Please contact a certified service technician if calibration is required. Stop Gate Distance Calibration The position of the stop gate [A] may need to be calibrated if feed errors begin occuring more frequently. -
Page 35: Folder Bypass Tray Installation
Folder Bypass Tray Installation Fold the delivery extension [A] onto the Delivery Module Move the delivery roller on top of the delivery extension Hold the handle and push it to move the delivery module down Put the Bypass Tray in place and pull the plungers [B] Release the plungers MyBinding.com 5500 NE Moore Court... -
Page 36: Setting Up A Job
2. Setting Up a Job Quick Start 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. - Page 37 Quick Start Screen 3: A) Letter Fold Fold Settings B) Concertina Fold The operator selects the desired fold C) Half Fold Knife 2 configuration within this sub-menu. D) Half Fold Knife 1 The creasing and folding process for E) Engineering Fold each fold setting is detailed in the F) Gate Fold Pro 385 Quick Reference Sheet.
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Page 38: The Run Screen
The Run Screen After completing the Quick Start process or by pressing the “play” button on the home screen, the Run Screen will appear. The Run Screen displays the system status and key job parameters. It also allows for manual modification of settings. The key job parameters and manual modification sub menus are described below in this section. -
Page 39: Modifying Settings
Modifying Settings Paper Size and Thickness Paper Size and Thickness The Paper Size sub-menu allows for selection of standard formats and custom paper sizes. Paper orientation and paper thickness is also selected within this sub-menu. Paper Size parameters must be chosen prior to loading paper. -
Page 40: Crease Settings
Crease Settings Crease Settings The operator switches creasing on / off and selects the desired folding option within this sub-menu. The many folding options are described below. A) Letter Fold B) Concertina Fold C) Half Fold Knife 2 D) Half Fold Knife 1 E) Engineering Fold F) Gate Fold G) Closed Gate Fold... - Page 41 Crease Settings Customizing crease position Pressing the button of the chosen folding option will open the customizing screen. The operator can adjust the position of the creases on the paper by increasing / decreasing the values at the right side of the screen.
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Page 42: Pro 385 Quick Reference Sheet
Pro 385 Quick Reference Sheet DigiFold Pro 385 Quick Reference Sheet Fold 2 Half Fold K1 K2 Fold 1 Deflect Fold 2 Double Parallel Fold Fold 1 Fold 2 Engineering Fold Fold 1 Gate Fold 2 Fold Fold 1 Closed Fold 2 Fold 1 Fold 2... -
Page 43: Custom Crease
Custom Crease Custom crease Press the marked button to enter this sub menu. This page allows the user to customize the number and the position of the creases on the sheets. When opened, this menu will list the creases of the last folding option chosen. -
Page 44: Fold Configuration
Fold Configuration Fold configuration The operator selects the desired folding offset and switches folding on / off within this sub-menu. Folding offset The operator can adjust the folding offset on the paper by increasing/ decreasing the value at the right side of the screen. -
Page 45: Roller Gap Adjustment
Raise the Delivery Module When switching the fold on, this screen will remind the user to take the Bypass Tray off and raise the Delivery Module. Press the green checkmark button after having completed the operation. Roller Gap Adjustment Roller Gap Adjustment This sub-menu allows the user to adjust the distance between the rollers manually. -
Page 46: Save A Job
Save a Job Save a job Select the marked button to access all saved jobs. See “Creating and Saving Jobs” in this section for how to use this menu. Batch Jobs Batch Jobs Select the marked button to set up batch jobs within this sub-menu. -
Page 47: Fans And Choke Settings
Fans and Choke settings Fans and Choke settings Select the marked button to enter this sub-menu. If automatic settings provide unsatisfactory results, fan settings may be adjusted manually from within this sub-menu. Press the marked arrow to get to the Choke settings menu. -
Page 48: Delivery
Delivery Delivery Press the marked button to enter this sub-menu. Distance between the single sheet and delivery roller position are set automatically depending on the size of the paper fed. These values can be adjusted manually by the user with custom settings. -
Page 49: Running Test Sheets
Running Test Sheets Run Test Sheets Selecting the “1” button will run one test sheet through the system. Action Buttons Action Buttons Press the “play” button to start the job. Press the “pause” button to hold the job. Press the “stop” button to abort the job. -
Page 50: Expert User Options
Save changes Load Job After having selected the desired job from the list on the left, the user can: -load it, -edit its name, -erase it. When a job is loaded, the user can make changes to it and save them by pressing the “save changes”... -
Page 51: Job Completed
Job completed Job completed This screen will appear when a job has been completed without errors. Press the marked checkmark button to get back to the Run Screen. Check Paper Size Check Paper Size If there is paper on the stack support when switching the Pro 385 on, the system will ask the user if the paper size is that of the last job used. - Page 52 Custom settings order When setting a job on the Pro385, always start with entering the format sizes: leght, width and thickness. Then continue with the adjustment of the crease, fold, roller gaps, fans, choke and delivery module according to the numbering of the picture above. If you do not follow this order some of the changes might be discarded.
