Plockmatic Pro XL User manual

T09350B
16 April 2021
Pro XL
Unpacking & Installation Instruction
Packing Instruction - Reverse the unpacking procedure

16 April 2021
Pro XL 1-2 T09350B
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.

16 April 2021
Pro XL 1-3 T09350B
Introduction
Please read the Safety Information before using this machine. It contains information related to USER SAFETY and PREVENTING
EQUIPMENT PROBLEMS.
How to read this manual
Notation conventions
Whenever necessary, the following points for attention are indicated in this manual.
WARNING:
Indicates a potentially hazardous situation which, if instructions are not followed, could result in death or serious injury.
CAUTION:
Indicates a potentiality hazardous situation which, if instructions are not followed, may result in minor or moderate injury or damage
to machine or property.
NOTE
This sign refers to:
Remarks for making the operation much easier. You get practical hints or knowledge to assist you in the machine operation such as:
Preparations required before operating
How to prevent papers from being misfed or damaged
Precautions required or actions to take after 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.

16 April 2021
Pro XL 1-4 T09350B
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 specied in this manual.
• Turn o󰀨 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 specically instructed).
• If any adjustment or operation check has to made with exterior covers o󰀨 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 o󰀨 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.

16 April 2021
Pro XL 1-5 T09350B
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 qualied electrician.
• Improper grounding of the equipment can result in electrical shock. Never connect the machine to a power source that lacks a ground
connection terminal. This machine is destined for specic purpose only. Any use going beyond this specic purpose is 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 modications to the machine. The manufacturer will not be liable for modications 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 ngers or other parts of the body to moving, rotating or cutting devices such as for instance between upper and lower
trimmer knives.
• Allways locate the equipment on a solid support surface with adequate strength tor the weight of the machine.
General safety

16 April 2021
Pro XL 1-1 Unpacking & Installation Instruction
Page intentionally blank.
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
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
1 Unpack and Installation

16 April 2021
Pro XL 1-2 Unpacking & Installation Instruction
1.0 Unpacking Instruction - Pro XL
1. Cut packaging straps [A] and remove top cover [B] of box.
WARNING!
Two people are required to pack/unpack the Pro XL, only qualied/
trained personnel should perform the procedures described in this
document.
NOTE: Box transparent for clarity.
2. Remove components [C] placed on top of unit and then ramp [D].
B
D
C
A

16 April 2021
Pro XL 1-3 Unpacking & Installation Instruction
[3] Remove outer cardboard box [E], plastic wrap [F] and protection foam
[G].
EGF
HH
[4] Fold down cardboard box base [H] & place ramp supports [K] under
pallet.
K

16 April 2021
Pro XL 1-4 Unpacking & Installation Instruction
[5] Place ramp [D] onto supports [K].
D
WARNING!
Two people are required to carefully roll down the Pro XL. NOTE: Cardboard base removed for clarity.
[6] Lower the feet [L] (x8) to raise machine. Remove Foam supports [M]
(x4) from under machine. Raise Feet [L] (x8) so the machine is resting on
the wheels.
LL
M
M
K

16 April 2021
Pro XL 1-5 Unpacking & Installation Instruction
[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.
Page intentionally blank.

16 April 2021
Pro XL 1-6 Unpacking & Installation Instruction
2.0 Installation Instruction - Pro XL
Pro XL
Actual Product Dimensions (For Reference)
Position Product Length Width Height
AutoCreaser Pro XL
1 AutoCreaser Pro XL 1690mm / 66.5” 730mm / 28.7” 1160mm / 45.7”
2 AutoCreaser Pro XL with feeder table fully extended 2540mm / 100” 730mm / 28.7” 1160mm / 45.7”
DigiFold Pro XL
1 DigiFold Pro XL 2130mm / 83.9” 730mm / 28.7” 1395mm/ 54.9”
2 DigiFold Pro XL with feeder table fully extended 2990mm / 117.7” 730mm / 28.7” 1395mm/ 54.9”
BST4000 optional DigiFold Pro XL only
BST4000 1800mm / 70.9” 480mm / 18.9” Adjustable
1
2
Access
Access
Width
2.1 Minimum space requirements
Width
Length
Inline
90°
Or

16 April 2021
Pro XL 1-7 Unpacking & Installation Instruction
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 rmly 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
Tolerance -10/+6%
8 – 4A
Page intentionally blank.

