T08135D ProXL Service Manual

PRO XL
SERVICE MANUAL
T08135D
18 February 2022
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 recievers may be expected within a distance of 10 m of the
apparatus concerned.
18 February 2022
Pro XL ii T08135D
Introduction
This manual contains instructions on the operation and maitenance of this machine. To get the 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 PROB-
LEMS.
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 prop-
erty.
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 miss-operation
Limitations like numerical limits, functions that cannot be used together or conditions, under which a particular function cannot be used or obtained.
Information.
[ ]
Keys that appear on the machine’s display panel.
18 February 2022
Pro XL iii T08135D
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.
• Turn off the power and disconnect the power plug (by pulling the plug, not the cable) if any of the following conditions exists:
• Before disassembling or assembling parts of the System and peripherals.
• 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 specifically instructed).
• If any adjustment or operation check has to made with exterior covers off or open while the main switch is turned on, keep hand away
from electrical or mechanically driven components.
• Note that components of the System and peripherals can be supplied with electric voltage even if the mail power switch is turned off and
the power cord is disconnected.
• 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 re-
quired to take adequate measures.
• The product (System) which is connected to this machine will be class A.
18 February 2022
Pro XL iv T08135D
General safety
WARNING:
• Always connect the equipment to a properly grounded power source (wall outlet). Wall outlet should be located near the system and eas-
ily accessible. If in doubt, have the power source checked by a qualified 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 specific purpose only. Any use going beyond this specific purpose is regarded 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 modifications to the machine. The manufacturer will not be liable for modifications made at the ma-
chine on your own and damages resulting 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 responsibilities 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 fingers 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.
• This equipment is not suitable for use in locations where children are likely to be present.
• This equipment is only intended for instructed and qualified operators.
• Operators and technicians shall be familiar with the safety information in this manual and other safety information supplied with this equip-
ment.
18 February 2022
Pro XL v T08135D
TABLE OF CONTENTS
1 Unpack and Installation
2 Preventive Maintenance Schedule
3 Replacement and Adjustment
4 Troubleshooting
5 Service Tables
6 Detailed Section Descriptions
7 Specifications
8 Master Wiring Diagram
18 February 2022
Pro XL vi T08135D
1 Unpack and Installation
1.0 Unpacking Instruction - Pro XL....................................................1-2
2.0 Installation Instruction - Pro XL...................................................1-6
2.1 Minimum space requirements..............................................1-6
2.2 Power requirements.............................................................1-7
2.3 Accessory check...................................................................1-8
2.4 Levelling the machine...........................................................1-9
2.5 Tilt knob installation............................................................1-10
2.6 Stacker installation (AutoCreaser Pro XL only) .................1-10
2.7 Stacker installation (DigiFold Pro XL only)......................... 1-11
2.8 Optional BST4000 installation (DigiFold Pro XL only)........1-12
2.9 Top shoot installation (DigiFold Pro XL only)......................1-14
2.10 Feeder table extension installation (optional).....................1-15
2.11 Fuse replacement (if required)...........................................1-16
3.0 Power On and Calibration Check - Pro XL................................1-17
3.1 Plug in and power on..........................................................1-17
3.2 Module alignment check.....................................................1-18
3.3 Creaser calibration check...................................................1-20
Page intentionally blank.
3.4 Fold calibration check (DigiFold Pro XL only).....................1-20
3.5 Checking for software updates...........................................1-21
4.0 Calibration Procedures - Pro XL................................................1-22
4.1 Feeder alignment to AutoCreaser/DigiFold Pro XL.............1-22
4.2 Creaser calibration....................................................................1-23
4.3 Fold calibration..........................................................................1-25
4.4 Updating software - single point download...............................1-26
4.5 Updating NVM values...............................................................1-26
18 February 2022
Pro XL 1-1 Unpacking & Installation Instruction
1.0 Unpacking Instruction - Pro XL
WARNING!
Two people are required to pack/unpack the Pro XL, only qualified/
trained personnel should perform the procedures described in this
document. 2. Remove components [C] placed on top of unit and then ramp [D].
1. Cut packaging straps [A] and remove top cover [B] of box.
C
NOTE: Box transparent for clarity.
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[3] Remove outer cardboard box [E], plastic wrap [F] and protection foam [4] Fold down cardboard box base [H] & place ramp supports [K] under
[G]. pallet.
F G E
H H
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[5] Place ramp [D] onto supports [K]. [6] Lower the feet [L] (x8) onto Machine Foot [N] (x8) to raise machine. Re-
move Foam supports [M] (x4) from under machine. Raise Feet [L] (x8) and
remove Machine Foot [N] (x8) so the machine is resting on the wheels.
WARNING!
Two people are required to carefully roll down the Pro XL. NOTE: Cardboard base removed for clarity.
K
M
L L
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[7] Carefully roll unit down the Ramp. Position the unit in the desired loca-
tion.
WARNING!
Two people are required to carefully roll down the Pro XL.
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2.0 Installation Instruction - Pro XL
2.1 Minimum space requirements

Pro XL
Length Access
Width including access

Width
Width
Inline
Access
1
O
r
90°
Actual Product Dimensions (For Reference)

Position Product Length Width Height Width including access
AutoCreaser Pro XL
1 AutoCreaser Pro XL 1690mm / 66.5” 730mm / 28.7” 1160mm / 45.7” 1740mm / 68.5”
2 AutoCreaser Pro XL with feeder table fully extended 2540mm / 100” 730mm / 28.7” 1160mm / 45.7” 1740mm / 68.5”
DigiFold Pro XL
1 DigiFold Pro XL 2130mm / 83.9” 730mm / 28.7” 1395mm/ 54.9” 1740mm / 68.5”
2 DigiFold Pro XL with feeder table fully extended 2990mm / 117.7” 730mm / 28.7” 1395mm/ 54.9” 1740mm / 68.5”
BST4000 optional DigiFold Pro XL only
BST4000 1800mm / 70.9” 480mm / 18.9” Adjustable N/A
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2.2 Power requirements
WARNING
1. Make sure that the wall outlet is near the main machine and easily
accessible. Make sure the plug is firmly inserted in the outlet.
2. Avoid multi-wiring.
3. Be sure to ground the machine.
4. Never place anything on the power cord.
Power supply Voltage [V ac] Current
Switched-mode 100 - 240V, 50/60Hz 8 – 4A

Tolerance -10/+6%
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2.3 Accessory check
Item Qty Description

Installation kit contents:
3
1 1 Safety instruction
2 1 AutoCreaser Pro XL Operator manual
DigiFold Pro XL Operator manual 1 2
3 1 Power cord kit
4 1 Fuse kit T12A
5 1 CAN termination plug
6 1 Digital thickness gauge
7 1 28T rotary perforation blade (7 TPI)
8 1 Rotary perforation / slitting anvil 4 5
9 8 Machine foot
10 1 Inch fraction chart
In feeder shelf:
11 2 Multi-purpose wrench
12 1 Hex key set
6 7 8 9
13 1 Sensor cleaning brush
14 1 Roller cleaning brush
Under feeder front cover:
15 1 Screwdriver Torx T20
16 1 USB memory stick for performing machine
software updates 10 11 12 15 16
17 1 Calibration strip for ultrasonic double
sheet detector
18 1 Interlock cheater
13 14 17 18
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2.4 Levelling the machine
1. Place one machine foot [A] under each screw (8x). 3. Use a spirit level and adjust the feet until the machine is level.
2. Use the provided multi-tool or another 19 mm wrench to raise the ma- 4. Use both multi-tools or two 19 mm wrenches to lock off the machine
chine off the floor. Check that the casters move freely and the machine feet [B].
does not rock.
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2.5 Tilt knob installation 2.6 Stacker installation (AutoCreaser Pro XL only)
1. If creaser tilt adjustment knob [A] is not installed, screw it in its socket 1. Hook the stacker [A] on the stacker brace [B] as shown.
as shown.
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2.7 Stacker installation (DigiFold Pro XL only)
4. Insert two screws [E] into shaft [F] to secure the conveyor in place
WARNING! 5. Plug in two electrical connectors [G] from the conveyor into the ma-
After installation check the exit guide [J] does not touch the fold roller [K]. chine
1. Open top cover and remove screws [A] to release exit guide [J].
2. Hook the conveyor [I] onto hooks [B].
F G
J K
6. Close conveyor cover [C] and screw it shut [D].

7. Install catch tray [H] and support hoop [L] if not installing BST4000.
8. Reinstall exit guide [J].
B A B
3. Remove screws [D] to open conveyor cover [C].
C L
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2.8 Optional BST4000 installation (DigiFold Pro XL only)
Installing the BST4000 in conjunction with the DigiFold Pro XL requires the BST4000 sensor moves to the DigiFold Pro XL delivery. This is because the
BST4000 sensor cannot always identify black or very dark printed sheets against the BST4000 black transport belt.
The following describes this procedure:
1. Release spring-loaded plunger [A] (x2). 7. Position BST4000 [E] as required.
2. Move delivery pivot plate [B] from position 1 to position 2.
3. Insert spring-loaded plunger [A] (x2).
4. Release stacker slide plate knob [C] (x2).
5. Move stacker slide plate [D] from position 1 to position 2.
6. Lock stacker slide plate knob [C] (x2).
E
Position 1: Stacker operating position without BST4000
8. Remove screws [H] (if not already removed) to open conveyor cover
[I].
B D C A
H
Position 2: Stacker operating position with BST4000
Continued on next page...

18 February 2022
9. Remove bracket [J]. 14. Detatch sensor [M] from BST4000 by releasing sensor retaining nut
10. Close conveyor cover [I] & secure with screws [H]. [N] & cable connection [O].
15. Release excess cable [P] from under BST4000.
O P
11. Loosen stacker slide plate knob [K].
12. Position bracket [J] onto spacer [L] & stacker slide plate knob [K].
13. Tighten stacker slide plate knob [K] to secure bracket [J].
16. Feed sensor [M] through bracket [J].
17. Secure sensor [M] with sensor retaining nut [N].
J 18. Connect excess cable [P] to sensor [M].
19. Ensure sensor [M] is aligned with cut-out [F].
20. Secure cable [P] and sensor [M] with cable ties.
J N
F F
L K
CAUTION!
After installation check the cables are secured away from moving parts.

18 February 2022
2.9 Top shoot installation (DigiFold Pro XL only)
21. Adjust sensor [M] sensitivity by releasing sensor retaining nut [N]. 1. Open DigiFold Pro XL top cover [A].
22. Adjust potentiometer screw [Q]. 2. Locate top shoot screws [B] (x8) into DigiFold top cover.
23. Resecure sensor [M] with sensor retaining nut [N]. 3. Secure top shoot with nuts [C] (x8).
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2.10 Feeder table extension installation (optional)
Install table extension if using sheets longer than 700 mm / 27.6” 3. Hook the table extension [B] into the lift [C] as shown.
1. Attach paper support from the install kit to the pull-out part of the table
extension using the included multi tool or another 7 mm wrench.
2. Ensure the built-in pull-out table [A] is fully stowed.
18 February 2022
2.11 Fuse replacement (if required)
WARNING
Make sure the power cord is unplugged before replacing the fuse.
This machine is shipped with a T6.3A fuse installed. This fuse works in
140-240 V ac environments. If this machine is going to be used in a 100-
140 V ac environment, the T6.3A fuse needs to be replaced with the T12A
fuse shipped with the machine.
Procedure:
1. Unlock the fuse holder knob [A] with a flat-head screwdriver and re-
move the T6.3A fuse and its black holder.
2. Replace the fuse with the T12A fuse and its matching grey fuse holder.
Lock the fuse holder in place. A
100-140V AC 140-240V AC
T12A 6.3x32 mm T6.3A 5x20 mm
18 February 2022
3.0 Power On and Calibration Check - Pro XL
3.1 Plug in and power on
WARNING
Do not plug in the machine with the wrong power cord.
1. Plug in the main power cord [A] between the machine and the wall 2. Plug in the CAN termination plug [B].
socket. 3. Turn on the main power switch [C].
18 February 2022
3.2 Module alignment check
2. Take a stiff sheet of paper [A] and slide it against the registration wall
To check that the machine has not lost its factory set alignment calibration [B].
during shipping and/or handling carry out the following procedure: NOTE: Paper [A] must adhere to Paper Guidelines section of this
manual.
1. With the machine powered off open the top cover. 3. Slide the sheet forwards until it comes in contact with creaser rollers.
Check if both corners [C] of the sheet enter the rollers at the same
time. Make sure that during this check the sheet remains parallel to
the registration wall.
4. If sheet [A] does not enter the rollers at the same time refer to “4.1
Feeder alignment to AutoCreaser/DigiFold Pro XL”.
Center in cut-out

18 February 2022
5. Close the top cover and power on the machine. 8. To adjust crease skew, loosen the crease adjustment knob by rotating
6. Run a proof sheet with a single crease and inspect the output. it counterclockwise.
9. Move the knob slightly, either to the left or to the right depending on
7. If the crease is skewed, adjustment is necessary. the direction of the crease skew.
NOTE:
Wrong crease positions are marked in red, correct crease position is
marked in green.
10. Rotate the knob clockwise to secure it.

11. Run another proof sheet to check if the crease is now perpendicular to
sheet edge. Repeat steps 6 to 10 if necessary.
18 February 2022
3.3 Creaser calibration check 3.4 Fold calibration check (DigiFold Pro XL only)
To check that the machine has not lost its factory set crease calibration To check that the machine has not lost its factory set fold calibration during
during shipping and/or handling carry out the following procedure: shipping and/or handling carry out the following procedure:
1. Turn off Fold, run a proof sheet with a half fold pattern. 1. Turn off Crease, run a proof sheet with knife 1 half fold pattern.
2. Measure the distance between the lead edge of the paper and the 2. Measure the distance between the lead edge of the paper and the
crease. The measurement should equal to the paper length divided by fold. The measurement should equal to the paper length divided by 2.
2. 3. Repeat steps 1 & 2 with knife 2 half fold pattern.
Crease
Fold
Measure
Measure
Feed direction
Feed direction
3. If the measurement is not within the machine tolerance (± 0.25 mm / ±

0.001”) continue to “4.2 Creaser calibration”. 4. If the measurement is not within the machine tolerance (± 0.25 mm / ±
0.001”) continue to “4.3 Fold calibration”.
18 February 2022
3.5 Checking for software updates
1. To check currently installed machine software version, go to Tools ->
Software version
2. To check if there are software updates available for this machine go
to Plockmatic Group website and log in to the Partner Centre (https://
plockmaticgroup.com/customer-login/). Find the latest software down-
load for this machine and compare version numbers.
3. If an update is available, follow “4.4 Updating software” or the techni-
cal bulletin supplied with the software.
18 February 2022
4.0 Calibration Procedures - Pro XL WARNING
Do not expose fingers or other parts of the body to moving, rotating
4.1 Feeder alignment to AutoCreaser/DigiFold Pro XL or cutting devices when running the machine without the covers
installed. Do not wear ties, lanyards or other things that might get
Removing DigiFold/AutoCreaser – Cover, Front trapped into the rollers and cause injuries.
1. Turn off the power switch and disconnect the power cord.
6. Release nuts on brackets [G] using a 13 mm wrench.
2. Remove 2x screws [A] using a T20 screwdriver or a 7 mm wrench.
7. Use bracket [H] to adjust angle between the modules. If the inboard
3. Remove tilt knob(s) [B] by rotating them counterclockwise.
(registered) corner of the sheet exits the rollers first, release nut [I] and
4. Lift the front cover up and then out.
tighten/loosen nut [J] to reduce the gap between the modules. If the
outboard (operator side) corner of the sheet touches the rollers first,
B
release nut [J] and tighten/loosen nut [I] to increase the gap between
modules.
8. Lock off bracket [H] and brackets [G]. Run a proof sheet with a single
crease. Check whether the sheets are “floating” in the creaser and
whether the crease is skewed.
9. Repeat steps 7 & 8 until the modules are aligned.
10. Reinstall covers that were removed as part of this procedure, unless
calibration of AutoCreaser/DigiFold Pro XL is required.
A
A
I J
Removing Feeder – Front cover F
5. To remove [C] unscrew skew adjustment locking knob [D] and use a 7
mm wrench or a T20 screwdriver to remove 3x bolts [E].
EE
C
G
EE
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4.2 Creaser calibration 5. If crease skew (difference between registered side and operator side)
is > 0.25 mm mechanical adjustment is necessary.
WARNING To calibrate the position one creaser use a 6 mm hex key to loosen 4x
Do not expose fingers or other parts of the body to moving, rotating screws [A].
or cutting devices when running the machine without the covers or
installed. Do not wear ties, lanyards or other things that might get To calibrate the position two creaser use a 6 mm hex key to loosen 4x
trapped into the rollers and cause injuries. screws [B].
1. Ensure feeder skew adjustment knob and creaser tilt knob are cen- Shift the creaser support blocks forward or back to correct for the mea-
tered. sured crease skew. Repeat steps 3.-5. until crease skew is < 0.25 mm.
2. Load paper in the feeder. For best results use 200 – 250 gsm paper at
least 450 mm in length (or longer).
3. Set up a half fold job and run a proof sheet.
4. Measure the distance between the lead edge of the paper and the A B
crease at the registered side and at the operator side.
Crease
Measure
Feed direction
Measure
A B

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6. When crease skew is < 0.25 mm the creaser NVM values can be 9. Exit Service mode and repeat steps 6.-7. If the error is within toleran-
calibrated. Set up a custom job with a single crease at 50 mm and run ce, proceed to step 10. If the error is out of tolerance, repeat step 8.
a proof sheet. 10. Repeat steps 10 & 11 until the crease position is within tolerance.
7. Measure the distance between the lead edge of the paper and the 11. Reverse removal procedure for all covers that have been removed.
crease. Calculate the error:
Position Error = Target Position - Measured Position

Crease
Measure
Feed direction
Measure
8. Increment the relevant distance NVM value by the error. To enter the
NVM screen follow procedure “4.5 Updating NVM values”:
• If the error is positive, increase the NVM. If the error is negative,
decrease the NVM
• The NVM is stored in units mm×10, so if the error is 0.5 mm change
the NVM by 5 units.
AutoCreaser Pro XL “Crease”
• Calibrating the first position creaser – NVM001 “Crease Tool 1
distance from Q20”
• Calibrating the second position creaser – NVM002 “Crease Tool 2
DigiFold Pro XL “Crease”
• Calibrating the first position creaser – NVM001 “Crease Tool 1
• Calibrating the second position creaser – NVM002 “Crease Tool 2
NOTE:
Section 5.3 contains instructions on accessing and changing NVM values.
18 February 2022
4.3 Fold calibration 4. Exit Service mode and repeat steps 1 & 2 If the error is within toleran-
WARNING ce, proceed to step 5. If the error is out of tolerance, repeat step 3.
or cutting devices when running the machine without the covers 5. Set up a custom job with a single knife 1 fold at 400 mm (or more if the
installed. Do not wear ties, lanyards or other things that might get paper length allows it) and run a proof sheet.
trapped into the rollers and cause injuries. 6. Measure the distance between the lead edge of the paper and the
Fold. If the error is within tolerance the calibration is complete. If it is
1. Set up a custom job with a single knife 1 fold at 100mm and run a out of tolerance, the relevant stretch NVM value must be updated:
proof sheet. • Calibrating the position fold knife 1 – NVM005 “Stretch fold knife
2. Measure the distance between the lead edge of the paper and the 1”
fold. Calculate the error: • Calibrating the position fold knife 1 – NVM006 “Stretch fold knife
2”
Fold Target Position
New Stretch Value = × Old Stretch Value
Measured Position
7. Repeat steps 5 & 6 until the crease position is within tolerance.

8. Repeat procedure for fold knife 2.
Measure 9. Reverse removal procedure for all covers that have been removed.
Feed direction
decrease the NVM
• The NVM is stored in units mm×10, so if the error is 0.5 mm change
the NVM by 5 units.
• Calibrating the fold knife 1 – NVM003 “Fold knife 1 distance from
Q40”
Q40”
18 February 2022
4.4 Updating software - single point download 4.5 Updating NVM values
Note: 1. Go to Tools [A] -> Service mode [B]
If any PCB is replaced, you must first load it individually with a valid 2. When prompted enter password 1974 and click the tick mark.
software. These instructions can be found in the technical bulletin 3. Use the Change Target button [C] to select the desired module. Cur-
supplied with the software. Single point download will only work for rently selected module is displayed in the top left corner of the screen:
upgrades of system where all PCB’s already have valid software of • canid(10) – feeder module
minimum launch version. • canid(20) – creaser/folder module
4. Click the NVM button [D] to see a list of NVMs for the selected module.
Procedure Single Point Download, Feeder/AutoCreaser/DigiFold system. 5. Select and change the desired NVM value. For some NVM values the
(Note! Feeder/AutoCreaser/DigiFold UI needs to be loaded separately) machine needs to be restarted for the change to take effect.
1. Copy the file PRO_XL_MACHINE-x.x.x.rman” to the root folder of an
USB stick.
2. Power off the machine [A]. A
3. Insert the USB stick in the USB port [B] on the right side of the user
interface.
D
A
B
E
4. Power on the machine [A]. A list of files should now be shown.

5. Select the file “PRO_XL_MACHINE-x.x.x.rman” and press the Install
button.
6. Press “Yes” in the dialog box that comes up.
7. Follow instructions on screen.
For further information refer to software technical bulletin.
6. When finished use the Exit Service button [E] to return to the Home
screen.
18 February 2022
2 Preventive Maintenance Schedule
2.1 Preventative Maintenance - Feeder Module............................................................................................................................................. 2-2
2.2 Preventative Maintenance - AutoCreaser Pro XL Module........................................................................................................................ 2-3
2.3 Preventative Maintenance - DigiFold Pro XL Module............................................................................................................................... 2-4
18 February 2022
Pro XL 2-1 Preventive Maintenance Schedule
2.1 Preventative Maintenance - Feeder Module
Preventative Maintenance - Feeder Module Total Sheet Count (Millions of Sheets)

Parts
Check Point Instruction Procedures 1M 2M 3M 4M 5M 6M 7M 8M 9M 10M 11M 12M
List
Use compressed air, tow-
el and brushes to clean
Paper path N/A N/A x x x x x x x x x x x x
the machine from paper
dust.
PL 2.0
Ultrasonic DSD Clean with moist cloth. Calibration: ADJ 3.8.1
& PL x x x x x x x x x x x x
Sensor (Q10) Recalibrate. Replacement: REP 3.4.13
3.0
Use rubber reactivator
Vacuum Belts alcohol fluid to clean.
PL 2.0 Replacement: REP 3.4.33 x x x x x x x x x x x x
(black belts) Check for wear, if worn
replace.
Registration
alcohol fluid to clean.
Belts (green PL 3.0 Replacement: REP 3.4.32 x x x x x x x x x x x x
Check for wear, if worn
belts)
replace.
Separation alcohol fluid to clean. Adjustment: ADJ 3.8.3
PL 3.0 x x x x x x x x x x x x
Pads Check for wear, if worn Replacement: REP 3.4.31
replace.
Anti-Static Check for wear, if worn
PL 3.0 Replacement: REP 3.4.30 x x x x x x x x x x x x
Brushes replace.
Vacuum Gasket PL 6.1 Replacement: REP 3.4.16 x x x x
replace.
Lift Timing Belt
Replace if worn PL 6.2 Replacement: REP 3.4.1 x x x x
(M1)
Vacuum Timing
Replace if worn PL 2.0 Replacement: REP 3.4.2 x x x x
Belt (M2)
Registration
Timing Belt Replace if worn PL 6.1 Replacement: REP 3.4.3 x x x x
(M3)
Blower Fans PL 3.0 Replacement: REP 3.4.4,
(FAN1, FAN2, Replace & PL REP 3.4.5, REP 3.4.6, x
FAN3, FAN4) 6.1 REP 3.4.7
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2.2 Preventative Maintenance - AutoCreaser Pro XL Module
Preventative Maintenance - Creaser Module Total Sheet Count (Millions of Sheets)

Parts
List
Paper path Use compressed air, tow- N/A N/A
x x x x x x x x x x x x
dust.
Input Sensor (Q20) Use compressed air to PL 14.0 Replacement: REP
clean sensor 3.5.11
Blade Home Sensor Use compressed air to PL 11.0 Replacement: REP
(Q21/Q22) clean sensor 3.5.7
Exit Sensor (Q25) Use compressed air to PL 15.0 Replacement: REP
clean sensor 3.6.3
Perforation Drive Tires Use rubber reactivator PL 12.0 Replacement: REP
alcohol fluid to clean. 3.5.9
replace.
Crease Blade Anti-Static Replace if worn PL 11.0 Replacement: REP
Strips 3.5.8
Input Rollers Check roller alignment, PL 14.0 Adjustment: ADJ
re-align if necessary 3.9.2
Replacement: REP
3.5.12
Creaser Accuracy Check creaser accuracy, N/A Adjustment: ADJ
recalibrate if necessary 3.9.4
Transmission Belt Replace if worn PL 16.0 Replacement: REP
x x x x
3.5.10
Timing Belt, Roller Drive Replace if worn PL 13.0 Replacement: REP
x x x x
(M21) 3.5.12
Creaser Timing Belt Replace if worn PL 15.0 Replacement: REP
x x x x
(M22/M23) 3.5.5
Creaser Buffer Tubes Replace if worn PL 11.0 Replacement: REP
x x x x
3.5.6
Cooling Fan (FAN8) Replace if worn PL 15.0 Replacement: REP
x
3.6.2
18 February 2022
2.3 Preventative Maintenance - DigiFold Pro XL Module
Preventative Maintenance - Folder Module Total Sheet Count (Millions of Sheets)
Parts
List
Paper path Use compressed air, tow- N/A N/A
dust.
Input Sensor (Q40) Use compressed air to PL Replacement: REP 3.5.11
clean sensor 24.0
Blade Home Sensor Use compressed air to PL Replacement: REP 3.7.14
(Q41/Q42) clean sensor 22.1
Crease Exit Sensor Use compressed air to PL Replacement: REP 3.7.15
(Q45) clean sensor 25.0
Fold Knife Position Use compressed air to PL Replacement: REP 3.7.13
Sensor (Q47) clean sensor 26.0
Gap Set Roller 3 Use compressed air to PL Replacement: REP 3.7.13
Exit Sensor (Q52) Use compressed air to PL Replacement: REP 3.7.15
clean sensor 25.0 & REP 3.7.6
Roller Position Sen- Use compressed air to PL Replacement: REP 3.7.19
sor (Q50) clean sensor 28.0
Creaser Tray Sen- Use compressed air to PL Replacement: REP 3.7.18
sor (Q54) clean sensor 28.0
Perforation Drive Use rubber reactivator PL Replacement: REP 3.5.9
Tires alcohol fluid to clean. 12.0
replace.
Crease Blade An- Replace if worn PL Replacement: REP 3.5.8
ti-Static Strips 22.0
Input Rollers Check roller alignment, PL Adjustment: ADJ 3.9.2
re-align if necessary. 24.0 Replacement: REP 3.5.12
18 February 2022
2.3 Preventative Maintenance - DigiFold Pro XL Module (continued)
Preventative Maintenance - Folder Module Total Sheet Count (Millions of Sheets)
Parts
List
Fold Rollers Check roller alignment, PL Adjustment: ADJ 3.10.1
re-align if necessary. 23.0
Creaser Accuracy Check creaser accuracy, N/A Adjustment: ADJ 3.9.4
recalibrate if necessary
Fold Accuracy Check fold accuracy, N/A Adjustment: ADJ 3.10.3
recalibrate if necessary
Transmission Belt Replace if worn PL Replacement: REP 3.5.10
x x x x
26.0
Timing Belt, Roller Replace if worn PL Replacement: REP 3.5.12
x x x x
Drive (M41) 23.0
Creaser Timing Belt Replace if worn PL Replacement: REP 3.5.5
(M43) (Optional 22.1
x x x x
Static Crease Unit PL
M42) 11.0
Creaser Buffer Replace if worn PL Replacement: REP 3.5.6
Tubes 11.0
x x x x
(Optional Static
Crease Unit Only)
Cooling Fan (FAN8) Replace if worn PL Replacement: REP 3.7.11
x
25.0
Fold Knife Timing Replace if worn PL Replacement: REP 3.7.8
x x x x
Belt (M44) 26.0
Delivery Fan Replace if worn PL Replacement: REP 3.7.25
x
(FAN9) 25.0
Delivery Roller Clean / Replace if worn PL Replacement: REP 3.7.24
Foam Tyres 28.0
Delivery Transport Clean / Replace if worn PL Replacement: REP 3.7.21
Belts 28.0
Folded Sheet Exit Replace if worn PL Replacement: REP 3.7.26
Anti-Static Strips 25.0
Creased Sheet Exit Replace if worn PL Replacement: REP 3.7.26
Anti-Static Strips 25.0
18 February 2022
3 Replacement and Adjustment
Contents
3.1 General Cautions............................................................................................................................................................................................ 3-4
3.2 Special Tools................................................................................................................................................................................................... 3-5
3.2.1 Special Tools............................................................................................................................................................................................ 3-5
3.2.2 Required Tools.......................................................................................................................................................................................... 3-6
3.3 Exterior and Covers........................................................................................................................................................................................ 3-7
REP 3.3.1 Feeder Cover, Rear..............................................................................................................................................................................3-7
REP 3.3.2 Feeder Cover, Front..............................................................................................................................................................................3-8
REP 3.3.3 Feeder Cover, Top................................................................................................................................................................................3-9
REP 3.3.4 Feeder Cover, Lift...............................................................................................................................................................................3-10
REP 3.3.5 Feeder, User Interface........................................................................................................................................................................ 3-11
REP 3.3.6 Stacker removal (DigiFold Pro XL only).............................................................................................................................................. 3-12
REP 3.3.7 Stacker Covers (DigiFold Pro XL only)............................................................................................................................................... 3-13
REP 3.3.8 AutoCreaser/DigiFold, Front Cover..................................................................................................................................................... 3-14
REP 3.3.9 AutoCreaser/DigiFold, Rear Cover..................................................................................................................................................... 3-14
REP 3.3.10 AutoCreaser/DigiFold, Lower Entry Guard........................................................................................................................................ 3-15
REP 3.3.11 AutoCreaser, Exit Cover.................................................................................................................................................................... 3-15
REP 3.3.12 DigiFold/AutoCreaser, Lower Exit Cover.......................................................................................................................................... 3-16
REP 3.3.13 Undocking Feeder and DigiFold/AutoCreaser modules.................................................................................................................... 3-16
3.4 Feeder Replacement Procedures ................................................................................................................................................................ 3-18
REP 3.4.1 Lift motor (M1).....................................................................................................................................................................................3-18
REP 3.4.2 Vacuum belt motor (M2)......................................................................................................................................................................3-19
REP 3.4.3 Registration belt motor (M3)............................................................................................................................................................... 3-20
REP 3.4.4 Sheet separation fan (FAN1).............................................................................................................................................................. 3-21
REP 3.4.5 Sheet float fan (FAN2)........................................................................................................................................................................3-22
REP 3.4.6 Vacuum fan (FAN3).............................................................................................................................................................................3-23
REP 3.4.7 Registration fan (FAN4)...................................................................................................................................................................... 3-24
REP 3.4.8 Lift home sensor (Q1).........................................................................................................................................................................3-25
REP 3.4.9 Lift top safety sensor (Q2)................................................................................................................................................................... 3-26
REP 3.4.10 Table extension sensor (Q3)............................................................................................................................................................. 3-27
REP 3.4.11 Paper stack height sensor (Q4)........................................................................................................................................................ 3-28
REP 3.4.12 Lift bottom safety sensor (Q8)........................................................................................................................................................... 3-29
REP 3.4.13 Double sheet detector (Q10)............................................................................................................................................................. 3-30
REP 3.4.14 Table empty sensor (Q11)................................................................................................................................................................. 3-31
REP 3.4.15 Separated paper (SP) sensor (Q12)................................................................................................................................................. 3-32
REP 3.4.16 Vacuum choke assembly.................................................................................................................................................................. 3-33
REP 3.4.17 Vacuum choke solenoid (SOL1)....................................................................................................................................................... 3-34
REP 3.4.18 Feeder sheet counter (CNT)............................................................................................................................................................. 3-35
REP 3.4.19 Main power switch (SW1)................................................................................................................................................................. 3-35
18 February 2022
Pro XL 3-1 Replacement and Adjustment
Contents (continued)
REP 3.4.20 Top interlock switch (SW2/SW4)....................................................................................................................................................... 3-36
REP 3.4.21 Bottom interlock switch (SW3/SW5)................................................................................................................................................. 3-36
REP 3.4.22 Feeder PCBs....................................................................................................................................................................................3-37
REP 3.4.23 User Interface (UI) PCB and memory card....................................................................................................................................... 3-38
REP 3.4.24 12V power supply (PSU-1)............................................................................................................................................................... 3-39
REP 3.4.27 Relays (REL301/REL302)................................................................................................................................................................. 3-41
REP 3.4.28 Fuse (F1)..........................................................................................................................................................................................3-42
REP 3.4.29 Fuse holder.......................................................................................................................................................................................3-43
REP 3.4.30 Anti-static brushes.............................................................................................................................................................................3-43
REP 3.4.31 Separation pads................................................................................................................................................................................3-44
REP 3.4.32 Registration belts..............................................................................................................................................................................3-45
REP 3.4.33 Vacuum belts....................................................................................................................................................................................3-46
3.5 AutoCreaser/DigiFold Replacement Procedures ......................................................................................................................................... 3-47
REP 3.5.1 Paper path assembly..........................................................................................................................................................................3-47
REP 3.5.2 Optional static creaser assembly installation - Creaser...................................................................................................................... 3-48
REP 3.5.3 Optional static creaser assembly installation - Folder......................................................................................................................... 3-51
REP 3.5.4 Creaser assembly...............................................................................................................................................................................3-53
REP 3.5.5 Static creaser drive belt...................................................................................................................................................................... 3-55
REP 3.5.6 Static creaser timing pulley buffers..................................................................................................................................................... 3-55
REP 3.5.7 Static creaser home sensor................................................................................................................................................................ 3-56
REP 3.5.8 Creasing blade anti-static strip............................................................................................................................................................ 3-56
REP 3.5.9 Perforator tires....................................................................................................................................................................................3-57
REP 3.5.10 Transmission belt..............................................................................................................................................................................3-57
REP 3.5.11 Input sensor, Creaser (Q20) or Folder (Q40).................................................................................................................................... 3-58
REP 3.5.12 Input rollers.......................................................................................................................................................................................3-59
REP 3.5.13 Interlock switch (SW21/22)............................................................................................................................................................... 3-61
REP 3.5.14 Creaser/Folder sheet counter (SOL21/41)........................................................................................................................................ 3-61
3.6 AutoCreaser Replacement Procedures........................................................................................................................................................ 3-62
REP 3.6.1 Stepper motors (M21/M22/M23)......................................................................................................................................................... 3-62
REP 3.6.2 Cooling fan (FAN8).............................................................................................................................................................................3-62
REP 3.6.3 Exit sensor (Q25)................................................................................................................................................................................3-63
REP 3.6.4 Creaser PCBs.....................................................................................................................................................................................3-64
3.7 DigiFold Replacement Procedures............................................................................................................................................................... 3-65
REP 3.7.1 Gap Set Motor (M46/M50).................................................................................................................................................................. 3-65
REP 3.7.2 Gap Set Motor (M45)..........................................................................................................................................................................3-65
REP 3.7.3 Delivery Belt Motor (M47)................................................................................................................................................................... 3-66
REP 3.7.4 Dynamic Creaser Blade Link.............................................................................................................................................................. 3-67
REP 3.7.5 Dynamic Creaser - Bearing, Power Link............................................................................................................................................. 3-67
18 February 2022
Contents (continued)
REP 3.7.6 Folder - Exit Sensor (Q52).................................................................................................................................................................. 3-68
REP 3.7.7 Folder - Motors (M41/M42/M43/M44), Generic REP.......................................................................................................................... 3-68
REP 3.7.8 Folder - Dynafold Knife Transmission Belt.......................................................................................................................................... 3-69
REP 3.7.9 Dynamic Creaser Timing Belt............................................................................................................................................................. 3-70
REP 3.7.10 DynaCrease Bushings...................................................................................................................................................................... 3-70
REP 3.7.11 Folder - FAN 8...................................................................................................................................................................................3-71
REP 3.7.12 Positioning Flags...............................................................................................................................................................................3-71
REP 3.7.13 Sensors (Q47/Q48/Q49/Q51) .......................................................................................................................................................... 3-72
REP 3.7.14 Sensors (Q41/Q42) ..........................................................................................................................................................................3-72
REP 3.7.15 Sensor (Q45) & LED (Q52)............................................................................................................................................................... 3-73
REP 3.7.16 Positioning Belt.................................................................................................................................................................................3-73
REP 3.7.17 Positioning Motor (M49).................................................................................................................................................................... 3-74
REP 3.7.18 Sensor (Q54)....................................................................................................................................................................................3-74
REP 3.7.19 Roller Position Sensor (Q50) & Lamp (Lamp 1)............................................................................................................................... 3-75
REP 3.7.20 Delivery Roller...................................................................................................................................................................................3-76
REP 3.7.21 Delivery Belts....................................................................................................................................................................................3-77
REP 3.7.23 Folder - PCBs...................................................................................................................................................................................3-80
REP 3.7.24 A5 Delivery Roller Drive Motor (M49) and belt.................................................................................................................................. 3-81
REP 3.7.25 Creased Sheet Stacker Fan (FAN 9)................................................................................................................................................ 3-83
REP 3.7.26 Exit Anti-Static Strips.........................................................................................................................................................................3-83
3.8 Feeder Adjustment Procedures..................................................................................................................................................................... 3-84
ADJ 3.8.1 Ultrasonic Double Sheet Detector Calibration..................................................................................................................................... 3-84
ADJ 3.8.2 Optical Distance Sensor Calibration.................................................................................................................................................... 3-85
ADJ 3.8.3 Separation Pad Adjustment................................................................................................................................................................. 3-86
3.9 AutoCreaser/DigiFold Adjustment Procedures.............................................................................................................................................. 3-87
ADJ 3.9.1 DigiFold/AutoCreaser alignment to feeder ......................................................................................................................................... 3-87
ADJ 3.9.2 DigiFold/AutoCreaser Input roller adjustment...................................................................................................................................... 3-89
ADJ 3.9.3 Transport Roller Calibration ................................................................................................................................................................ 3-90
ADJ 3.9.4 DigiFold/AutoCreaser creaser position calibration.............................................................................................................................. 3-91
ADJ 3.9.5 DigiFold/AutoCreaser Static creaser bridge adjustment...................................................................................................................... 3-93
3.10 DigiFold Adjustment Procedures................................................................................................................................................................... 3-94
ADJ 3.10.1 Fold roller adjustment........................................................................................................................................................................3-94
ADJ 3.10.2 Knife calibration check.......................................................................................................................................................................3-98
ADJ 3.10.3 Knife position calibration.................................................................................................................................................................... 3-98
ADJ 3.10.4 Setting the Fold Knifes...................................................................................................................................................................... 3-99
ADJ 3.10.5 Delivery Roller home position.......................................................................................................................................................... 3-101
ADJ 3.10.6 DynaCrease Blade Eccentrics......................................................................................................................................................... 3-102
ADJ 3.10.7 DynaCrease Bridge crease depth .................................................................................................................................................. 3-103
18 February 2022
3.1 General Cautions CAUTION
WARNING! ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or
Unless instructed otherwise, turn off the main power and unplug the machine before communications problems. Failure to use proper ESD procedures will cause dam-
attempting any of the procedures in this section. age to electronic components (example: PCBs). ESD problems can be minimized by
To avoid hazardous situations like for instance electric shock or danger while exposed maintaining all machine ground connections, ensuring the proper handling of circuit
to moving, rotating or cutting devices, exercise extreme care when operating modules boards/ sensors, refer to this procedure 3.1.
with covers, guards or protection removed or when electrical or mechanical interlock - Use ESD protection when working near PCBs. Failure to use ESD protection is likely
devices are overrided or bypassed. to result in a PCB failure.
WARNING!
Turn off the SquareFold Trimmer Power switch and disconnect the Main Power Cord
before disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.
Using the ESD Ground Strap
Purpose
The purpose of the ESD (Electrostatic Discharge) ground strap is to pre-
serve the inherent reliability and quality of electronic components handled
by the Service Representative. The strap should be used whenever han-
dling the circuit boards or any other ESD sensitive components.
Procedure
NOTE:
All procedures requiring use of the ESD ground strap will contain a caution
referring to this procedure.
1. Switch off the main power switch.