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Page 53: Job Preparation
Job Preparation Loading Paper Choose paper size in Graphical User Interface (Quick Start or Manual selection) Open Feeder Top Cover Load Paper NOTE: Paper Size parameters must be chosen prior to loading paper. After choosing paper size, the Backstop and Side Lay are shifted automatically to the proper locations. Crease Pressure You must set the crease pressure correctly to make a good crease. -
Page 54: Setting Crease Pressure
Setting Crease Pressure Access the Tools menu (see Expert User Options Section in this manual) Select the two marked arrows to move the blade to the “Top Dead Centre” Raise the exit guard Using a 5mm allen key, unlock the socket head screws positioned at each end of the creasing blade. - Page 55 Page intentionally blank. MyBinding.com 5500 NE Moore Court Hillsboro, OR 97124 Toll Free: 1-800-944-4573 Local: 503-640-5920...
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Page 56: Expert User Options
3. Expert User Options Accessing Expert User Options Expert User Options Press the marked button to access expert user options. Expert User Main Menu Expert User Menu From within this sub-menu, the operator can choose between: -DSD switch button -Conversion button -Service -Settings in production -Tools... -
Page 57: Conversion Button
Conversion button Conversion button Press the marked button to toggle between inches and millimiters. Service menu Service Menu This is only for certified service technicians. Please contact a certified service technician if service is required. Plint Plint This is only for certified service technicians. -
Page 58: Settings In Production
Settings in production Settings in production This is only for certified service technicians. Please contact a certified service technician if service is required. Tools menu Tools menu Press the marked button to enter this sub-menu. This sub-menu allows the user to move rollers and knives to clear paper jams. - Page 59 Page intentionally blank. MyBinding.com 5500 NE Moore Court Hillsboro, OR 97124 Toll Free: 1-800-944-4573 Local: 503-640-5920...
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Page 60: Troubleshooting - General
4. Troubleshooting - General Misfeeds/Jams Misfeed/Jam in Feeder Area Open the Feeder Top Plate [A] Clear any obstructions in the feed area If sheet has been misfed and is not damaged, reposition and restart If sheet is damaged, replace it Once the area has been cleared, press the green checkmark button on the screen MyBinding.com 5500 NE Moore Court... -
Page 61: Jam Between Units Or Jam In Creaser/Folder
Jam between Units or Jam in Creaser/Folder Open the Creaser / Folder Top Cover [A] If the sheet has been misfed and isn’t damaged, reposition and restart If the sheet has entered the rollers, use the GUI: press home, then expert, then tools and use the arrows to move the rollers Once the area has been cleared, press green checkmark button on the screen MyBinding.com... -
Page 62: Recommended Settings Adjustments
Recommended Settings Adjustments It is always recommended to use default settings, however, if default settings are not providing satisfactory results, operator adjustments may be required. The floating portion of the paper stack should be equally distributed, i.e. gaps between each sheet of paper should be equal. To achieve this, the operator may adjust any of the following parameters: -FAN1 Power (Feed Belt Suction Fan): may need to be adjusted to create the proper amount of suction from behind the feed belts;... - Page 63 Recommended Settings Adjustments (continued) The operator can also modify the following settings if default settings are generating misfeeds or jams too frequently: -Stop Gate Position: The stop gate may need to be moved up to ensure single sheet feeding or down to allow for thicker sheets to feed without jamming; -Hsys: The Hsys parameter is the distance between the vacuum drum and unseparated paper stack.
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Page 64: Troubleshooting - Fault Codes
5. Troubleshooting - Fault Codes Pro 385 Fault codes General When there is a misfeed or fault condition in the Pro 385, a message and fault code will be displayed on the GUI. Some fault codes may be rectified by the operator, but some fault codes may only be rectified by a certified service technician. -
Page 65: Pro 385 Jam Codes
Pro 385 Jam Codes JAM 101 - Feed not initiated This code is displayed if the DSD Sensor (Q10) was not activated in time. This means that the paper cannot be pulled by the vacuum. Actions: -See Section 4 - Misfeed/Jam in Feeder Area -Lower stop gate -Adjust choke feed angle -Change choke pick up angle... - Page 66 Pro 385 Jam Codes (Continued) JAM 105 - Feeder Exit Jam C This code is displayed if the exit sensor (Q7) was activated for too long: this means that there is a paper jam between the rollers. Actions: -Shake papers to reduce static friction -See Section 4 - Jam in Feeder Area -Ensure that there are no obstructions in the paper path JAM 106 - No Paper...
