Morgana Pro XL Unpacking And Installation Instructions

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Pro XL / Ultra

Unpacking & Installation Instruction

Packing Instruction - reverse the unpacking procedure

T09350E

24 September 2024

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Summary of Contents for Morgana Pro XL

Page 1 Pro XL / Ultra Unpacking & Installation Instruction Packing Instruction - reverse the unpacking procedure T09350E 24 September 2024...
Page 2 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. 24 September 2024 T09350E Pro XL / Ultra...
Page 3 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 User Interface. 24 September 2024 T09350E Pro XL / Ultra...
Page 4 The machine is to be used only by authorized and instructed persons. The responsibility on operating the machine must be strictly laid down and observed so that there are no unclear com- continued on next page petences regarding safety aspects. 24 September 2024 T09350E Pro XL / Ultra...
Page 5: Safety During Operation
Disconnect the power cord from the power source and call your viduals involved. authorized technician to correct the problem. continued on next page 24 September 2024 T09350E Pro XL / Ultra...
Page 6: Electromagnetic Compliance
Danger of explosion if batteries are incorrectly replaced. • Replace only with the same or equivalent type recommended by the manufacturer. • Dispose of used batteries according to the manufacturer’s instructions. Intentionally blank. continued on next page 24 September 2024 T09350E Pro XL / Ultra...
Page 7 A separate earth have read and understood the removing used connection needs to be user manual. Refer to service 24 September 2024 T09350E glue, must be worn. fitted during installation. manual for more information. Pro XL / Ultra...
Page 8 Eye protection, against UV lights can cause skin burns, eye damage, Connect equipment only to an possible splashes of glue, including permanent blindness and skin cancer. earthed (grounded) outlet. must be worn. 24 September 2024 T09350E Pro XL / Ultra viii...
Page 9: Table Of Contents
1.2.7 Stacker installation (DigiFold Pro XL and DigiFold Ultra) ..........................1-20 1.2.8 BST4000 installation (optional) (DigiFold Pro XL and DigiFold Ultra) ......................1-21 1.2.9 Top shoot installation (DigiFold Pro XL and DigiFold Ultra) ..........................1-23 1.2.10 Feeder table extension installation (optional) ..............................1-24 1.2.11...
Page 10 1.5.11 Transport Roller calibration .................................... 1-104 1.5.12 Cross Cutter calibration ....................................1-107 1.5.13 Crease position calibration .................................... 1-109 1.5.14 Knife position calibration ....................................1-112 1.5.15 Software updates ......................................1-113 24 September 2024 Pro XL / Ultra Unpacking & Installation Instruction...
Page 11: Unpacking Instruction
NOTE: For DigiFold Ultra installation, skip to Section 1.1.2. WARNING! 2. Remove components [C] placed on top of unit and then ramp [D]. Two people are required to pack/unpack the Pro XL, only qualified/ trained personnel should perform the procedures described in this document.
Page 12 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. Continued on next page... 24 September 2024 Pro XL / Ultra Unpacking & Installation Instruction...
Page 13 Do not turn each screw more than two full revolutions before adjust- ing the other screws; otherwise, the module might become unstable and tilt over. NOTE: Cardboard base removed for clarity. Continued on next page... 24 September 2024 Pro XL / Ultra Unpacking & Installation Instruction...
Page 14 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. 24 September 2024 Pro XL / Ultra Unpacking & Installation Instruction...
Page 15: Digifold Ultra