2. Make sure the power cord connects the machine to the wall outlet. The
power cord and wall outlet must have ground.
3. Connect the claw end of the grounding cord to a chassis ground, such
as earth wires screwed to chassis ground, unpainted frame or an un-
painted bracket secured to the frame.
4. Connect the snap end of the blue cord to the snap on the adjustable
wrist strap.
5. Place the adjustable wrist strap securely on the wrist. Wait for one
minute to let the electrostatic be discharged from your body.
6. ESD sensitive components can now be handled without causing any
ESD related damage.
7. New replacement PCBs and ESD sensitive components, as well as
old defective PCBs should be handled during unpacking and repack-
ing using the ESD ground strap. During the transfer from or to the
packaging material, the PCB should be placed on the ESD bag the
replacement PCB came in.
18 February 2022
3.2 Special Tools
3.2.1 Special Tools
Item Quantity Description

In feeder shelf:
1 2 Multi-purpose wrench
2 1 Sensor cleaning brush 1
3 1 Roller cleaning brush
Under feeder cover:
4 1 Calibration strip for ultrasonic double sheet detector
(Q10)
5 1 Interlock cheater
Ordered separately:
4 5
6 1 USB to STM32F dongle
7 1 Harness SW load adapter 16/8p
8 1 Knife setting tool (Pro XL)
6 7
8
2 3
18 February 2022
3.2.2 Required Tools
Plockmatic Recommended tools Plockmatic Recommended tools
Use Size Qty Tool Use Qty Tool
Hex Screw/nut M3 5,5 2 Spanner/box or open end wrench Ruler min. 30cm
Measuring** 1
Hex Screw/nut M4 7 2
Hex Screw/nut M5 8 2 Caliper
Hex Screw/nut M6 10 2 Measuring** 1

Hex Screw/nut M10 16 1 Hex nut driver is helpful at smaller sizes. ESD protection set
Try to find thin wall type.
Hex Screw/nut M12 18 1 Handling of PCB's 1

Feeler gauge, set of 10, 0,1mm - 1mm
Insex/tap screw* 2 1 Allen wrench
Measuring 1
Insex/tap screw* 2,5 1
Insex/tap screw* 3 1
Plier (Alligator type) medium size
General repair 1
Slotted screw* 4,7x0,6 1 Screwdriver Plier (small, flat grip)

Slotted screw* 5,5x0,8 1 General repair 1
Slotted screw* 7,5x1 1

Wire cutter
Slotted screw* 9,2x1,2 1
General repair 1
Slotted screw* 10x1,6 1
Screwdriver Pozidriv Multimeter >250Volts, Amps & Ohms
Pozidriv screw* No. 1 1
Problem solving 1
Pozidriv screw* No. 2 1 Water level

Installation 1
Torx Screw* T10 1 Torx driver
* Thread size varies depending on type of screw
Torx Screw* T20 1
** For measuring, a millimeter scale is recommended as all adjustable NWM / EEPROM-values are in
Torx Screw* T30 1 1/10 of a mm.
18 February 2022
3.3 Exterior and Covers
REP 3.3.1 Feeder Cover, Rear
Parts List (PL 1.0) Exterior.
Removal Rear cover

1. Turn off the main power and disconnect the power cord.
2. Remove screws (x2) [A].
3. Lift and unhook the rear cover [B].
Replacement
Reverse the removal procedure.
CAUTION:
The bare metal areas behind the screws [A] are for safety earth bonding
between the Rear Cover [B] and the machine chassis frame. Make sure
you have good earth bonding between these areas, the screws and the
chassis frame of the machine.
18 February 2022
REP 3.3.2 Feeder Cover, Front
Parts List (PL 1.0) Exterior.
Feeder front cover consists of two parts [A] and [B]. For most maintenance 2. To remove [B] use a 7 mm wrench or a T20 screwdriver to remove 3x
and service tasks that require the removal of the front cover only [A] needs bolts [E].
to be removed.
1. To remove [A] unscrew skew adjustment locking knob [C] and use a 7
mm wrench or a T20 screwdriver to remove 3x bolts [D].
E B E
D A B
Replacement
18 February 2022
REP 3.3.3 Feeder Cover, Top
Parts List (PL 1.1) Hardware.
To remove feeder top cover:
1. Use a 7 mm wrench or a T20 screwdriver to loosen 2x bolts [A]. There

is no need to remove them completely. B
2. Use a 2.5 mm hex key to remove bolt [B].
3. Use a 7 mm wrench or a T20 screwdriver to remove bolt [C] (access
from underneath).
4. Lift the cover off.
Replacement
18 February 2022
REP 3.3.4 Feeder Cover, Lift
Parts List (PL 4.0) Paper Table.
To gain access to sensors and harnesses within the paper table:
1. Use a 7 mm wrench or a T20 screwdriver to remove bolt [A].

2. Open the cover [B].
WARNING:
Do not run the machine with this cover open. Doing so will result in dam-
age.
Replacement
18 February 2022
REP 3.3.5 Feeder, User Interface
Parts List (PL 2.1) User Interface.
To remove the user interface (UI):
1. Remove Feeder – Cover, Front (REP 3.3.2)

2. Remove Feeder – Cover, Top (REP 3.3.3)
3. Disconnect connectors [A] and [B]
4. Use a 7 mm wrench or a T20 screwdriver to loosen bolts (x2) [C].
There is no need to remove them completely.
5. Use a T20 screwdriver to remove bolts (x2) [D].
6. Lift the UI off.
A B
C C
Replacement
18 February 2022
REP 3.3.6 Stacker removal (DigiFold Pro XL only)
(Spare PL 28.0 Fold Delivery)
WARNING!
After installation check the exit guide [J] does not touch the fold roller [K]. 3. Disconnect two electrical connectors [G] from the conveyor into the
1. Remove catch tray [H] and support hoop [L] machine
F G
L 4. Open top cover and release screws [A] to remove exit guide [J].
5. Remove two screws [E] from shaft [F] to detatch the conveyor.
6. Unhook the conveyor [I] from hooks [B].
2. Remove screws [D] to open conveyor cover [C].
J K
B A B
18 February 2022
REP 3.3.7 Stacker Covers (DigiFold Pro XL only)
(Spare PL 28.0 Fold Delivery)
2. Remove Stacker (REP 3.3.6) (optional for ease of access).
3. Remove screws [A] (9x) to remove Panel [B].
4. Remove screws [C] (3x) to remove Panel [D].
5. Remove screw [E] (3x) to remove Panel [F].
A
A AA
F
B
Replacement
Reverse removal procedure
18 February 2022
REP 3.3.8 AutoCreaser/DigiFold, Front Cover REP 3.3.9 AutoCreaser/DigiFold, Rear Cover
Parts List (Creaser PL 9.0) (Folder PL 20.0) Exterior. Parts List (Creaser PL 9.0) (Folder PL 20.0) Exterior.
1. Turn off the power switch and disconnect the power cord. 1. Turn off the power switch and disconnect the power cord.
2. Remove 2x screws [A] using a T20 screwdriver or a 7 mm wrench. 2. Remove 2x screws [A] using a T20 screwdriver or a 7 mm wrench.
3. Remove tilt knobs [B] by rotating them counterclockwise. 3. Lift the rear cover up and then out.
4. Lift the front cover up and then out.
A
A
Replacement Replacement
Reverse the removal procedure. Reverse the removal procedure.
18 February 2022
REP 3.3.10 AutoCreaser/DigiFold, Lower Entry Guard REP 3.3.11 AutoCreaser, Exit Cover
Parts List (Creaser PL 9.0) (Folder PL 20.0) Exterior. Parts List (PL 9.0) Exterior.
1. Turn off the power switch and disconnect the power cord. 1. Turn off the power switch and disconnect the power cord.
2. Undock the modules (REP 3.3.13) 2. Remove creaser front cover (REP 3.3.8)
3. Remove front cover (REP 3.3.8) 3. Remove creaser rear cover (REP 3.3.9)
4. Remove rear cover (REP 3.3.9) 4. Open top cover and remove the rotary tool carrier [A]
5. Remove 4x screws [A] (2x on either side) using a T20 screwdriver or a 5. Disconnect sensor cable [B].
7 mm wrench. 6. Remove 4x screws [C] (2x on either side) using a T20 screwdriver or a
6. Remove lower entry guard [B]. 7 mm wrench.
7. Remove exit cover.
B A
A B C
Reverse the removal procedure. Reverse the removal procedure.
18 February 2022
REP 3.3.12 DigiFold/AutoCreaser, Lower Exit Cover REP 3.3.13 Undocking Feeder and DigiFold/AutoCreaser modules
Parts List (Creaser PL 9.0) (Folder PL 20.0) Exterior. Parts List (Creaser PL 9.1) (Folder PL 20.1) Exterior Hardware.
1. Turn off the power switch and disconnect the power cord. WARNING:
2. Remove front cover (REP 3.3.8) Tilt hazard. The DigiFold/AutoCreaser module is top heavy. Follow instruc-
3. Remove rear cover (REP 3.3.9) tions below.
4. DigiFold - Crease only tray. 1. Make sure that the main power switch is off and that the machine is
or unplugged from the wall outlet before undocking the machines. See
AutoCreaser - Unhook stacker tray section 1 Installation Procedure step 3.1 Power On.
5. DigiFold - Remove 10 screws [A] (x5 on either side) using a T20 2. Tilt hazard. The DigiFold/AutoCreaser module is top heavy. Rolling
screwdriver or a 7 mm wrench. the machine in the direction highlighted by the green arrows will help
or prevent tilting the machine. Be very careful rolling the machine in the
AutoCreaser - Remove 6 screws [A] (x3 on either side) using a T20 direction highlighted by the red arrows.
screwdriver or a 7 mm wrench.
SAFE TILT HAZARD
6. Remove lower exit cover [B].
Replacement
18 February 2022
REP 3.3.13 Undocking Feeder and DigiFold/AutoCreaser modules
(continued)
1. Remove stacker(s).
2. Raise 4x adjustable feet [A] on the DigiFold/AutoCreaser module
using the included multi-tool (located in feeder shelf) or another 19 mm
wrench. B C
4. Move the DigiFold/AutoCreaser module a small distance away from

the feeder module.
A
5. Disconnect power connectors [P12], [FAN8], [J110], [J308] (Folder
only) and data connector [J23].
3. Remove 12x docking bolts [B] and [C] using a 5 mm hex wrench.
J23 P12 FAN8 J110 J308

Folder only
Replacement
Reverse removal procedure and carry out DigiFold/AutoCreaser alignment

to feeder (ADJ 3.9.1).
18 February 2022
3.4 Feeder Replacement Procedures
REP 3.4.1 Lift motor (M1)
Parts List (PL 6.2) Lift Mechanism.
WARNING: A B
Make sure that the main power switch is off and that the machine is un-
plugged from the wall outlet before removing or replacing any electrical
components inside the machine.
1. Remove feeder rear cover (REP 3.3.1)

2. Disconnect M1 connector.
3. Loosen screw [A] by using a 7 mm wrench or a T20 driver. There is no
need to remove this screw.
4. Release lift timing belt tension by unhooking spring [B].
5. Loosen 4x M6 nuts [C] by using a 10 mm wrench. There is no need to
remove these nuts.
6. To remove the motor move it out and then down.
Replacement
Reverse removal procedure. Ensure timing pulleys [D] and [E] are clocked C
correctly.
D E
Timing belt routing – top view.
18 February 2022
REP 3.4.2 Vacuum belt motor (M2)
Parts List (PL 2.0) Top View.
WARNING: A
plugged from the wall outlet before removing or replacing any electrical B C

3. Remove M4 nuts [A] (x4).
4. Unhook the timing belt from the timing pulley and remove the motor.
Replacement
Reverse removal procedure. Ensure timing pulleys [B] and [C] are clocked
correctly.
18 February 2022
REP 3.4.3 Registration belt motor (M3)
Parts List (PL 6.1) Feeding Mechanism.
WARNING:

2. Undock the modules (REP 3.3.13)
4. Remove 4x M4 nuts [A] by using a 7 mm wrench or socket.
5. Unhook the timing belt from the timing pulley and remove the motor
[B].
A A
Replacement
Reverse removal procedure.
18 February 2022
REP 3.4.4 Sheet separation fan (FAN1)
Parts List (PL 3.0) Exit Side. A
WARNING:

2. Disconnect FAN1 connector.
3. Remove 2x screws [A] by using a T20 screwdriver or a 7 mm wrench.
4. Remove the fan by sliding it downwards.
Replacement
18 February 2022
REP 3.4.5 Sheet float fan (FAN2)
WARNING:

3. Loosen 2x screws [A] by using a 7 mm wrench.
4. Remove the fan by sliding it outwards and then right.
A
Replacement
18 February 2022
REP 3.4.6 Vacuum fan (FAN3)
WARNING:

3. Remove 2x screws [A] by using a 7 mm wrench.
4. Remove the fan.
A
Replacement
18 February 2022
REP 3.4.7 Registration fan (FAN4)
Parts List (PL 3.0) Exit Side.
WARNING:

4. Remove 2x nuts [B] using a 7 mm wrench.
5. Remove stiffener [C]
6. Remove 2x screws [D] by using a 7 mm wrench.
7. Remove the fan. A C B
Replacement
18 February 2022
REP 3.4.8 Lift home sensor (Q1)
Parts List (PL 6.2) Lift Mechanism.
WARNING:

2. Disconnect Q1 connector [A].
3. If the lift sensor flag is covering the sensor, move the lift up manually
by pulling the belt [B] in the indicated direction.
4. Remove screw [C] using a 2.5 mm hex key.
5. Remove the sensor by compressing the plastic retaining clips.
B A
Replacement
18 February 2022
REP 3.4.9 Lift top safety sensor (Q2)
WARNING:

3. Remove screw [B] using a 2.5 mm hex key.
4. Remove the sensor by compressing the plastic retaining clips.
Replacement
B A
18 February 2022
REP 3.4.10 Table extension sensor (Q3)
WARNING: A
1. Open feeder lift cover (REP 3.3.4)

3. Remove the sensor retaining bracket by using a T20 screwdriver and B
a 7 mm wrench to remove 2x screws [B].
4. Remove the sensor from the retaining bracket by compressing the
plastic retaining clips.
Replacement
18 February 2022
REP 3.4.11 Paper stack height sensor (Q4)
A
WARNING:
1. Remove feeder top cover (REP 3.3.3)

3. Use a T20 screwdriver or a 7 mm wrench to remove 2x screws [B].
4. Remove the sensor.
Replacement
Reverse removal procedure. After replacing the sensor carry out calibra-
tion procedure ADJ 3.8.2
18 February 2022
REP 3.4.12 Lift bottom safety sensor (Q8)
WARNING:
Make sure that the main power switch is off and that the machine is un- B
1. Remove feeder front cover (REP 3.3.2)

2. Disconnect Q8 connector.
3. Use a 7 mm wrench to remove screw [A].
4. Remove the sensor from the retaining bracket by compressing the
plastic retaining clips [B].
Replacement A
18 February 2022
REP 3.4.13 Double sheet detector (Q10)
Parts List (PL 2.0) Top View. 10. Disconnect FAN1 connector.
WARNING: 11. Loosen 4x M4 nuts [F] using a 7 mm wrench or socket. There is no
Make sure that the main power switch is off and that the machine is un- need to remove the nuts.
plugged from the wall outlet before removing or replacing any electrical 12. Remove the separation fan assembly by sliding it down.
components inside the machine. 13. Disconnect transmitter connector Q10T [G]
14. Remove 2x M4 nuts [H] using a 7 mm wrench or socket.
1. Undock the modules (REP 3.3.13) 15. Remove the sensor.
2. Remove feeder top cover (REP 3.3.3)
To remove the receiver:
3. Disconnect receiver connector Q10R [A]
4. Use a 7 mm wrench or socket to remove 2x M4 nuts [B]
5. Remove 2x rubber grommets
6. Remove the sensor by lifting it up.
A F
B B
H H
To remove the transmitter:
7. Remove 2x screws [C] using a T20 screwdriver or a 7 mm wrench.
8. Remove 2x nuts [D] using a 7 mm wrench.
9. Remove stiffener [E]
Replacement
Reverse removal procedure. Note that the transmitter and the receiver
must be replaced as a matched pair. Do not mix transmitters and receivers
with different serial numbers.
C E D
After replacing the sensor carry out calibration procedure ADJ 3.8.1
18 February 2022
REP 3.4.14 Table empty sensor (Q11)
WARNING:
1. Open feeder lift cover (REP 3.3.4)

3. Remove the sensor from its retaining bracket by using a 2.5 mm hex
key to remove screw [B].
Replacement
A B
18 February 2022
REP 3.4.15 Separated paper (SP) sensor (Q12)
WARNING:

2. Remove vacuum fan (REP 3.4.6)
3. Disconnect sensor connector Y-P1
4. Loosen 4x M3 screws [A] using a 5.5 mm wrench or socket.
5. Remove the SP sensor.
Replacement
Reverse removal procedure. Ensure that the front face of the sensor does
not protrude in the paper path.
18 February 2022
REP 3.4.16 Vacuum choke assembly
WARNING: Replacement
Make sure that the main power switch is off and that the machine is un- Reverse removal procedure. If applying new gaskets ensure the surface
plugged from the wall outlet before removing or replacing any electrical is clean and degreased. Ensure the choke closes fully when pushed up by
components inside the machine. the solenoid spring and that the gasket seals against the vacuum chamber.
If not, adjust solenoid position.
2. Disconnect 2x solenoid terminals [A]
3. Remove 3x M3 screws [B] using a 5.5 mm socket or wrench.
4. Remove 2x M4 locknuts [C] using a 5.5 mm socket or wrench.
5. Remove the vacuum choke assembly.
6. If gaskets [D] are worn, slide out choke cover [E] from the assembly
and replace the gaskets.
B A
18 February 2022
REP 3.4.17 Vacuum choke solenoid (SOL1)

2. Remove vacuum choke assembly (REP 3.4.16)
3. Remove M4 nut [A] using a 7 mm wrench or socket. A
4. Remove 3x M3 screws [B] using a 5.5 mm wrench or socket.
Replacement
18 February 2022
REP 3.4.18 Feeder sheet counter (CNT) REP 3.4.19 Main power switch (SW1)
Parts List (PL 6.0) Rear Side. Parts List (PL 6.0) Rear Side.
WARNING: WARNING:
Make sure that the main power switch is off and that the machine is un- Make sure that the main power switch is off and that the machine is un-
plugged from the wall outlet before removing or replacing any electrical plugged from the wall outlet before removing or replacing any electrical
components inside the machine. components inside the machine.
1. Remove feeder rear cover (REP 3.3.1). 1. Remove feeder rear cover (REP 3.3.1).
2. Disconnect counter cable [A]. 2. Disconnect cables [A].
3. Remove the counter from the retaining bracket by compressing the 3. Remove the Power switch from the framet by compressing the plastic
plastic retaining clips. retaining clips.
A
A
Replacement
NOTE:
To ensure maintenance activities are correctly scheduled in the future:
• When installing a new counter, reset it to the value of the old counter.
• Alternatively, write the value displayed by the old counter on the ma-
chine frame next to the new counter. Replacement
18 February 2022
REP 3.4.20 Top interlock switch (SW2/SW4) REP 3.4.21 Bottom interlock switch (SW3/SW5)
Parts List (PL 6.1) Feeding Mechanism. Parts List (PL 5.0) Saftey Base.
WARNING: WARNING:
1. Remove feeder rear cover (REP 3.3.1) 1. Remove feeder front cover (REP 3.3.2)
2. Remove vacuum choke assembly (REP 3.4.16) 2. Disconnect 4x interlock switch cables [A]
3. Disconnect 4x interlock switch cables [A] 3. Remove 2x bolts [B] using a T20 screwdriver or a 7 mm wrench
4. Remove 2x bolts [B] using a T20 screwdriver or a 7 mm wrench 4. Remove the interlock switch.
5. Remove the interlock switch.
A B
Reverse removal procedure. Reverse removal procedure.
18 February 2022
REP 3.4.22 Feeder PCBs
Parts List (PL 6.0) Rear Side.
WARNING:
PCB T
CAUTION:
ESD hazard. Electrostatic discharge (ESD) can cause software crashes,
data and/or communications problems. Failure to use proper ESD proce- PCB G
dures will cause damage to electronic components (example: PCBs). ESD
problems can be minimized by maintaining all machine ground connec-
tions, ensuring the proper handling of circuit boards/ sensors, and follow-
ing general safety procedures outlined in Section 3.1. Use ESD protection PCB H
when working near PCBs. Failure to use ESD protection is likely to result
in a PCB failure.
General procedure for all PCBs: PCB K
1. Remove feeder rear cover (REP 3.3.1).

2. Identify the PCB to be removed and detach its connectors.
3. Remove the PCB. PCB L
4. Mount the new PCB.
5. Re-mate connectors. See Section 4.2 for connector identification by
PCB type. PCB D
6. [PCBs T, G, H, K only] Ensure DIP switches are in the correct position
(Section 4.4.3).
7. [PCBs T, G, H, K only] Load software according to Section 5.4
In case main CPU PCB T is replaced, manually enter NVM values (Section
5.3) and then carry out calibration procedures ADJ 3.8.1 and ADJ 3.8.2.
PCB B PCB DD PCB R PCB C
18 February 2022
REP 3.4.23 User Interface (UI) PCB and memory card
Parts List (PL 2.1) User Interface.
WARNING:
B
CAUTION:
data and/or communications problems. Failure to use proper ESD proce-
ing general safety procedures outlined in Section 3.1. Use ESD protection
in a PCB failure.
1. Remove UI assembly from the machine (REP 3.3.5)
2. To remove the microSD memory card: push it into the slot until you
hear a click. The card will then be pushed out of the slot.
3. To remove the touchscreen and PCB assembly from the housing: use
a 7 mm wrench to loosen 3x nuts [B] and then slide the cover off. B B
Replacement
Reverse removal procedure. Only replace the microSD card with an official
spare part, otherwise the user interface will not function. After replacing the
memory card or the entire UI touchscreen and PCB assembly reload UI
software (Section 5.4)
18 February 2022
REP 3.4.24 12V power supply (PSU-1) REP 3.4.25 24V power supply (PSU-3)
Parts List (PL 6.0) Rear Side. Parts List (PL 6.0) Rear Side.
WARNING: WARNING:
1. Remove feeder rear cover (REP 3.3.1) 1. Remove feeder rear cover (REP 3.3.1)
2. Use a Pozidrive or a flat screwdriver to loosen screws [A] and remove 2. Use a Pozidriv or a flat screwdriver to loosen screws [A] and remove
PSU-1 wires. PSU-3 wires.
3. Use a 2.5 mm hex key to remove 2x screws [B] 3. Use a 2.5 mm hex key to remove 2x screws [B]
4. Remove the power supply. 4. Remove the power supply.
B B
A A
Use a multimeter to check voltage is 12V ± 0.5V. Use a multimeter to check voltage is 24V ± 0.5V.
18 February 2022
REP 3.4.26 55V power supply (PSU-2)
WARNING:
A
2. Remove PSU-3 (REP 3.4.25)
3. Use a Pozidriv or a flat screwdriver to loosen screws [A] and remove
PSU-2 wires. B
4. Use a T20 screwdriver or a 7 mm wrench to loosen 2x screws [B].
There is no need to remove these screws.
5. Remove the power supply by moving it down and then out.
A
Replacement
Reverse removal procedure. B
Use a multimeter to check voltage is 55V ± 0.5V
18 February 2022
REP 3.4.27 Relays (REL301/REL302)
WARNING:
components inside the machine. B B
The procedure is the same for REL301 (left, feeds PSU-2) and REL302
(right, feeds PSU-3)

2. Disconnect 4x relay cables [A].
3. Use a T20 screwdriver or a 7 mm wrench to remove screws [B]
(x4).
4. Remove the relay. A A
Replacement
A1 11 14
A2 31 34
18 February 2022
REP 3.4.28 Fuse (F1)
WARNING:
1. Unlock the fuse holder knob [A] with a flat-head screwdriver and
remove the fuse and its holder.
2. Replace the fuse with the same type. Lock the fuse holder in place.
100-140 V ac 140-240 V ac
T12A 6.3x32 mm T6.3A 5x20 mm
18 February 2022
REP 3.4.29 Fuse holder REP 3.4.30 Anti-static brushes
Parts List (PL 6.0) Rear Side. Parts List (PL 3.0) Exit Side.
WARNING: To remove anti-static brushes from feeder output:
plugged from the wall outlet before removing or replacing any electrical 1. Undock the modules (REP 3.3.13).
components inside the machine. 2. Use a 7 mm wrench or socket to remove 8x M4 nuts.
3. Remove 2x anti-static brushes.
2. Disconnect 2x fuse holder cables [A].
3. Use a 14 mm wrench to remove nut [B].
4. Remove the Fuse holder by pushing it through the frame.
Replacement
Replacement Reverse removal procedure. Carry out calibration procedure ADJ 3.9.1.
18 February 2022
REP 3.4.31 Separation pads
To remove paper separation pads:

3. Remove 2x nuts [B] using a 7 mm wrench.
4. Remove stiffener [C]
5. Disconnect FAN1 connector and release the cable from cable ties.
E D
8. Use a 2.5 mm hex key to remove 2x screws [F] and the associated
washers.
9. Remove the separation pads.
A C B
6. Loosen 4x M4 nuts [D] using a 7 mm wrench or socket. There is no

need to remove the nuts. To improve access to the nuts consider
removing FAN4 [E] (REP 3.4.7)
7. Remove the separation fan assembly by sliding it down.
F
Replacement
Reverse removal procedure. Adjust the separation pads according to ADJ
3.8.3. Carry out calibration procedure ADJ 3.9.1.
18 February 2022
REP 3.4.32 Registration belts
WARNING: C B
To remove 6x paper registration belts (green belts):

2. Remove registration fan (REP 3.4.7)
3. Remove 4x M4 nuts [A] by using a 7 mm socket or wrench.
6. Remove the registration assembly [D].

7. Remove 2x M6 bolts [E] by using a 5 mm hex key.
8. Remove 2x clips [F] by using a flat tipped screwdriver.
9. Remove rollers and registration belts.
4. Remove 2x M4 bolts [B] by using a T20 screwdriver or a 7 mm

socket. F
5. Use a 2.5 mm hex key to loosen a set screw and remove timing
pulley [C]. If necessary, first release belt tension by loosening reg-
istration motor bolts. Replacement
Reverse removal procedure. Carry out calibration procedure ADJ 3.9.1.
18 February 2022
REP 3.4.33 Vacuum belts
To remove 6x vacuum feed belts (black belts):
1. Remove feeder top cover (REP 3.3.3).
2. Loosen 4x screws [A] using a 7 mm wrench and release timing belt E
tension.
3. Remove timing belt from timing pulley [B].
4. Remove 2x screws [C] using a 2.5 mm hex key.
5. Remove 2x screws [D] using a 3 mm hex key. Remove bracket [E].
6. Unhook rear vacuum roller [F] and remove belts.
Replacement
A C F
18 February 2022
3.5 AutoCreaser/DigiFold Replacement Procedures
REP 3.5.1 Paper path assembly
Parts List (Creaser PL 10.0) (Folder PL 21.0) Top View.
To remove the dummy paper path assembly:
1. Remove front cover (REP 3.3.8).
2. Remove rear cover (REP 3.3.9).
3. Remove 2x screws [A] using a 6 mm hex key. Remove support
block.
4. Remove 4x screws [B] using a T20 screwdriver or a 7 mm wrench.
5. Unhook spring [C] from the machine frame.
6. Lift out the paper path assembly.
Replacement
C
A
18 February 2022
REP 3.5.2 Optional static creaser assembly installation - Creaser
WARNING:
A
B
1. Remove dummy paper path assembly.
2. Lower the static creaser unit in place. Ensure the pin enters the bush-
ing.
Front of machine Rear of machine

4. Install creaser skew adjustment mechanism by using a 10 mm wrench
to carefully tighten 2x tilt cams [C]. Note the orientation of the tilt cams.
Then push the clamp [B] against the top cam and tighten it.
Short
Long C
3. Install 2x top support blocks [A]. Note the types of screws used on the
front and back of the machine are different.
At the rear of the machine center the block in the slots.
At the front of the machine install the clamp [B] as shown, but do not
tighten it yet.
18 February 2022
(continued) 7. At the rear of the machine: disconnect connectors [B, P6] and [D, P5]
5. Inside the machine: connect creaser home sensor Q21. from PCBs B and D. Remove the jumper cable from the cable holders
and discard it.
PCB B
B,P6
Q21
6. Install creaser motor using the supplied screws [D] and a 4 mm hex
key. Use the slots in the mounting bracket to tension the belt by push-
ing the motor down when tightening the screws.
Connect motor connector M22.
D,P5
Remove
PCB D
D
18 February 2022
(continued)
8. Install PCB C. Ensure PCB DIP switches are set as indicated.
9. Connect loose connectors [B, P6], [C, P5], [C, P6], [C, P1], [C, P3], [C,
P7], [C, P9] and [D, P5]. No loose harness connectors should remain
after this step.
10. If units are undocked reverse procedure REP 3.3.13 and follow adjust-
ment procedure 3.9.1.
11. Power on the machine, go into Service mode and change creaser
NVM007 “CR Tool 1 kit” from 0 to 1.
12. Continue to ‘Adjustment 3.9.4’ to calibrate the new static creaser.
B,P6 PCB C
DIP switch setting
C,P9 1 2 3 4 5 6
ON
OFF
C,P7
C,P3
C,P5
C,P1
C,P6
D,P5
18 February 2022
REP 3.5.3 Optional static creaser assembly installation - Folder
A
WARNING:
components inside the machine. B
1. Remove dummy paper path assembly.
2. Lower the static creaser unit in place. Ensure the pin en-
ters the bushing.

4. Install creaser skew adjustment mechanism by using a 10 mm wrench
to carefully tighten 2x tilt cams [C]. Note the orientation of the tilt cams.
Then push the clamp [B] against the top cam and tighten it.
B
Short
Long
3. Install 2x top support blocks [A]. Note the types of screws used on the
C
front and back of the machine are different.
At the rear of the machine center the block in the slots.
At the front of the machine install the clamp [B] as shown, but do not
tighten it yet.

18 February 2022
REP 3.5.3 Optional static creaser assembly installation - Folder
8. Feed motor cable [C, P7] through frame (highlighted) directly to PCB
(continued)
C.
5. Inside the machine: Connect creaser home sensor Q41. 9. Connect loose connectors [C, P1], [C, P3], [C, P5], and [C, P9]. No
loose harness connectors should remain after this step.
10. If units are undocked reverse procedure REP 3.3.13 and follow adjust-
ment procedure 3.9.1.
11. Power on the machine, go into Service mode and change creaser
NVM015 “CR Tool 1 kit” from 0 to 1. Section 5.3 contains instructions
on changing NVM values.
12. Continue to ‘Adjustment 3.9.4’ to calibrate the new static creaser.
Q41 PCB C
DIP switch setting
1 2 3 4 5 6
ON
6. Install creaser motor using the supplied screws [D] and a 4 mm hex OFF
key. Use the slots in the mounting bracket to tension the belt by push- C,P9
ing the motor down when tightening the screws.
7. Install PCB C. Ensure PCB DIP switches are set as indicated.
C,P7 PCB D
DIP switch setting
C,P5 1 2 3 4 5 6
ON
OFF
C,P3
C,P1
18 February 2022
REP 3.5.4 Creaser assembly
Parts List (PL 11.0) Static Creasing Unit. 6. Disconnect: AutoCreaser Q21 / Q22 connector.
DigiFold Q41 / Q42 connector.
WARNING:
This procedure applies to both the standard and the optional static creaser
assemblies.
1. Open creaser top cover and remove both rotary tool carriers. Q21/22
2. Remove machine front cover (REP 3.3.8)
3. Remove machine rear cover (REP 3.3.9)
4. Remove machine lower exit cover (REP 3.3.12)
5. Loosen 4x motor screws [A] using a 4 mm hex key. There is no
need to remove these screws. Release timing belt tension and
unhook the timing belt from the motor timing pulley.
7. Remove creaser skew adjustment mechanism by using a 10 mm

wrench to unscrew 2x tilt cams [B].
8. Remove screws from 2x top support blocks [C] using 5 mm and 6
mm hex keys. Remove the blocks by lifting them upwards.
A C
18 February 2022
9. Pull out the creaser mechanism.
Replacement
Reverse removal procedure. Calibrate the creaser by following procedure
ADJ 3.9.4.
18 February 2022
REP 3.5.5 Static creaser drive belt REP 3.5.6 Static creaser timing pulley buffers
Parts List (PL 11.0) Static Creasing Unit. Parts List (PL 11.0) Static Creasing Unit.
1. Take out the static creaser assembly (REP 3.5.4) 1. Carry out REP 3.5.4 up to step 6.
2. Remove the creaser bridge and pull out the creasing blade. 2. Remove the creaser camshaft.
3. Remove 7x screws [A] using a T20 screwdriver or a 7 mm wrench. 3. Use two 16 mm wrenches to remove nut [A].
4. Remove 2x nuts [B] using a 10 mm wrench or socket. 4. Slide bearing [B] off the shaft.
5. Remove 2x nuts [C] using a 13 mm wrench or socket. 5. Loosen set screw [C] using a 3 mm hex key and slide cam [D] off
6. Remove side plate [D]. the shaft.
7. Remove belt [E]. 6. Slide timing pulley [E] off the shaft.
7. Remove 2x buffer tubes [F].
B D
C F
E
A B D E
C
Replacement
Replacement Reverse removal procedure. When reassembling cam [D] ensure set
Reverse removal procedure. Calibrate the creaser by following procedure screw [C] is aligned with the bore in the shaft. Calibrate the creaser by fol-
ADJ 3.9.4. lowing procedure ADJ 3.9.4.
18 February 2022
REP 3.5.7 Static creaser home sensor REP 3.5.8 Creasing blade anti-static strip
Parts List (PL 11.0) Static Creasing Unit. Parts List (PL 11.0) Static Creasing Unit.
1. Take out the static creaser assembly (REP 3.5.4) Anti-static strips on the creasing blades may get worn over time and need
2. Remove the creaser bridge and pull out the creasing blade. replacement:
3. Remove 2x screws [A] using a T10 screwdriver.
4. Remove the sensor [B]. 1. Remove the creaser bridge and pull out the creasing blade.
2. Peel off 2x self-adhesive anti-static strips [A].
Reverse removal procedure. Ensure the sensor activation flag is posi- Reverse removal procedure. Clean the surfaces thoroughly before apply-
tioned in the center of the sensor slot by sliding bracket [C] to suit. ing new anti-static strips.
B C A
18 February 2022
REP 3.5.9 Perforator tires REP 3.5.10 Transmission belt
Parts List (PL 12.0) Rotary Tool Carrier. Parts List (PL 16.0) Rear Side.
1. Open creaser top cover and remove the rotary tool carrier. To remove the creaser inboard timing belt:
2. Use a T20 screwdriver to remove 2x screws [A].
3. Use a 5 mm hex key to remove 2x screws [B]. Remove side plate 1. Remove machine rear cover (REP 3.3.9).
[C]. 2. Loosen nut [A] using a 13 mm wrench or socket.
4. Use a 4 mm hex key to remove screw [D] and slide off bearing [E]. 3. Use handle [B] to release belt tension.
5. Loosen 5x wheel set screws [F] with a 2 mm hex key. 4. Remove belt [C].
6. Slide the wheels off the shaft and remove tires [G].
Replacement
F G C
B A C
A E D B
Replacement
18 February 2022
REP 3.5.11 Input sensor, Creaser (Q20) or Folder (Q40)
Parts List (PL 14.0) Entry Side.
WARNING:
1. Undock the modules (REP 3.3.13).
2. Remove machine rear cover (REP 3.3.9).
3. Remove dummy paper path assembly (REP 3.5.1) or if the optional
static creaser assembly has been installed, remove the creaser
(REP 3.5.3).
4. Locate and disconnect sensor Q20 or Q40 connector [A].
5. Remove 2x bolts [B] using a 4 mm hex key.
6. Pull out sensor Q20 [C].
C B
Replacement
Reverse removal procedure. After replacing the sensor and re-docking
modules carry out adjustment procedure (ADJ 3.9.1), calibrate creaser(s)
(ADJ 3.9.4) and Fold Knives (ADJ 3.10.3).
NOTE:
When reconnecting harness, ensure connectors are lined up correctly as
shown below.
18 February 2022
REP 3.5.12 Input rollers
Parts List (PL 14.0) Entry Side.
1. Undock the modules (REP 3.3.13). 7. Release timing belt tension [F] (REP 3.5.10) and remove timing
2. Remove machine front cover (REP 3.3.8) and rear cover (REP belt from pulley [G].
3.3.9). 8. Remove timing pulley [G] by releasing 2x set screws using a 2.5
3. Remove input sensor (REP 3.5.11). mm hex key.
4. Release 4x bolts [A] using a 4 mm hex key and remove timing belt
[B].
5. Remove timing pulley [C] by releasing 2x set screws using a 2.5
mm hex key.
6. Remove 4x bolts [D] and remove entry guard [E].
G F
A E D
18 February 2022
9. Remove screw and washer [H]. 12. Slide top input roller [K] out towards the rear of the machine. If
10. Remove circlip and spacer [I]. necessary, use a mallet to unseat the bearings.
11. Remove 3x bolts [J] using a 3 mm hex key. 13. Slide top input roller [L] out towards the rear of the machine. If
necessary, use a mallet to unseat the bearings.
L K
H J I
Replacement
Reverse removal procedure. After replacing the sensor and re-docking
modules carry out adjustment procedure (ADJ 3.9.1), calibrate creaser(s)
(ADJ 3.9.4) and Fold Knives (ADJ 3.10.3).
18 February 2022
REP 3.5.13 Interlock switch (SW21/22) REP 3.5.14 Creaser/Folder sheet counter (SOL21/41)
Parts List (Creaser PL 13.0) (Folder PL 23.0) Front Side. Parts List (Creaser PL 16.0) (Folder PL 26.0) Rear Side.
WARNING: WARNING:
1. Remove creaser front cover (REP 3.3.8) 1. Remove creaser rear cover (REP 3.3.9).
2. Remove 2x bolts [A] using a 3 mm hex key. 2x spacers will be- 2. Disconnect counter SOL21/41 connector [A].
come loose as you remove the bolts. 3. Compress the plastic tabs on the sides of the counter and push the
3. Disconnect interlock switch connectors and remove the switch [B]. counter through the frame to remove it.
B A
Replacement
NOTE:
To ensure maintenance activities are correctly scheduled in the future:
Replacement • When installing a new counter, reset it to the value of the old counter.
Reverse removal procedure. Ensure the connector labels correspond to • Alternatively, write the value displayed by the old counter on the ma-
pin numbers indicated on the interlock switch. chine frame next to the new counter.
18 February 2022
3.6 AutoCreaser Replacement Procedures REP 3.6.2 Cooling fan (FAN8)
REP 3.6.1 Stepper motors (M21/M22/M23)
Parts List (PL 15.0) Exit Side. WARNING:
WARNING:
components inside the machine. 1. Remove creaser lower exit cover (REP 3.3.12).
2. Disconnect FAN8 connector [A].
All three motors in the creaser are removed in a similar fashion:
3. Remove 2x bolts [B] using a 3 mm hex key.
4. Remove FAN8.
1. Remove creaser lower exit cover (REP 3.3.12)
2. To remove M21 also remove creaser front cover (REP 3.3.8)
3. Locate and disconnect motor connector.
4. Remove 4x screws using a 4 mm hex key.
5. Lift the motor up and out.
B A
M23 M22 M21
(optional)
Replacement
Reverse removal procedure. When tightening motor bolts push the motor Replacement
downwards to tighten timing belt. Reverse removal procedure.
18 February 2022
REP 3.6.3 Exit sensor (Q25)
WARNING: B
1. Open creaser top cover and remove the rotary tool carrier [A].
2. Disconnect Q25 connector [B].
3. Remove creaser exit cover (REP 3.3.11).
4. Remove bolt [C] using a 2.5 mm hex key and remove the sensor.
Replacement
18 February 2022
REP 3.6.4 Creaser PCBs
WARNING:
CAUTION:
data and/or communications problems. Failure to use proper ESD proce-
ing general safety procedures outlined in Section 3.1. Use ESD protection
in a PCB failure.
General procedure for all PCBs: PCB A
1. Remove creaser rear cover (REP 3.3.9).