16 April 2021
Pro XL 1-8 Unpacking & Installation Instruction
Item Qty Description
Installation kit contents:
1 1 Safety instruction
2 1 AutoCreaser Pro XL Operator manual
DigiFold Pro XL Operator manual
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
9 8 Machine foot
10 1 Inch fraction chart
In feeder shelf:
11 2 Multi-purpose wrench
12 1 Hex key set
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
17 1 Calibration strip for ultrasonic double
sheet detector
18 1 Interlock cheater
2.3 Accessory check
1
6
10
2
7
11
3
5
9
13 14
15
4
8
12 16
17 18

16 April 2021
Pro XL 1-9 Unpacking & Installation Instruction
2.4 Levelling the machine
1. Place one machine foot [A] under each screw (8x).
2. Use the provided multi-tool or another 19 mm wrench to raise the ma-
chine off the oor. Check that the casters move freely and the machine
does not rock.
3. Use a spirit level and adjust the feet until the machine is level.
4. Use both multi-tools or two 19 mm wrenches to lock off the machine
feet [B].
A
B

16 April 2021
Pro XL 1-10 Unpacking & Installation Instruction
2.6 Stacker installation (AutoCreaser Pro XL only)
1. Hook the stacker [A] on the stacker brace [B] as shown.
A
B
A
2.5 Tilt knob installation
1. If creaser tilt adjustment knob [A] is not installed, screw it in its socket
as shown.

16 April 2021
Pro XL 1-11 Unpacking & Installation Instruction
2.7 Stacker installation (DigiFold Pro XL only)
1. Open top cover and remove screws [A] to release exit guide [J].
2. Hook the conveyor [I] onto hooks [B].
3. Remove screws [D] to open conveyor cover [C].
4. Insert two screws [E] into shaft [F] to secure the conveyor in place
5. Plug in two electrical connectors [G] from the conveyor into the ma-
chine
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].
BB A
D
E
C
H
L
KJ
I
WARNING!
After installation check the exit guide [J] does not touch the fold roller [K].
F G

16 April 2021
Pro XL 1-12 Unpacking & Installation Instruction
2.8 Optional BST4000 installation (DigiFold Pro XL only)
1. Release spring-loaded plunger [A] (x2).
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
Position 2: Stacker operating position with BST4000
A
BCD
7. Position BST4000 [E] as required.
Continued on next page...
8. Remove screws [H] (if not already removed) to open conveyor cover
[I].
H
I
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:

16 April 2021
Pro XL 1-13 Unpacking & Installation Instruction
J
J
KL
M
O
N
P
Continued on next page...
9. Remove bracket [J].
10. Close conveyor cover [I] & secure with screws [H].
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].
14. Detatch sensor [M] from BST4000 by releasing sensor retaining nut
[N] & cable connection [O].
15. Release excess cable [P] from under BST4000.
16. Feed sensor [M] through bracket [J].
17. Secure sensor [M] with sensor retaining nut [N].
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
F
N
F
CAUTION!
After installation check the cables are secured away from moving parts.

16 April 2021
Pro XL 1-14 Unpacking & Installation Instruction
Q
2.9 Top shoot installation (DigiFold Pro XL only)
1. Open DigiFold Pro XL top cover [A].
2. Locate top shoot screws [B] (x8) into DigiFold top cover.
3. Secure top shoot with nuts [C] (x8).
A
C
B
21. Adjust sensor [M] sensitivity by releasing sensor retaining nut [N].
22. Adjust potentiometer screw [Q].
23. Resecure sensor [M] with sensor retaining nut [N].

16 April 2021
Pro XL 1-15 Unpacking & Installation Instruction
2.10 Feeder table extension installation (optional)
Install table extension if using sheets longer than 700 mm / 27.6”
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.
3. Hook the table extension [B] into the lift [C] as shown.
A
B
C