Two people are required to pack/unpack the DigiFold Ultra, only qualified/trained personnel should perform the procedures described in this document. 1. Cut packaging straps [A] and remove top cover [B] of box. Continued on next page... 24 September 2024 Pro XL / Ultra Unpacking & Installation Instruction...
Page 16 [H]. stacker [K], support [L], plastic wrap [M] and installation kit [N]. NOTE: Plastic wrap [M] not shown. NOTE: Do not discard waste bin [E]. Continued on next page... 24 September 2024 Pro XL / Ultra Unpacking & Installation Instruction...
Page 17 7. Tilt the unit to one side to remove one beam [P], tilt the unit to the other side to remove the remaining beam [P]. WARNING! Two people are required to remove the beams [P]. Continued on next page... 24 September 2024 Pro XL / Ultra Unpacking & Installation Instruction...
Page 18 Two people are required to carefully roll down the DigiFold Ultra. WARNING! Do not turn each screw more than two full revolutions before adjust- ing the other screws; otherwise, the module might become unstable and tilt over. 24 September 2024 Pro XL / Ultra 1-10 Unpacking & Installation Instruction...
Page 19: Installation Instruction - Pro Xl And Digifold Ultra
1690 mm / 66.5” 725 mm / 28.6” 1160 mm / 45.7” 1740 mm / 68.5” AutoCreaser Pro XL with feeder table fully extended 2540 mm / 100” 725 mm / 28.6” 1160 mm / 45.7” 1740 mm / 68.5”...
Page 20 Optional Table Extension Default Length 23.5 Optional Table Extension Pullout Section Length 12.4 Width 28.6 Clearance for operation and service 1740 68.5 Height (not shown in the images above) 1432 56.4 24 September 2024 Pro XL / Ultra 1-12 Unpacking & Installation Instruction...
Page 21 BST4000 Height (not shown in the images above) 1000 39.4 Trim Waste Conveyor Length 2310 Trim Waste Conveyor Width 29.1 Trim Waste Conveyor Height (not shown in the images above) 1270 24 September 2024 Pro XL / Ultra 1-13 Unpacking & Installation Instruction...
Page 22 Trim Waste Conveyor angled to DigiFold Ultra Width 2383 mm / 93.8” BST4000 angled to DigiFold Ultra Length 4757 mm / 187.3” Trim Waste Conveyor angled to DigiFold Ultra Length 4743 mm / 186.7” 24 September 2024 Pro XL / Ultra 1-14 Unpacking & Installation Instruction...
Page 23: Power Requirements
4. Never place anything on the power cord. Power supply Voltage [V ac] Current Switched-mode 100 - 240 V, 50/60 Hz 8 – 4 A Tolerance -10/+6% Page intentionally blank. 24 September 2024 Pro XL / Ultra 1-15 Unpacking & Installation Instruction...
Page 24: Accessory Check
Machine foot (Ultra) Inch fraction chart 56T Rotary perforation blade (14 TPI) (Ultra only) * Narrow static creaser blade if AutoCreaser ** Narrow DynaCrease blade if DigiFold Pro XL or Ultra Feeder Magnetic paper guide Feeder paper guide Stacker backstop...
Page 25 Screwdriver Torx T20 USB memory stick for performing machine software updates Calibration strip for ultrasonic double sheet detector Interlock cheater AutoCreaser Pro XL & DigiFold Pro XL DigiFold Ultra USB to STM32F Dongle SW loading adapter 16p to 8p VFL Interlock Termination Plug (Ultra only)
Page 26: Levelling The Pro Xl And Digifold Ultra
1.2.4 Levelling the Pro XL and DigiFold Ultra 1. Pro XL: place one machine foot [A] under each screw (8x). 3. Use a spirit level and adjust the feet until the machine is level. DigiFold Ultra: place one machine foot [A] under each screw (12x).
Page 27: Tilt Knob Installation
1.2.6 Stacker installation (AutoCreaser Pro XL only) 1. If creaser tilt adjustment knob [A] is not installed, screw it in its socket NOTE: For stacker installation to DigiFold Pro XL or DigiFold Ultra, as shown. skip to Section 1.2.7. 1. Hook the stacker [A] on the stacker brace [B] as shown.
Page 28: Stacker Installation (Digifold Pro Xl And Digifold Ultra)
1.2.7 Stacker installation (DigiFold Pro XL and DigiFold Ultra) 4. Install screws [E] (2x) to secure the conveyor in place. 5. Plug in electrical connectors [G] (2x). Tighten screws [F] (2x). 1. Open top cover and release screws [A] (2x) to remove exit guide [J].