2. Identify the PCB to be removed and detach its connectors.
3. Remove the PCB. PCB B
4. Mount the new PCB.
5. Re-mate connectors. See Section 4.2 for connector identification
by PCB type. PCB C
6. Ensure DIP switches are in the correct position (Section 4.4.4). (optional)
7. Load software according to Section 5.4.
PCB D
In case main CPU PCB A is replaced, manually enter NVM values (Section
5.3) and then carry out calibration procedure ADJ 3.9.4 (for both creasers
if the optional creaser is installed).
18 February 2022
3.7 DigiFold Replacement Procedures REP 3.7.2 Gap Set Motor (M45)
REP 3.7.1 Gap Set Motor (M46/M50) Parts List (PL 23.0) Front Side.
Parts List (PL 26.0) Rear Side. 1. Turn off the main power and disconnect the power cord.
1. Turn off the main power and disconnect the power cord. 2. Remove Folder Front Cover (REP 3.3.8).
2. Remove Folder Rear Cover (REP 3.3.9). 3. Disconnect Motor Connector.
3. Disconnect Motor Connectors. 4. Remove bracket mounting screws [A] (3x).
4. Disconnect Sensor Connectors. 5. Remove motor/bracket assembly.
5. Remove screws [A] (3x). 6. Remove screws [B] (4x) and slide motor out of bracket.
6. Remove screws [B] (1x). 7. Remove set screw [C] and gear-wheel.
7. Remove nut [C] (1x).
8. Remove Motor Bracket [D].
9. Remove screws [E] (4x).
10. Remove Motor.
A
A
C
B
E E
Reverse removal procedure and carry out calibration procedure (ADJ Reverse removal procedure and carry out calibration procedure (ADJ
3.10.1) 3.10.1)
18 February 2022
REP 3.7.3 Delivery Belt Motor (M47)
Parts List (PL 28.0) Fold Delivery.
1. Turn off the main power and disconnect the power cord
2. Remove Stacker (REP 3.3.6)
3. Remove screws [A] (2x) and cover plate
4. Disconnect motor connector
5. Remove screws [B] (4x) and remove motor from delivery assembly
6. Remove set screw [C] and gear-wheel
B 4X
Replacement
18 February 2022
REP 3.7.4 Dynamic Creaser Blade Link REP 3.7.5 Dynamic Creaser - Bearing, Power Link
Parts List (PL 22.0) DynaCrease Assembly. Parts List (PL 22.1) DynaCrease Assembly.
1. Turn off the main power and disconnect the power cord 1. Turn off the main power and disconnect the power cord
2. Unlock Bridge Assembly [A] 2. Remove Dynamic Creaser Assembly (REP 3.5.4)
3. Remove Blade Set from Dynamic Creaser Unit 3. Remove Blade Set from Dynamic Creaser
4. Remove screws [B] (2x) 4. Remove screws [A] (2x) and remove Power Link Bearing [B]
5. Remove blade link [C]
A
B
Replacement
Replacement Reverse removal procedure
18 February 2022
REP 3.7.6 Folder - Exit Sensor (Q52) REP 3.7.7 Folder - Motors (M41/M42/M43/M44), Generic REP
Parts List (PL 25.0) Exit Side. Parts List (PL 25.0) Exit Side.
1. Turn off the main power and disconnect the power cord The four drive motors are all located underneath the Creaser/Folder As-
2. Remove screws [A] (2X) semblies. The Repair/Adjustment process for each is similar:
3. Make sure not to drop spacers [B] (2X) inside the machine
4. Disconnect connector 1. Turn off the main power and disconnect the power cord
5. Remove Exit Sensor receiver. 2. Detach Folder from Feeder (REP 3.3.13)
3. Disconnect relevant motor connector
6. To change the Transmitter follow procedure 3.7.15.
4. Remove motor mounting screws and remove motor
5. Disconnect set screws [A] and remove pulley wheel
6. If replacing M41 [B], perform “ADJ 3.9.2 Roller Adjustment”
A
Reverse removal procedure Reverse removal procedure
18 February 2022
REP 3.7.8 Folder - Dynafold Knife Transmission Belt
D E
2. Remove Rear Cover (REP 3.3.9)
3. Remove screws and washers [A] (3x)
4. Remove Cam Pulley Support Plate [B]
5. Remove Pivot Axle [C] and screw [D] to remove link plate [E] C
6. Loosen motor screws [F] (4x) to release belt tension
7. Remove belt
Replacement
18 February 2022
REP 3.7.9 Dynamic Creaser Timing Belt REP 3.7.10 DynaCrease Bushings
Parts List (PL 22.1) DynaCrease Assembly. Parts List (PL 22.1) DynaCrease Assembly.
1. Turn off the main power and disconnect the power cord WARNING:
2. Remove Dynamic Creaser Assembly (REP 3.5.4)
plugged before removing or replacing any electrical components inside the
3. Remove Blade Assembly machine.
4. Remove nuts/washers [A] (4x) from tie bars and remove top tie bars
5. Remove screws [B] (2x, both sides) and remove input/output
2. Remove Dynamic Creaser Assembly (REP 3.5.4)
guides [C]
3. Remove Bridge assembly
6. Remove Side Plate [D]
4. Remove Screw [A] and Upper Guide Block [B].
7. Remove timing belt
5. Replace Bush [C].
6. Repeat for opposing bush.
A
4x A
Reverse removal procedure and calibrate (ADJ 3.9.4). Reverse removal procedure and calibrate (ADJ 3.9.4).
18 February 2022
REP 3.7.11 Folder - FAN 8 REP 3.7.12 Positioning Flags
Parts List (PL 25.0) Exit Side. Parts List (PL 23.0) Front Side, (PL 26.0) Rear Side.
1. Turn off the main power and disconnect the power cord. 1. Turn off the main power and disconnect the power cord.
2. Remove screws [A] (2X) from both sides. 2. Remove Folder Cover, Rear (REP 3.3.9).
3. Remove Access Panel [B]. 3. Remove screws [A] (3x) on relevant flag.
4. Disconnect FAN connector. 4. Remove flag [B].
5. Remove screws [C] (2x).
6. Remove FAN.
C
B
Front of machine
A A
B
B
NOTE: Back of machine

When reconnecting harness, make sure connectors are lined up correct- A
ly, as shown in picture above.
Replacement
Replacement Reverse removal procedure and carry out calibration procedure (ADJ
Reverse removal procedure 3.10.1)
18 February 2022
REP 3.7.13 Sensors (Q47/Q48/Q49/Q51) REP 3.7.14 Sensors (Q41/Q42)
Parts List (PL 23.0) Front Side, (PL 26.0) Rear Side. Parts List (PL 11.0) Static Creasing Unit, (PL 22.1) DynaCrease Assembly.
2. Remove Folder Cover, Rear (REP 3.3.9) 2. Remove Dynacrease for Q42 [A] / Static Creasing Unit for Q41 [B]
3. Remove screw and clamp [A] on relevant sensor 3. Remove screws (2x) on relevant sensor
4. Disconnect connector 4. Disconnect connector
5. Remove sensor 5. Remove sensor
A
Q48
Back of machine
Front of machine B
A
Q49
A
Q51
A
Replacement Q47 A
If any of Q48/Q49/Q51 are replaced reverse removal procedure and carry
out calibration procedure (ADJ 3.10.1) Replacement
If Q47 is replaced reverse removal procedure and carry out calibration Reverse removal procedure
procedure (ADJ 3.10.3)
18 February 2022
REP 3.7.15 Sensor (Q45) & LED (Q52) REP 3.7.16 Positioning Belt
Parts List (PL 25.0) Exit Side. Parts List (PL 28.0) Fold Delivery.
2. Remove Stacker (REP 3.3.6). 2. Remove Stacker Covers (REP 3.3.7).
3. Remove Exit Cover (REP 3.3.11). 3. Remove Cable Tie [A].
4. Remove screws [A] (2X). 4. Remove screws [B] (4x).
5. Remove screws [B] (2X). 5. Remove Positioning Belt [C].
6. Slide shields out [C].
7. Remove screw [D] .
8. Remove screws [E] (2X).
9. Disconnect connector.
10. Remove sensor.
A B B
A
D E
18 February 2022
REP 3.7.17 Positioning Motor (M49) REP 3.7.18 Sensor (Q54)
Parts List (PL 28.0) Fold Delivery. Parts List (PL 28.0) Fold Delivery.
2. Remove Stacker Covers (REP 3.3.7) 2. Remove Stacker Covers (REP 3.3.7)
3. Disconnect Motor connector 3. Remove screws [A] (2x)
4. Remove screws [A] (4x) 4. Remove Sensor [B]
5. Remove Motor Bracket [B]
6. Remove screws [C] (4x)
7. Remove screw [D]
A
C B
Replacement D Replacement
Reverse removal procedure Reverse removal procedure
18 February 2022
REP 3.7.19 Roller Position Sensor (Q50) & Lamp (Lamp 1)
2. Remove Stacker Covers (REP 3.3.7).
3. Remove Nuts and Spacers [A] (2x).
4. Remove Lamp [B].
5. Unplug Sensor [C] and remove.
B A
Replacement
If Q50 is replaced, reverse removal procedure and carry out calibration
procedure (ADJ 3.10.5).
If Lamp is replaced reverse removal procedure.
18 February 2022
REP 3.7.20 Delivery Roller
Parts List (PL 28.0) Fold Delivery. C D E
2. Remove screws [A] (4x) and remove bottom cover [B].
3. Disconnect cables to Motor M49 [C], Earth Terminal [D] and Switch
SW45 [E].
4. Remove screws [F] (6x) and remove top cover [G].
5. Feed cables out of roller.
6. Remove screws [H] (2x) and remove delivery roller.
F G
B
18 February 2022
REP 3.7.21 Delivery Belts
2. Remove Delivery (REP 3.3.6).
3. Remove Stacker Covers (REP 3.3.7). C
4. Remove Screws [A] (2x) and Delivery Pivot Plate [B].
5. Remove Screws [C] (10x) and Delivery End Plate [D].
H
6. Remove Screw [E] and Back Side Cover [F].
7. Remove Screws [G] (2x) and Front Cover [H].
B A
F E G
C C
18 February 2022
REP 3.7.21 Delivery Belts (continued)
8. Remove Screws and Washers [I] (2x).
9. Loosen Screws [J] (4x) and remove Belt [K].
10. Remove Screws and Washers [L] (2x) and Clips [M] (2x).
11. Remove Shaft [N] and Clip [O].
12. Remove Screws and Washers [P] (4x) and Screws [Q] (4x).
13. Remove Screw [R] and Nut [S]. R
14. Disconnect Motor M47.
15. Loosen Screws [T] (4x) to allow Motor [U] to move. S T
16. Remove Screw [V] and Gear [W].
U
M L V
W
O L N I
J
P M Q J
P C
18 February 2022
REP 3.7.22 Delivery Belts (continued)
17. Disconnect Position Sensor [X].

18. Remove Nuts [Y] (8x) and Side Plate [Z].
19. Replace belts.
Replacement
Reverse removal procedure, ensuring grounding wires are correctly at-
tached.
18 February 2022
REP 3.7.23 Folder - PCBs
WARNING!
Turn off the Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
CAUTION
ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or
communications problems. Failure to use proper ESD procedures will cause dam-
age to electronic components (example: PCBs). ESD problems can be minimized by
maintaining all machine ground connections, ensuring the proper handling of circuit
boards/ sensors, and following general safety procedures outlined in Section 3.1.
- Use ESD protection when working near PCBs. Failure to use ESD protection is likely
to result in a PCB failure.
General: PCB “A”

1. Remove connectors
2. Remove PCB
3. Mount new PCB
PCB “C” PCB “D”
4. Re-mate connectors
optional
5. Make sure the DIP switches are in the correct position (see either sec-
tion 4 or section 8 of the Service Manual)
6. Load software according to Service Manual (GP 5.4) PCB “B” PCB “E”
PCB “H” PCB “K”
PCB “MM”
18 February 2022
REP 3.7.24 A5 Delivery Roller Drive Motor (M49) and belt
Parts List (PL 28.0) Fold Delivery. 8. Remove tie bars [F] (3X).
2. Remove the Delivery Roller (REP 3.7.20). F
3. Remove circlip [A].
4. Slide the Support Post [B] out and remove it.

5. Remove screws [C] (3X). 9. Note belt tension and remove screws and washers [G] (4X).
6. Remove screws [D] (2X).
7. Remove plate [E]. G
B C
18 February 2022
REP 3.7.24 A5 Delivery Roller Drive Motor (M49) and belt (continued)
10. Remove set screw [H] to remove pulley [I].

11. Remove M49 motor [J].
12. Remove plate [K].
13. Remove belt [L].
H J
K
I
L
A5 Roller belt routing
Replacement
Reverse removal procedure. Make sure belt routing and tension is as it
was before.
18 February 2022
REP 3.7.25 Creased Sheet Stacker Fan (FAN 9) REP 3.7.26 Exit Anti-Static Strips
Parts List (PL 25.0) Exit Side. Parts List (PL 25.0) Exit Side.
2. Remove Delivery (REP 3.3.6). 2. Remove Delivery (REP 3.3.6).
3. Disconnect Fan 9. 3. Remove screws [A] (4X).
4. Remove Screws [A] (2x) and Fan [B]. 4. Remove screws [B] (4X).
5. Remove Anti-Static Strip [C] (x2).
B
A B A
18 February 2022
3.8 Feeder Adjustment Procedures
ADJ 3.8.1 Ultrasonic Double Sheet Detector Calibration 2. Enter Service Mode (see section 5.1 on how to do that) and click
the Calibration button.
Ultrasonic double sheet detector (US DSD) Q10 is used to detect whether
two or more sheets are leaving the feeder table area at the same time. If
the sensor is giving false readings or if it has been replaced, it needs to be
re-calibrated. The calibration result is stored in feeder NVM001 “DSD US
PWM Duty Cycle (%)”.
1. Slide the included US DSD calibration strip 399-014-01 under the

vacuum belts in the US DSD so that the plastic window is aligned
to the ultrasonic transmitter and receiver. Removing feeder top
cover (REP 3.3.3) may help with alignment.
3. Click “Calibrate ultrasonic double sheet detector Q10”.
4. Once the automatic calibration procedure has been completed a

confirmation message will appear on the screen.
5. Remove the calibration strip.
18 February 2022
ADJ 3.8.2 Optical Distance Sensor Calibration
Feeder optical distance sensor Q4 is used to monitor the height of the 3. Enter Service Mode (see section 5.1 on how to do that) and click
paper stack on the table and to position the stack in front of the SP sen- the Calibration button.
sor Q12 during cycle start. If the optical distance sensor is giving false
readings or has been replaced it needs to be re-calibrated. The calibration
result is stored in feeder NVM002 – NVM006.
1. Clean the sensor using the included brush to ensure there is no

interference from paper or toner dust during calibration.
4. Click “Calibrate lift optical distance sensor Q4”.
2. Place a single white sheet of paper on the feeder table.
5. Feeder lift will move up to its top position and then down in steps.
Once the automatic calibration procedure has been completed a
confirmation message will appear on the screen.
18 February 2022
ADJ 3.8.3 Separation Pad Adjustment
Rubber separation pads are used in the feeder to prevent several sheets
from exiting the feeder table area at the same time. Separation pad posi-
tion is set at the factory. If frequent misfeeds or double sheets occur the
separation pad position may need to be adjusted by the following proce-
dure:
1. Use a steel ruler or several stiff sheets of paper to check the gap
between the separation pads [B] and the lowest point of the vacu-
um belt roller is even and around 1 mm (0.04”). If it is, the cause of
misfeeds or double feeds is likely feeder parameters.
2. If not, use the included 2.5 mm hex key to loosen 2x bolts [A].
3. The separation pads [B] should now freely move up and down.
4. Use a steel ruler or several stiff sheets of paper to set the gap
between the separation pads [B] and the vacuum belts to 1 mm
(0.04”).
5. Tighten the bolts [A].
18 February 2022
3.9 AutoCreaser/DigiFold Adjustment Procedures
AutoCreaser ADJ 3.9.1 DigiFold/AutoCreaser alignment to feeder
It is necessary to complete these procedures in the sequence below:
To align creaser and feeder modules:
1. ADJ 3.9.1 Alignment to feeder 1. Ensure that feeder skew adjustment knob is centered in slot.
2. ADJ 3.9.2 Input roller adjustment 2. Open creaser top cover.
3. ADJ 3.9.3 Transport roller calibration
4. ADJ 3.9.4 Crease position calibration
DigiFold
It is necessary to complete these procedures in the sequence below:
1. ADJ 3.9.1 Alignment to feeder

2. ADJ 3.9.2 Input roller adjustment
3. ADJ 3.10.1 Fold roller adjustment
4. ADJ 3.9.3 Transport roller calibration
5. ADJ 3.9.4 Crease position calibration
6. ADJ 3.10.3 Knife position calibration
Center in cut-out

18 February 2022
ADJ 3.9.1 DigiFold/AutoCreaser alignment to feeder (continued)
3. Take a stiff sheet of paper [A] and slide it against the registration wall 6. Release nuts on 2x brackets [D] using a 13 mm wrench.
[B]. 7. Use bracket [E] to adjust angle between the modules. If the inboard
4. Slide the sheet forwards until it comes in contact with creaser rollers. (registered) corner of the sheet exits the rollers first, release nut [F]
Turn the rollers forward by hand to pull the sheet in. Check if both cor- and tighten/loosen [G] to reduce the gap between the modules. If the
ners [C] of the sheet enter and exit the rollers at the same time. Make outboard (operator side) corner of the sheet touches the rollers first,
sure that during this check the sheet remains parallel to the registra- release nut [G] and tighten/loosen nut [F] to increase the gap between
tion wall. modules.
8. Lock off bracket [E] and 2x brackets [D]. Run a proof sheet with a sin-
gle crease. Check whether the sheets are “floating” in the creaser and
whether the crease is skewed.
9. Repeat steps 7 & 8 until the modules are aligned.
B 10. Reinstall covers that were removed as part of this procedure.
F G
C
D
5. If they do not enter or exit the roller at the same time the machine D
alignment needs to be corrected. Remove creaser front cover (REP
3.3.8) and feeder front cover (REP 3.3.2).
18 February 2022
ADJ 3.9.2 DigiFold/AutoCreaser Input roller adjustment
NOTE:
Complete “ADJ 3.9.1 Alignment to feeder” before continuing with this A
procedure.
Creaser input rollers receive registered sheets from the feeder and move
them forward in an accurate manner. If the sheet is “floating” sideways in
the creaser despite being registered in the feeder, input rollers may need
adjustment.
1. (Optional) Undock the modules (REP 3.3.13). Undocking helps
with access to the rollers. However, this procedure can also be car-
ried out without undocking.
2. Remove creaser front cover (REP 3.3.8).
3. To check roller gap, insert 3x 80gsm (0.1 mm thick) 25 mm wide
paper strips [A] between the rollers as shown. Pull the strips paral-
lel to paper movement direction. The forces on all strips should be
equal (approximately 4.5 ± 0.5 N).
4. If the force on all strips is not equal, roller tilt must be adjusted.
Loosen screw [B] using a T20 screwdriver and 2x set screws [C]
using a 2.5 mm hex key. Use the lever to adjust roller tilt. Check
force by pulling on the paper strips. When the force is equal on all
strips tighten 2x set screws [C].
5. If the force on the strips is equal, but not within tolerance (4.5 ±
0.5 N), roller gap must be adjusted. Loosen screw [B] using a T20
screwdriver. Use the lever to adjust roller gap. Check force by pull-
ing on the paper strips. Tighten screw [B] when force on all strips is
within tolerance.
6. Re-dock and replace covers. Check creaser accuracy and re-cali-
brate if necessary (section 3.9.4).
C C
B
NOTE:
This adjustment should be carried out with the input roller drive belt ten-
sioned.
18 February 2022
ADJ 3.9.3 Transport Roller Calibration
NOTE:
Complete “ADJ 3.9.2 Input roller adjustment” before continuing with this
procedure. If calibrating a folder complete “ADJ 3.10.1 Fold roller adjust-
ment” before continuing with this procedure.
Transport roller calibration replaces “stretch” on previous Morgana prod- Cr.1Cr.2
Crease positions Cr.3
ucts. There are three distinct steps to this procedure which must be fol-
lowed in order.
Step 1 – calibrate rollers with 0.1 mm thick paper

1. Take a 0.1 mm thick sheet at least A3 / SRA3 (The longer the sheet
the more accurate the calibration).
2. Using the DynaCrease set up a custom job with three creases at: Measure
• Crease 1 - 50mm Feed direction

• Crease 2 - 100mm
• Crease 3 - 100mm from the end of the sheet
3. Run a sheet and measure the distance between creases 2 and 3.

(SRA 3 should be 250 mm).
4. Adjust NVM 016 “Transport ratio 0.1” to compensate for any devia- Step 3 – line speed compensation
tion. (To enter the NVM screen follow procedure “4.5 Updating NVM 1. Take a stiff sheet (0.2 mm or more)
values”) 2. Using the DynaCrease set up a single crease in the centre of the
5. Repeat steps 3 and 4 until correct. sheet.
3. Run the job at:
Step 2 – calibrate rollers with 0.4 mm thick paper
1. Take a 0.4 mm thick sheet at least A3 / SRA3, but the longer the bet- • 200 mm/s
ter. • 560 mm/s
2. Using the DynaCrease set up a custom job with three creases at: • 1100 mm/s
• Crease 1 - 50mm 4. Compare the 3x sheets. look for the difference, not the measured posi-
• Crease 2 - 100mm tion.
• Crease 3 - 100mm from the end of the sheet 5. Adjust NVM 018 “Edge offset time uS” to compensate for any devia-
tion. (To enter the NVM screen follow procedure “4.5 Updating NVM
3. Run a sheet and measure the distance between creases 2 and 3. values”)
(SRA 3 should be 250 mm). 6. Repeat steps 3 to 5 until correct.
4. Adjust NVM 017 “Transport ratio 0.4” to compensate for any devia-
tion. (To enter the NVM screen follow procedure “4.5 Updating NVM
values”)
5. Repeat steps 3 and 4 until correct.
18 February 2022
ADJ 3.9.4 DigiFold/AutoCreaser creaser position calibration
NOTE: 5. If crease skew (difference between registered side and operator side)
Complete “ADJ 3.9.3 Transport roller calibration” before continuing with is > 0.25 mm mechanical adjustment is necessary. Use a 6 mm hex
this procedure. key to loosen 4x screws [A] to calibrate the static creaser. Shift the
In order to compensate for small variations in each machine and ensure creaser support blocks forward or back to correct for the measured
creasing position accuracy the static creaser is calibrated at the factory. If crease skew. Repeat steps 3.-5. until crease skew is < 0.25 mm.
creasing accuracy is out of specification or if the creasing unit has been
A B
replaced, a re-calibration is necessary.
Before calibrating the static creaser ensure that creaser input rollers are
correctly adjusted (ADJ 3.9.2) and that modules are fully aligned (ADJ
3.9.1).
NOTE:
If the optional static creaser is installed, this procedure needs to be carried
out twice – once for each creaser.
1. Ensure feeder skew adjustment knob and creaser tilt knob are cen-
tered.
2. Load paper in the feeder. For best results use 200 – 250 gsm paper at
least 450 mm in length (or longer).
3. Set up a half fold job and run a proof sheet.
4. Measure the distance between the lead edge of the paper and the
crease at the registered side and at the operator side.
Crease
Measure
Feed direction
Measure
A B
18 February 2022
6. When crease skew is < 0.25 mm the creaser NVM values can be 9. Exit Service mode and repeat steps 6.-7. If the error is within toleran-
calibrated. Set up a custom job with a single crease at 50 mm and run ce, proceed to step 10. If the error is out of tolerance, repeat step 8.
a proof sheet. 10. Repeat steps 10 - 11 until the crease position is within tolerance.
crease. Calculate the error:

Crease
Measure
Feed direction
Measure
8. Increment the relevant distance NVM value by the error:

decrease the NVM
• The NVM is stored in units mm×10, so if the error is 0.5 mm
change the NVM by 5 units.
AutoCreaser Pro XL
• Calibrating the (first) static creaser – NVM001 “Crease Tool 1
• Calibrating the (second) static creaser – NVM002 “Crease Tool 2
DigiFold Pro XL
• Calibrating the (first) static creaser – NVM001 “Crease Tool 1
• Calibrating the (Second) Dyna-crease – NVM002 “Crease Tool 1
NOTE:
Section 5.3 contains instructions on accessing and changing NVM values.
18 February 2022
ADJ 3.9.5 DigiFold/AutoCreaser Static creaser bridge adjustment
If crease depth adjustment range is insufficient (for example, the deepest
crease is too shallow), creaser bridge can be adjusted:
1. Remove creaser bridge from the machine.

2. Loosen 2x set screws [A] using a 2.5 mm hex key.
3. Change the alignment of the eccentric shaft [B] to the gear [C]. If the
crease is too shallow rotate the shaft in the indicated direction.
4. Tighten 2x set screws [A].
B A C
Nominal shaft position - in line
Nominal handle position - in line
18 February 2022
3.10 DigiFold Adjustment Procedures
ADJ 3.10.1 Fold roller adjustment
WARNING
Do not expose fingers or other parts of the body to moving, rotating or cutting devices when running the machine with the covers off. Do not
wear ties, lanyards or other things that might get trapped into the rollers and cause injuries.
NOTE:
Complete “ADJ 3.9.2 Input roller adjustment” before continuing with this
procedure.
interlock cheater Press the interlock

cheater down on the
interlock.
1
While holding the
interlock cheater down, 2. Select the “tools” icon to get to the expert menu.
rotate it by 90° clockwise
to lock into position.
1. Open top cover and insert interlock cheater.
3. Enter Service Mode (see section 5.1 on how to do that) and click the
Calibration button. Select ‘Roller gaps’.

18 February 2022
ADJ 3.10.1 Fold roller adjustment (continued)
WARNING
4. Select “Calibrate”. This moves fold rollers to 0.1

6. At each end of roller gap 1 enter two strips of 80gsm media to check
roller gap parallelism. If Fold knives obstruct the paper path press the
“Move fold knives” button this cycles the knives to the second position.
7. Pull the slips of paper out of the rollers by hand, noting the force re-
quired to do so (approximately 3.0+/-0.5N). Both slips will require the
same force if the rollers are parallel. Ideally, the slips will be difficult to
pull out, but not stuck in place.
5. To adjust roller gaps use the ‘+/-’ icons for the relevant roller gap. 8. If both sides are not equal adjust Cam [C] until both sides are level.

18 February 2022
WARNING
9. At each end of roller gap 2 enter two strips of 80gsm media to check 12. At each end of roller gap 3 enter two strips of 80gsm media to check
roller gap parallelism. If Fold knives obstruct the paper path press the roller gap parallelism. If Fold knives obstruct the paper path press the
“Move fold knives” button this cycles the knives to the second position. “Move fold knives” button this cycles the knives to the second position.
10. Pull the slips of paper out of the rollers by hand, noting the force re- 13. Pull the slips of paper out of the rollers by hand, noting the force re-
quired to do so (approximately 3.0+/-0.5N). Both slips will require the quired to do so (approximately 3.0+/-0.5N). Both slips will require the
same force if the rollers are parallel. Ideally, the slips will be difficult to same force if the rollers are parallel. Ideally, the slips will be difficult to
pull out, but not stuck in place. pull out, but not stuck in place.
E
11. If both sides are not equal adjust Cam [D] until both sides are level. 14. If both sides are not equal adjust Cam [E] until both sides are level.
18 February 2022
WARNING
or cutting devices when running the machine with the covers off. Do
not wear ties, lanyards or other things that might get trapped into the
rollers and cause injuries.
Intentionally blank.
15. Enter one strip into the centre of roller gap 1. The strip will be difficult
to pull out, but not stuck in place (approximately 3.0+/-0.5N). Repeat
this for roller gaps 2-3 in order. For adjustment continue to step 16. If
Fold knives obstruct the paper path press the “Move fold knives” but-
ton this cycles the knives to the second position.
16. In order from 1 to 3 adjust Roller Gaps if they are either too loose or
too tight. To do this change the relevent roller gap value described in
step 5. Then repeat procedure from step 4.
18 February 2022
ADJ 3.10.2 Knife calibration check ADJ 3.10.3 Knife position calibration
To check that the machine has not lost its factory set fold calibration during
shipping and/or handling carry out the following procedure: NOTE:
Complete “ADJ 3.9.4 Creaser position calibration” before continuing with
1. Turn off Crease, run a proof sheet with knife 1 half fold pattern. this procedure.
1. Set up a custom job with a single knife 1 fold at 100mm and run a
proof sheet.
fold. Calculate the error:

Fold
Measure
Feed direction
fold. The measurement should equal to the paper length divided by 2.
3. Repeat steps 1 & 2 with knife 2 half fold pattern.
Fold

decrease the NVM
Measure • The NVM is stored in units mm×10, so if the error is 0.5 mm change
the NVM by 5 units.
Feed direction Q40”
Q40”
4. Exit Service mode and repeat steps 1 & 2. If the error is within toleran-
ce, proceed to step 5. If the error is out of tolerance, repeat step 3.
4. If the measurement is not within the machine tolerance (± 0.25 mm / ± 5. Repeat procedure for fold knife 2.
0.001”) continue to “ADJ 3.10.3 Knife calibration”. 6. Reverse removal procedure for all covers that have been removed.
18 February 2022
ADJ 3.10.4 Setting the Fold Knifes
The Fold Knifes are driven by a stepper motor and are controlled by a cam
follower and cam profile. The position of the Cam [A] is critical as it con-
C
trols the start & stop positions of the Fold Knives.
1. Remove Folder Cover, Rear (REP 3.3.9).

2. Loosen the Front and Rear Shaft Fixing Cap Head Screws [B] (2x) on
each side of the Cam eccentric shaft and position the flat [C] on the
shaft vertically.
3. Loosen screws [D] (4x) to release belt tension.
A B
18 February 2022
ADJ 3.10.4 Setting the Fold Knifes (Continued)
6. Rotate the Cam clockwise until the jig assembly fits correctly, adjust
4. Remove cable holders [E] and cables so they do not make contact
the eccentric shaft if required, tighten the two Shaft Fixing Cap Head
with moving parts or Jig [F].
Screws [B] (2x) on the ends of the eccentric shaft. Use a spanner to
hold location of shaft when tightening [C].
7. Remove Jig [F] and flip (Side ‘B’). Then Insert one bolt [G] to the knife
drive hub on the left. Rotate Cam [A] to move the inserted bolt under
motor bracket.
5. Rotate the Knife Drive Hubs fully counter clockwise and fit the Setting
Jig [F] (Side ‘A’) using the three shoulder Bolts supplied [G]. This locks
the knives in one of the two correct stop positions.
G G
G 8. Insert the last two Bolts [G], align the bolts to the center of the knife
drive hubs at the center point of the drive hub holes (get as close as
possible if Bolts [G] cannot fully enter holes).
9. Re-check the positions of the Setting Jig. Repeat above procedure if
the shoulder screws do not slide into the jig smoothly.
10. Re-tighten screws [D] and make sure the tension on the belt is correct.
11. Return covers and carry out Knife calibration ADJ 3.10.3.
18 February 2022
ADJ 3.10.5 Delivery Roller home position
The delivery roller is positioned based on readings from linear potenti-

NOTE:
ometer Q50. The positioning of this potentiometer may vary slightly from
If “Value out of range!” is displayed and the delivery roller is in the correct
machine to machine, so it needs to be calibrated.
position check:
• Q50 potentiometer functionality.
1. Move the delivery roller [A] by hand to its minimum position [B].
• Sliding contact is in contact with potentiometer.
2. Enter Service Mode (see section 5.1) then select Calibration.
3. Select Calibrate (the value is saved and adjustment is complete).
A B
18 February 2022
ADJ 3.10.6 DynaCrease Blade Eccentrics
Adjusting the ‘Blade Bolts’ may be required to remove any signs of ‘un-
even profile’, and adjusting the ‘Blade Adjusters’ will enable the crease to
be made heavier or lighter on the desired side.
1. Remove Blade Set