- Page 67 Pro 385 Jam Codes (Continued) JAM 205 - Q21 Blade 1 home sensor not actuated in time during run Q21 Blade 1 home sensor not actuated in time during run means that that the Q21 Blade 1 home sensor was not actuated in time during run. Actions: -Check creaser 1 position (see setting crease pressure) -Ensure that there are no obstructions in the paper path...
- Page 68 Pro 385 Jam Codes (Continued) JAM 302 - Jam between units C Jam between units C occurs when Q40 sensor is activated for too long. This means that the paper got stuck between the rollers. Actions: -See Section 4 - Jam in the Folder -Check input guides -Check that creaser tools are in open position (see setting crease pressure) -Ensure that there are no obstructions in the paper path...
- Page 69 Pro 385 Jam Codes (Continued) JAM 311 - Folder position error This error occurs when the Q47 folder knife drive home sensor not actuated in time during run. Actions: -Remove any misfed sheet(s) -Ensure that there are no obstructions in the paper path JAM 312 - Exit sensor not covered in time This error occurs when the Q52 sensor is not actuated in time during run.
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Page 70: Pro 385 Error Codes
Pro 385 Error Codes General Error Code description: “mechanical error” This error appears when there is a mechanical error in one of the modules of the Pro 385. Press the checkmark button to clear this error. If pressing the button does not clear the error, contact a certified service technician. - Page 71 Pro 385 Error Codes (Continued) Empty paper stack This error appears when the paper stack is empty. Load the machine with more paper and press the ckeckmark button to clear this error. Press the arrow button to move the stack support down. Close top cover Close the feeder’s top cover to clear this error.
- Page 72 Pro 385 Error Codes (Continued) Remove stack of paper Remove paper from the stack support. After having removed the paper, the green checkmark button will appear, press it to clear this error. Interrupted initialisation If initialisation is interrupted (e.g. a cover is opened), the “interrupted initialisation”...
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Page 74: Remarks
6. Remarks Do’s And Don’ts • Always follow all warnings marked on, or supplied with, the equipment. • Always exercise care in moving or relocating the equipment. Caution Unplug the power cord from the wall outlet and machine before you move or relocate the equipment. -
Page 75: Where To Put Your Machine
Where to Put Your Machine Machine Environment • Always locate the equipment on a solid support surface with adequate strength for the weight of the machine • Always keep magnets and all devices with strong magnetic fields away from the machine •... -
Page 76: Access To Machine
Access to Machine Place the machine near the power source, providing clearance as shown. AutoCreaser Pro 385 Service Access 1000 mm 39.4” Operator Access 1400 mm 55.1” DigiFold Pro 385 Service Access 1000 mm 39.4” Operator Access MyBinding.com 1500 mm 5500 NE Moore Court 59”... -
Page 77: Maintaining Your Machines
Maintaining Your Machines Never attempt any maintenance function that is not specifically described in this documentation. Pro 385 Maintenance Recommended Weekly Operator Maintenance • Clean in feed rollers and output drive hubs using the supplied cleaning kit • Remove and clean the blade assembly •... -
Page 78: Limitations Of The Pro 385
Limitations of the Pro 385 • The monthly sheet volume average for the AutoCreaser Pro385 is 450k, the monthly sheet volume average for the DigiFold Pro385 is 320k. • If sheets entering the Pro 385 are not uniform and square, the output quality will vary accord- ingly. - Page 79 Page intentionally blank. MyBinding.com 5500 NE Moore Court Hillsboro, OR 97124 Toll Free: 1-800-944-4573 Local: 503-640-5920...
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Page 80: Specifications
+6% / -10%, Operating temperature 10-30°C Humidity 30-80% RH Sound emissions 80 dB Morgana use open source code in parts of this product Machine Specifications - Creaser Pro385 Specifications Remarks Upstream Device Compatibility Feeder Pro385 Power Source 100-240 V / 50-60 Hz... - Page 81 Product Length Width Height Weight Feeder Module 1088 mm/ 693 mm/ 1073 mm/ 175 kg/386 lb 42,8 in 27,3 in 42,2 in Creasing Module 328 mm/12,9 in 652 mm/25,7 in 1165 mm/45,9 in 80 kg/176 lb Folder Module 379 mm/14,9 in 652 mm/25,7 in 1265 mm/49,8 in 140 kg/309 lb...
- Page 82 Quality Conditions: • Paper size is assumed to be perfect • Sheets are assumed to be perfectly 90° • Tolerances are referring to deviations within one job Crease Position Variation ± 0,20 mm ± 0,20 mm Crease skew ± 0,25 mm ±...
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Page 83: Eu Declaration Of Conformity
EU DECLARATION OF CONFORMITY ..... N0004413 (A.2) Manufacturer ... Morgana Systems Ltd, Davy Avenue, Milton Keynes MK5 8HJ, United Kingdom This Declaration of Conformity is issued under the sole responsibility of the manufacturer Object of the Declaration Type/Model F128-001 F129-001...
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