Page 29: Bst4000 Installation (Optional) (Digifold Pro Xl And Digifold Ultra)
BST4000 installation (optional) (DigiFold Pro XL and DigiFold Ultra) 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.
Page 30 16. Ensure sensor [M] is aligned with cut-out [F]. 17. Secure cable [P] and sensor [M] with cable ties. CAUTION! After installation check the cables are secured away from moving parts. Continued on next page... 24 September 2024 Pro XL / Ultra 1-22 Unpacking & Installation Instruction...
Page 31: Top Shoot Installation (Digifold Pro Xl And Digifold Ultra)
1.2.9 Top shoot installation (DigiFold Pro XL and DigiFold Ultra) 18. Adjust sensor [M] sensitivity by releasing sensor retaining nut [N]. 1. Open top cover [A]. 19. Adjust potentiometer screw [Q]. 2. Locate top shoot screws [B] (x8) on the top cover.
Page 32: Feeder Table Extension Installation (Optional)
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. 24 September 2024 Pro XL / Ultra 1-24 Unpacking & Installation Instruction...
Page 33: Fuse Replacement (If Required)
2. Replace the fuse with the T12A fuse and its matching grey fuse holder. Lock the fuse holder in place. 100-140V AC 140-240V AC T12A 6.3x32 mm T6.3A 5x20 mm 24 September 2024 Pro XL / Ultra 1-25 Unpacking & Installation Instruction...
Page 34: Kit Content
For regions with main voltage 220-240 V, set switch A to 230 V. Bracket Nut M4 Nut M4 Self-adhesive cable holder Screw M4x16 Voltage detector pen 220-240 V ac 100-127 V ac Continued on next page... 24 September 2024 Pro XL / Ultra 1-26 Unpacking & Installation Instruction...
Page 35 Knives are very sharp: extreme caution should be taken. Keep your hands clear of the knives. 5. Remove cover [E]. 3. Rotate timing pulley [B] to close cutting knives [C]. Continued on next page... 24 September 2024 Pro XL / Ultra 1-27 Unpacking & Installation Instruction...
Page 36 7. Tighten the nuts [G] (3x). 10. Insert cable [L] in cable holders [J]. 8. Place antistatic bar [H] and tighten nuts [I] (2x). Continued on next page... 24 September 2024 Pro XL / Ultra 1-28 Unpacking & Installation Instruction...
Page 37 14. Attach connector P34 [O] to connector J34 [P]. Rear Side 17. Dock SCS and folder modules (reverse REP 3.3.21 service manual). 18. Slitter/Cutter section alignment to Folder (ADJ 3.12.5 service manual). 24 September 2024 Pro XL / Ultra 1-29 Unpacking & Installation Instruction...
Page 38 2. Open the front door and insert interlock cheater. 4. Access the Service Menu and change target to Folder. Continued on next page... 24 September 2024 Pro XL / Ultra 1-30 Unpacking & Installation Instruction...
Page 39 Antistatic bar. 6. Open the transparent chute door [A] to access antistatic bar. 8. If the pen lights up red, the bar is working. Continued on next page... 24 September 2024 Pro XL / Ultra 1-31 Unpacking & Installation Instruction...
Page 40 Turn off the power switch and disconnect the Main Power Cord/s, Check connections in harnesses, reassemble the module entirely, plug in and turn on again. • See service manual. Page intentionally blank. 24 September 2024 Pro XL / Ultra 1-32 Unpacking & Installation Instruction...
Page 41: Trim Waste Conveyor (Twc) (Optional) (Digifold Ultra Only)
• Socket, 10 mm Page intentionally blank. NOTE: You need either a 10 mm wrench (2x) or a 10 mm wrench (1x) and a 10 mm socket (1x). 24 September 2024 Pro XL / Ultra 1-33 Unpacking & Installation Instruction...
Page 42: Accessory Check
Description Part Screw 99471 Screw M6x8 99616 Screw M4x6 99567 O-ring Pulley 122-106931 Star shaped Knobs 122-110217 Bushing 103-102774 Castors 102-104515 Nut Cap 98011 Continued on next page... 24 September 2024 Pro XL / Ultra 1-34 Unpacking & Installation Instruction...
Page 43 99399 Screw M6x12 99400 Screw M4x12 99100 Screw M4x6 99053 Knob 101-106986 Washer 97028 98056 98001 Link screw 47194 Washer 97029 Nut Plate 47164 Continued on next page... 24 September 2024 Pro XL / Ultra 1-35 Unpacking & Installation Instruction...