2. Loosen Screw [B] for the desired Blade Bolt [A].
3. Turn Blade Bolts [A] so the holes are at extremes to the counterpart
bolt.
4. Tighten Screw [B].
Intentionally blank.
B B
18 February 2022
ADJ 3.10.7 DynaCrease Bridge crease depth
Adjusting the DynaCrease Bridge crease depth may be required to remove

any signs of ‘uneven depth’, adjusting this will enable the crease to be A A
made heavier or lighter on the desired side.
2. Remove DynaCrease Assembly (REP 3.5.4).
3. Loosen screws [A] (x8) on the DynaCrease Assembly.
4. Move force adjustment knob [B] to maximum pressure “+” and lock in
position.
5. Insert one sheet of paper 0.1mm (90gsm) [C] between blade and anvil.
6. Rotate crankshaft [D] to close blade and anvil and hold in position.
7. Press down on bridge assembly and tighten screws [A] (x8). B
8. Insert one sheet of paper 0.25mm (250gsm) [C] between blade and
anvil.
9. Rotate crankshaft [D] one full rotation.
10. Remove sheet of paper 0.25mm (250gsm) (mark crease as maxi-
mum).
11. Move force adjustment knob [B] to minimum pressure “-” and lock in
position.
12. Reinsert sheet of paper 0.25mm (250gsm) (away from first crease).
13. Rotate crankshaft [D] one full rotation.
14. Compare the two creases:
• Maximum crease - deep
• Minimum crease - shallow
15. Check that the crease depth is equal on both sides, if not repeat fom C
step 3.
16. Once complete replace DynaCrease Assembly (REP 3.5.4) and cali-
brate (ADJ 3.9.4).
18 February 2022
4 Troubleshooting
4.1 Introduction to Troubleshooting....................................................................................................................................................................... 4-4
4.2 Printed Circuit Board (PCB) Overview............................................................................................................................................................ 4-4
4.2.1 CPU APP32 PCB Connector.................................................................................................................................................................... 4-5
4.2.2 CPU APP32 PCB LEDs and Measuring Points........................................................................................................................................ 4-6
4.2.3 Stepper Motor Driver M21H PCB Connector Placement and Pin Positions............................................................................................. 4-7
4.2.4 Stepper Motor Driver M21H PCB LEDs and Measuring Points................................................................................................................ 4-8
4.2.5 PTC PCB Connector Placement and Pin Positions.................................................................................................................................. 4-9
4.2.6 SP Sensor Connector Placement, Pin Positions and LEDs................................................................................................................... 4-10
4.2.7 User Interface Module Connector Placement, Pin Positions and LEDs................................................................................................. 4-11
4.2.8 Motor Driver M04L PCB Connector Placement and Pin Positions......................................................................................................... 4-12
4.2.9 Motor Driver M04L PCB LEDs................................................................................................................................................................ 4-13
4.3 Wiring Overview............................................................................................................................................................................................ 4-14
4.4 Communication Flowcharts........................................................................................................................................................................... 4-15
4.4.1 Controller Area Network (CAN) Bus Overview....................................................................................................................................... 4-15
4.4.2 XCAN Flowchart..................................................................................................................................................................................... 4-17
4.4.3 Feeder - ICAN Flowchart........................................................................................................................................................................ 4-18
4.4.4 Creaser - ICAN Flowchart...................................................................................................................................................................... 4-19
4.4.5 Folder - ICAN Flowchart......................................................................................................................................................................... 4-20
4.5 Power Flowcharts.......................................................................................................................................................................................... 4-21
4.5.1 Feeder – 55V Flowchart......................................................................................................................................................................... 4-21
4.5.4 Creaser – 55V Flowchart........................................................................................................................................................................ 4-24
4.5.5 Creaser – 12V Flowchart........................................................................................................................................................................ 4-25
4.5.6 Folder – 55V Flowchart.......................................................................................................................................................................... 4-26
4.6 Fault Code Descriptions................................................................................................................................................................................ 4-29
4.6.1 Feeder Fault Codes................................................................................................................................................................................ 4-30
4.6.2 Creaser Fault Codes.............................................................................................................................................................................. 4-33
4.6.3 Folder Fault Codes................................................................................................................................................................................. 4-35
4.7 Repair And Analysis Procedures - RAPS..................................................................................................................................................... 4-40
RAP 101 Sensors General Troubleshooting.................................................................................................................................................... 4-41
RAP 102 Motors General Troubleshooting....................................................................................................................................................... 4-41
RAP 201 Primary Circuit ...................................................................................................................................................................................4-42
RAP 202 Interlock Circuits.................................................................................................................................................................................4-43
RAP 203 PSU 12/24/55V Adjustment................................................................................................................................................................ 4-44
RAP 204 PTC PCBs...........................................................................................................................................................................................4-45
18 February 2022
Pro XL 4-1 Troubleshooting
RAP 205 User Interface Module.........................................................................................................................................................................4-46
RAP 206 Feeder ICAN Circuit............................................................................................................................................................................4-47
RAP 207 PCB T, PCB G 12VDC ...................................................................................................................................................................... 4-48
RAP 208 PCB K, PCB Y 12VDC ...................................................................................................................................................................... 4-49
RAP 209 PCB H, PCB J 12VDC ...................................................................................................................................................................... 4-50
RAP 210 SP SENSOR Q12 PCB “Y” ................................................................................................................................................................ 4-51
RAP 211 US DSD Sensor Q10..........................................................................................................................................................................4-52
RAP 212 PCB G, 55VDC .................................................................................................................................................................................4-53
RAP 213 PCB H, 55VDC .................................................................................................................................................................................4-54
RAP 214 PCB K, 55VDC ..................................................................................................................................................................................4-55
RAP 215 PCB L, 24VDC ..................................................................................................................................................................................4-56
RAP 216 Feeder Fans ......................................................................................................................................................................................4-57
RAP 217 Q11, Table Empty Sensor (feeder).................................................................................................................................................... 4-58
RAP 218 Q4, Paper Stack Height Sensor (feeder).......................................................................................................................................... 4-58
RAP 219 Q1, M1 Home Position Sensor (feeder)............................................................................................................................................ 4-59
RAP 220 Q2 & Q8, Lift Top/Bottom Safety Sensors (feeder)........................................................................................................................... 4-59
RAP 221 M1, Lift Motor (feeder)......................................................................................................................................................................4-60
RAP 222 M2, Vacuum Belt Motor (feeder)....................................................................................................................................................... 4-60
RAP 223 M3, Registration Belt Motor (feeder)................................................................................................................................................. 4-61
RAP 224 SOL 1, Vacuum Lid Solenoid (feeder)............................................................................................................................................... 4-61
RAP 225 PCB XX Overload or Overheated (feeder)........................................................................................................................................ 4-62
RAP 226 Counter (feeder)................................................................................................................................................................................4-63
RAP 227 EEPROM (feeder) ............................................................................................................................................................................4-63
RAP 301 PCB A 12VDC ...................................................................................................................................................................................4-64
RAP 302 PCB B, PCB C, PCB D 12VDC ......................................................................................................................................................... 4-65
RAP 303 Creaser ICAN Circuit..........................................................................................................................................................................4-66
RAP 304 PCB B, 55VDC ..................................................................................................................................................................................4-67
RAP 305 PCB D, 55VDC .................................................................................................................................................................................4-68
RAP 306 PCB C, 55VDC .................................................................................................................................................................................4-69
RAP 307 Q20, Edge Detection Sensor (creaser)............................................................................................................................................. 4-70
RAP 308 Q21, Position Blade Drive 1 Sensor (creaser).................................................................................................................................. 4-70
RAP 309 Q22, Position Blade Drive 2 Sensor (creaser).................................................................................................................................. 4-71
RAP 310 Q25, Exit Sensor (creaser)............................................................................................................................................................... 4-71
RAP 311 M21, Roller Drive Motor (creaser)..................................................................................................................................................... 4-72
RAP 312 M22, Blade Drive 1 Motor (creaser).................................................................................................................................................. 4-72
RAP 313 M23, Blade Drive 2 Motor (creaser).................................................................................................................................................. 4-73
RAP 314 PCB XX Overload or Overheated (creaser)...................................................................................................................................... 4-74
RAP 315 Counter (creaser)..............................................................................................................................................................................4-75
RAP 316 EEPROM (creaser)...........................................................................................................................................................................4-75
18 February 2022
RAP 401 PCB A, PCB B, PCB H 12VDC ........................................................................................................................................................ 4-77
RAP 402 PCB E, PCB D, PCB C 12VDC ........................................................................................................................................................ 4-78
RAP 403 PCB MM, PCB K 12VDC ................................................................................................................................................................. 4-79
RAP 404 Folder ICAN Circuit.............................................................................................................................................................................4-80
RAP 405 PCB B, 55VDC ..................................................................................................................................................................................4-81
RAP 406 PCB C, 55VDC .................................................................................................................................................................................4-82
RAP 407 PCB D, 55VDC .................................................................................................................................................................................4-83
RAP 408 PCB E, 55VDC ..................................................................................................................................................................................4-84
RAP 409 PCB H, PCB “K” 55VDC ................................................................................................................................................................... 4-85
RAP 410 PCB MM 24VDC ...............................................................................................................................................................................4-86
RAP 411 Q40, Infeed Sensor (folder).............................................................................................................................................................. 4-87
RAP 412 Q41, Blade Position Drive 1 Sensor (folder).................................................................................................................................... 4-87
RAP 413 Q42, Blade Position Drive 2 Sensor (folder).................................................................................................................................... 4-88
RAP 414 Q45, Crease Exit Sensor (folder)..................................................................................................................................................... 4-88
RAP 415 Q47, Fold Knife Cam Position Sensor (folder)................................................................................................................................. 4-89
RAP 416 Q48 Q49 Q51, Motor M45 M46 M50 Position Sensors ..........................................................................................................................
(folder).................................................................................................................................................................................................... 4-90
RAP 417 Q52, Fold Exit Sensor (folder)........................................................................................................................................................ 4-90
RAP 418 M41, Roller Drive Motor (folder)........................................................................................................................................................ 4-91
RAP 419 M42, Blade Drive 1 Motor (folder)..................................................................................................................................................... 4-91
RAP 420 M43, Blade Drive 2 Motor (folder)..................................................................................................................................................... 4-92
RAP 421 M44, Fold Knife Motor (folder).......................................................................................................................................................... 4-92
RAP 422 M45 M46 M48 M50, Motors (folder).................................................................................................................................................. 4-93
RAP 423 M47, Delivery Belt Motor (folder)...................................................................................................................................................... 4-94
RAP 424 M49, Delivery Roller Drive Motor (folder).......................................................................................................................................... 4-94
RAP 425 PCB XX Overload or Overheated (folder)......................................................................................................................................... 4-95
RAP 426 PCB MM Overload or Overheated (folder)........................................................................................................................................ 4-96
RAP 427 Counter (folder).................................................................................................................................................................................4-97
RAP 428 EEPROM (folder)..............................................................................................................................................................................4-97
18 February 2022
4.1 Introduction to Troubleshooting 4.2 Printed Circuit Board (PCB) Overview
This troubleshooting section includes the following: The electronics in this system are distributed and divided into main CPU
boards, motor drive boards, and many other support printed circuit boards
• Detailed PCB images showing the location of connectors, pin posi- (PCBs) that drive sensors, fans and other components. Each PCB has its
tions, measuring points, and critical components (LEDs, DIP switches, own processor. The PCBs communicate via an internal CAN (ICAN) bus
etc.) within modules (e.g. within the Feeder) and via an external CAN (XCAN)
• ICAN and XCAN communication flowcharts for the system bus between modules (e.g. between the Feeder and Creaser).
• Voltage flowcharts for the system
• Fault code descriptions
CAUTION!
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes,
data and / or communication problems. Failure to use proper ESD proce-
tions, ensuring the proper handling of circuit boards / sensors. Use ESD
protection when working near PCBs. Failure to use ESD protection is likely
18 February 2022
4.2.1 CPU APP32 PCB Connector
18 February 2022
4.2.2 CPU APP32 PCB LEDs and Measuring Points
LED function:
Deactivated=no voltage present.
Activated= voltage present, but not necessarily the correct voltage level.
18 February 2022
4.2.3 Stepper Motor Driver M21H PCB Connector Placement and Pin Positions
18 February 2022
4.2.4 Stepper Motor Driver M21H PCB LEDs and Measuring Points
18 February 2022
4.2.5 PTC PCB Connector Placement and Pin Positions
Positive temperature coefficient (PTC) resistors on these PCBs provide
overload / short-circuit protection for the power supplies.
18 February 2022
4.2.6 SP Sensor Connector Placement, Pin Positions and LEDs
LED function:
Deactivated=no voltage present.
Activated= voltage present, but not necessarily the correct voltage level.
18 February 2022
4.2.7 User Interface Module Connector Placement, Pin Positions and LEDs
18 February 2022
4.2.8 Motor Driver M04L PCB Connector Placement and Pin Positions
= Pin Number 1
J5 = Pin Number 2
J3
J6 POWER IN
J8
J1
J4 J7
18 February 2022
4.2.9 Motor Driver M04L PCB LEDs
D2 D13
12V Present 24V present
D3
Software running
18 February 2022
4.3 Wiring Overview Wiring colour codes in this machine follow IEC 757:
Wiring in this machine is organized in harnesses with separate wiring Colour Colour Code
looms for power distribution and sensors / communication. IEC 757
For detailed information please see: Black BK
Brown BN
• Section 8 of this Service Manual for wiring diagrams of this machine Red RD
• Pro XL Parts List T07103 for a list of harness part numbers and con-
Orange OG
nection references.
Yellow YE
All harness connectors are labelled in the following way: Green GN
Blue incl. light blue BU
Violet (purple) VT
B, P6 Grey (slate)
White
Pink
GY
WH
PK
Gold GD
Turquoise TQ
Silver SR
PCB ID Connector number Green and yellow GNYE
Typical colour and wire cross-section usage:
Colour Size Usage
White (WH) AWG24 Signal
Grey (GY) AWG24 Signal
Yellow (YL) AWG24 Signal
Brown (BN) AWG24 Signal
Red (RD) AWG24 (+) for diodes, sensors etc.
Black (BK) AWG24 (-) for sensors, signals etc.
Red (RD) AWG22 (+) for fans
Black (BK) AWG22 (-) for fans
Orange (OG) AWG22 (+) for solenoids
Violet (VT) AWG22 (-) for solenoids
Orange (OG) AWG16 (+) for motors, solenoids
Violet (VT) AWG16 (-) for motors, solenoids
18 February 2022
4.4 Communication Flowcharts
4.4.1 Controller Area Network (CAN) Bus Overview
The Controller Area Network (CAN) bus is a communication system that allows microcontrollers to exchange messages using a wire pair. Each device
connected to the CAN bus can send messages to all other devices on the network and receives all messages transmitted on the network.
CAN high
120Ω 120Ω
CAN low
CPU Motor board 1 Motor board 2
There are two separate CAN buses in this machine:
• Internal CAN (ICAN) – used to exchange messages among microcontrollers within in a single module (e.g. within the feeder)
• External CAN (XCAN) – used by module main CPUs to exchange messages across multiple modules (e.g. between feeder and creaser)
These two buses work on the same principle but are used for different purposes.
18 February 2022
Each bus consists of two wires (CAN high and CAN low) which are tied together at each end with a “terminator” – a 120Ω resistor. On the ICAN bus (con-
necting PCBs within each module) this termination resistance is set with DIP switch 6 on PCBs. If this is on, the PCB is at one end of the CAN bus. The
rest of the DIP switches are used to set the address of the PCB on the CAN bus. The address is encoded in binary format. On the XCAN bus (connecting
modules to each other) the terminator can be a physical D-sub plug with a 120Ω resistor between pins 2 and 7.
ICAN address & termination XCAN termination
DIP switch sets PCB address

Switch 6 is CAN termination
18 February 2022
4.4.2 XCAN Flowchart
Feeder Creaser/Folder
User Interface CPU APP32 D-SUB D-SUB CPU APP32 D-SUB D-SUB
Module SOCKET PLUG SOCKET PLUG
PCB V PCB T PCB A
J6 J8 J7 J23 J24 J8 J7 J23
XCAN termination XCAN

DIP switch 6 term.
18 February 2022
4.4.3 Feeder - ICAN Flowchart
1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6
ON ON ON ON ON
OFF OFF OFF OFF OFF
CPU APP32 Motor M1 Motor M2 Motor M3 SP Sensor

M21H M21H M21H Q12
PCB T PCB G PCB H PCB K PCB Y
J10 J5 J6 J5 J6 J5 J6 J1
ICAN termination ICAN termination

DIP switch 6 DIP switch 6
18 February 2022
4.4.4 Creaser - ICAN Flowchart
OPTIONAL
1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6
ON ON ON ON
OFF OFF OFF OFF
CPU APP32 Motor M21 Motor M22 Motor M23

M21H M21H M21H
PCB A PCB B PCB C PCB D
J10 J5 J6 J5 J6 J5
ICAN termination ICAN termination

DIP switch 6 DIP switch 6
18 February 2022
4.4.5 Folder - ICAN Flowchart
1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6
ON ON ON ON
OFF OFF OFF OFF
PCB A PCB B PCB H PCB MM
CPU APP32 M21H M21H M04L
J10 J5 Motor M41 J6 J5 Motor M47 J6 J6 Motor M45 J5

Motor M46
ICAN termination Motor M50
DIP switch 6 Motor M48
1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6
ON ON ON ON
OFF OFF OFF OFF
PCB C PCB D PCB E PCB K
M21H M21H M21H M21H
Motor M42 J5 J6 Motor M43 J5 J6 Motor M44 J5 J6 Motor M49 J5
ICAN termination
DIP switch 6
1 2 3 4 5 6
ON
OFF
DIP switch setting if
PCB "C" is connected
18 February 2022
4.5 Power Flowcharts
4.5.1 Feeder – 55V Flowchart
Main interlock relay REL301 principle of operation: To activate 55V measured at:
REL301 all interlock switches must be activated to give 12V on A1 • PCB G
side of REL301 coil and software control signal from CPU PCB T • PCB H
in feeder module must be activated to sink A2 side of REL301 to • PCB K
GND.
18 February 2022
Interlock relay REL302 principle of operation: To activate 24V measured at:

REL301 all interlock switches must be activated to give 12V
on A1 side of REL302 coil and software control signal from • PCB L
CPU PCB T in feeder module must be activated to sink A2
side of REL302 to GND.
18 February 2022
12V measured at:
• PCB T
18 February 2022
4.5.4 Creaser – 55V Flowchart
24V measured at:
• PCB B
• PCB C
• PCB D
Main interlock relay REL301 principle of operation: To

activate REL301 all interlock switches must be activated to
give 12V on A1 side of REL301 coil and software control
signal from CPU PCB T in feeder module must be activated
to sink A2 side of REL301 to GND.
18 February 2022
4.5.5 Creaser – 12V Flowchart
FEEDER UNIT CREASER UNIT
12V measured at:
• PCB A
18 February 2022
4.5.6 Folder – 55V Flowchart
FOLDER UNIT
Stepper Motor
J9 Driver
PCB "B"
Stepper Motor
J9 Driver
PCB "C"
Stepper Motor
J9 Driver
PCB "D"
Stepper Motor
J9 Driver
PCB "E"
Stepper Motor Stepper Motor
J9 Driver J11 J9 Driver
PCB "H" PCB "K"
18 February 2022
J308 P308
(+) J4‐1 (‐) J4‐5 FAN 8
PTC1(D1) (+) 6
(‐) 13
&
FAN 9
(+) J4‐2 (‐) J4‐6 PCB MM PCB K

(+) 7 J9 M04L J8 M21H
PTC2(D2) (‐) 14
M45 M46 M50 SOL 42
FOLDER UNIT
18 February 2022
FEEDER UNIT FOLDER UNIT
SOL21
J3 Stepper Motor Driver Stepper Motor Driver
J6 CPU PCB"A" J10 J5 PCB"B" J6 J5 PCB"H"
Stepper Motor Driver Stepper Motor Driver Stepper Motor Driver

J5 PCB"E" J6 J5 PCB"D" J6 J5 PCB"C"
M04L Motor Driver Stepper Motor Driver
J6 PCB"MM" J5 J5 PCB"K"
Top Cover Switch
SW41‐1 SW41‐2
18 February 2022
4.6 Fault Code Descriptions
When the machine detects an error a fault code is shown on the screen. There are two types of fault codes: jam codes and fault codes.
Jam codes (3 digits)
FE - 102 These are part of normal operation of the machine and generally arise
due to paper jams somewhere in the system. Jam codes can be remedied
}
} Error ID
by an operator. However, if jam codes occur repeatedly or at the wrong
times, there may be a sensor malfunction which should be investigated by
Service.
Machine ID
Malfunction codes (3 digits)
FE - 2 02 10 These are shown when the machine has detected an internal issue. If the
issue is related to the power system, the machine will automatically shut
}
}
}
}
off relays feeding power supply units.

The tables in this section contain a short description for each fault code
Error ID along with suggested actions to diagnose the root cause of the issue.
Device ID
Device Group ID
Machine ID
18 February 2022
4.6.1 Feeder Fault Codes
Code Description Action Goto RAP
FE - 101 Misfeed Remove misfed sheet(s) and restart cycle. Check Q10. RAP 211
FE - 102 Double sheet Remove misfed sheet(s) and restart cycle. Check Q10. RAP 211
FE - 103 Sheet too long Remove misfed sheet(s) and restart cycle. Check Q10. RAP 211
FE - 104 Sheet too short Remove misfed sheet(s) and restart cycle. Check Q10. RAP 211
FE - 106 Out of paper Place paper on table and restart cycle. Check Q11. RAP 217
FE - 108 Paper table overloaded Only load paper up to marking on the registration wall. Check Q4. RAP 218
FE - 109 Too much paper Only load paper up to marking on the registration wall. Check Q4. RAP 218
FE - 112 Double sheet detector (DSD) blocked Remove misfed sheet(s). Check Q10. RAP 211
FE - 10003 EEPROM memory fault PCB T Perform NVM reset. Reinstall machine software. RAP 217
FE - 10004 Interlock state mismatch with voltage Check SW2/SW4 and SW3/SW5. Check REL301 and REL302. RAP 202
FE - 10090 PCB T power fault Check 12V circuit (PSU, PTC, wiring). RAP 207
FE - 10091 PCB T fault Check PCB connectors. PCB software. DIP Switches. RAP 207
FE - 10200 No CAN communication with SP sensor Check ICAN circuit and 12V supply to the PCB. Reinstall PCB software. RAP 210
Q12 PCB Y RAP 206
FE - 10201 SP sensor software mismatch Reinstall machine software with latest from Partner Centre. N/A
FE - 10206 SP sensor Q12 calibration fault Clean Q12. Ensure no direct sunlight shines on the sensor. Check Q12. RAP 210
FE - 10300 No CAN communication with DFA board Check connections to PCB PM (DFA box) N/A
FE - 10301 DFA software is not compatible with feeder Reinstall machine software with latest from Partner Centre. N/A
software, need to update DFA software
FE - 20100 No CAN communication with M1 PCB G Check ICAN circuit and 12V supply to the PCB. Reinstall PCB software. RAP 206, 207
FE - 20101 M1 PCB G software mismatch Reinstall machine software with latest from Partner Centre. N/A
FE - 20110 Motor voltage too low at M1 PCB G Check 55V circuit (relay, PSU, PTC, wiring). RAP 212
FE - 20111 Motor voltage low at M1 PCB G Check 55V circuit (relay, PSU, PTC, wiring). RAP 212
FE - 20112 Motor voltage high at M1 PCB G Check 55V circuit (relay, PSU, PTC, wiring). RAP 203
FE - 20113 Motor voltage too high at M1 PCB G Check 55V circuit (relay, PSU, PTC, wiring). RAP 203
FE - 20123 Motor M1 board PCB G overload Check motor movement. Check motor wiring to PCB. RAP 225
FE - 20124 Motor M1 board PCB G overheated Let the machine cool down. Check motor movement. RAP 225
FE - 20190 PCB G power fault Check 12V and 55V circuits (relay, PSU, PTC, wiring). RAP 207
FE - 20200 No CAN communication with M2 PCB H Check ICAN circuit and 12V supply to the PCB. Reinstall PCB software. RAP 206, 209
FE - 20201 M2 PCB H software mismatch Reinstall machine software with latest from Partner Centre. N/A
FE - 20210 Motor voltage too low at M2 PCB H Check 55V circuit (relay, PSU, PTC, wiring). RAP 213
18 February 2022
FE - 20211 Motor voltage low at M2 PCB H Check 55V circuit (relay, PSU, PTC, wiring). RAP 213
FE - 20212 Motor voltage high at M2 PCB H Check 55V circuit (relay, PSU, PTC, wiring). RAP 203
FE - 20213 Motor voltage too high at M2 PCB H Check 55V circuit (relay, PSU, PTC, wiring). RAP 203
FE - 20223 Motor M2 board PCB H overload Check motor movement. Check motor wiring to PCB. RAP 225
FE - 20224 Motor M2 board PCB H overheated Let the machine cool down. Check motor movement. RAP 225
FE - 20290 PCB H power fault Check 12V and 55V circuits (relay, PSU, PTC, wiring). RAP 209
FE - 20300 No CAN communication with M3 PCB K Check ICAN circuit and 12V supply to the PCB. Reinstall PCB software. RAP 206, 208
FE - 20301 M3 PCB K software mismatch Reinstall machine software with latest from Partner Centre. N/A
FE - 20310 Motor voltage too low at M3 PCB K Check 55V circuit (relay, PSU, PTC, wiring). RAP 214
FE - 20311 Motor voltage low at M3 PCB K Check 55V circuit (relay, PSU, PTC, wiring). RAP 214
FE - 20312 Motor voltage high at M3 PCB K Check 55V circuit (relay, PSU, PTC, wiring). RAP 203
FE - 20313 Motor voltage too high at M3 PCB K Check 55V circuit (relay, PSU, PTC, wiring). RAP 203
FE - 20323 Motor M3 board PCB K overload Check motor movement. Check motor wiring to PCB. RAP 225
FE - 20324 Motor M3 board PCB K overheated Let the machine cool down. Check motor movement. RAP 225
FE - 20390 PCB K power fault Check 12V and 55V circuits (relay, PSU, PTC, wiring). RAP 208
FE - 30121 Motor M1 is broken or disconnected Check motor movement. Check motor wiring to PCB. RAP 221
FE - 30130 Lift motor M1 initialization error Check Q1. Check lift home sensor flag. Check motor movement. RAP 219, 221
FE - 30136 Lift did not reach home position in time Check Q1. Check lift home sensor flag. Check motor movement. RAP 219, 221
(15s)
FE - 30137 Lift did not leave home position in time (1s) Check Q1. Check lift home sensor flag. Check motor movement. RAP 219, 221
FE - 30170 Lift top safety sensor Q2 activated during Check lift for obstructions. Check Q2. RAP 220
down move
FE - 30171 Lift bottom safety sensor Q8 activated dur- Check lift for obstructions. Check Q8. RAP 220
ing up move
FE - 30172 Lift top (Q2) and bottom (Q8) safety sen- Check lift for obstructions. Check Q2 and Q8. RAP 220
sors activated
FE - 30173 Lift top safety sensor Q2 activated Check lift for obstructions. Check Q2. RAP 220
FE - 30174 Lift bottom safety sensor Q8 activated Check lift for obstructions. Check Q8. RAP 220
FE - 30175 Lift top safety sensor Q2 activated during Check lift for obstructions. Check Q2. RAP 220
cycle
FE - 30176 Lift bottom safety sensor Q8 activated dur- Check lift for obstructions. Check Q8. RAP 220
ing cycle
18 February 2022
FE - 40131 FAN1 blocked or disconnected Check FAN1 moves freely. Check FAN1 connection. Check 24V circuit. RAP 216
FE - 50121 Solenoid SOL1 is broken or disconnected Check SOL1 moves freely. Check SOL1 connection. Check 24V circuit. RAP 215, 209
FE - 50122 Solenoid SOL1 driver PCB H broken Check SOL1 moves freely. Check SOL1 connection. Check 24V circuit. RAP 215, 209
FE - 50123 Solenoid SOL1 overload Check SOL1 moves freely. Check SOL1 connection. Check 24V circuit. RAP 215, 209
FE - 60405 Distance sensor Q4 not calibrated Recalibrate Q4 (ADJ 3.6.2). RAP 218
FE - 61005 DSD sensor Q10 not calibrated Recalibrate Q10 (ADJ 3.6.1). (ADJ 3.6.1)
FE - 70110 12V voltage too low Check 12V circuit (PSU, PTC, wiring) RAP 207, 203
FE - 70113 12V voltage too high Check 12V circuit (PSU, PTC, wiring) RAP 203
FE - 70210 55V voltage too low Check 55V circuit (relay, PSU, PTC, wiring). RAP 212, 213,
214
FE - 70213 55V voltage too high Check 55V circuit (relay, PSU, PTC, wiring). RAP 203
FE - 70233 55V off timeout (3 s) Check 55V circuit (relay, PSU, PTC, wiring). N/A
FE - 70234 55V low timeout (4 s) Check 55V circuit (relay, PSU, PTC, wiring). N/A
FE - 70310 24V voltage too low at PCB L Check 24V circuit (relay, PSU, PTC, wiring). N/A
FE - 70313 24V voltage too high at PCB L Check 24V circuit (relay, PSU, PTC, wiring). RAP 202
FE - 70333 24V off timeout (3 s) Check 24V circuit (relay, PSU, PTC, wiring). N/A
FE - 70334 24V low timeout (4 s) Check 24V circuit (relay, PSU, PTC, wiring). N/A
FE - 20 Downstream unit jam (DFA kit) Unit connected to DFA kit has sent a hard stop or soft stop N/A
message
FE - 21 Downstream unit offline (DFA kit) Unit connected to DFA kit not online N/A
FE - 22 Downstream unit cycle up timeout (DFA kit) Unit connected to DFA kit not ready to receive paper within 2 N/A
minutes of feeder cycle up
18 February 2022
4.6.2 Creaser Fault Codes

CR - 201 Sheet late from feeder output Q7 to creaser Remove misfed sheet(s) and restart cycle. Check Q20. RAP 307
input Q20
CR - 202 Creaser input sensor Q20 blocked Remove misfed sheet(s) and restart cycle. Check Q20. RAP 307
CR - 205 Creaser 1 home sensor Q21 not activated Check creaser moves freely. Clean Q21. Check creaser flag. RAP 308
CR - 206 Creaser 2 home sensor Q22 not activated Check creaser moves freely. Clean Q22. Check creaser flag. RAP 309
CR - 207 Sheet late from input sensor Q20 to output Remove misfed sheet(s) and restart cycle. Check Q20 and Q25. RAP 307, 310
sensor Q25
CR - 208 Creaser output sensor Q25 blocked Remove misfed sheet(s) and restart cycle. Check Q25. RAP 310
CR - 209 Clean creaser input sensor Q20 Check Q20. RAP 307
CR -10003 EEPROM memory fault PCB A Perform NVM reset. Reinstall machine software. RAP 307
CR -10004 Interlock SW21/SW22 state mismatch with Check SW21/SW22. Check REL301 and REL302 state in feeder. RAP 202
voltage
CR -10090 PCB A power fault Check 12V circuit (PSU, PTC, wiring). RAP 301
CR -10091 PCB A fault Check PCB connectors. Reinstall PCB software.
CR -20100 No CAN communication with M21 PCB B Check ICAN circuit and 12V supply to the PCB. Reinstall PCB RAP 302, 303
software.
CR -20101 M21 PCB B software mismatch Reinstall machine software with latest from Partner Centre. N/A
CR -20110 Motor voltage too low at M21 PCB B Check 55V circuit (relay, PSU, PTC, wiring). RAP 304
CR - 20111 Motor voltage low at M21 PCB B Check 55V circuit (relay, PSU, PTC, wiring). RAP 304
CR -20112 Motor voltage high at M21 PCB B Check 55V circuit (relay, PSU, PTC, wiring). RAP 203
CR -20113 Motor voltage too high at M21 PCB B Check 55V circuit (relay, PSU, PTC, wiring). RAP 203
CR -20123 Motor M21 board PCB B overload Check motor movement. Check motor wiring to PCB. RAP 314
CR -20124 Motor M21 board PCB B overheated Let the machine cool down. Check motor movement. RAP 314
CR -20190 PCB B power fault Check 12V and 55V circuits (relay, PSU, PTC, wiring). RAP 302
CR -20200 No CAN communication with M22 PCB C Check ICAN circuit and 12V supply to the PCB. Reinstall PCB RAP 202, 303
software.
CR -20201 M22 PCB C software mismatch Reinstall machine software with latest from Partner Centre. N/A
CR -20210 Motor voltage too low at M22 PCB C Check 55V circuit (relay, PSU, PTC, wiring). RAP 306
CR -20211 Motor voltage low at M22 PCB C Check 55V circuit (relay, PSU, PTC, wiring). RAP 306
CR -20212 Motor voltage high at M22 PCB C Check 55V circuit (relay, PSU, PTC, wiring). RAP 203
CR -20213 Motor voltage too high at M22 PCB C Check 55V circuit (relay, PSU, PTC, wiring). RAP 203
18 February 2022
CR -20223 Motor M22 board PCB C overload Check motor movement. Check motor wiring to PCB. RAP 314
CR -20224 Motor M22 board PCB C overheated Let the machine cool down. Check motor movement. RAP 314
CR -20290 PCB C power fault Check 12V and 55V circuits (relay, PSU, PTC, wiring). RAP 302
CR -20300 No CAN communication with M23 PCB D Check ICAN circuit and 12V supply to the PCB. Reinstall PCB RAP 302, 303
software.
CR -20301 M23 PCB D software mismatch Reinstall machine software with latest from Partner Centre. N/A
CR -20310 Motor voltage too low at M23 PCB D Check 55V circuit (relay, PSU, PTC, wiring). RAP 305
CR -20311 Motor voltage low at M23 PCB D Check 55V circuit (relay, PSU, PTC, wiring). RAP 305
CR -20312 Motor voltage high at M23 PCB D Check 55V circuit (relay, PSU, PTC, wiring). RAP 203
CR -20313 Motor voltage too high at M23 PCB D Check 55V circuit (relay, PSU, PTC, wiring). RAP 203
CR -20323 Motor M23 board PCB D overload Check motor movement. Check motor wiring to PCB. RAP 314
CR -20324 Motor M23 board PCB D overheated Let the machine cool down. Check motor movement. RAP 314
CR -20390 PCB D power fault Check 12V and 55V circuits (relay, PSU, PTC, wiring). RAP 302
CR -30121 Motor M21 is broken or disconnected Check motor movement. Check motor wiring to PCB. RAP 311
CR -30171 Motor M21 diagnostic timeout (6s) Check motor movement. Check motor wiring to PCB. RAP 311
CR -30236 Creaser 1 lost position Check creaser moves freely. Clean Q21. Check creaser flag. RAP 312, 308
CR -30271 Motor M22 diagnostic timeout (6s) Check creaser moves freely. Clean Q21. Check creaser flag. RAP 312, 308
CR -30272 Motor M22 mechanical problem Check motor movement. Check motor wiring to PCB. RAP 312
CR -30336 Creaser 2 lost position Check creaser moves freely. Clean Q22. Check creaser flag. RAP 313, 309
CR -30371 Motor M23 diagnostic timeout (6s) Check creaser moves freely. Clean Q22. Check creaser flag. RAP 313, 309
CR -30372 Motor M23 mechanical problem Check motor movement. Check motor wiring to PCB. RAP 313
CR -62006 Creaser input sensor Q20 calibration failed Clean Q20. Check Q20 in service. RAP 307
CR -62070 Creaser input sensor Q20 covered Clean Q20. Check Q20 in service. RAP 307
CR -62270 Interlock circuit failure (SW22) Check SW21/SW22. Check REL301 and REL302 state in feeder. RAP 202
CR -62570 Creaser exit sensor Q25 covered Remove misfed sheet(s) and restart cycle. Check Q25. RAP 312
18 February 2022
4.6.3 Folder Fault Codes
FO - 301 Sheet late to exit feeder Remove misfed sheet(s) and restart cycle. Check Q40. RAP 411
FO - 302 Folder input sensor Q40 covered too Remove misfed sheet(s) and restart cycle. Check Q40. RAP 411
long
FO - 303 Folder input sensor Q40 not uncovered in Remove misfed sheet(s), check paper path for obstructions re- RAP 411
time start cycle.
FO - 304 Folder input sensor Q40 blocked Remove misfed sheet(s) and restart cycle. Clean Q40. RAP 411
FO - 305 Creased sheet output sensor Q45 Remove misfed sheet(s) and restart cycle. Check Q45. RAP 414
blocked
FO - 306 Folded sheet output sensor Q52 Remove misfed sheet(s) and restart cycle. Check Q52. RAP 417
blocked
FO - 307 Creased sheet output sensor Q45 uncovered Remove misfed sheet(s) and restart cycle. Check Q45. RAP 414
too early
FO - 308 Folded sheet output sensor Q52 uncovered too Remove misfed sheet(s) and restart cycle. Check Q52. RAP 417
early
FO - 309 Static creaser lost position Check creaser moves freely. Clean Q41. Check creaser flag. RAP 412
FO - 310 DynaCrease lost position Check creaser moves freely. Clean Q42. Check creaser flag. RAP 413
FO - 311 Fold knives lost position Check fold mechanism moves freely. Clean Q47. RAP 415
FO - 312 Folded sheet output sensor Q52 covered too Check conveyor. Remove misfed sheet(s) and restart cycle. RAP 417
long Check Q52.
FO - 313 Folded sheet late to exit folder (Q52) Check conveyor. Remove misfed sheet(s) and restart cycle. RAP 417
Check Q52.
FO - 314 Creased sheet output sensor Q45 covered too Check stacker. Remove misfed sheet(s) and restart cycle. Check RAP 414
long Q45.
FO - 315 Creased sheet late to exit folder (Q45) Check Remove misfed sheet(s) and restart cycle. Check Q45. RAP 414
stacker.
FO - 316 Clean folder input sensor Q40 Clean Q40. Check Q40 in service. RAP 411
FO - 317 Adjust folded sheet output sensor Q52 Adjust Q52 transmitter angle to minimize value displayed in ser- N/A
vice (should be <200mV)
FO - 901 Job parameters out of sync Restart the machine. N/A
FO - 902 Job parameter error: missing Fold 1 Edit job parameters, ensure both folds are set. See Operator
manual
18 February 2022
FO - 903 Job parameter error: missing Fold 2 Edit job parameters, ensure both folds are set. See Operator
manual
FO - 904 Job parameter mismatch Restart the machine. N/A
FO - 905 DynaCrease distance between creases below Increase distance between creases or switch to static creaser. N/A
minimum Increase distance between
creases or switch to static creaser.
FO - 910 Job calculation error Restart the machine. N/A
FO -10004 Interlock state mismatch with voltage Check SW41/SW42. Check REL301 and REL302 state in feeder. RAP 202
FO -24100 No CAN communication with M41 PCB Check ICAN circuit and 12V supply to the PCB. Reinstall PCB RAP 401, 404
B software.
FO -24101 M41 PCB B software mismatch Reinstall machine software with latest from Partner Centre. N/A
FO -24110 Motor voltage too low at M41 PCB B Check 55V circuit (relay, PSU, PTC, wiring). RAP 405
FO -24111 Motor voltage low at M41 PCB B Check 55V circuit (relay, PSU, PTC, wiring). RAP 405
FO -24112 Motor voltage high at M41 PCB B Check 55V circuit (relay, PSU, PTC, wiring). RAP 203
FO -24113 Motor voltage too high at M41 PCB B Check 55V circuit (relay, PSU, PTC, wiring). RAP 203
FO -24123 Motor M41 board PCB B overload Check motor movement. Check motor wiring to PCB. RAP 425
C software.
FO -24201 M42 PCB C software mismatch Reinstall machine software with latest from Partner Centre. N/A
FO -24210 Motor voltage too low at M42 PCB C Check 55V circuit (relay, PSU, PTC, wiring). RAP 406
FO -24211 Motor voltage low at M42 PCB C Check 55V circuit (relay, PSU, PTC, wiring). RAP 406
FO -24212 Motor voltage high at M42 PCB C Check 55V circuit (relay, PSU, PTC, wiring). RAP 203
FO -24213 Motor voltage too high at M42 PCB C Check 55V circuit (relay, PSU, PTC, wiring). RAP 203
FO -24223 Motor M42 board PCB C overload Check motor movement. Check motor wiring to PCB. RAP 425
D software.
FO -24301 M43 PCB D software mismatch Reinstall machine software with latest from Partner Centre. N/A
FO -24310 Motor voltage too low at M43 PCB D Check 55V circuit (relay, PSU, PTC, wiring). RAP 407
FO -24311 Motor voltage low at M43 PCB D Check 55V circuit (relay, PSU, PTC, wiring). RAP 407
FO -24312 Motor voltage high at M43 PCB D Check 55V circuit (relay, PSU, PTC, wiring). RAP 203
FO -24313 Motor voltage too high at M43 PCB D Check 55V circuit (relay, PSU, PTC, wiring). RAP 203
FO -24323 Motor M43 board PCB D overload Check motor movement. Check motor wiring to PCB. RAP 425
18 February 2022
FO -24400 No CAN communication with M44 PCB E Check ICAN circuit and 12V supply to the PCB. Reinstall PCB RAP 402, 404
software.
FO -24401 M44 PCB E software mismatch Reinstall machine software with latest from Partner Centre. N/A
FO -24410 Motor voltage too low at M44 PCB E Check 55V circuit (relay, PSU, PTC, wiring). RAP 408
FO -24411 Motor voltage low at M44 PCB E Check 55V circuit (relay, PSU, PTC, wiring). RAP 408
FO -24412 Motor voltage high at M44 PCB E Check 55V circuit (relay, PSU, PTC, wiring). RAP 203
FO -24413 Motor voltage too high at M44 PCB E Check 55V circuit (relay, PSU, PTC, wiring). RAP 203
FO -24423 Motor M44 board PCB E overload Check motor movement. Check motor wiring to PCB. RAP 425
FO -24700 No CAN communication with M47 PCB H Check ICAN circuit and 12V supply to the PCB. Reinstall PCB RAP 401, 404
software.
FO -24701 M47 PCB H software mismatch Reinstall machine software with latest from Partner Centre. N/A
FO -24710 Motor voltage too low at M47 PCB H Check 55V circuit (relay, PSU, PTC, wiring). RAP 409
FO -24711 Motor voltage low at M47 PCB H Check 55V circuit (relay, PSU, PTC, wiring). RAP 409
FO -24712 Motor voltage high at M47 PCB H Check 55V circuit (relay, PSU, PTC, wiring). RAP 203
FO -24713 Motor voltage too high at M47 PCB H Check 55V circuit (relay, PSU, PTC, wiring). RAP 203
FO -24723 Motor M47 board PCB H overload Check motor movement. Check motor wiring to PCB. RAP 425
FO -24900 No CAN communication with M49 PCB K Check ICAN circuit and 12V supply to the PCB. Reinstall PCB RAP 403, 404
software.
FO -24901 M49 PCB K software mismatch Reinstall machine software with latest from Partner Centre. N/A
FO -24910 Motor voltage too low at M49 PCB K Check 55V circuit (relay, PSU, PTC, wiring). RAP 409
FO -24911 Motor voltage low at M49 PCB K Check 55V circuit (relay, PSU, PTC, wiring). RAP 409
FO -24912 Motor voltage high at M49 PCB K Check 55V circuit (relay, PSU, PTC, wiring). RAP 203
FO -24913 Motor voltage too high at M49 PCB K Check 55V circuit (relay, PSU, PTC, wiring). RAP 203
FO -24923 Motor M49 board PCB K overload Check motor movement. Check motor wiring to PCB. RAP 425
FO -25000 No CAN communication with M45, M46, M48 & Check ICAN circuit and 12V supply to the PCB. Reinstall PCB RAP 404
M50 PCB MM software.
FO -25001 M45, M46, M48 & M50 PCB MM software Reinstall machine software with latest from Partner Centre. N/A
mismatch
FO -25010 Motor voltage too low at M45, M46, M48 & Check 24V circuit (relay, PSU, PTC, wiring). RAP 410
M50 PCB MM
FO -25011 Motor voltage low at M45, M46, M48 & M50 Check 24V circuit (relay, PSU, PTC, wiring). RAP 410 (203)
PCB MM
18 February 2022
FO -25012 Motor voltage high at M45, M46, M48 & M50 Check 24V circuit (relay, PSU, PTC, wiring). RAP 203
PCB MM
FO -25013 Motor voltage too high at M45, M46, M48 & Check 24V circuit (relay, PSU, PTC, wiring). RAP 203
M50 PCB MM
FO -25023 Motor M45, M46, M48 & M50 board PCB MM Check motor movement. Check motor wiring to PCB. RAP 426
overload
FO -34121 Motor M41 is broken or disconnected Check motor movement. Check motor wiring to PCB. RAP 418
FO -34171 Motor M41 diagnostic timeout Check motor movement. Check motor wiring to PCB. RAP 418
FO -34230 Static creaser motor M42 did not reach home Check creaser moves freely. Clean Q41. Check creaser flag. RAP 419, 412
sensor Q41 within 5s
FO -34236 Static creaser lost position Check creaser moves freely. Clean Q41. Check creaser flag. RAP 419, 412
FO -34271 Motor M42 diagnostic timeout Check creaser moves freely. Clean Q41. Check creaser flag. RAP 419, 412
FO -34272 Motor M42 mechanical problem Check motor movement. Check motor wiring to PCB. RAP 419
FO -34330 DynaCrease motor M43 did not reach home Check creaser moves freely. Clean Q42. Check creaser flag. RAP 420, 413
sensor Q42 within 5s
FO -34336 DynaCrease lost position Check creaser moves freely. Clean Q42. Check creaser flag. RAP 420, 413
FO -34371 Motor M43 diagnostic timeout Check creaser moves freely. Clean Q42. Check creaser flag. RAP 420, 413
FO -34372 Motor M43 mechanical problem Check motor movement. Check motor wiring to PCB. RAP 420
FO -34430 Fold knife motor M44 did not reach home sen- Check motor movement. Clean sensor. RAP 421, 415
sor Q47 within 5s
FO -34530 Roller gap set 2 motor M45 did not reach home Check motor movement. Clean sensor. RAP 421, 415
sensor Q48 in time
sensor Q49 in time
FO -34830 Delivery roller (M48) failed to reach position Check delivery roller for mechanical obstructions. RAP 422
FO -34930 Delivery roller (M49) failed to reach position Check delivery roller for mechanical obstructions. RAP 424
FO -34973 Delivery roller (M49) incorrect movement direc- Check motor wiring to PCB. RAP 424
tion
FO -34974 Delivery roller (M49) failed to move Check delivery roller for mechanical obstructions. RAP 424
sensor Q51 in time
18 February 2022
FO -62070 Folder input sensor Q40 covered Clean Q40. Check Q40 in service. RAP 411
FO -62270 Interlock circuit failure Check SW41/SW42. Check REL301 and REL302 state in feeder. RAP 202
FO -62570 Folder exit sensor Q52 covered Remove misfed sheet(s) and restart cycle. Check Q52. RAP 417
FO -64006 Clean folder input sensor Q40 (calibration Clean Q40. Check Q40 in service. RAP 411
failed)
18 February 2022
4.7 Repair And Analysis Procedures - RAPS
18 February 2022
RAP 101 Sensors General Troubleshooting RAP 102 Motors General Troubleshooting
This RAP is for troubleshooting a sensor problem. This RAP is for troubleshooting a motor open or short circuit problem.
Initial Actions Initial Actions

- Ensure that all PCBs and jack/plug connectors identified in the BSD (Block Schematic Dia - Ensure that all PCBs and jack/plug connectors identified in the BSD (Block Schematic Dia
gram) are properly connected. gram) are properly connected.
- NOTE! For measuring references see schematics in each RAP or the complete schematics - NOTE! For measuring references see schematics in each RAP or the complete schematics
located in section 8. located in section 8.
Procedure Procedure
WARNING! WARNING!
Turn off the Pro XL Main Power Switch and disconnect the Main Power Cord before Turn off the Pro XL Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring resis- disconnecting, removing or replacing any electrical components or measuring resis-
tance inside the machine. tance inside the machine.
Enter Service Mode and select the sensor. • For measuring references see BSD (Block Schematic Diagram) located in the motor RAP.
The sensor is changing state when manually activated. Power off and disconnect the motor and the PCB connector.
N Y Check the cabling for continuity and short circuit between the motor connector and the PCB
The sensor seems to work. Check for possible mechanical problems. To eliminate connector,
an itermittent electrical connection follow the “N” branch. There is continuity and no short circuits
• For measuring references see BSD (Block Schematic Diagram) located in the sensor Y N
RAP. Repair/replace harness.
Disconnect the sensor and check that the sensor is powered correctly. Replace the Motor.
The sensor is powered correctly. Success
Y N N Y
Disconnect the plug where the sensor is connected to the PCB and check that the Exit
power supplied from the PCB to the sensor is correct. The power supplied to the
sensor is correct. Replace the PCB.
Y N
Troubleshoot/Replace the PCB.
Repair/Replace wire harness.
Disconnect the sensor connector and the connector at the PCB and Check all wires for
continuity and short circuit. Check all wires for short circuit to chassie/GND.
There are continuity for all wires and no short circuit
Y N
Repair/Replace wire harness.
1. Replace the sensor.
2. Replace the PCB.
18 February 2022
RAP 201 Primary Circuit
This RAP is for troubleshooting an open Primary circuit.
This RAP presumes that the Fuse F1 is not blown.
Initial Actions
- Make sure all connectors in the BSD are connected properly.
Procedure
WARNING!
Turn off the Pro XL Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring resis-
tance inside the machine.
From now on, keep machine powered off and the Main Power cord removed. VERY im-
portant!
Check continuity between following wires

12V PSU-1 [L] to [SW1-4] and 12V PSU-1 [N] to [SW1-1]
[SW1-2] BK,2 to BK,2 Power Entry and [SW1-5] BK,1 to BK,1 Power Entry
If there is a continuity problem - repair/replace the harness.
If not move to next step.
Keep Main Power cord removed (VERY important).

Disconnect all wires from SW1. Activate SW1. Check continuity between following wires
[SW1-4] to [SW1-5] (SW1 terminals, not harness connectors)
[SW1-1] to [SW1-2] (SW1 terminals, not harness connectors)
Replace SW1 if there is a continuity problem or,
if SW1 is indeed correct, replace the Power Entry (inlet).
18 February 2022
RAP 202 Interlock Circuits
Principle Of Operation:
This RAP is for understanding and troubleshooting the PRO XL interlock circuits. Refer to the schematics below.
Initial Actions The software switches will signal to CPU PCB “T” to activate REL 301 and REL 302.
This RAP presumes that the 12V PSU is working correctly and that 12V is present at
12V power to the relays is supplied from PCB “B”.
CPU PCB “T” in the feeder.
When all hardware switches are closed REL 301 will be activated when CPU PCB “T” P5-1
is low.
Procedure When all hardware switches are closed REL 302 will be activated when CPU PCB “T” P5-3
is low.
WARNING!
Turn off the PRO XL Main Power Switch and disconnect the Main Power Cord before
Troubleshooting:
Overview: Refer to “Principle of operation” and to schematics below..
The interlock system controls mains power to the 24V and 55V PSU, i.e. switches on and
off the power supplies by activating REL 301 & REL 302. - Check all software switches in service menu “Sensors”
The 12VDC power supply is always on when PRO XL is powered on. - Check 12V supply from PCB “B”
- Check all hardware switches, i. e. verify that there is continuity and no short circuit from
The interlock system is made up of two parts, software and hardware switches. PCB “B” to CPU PCB “T”.
The software switches is a “digital” signal and can be checked in “Sensors” in the service -Remember to check Interlock Switch in Creaser/Folder or disconnect and install a jumper
menu. plug to J12
-If the relay doesn’t disengage when powered off it must be replaced (Fault FE-10004)
The hardware switches opens and closes the 12V DC circuit that is powering REL 301 and
REL 302. The hardware switches can NOT be checked in the service menu.. I problem remains:
- Replace CPU PCB “T”
- Replace REL 301 and/or REL 302
18 February 2022
RAP 203 PSU 12/24/55V Adjustment
This RAP is for adjusting PSU 12V, 24V or 55V
Initial Actions
None
PSU(24V)
Procedure
WARNING!
disconnecting, removing or replacing any electrical components or measuring
For safety reasons, interlock relays will deactivate after 45 seconds (if voltage is too low),
or after 5 seconds (if voltage is too high) after the relay been activated in the Service Menu.
In case of a time out, turn the TRIM knob to increase/decrease and then activate the relay
again.
If you do not succeed in adjusting the PSU, replace it.
NOTE!
Turn the TRIM knob clockwise to increase and counter-clockwise to decrease the output
voltage. Note that 1/4 turn is approximately 3,0 VDC.
Ideal level Adjust to

PSU Measure between
[VDC] [VDC]
(12V) 12V 11.8-12.3 V V- to V+ at PSU(12V), Black V-, Red V+
(24V) 24V 23.8-24.3 V V- to V+ at PSU(26V), Black V-, Red V+
(55V) 55V 54,8-55,3V V- to V+ at PSU(55V)), Black V-, Orange V+
PSU(55V)
PSU(12V)
18 February 2022
RAP 204 PTC PCBs
PCB “B” 12V Overload / Short-Circuit Protection
This RAP is for understanding and troubleshooting the PTC PCBs. PCB “DD” 12V Overload / Short-Circuit Protection
Input LED D10
Initial Actions
Overview:
Positive temperature coefficient (PTC) resistors on these PCBs provide overload / short-
circuit protection for the power supplies.
An excessive load or short-circuit will force the PTC resitor into high ohmic state and the
power will be cut.
Refer to pictures below:
PCB “B” and “BB” provides short-circuit protection for the 12 V power supply.
LED 10 indicates power input to the PTC PCB.
LED 1 - 6 indicates power output from the PTC PCB
LED function:
Deactivated=no voltage present. Activated= voltage present,
PCB “C” provides short-circuit protection for the 55 V power supply. not necessarily the correct voltage level.
LED 8 indicates power input to the PTC PCB.
PCB “C” 55V Overload / Short-Circuit Protection
PCB “D” provides short-circuit protection for the 24 V power supply. PCB “D” 24V Overload / Short-Circuit Protection
LED 10 indicates power input to the PTC PCB. PCB “R” 55V Overload / Short-Circuit Protection
Procedure
WARNING!
Turn on POWER / close the interlock.

Verify a working power input by checking the input LED (D10 or D8)
Verify a working power output by checking the output LEDs.
A deactivated LED indicates a problem with the load connected to that output.
Turn off POWER and disconnect the output connector.
Turn on POWER / close the interlock.
Verify that the output LED turns on when the load is disconnected - the PTC PCB is work- D7
ing..
Locate the load connected to the specific output. Troubleshoot each component including
wiring to isolate the problem. LED function:
not necessarily the correct voltage level.
18 February 2022
RAP 205 User Interface Module Input LED D10
This RAP is for troubleshooting the User Interface Module.
The objective is to determine that voltages are OK, the UI module communicates correctly
and to identify possible failed components.
Initial Actions
• Ensure that all PCBs and jack/plug connectors identified in the BSD are properly con-
nected
• Make sure that all DIP switch settings are correct, see BSD
• Re-load the latest software to the User Interface Module
Procedure
WARNING! PTC PCB “B”
Power on the PRO XL system.
POWER
Verify that LED D7 on the UI PCB “V” is lit. LED D7 indicates 12VDC present.
If LED D7 is NOT activated check:
LED D5 on PCB “B” is activated. LED D5 indicates a 12VDC output to the UI.
Check wiring from plug P7 on PCB “V” to plug P2 on PCB “B” via plug/connector P/J351,
refer to BSD. Check all wires for continuity and no short circuits.
COMMUNICATION CIRCUIT
The UI module communicates with CPU PCB “T” on a CAN-bus (XCAN), refer to BSD.
To work correctly the bus needs termination resistors at both ends (PCB “V” DIP switch #6
in ON-position will terminate at one end and a termination plug connected to J23 on the
other end).
Disconnect any external units connected to J23 (CAN OUT) and connect a working
termination plug.
Check that DIP #6 on CPU PCB T is set to ON.
Check wiring from plug P6 on PCB “V” to plug P8 on CPU PCB “T” via plug/connector P/
J351.
Check wiring from J23 to P7 on CPU PCB “T”.
Check all wires for continuity and no short circuits.
IF PROBLEM REMAINS
Double check software versions and reload software in UI and CPU PCB “T”.
Replace CPU PCB “T”.
Replace User Interface Module.
18 February 2022
RAP 206 Feeder ICAN Circuit CAN high
This RAP is for troubleshooting a communication problem related to the ICAN bus in the
120Ω 120Ω
Feeder Unit.
CAN low
The primary objective is to determine if the ICAN bus is OK and if connected PCBs are pow-
ered and working correctly.
Initial Actions
• Ensure that all PCBs and jack/plug connectors are properly connected CPU Motor board 1 Motor board 2
• Verify that correct software is loaded on all PCBs
Procedure
WARNING!
1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6
ON ON ON ON ON
OFF OFF OFF OFF OFF
disconnecting, removing or replacing any electrical components or measuring resis- CPU APP32 Motor M1 Motor M2 Motor M3 SP Sensor
tance inside the machine. M21H M21H M21H Q12
J10 J5 J6 J5 J6 J5 J6 J1
OVERVIEW
The PCBs in the Feeder are connected on a CAN bus ( Controller Area Network) ICAN termination
DIP switch 6
ICAN termination
DIP switch 6
The bus consists of a two wires with a 120ohm “termination resistor” at both ends.
The first and the last PCB on the bus (PCB “T” & “Y”) must have DIP switch #6 set to “ON”
to activate the “termination resistor”.
INITIAL CHECKS
-Verify that all PCB on the bus are powered correctly (12VDC).
-Double check all connectors on the PCBs. Refer to BSD to the left to identify the connec-
tors related to the CAN bus.
TROUBLESHOOTING
POWER
-In the case of a power failure on a PCB refer to specific 12VDC power RAP for that PCB..
COMMUNICATION
-Check all wires related to the CAN bus for continuity and no short circuit.
Wires from T, P10 to G, P5 G, P6 to H, P5 H, P6 to K, P5 K, P6 to Y, P1.
Refer to BSD to the left
IF PROBLEM REMAINS
-Replace the PCB reporting the error code.
-Or, if possible, switch places with another PCB, it is possible that a preceding PCB on the
BUS is causing the problem.
NOTE when switching/moving PCB pay attention to DIP switch settings and software.
18 February 2022
RAP 207 PCB T, PCB G 12VDC Input LED D10
This RAP is for troubleshooting a problem with the 12VDC supply to PCB T and PCB G. PTC PCB “B”
Initial Actions
• Ensure that all PCBs and jack/plug connectors are properly connected
Procedure
WARNING!
INITIAL CHECKS
-Verify that PCB “B” has input power. LED D10 is lit when input power is present.
-Verify output power to PCB “T” & “G” from PCB “B”. LED D1 on PCB “B” is lit when output
is present.
If LED in not activated or turns off go to PTC RAP
-Verify 12VDC input to CPU PCB “T”. D5 on PCB “T”. LED D5 is lit when 12VDC is present.
-Verify 12VDC input to PCB “G”. LED D2 is lit when 12VDC is present.
TROUBLESHOOTING
-Check all wires from B, P2 to T, P6 for continuity and no short circuits.
-Check all wires from T, P10 to G, P5 for continuity and no short circuits.
-Disconnect plug P2, P3 and P9 from PCB “T” to check if power is restored. If the case
identify faulty component connected to P2, P3 or P9.
IF PROBLEM REMAINS
Replace CPU PCB “T” and/or PCB “G” and/or PCB “B”.
18 February 2022
RAP 208 PCB K, PCB Y 12VDC
This RAP is for troubleshooting a problem with the 12VDC supply to PCB K and PCB Y.
Initial Actions
Procedure
WARNING!
INITIAL CHECKS
-Verify output power to PCB “K” & “Y” from PCB “B”. LED D4 on PCB “B” is lit when output
is present.
If LED is not activated or turns off go to PTC RAP
-Verify 12VDC input to PCB “K”. D2 on PCB “K” is lit when 12VDC is present.
SP Sensor PCB “Y”
-Verify 12VDC input to PCB “Y”. LED D20 is lit when 12VDC is present.
TROUBLESHOOTING
-Check all wires from B, P2 to K, P5 for continuity and no short circuits.
-Check all wires from K, P6 to Y, P1 for continuity and no short circuits.
-Disconnect plug P4, P6 and P7 from PCB “K” to check if power is restored. If the case
identify faulty component connected to P4, P6 or P7.
Input LED D10 PTC PCB “B” Stepper Motor PCB “K”, M21H
IF PROBLEM REMAINS
Replace PCB “K” and/or PCB “Y”.
18 February 2022
RAP 209 PCB H, PCB J 12VDC
This RAP is for troubleshooting a problem with the 12VDC supply to PCB H and PCB J.
Initial Actions
• Make sure that all DIP switch settings are correct, see BSD Input LED D10 PTC PCB “B” Stepper Motor PCB “K”, M21H
Procedure
WARNING!
INITIAL CHECKS
-Verify output power to PCB “H” & “J” from PCB “B”. LED D2 on PCB “B” is lit when output
is present.
-Verify 12VDC input to PCB “H”. D2 on PCB “H” is lit when 12VDC is present.
-Verify 12VDC input to PCB “J”. LED D3 is lit when 12VDC is present.
TROUBLESHOOTING
-Check all wires from B, P2 to H, P5 for continuity and no short circuits.
-Check all wires from H, P6 to J, P1 for continuity and no short circuits.
-Disconnect plug P2 from PCB “J” to check if power is restored.
-Disconnect plug P6 from PCB “H” to check if power is restored.
IF PROBLEM REMAINS
Replace PCB “H” and/or PCB “J”.
18 February 2022
RAP 210 SP SENSOR Q12 PCB “Y”
The primary objective is to determine if the PCB communicates correctly and voltages are OK
Initial Actions
• Make sure software in SP sensor Q12 is correct and updated
Procedure
WARNING!
INITIAL CHECKS
-Verify input power to SP Sensor Q12, PCB “Y”. Check LEDS on PCB “Y”
LED D20 indicates 12VDC
LED D21 indicates 3.3VDC
-Check that PCB “G”, “K” and “H” is powered and working OK.
SP Sensor Q12 is connected last on the CAN-Bus - all preceding PCBs must therefore
be working OK. Refer to schematics to the left.
TROUBLESHOOTING
POWER
-SP Sensor Q12 is powered from PCB “K”.
Check all wires from K, P6 to Y, P1 for continuity and no short circuits.
-Check power in to PCB “K”
(LED D30 indicates 55VDC, Should not affect SP Sensor)
Check all wires from PCB B, P2 to K, P5.
(Check all wires from PCB C, P2 to K, P9, Should not affect SP Sensor).
1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6
COMMUNICATION ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
- Check CAN Bus connection from CPU PCB “T” to SP Sensor Q12 PCB “Y” through PCB
“G”, PCB “H” and PCB “K”. Refer to schematics to the left. Check all wires for continuity and
CPU APP32 Motor M1 Motor M2 Motor M3 SP Sensor
short circuit. M21H M21H M21H Q12
IF PROBLEM REMAINS J10 J5 J6 J5 J6 J5 J6 J1
-Reload software in SP Sensor Q12, PCB “Y” ICAN termination ICAN termination
-Replace SP sensor PCB “Y” DIP switch 6 DIP switch 6
-Replace Stepper Motor PCB “K”
18 February 2022
RAP 211 US DSD Sensor Q10
This RAP is for troubleshooting a problem with the Ultra Sonic DSD Sensor, Q10.
The objective is to determine if the problem is related to power failure, cabling or the sensor
itself.
Initial Actions
• Ensure that all connectors from sensor Q10 to PCB “T” and and jack/plug connectors
are properly connected
• Calibrate US DSD Sensor Q10, see ADJ 3.8.1.
Procedure
WARNING!
OVERVIEW
Sensor Q10 is used to estimate the paper thickness i.e. detect double sheet feeds.
The sensor consists of two separate parts, a transmitter and a receiver each using both
ultrasonic sound and infra red light to sense paper thickness.
The sensor must be calibrated to operate correctly, see ADJ 3.8.1.
INITIAL CHECKS
-Verify that all connectors are properly connected.
Connector on Q10 transmitter and Q10 receiver,
Connectors on CPU PCB “T” plug P1, P2 and P4. D7
Connector P2 on PTC PCB “D”.
-Check that PTC PCB “B” is powered correctly and LED D7 on PCB “D” is activated - LED function:
24VDC power to Q10 transmitter. not necessarily the correct voltage level.
TROUBLESHOOTING
POWER
-In the case of a power failure check all wires from B, P2 to Q10T for continuity and no short
circuit.
Check FAN 8.
CONNECTION TO CPU PCB “T”
-Check all wires from Q10T, Q10R to PCB T, P1 T,P2 AND plug T,P4 for continuity and no
short circuit.
IF PROBLEM REMAINS
-Double check sensor calibration, ADJ 3.8.1.
-Replace sensor Q10.
-Replace CPU PCB “T”
18 February 2022
RAP 212 PCB G, 55VDC
PTC PCB “C” Stepper Motor PCB “G”, M21H
This RAP is for troubleshooting a problem with the 55VDC supply to PCB G.
Initial Actions
Procedure
WARNING!
D7
LED function:
INITIAL CHECKS Deactivated=no voltage present. Activated= voltage present,
-Verify that PCB “C” has input power. LED D8 is lit when input power is present. not necessarily the correct voltage level.
-Verify output power to PCB “G” from PCB “C”. LED D3 on PCB “C” is lit when output is
present.
-Verify 55VDC input to PCB “G”. D30 on PCB “G” is lit when 55VDC is present.
TROUBLESHOOTING
-Check all wires from C, P2 to G, P9 for continuity and no short circuits.
-Disconnect plug P7 from PCB “G” and check if power is restored.
IF PROBLEM REMAINS
Replace PCB “G” or
Switch PCB “G” with PCB “H” or PCB “K” to find out if the problem
moves with the PCB.
18 February 2022
RAP 213 PCB H, 55VDC
This RAP is for troubleshooting a problem with the 55VDC supply to PCB H.
Initial Actions
Procedure
WARNING!
D7
LED function:
-Verify output power to PCB “H” from PCB “C”. LED D4 on PCB “C” is lit when output is
present.
TROUBLESHOOTING
-Check all wires from C, P2 to H, P9 for continuity and no short circuits.
-Disconnect plug P7 from PCB “H” and check if power is restored.
IF PROBLEM REMAINS
Replace PCB “H” or
Switch PCB “H” with PCB “G” or PCB “K” to find out if the problem
moves with the PCB.
18 February 2022
RAP 214 PCB K, 55VDC
This RAP is for troubleshooting a problem with the 55VDC supply to PCB K.
Initial Actions
Procedure
WARNING!
D7
LED function:
-Verify output power to PCB “K” from PCB “C”. LED D5 on PCB “C” is lit when output is
present.
TROUBLESHOOTING
-Check all wires from C, P2 to K, P9 for continuity and no short circuits.
-Disconnect plug P7 from PCB “K” and check if power is restored.
IF PROBLEM REMAINS
Replace PCB “K” or
Switch PCB “K” with PCB “G” or PCB “H” to find out if the problem
moves with the PCB.
18 February 2022
RAP 215 PCB L, 24VDC
PTC PCB “D”
This RAP is for troubleshooting a problem with the 24VDC supply to PCB L.
Initial Actions
Procedure
WARNING!
INITIAL CHECKS
-Verify that PCB “D” has input power. LED D8 is lit when input power is present.
-Verify output power to PCB “L” from PCB “D”. LED D7 on PCB “D” is lit when output is
present.
-Verify 24VDC input to PCB “L”. D1 on PCB “L” is lit when 24VDC is present.
TROUBLESHOOTING
-Check all wires from D, P2 to L, P2 for continuity and no short circuits.
-Check all wires from L,P3 to T, P1. This is the feedback 24VDC signal to CPU PCB ”T”.
-Check (see RAPs) RAP SOL 1, FAN 8 and DSD Q10. All components connects to same
PTC output on PCB “D”.
IF PROBLEM REMAINS
Replace PCB “L” and/or CPU PCB “T”
18 February 2022
RAP 216 Feeder Fans
This RAP is for troubleshooting a problem with a Fan in the Feeder unit.
Initial Actions
Procedure
WARNING!
INITIAL CHECKS
-Verify that PCB “D” has input power. LED D8 is lit when input power is present.
-Verify output power to the FAN in question.
-.
TROUBLESHOOTING
-Check all wires from D, P2 to the FAN in question.
-Check all wires from CPU PCB “T” to the FAN in question.
IF PROBLEM REMAINS
Replace FAN.
18 February 2022
RAP 217 Q11, Table Empty Sensor (feeder) RAP 218 Q4, Paper Stack Height Sensor (feeder)
This RAP is for troubleshooting sensor Q11, Empty Table Sensor, in the feeder unit. This RAP is for troubleshooting sensor Q4, Paper Stock Height Sensor, in the feeder unit.
Procedure Procedure
WARNING! WARNING!
Turn off the PRO XL Main Power Switch and disconnect the Main Power Cord before Turn off the PRO XL Main Power Switch and disconnect the Main Power Cord before
Refer to the troubleshooting procedure laid out in RAP 101, Sensors General Trou- Refer to the troubleshooting procedure laid out in RAP 101, Sensors General Trou-
bleshooting. bleshooting.
18 February 2022
RAP 219 Q1, M1 Home Position Sensor (feeder) RAP 220 Q2 & Q8, Lift Top/Bottom Safety Sensors (feeder)
This RAP is for troubleshooting sensor Q1, M1 Home Position Sensor, in the feeder unit. This RAP is for troubleshooting sensor Q2 and Q8, Lift Top and Bottom Safety Sensors, in
the feeder unit.
Procedure Procedure
WARNING! WARNING!
18 February 2022
RAP 221 M1, Lift Motor (feeder) RAP 222 M2, Vacuum Belt Motor (feeder)
This RAP is for troubleshooting motor M1, Lift Motor, in the feeder unit. This RAP is for troubleshooting motor M2, Vacuum Belt Motor, in the feeder unit.
Procedure Procedure
WARNING! WARNING!
Refer to the troubleshooting procedure laid out in RAP 102, Motors General Trouble- Refer to the troubleshooting procedure laid out in RAP 102, Motors General Trouble-
shooting. shooting.
18 February 2022
RAP 223 M3, Registration Belt Motor (feeder) RAP 224 SOL 1, Vacuum Lid Solenoid (feeder)
This RAP is for troubleshooting motor M3, Registration Belt Motor, in the feeder unit. This RAP is for troubleshooting motor SOL 1, Vacuum Lid Solenoid, in the feeder unit.
Procedure Procedure
WARNING! WARNING!
Refer to the troubleshooting procedure laid out in RAP 102, Motors General Trouble-
shooting.
18 February 2022
RAP 225 PCB XX Overload or Overheated (feeder)
This RAP is for troubleshooting an overload and/or overheating problem with one of the step-
per motor PCBs in the feeder unit.
The cause of an overload or overheating problem could be excessive load, insufficient cool-
ing of the driver PCB or an electrical problem.
Initial Actions
• Allow the machine to cool down before troubleshooting the problem
Procedure
WARNING!
INITIAL CHECKS
Check motor functionality in service menu.
TROUBLESHOOTING
-Check for excessive mechanical resistance in the assembly.
-Check motor and wiring, refer to schematics to the left and/or motor RAP.
IF PROBLEM REMAINS
-If the problem isn’t obvious consider switching places with two driver PCBs to rule out a
faulty PCB. PCBs “G” “H” and”K” can be switched - REMEMBER DIP SWITCHES / SW.
-Replace Motor and/or PCB.
18 February 2022
RAP 226 Counter (feeder) RAP 227 EEPROM (feeder)
This RAP is for troubleshooting the chassis counter in the feeder unit. This RAP determines if there is corrupted software or if the CPU PCB “T” needs to be
replaced.
Initial Actions
Initial Actions
• None
Procedure Procedure
WARNING! WARNING!
Perform NVM reset according to General Procedures Section 5.3.4

Success
N Y
Exit
Re-load software to PCB “T” (Feeder) and perform NVM reset.
Success
N Y
Exit
Replace PCB “T” (Feeder)
18 February 2022
RAP 301 PCB A 12VDC Input LED D10
This RAP is for troubleshooting a problem with the 12VDC supply to CPU PCB A PTC PCB “DD”
Initial Actions
Procedure
WARNING!
INITIAL CHECKS
-Verify that PCB “DD” in the Feeder Unit has input power. LED D10 is lit when input power
is present.
-Verify output power to PCB “A” from PCB “DD”. LED D2 on PCB “DD” is lit when output is
present.
-Verify 12VDC input to CPU PCB “A”. D5 on PCB “A” is lit when 12VDC is present.
TROUBLESHOOTING
-Check all wires from PCB “DD”, P2 in the feeder to PCB “A”, P6 in the Creaser for continu-
ity and no short circuits. NOTE All wires connects through connector P/J12.
-Disconnect all plugs except P6 on CPU PCB “A” and check if power is restored. If the
case, identify the faulty component.
IF PROBLEM REMAINS
Replace CPU PCB “A”
18 February 2022
RAP 302 PCB B, PCB C, PCB D 12VDC Input LED D10
This RAP is for troubleshooting a problem with the 12VDC supply to PCB B, C and D. PTC PCB “DD”
Initial Actions
Procedure
WARNING!
INITIAL CHECKS
is present.
-Verify output power to PCB “B” from PCB “DD”. LED D3 on PCB “DD” is lit when output is
present.
-Verify output power to PCB “C” (Optional) from PCB “DD”. LED D4 on PCB “DD” is lit when
output is present.
-Verify 12VDC input to PCB “B”, PCB C (Optional) and PCB D. LED D2 on Stepper Motor
Driver PCB M21H is lit when 12VDC is present.
TROUBLESHOOTING
-Check all wires from PCB “DD”, P2 in the feeder to PCB “B”, P5 in the Creaser for continu-
-Check all wires from PCB “B”, P6 in the feeder to PCB “D”, P5 in the Creaser for continuity
and no short circuits.
TROUBLESHOOTING >> IF OPTIONAL PCB C IS INSTALLED

-Check all wires from PCB “DD”, P2 in the feeder to PCB “B”, P5 in the Creaser for continu- IF PROBLEM REMAINS
ity and no short circuits. NOTE All wires connects through connector P/J12. Replace PCB “B”, “C”, “D”, “DD”
-Check all wires from PCB “DD”, P2 in the feeder to PCB “C”, P5 in the Creaser for continu-
-Check all wires from PCB “C”, P6 in the feeder to PCB “D”, P5 in the Creaser for continuity
18 February 2022
RAP 303 Creaser ICAN Circuit
Creaser Unit. OPTIONAL
The primary objective is to determine if the ICAN bus is OK and if connected PCBs are pow- 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6
ered and working correctly. ON

OFF
ON
OFF
ON
OFF
ON
OFF
Initial Actions
• Ensure that all PCBs and jack/plug connectors are properly connected CPU APP32 Motor M21 Motor M22 Motor M23
• Make sure that all DIP switch settings are correct, see BSD M21H M21H M21H
• Verify that correct software is loaded on all PCBs PCB A PCB B PCB C PCB D
Procedure J10 J5 J6 J5 J6 J5
WARNING! ICAN termination ICAN termination

Turn off the PRO XL Main Power Switch and disconnect the Main Power Cord before DIP switch 6 DIP switch 6
OVERVIEW
The PCBs in the Creaser are connected on a CAN bus ( Controller Area Network)
The bus consists of a two wires with a 120ohm “termination resistor” at both ends.
The first and the last PCB on the bus (PCB “A” & “D”) must have DIP switch #6 set to “ON”
to activate the “termination resistor”.
INITIAL CHECKS
TROUBLESHOOTING
POWER
COMMUNICATION
Wires from A, P10 to B, P5 B, P6 to ( C, P5 C,P6 ) to D, P5
IF PROBLEM REMAINS
18 February 2022
RAP 304 PCB B, 55VDC
PTC PCB “R” Stepper Motor PCB “B”, M21H
This RAP is for troubleshooting a problem with the 55VDC supply to PCB B.
Initial Actions
Procedure
WARNING!
D7
LED function:
-Verify that PCB “R” in Feeder has input power. LED D8 is lit when input power is present. not necessarily the correct voltage level.
-Verify output power to PCB “B” from PCB “R”. LED D3 on PCB “R” is lit when output is
present.
-Verify 55VDC input to PCB “B”. D30 on PCB “B” is lit when 55VDC is present.
TROUBLESHOOTING
-Check all wires from R, P2 to B, P9 for continuity and no short circuits.
NOTE All wires connects through connector P/J110.
-Disconnect plug P7 from PCB “B” and check if power is restored.
IF PROBLEM REMAINS
Replace PCB “B” or
Switch PCB “B” with PCB “D” to find out if the problem
moves with the PCB.
18 February 2022
RAP 305 PCB D, 55VDC
PTC PCB “R” Stepper Motor PCB “D”, M21H
This RAP is for troubleshooting a problem with the 55VDC supply to PCB D.
Initial Actions
Procedure
WARNING!
D7
LED function:
-Verify output power to PCB “D” from PCB “R”. LED D5 on PCB “R” is lit when output is
present.
-Verify 55VDC input to PCB “D”. D30 on PCB “D” is lit when 55VDC is present.
TROUBLESHOOTING
-Check all wires from R, P2 to D, P9 for continuity and no short circuits.
-Disconnect plug P7 from PCB “D” and check if power is restored.
IF PROBLEM REMAINS
Replace PCB “D” or
Switch PCB “D” with PCB “B” to find out if the problem
moves with the PCB.
18 February 2022
RAP 306 PCB C, 55VDC
PTC PCB “R” Stepper Motor PCB “C”, M21H
This RAP is for troubleshooting a problem with the 55VDC supply to PCB C.
Initial Actions
Procedure
WARNING!
D7
LED function:
INITIAL CHECKS not necessarily the correct voltage level.
-Verify that PCB “R” in Feeder has input power. LED D8 is lit when input power is present.
-Verify output power to PCB “C” from PCB “R”. LED D4 on PCB “R” is lit when output is
present.
-Verify 55VDC input to PCB “C”. D30 on PCB “C” is lit when 55VDC is present.
TROUBLESHOOTING
-Check all wires from R, P2 to C, P9 for continuity and no short circuits.
-Disconnect plug P7 from PCB “C” and check if power is restored.
IF PROBLEM REMAINS
Replace PCB “C” or
Switch PCB “C” with PCB “B” or PCB “D” to find out if the problem
moves with the PCB.
18 February 2022
RAP 307 Q20, Edge Detection Sensor (creaser) RAP 308 Q21, Position Blade Drive 1 Sensor (creaser)
This RAP is for troubleshooting sensor Q20, Edge Detection Sensor, in the creaser unit. This RAP is for troubleshooting sensor Q21, Position Blade Drive 1 Sensor, in the creaser
unit.
Initial Actions
Initial Actions
Procedure Procedure
WARNING! WARNING!
18 February 2022
RAP 309 Q22, Position Blade Drive 2 Sensor (creaser) RAP 310 Q25, Exit Sensor (creaser)
This RAP is for troubleshooting sensor Q22, Position Blade Drive 2 Sensor, in the creaser This RAP is for troubleshooting sensor Q25, Exit Sensor, in the creaser unit.
unit.
Initial Actions
Initial Actions
Procedure Procedure
WARNING! WARNING!
18 February 2022
RAP 311 M21, Roller Drive Motor (creaser) RAP 312 M22, Blade Drive 1 Motor (creaser)
This RAP is for troubleshooting motor M21, Roller Drive Motor, in the creaser unit. This RAP is for troubleshooting motor M22, Blade Drive 1 Motor, in the creaser unit.
Procedure Procedure
WARNING! WARNING!
shooting. shooting.
18 February 2022
RAP 313 M23, Blade Drive 2 Motor (creaser)
This RAP is for troubleshooting motor M23, Blade Drive 2 Motor, in the creaser unit.
Initial Actions
Procedure
WARNING!
shooting.
18 February 2022
RAP 314 PCB XX Overload or Overheated (creaser)
This RAP is for troubleshooting an overload and/or overheating problem with one of the step-
per motor PCBs in the creaser unit.
Initial Actions
Procedure
WARNING!
INITIAL CHECKS
TROUBLESHOOTING
IF PROBLEM REMAINS
faulty PCB. PCBs “G” “H” and”K” can be switched - REMEMBER DIP SWITCHES / SW.
18 February 2022
RAP 315 Counter (creaser) RAP 316 EEPROM (creaser)
This RAP is for troubleshooting the chassis counter in the creaser unit.
This RAP determines if there is corrupted software or if the CPU PCB “A” needs to be
replaced.
Initial Actions
Initial Actions
Procedure
Procedure
WARNING!
WARNING! Turn off the PRO XL Main Power Switch and disconnect the Main Power Cord before
Turn off the PRO XL Main Power Switch and disconnect the Main Power Cord before disconnecting, removing or replacing any electrical components or measuring resis-
disconnecting, removing or replacing any electrical components or measuring resistance inside the machine.
Success
N Y
Exit
Re-load software to PCB “A” (Creaser) according to GP X:Y and perform NVM reset accord-
ing to GP X.X.X
Success
N Y
Exit
Replace PCB “A” (Creaser)
18 February 2022
Folder
18 February 2022
RAP 401 PCB A, PCB B, PCB H 12VDC Input LED D10
This RAP is for troubleshooting a problem with the 12VDC supply to CPU PCB A and Stepper PTC PCB “DD”
Motor PCB B and H
Initial Actions
Procedure
WARNING!
INITIAL CHECKS
is present.
-Verify output power to PCB “A” PCB “DD”. LED D2 on PCB “DD” is lit when output is
present.
-Verify 12VDC input to CPU PCB “A”. D5 on PCB “A” is lit when 12VDC is present.
- Verify 12VDC input to PCB “B” and PCB “H”. LED D2 is lit when 12 VDC is present.
-The PCBs are connected in a row, PCB “A” powers PCB “B” wich in turn powers PCB “H”.
TROUBLESHOOTING
-Check all wires from PCB “DD”, P2 in the feeder to PCB “A”, P6 in the Creaser for continu-
-Check all wires from PCB “A”, P10 to PCB “B”, P5 for continuity and no short circuit.
-Check all wires from PCB “B”, P6 to PCB “H”, P5 for continuity and no short circuit.
-Disconnect all plugs except P6 on CPU PCB “A” and check if power is restored. If the
case, identify the faulty component.
IF PROBLEM REMAINS
Replace CPU PCB “A”
Replace PCB “B”
Replace PCB “H”
18 February 2022
RAP 402 PCB E, PCB D, PCB C 12VDC Input LED D10
PTC PCB “DD”
This RAP is for troubleshooting a problem with the 12VDC supply to Stepper Motor PCB “E”,
PCB “D” and PCB “C”. (In Fe)
Initial Actions
Procedure
WARNING!
INITIAL CHECKS
is present.
-Verify output power to PCB “E” PCB “DD”. LED D3 is lit when output is present.
-Verify 12VDC input to CPU PCB “E”. D2 on PCB “E” is lit when 12VDC is present.
- Verify 12VDC input to PCB “D” and PCB “C”. LED D2 is lit when 12 VDC is present.
-The PCBs are connected in a row, PCB “E” powers PCB “D” wich in turn powers PCB “C”.
TROUBLESHOOTING
-Check all wires from PCB “DD”, P2 in the feeder to PCB “E”, P5 in the Creaser for continu-
-Check all wires from PCB “E”, P6 to PCB “D”, P5 for continuity and no short circuit.
-Check all wires from PCB “D”, P6 to PCB “C”, P5 for continuity and no short circuit.
IF PROBLEM REMAINS
Replace PCB “E”
Replace PCB “D”
Replace PCB “C”
18 February 2022
RAP 403 PCB MM, PCB K 12VDC Input LED D10
This RAP is for troubleshooting a problem with the 12VDC supply to Stepper Motor PCB PTC PCB “DD”
“MM” and Stepper Motor PCB “H”.
Initial Actions
Procedure
WARNING!
disconnecting, removing or replacing any electrical components or measuring resis- D2 Stepper Motor DriverD13
M04L”
tance inside the machine. 12V Present 24V present
INITIAL CHECKS D3

Software running
is present.
-Verify output power to PCB “MM” PCB “DD”. LED D4 PCB “DD” is lit when output is pre-
sent.
-Verify 12VDC input to PCB “MM”. D2 on PCB “MM” is lit when 12VDC is present.
Stepper Motor Driver M21H
- Verify 12VDC input to PCB “K” LED D2 is lit when 12 VDC is present.
-The PCBs are connected in a row, PCB “MM” powers PCB “K”.
TROUBLESHOOTING
-Check all wires from PCB “DD”, P2 in the feeder to PCB “MM”, P6 in the Creaser for conti-
nuity and no short circuits. NOTE All wires connects through connector P/J12.
-Check all wires from PCB “MM”, P5 to PCB “K”, P5 for continuity and no short circuit.
IF PROBLEM REMAINS
Replace PCB “MM”
Replace PCB “K”
Replace PCB “DD”
18 February 2022
RAP 404 Folder ICAN Circuit 1 2 3 4 5 6
ON
1 2 3 4 5 6
ON
1 2 3 4 5 6
ON
1 2 3 4 5 6
ON
OFF OFF OFF OFF
Folder Unit. PCB A PCB B PCB H PCB MM
The primary objective is to determine if the ICAN bus is OK and if connected PCBs are pow- CPU APP32 M21H M21H M04L
ered and working correctly. J10 J5 Motor M41 J6 J5 Motor M47 J6 J6 Motor M45 J5
Motor M46
Initial Actions ICAN termination Motor M50
DIP switch 6 Motor M48
• Verify that correct software is loaded on all PCBs
Procedure
1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6
ON ON ON ON
OFF OFF OFF OFF
WARNING!
Turn off the PRO XL Main Power Switch and disconnect the Main Power Cord before PCB C PCB D PCB E PCB K
disconnecting, removing or replacing any electrical components or measuring resis- M21H M21H M21H M21H
Motor M42 J5 J6 Motor M43 J5 J6 Motor M44 J5 J6 Motor M49 J5
ICAN termination
OVERVIEW DIP switch 6
The PCBs in the Feeder are connected on a CAN bus ( Controller Area Network)
1 2 3 4 5 6
The bus consists of a two wires with a 120ohm “termination resistor” at both ends. ON
The first and the last PCB on the bus (PCB “A” & “D or C” ) must have DIP switch #6 set to OFF
DIP switch setting if
“ON” to activate the “termination resistor”. PCB "C" is connected
INITIAL CHECKS
TROUBLESHOOTING
POWER
COMMUNICATION
Wires from A, P10 to B, P5 B, P6 to H, P5 H, P6 to MM, P6 MM, P5 to K, P5 . K,
P6 to E, P5 E, P6 to D, P5 D, P6 to C, P5
IF PROBLEM REMAINS
18 February 2022
RAP 405 PCB B, 55VDC
PTC PCB “R” Stepper Motor PCB “B”, M21H
This RAP is for troubleshooting a problem with the 55VDC supply to PCB B.
Initial Actions
Procedure
WARNING!
D7
LED function:
-Verify output power to PCB “B” from PCB “R”. LED D1 on PCB “R” is lit when output is
present.
-Verify 55VDC input to PCB “B”. D30 on PCB “B” is lit when 55VDC is present.
TROUBLESHOOTING
-Check all wires from R, P4 to B, P9 for continuity and no
short circuits.
-Disconnect plug P7 from PCB “B” and check if power is restored.
IF PROBLEM REMAINS
Replace PCB “B” or
Switch PCB “B” with PCB “C” or another Drive M21H PCB to
find out if the problem moves with the PCB.
18 February 2022
RAP 406 PCB C, 55VDC
PTC PCB “R” Stepper Motor PCB “C”, M21H
This RAP is for troubleshooting a problem with the 55VDC supply to PCB H.
Initial Actions
Procedure
WARNING!
D7
LED function:
-Verify output power to PCB “C” from PCB “R”. LED D2 on PCB “R” is lit when output is
present.
-Verify 55VDC input to PCB “C”. D30 on PCB “C” is lit when 55VDC is present.
TROUBLESHOOTING
-Check all wires from R, P4 to C, P9 for continuity and no
short circuits.
-Disconnect plug P7 from PCB “C” and check
if power is restored.
IF PROBLEM REMAINS
Replace PCB “C” or
Switch PCB “C” with PCB “B” or another
Drive M21H PCB to find out if the problem
moves with the PCB.
18 February 2022
RAP 407 PCB D, 55VDC
PTC PCB “R” Stepper Motor PCB “D”, M21H
This RAP is for troubleshooting a problem with the 55VDC supply to PCB D.
Initial Actions
Procedure
WARNING!
D7
LED function:
-Verify output power to PCB “D” from PCB “R”. LED D3 on PCB “R” is lit when output is
present.
-Verify 55VDC input to PCB “D”. D30 on PCB “D” is lit when 55VDC is present.
TROUBLESHOOTING
-Check all wires from R, P2 to D, P9 for continuity and
no short circuits.
-Disconnect plug P7 from PCB “D” and check if
power is restored.
IF PROBLEM REMAINS
Replace PCB “D” or
Switch PCB “D” with PCB “B” or another
Drive M21H PCB to find out if the problem
moves with the PCB.
18 February 2022
RAP 408 PCB E, 55VDC
PTC PCB “R” Stepper Motor PCB “E”, M21H
This RAP is for troubleshooting a problem with the 55VDC supply to PCB E.
Initial Actions
Procedure
WARNING!
D7
LED function:
-Verify output power to PCB “E” from PCB “R”. LED D4 on PCB “R” is lit when output is
present.
-Verify 55VDC input to PCB “E”. D30 on PCB “E” is
lit when 55VDC is present.
TROUBLESHOOTING
-Check all wires from R, P2 to D, P9 for continuity
-Disconnect plug P7 from PCB “D” and check if
power is restored.
IF PROBLEM REMAINS
Replace PCB “E” or
Switch PCB “E” with PCB “B” or another Drive
M21H PCB to find out if the problem
moves with the PCB.
18 February 2022
RAP 409 PCB H, PCB “K” 55VDC
PTC PCB “R” Stepper Motor PCB “H” & “K”, M21H
This RAP is for troubleshooting a problem with the 55VDC supply to PCB H and PCB “K”.
Initial Actions
Procedure
WARNING!
D7
LED function:
-Verify output power to PCB “H” and “K” from PCB “R”. LED D6 on PCB “R” is lit when
output is present.
TROUBLESHOOTING
-Check all wires from R, P2 to H, P9 for continuity and no short circuits.
-Check all wires from H, P11 to K, P9 for continuity and no short circuits.
-Disconnect plug P7 from PCB “H” and check if power is restored.
IF PROBLEM REMAINS
Replace PCB “H” and/or PCB”K” or
Switch PCB “H” and PCB “K” with PCB “E” and PCB “D” to
find out if the problem
moves with the PCBs.
18 February 2022
RAP 410 PCB MM 24VDC
PTC PCB “D” (in Feeder) Stepper Motor PCB “MM” M04L
This RAP is for troubleshooting a problem with the 24VDC supply to PCB MM.
D2 D13
12V Present 24V present
Initial Actions
Procedure D3
Software running
WARNING!
D7
LED function:
-Verify that PCB “D” in Feeder has input power. LED D8 is lit when input power is present. not necessarily the correct voltage level.
-Verify output power to PCB “MM” from PCB “D”. LED D2 on PCB “D” is lit when output is
present.
-Verify 24VDC input to PCB “MM”. D13 on PCB “MM” is lit when 24VDC is present.
TROUBLESHOOTING
-Check all wires from MM, P9 to D, P4 for continuity and no short circuits.
-Disconnect plug P10 from PCB “MM” and check if power is restored.
IF PROBLEM REMAINS
Replace PCB “MM”
Replace PCB “D”
18 February 2022
RAP 411 Q40, Infeed Sensor (folder) RAP 412 Q41, Blade Position Drive 1 Sensor (folder)
This RAP is for troubleshooting sensor Q40, Infeed Sensor, in the folder unit. This RAP is for troubleshooting sensor Q41, Blade Position Drive 1 Sensor, in the folder unit.
Procedure Procedure
WARNING! WARNING!
18 February 2022
RAP 413 Q42, Blade Position Drive 2 Sensor (folder) RAP 414 Q45, Crease Exit Sensor (folder)
This RAP is for troubleshooting sensor Q42, Blade Position Drive 2 Sensor, in the folder unit. This RAP is for troubleshooting sensor Q45, Crease Exit Sensor, in the folder unit.
Procedure Procedure
WARNING! WARNING!
18 February 2022
RAP 415 Q47, Fold Knife Cam Position Sensor (folder)
This RAP is for troubleshooting sensor Q47, Fold Knife Cam Position Sensor, in the folder
unit.
Initial Actions
Procedure
WARNING!
Refer to the troubleshooting procedure laid out in RAP 101, Sensors General Trou-
bleshooting.
18 February 2022
RAP 416 Q48 Q49 Q51, Motor M45 M46 M50 Position Sensors RAP 417 Q52, Fold Exit Sensor (folder)
(folder)
This RAP is for troubleshooting sensor Q52, Fold Exit Sensor, in the folder unit.
This RAP is for troubleshooting sensors Q48, Q49 and Q51 Motor Position Sensors, in the
folder unit. Initial Actions
Initial Actions
Procedure
Procedure WARNING!
WARNING! disconnecting, removing or replacing any electrical components or measuring resis-
Turn off the PRO XL Main Power Switch and disconnect the Main Power Cord before tance inside the machine.
bleshooting.
bleshooting.
18 February 2022
RAP 418 M41, Roller Drive Motor (folder) RAP 419 M42, Blade Drive 1 Motor (folder)
This RAP is for troubleshooting motor M41, Roller Drive Motor, in the folder unit. This RAP is for troubleshooting motor M42, Blade Drive 1 Motor, in the folder unit.
Procedure Procedure
WARNING! WARNING!
shooting. shooting.
18 February 2022
RAP 420 M43, Blade Drive 2 Motor (folder) RAP 421 M44, Fold Knife Motor (folder)
This RAP is for troubleshooting motor M43, Blade Drive 2 Motor, in the folder unit. This RAP is for troubleshooting motor M44, Fold Knife Motor, in the folder unit.
Procedure Procedure
WARNING! WARNING!
shooting. shooting.
18 February 2022
RAP 422 M45 M46 M48 M50, Motors (folder)
This RAP is for troubleshooting motor M45 M46 M48 and M50 in the folder unit.
Initial Actions
Procedure
WARNING!
shooting.
18 February 2022
RAP 423 M47, Delivery Belt Motor (folder) RAP 424 M49, Delivery Roller Drive Motor (folder)
This RAP is for troubleshooting motor M47, Delivery Belt Motor, in the folder unit. This RAP is for troubleshooting motor M49, Delivery Roller Drive Motor, in the folder unit.
Procedure Procedure
WARNING! WARNING!
shooting. shooting.
18 February 2022
RAP 425 PCB XX Overload or Overheated (folder)
This RAP is for troubleshooting an overload and/or overheating problem with one of the
M21H stepper motor PCBs in the folder unit.
Initial Actions
Procedure
WARNING!
INITIAL CHECKS
TROUBLESHOOTING
IF PROBLEM REMAINS
faulty PCB. PCBs “B, C, D, E, H K” can be switched - REMEMBER DIP SWITCHES / SW.
18 February 2022
RAP 426 PCB MM Overload or Overheated (folder)
This RAP is for troubleshooting an overload and/or overheating problem with the M04L step-
per motor PCBs in the folder unit.
Initial Actions
Procedure
WARNING!
INITIAL CHECKS
Check motor “M45” “M46” “48” and “M50” functionality in service menu.
TROUBLESHOOTING
-Check for excessive mechanical resistance in the assemblies.
-Check motors and wiring, refer to schematics to the left and/or motor RAPs.
IF PROBLEM REMAINS
-Replace Motor and/or PCB.”MM”
18 February 2022
RAP 427 Counter (folder) RAP 428 EEPROM (folder)
This RAP is for troubleshooting the chassis counter in the folder unit. This RAP determines if there is corrupted software or if the CPU PCB “A” needs to be
replaced.
Initial Actions
Initial Actions
• None
Procedure
WARNING! Procedure
disconnecting, removing or replacing any electrical components or measuring resis- WARNING!
tance inside the machine. Turn off the PRO XL Main Power Switch and disconnect the Main Power Cord before

Success
N Y
Exit
Re-load software to PCB “A” (Folder) according to GP X:Y and perform NVM reset accord-
ing to GP X.X.X
Success
N Y
Exit
Replace PCB “A” (Folder)
18 February 2022
5 Service Tables
5.1 Service Program Mode................................................................................................................................................................................... 5-2
5.1.1 Entering and Exiting the SP Mode............................................................................................................................................................ 5-2
5.1.2 Software Versions and Status.................................................................................................................................................................. 5-3
5.1.3 Checking Motors and Fans....................................................................................................................................................................... 5-3
5.1.4 Checking Solenoids.................................................................................................................................................................................. 5-3
5.1.5 Checking Sensors.................................................................................................................................................................................... 5-3
5.1.6 Checking Voltmeters................................................................................................................................................................................. 5-4
5.1.7 Non-Volatile Memory (NVM)..................................................................................................................................................................... 5-4
5.1.8 Dead Cycle............................................................................................................................................................................................... 5-4
5.1.9 Calibration................................................................................................................................................................................................ 5-4
5.2 Service Program Mode Tables........................................................................................................................................................................ 5-5
5.2.1 Feeder Motors.......................................................................................................................................................................................... 5-5
5.2.2 Feeder Solenoids..................................................................................................................................................................................... 5-5
5.2.3 Feeder Sensors........................................................................................................................................................................................ 5-6
5.2.4 Feeder Voltmeters.................................................................................................................................................................................... 5-7
5.2.5 Creaser Motors......................................................................................................................................................................................... 5-7
5.2.6 Creaser Solenoids.................................................................................................................................................................................... 5-7
5.2.7 Creaser Sensors....................................................................................................................................................................................... 5-8
5.2.8 Creaser Voltmeters................................................................................................................................................................................... 5-8
5.2.9 Folder Motors........................................................................................................................................................................................... 5-8
5.2.10 Folder Solenoids....................................................................................................................................................................................... 5-9
5.2.11 Folder Sensors....................................................................................................................................................................................... 5-10
5.2.12 Folder Voltmeters................................................................................................................................................................................... 5-11
5.3 Non-Volatile Memory (NVM) Values.............................................................................................................................................................. 5-12
5.3.1 Accessing NVM values........................................................................................................................................................................... 5-12
5.3.2 Feeder NVM values................................................................................................................................................................................ 5-13
5.3.3 Creaser NVM values.............................................................................................................................................................................. 5-13
5.3.4 Folder NVM values................................................................................................................................................................................. 5-14
5.4 Update Software........................................................................................................................................................................................... 5-15
5.4.1 Single point download............................................................................................................................................................................ 5-15
5.4.2 Loading software on a replacement PCB............................................................................................................................................... 5-16
5.5 Tag Label Locations...................................................................................................................................................................................... 5-17
18 February 2022
Pro XL 5-1 Service Tables
5.1 Service Program Mode
The Service Program (SP) mode is used to check electrical data, check
electrical components and adjust values. Service Program mode is pro-
vided and controlled from the User Interface (UI). Where applicable, a
sub-menu appears after a function is selected.
5.1.1 Entering and Exiting the SP Mode
1. Go to Tools -> Service mode

2. When prompted enter password 1974 and click the tick mark.
3. Use the Change Target button to select the desired module. Currently
selected module is displayed in the top left corner of the screen:
• canid(10) – feeder module
• canid(20) – creaser/folder module
4. When finished use the Exit Service button to return to the Home
screen.
18 February 2022
5.1.2 Software Versions and Status 5.1.4 Checking Solenoids
1. Enter Service Program mode (Section 5.1.1) 1. Enter Service Program mode (Section 5.1.1)
2. Use the Change Target button to choose the desired module. 2. Use the Change Target button to choose the desired module.
3. Click SW and Status button to see currently installed software ver- 3. Click Solenoids to see solenoids and relays present in this module.
sions in each PCB of this module. 4. Select the solenoid / relay to be checked. Click Play / Stop to tog-
gle the solenoid on / off.
5.1.3 Checking Motors and Fans
NOTE:
1. Enter Service Program mode (Section 5.1.1) If lids are open, ensure interlock cheaters are installed, otherwise the sole-
2. Use the Change Target button to choose the desired module. noids will not run.
3. Click Motors to see motors and fans present in this module.
WARNING
4. Select the motor / fan to be checked. Depending on the selected
Do not expose fingers or other parts of the body to moving, rotating or cut-
motor / fan different options will be available to continuously run or
ting devices when running the machine with the interlock cheater installed.
cycle the motor. Related information such as motor voltage, motor
Do not wear ties, lanyards or other things that might get trapped into the
speed and the status of relevant sensors will be displayed and
continuously updated.
NOTE: 5.1.5 Checking Sensors

If lids are open, ensure interlock cheaters are installed, otherwise the mo-
tors will not run. 1. Enter Service Program mode (Section 5.1.1)
2. Use the Change Target button to choose the desired module.
3. Click Sensors to see the sensors and switches present in this
WARNING
module.
4. Select the sensor to be checked. A live reading will be displayed.
Cover / uncover the sensor to verify the value is changing. See
Section 5.2 for the state definitions of each sensor.
NOTE:
If lids are open, ensure interlock cheaters are installed, otherwise the mo-
tors will not run.
WARNING
18 February 2022
5.1.6 Checking Voltmeters 5.1.8 Dead Cycle
1. Enter Service Program mode (Section 5.1.1) Dead cycle is a modified machine cycle without paper. All functions in the
2. Use the Change Target button to choose the desired module. machine initiate to run (e.g. motors and solenoids). This cycle is intended
3. Click Voltmeters to see the voltage readings in this module. to be used during factory testing but may also be useful for troubleshoot-
4. Select the Voltmeter to be checked. A live reading will be dis- ing. To initiate dead cycle:
played. See Section 5.2 for the correct voltages.
1. Enter Service Program mode (Section 5.1.1)
NOTE: 2. Click the Dead Cycle button and click Start Dead Cycle.
If lids are open, ensure interlock cheaters are installed, otherwise the mo- 3. To switch off Dead Cycle mode press “Stop”.
tors will not run.
5.1.9 Calibration
WARNING The calibration menu provides access to automated calibration routines.
Do not expose fingers or other parts of the body to moving, rotating or cut- For detailed instructions on how to calibrate this machine see the following
ting devices when running the machine with the interlock cheater installed. Sections of this manual:
• ADJ 3.8.1 Ultrasonic Double Sheet Detector Calibration
5.1.7 Non-Volatile Memory (NVM) • ADJ 3.8.2 Optical Distance Sensor Calibration
Non-Volatile Memory values are used to store machine settings that need • ADJ 3.8.3 Separation Pad Adjustment
to be preserved between restarts (for example, calibration values). The • ADJ 3.9.1 DigiFold/AutoCreaser alignment to feeder
values for each module are stored on its main CPU. • ADJ 3.9.2 DigiFold/AutoCreaser Input roller adjustment
• ADJ 3.9.3 Transport roller calibration
WARNING • ADJ 3.9.4 DigiFold/AutoCreaser creaser position calibration
Changing NVM values can jeopardize the way the machine operates • ADJ 3.9.5 DigiFold/AutoCreaser static creaser bridge adjustment
considerably. Be sure that changing the NVM value is the correct solu- • ADJ 3.10.1 Fold roller adjustment
tion before doing so. If changes are made which cause the unit to operate • ADJ 3.10.2 Knife calibration check
incorrectly, refer to the NVM default settings (Section 5.3.2 to 5.3.4) then • ADJ 3.10.3 Knife position calibration
recalibrate. • ADJ 3.10.4 Setting the fold knives
• ADJ 3.10.5 Delivery roller home position
1. Enter Service Program mode (Section 5.1.1) • ADJ 3.10.6 DynaCrease blade eccentrics
2. Use the Change Target button to choose the desired module. • ADJ 3.10.7 DynaCrease bridge crease depth
3. Click NVM to see a list of NVM values for this module.
4. Select the value to be changed. Use the +/- buttons to increment
it or type in a new value. Click the green tick mark to confirm.
See Section 5.3 for a detailed description of NVM values for this
machine.
18 February 2022
5.2 Service Program Mode Tables
5.2.1 Feeder Motors
Motor Normal Reading Function

M1 Home sensor: Lift motor
0 – uncovered, Home sensor Q1 – lift home sensor. During initialization the lift moves down until this sensor is
1 – covered covered.
Other sensor: Other sensor Q2 – lift top safety sensor.
0 – covered, Aux sensor Q8 – lift bottom safety sensor.
1 – uncovered
Aux sensor:
0 – covered,
1 – uncovered
Voltage: 55V
M2 Voltage: 55V Vacuum belt motor (black belts)
M3 Voltage: 55V Alignment belt motor (green belts)
FAN1 N/A Front paper separation fan
FAN2 N/A Side float fan
FAN3 N/A Vacuum fan
FAN4 N/A Registration fan (green belts)
FAN7 N/A Electronics cooling fan (optional)
FAN8 N/A Next unit cooling fan (optional)
5.2.2 Feeder Solenoids
Solenoid Normal Reading Function

SOL1 N/A Vacuum choke solenoid. ON – no vacuum through black feed belts. OFF – vacuum through black
feed belts (if FAN3 is on)
SOL2 / CNT N/A Mechanical chassis counter. Turning ON increments counter by 1.
REL1 N/A Controls 24V PSU
REL2 N/A Controls 55V PSU
18 February 2022
5.2.3 Feeder Sensors
Sensor Normal Reading Function

Q1 0 – uncovered, Lift home position
1 – covered
Q2 0 – covered, Lift top safety sensor (vacuum belts)
1 – uncovered
Q3 0 – covered, Table extension sensor
1 – uncovered
Q4 0 – fully covered Optical distance sensor. Value shows distance in mm x 10 from sensor to the top of paper stack on
1820 – fully uncovered feeder table
Q7 1700 Optical double sheet detector (optional)
Q8 0 – covered, Lift bottom safety sensor (safety base)
1 – uncovered
Q10 Digital: Ultrasonic double sheet detector
0 – uncovered,
1 – covered
Voltage:
<100 mV – uncovered or double
sheet
>500 mV – covered with a single
sheet
Q11 0 – covered, Table empty sensor
1 – uncovered
Q12 0 – fully covered SP sensor array
16 – fully uncovered
SW4 0 – pressed, Top interlock soft switch
1 – released
SW5 0 – pressed, Bottom interlock soft switch
1 – released
18 February 2022
5.2.4 Feeder Voltmeters
Voltmeters Normal Reading Function

PSU-12V 12V Voltage at PCB T – main CPU APP32
PSU-24V 24V Voltage at PCB L – supplies all fans

M1 55V Voltage at PCB G – lift motor driver M21H
M2 55V Voltage at PCB H – vacuum belt motor driver M21H
M3 55V Voltage at PCB K – registration belt motor driver M21H
5.2.5 Creaser Motors

M21 N/A Roller drive motor
M22 Home sensor: Creaser 1 motor (optional)
0 – uncovered, Home sensor Q21
1 – covered
M23 Home sensor: Creaser 2 motor
1 – covered
5.2.6 Creaser Solenoids

SOL21 N/A Mechanical chassis counter. Turning ON increments counter by 1.
Q20LED N/A Input sensor Q20
18 February 2022
5.2.7 Creaser Sensors

Q20 Digital: Input sensor. Turn on Q20LED under Solenoids to check this sensor.
0 – uncovered,
1 – covered
Voltage:
<200 mV – uncovered with
Q20LED on
>200 mV – covered (or uncovered
with Q20LED off)
Q21 0 – uncovered, Creaser 1 home sensor (optional)
1 – covered
Q22 0 – uncovered, Creaser 2 home sensor
1 – covered
SW22 0 – released, Top cover interlock soft switch
1 – pressed
Q25 0 – uncovered, Exit sensor
1 – covered
5.2.8 Creaser Voltmeters

M21 55V Voltage at PCB B – roller motor driver M21H
M22 55V Voltage at PCB C – creaser 1 motor driver M21H (optional)

M23 55V Voltage at PCB D – creaser 2 motor driver
5.2.9 Folder Motors

M41 N/A Roller drive motor
M42 Home sensor: Creaser 1 motor (optional)
1 – covered
M43 Home sensor: Creaser 2 motor
1 – covered
18 February 2022
5.2.9 Folder Motors (continued)

M44 Home sensor: Fold Knife Motor
1 – covered
M45 Home sensor: Gap Set Motor 2
1 – covered
1 – covered
M47 Home sensor: Delivery Belt Motor
1 – covered
M49 N/A Delivery Belt Motor
1 – covered
5.2.10 Folder Solenoids

SOL41 N/A Mechanical chassis counter. Turning ON increments counter by 1.
Q40LED N/A Input sensor Q40

Q52LED N/A Exit sensor Q52
18 February 2022
5.2.11 Folder Sensors
Q40 Digital: Input sensor. Turn on Q40LED under Solenoids to check this sensor.
0 – uncovered,
1 – covered
Voltage:
Q40LED on
with Q40LED off)
Q41 0 – uncovered, Creaser 1 home sensor (optional)
1 – covered
Q42 0 – uncovered, Creaser 2 home sensor
1 – covered
SW22 0 – released, Top cover interlock soft switch
1 – pressed
Q45 0 – uncovered, Crease Exit sensor
1 – covered
Q47 0 – uncovered, Fold Knife position
1 – covered
Q48 0 – uncovered, Gap Set 2 position
1 – covered
1 – covered
Q50 0 – uncovered, Delivery Roller Position sensor
1 – covered
1 – covered
Q52 Digital: Fold Exit sensor. Turn on Q52LED under Solenoids to check this sensor.
0 – uncovered,
1 – covered
Voltage:
Q52LED on
with Q52LED off)
Q54 0 – uncovered, Crease Tray sensor
1 – covered
18 February 2022
5.2.12 Folder Voltmeters

M41 55V Voltage at PCB B – roller motor driver M21H
M42 55V Voltage at PCB C – creaser 1 motor driver M21H (optional)

M43 55V Voltage at PCB D – creaser 2 motor driver
M44 55V Voltage at PCB E – fold knife motor driver
M45 24V Voltage at PCB MM – gap set 2 motor driver
M47 55V Voltage at PCB H – delivery belt motor driver
M49 55V Voltage at PCB K – delivery roller motor driver
18 February 2022
5.3 Non-Volatile Memory (NVM) Values
5.3.1 Accessing NVM values
To access NVM values stored in the machine:
1. Enter Service Program mode (Section 5.1.1)

2. Use the Change Target button to choose the desired module.
NOTE:
Each module in this machine has its own set of NVM values.
3. Click the NVM button to see a list of NVMs for the selected mod-
ule.
4. Select and change the desired NVM value. For some NVM values
the machine needs to be restarted for the change to take effect.
To access NVM backup values:
1. Remove feeder front cover (REP 3.3.2) or remove folder/creaser

front cover (REP 3.3.8)
2. Look for an NVM table sticker containing factory setting values.
18 February 2022
5.3.2 Feeder NVM values
Index Name Default value Description

1 DSD US PWM Duty Cycle (%) 19 Controls ultrasonic double sheet detector (Q10) sensitivity. Set by completing calibration proce-
dure ADJ 3.8.1
2 Q4 0mm:mV 2100
3 Q4 32mm:mV 1050
NVM002 – NVM006 control the sensitivity of optical distance sensor (Q4). Set by completing
4 Q4 82mm:mV 600
calibration procedure ADJ 3.8.2
5 Q4 132mm:mV 400
6 Q4 182mm:mV 300
7 Sheet counter to thousand 0 Number of sheets processed since last increment to NVM008. Resets at 1000.
8 Sheet counter thousands 0 Thousands of sheets processed in the lifetime of this machine.
9 Standalone mode 0 Set to 0 if the feeder is part of an AutoCreaser or a DigiFold. Set to 1 if the feeder is used
standalone to feed third party devices. Set to 2 if DFA kit is used to communicate to third party
devices.
5.3.3 Creaser NVM values

1 Crease Tool 1 distance from Q20 350 First (optional) creaser distance from input sensor in mm x 10 (350 = 35.0 mm). Set by com-
pleting calibration procedure ADJ 3.9.4
2 Crease Tool 2 distance from Q20 1290 Second creaser distance from input sensor in mm x 10 (1290 = 129.0 mm). Set by complet-
ing calibration procedure ADJ 3.9.4
3 Stretch Tool 1 1000 Roller diameter compensation for the first (optional) creaser (1000 = 100.0%). Set by com-
4 Sheet counter to thousand 0 Number of sheets processed since last increment to NVM005. Resets at 1000.
5 Sheet counter thousands 0 Thousands of sheets processed in the lifetime of this machine.
6 Stretch Tool 2 100 Roller diameter compensation for the second creaser (1000 = 100.0%). Set by completing
7 CR_Tool_1_kit 0 Number of sheets processed since last increment to NVM008. Resets at 1000.
18 February 2022
5.3.4 Folder NVM values

1 Crease Tool 1 distance from Q40 350 First (optional) creaser distance from input sensor in mm x 10 (350 = 35.0 mm). Set by com-
2 Crease Tool 2 distance from Q40 1350 Second creaser distance from input sensor in mm x 10 (1350 = 135.0 mm). Set by complet-
ing calibration procedure ADJ 3.9.4
3 Fold Knife 1 Distance From Q40 2170 Fold Knife 1 distance from input sensor in mm x 10 (2170 = 217.0 mm). Set by completing
4 Fold Knife 2 Distance From Q40 2690 Fold Knife 2 distance from input sensor in mm x 10 (2690 =269.0 mm). Set by completing
5 Stretch fold knife 1 1000 Not used.
6 Stretch fold knife 2 1000 Not used.
7 M45 gap set roller 2 start angle 1590 Roller 2 gap set motor M45 home sensor Q48 position in degrees x 10 from horizontal (1590
= 159.0°). Set by completing calibration procedure ADJ 3.10.1
9 Delivery Roller Home Position - 3152 Linear potentiometer reading (in mV) at the minimum delivery roller position. Set by complet-
Motor 48 ing calibration procedure ADJ 3.10.5
10 Stretch Static Creaser 1000 Not used.
12 Stretch DynaCreaser 1000 Not used.
13 Sheet counter 0 Number of sheets processed since last increment to NVM014. Resets at 1000.
14 Sheet counter (*1000) 0 Thousands of sheets processed in the lifetime of this machine.
15 CR_Tool_1 kit 0 Set to 1 if the optional static creaser kit is installed. Set to 0 otherwise.
16 Transport ratio 0.1 sheet 624 Roller diameter compensation for 0.1 mm thick sheets. Set by completing calibration proce-
dure ADJ 3.9.3
17 Transport ratio 0.4 sheet 660 Roller diameter compensation for 0.4 mm thick sheets. Set by completing calibration proce-
dure ADJ 3.9.3
18 Edge offset time uS 2200 Input sensor Q40 processing delay compensation (in µs). Set by completing calibration pro-
cedure ADJ 3.9.3
18 February 2022
5.4 Update Software
To check if there are software updates available for this machine go to
Plockmatic Group website and log in to the Partner Centre (https://plock-
maticgroup.com/customer-login/). Find the latest software download for
this machine and compare version numbers.
5.4.1 Single point download
This machine supports single point download for software updates. This
means that all PCBs in all modules of this machine can be updated cen-
trally.
1. Download the latest software package for this machine from Plock-
matic Group Partner Centre
2. Copy “.rman” installation files to the root folder of a USB stick. Typi-
cally there are two “.rman” files provided in the release – one for
machine software and one for UI software.
3. With the machine powered off insert the USB stick the in the USB
port on the right side of the user interface cover.
4. Power on the machine and wait for the software update screen to
appear. This may take up to 30 s.
5. Select the desired installation file and press the Install button.
6. (For machine software installation only) A list of PCBs will be
shown indicating which ones will be updated (green tick). To manu-
ally force an update, click the red X to change it into a green tick.
Click Program.
7. Wait for the installation to finish, remove the USB stick and restart
the machine.
8. To check the software has correctly updated go to Tools -> Soft-
ware version
18 February 2022
5.4.2 Loading software on a replacement PCB
CAUTION!
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes,
data and / or communication problems. Failure to use proper ESD proce-
tions, ensuring the proper handling of circuit boards / sensors. Use ESD
protection when working near PCBs. Failure to use ESD protection is likely
If replacing a PCB the new PCB may not have any software installed on it.
In this case it may not be possible to use the single point download proce-
dure described in Section 5.4.1. To load software on individual PCBs the
following special tools are required:
A. USB to STM32F dongle (art. no. 960-108436) – for all PCBs

B. Harness SW load adapter 16/8p (art. no. 960-110000) – for SP
sensor only.
NOTE:
These tools are ordered separately.
1. Install the replacement PCB in the machine.

2. Download the latest software package for this machine from Plock-
matic Group Partner Centre
3. Run the “.exe” file for the PCB to be updated and follow the on-
screen instructions.
4. Switch off the machine and use the dongle [A] to connect the PCB
to your computer. Use adapter [B] if updating the SP sensor.
5. Power the machine on and click the Program button on your com-
puter.
6. When the process has finished power off the machine and discon-
nect the dongle from the PCB.
7. Power the machine back on. To check the software has correctly
updated go to Tools -> Software version and compare version
numbers.
18 February 2022
5.5 Tag Label Locations
Tag labels are used to mark upgrades installed on each unit. Follow the
instructions in relevant technical bulletins to fill out the tag labels.
Feeder TAG label Creaser/ Folder TAG label
18 February 2022
6 Detailed Section Descriptions
6.1 Parts List......................................................................................................................................................................................................... 6-2
6.2 Principle of Operation...................................................................................................................................................................................... 6-3
6.2.1 Feeder...................................................................................................................................................................................................... 6-3
6.2.2 Creaser..................................................................................................................................................................................................... 6-6
6.2.3 Folder....................................................................................................................................................................................................... 6-8
18 February 2022
Pro XL 6-1 Detailed Section Description
6.1 Parts List
Please refer to Pro XL Parts List T07103 for:
• A detailed list of components by location and by category.

• Spare part ordering numbers.
18 February 2022
6.2 Principle of Operation
6.2.1 Feeder
The feeder module is designed to separate a stack of papers and feed
them one by one without overlap to the next unit downstream.
Job setup
Paper size, thickness, gsm and other required parameters are entered by
the operator in the UI and sent to all connected units via XCAN. Each unit
calculates its required line speed and cycle time and publishes this infor-
mation via XCAN. Feeder adapts to the downstream units and feeds at the
maximum speed and minimum gap between sheets that the downstream
units can process (unless the operator has specified otherwise).
Initialization
Before the feeder can cycle up it automatically performs an initialization

routine:
1. Lift motor [M1] moves downward until it reaches its home sensor
[Q1].
2. Double sheet detection sensor [Q10] is checked for obstructions
(jam code FE-112).
M1 Q1
18 February 2022
Cycle up
1. Table empty sensor [Q11] status is checked. If no paper is detect-
ed, the cycle is stopped (jam code FE-106). M2 Q10 Q12 M4 FAN2
2. Optical distance sensor [Q4] is used to check paper stack height. If
the lift is overloaded, the cycle is stopped (FE-108 or FE-109).
3. Lift motor [M1] drives lift upward to its process position. Optical dis-
tance sensor [Q4] and SP sensor [Q12] are used to position the lift.
4. Separation fan [FAN1], side fan [FAN2], vacuum fan [FAN3] and
registration fan [FAN4] are turned on. Registration belt motor [M3]
is turned on.
5. From now on lift is dynamically positioned using density readings
from SP sensor [Q12].
6. When the next unit is ready to receive paper, the feed cycle is
started:
6.1. Solenoid [SOL1] is released to close vacuum choke. The
top sheet in the pile is pulled to the vacuum belts.
6.2. Motor [M2] is started and feeds the sheet forward to the
registration area.
6.3. Ultrasonic double sheet detector [Q10] is used to verify
that only a single sheet is present. If no sheet is present another
feed cycle is attempted. If this fails 3 times a misfeed error is FAN4 M3 Q10 FAN1 Q11
thrown (jam code FE-101). If more than one sheet is present a
double sheet jam is triggered (FE-102) and the cycle is stopped.
6.4. Once the sheet reaches the green belts solenoid [SOL1] is
activated to shut off vacuum. This allows the sheet to register.
6.5. Motor [M3] continues feeding the sheet into the next
unit. If sensor [Q10] is not uncovered in time, the sheet may have
slipped or become jammed (jam code FE-103). Once sensor [Q10]
has been uncovered, the next feed cycle can start.
18 February 2022
Safety
FAN2 Q2 FAN3 SOL1 SW2/SW4
1. If at any point during standby or cycle the interlock circuit is
breached, 24V and 55V power supply units are shut off and an
error is displayed on the screen. The interlock circuit consists of
[SW2/SW4], [SW3/SW5] and a signal from downstream machines
via connector P12.
2. If during the cycle the lift interferes with the vacuum belts, the belts
are lifted upwards and top safety sensor [Q2] is activated. The lift
then backs off. If the lift continues to overrun, top interlock switch
[SW2/SW4] may be activated.
3. If during the cycle the lift interferes with the safety base, the base
is pushed downwards and bottom safety sensor [Q8] is activated.
This immediately stops the cycle. If the lift continues to overrun,
bottom interlock switch [SW3/SW5] may be activated.
4. If during the cycle the feeder table extension moves, the cycle is
stopped (jam code FE-113 or FE-114).
SW3/SW5 Q8
18 February 2022
6.2.2 Creaser
The creaser module is designed to accept incoming papers from upstream Q20
units, accurately crease or perforate them and feed them out onto a
stacker.
Job setup
Paper size, thickness, gsm and other required parameters are entered
by the operator in the UI and sent to all connected units via XCAN. The
creaser calculates its required line speed and cycle time and publishes this
information via XCAN.
Initialization
Before the creaser can cycle up it automatically performs an initialization

routine:
1. Input sensor [Q20] is turned on and calibrated.

2. (If creaser 1 is installed) Creaser 1 motor [M22] drives the creaser
camshaft until it reaches its home sensor [Q21].
3. Creaser 2 motor [M23] drives the creaser camshaft until it reaches
its home sensor [Q22].
Q22 Q21 M23 M22
18 February 2022
Cycle up
1. Motor [M21] drives rollers at the target line speed.

2. Input sensor [Q20] detects incoming paper. If the sensor is covered SW21/SW22 Q25
too long, the cycle is stopped (jam code CR-202).
3. Motor [M21] transports the paper and stops it at the creasing posi-
tion.
4. Creaser drive motor(s) [M22 & M23] complete a full rotation to
crease the paper. If the creaser fails to complete a full rotation, the
cycle is stopped (jam codes CR-205 or CR-206)
5. Motor [M21] transports the paper out to the stacker.
6. Exit sensor [Q25] verifies that the paper has exited the machine.
If the sensor is covered too long, the cycle is stopped (jam code
CR-208)
Safety

breached, 24V and 55V power supply units in the feeder are shut
off and an error is displayed on the screen. The interlock circuit in
the creaser consists of [SW21/SW22].
M21
18 February 2022
6.2.3 Folder M45 SW21/SW22 Q40
The folder module is designed to accept incoming papers from upstream
units, accurately crease and/or fold and/or perforate them and feed them
out onto a stacker.
Job setup Q42

Q48 (not shown)
Paper size, thickness, gsm and other required parameters are entered by Q41 if fitted
the operator in the UI and sent to all connected units via XCAN. The folder (not shown)
calculates its required line speed and cycle time and publishes this infor-
mation via XCAN.
Initialization
Before the folder can cycle up it automatically performs an initialization

routine:
1. Input sensor [Q40] is turned on and calibrated. M41 M43 M42

2. (If creaser 1 is installed) Creaser 1 motor [M42] drives the creaser
camshaft until it reaches its home sensor [Q41]. M46 Q52
3. Creaser 2 motor [M43] drives the creaser camshaft until it reaches
its home sensor [Q42].
4. Gap set roller motors [M50], [M45] & [M46] drive the gap set flags
until they reach the corresponding home sensors [Q51], [Q48] &
M50
[Q49].
5. Fold kife motor [M44] drives the cam until the flag reaches its home LED52
sensor [Q47].
6. Fold output sensor [Q52] and creaser output sensor [Q54] is turned Q51
on.
7. Delivery roller [M49] drives to set position based on the folded
sheet length.
Q54
Q47 M44 Q49

18 February 2022
Cycle up
Crease position 1 (option) and/or cross perforation (option)

1. Gap set roller motor [M50] drive the gap set flag until it reaches the
correct position for inputted paper thickness on sensor [Q51].
3. Input sensor [Q40] detects incoming paper. If the sensor is covered
too long, the cycle is stopped (jam code FO-202).
4. Motor [M41] transports the paper and stops it at creasing position 1
(option) if fitted.
5. Creaser drive motor [M42] completes a full rotation to crease the
paper. If the creaser fails to completes a full rotation, the cycle is
stopped (jam codes FO-205 or FO-206)
6. Motor [M41] transports the paper out to the creaser stacker.
7. Exit sensor [Q54] verifies that the paper has exited the machine.
If the sensor is covered too long, the cycle is stopped (jam code
FO-208)
Folding and/or crease position 2

1. Gap set roller motor [M50], [M45] & [M46] drive the gap set flags Component locations shown on previous page
until they reach the correct position for inputted paper thickness on
sensors [Q51], [Q48] & [Q49].
3. Input sensor [Q40] detects incoming paper. If the sensor is covered
too long, the cycle is stopped (jam code FO-302/FO-303/FO-304).
4. Creaser drive motor [M43] completes a full rotation to crease the
paper. If the creaser fails to complete a full rotation, the cycle is
stopped (jam codes FO-309 or FO-310)
5. Fold knife motor [M44] completes a full rotation to fold the paper. If
the fold knives K1 & K2 fail to complete a full rotation, the cycle is
stopped (jam codes FO-311)
6. Exit Sensor (Q52) verifies that the paper has left the Folder suc-
cessfully
Safety
breached, 24V and 55V power supply units in the feeder are shut
off and an error is displayed on the screen. The interlock circuit in
the creaser consists of [SW21/SW22].
18 February 2022
7 Specifications
7.1 General........................................................................................................................................................................................................... 7-2
7.2 Physical Characteristics.................................................................................................................................................................................. 7-2
7.3 Paper Handling............................................................................................................................................................................................... 7-3
7.4 Output Quality................................................................................................................................................................................................. 7-4
7.5 Declaration of Conformity................................................................................................................................................................................ 7-4
18 February 2022
Pro XL 7-1 Specifications
7.1 General
Power source Voltage: 100-240V AC (tolerance -10/+6%)
Current: 8-4A
Frequency: 50/60 Hz
Power consumption Standby: 55W
Maximum: 750W
Operating temperature 10-30°C (50-86°F)
Humidity 30-80% RH
Sound emissions 80dB
7.2 Physical Characteristics

Product Length Width Height Weight
AutoCreaser Pro XL
AutoCreaser Pro XL 1690mm (66.5”) 730mm (28.7”) 1160mm (45.7”) 250kg (551lbs)
AutoCreaser Pro XL with feeder table fully extended 2540mm (100”) 730mm (28.7”) 1160mm (45.7”) 250kg (551lbs)
AutoCreaser Pro XL Packaged 1200mm (47.2”) 800mm (31.5”) 1400mm (55.1”) 305kg (672lbs)
DigiFold Pro XL
DigiFold Pro XL 2130mm (83.9”) 730mm (28.7”) 1395mm (54.9”) 313kg (689lbs)
DigiFold Pro XL with feeder table fully extended 2990mm (117.7”) 730mm (28.7”) 1395mm (54.9”) 313kg (689lbs)
DigiFold Pro XL Packaged 1200mm (47.2”) 800mm (31.5”) 1400mm (55.1”) 368kg (810lbs)
BST4000 optional DigiFold Pro XL only
BST4000 1800mm (70.9”) 480mm (18.9”) Adjustable 70kg (154lbs)
BST4000 Packaged 1500mm (59,0”) 550mm (21.7”) 540mm (21.3”) 85kg (187lbs)
18 February 2022
7.3 Paper Handling
Feeder Module
Max stack: 200 mm (100 mm for sheet lengths above 700 mm)
7.9” (3.9” for sheet lengths above 27.6”)
Max paper size W x L: 385 x 700 mm (385 x 1300 mm with table extension)
15.2” x 27.6” (15.2” x 51” with table extension)
Min paper size W x L: 93 x 210 mm
3.7” x 8.3”
Max paper thickness: 0.4 mm (400 gsm)
0.0157”
Min paper thickness: 0.09 mm (80 gsm)
0.0035”
Max paper curl ±6 mm
±0.24”
Static crease module (Optional module)
Minimum crease to 0.1mm
crease distance 0.004”
Creasing resolution 0.1mm
0.004”
Stacker max paper 385 x 1040 mm
size W x L 15.2” x 41”
DynaCrease module (Folder only)
Minimum crease to 0.1mm *To achieve crease to crease distances below 70mm
crease distance 0.004” * / 2.8”, the DynaCrease will run at a reduced speed.
Creasing resolution 0.1mm
0.004”
Stacker max paper 385 x 1040 mm
size W x L 15.2” x 41”
Stacker capacity (creased sheets)
Stacker capacity 120 mm 4.7”
18 February 2022
7.4 Output Quality 7.5 Declaration of Conformity
Conditions:
• Paper size is assumed to be perfect. EU DECLARATION OF CONFORMITY [1]

• Sheets are assumed to be perfectly 90°. No.[2] .......................... N0007378 (A.3)
• Tolerances are referring to deviations within one job. Manufacturer [3] ........ Plockmatic International AB, Telefonvägen 30, S-126 26 Hägersten, Sweden
This Declaration of Conformity is issued under the sole responsibility of the manufacturer [4]
A4 A3 Object of the Declaration [5]
Letter Ledger Model/Type [6] F142-001 F142-011 F142-021
Name [7] Feeder Pro XL AutoCreaser Pro XL DigiFold Pro XL
± 0.20mm ± 0.20mm
Crease position variation Description [8] Sheet feeder Feeder/creaser Feeder/folder
± 0.008” ± 0.008”
The object of the declaration is in conformity with the relevant Union harmonization legislation: [9]
± 0.25mm ± 0.40mm
Crease skew Directive [10] Standard [11]
± 0.010” ± 0.016” 2014/30/EU (EMC) EN 55032:2015, EN 55035:2017, IEC 61000-3-2:2014, IEC 61000-3-3:2013, IEC 61000-
6-2:2005, EN 61000-6-2:2019, EN 61000-6-4:2007+A1:2011
2015/863/EU (RoHS) EN 50581:2012, EN 62321:2009
Quality definitions 2014/35/EU (LVD) EN 62368-1:2014 + A11:2017
Additional information [12] International certification: UL 62368-1, 2nd Edition, CSA C22.2 No. 62368-1:2014, IEC 62368-1:2014, FCC Part 15
(2015) Subpart B Section 15, Class A.
Measurements refer to any crease position. Signed for and on behalf of [13] Hägersten, 2020-02-06 08:57
Bengt Olenfalk
L1 Group Quality Manager
БЪЛГАРСКИ; 1) ЕС Декларация за съответствие; 2) Номер; 3) Производител; 4) Настоящата декларация за съответствие е издадена на отговорността на производителя; 5) Предмет на декларацията; 6) Модел/Тип; 7)
Назначение; 8) Описание; 9) Предметът на декларацията, описан по-горе, отговаря на съответното законодателство на Съюза за хармонизация; 10) Директива; 11) Стандарт ; 12) Допълнителна информация; 13)
Подписано за и от името на
ČESKÝ; 1) EU Prohlášení o shodě; 2) Číslo; 3) Výrobce; 4) Toto prohlášení o shodě se vydává na výhradní odpovědnost výrobce; 5) Předmět prohlášení; 6) Model/Typ; 7) Označení; 8) Popis; 9) Výše popsaný předmět prohlášení je
ve shodě s příslušnými harmonizačními právními předpisy Unie; 10) Směrnice; 11) Norma; 12) Dodatečné informace; 13) Podepsáno za a jménem na
DANSK; 1) EU-Overensstemmelseserklæring; 2) Nummer; 3) Producent; 4) Denne overensstemmelseserklæring udstedes på fabrikantens ansvar; 5) Erklæringens genstand; 6) Model/Type; 7) Betegnelse; 8) Beskrivelse; 9)
Genstanden for erklæringen, som beskrevet ovenfor, er i overensstemmelse med den relevante EU-harmoniseringslovgivning; 10) Direktiv; 11) Standard; 12) Yderligere information; 13) Underskrevet for og vegne
DEUTSCH; 1) EU-Konformitätserklärung; 2) Nummer; 3) Hersteller; 4) Die alleinige Verantwortung für die Ausstellung dieser Konformitätserklärung trägt der Hersteller; 5) Gegenstand der Erklärung; 6) Modell/Typ; 7) Bezeichnung; 8)
Beschreibung; 9) Der oben beschriebene Gegenstand der Erklärung erfüllt die einschlägigen Harmonisierungsrechtsvorschriften der Union; 10) Direktive; 11) Standard; 12) Weitere Informationen; 13) Zur Unterzeichnung und Namen
EESTI; 1) ELi Vastavusdeklaratsioon; 2) Number; 3) Valmistaja; 4) Käesolev vastavausdeklaratsioon on välja antud tootja ainuvastutusel; 5) Deklareeritav; 6) Mudel/Type; 7) Nimetus; 8) Kirjeldus; 9) Eelkirjeldatud deklareeritav toode
on kooskõlas asjaomaste liidu ühtlustamisaktidega; 10) Direktiivi; 11) Standard; 12) Lisainfo; 13) Allkirjastatud ja nimel
Paper SUOMI; 1) EU-Vaatimustenmukaisuusvakuutus; 2) Määrä; 3) Valmistaja; 4) Tämä vaatimustenmukaisuusvakuutus on annettu valmistajan yksinomaisella vastuulla; 5) Vakuutuksen kohde; 6) Malli/Tyyppi; 7) Nimitys; 8) Kuvaus; 9)
Edellä kuvattu vakuutuksen kohde on asiaa koskevan unionin yhdenmukaistamislainsäädännön vaatimusten mukainen; 10) Direktiivi; 11) Standardi; 12) Lisäinformaatio; 13) Allekirjoitettu ja puolesta
Transport
FRANÇAIS; 1) Déclaration UE de conformité; 2) Nombre; 3) Fabricant; 4) La présente déclaration de conformité est établie sous la seule responsabilité du fabricant; 5) Objet de la déclaration; 6) Modèle/type; 7) Désignation; 8)
Description; 9) L’objet de la déclaration décrit ci-dessus est conforme à la législation d’harmonisation de l’Union applicable; 10) Directif; 11) Standard; 12) Information Supplémentaire; 13) Signé pour et au nom de
GAEILGE; 1) Dearbhú comhréireachta AE; 2) Uimhir; 3) Manufacturer; 4) Tá an dearbhú comhréireachta arna eisiúint faoi fhreagracht an mhonaróra; 5) Cuspóir an dearbhaithe; 6) Cineál; 7) Ainmniú; 8) Tuairisc; 9) Is é cuspóir an
Direction dearbhaithe a thugtar i gcomhréir leis an reachtaíocht chomhchuibhithe ábhartha an Aontais; 10) Treoir; 11) Caighdeánach; 12) Eolas breise; 13) Arna shíniú le haghaidh agus thar ceann an
ΕΛΛΗΝΙΚΗ; 1) Δηλωση συμμορφωσησ ΕΕ; 2) αριθμός; 3) Κατασκευαστής; 4) Η παρούσα δήλωση συμμόρφωσης εκδίδεται με αποκλειστική ευθύνη του κατασκευαστή; 5) Αντικείμενο της δήλωσης; 6) Μοντέλο/Τύπος; 7) Ονομασία;
8) Περιγραφή; 9) Ο στόχος της δήλωσης που περιγράφεται παραπάνω είναι σύμφωνος με τη σχετική ενωσιακή νομοθεσία εναρμόνισης; 10) διευθυντικός; 11) Πρότυπο; 12) Επιπλέον πληροφορίες; 13) Υπογραφή για λογαριασμό και
εξ ονόματος του
HRVATSKI; 1) EU Izjava o sukladnosti; 2) Broj; 3) Proizvođač; 4) Za izdavanje EU izjave o sukladnosti odgovoran je isključivo proizvođač; 5) Predmet deklaracije; 6) Model/Tip; 7) Oznaka; 8) Deskripcija; 9) Predmet navedene izjave u
skladu je s mjerodavnim zakonodavstvom Unije o usklađivanju; 10) Direktiva; 11) Standard; 12) Dodatne informacije; 13) Potpisao za iu ime
MAGYAR; 1) EU–Megfelelőségi nyilatkozat; 2) Szám; 3) Gyártó; 4) Ezt a megfelelőségi nyilatkozatot a gyártó kizárólagos felelőssége mellett adják ki; 5) A nyilatkozat tárgya; 6) Modell/Típus; 7) Kijelölés; 8) Leírás; 9) A fent ismertetett
nyilatkozat tárgya megfelel a vonatkozó uniós harmonizációs jogszabályoknak; 10) Irányelv; 11) Standard; 12) További információ; 13) Aláírva nevében
ÍSLENSKA; 1) ESB Leyfisyfirlýsing; 2) Fjöldi; 3) Framleiðandi; 4) Þessi samræmisyfirlýsing er sett alfarið á ábyrgð framleiðanda; 5) Markmið yfirlýsingarinnar; 6) Gerð; 7) Tilnefning; 8) Lýsing; 9) Markmið yfirlýsingarinnar lýst er hér að
ofan er í samræmi við viðeigandi Union samhæfingu löggjafar; 10) Tilskipun; 11) Standard; 12) Viðbótarupplýsingar; 13) Undirritað fyrir og fyrir hönd
ITALIANO; 1) Dichiarazione di conformità UE; 2) Numero; 3) Produttore; 4) La presente dichiarazione di conformità è rilasciata sotto la responsabilità esclusiva del fabbricante; 5) Oggetto della dichiarazione; 6) Modello/Tipo; 7)
Designazione; 8) Descrizione; 9) L’oggetto della dichiarazione di cui sopra è conforme alla pertinente normativa di armonizzazione dell’Unione; 10) Direttiva; 11) Standard; 12) Informazioni aggiuntive; 13) Firmato e per conto di
LATVIEŠU; 1) ES Atbilstības deklarācija; 2) Numurs; 3) Ražotājs; 4) Šī atbilstības deklarācija ir izdota vienīgi uz ražotāja atbildību; 5) Deklarācijas priekšmets; 6) Modelis/tips; 7) Apzīmējums; 8) Apraksts; 9) Iepriekš aprakstītais
deklarācijas priekšmets atbilst attiecīgajam Savienības saskaņošanas tiesību aktam; 10) Direktīva; 11) Standarts; 12) Papildus informācija; 13) Parakstīts vārdā
LIETUVIŲ; 1) ES Atitikties deklaracija; 2) Skaičius; 3) Gamintojas; 4) Ši atitikties deklaracija išduota tik gamintojo atsakomybe; 5) Deklaracijos objektas; 6) Modelis/tipas; 7) Pavadinimas; 8) Aprašymas; 9) Pirmiau aprašytas deklaracijos
objektas atitinka susijusius derinamuosius Sąjungos teisės aktus; 10) Direktyva; 11) Standartinė; 12) Papildoma informacija; 13) Pasirašyta ir vardu
MALTESE; 1) Dikjarazzjoni ta’ konformità tal-UE; 2) Numru; 3) Manifattur; 4) Din id-dikjarazzjoni ta’ konformità tinħareg taħt ir-responsabbiltà unika tal-manifattur; 5) Għan tad-dikjarazzjoni; 6) Mudell/Tip; 7) Deżinjazzjoni; 8)
Deskrizzjoni; 9) L-għan tad-dikjarazzjoni deskritt hawn fuq huwa konformi mal-leġislazzjoni ta’ armonizzazzjoni rilevanti tal-Unjoni; 10) Direttiva; 11) Standard; 12) informazzjoni addizzjonali; 13) Iffirmat għal u f'isem il
NEDERLANDS; 1) EU-Conformiteitsverklaring; 2) Nummer; 3) Fabrikant; 4) Deze conformiteitsverklaring wordt verstrekt onder volledige verantwoordelijkheid van de fabrikant; 5) Voorwerp van de verklaring; 6) Model/Type; 7)
Benaming; 8) Beschrijving; 9) Het hierboven beschreven voorwerp is in overeenstemming met de desbetreffende harmonisatiewetgeving van de Unie; 10) Richtlijn; 11) Standaard; 12) Aanvullende informatie; 13) Ondertekend voor en
namens
NORSK; 1) EU-Erklæring; 2) Nummer; 3) Produsent; 4) Denne samsvarserklæringen er utstedt under ansvar av produsenten; 5) Formålet med erklæringen; 6) Type; 7) Betegnelse; 8) Beskrivelse; 9) Formålet med erklæringen som er
L2 beskrevet ovenfor er i samsvar med relevante Union harmoniseringslovgivning; 10) Direktiv; 11) Standard; 12) Ytterligere informasjon; 13) Signert for og vegne av
POLSKI; 1) Deklaracja zgodności UE; 2) Numer; 3) Producent; 4) Niniejsza deklaracja zgodności wydana zostaje na wyłączną odpowiedzialność producenta; 5) Przedmiot deklaracji; 6) Model/Typ; 7) Oznaczenie; 8) Opis; 9)
Wymieniony powyżej przedmiot niniejszej deklaracji jest zgodny z odnośnymi wymaganiami unijnego prawodawstwa harmonizacyjnego; 10) Dyrektywa; 11) Standard; 12) Dodatkowe informacje; 13) Podpisano imieniu
PORTUGUÊS; 1) Declaração UE de conformidade; 2) Número; 3) Fabricante; 4) A presente declaração de conformidade é emitida sob a exclusiva responsabilidade do fabricante; 5) Objecto da declaração; 6) Modelo/Tipo; 7) A
denominação; 8) Descrição; 9) O objeto da declaração acima descrito está em conformidade com a legislação de harmonização da União aplicável; 10) Directiva; 11) Padrão; 12) Informações adicionais; 13) Assinado por e nome
ROMÂNĂ; 1) Declarația UE de conformitate; 2) Număr; 3) Producător; 4) Prezenta declarație de conformitate este emisă pe răspunderea exclusivă a producătorului; 5) Obiectul declarației; 6) Model/Tip; 7) Desemnare; 8) Descriere; 9)
Obiectul declarației descris mai sus este în conformitate cu legislația relevantă de armonizare a Uniunii; 10) Directivă; 11) Standard; 12) Informatii aditionale; 13) Semnat pentru și în numele
SLOVENSKÝ; 1) EÚ Vyhlásenie o zhode; 2) Číslo; 3) Výrobca; 4) Toto vyhlásenie o zhode sa vydáva na výhradnú zodpovednosť výrobcu; 5) Predmet vyhlásenia; 6) Model/Typ; 7) Označenie; 8) Popis; 9) Uvedený predmet vyhlásenia
Crease position variation je v zhode s príslušnými harmonizačnými právnymi predpismi Únie; 10) Smernice; 11) Štandardné; 12) Doplňujúce informácie; 13) Podpísané za av mene na
SLOVENŠČINA; 1) Izjava EU o skladnosti; 2) Število; 3) Proizvajalec; 4) Ta izjava o skladnosti je izdana na lastno odgovornost proizvajalca; 5) Predmet izjave; 6) Model/Type; 7) Oznaka; 8) Opis; 9) Predmet navedene izjave je v
Measurement (L1+L2) / 2 from sheet to sheet

skladu z ustrezno zakonodajo Unije o harmonizaciji; 10) Direktiva; 11) Standardna; 12) Dodatne informacije; 13) Podpisano za in v imenu
ESPAÑOL; 1) Declaración UE de conformidad; 2) Número; 3) Fabricante; 4) La presente declaración de conformidad se expide bajo la exclusiva responsabilidad del fabricante; 5) Objeto de la declaración; 6) Tipo de modelo; 7)
Designación; 8) Descripción; 9) El objeto de la declaración descrita anteriormente es conforme con la legislación de armonización pertinente de la Unión; 10) Directiva; 11) Estándar; 12) Información Adicional; 13) Firmado por y
nombre
SVENSKA; 1) EU-Försäkran om överensstämmelse; 2) Nummer; 3) Tillverkare; 4) Denna försäkran om överensstämmelse utfärdas på tillverkarens eget ansvar; 5) Föremålet för försäkran; 6) Modell/Typ; 7) Beteckning; 8) Beskrivning;
9) Föremålet för försäkran ovan överensstämmer med den relevanta harmoniserade unionslagstiftningen; 10) Direktiv; 11) Standard; 12) Extra information; 13) Undertecknat för och på uppdrag av
Crease skew
Measurement L1 - L2
18 February 2022
8 Master Wiring Diagram
8.1 Master Wiring Diagram - Feeder..................................................................................................................................................................... 8-2
8.2 Master Wiring Diagram - Creaser................................................................................................................................................................... 8-3
8.3 Master Wiring Diagram - Folder...................................................................................................................................................................... 8-4
18 February 2022
Pro XL 8-1 Wiring
8.1 Master Wiring Diagram - Feeder
1 2 3 4 5 6 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
2x Twisted Pairs P351 J351
CPU APP 32
McF-20
J8 P8 B,P2-18 RD 1 1 RD
1 2 3 4 5 6
V
ON
A
1 1 B,P2-20 WH 2 2 WH OFF A
XCAN(H) WH BK 3 3
P10 J10 B,P2-19 BK
XCAN IN
2 2
XCAN(L) BK B,P2-17 BK 4 4 BK
T
3 3 5 5
1 1 START BK GN
M1 HOME RD +12V 4 4 6 6
NC
POSITION 2 2 BK P7 J7 DF11-10 BB INTERFACE
RD
RD
RD
5 5
BK
BK
BK
RD +12V 7 7
UI
GND
Q1 SENSOR 3 3 6 6 BK RD 1 +12V(IN)
+12V 8 8
P5 START RD
10
1 4 4 BU 2
1
2
3
4
5
6
7
8
9
RD RD ICAN(H) - - WH +12V(IN)
2 5 5 BK 9 GND
J5 NC
5mm WH - -
M21H J7 P7
3 6 6 BK 10 GND
ICAN(L)
GND 10
BK BK WH 9 9
B M1 LIFT MOTOR
1
2
3
4
5
6
7
8
GND 9
7 7 YL 4 B
ICAN(H)
GN CAN(H),IN
ICAN(L)
NC
GND
+12V
+12V
+12V
NC
NC
SHARP snap in CT 3-p 1 1 1 1 J7 P7 BK 10 10 6
G
EE-SX4235A-P2 MA- OG BN 8 8 BK BK CAN(L),IN
2 2 GND BK 11 11 BK COLOUR
M1
101-102822 2 2 1 1
MA+ VT BK BK 9 9 GND
RD 12 12
XCAN OUT
XCAN(H)
D-SUB Female 9-pole

WH TOUCH
CAN OUT
3 3 3 3 2 2 BN P6 J6 DF11-14
LIFT TOP MB+ OG BU BK 10 10 GND 16 16
5
960-108072 XCAN(L) BK
P3 J3 DISPLAY
9
SAFETY 4 4 4 4 3 3 WH 11
MB- VT RD 17 17 BK
4
EXIT BK
123456 BK START
8
SENSOR 4 4 7
Q2 1 1 14 14 NC 18 18 BU
3
NC
RD +5V DIRECT ON J9 P9 MnF
4P MnF
101-109255 RD
7
1 5 5 YL 4 CAN(H),OUT
RD 2 2 19 19
GN
2
WH GND BK
6
2 SEN1 IN (DIG) 1 1 6 6 BK 6 CAN(L),OUT
P9 J91
5mm 3 3
WH
OFF OG C,P2-1 +5V VIA RES. 20 20
1
BK GND
POWER IN/OUT RD 5
3
BK 4 4 2 2 7 7 BK
C RD
5 5
+5V DIRECT Switch setup
GND BK C,P2-7
OPTION 1 1 1 1
NC
8 8 J23 BN 12 EXIT C
NC
SHARP snap in
EE-SX4235A-P2
101-102822
CT 3-p WH
6 6
SEN2 IN (DIG) J11 P11 5 5
+12V
2 2 2
+3,3V EXT. CONNECTION
BK GND 1 1 Rx1 +5V
J/P2 RD/BK Back light
RD
7 7 POWER IN/OUT 7 7 3 3 3
OPTION
USB A type
RD +5V DIRECT 2 2 BK Tx1 +12V FFC 4P
ICAN(H)
ICAN(L)
LIFT BOTTOM 8 8 GND 4 4 4 J/P5 Touch
WH SEN3 IN(DIG) GND 960-108542 960-108361
+12V
+12V
PCB DC/DC
9 GND
10GND
SAFETY 9 9 5 5 5 (Chassis UI)
B A FFC 40P
14 NC
BK GND MnF USART, TIME J/P3 Data I/O
SENSOR
Q8
10 10 6 6 6
Converter T,P3-3 RD
J6
26P DF11 GND USART, TIME
1D/2D READER
1
2
4
6
1 AMP-CT
RD 7 7 7 RD
2 960-108171 J216 NC 1
Q4
P26 J26 8 8 8
P6
UPPER BIN
5mm WH 2
RD NC N.o in Data sheet OK 2
3 P1 P2 3 960-108167 9 9 9 RD
10
14
D BK BK SPI T,P2-10 WH BK D
1
2
4
6
9
BK 3
123456
1 +12V 1 1 +5V
10 10 10
RD
RD
BK
+5V RD PAIR: WH/BK
SHARP snap in CT 3-p 2 +12V 2 4 SPI 1 3 RD 960-109182
EE-SX4235A-P2 +5V BK GND
11 11 11 ON Q7 IR LED
Q
101-102822
3 GND +5V 3 SPI 2 2 BK T,P3-4 BK
4 4 12 12 12
RS232 P-I
BK D-Sub HD 15P
GND GND SPI 3 1 WH No Light. Invisible IR
B,P2-8
B,P2-6
B,P2-5
B,P2-7
GND
5
13 13 13
RS232 TX OFF RD
Little Red diode mounted on PCB
14 14 14 PAPER STACK
RS232 RX RD
Q7 PHT
J 15 15 15 HEIGHT SENSOR SHIELD
RD
RD
RD
BK
BK
BK
RESET
Q12
6471
16 16 16 960-960251
BOOT0 BK BK 4
EE
WH
P5
T,P1-18
10
SP Sensor J1 P1 RD 3
1
2
4
6
9
DF11 CHASSI GND T,P1-19 GY
E T,P1-20 YL 2 E
REGISTRATION P3 J3 J5 10P DF11 VACUUM BELT 1 1
Y P6 J6 J7 P7 J7 P7
BN
J1 P1 +3,3V RD 1 EDGE
GND 10
BELT MOTOR MOTOR 2 2
1
2
4
ICAN(L) 6
GND 9
1 1 +5V 960-111452 DETECTION DSD-2
ICAN(H)
RD +5V DIRECT RD
+12V
+12V
1 1 1 1 1 1 2 2 1 1 3 3 THICK PAPER
+12V
10 10
RD
10 10
+12V MA- BK WH SEN2 IN (DIG) MA- BK PLUG IN +12V RD BK SHIELD
M3 M2
2 2 3 3 2 2 4 4
M21H M21H CHASSI GND
GND BK GND MA+ GN BK GND MA+ GN GND
4 4 4 4 3 3 3 3 5 5
CAN(H) WH ICAN(H) MB+ RD 26P DF11 MB+ RD GND BK
6 6 6 6 960-108072 960-108072
H
6 6
K
4 4 4 4
960-109107 CAN(L) BK ICAN(L) MB- BU MB- BU AN/DIG I/0 A (0-3,3V) WH
14P DF11 123456 122-109257 123456 122-109257 7 7
P8 J8
GND BK
3 3 ON J9 P9 MnF ON J9 P9 MnF AN/DIG I/0 B (0-3,3V)
8 8
BN
P4 J4
Q10 DSD1 Double Sheet
Q11
F 7 7 1 1 1 1 1 1 9 9 BK F
P4 J4 Detector
GND McF 4P
POWER OUT
+5V
2 2
WH
2 2 OFF POWER IN/OUT
GND
2 2
OG C,P2-3
2 2
+12V
OFF POWER IN/OUT
GND
2 2
OG C,P2-2 CT 3P P1 J1 P2 J2 AN/DIG I/0 C (0-3,3V)
10 10 WH
Q10R 1 1
BLOWER (FAN1)
+
123456 +12V
8 8 1 1
+5V Switch setup BK C,P2-9
3 3
NC Switch setup BK C,P2-8
1 1 RD 1 1 1 1 1 1
+5V DIRECT GND
11 11 BK DF11-6P 960-108441 D,P2-1 RD
2 2
RD
-
ON +3,3V 9 9
RD
4 4
+3,3V
J11 P11 4 4
GND J11 P11 2 2 WH 2 2
PK
GY 2 2
RD
WH
2 2
SENS1 IN (DIG) AN/DIG I/0 D (0-3,3V)
12 12 WH RD
1 1
RD 1 12VDC
D,P2-7 BK
3 3
BK
YL TACHO SEPARATION
GND BK GND 1 1 5 5 1 1 3 3 13 13 2 2 T,P1-13 YL
3 3 BK 3 3 3 3
OFF 5 5 16P DF11 POWER IN/OUT OG L,P4-2 AUX S. IN (0-5V) POWER IN/OUT YE BK GND AN/DIG I/0 E (0-3,3V) YL FAN1-3 TACHO WH WH 2 DSD AN. BN 4 4 BN PWM FAN
2 2 SOL1 6 6 2 2 4 4 14 14 3 3
ICAN(H)
ICAN(H)
4 4 4 4
ICAN(L)
ICAN(L)
GND VT OD (36V/1,0A) GND GN RD +5V DIRECT AN/DIG I/0 F (0-3,3V) YL FAN2-3 TACHO BK BK 3 GND
Switch setup 7 7 TABLE EMPTY SENSOR 15 15 YL 4 4
+12V
+12V
+12V
+12V
10P DF11 5 5 5 5 5 5 TACHO McF 4P
BLOWER (FAN2)
9 GND
10GND
9 GND
10GND
BN WH SENS2 IN (DIG) AN/DIG I/0 G (0-3,3V) FAN3-3 SHIELD BK
14 NC
MnF
8 8 MnF 16 16 YL UPPER 1 1
6 6 J/P Q10R
VACUUM LID 6 6 WH
6 6 BK GND AN/DIG I/0 H (0-3,3V) FAN4-3 TACHO D,P2-2 RD RD +
J5 J6 7 7 17 17 YL 2 2 BK -
1
2
4
6
1
2
4
6
8P KK 7 7 TACHO
Q3
AN/DIG I/0 J (0-3,3V) SIDE FAN
10P DF11 SOLENOID TABLE EXTENSION +5V DIRECT
18 18 WH
FAN7-3 D,P2-8 BK
YL 3 3 YL
G McF 6-p 8 8 DF11-6P G
SENSOR 8 8 AN/DIG I/0 K (0-3,3V) EE,P2-4 2 2 T,P1-14 TACHO
P5 P6 1
Q10T-2 RD
9 9
SENS3 IN (DIG)
GND AN/DIG I/0 L (0-3,3V)
19 19 GY EE,P2-5
T,P4-8 WH
5 5
WH 2 PAPER DET.
BN 4 4 BN PWM
10
14
RD T,P2-12 BK BK
10
3 PWM
1
2
4
6
BK 9
1
2
4
6
BK 9
2 McF 8-p 10 10 20 20 YL 6 6
AN/DIG I/0 M (0-3,3V) EE,P2-6
RD
RD
RD
RD
RD
RD
+5V DIRECT
BK
BK
BK
BK
5mm WH RD RD 1 24-36VDC McF 4P
3 SW4-3 WH 11 11 SENS4 IN (DIG) 3 3 BLOWER (FAN3)
BK BK BK 4 GND 1 1 +
B,P2-14 B,P2-15
SHARP snap in SW4-4 BK 12 12 GND SHIELD
4 4
BK 960-108440
D,P2-3 RD
2
RD
2 BK -
CT 3-p 13 13 D,P2-9 BK VACUUM FAN
EE-SX4235A-P2 +5V DIRECT
B,P2-16 B,P2-13
101-102822 14 14 J/P Q10T LOWER
Q10T T,P1-15 YL 3 3 YL TACHO
SW5-3
SW5-4
WH
BK 15 15
SENS5 IN (DIG)
GND J3 P3 BN 4 4 BN PWM
16 16 1 1
+5V DIRECT +3,3V McF 4P
BLOWER (FAN4)
H 2 2 H
TACHO FAN8-3 YL 17 17 SENS6 IN (DIG) +5V
3 3
D,P2-5 RD
1 1
RD +
18 18 GND +12V RD EE,P1-1 D,P2-11 2 2 BK - REGISTRATION
4 4 BK FAN
19 19 +5V DIRECT GND
5 5
BK EE,P1-8
PWM TO FAN1 T,P1-16 YL 3 3 YL TACHO
20 20 SENS7 IN (DIG) DIG I/O N (0-5V) BN BN 4 4 BN PWM
21 21 6 6 PWM TO FAN2
GND DIG I/O P (0-5V) BN
22 22 7 7 PWM TO FAN3
+5V DIRECT DIG I/O Q (0-5V) BN McF 4P
BLOWER (FAN7)
23 23 8 8 PWM TO FAN4
SENS8 IN (DIG) DIG I/O R (0-5V) BN 1 1 +
9 9 BN PWM TO FAN7 D,P2-3 RD RD
24 24 GND DIG I/O S (0-5V) 2 2 BK -
PWM TO FAN8 D,P2-9 BK COOLING FAN
25 25 10 10 BN
I +5V VIA RES. DIG I/O T (0-5V) T,P1-17 YL 3 3 YL TACHO PSU:s AREA I
26 26 11 11
+5V VIA RES. DIG I/O U (0-5V) BN 4 4 BN PWM
DIG I/O V (0-5V) 12 12
P2 J110
P2
1
J21 FAN8 LOCATED IN FOLDER OR CREASER
GND CONTROLLED FROM FEEDER PCB'S
P1 J1 +55V OUT(PTC3/D3) 1 1
OG OG
1 2 2
A_LED_OUT
55V TO FOLDER/CREASER
+55V OUT(PTC4/D4) 2 2
OG OG
2 3 3
GND
OG 1 1 +IN
+55V OUT(PTC5/D5) 3 3 3 4 4 McF 4P
BLOWER (FAN8)
OG 2 2 +IN
+55V OUT(PTC6/D6) 4 4
OG
OG
OG
OG
4 J2 P2 -
B_LED_OUT
RD
1 1
RD +
J BK 3 3 -IN 2 2 BK - J
+55V OUT(PTC7/D7) 5 5
OG OG
5
P1 J1 1 1 +55VDC TO PCB "G" 9 9 A_PWM_OUT_0-5V McF 2P BK COOLING FAN
BK 4 4 -IN +55V OUT(PTC3/D3) OG G,P9-1
YL 3 3 YL
+55V OUT(PTC7/D7) 6 6 10 10
2 2 +55VDC TO PCB "H" T,P4-17 TACHO PCB:s AREA
1 +IN +55V OUT(PTC4/D4) OG EE,P1-5 WH B_PWM_OUT_0-5V
OG 1 H,P9-1
BN 4 4 BN FOLDER/CREASER
R
MnF
-OUT 7 7 7 3 3 +55VDC TO PCB "K" 11 11 C_PWM_OUT_0-5V
+24V_FeedBack PWM
P5 J5
BK BK OG 2 2 +IN +55V OUT(PTC5/D5) OG K,P9-1 WH
-OUT 8 8
BK BK
8 4 4 Q10T-3 BK
12 12 D_PWM_OUT_0-5V
BK 3 3 -IN
BK
WH
-OUT 9 9 BK 9 5 5 To DSD sensor 13 13 OUT D OC (50V/20mA)
BK BK 4 4 -IN 1 1
P3
CNT CHASSIS COUNTER DF11-6 OUT E OD (36V/1,0A) P316-2
14 14 WH
3
2
1
-OUT 10 10BK BK 10 6 6 OUT C OC (50V/20mA) 2 2
C
CT
OUT E OD (36V/1,0A)
-OUT 11 11 BK BK 11 7 7 15 15
J3
MnF PGND TO PCB "G" - + 1 RD OUT B OC (50V/20mA) 3 3 960-108169
-OUT BK G,P9-2 000000 +12V
OUT F OD (36V/1,0A) P316-3
WH
-OUT 12 12 8 8 16 16
PGND TO PCB "H" 2 WH
-OUT BK H,P9-2 ON/OFF min 3,3V OUT A OC (50V/20mA) 4 4
3
2
1
3 BK OUT F OD (36V/1,0A)
9 9 BK RD 17 17
PGND TO PCB "K" GND +12V
GND
VFB
K MnF -OUT K,P9-2 SH.LINK 4 BK
GND
5 5
P2 J2 Split PCB
J1 P1 K
ICAN(H)
PTC375 x7 BK 7 7
ICAN(L)
10 10 GND
J4 P4
5 6 6
+ +
COUNTER-
+12V
P3
+12V
+12V
+12V
J3
GND
GND
GND
11 11 _ 18 18 +12V RD 1 1 1 1
NC
NC
SHORTED
SHORTED
+55V OUT(PTC1/D1) 1 1 12 COUNTER
5 5
OG OG OG 1 1 +IN 12 12 GND OG 2 2 2 2
J6
_ 24 24
+55V OUT(PTC2/D2) 2 2 13
10
3 3 3 3
1
2
3
4
5
6
7
8
9
OG OG
P3 J3 3 3 BK 2 2 -IN MnF
4 4 4 4
P6
1-5
1-5
OG 1 1 +IN 4 4 J4 P4
L
5 5 5 5
BK 10
5 5 14
- -
1
2
3
4
5
6
7
8
BK 9
BK 2 2 -IN -OUT BK BK 1 1 6 6 6 6
RD
RD
6 6 15 2 2 BK
SHORTED
SHORTED
-OUT BK BK 7 7 7 7
960-108695 3 3 8 8 8 8 L
L MnF 15p MNL female 4 4
6-10
6-10
9 9 9 9
OG 5 5 10 10 10 10
BK
BK - 6 6 B,P2-2
B,P2-4
B,P2-3
B,P2-1
J4
10
McF McF
- + OG
1
2
3
4
5
6
7
8
9
BK 960-108695 MnF
OG + + OG
OG + - BK PTC375 x7
J2 P2 FAN7-1 P4
10
1
2
3
4
5
6
7
8
9
OG - BK
REL301 55V PSU BK P1 J1 +24V OUT(PTC3/D3) 1 1
RD
FAN1 +
FAN1-1
M +24V OUT(PTC4/D4) 2 2 FAN2+
M
RD 1 1 +IN RD FAN2-1
BK,2
31 34
BU N PSU-2 RD 2 2 +IN +24V OUT(PTC5/D5)
+24V OUT(PTC6/D6)
3
4
3
4
RD
FAN3 +, FAN7+
FAN4 +
FAN3-1
BK,2
BK 3 3 -IN RD FAN4-1
+24V OUT(PTC7/D7) 5 5 FAN8 +, Q10T+
BK 4 4 -IN RD
11 14 (55V) 6 6 24V TO PCB "L"
L +24V OUT(PTC7/D7) RD
D
BK,1 BN 7 7
B
MnF FAN1 -
-OUT BK FAN1-2 SOL1
J2 P2 8 8
BK,1 FAN2-
-OUT BK FAN2-2
-OUT 9 9 BK FAN3 -, FAN7- FAN3-2
A1 A2 GND
1 1
BK
GND TO PCBs "T", "G"
T,P6-9 -OUT 10 10BK FAN4 - FAN4-2
N Meanwell RSP-1000-48 +12V (1) (PTC1/D1)
2 2
RD
+12VDC TO PCBs "T", "G"
T,P6-1 -OUT 11 11 BK FAN8 -, Q10T- N
3 3 GND TO PCBs "T", "G" 12 12BK GND TO PCB "L"
GND BK T,P6-10 -OUT
4 4 +12VDC TO PCBs "T", "G"
+12V (1) (PTC1/D1) RD T,P6-2 MnF
5 5 GND TO PCB "H", "J"
GND BK PTC375 x7 FAN7-2
J4 P4
H,P5-9
6 6
CONNECTION TO DOWNSTREAM UNIT

WH +12VDC TO PCB "H", "J" 14P MnF
RD-BK RD-BK 960-108165 +12V (2) (PTC3/D2) RD H,P5-1
24V PSU GND
7 7
BK
GND TO PCB "H", "J"
H,P5-10 +24V OUT(PTC1/D1)
1 1 RD
RD
6
MAINS POWER TO ANTISTATIC
24V OUT Extern.

8 8 +12VDC TO PCB "H", "J" 2 2 7
+12V (2) (PTC3/D2) +24V OUT(PTC2/D2)
PSU-3 RD H,P5-2 RD RD 24V OUT Extern.
GND 9 9 3 3
REL302 +12V (3) (PTC5/D3) 10 10 RD +12VDC TO SW2 4 4
KIT IN FOLDER/CREASER
O GND 11 11 -OUT 5 5 BK
BK
13 GND OUT Extern. O
12 12 BK +12VDC TO SW2 -OUT 6 6 14
N
+12V (3) (PTC5/D3) BK BK
+
GND OUT Extern.
BK,2 BU RD 13 13 GND TO PCB "K","Y"
GND BK K,P5-9 960-108695
31 34
P1 J1
MnF
14 14 +12VDC TO PCB "K","Y" J308
+ RD +12V (4) (PTC7/D4) RD K,P5-1
GND 15 15 GND TO PCB "K","Y"
11 14 - BK BK K,P5-10 DO NOT USE EMPTY PINS BECAUSE 8P MnF FITS
L
J27 1 1
BK,1 BN RD +12V(IN) +12V (4) (PTC7/D4) 16 16 RD GND TO PCB "K","Y" K,P5-2 EMPTY PINS
1 - BK RD
2 2
+12V(IN) GND 17 17 BK GND TO UI
P107-4
2
BK,1 A1 A2 RD
3 3
+12V(IN) +12V (5) (PTC9/D5) 18 18 RD +12VDC TO UI
P107-1
BK,2 Meanwell RSP-320-24 4 4
GND 19 19 BK GND TO UI
3 +12V(IN) P107-3
P GN/YE 5 5
+12V(IN) +12V (5) (PTC9/D5) 20 20 WH +12VDC TO UI
P107-2 P
6 6
Mate n Lok BK GND GND 21 21
3-P 7 7
BK GND +12V (6) (PTC12/D6) 22 22
RD-BK WH 8 8
BK GND GND 23 23
9 9 GND +12V (6) (PTC12/D6) 24 24
10 10 GND GND 25 25
J/P316
5 5 10P McF
+12V (6) (PTC12/D6) 26 26
2 2 26P DF11
WH WH T,P5-1
3 3
Q WH WH T,P5-3 Q
4 4
1 1
RD/BK RD/BK LIFT SAFETY SWITCHES
6 6
6-p Molex McF
DD GND
+12V (1) (PTC1/D1)
1
2
J2 P2
1
2
BK
RD
TOP INTERLOCK
SWITCH
T,P4-11
BOTTOM INTERLOCK
SWITCH
T,P4-14
RD 3 3
RD GND BK
++-
4 4 SW4 SOFT
PSU-1
R RD +12V (1) (PTC1/D1) RD McF 10P SW5 SOFT R
5 5 1
AC POWER SWITCH BK GND
6 6
BK RD
2
12V OUT Extern. WH 3 4 BK T,P4-12 WH 3 4 BK T,P4-15
BK 960-108165 +12V (2) (PTC3/D2) RD RD 12V OUT Extern.
BK,2 2 1
BK,2 BK,2 N BK GND
7 7
BK BK
3 RD
SW2 HARD SW3 HARD
P1 J1
GND OUT Extern.
SW15
BK,1 4
BK,1 BK,1 L +12V (2) (PTC3/D2)
8 8
RD BK
4 GND OUT Extern. BK 1 2 RD-BK 1 2 RD-BK
GND 9 9 BK 5
1 1 10 10 6
RD RD +12V(IN) +12V (3) (PTC5/D3) RD
++
2 2 7
RD RD
3 3
+12V(IN) GND 11 11 BK
RD RD +12V(IN) +12V (3) (PTC5/D3) 12 12 RD 8
AC POWER IN 4 4
+12V(IN) 13 13 9
CONNECTION TO FOLDER/CREASER
FILTER 16A GND

S INLET FN2030-16-06 5 5 14 14 BK S
+12V(IN) +12V (4) (PTC7/D4) 10
6 6 RD
BK BK GND GND 15 15
-
BU N BU BU N BK,2 7 7 BK J307
GN/YE GND GND GND GND BK BK
8 8
GND +12V (4) (PTC7/D4) 16 16
RD P12
BN L BN BN L BK,1
F1 T12A/6.3A
BK BK
9
GND
9 GND GND 17 17
RD-RD 12 +12VDC
12VDC PSU +12V (5) (PTC9/D5) 18 18 BK-BK 11 GND
10 10 GND RD-RD 910
Fuse T12A 100 - 140 Vac GND 19 19
Meanwell LRS-75-12 +12VDC INTERLOCK JUMPER
Fuse T6.3A 200 - 240 Vac BK-BK 8 GND
+12V (5) (PTC9/D5) 20 20 Molex 5559 12-P
10P McF
Rating 100-240 Vac 8-4 A GND 21 21 7
4
3
RD-RD 56
-
-
-
-
-
-
-
-
-
-
Leakage current tot 4,55mA w std inlet 10A, 4,85mA w FN-2030-16 +12V (6) (PTC12/D6) 22 22 +12VDC
T BK-BK GND WH T
GND 23 23
RD-BK 34 <<INTERLOCK
+12V (6) (PTC12/D6) 24 24 RD-BK 2 INTERLOCK>>
EXT. UNIT NOT CONNECTED
GND 25 25 1
+12V (6) (PTC12/D6) 26 26
26P DF11
U U
142-115911A
1 2 3 4 5 6 7 8 9 10 11 12 13 14 24 25 26 27 28
18 February 2022
Pro XL 8-2 Wiring
8.2 Master Wiring Diagram - Creaser
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
PCB PLACEMENT PHT

BU
RD
Connector: Q23Pht
3 WH
4 BK
-
-
Connector: Q24Pht
3 WH
4 BK
-
-
PhotoDiode
Q20 PHT Q20 DF11
DF11
BU 1 1 WH
2
RD 2
B
BK
EDGE DETECTION-1 3 3
GN BK
4 4
YL RD
Q20 IR LED
A
McF
Connector: Q23LED Connector: Q24LED
LED GN
YL 2 BK 2 BK
C 1 RD 1 RD
RD
RD
RD
BK
BK
BK
McF McF
P5
10
1
2
3
4
5
6
7
8
9
ROLLER
J5
M21H J7 P7 DRIVE
GND 10
1
2
3
4
5
6
7
8
GND 9
MnF
MOTOR
ICAN(H)
MnF
ICAN(L)
GND
+12V
+12V
+12V
1 1 OG 1 1
D MA- GN
2 2 VT 2 2
MA+ BK
M21
B
3 3 3 3
960-108072 MB+ OG BU
4 4 4 4
MB- VT RD
123456 101-102441
ON M21
101-109255
CPU APP 32
MnF
1 1
123456 J1 P1 OFF GND
2 2
OG
BK
E
P5 J5 960-108070 ON +3,3V
+5V
1
2
1
2 Switch setup
J9 P9
BK
1 1
OUT E OD (36V/1,0A) OFF +12V
3 3
2 2 4 4
BK OUT E OD (36V/1,0A) GND
3 3 5 5
B
BK OUT F OD (36V/1,0A) GND BK
C
4 4 6 6
BK OUT F OD (36V/1,0A) AN/DIG I/0 A (0-3,3V) WH
5 5 7 7
A
GND GND BK
8 8
F 10 10 AN/DIG I/0 B (0-3,3V) WH
+12V 9 9 BK
6 +12V GND
Res. 235 ohm RD 6 10 10WH
8 8
Res. 235 ohm RD +12V
20 20
ICAN(H)
ICAN(L)
24 24
+12V
+12V
+12V
8 GND
9 GND
10GND
NC
NC
13 NC
14 NC
NC
7 NC
CONNECTION
J6
11
12
P2 J21 J7 P7
G
1
2
3
4
5
6
D 1
BK 2 GND XCAN(H) 1
1 P6
XCAN OUT
11
BK 10
12
13
14
D-SUB Female 9-pole
2 WH
TERMINATION PLUG
CAN OUT
1
2
3
4
5
6
7
8
9
A_LED_OUT 2
RD XCAN(L) 2
RD
RD
RD
BK
BK
BK
9
3 3
TERMINATION(S) ONLY CONNECTED IF THE

9
4
EXIT BK
UNIT IS THE FIRST OR/AND LAST MACHINE

8
4
4 4
8
3
18 18 NC
3
7
5
GND 5
7
GN
2
2
6
6
H 6 6
1
+5V VIA RES.
1
RD
Q25 CT 3P P/J206 P4 J4 NC
7
8
7
8 J23
1 1 RD 1 1 1 1 NC
RD +5V DIRECT
2 2 WH 2 2 2 2
J8 P8
WH SENS1 IN (DIG)
3 3 3 3
TERMINATION PLUG
3 3 BK
IN THE SYSTEM.
BK GND
1
1
4 4
D-SUB Male 9-pole
6
CAN IN
2
EXIT SENSOR 1
6
XCAN(H) 1
2
XCAN IN
7
WH
3
2 2
8
3
XCAN(L) BK
4
I McF 4P
3 3
9
4
START
5
SWX BK
4 4
9
5
GN
1 2 NC
5 5
GND
WH 23 23 SW22 IN (DIG)
3 4
6 6
SW22 SOFT P24
CONNECTION TO FEEDER
START RD
J12
+12V to PCB "B"
WH 3 4 BK 24 24 GND
25 25 +5V VIA RES.
NO NO NO NO
12
+12VDC RD-RD CONNECTION MnF
GND(12V) 11 26 26 +5V VIA RES.
BK-BK 1
+12V to PCB "A" SW21 HARD
J10 P10
+12VDC 10 OG
J GND(12V) 9
RD-RD
BK-BK 1 2 2
BK
8
1 1 D,P9
P3 J33
CONNECTION 7
+12V to PCB "C" & "D" TOP COVER SWITCH SOL21 CHASSIS COUNTER
DF11-6 +12V
+12VDC 6
RD-RD RD/BK 2 2
5 +12V
CONNECTION GND BK-BK - 3 3 3
<<INTERLOCK 4 0000000 + +12V
1
RD 4 +12V +12V
3 2 4 4 4
RD/BK ON/OFF min 3,3V BK GND ICAN(H) RD
C,P6
INTERLOCK>>
2 GND 3 5 5 5 5
WH N_DIG I/O NC
10
11
12
13
14
1 4 BK
1
2
3
4
5
6
7
8
9
SH.LINK 6 6
5
RD
ICAN(L) BK
BK
COUNTER-
K 7 7
NC
8 8
GND
GND 9 9
12 12 10
GND 10
11 11
NC
RD
RD
RD
BK
BK
BK
12 12
NC
NC 13 13
D,P5
10
1
2
3
4
5
6
7
8
9
ICAN(H)
ICAN(L)
L +12V NC 14 14
+12V
+12V
GND
GND
GND
NC
NC
J6
10
1
2
3
4
5
6
7
8
9
RD
RD
RD
BK
BK
BK
P6 P5
10
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
BLADE
RD
RD
BK
BK
J5
Q22 M21H J7 P7 DRIVE 2
GND 10
POSITION
1
2
3
4
5
6
7
8
GND 9
M MnF
MOTOR
+12V
+12V
+12V
MnF
ICAN(H)
GND
BLADE DRIVE 2
ICAN(L)
1 1 OG 1 1 GN
P1 J1
1 MA-
2 2 VT 2 2
MA+ BK
3mm
2 2 2 +5V 150R
960-108072 MB+
3 3
OG
3 3
BU M23
4 4 4 4
3 RD1 1 +5V 150R MB- VT RD
123456 101-102441
ON
M23
1 1
CT 3P +5V DIRECT 1 1
MnF 101-109255
2 2 OG
WH SEN1 IN (DIG)
960-960217 OFF
N 2 2
3 3 GND BK
BK GND
SHARP GP1S51 4 4 Switch setup
5 5
+5V DIRECT
SEN2 IN (DIG)
J9 P9
6 6
GND
7 7
D
P34 8 8
26-P
RD-BK 1
O
WH 2
3
P3 J3
4 P8 J8
1 1
Molex 5557 POWER IN/OUT
4-p 2 2
3 3
NC
P110 4
5
4
5
GND
Sen IN 0-5V
ICAN(H)
P
ICAN(L)
1 +55VDC TO PCB "B" 6 6
55V FROM FEEDER
+12V
+12V
+12V
OG WH OD 36V/1A
8 GND
9 GND
10GND
7 7
11 NC
12 NC
13 NC
14 NC
2
NC
7 NC
+55VDC TO PCB "C"
OG 8 8
3
1
2
3
4
5
6
+55VDC TO PCB "D"
OG
-
OPTIONAL CR1
C,P6-4
C,P6-6
J12-6
J12-5
-
Q 7 PGND TO PCB "B"
BK
RD
RD
RD
BK
BK
BK
8 PGND TO PCB "C"

BK
P5
10
9
1
2
3
4
5
6
7
8
9
PGND TO PCB "D"

BK BLADE
- J5
M21H J7 P7 DRIVE 1
GND 10
1
2
3
4
5
6
7
8
GND 9
- Q21 MnF MnF

MOTOR
ICAN(H)
ICAN(L)
GND
+12V
+12V
+12V
POSITION 1 1 OG 1 1
R
BLADE DRIVE 1 MA- GN
1 2 2 2 2
MA+ VT BK
M22
C
15P MNL male 3 3 3 3
MB+ OG
3mm
2
P1 J1 960-108072
MB-
4 4
VT
4 4
BU
RD BK OG
3 RD1 1 +5V 150R 123456 6 ON = CAN end termination YL RD
34HY (Big motor)
ON M22
101-102441
6
MnF
1 1
1 1 OG P110-2
101-109255 (CABLE SIDE)
+5V DIRECT
OFF 1 2 3 4 5 ON
CT 3P 2 2
WH2 2 GND BK P110-8
SEN1 IN (DIG)
960-960217
J9 P9
S BK3 3
GND Switch setup
SHARP GP1S51 OG BK
4
5
4
5
+5V DIRECT OFF MY 1402 (Small motor)
YL RD
ICAN(H)
SEN2 IN (DIG)
ICAN(L)
6 6
+12V
+12V
Switch setup
+12V
GND
GND
9 GND
10GND
(CABLE SIDE)
11 NC
12 NC
13 NC
14 NC
NC
NC
7 7
8 8
J6
7
8
1
2
3
4
5
6
26-P
T P3 J3 P6
BK 10
11
12
13
14
7
BK 9
1
2
3
4
5
6
8
RD
RD
RD
BK
D,P5-10
D,P5-1
D,P5-2
D,P5-4
D,P5-6
D,P5-9
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
18 February 2022
Pro XL 8-3 Wiring
8.3 Master Wiring Diagram - Folder
ROLLER
CPU APP 32 J10 P10 P5 J5 M21H J7 P7 M41
DRIVE
MOTOR
B
MnF
1 1 1 1 1 1 OG 1 1 BN
+12V RD RD +12V MA-
2 2 2 2 2 2 2 2
+12V RD RD +12V MA+ VT BK
+12V
3 3 3 3
+12V MB+
3 3
OG
3 3
BU M41
4 4 4 4 4 4 4 4
ICAN(H) RD RD ICAN(H) MB- VT RD
5 5 5 5
NC NC
ICAN(L)
6 6
BK BK
6 6
ICAN(L)
MnF 101-109255
7 7 7 7
NC
GND
8 8 8 8
NC
GND J9 P9 MnF
GND9 9 BK BK 9 9 GND POWER IN/OUT
1 1
OG P110-12
GND10 10 BK BK 10 10 GND GND
2 2
BK P110-14
11 11 960-108072
NC
12 12
NC
NC 13 13 123456
ON
NC 14 14
J6 P6 P5 J5
OPTIONAL Switch setup
OFF +12V
1
2
1
2
RD RD
1
2
1
2
+12V
DELIVERY BELT UNIT
BLADE
+12V
+12V
3 3
RD RD
3 3
+12V
+12V
A5 ROLLER
4 4 4 4 POSITION
M21H J7 P7 MnF
DRIVE 1
MOTOR NC
5 5
RD RD
5 5
ICAN(H)
NC SHIELD CHASSI GND SHIELD CHASSI GND SENSOR
1 1 6 6 6 6
C
MA- BN BK BK ICAN(L)
MA+
2
3
2
3
BK
M42
NC
7
8
7
8
7
8
7
8
NC J7 P7 MnF Q50
MB+ BU GND GND 1 1 OG
4 4 GND9 9 BK BK 9 9 MA- J/P304
P3 J3 MB- RD
101-109255 GND10 10 BK BK 10 10
GND
GND MA+
2 2
VT
Q41 3 3 1 1 1
M21H
1 1 11 11 MB+ OG A,P1-1 RD RD RD +3,3V
POSITION NC 960-108072 4 4 2 2 2
BLADE DRIVE 1 2 2 12 12 MB- VT A,P1-10 WH WH WH SIGN.
1 WH SENS1 IN (DIG) J9 P9 NC
13 13 P9 J9 123456 BK
3 3
BK BK
3
GND
H
3 3 A,P1-9
NC
ON
Q54
2 BK GND
NC 14 14 MnF
3mm 4 4
960-108072 POWER IN/OUT 1 1
OG P110-13 P110-4 OG
1 1
POWER IN/OUT
3P CT
3 5 5
GND
2 2
BK P110-15 P110-10 BK
2 2
GND OFF J/P-Q54 SENSOR
6 6 123456 Switch setup Crease Tray
SOL41 CHASSIS COUNTER DF11-6 CT 3-p 7 7 ON 5 5
4
1
4
1 RD 3 1
-
0000001 + 960-960217
8 8
26-p
OFF P11 J11 A,P1-2 RD RD
P3 J3
6 6
P6 J6
1
ICAN(H)
J5 P5 WH 2 2 WH 2 2
ICAN(L)
+12V
2 MnF A,P1-8 WH
SHARP GP1S51
+12V
+12V
+12V
1 1 7 7 BK 3 3 BK 1 3
ON/OFF min 3,3V
Switch setup
GND
9 GND
10GND
3 K,P9-1 OG POWER IN/OUT A,P1-7 BK
14 NC
NC
NC
GND
SH.LINK 4 BK 1 1 P1 J1 +12V
1 1
RD RD
1 1
+12V K,P9-2 BK
2 2
GND 6P McF
J6
5 2 2 2 2 960-108072 OPTICAL
1
2
3
4
5
6
7
8
COUNTER- 2 2 +12V RD RD +12V
3 3 RD 1 1 +5V 150R 3 3 3 3 123456 BLADE SHIELD DISTANCE METER
+12V +12V CHASSI GND
RD
BK 4 4
+12V
ICAN(H)
4 4
RD RD
4 4
ICAN(H) ON J7 P7 DRIVE 2 P6 SHIELD
CHASSI GND
10
14
GND
1
2
3
4
5
6
7
8
BK 9
5 5 5 5
WH 5 5 NC MnF
MOTOR SW45
RD
RD
RD
NC
BK
BK
6 6
N_DIG I/O
ICAN(L)
6 6
BK BK
6 6
ICAN(L) OFF MA-
1 1 BN
PWM FAN8 J310-2 BN P_DIG I/O 2 2
7 7 7 7 7 7
NC Switch setup MA+ BK WH 9 9 WH x x BK
PWM FAN9 J310-4 BN
8 8
Q_DIG I/O NC
GND
8 8 8 8
GND MB+
3 3
BU M43 BK 10 10
4 4
9 9 GND 9 9 BK BK 9 9 GND MB- RD
9 BK
10 BK
LAMP1 CONTROL WH S_DIG I/O
RD
RD
J304-12
10 10 GND 10 10 10 10GND 101-109255
BK BK
P6
1
2
3
4
5
6
7
8
11 11 11 11 4 960-107077
NC
12 12 11 11 RD 1 1 +12V STACKER
12 12
123456
J1 P1 13
NC
13 NC 1 1
MnF
J6 JST A,P1-3 RD
12 12 WH 2 2 PWM
LED LIGHT
GND 10
ON POWER IN/OUT DF11 1 1 A,P3-9 WH
1
2
3
4
5
6
7
8
GND 9
OG P110-1
2 2 13 13 BK 3 3 GND
ICAN(H)
14 14 NC
ICAN(L)
1 1 +24VDC 2 RD BK
LAMP1
+12V
+12V
+12V
GND
GND
NC
NC
BK P110-7 A,P1-11
+3,3V RD J304-1 Q50 +3,3V 2 5
OFF
OUT
2 2
A
+5V RD J304-5 Q54 +5V
J9 P9 3 3
PCB WHITE LED LAMP
Q42
3 3 5P CT
+12V RD J304-11 LAMP1 +12V POSITION
GND
4
5
4
5
BK BLADE DRIVE 2 1 1 +5V
M46 MOTOR
POSITION Q49 P3 J3
GND 4 4
GND BK 1 WH 2 2
SENS1 IN (DIG) SENSOR 123456 4-P
ON J10 P10
6 6
AN/DIG I/0 A (0-3,3V) RD 3 3
GND
If PCB "C" is connected 1 1 1
7 7 2 BK RD RD +5V
123456
4P MnF x 3
GND
8 8
BK J304-7 Q54 GND 3mm 4 4
5mm 2 2 2
5 5 WH Sensor 1 1 1 RD
ON
AN/DIG I/0 B (0-3,3V) WH J304-6 Q54 SIGNAL 3 RD WH M50
GND
9 9 BK J304-3 Q50 GND
INFEED SENSOR 6 6
3
BK
BK
3 3 GND OFF J8 P8
OG
VT 2 2
YL
GAP SET
ROLLER 1
AN/DIG I/0 C (0-3,3V)
10 10 WH 7 7 SHARP snap in CT 3-p 4 4 McF 3 3 M50 BK 24 24 BK
Switch setup
J304-2 Q50 SIGNAL CT 3-p OG BK MOTOR
+5V OUT1A 1 1
OFF
EE-SX4235A-P2
11 11 BK KK RD
GND J304-13 LAMP1 GND Q40 PHT 8 8
26-p
101-102822
5 5 2 2 VT 4 4
OG 128-109763 BK 25 25 BK
AN/DIG I/0 D (0-3,3V)
12 12 WH BK 4 960-960217 WH Sensor 2 MA OUT2A 3
13 13
Q40 RD 3 SHARP GP1S51 P3 J3 Switch setup 6 6 3
Q48
OUT1B
AN/DIG I/0 E (0-3,3V) WH M45 MOTOR BK GND OUT2B 4 4
M45 1 1 RD
M21H
14 14 2 OG 25P DSUB
AN/DIG I/0 F (0-3,3V) RD 1 1 RD POSITION 7 7 2 2 GAP SET
15 15 1 RD +5V OUT1A 5 5 VT YL
AN/DIG I/0 G (0-3,3V) RD BK 2 2
BK
SENSOR
8 8 6 6 3 3 M45 ROLLER 2
CHASSI GND CHASSI GND
P1 J1
D
OG BK MOTOR
3 3 1 WH Sensor 3 MB OUT2A 7
MM
BK BK RD 7 4 4
9 9 VT OG 128-109763
20 20 RD
4 4
RD
KK
2 2 +5V 150R 5mm 2
WH BK GND
OUT1B
OUT2B 8 8
AN/DIG I/0 M (0-3,3V) BK 4 3
BK
RD 1 1 +5V 150R 26P DF11 OUT1A 9 9 1 1 RD
ICAN(H)
M46
ICAN(L)
RD 3 OG
J2 P2
McF SHARP snap in 2 2 GAP SET
+12V
+12V
+12V
CT 3-p 10 10
Q40 IR LED
GND
GND
GND
2 VT YL
EE-SX4235A-P2
MC OUT2A 11 M46 ROLLER 3
NC
NC
3 3
M04L
1 101-102822
OUT1B 11 OG
1 1 BK MOTOR
J5
10
GND 2 2 BK OUT2B 12 12 4 4 128-109763
1
2
3
4
5
6
7
8
9
VT OG
Q51
A_LED_OUT RD M50 MOTOR
GND
3 3 OUT1A 13 13
BK FOLD EXIT SENSOR POSITION 960-110864
4 4 RD P5 SENSOR
14
MD OUT2A 15
14
BK 10
B_LED_OUT
Q45
1
2
3
4
5
6
7
8
BK 9
5 5 J/P306 OUT1B 15
P4 J4
RD
RD
RD
BK
KK 1
CT 3P
P/J-Q45 960-108070
GND
6
BK
6 RD
BK 4 4 BK 4
RD OUT2B 16 16
1 1 RD 1 1 1 1
C_LED_OUT
- - 5mm 2
WH
COOLING UNIT
M04L 960-112803
RD +5V DIRECT GND 3 3 RD 3 3 16P
2 2 2 2 RD BK
2 2 WH WH SENS1 IN (DIG) D_LED_OUT 8 8 RD - - 2
3 3 BK 3 3 3 3 12 12 - - 1 Q52 PHT SHARP snap in CT 3-p
BK GND EE-SX4235A-P2
PLUG IN J2
4 4 4 4 +12V 17 17 JST
P6
101-102822
10
11
12
13
14
+5V DIRECT
1
2
3
4
5
6
7
8
9
CREASE EXIT SENSOR 5 5 5 5
GND 7 7 BK 4P DF11 1 1
96997 6 6
J310-1 YL
6 6
SENS2 IN (DIG) RD +24VDC
TACHO GND 18 18 J/P305 CT
Q52 LED(IR) J6 2 2
GP2A200LCS0F 7 7 1
GND10
11
12
NC 13
NC 14
FAN8
+-
+5V DIRECT 1 1
1
2
3
4
5
6
7
8
GND9
3 3
ICAN(H)
ICAN(L)
RD
GND
McF 6P
8 8
NC
NC
NC
NC
ICAN(H)
+12V
+12V
+12V
ICAN(L)
2 2 2 BK
+12V
+12V
+12V
J310-3 YL SENS3 IN (DIG)
4 GND
GND
9 GND
10GND
9 9 4
NC
NC
13 NC
14 NC
NC
NC
TACHO GND 3
10 10
BK FOLD
J5
2P McF
11
12
FAN9 +5V DIRECT 4-P
J7 P7
1
2
3
4
5
6
7
8
KNIFE
M21H
DF11
P9 J9
11 11 SENS4 IN (DIG)
12 12 GND
P3 J3
MOTOR P5
Q47
1 1 BN
E
13 13 MA-
BK 10
11
12
13
14
1
2
3
4
5
6
7
8
9
+5V DIRECT POSITION 2 2
RD
RD
RD
BK
BK
14 14 MA+ BK
SWX 15 15
SENS5 IN (DIG) FOLD KNIFE CAM
1 WH
1
2
1 +5V
2 MB+
3 3
BU M44
GND SENS1 IN (DIG) 4 4 H,P11-2
1 2 16 16 3 3 MB- RD
+5V DIRECT 2 BK GND H,P11-1
3 4 17 17 SW44 IN (DIG) 3mm 4 4 MnF 101-109255
+12V PCB "MM", "K"
18 18 3 RD 5 5
OG
GND
BK
19 19 6 6
NO NO NO NO
+5V DIRECT
CONNECTION
P9 P5
10
J7 P7
MnF
20 20 7 7
J/P302
1
2
1
2
3
4
5
6
7
8
9
SENS7 IN (DIG) CT 3-p
21 21 8 8 J3 P3
22 22
GND
1 1 960-960217 26-p
J9 J5 OG 1 1 OG 1 1 BK
1
DELIVERY
TERMINATION PLUG
GND 10
+5V DIRECT
XCAN OUT
XCAN(H) +5V 1 1 2 2 GN
D-SUB Female 9-pole
WH SHARP GP1S51 VT 2 2 VT
POWER IN/OUT 1
2
1
2
3
4
5
6
7
8
GND 9
CAN OUT
J12
5
WH23 23 2 2
M47 BELT
ICAN(H)
SW42 IN (DIG)
P1 J1
ICAN(L)
2 2
5
XCAN(L) 3 3
GND
BK OG 3 3 OG
+12V
+12V
+12V
GND
NC
NC
SW42 SOFT
TERMINATION(S) ONLY CONNECTED IF THE
9
SENS1 IN WH RD 7
5
3 4 BK 24 24 3 3
UNIT IS THE FIRST OR/AND LAST MACHINE
9
WH GND 3 3 4 4 MOTOR
4
EXIT BK VT 4 4 VT
8
Switch setup GND BU 11

4
12
RD-RD 25 25 4 4 2 2 +5V 150R BK
8
+12VDC +5V VIA RES.

3
11 NC 122-109257
3
7
GND(12V) BK-BK 26 26 5 5
SW41 HARD +5V VIA RES 270. RD 1 1 +5V 150R
7
GN
2
J7 P7
10 GND
+12VDC RD-RD
1 2 P6 J6
6
RD-BK
K
6 6
J5 P5
6
9
BK-BK +5V VIA RES.
1
GND(12V) RD MnF
1
J23
8 7 7 1 1 OG 10 10 1 1 RD
NC OG OG
7
6 TOP COVER SWITCH NC
8 8 +12V
1 1
RD RD
1 1
+12V
MA-
2 2 11 11 2 2 DELIVERY
+12VDC RD-RD MA+ VT VT VT YL
GND(12V) 5
BK-BK +12V
2 2
RD RD
2 2
+12V MB+
3 3
OG OG
12 12
OG
3 3
BK M49 ROLLER DRIVE
P6 J6 J8 P8
3 3 3 3
<<INTERLOCK 4
RD-BK +12V +12V 4 4
VT 13 13 VT 4 4 MOTOR
TERMINATION PLUG
960-108072
M21H
INTERLOCK>> 3
RD-BK 4 4 4 4 MB- VT OG
1
128-109763
1
ICAN(H)
D-SUB Male 9-pole
2
123456 ICAN(H) RD RD
IN THE SYSTEM.
6
5 5 5 5
CAN IN
1 1
6
1 1 1 NC 960-108072
ON J8 P8
2
XCAN IN
RD +12V XCAN(H) WH NC
7
2 2 6 6 6 6
7
123456
3
+12V PCB "A", "B", "H" 2 2 ICAN(L)

3
XCAN(L) BK ICAN(L) BK BK
RD +12V OG 5 5 OG
8
3 3 7 7 7 7
8
ON
4
3 3
OFF NC
4
+12V START BK NC 6 6
VT 14 14 VT SOLENOID
9
4 4 8 8 8 8 OD 36V/1A VT
9
4 4 GND
5
GN
ICAN(H) NC GND 7 7
5 5 GND
5 5
GND 9 9 BK BK 9 9 GND
OFF 8 8
OG OG
SOL42
DELIVERY
P24
NC 6 6
GND 10 10 BK 10 10GND RD
6 6
ICAN(L) START RD BK
11 11 Switch setup
VT ROLLER BRAKE
7 7 NC
NC CONNECTION 12 12
8 8 NC
GND
BK 9 9 GND P9 J9 13
14
13 NC
14 NC
BK 6 6 BK
BK 7 7 BK
10 10 MnF
BK GND 1 1
OG POWER IN/OUT
2 2 BK 8 8 BK
BK GND
BK 9 9 BK
+12V PCB "E", "D", "C"

CHASSI GND CHASSI GND
4 x AWG16
14P MnF
P110
12 +55VDC TO PCB "B"
55V FROM FEEDER
OG B,P9-1
13 +55VDC TO PCB "C"
OG C,P9-1
14 PGND TO PCB "B"
BK B,P9-2
15 PGND TO PCB "C"
BK C,P9-2
1 +55VDC TO PCB "D"
OG D,P9-1
2 +55VDC TO PCB "E"
OG
3
4 +55VDC TO PCB "H", "K"
OG H,P9-1
5
7 PGND TO PCB "D"
BK D,P9-2
8 PGND TO PCB "E"
BK
9
10BK PGND TO PCB "H", "K"
H,P9-2
11BK
15P MNL male
+24VDC TO PCB "MM"
P308 PGND TO PCB "MM"

McF 4P
BLOWER (FAN8)
1 1 1 RD +
RD
2 BK
2 2 BK - COOLING FAN
3 J/P310 YL 3 3 TACHO PCB:s AREA
24V FROM FEEDER
YL
4 BN 4 4 FOLDER/CREASER
A,P4-5 YL 1 1 BN PWM
5
A,P3-6 BN 2 2
6 RD
24V IN Extern. RD A,P4-8 YL 3 3
7 RD
24V IN Extern. RD A,P3-7 BN 4 4
8 5 5
9 6 6
6 ON = CAN end termination
10 McF 4P 123456
11 McF 6P
1 1
BLOWER (FAN9) ON
RD RD +
12 2 2 -
13BK
BK BK Delivery Fan OFF
BK YL 3 3 TACHO FOLDER
YL Switch setup
GND IN Extern.
14 BK
GND IN Extern. BK BN 4 4 BN PWM
14P MnF male

DO NOT USE EMPTY PINS BECAUSE 8P MnF FITS
EMPTY PINS 143-115912A
18 February 2022
Pro XL 8-4 Wiring

T08135D ProXL Service Manual

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PRO XL

The product (System) which is connected to this machine will be class A

How to read this manual

Safety during operation

NOTE: Box transparent for clarity.

Page intentionally blank.

2.1 Minimum space requirements

Width including access

Actual Product Dimensions (For Reference)

Power supply Voltage [V ac] Current

Switched-mode 100 - 240V, 50/60Hz 8 – 4A

Page intentionally blank.

Item Qty Description

6. Close conveyor cover [C] and screw it shut [D].

3. Remove screws [D] to open conveyor cover [C].

Continued on next page...

Continued on next page...

2. Ensure the built-in pull-out table [A] is fully stowed.

T12A 6.3x32 mm T6.3A 5x20 mm

3.1 Plug in and power on

Continued on next page...

10. Rotate the knob clockwise to secure it.

3. If the measurement is not within the machine tolerance (± 0.25 mm / ±

Page intentionally blank.

Continued on next page...

Position Error = Target Position - Measured Position

7. Repeat steps 5 & 6 until the crease position is within tolerance.

4. Power on the machine [A]. A list of files should now be shown.

Preventative Maintenance - Feeder Module Total Sheet Count (Millions of Sheets)

Preventative Maintenance - Creaser Module Total Sheet Count (Millions of Sheets)

1. Switch off the main power switch.

Item Quantity Description

Hex Screw/nut M5 8 2 Caliper

Hex Screw/nut M6 10 2 Measuring** 1

Hex Screw/nut M16 24 1

Slotted screw* 4,7x0,6 1 Screwdriver Plier (small, flat grip)

Slotted screw* 7,5x1 1

Pozidriv screw* No. 2 1 Water level

Removal Rear cover

To remove feeder top cover:

1. Use a 7 mm wrench or a T20 screwdriver to loosen 2x bolts [A]. There

1. Use a 7 mm wrench or a T20 screwdriver to remove bolt [A].

1. Remove Feeder – Cover, Front (REP 3.3.2)

(Spare PL 28.0 Fold Delivery)

4. Move the DigiFold/AutoCreaser module a small distance away from

J23 P12 FAN8 J110 J308

Reverse removal procedure and carry out DigiFold/AutoCreaser alignment

1. Remove feeder rear cover (REP 3.3.1)

1. Remove feeder rear cover (REP 3.3.1)

1. Remove feeder rear cover (REP 3.3.1)

1. Undock the modules (REP 3.3.13)

1. Remove feeder rear cover (REP 3.3.1)

1. Remove feeder rear cover (REP 3.3.1)

1. Undock the modules (REP 3.3.13)

1. Remove feeder rear cover (REP 3.3.1)

1. Remove feeder rear cover (REP 3.3.1)

1. Open feeder lift cover (REP 3.3.4)

1. Remove feeder top cover (REP 3.3.3)

1. Remove feeder front cover (REP 3.3.2)