Page 44 172-121935 Guide Pulley Assembly 172-121200 Conveyor Belt Cover Lower 172-121936 Conveyor OB Belt Cover 172-121933 465-01-040 Spacer 56693 Screw M4x6 99567 Spacer 60607 98061 Continued on next page... 24 September 2024 Pro XL / Ultra 1-36 Unpacking & Installation Instruction...
Page 45 Contents, bag 5 Item Description Part Conveyor Mounting Plate 142-121850 Screw M 4x10 99471 Continued on next page... 24 September 2024 Pro XL / Ultra 1-37 Unpacking & Installation Instruction...
Page 46 Upper Beam Belt Support Roller Waste Guide R Waste Bin Guide R Waste Guide R Top Waste Bin Guide L Waste Guide Holder Waste Guide Continued on next page... 24 September 2024 Pro XL / Ultra 1-38 Unpacking & Installation Instruction...
Page 47 Item Description Item Description Support Base Caster Bracket Support Bracket Conveyor Belt Conveyor Paper Shroud Static Brush with nuts Conveyor Side Mounting Plate 24 September 2024 Pro XL / Ultra 1-39 Unpacking & Installation Instruction...
Page 48 2. Remove screws [A] (3x). Remove Pulley Cover [B]. Screw No 6 must be installed in Pulley No 7. NOTE Pulley must be placed on the edge of the shaft. Continued on next page... 24 September 2024 Pro XL / Ultra 1-40 Unpacking & Installation Instruction...
Page 49 4. Install Conveyor Mounting Plate [F] with screws No 34 [G] (4x) on the Base Shelf is shown transparent for clarity. Base Shelf [H] from the inside. 24 September 2024 Pro XL / Ultra 1-41 Unpacking & Installation Instruction...
Page 50 60 mm / 2.4”. 2. Install screws No 11 [B] (2x). 3. Tighten screws [A] (2x) and [B] (2x). Continued on next page... 24 September 2024 Pro XL / Ultra 1-42 Unpacking & Installation Instruction...
Page 51 The two Nut Plate assemblies should be mirrored. 8. Set the distance [M] to app. 30 mm / 1.2”. The exact distance will be adjusted later. 30 mm (1.2”) Continued on next page... 24 September 2024 Pro XL / Ultra 1-43 Unpacking & Installation Instruction...
Page 52 Straight 13. Install the Belt hold down roller [P] inside the Conveyor belt [O] and secure it using screws No 13 [Q] (2x). Left Continued on next page... 24 September 2024 Pro XL / Ultra 1-44 Unpacking & Installation Instruction...
Page 53 TWC frame by tensioning the belt. Ensure the clips on the bearings TWC frame. are on the outside of the TWC frame. Straight or Right installation Left installation Continued on next page... 24 September 2024 Pro XL / Ultra 1-45 Unpacking & Installation Instruction...
Page 54 Idler roller end. Orientation of the rollers is not critical as long as [W] (2x). they are properly seated in the grooves [Y]. Continued on next page... 24 September 2024 Pro XL / Ultra 1-46 Unpacking & Installation Instruction...
Page 55 Support Rollers [X] inside the Conveyor belt. 19. Install the Middle Waste Guides [AB] (2x). NOTE Don’t pull waste guides downwards to set in place jet. Continued on next page... 24 September 2024 Pro XL / Ultra 1-47 Unpacking & Installation Instruction...
Page 56 22. Install Paper Shroud [AD] using the screw No 2 (AE) and Spacer No 31 [AF]. Do not tighten the screw and spacer jet. TWC is placed Left to DigiFold Ultra Continued on next page... 24 September 2024 Pro XL / Ultra 1-48 Unpacking & Installation Instruction...
Page 57 26. Install the Caster Bracket [AH] to the TWC frame using screws No 2 [AI] (6x). Tighten screws [AE] and Spacers [AF]. 24. Install the Casters [AG] (2x) to the Caster Bracket [AH]. Continued on next page... 24 September 2024 Pro XL / Ultra 1-49 Unpacking & Installation Instruction...
Page 58 28. Install Deflect Bracket [AJ] using the Nut Caps No 5 [AK] (4x). TWC is placed Straight to DigiFold Ultra NOTE This is the end of assembling the TWC placed straight to the DigiFold Ultra. Continued on next page... 24 September 2024 Pro XL / Ultra 1-50 Unpacking & Installation Instruction...
Page 59 29. Install Guide Pulley Assy [AL] using the screw No 2 [AM]. NOTE This is the end of assembling the TWC placed right to the DigiFold Ultra. Continued on next page... 24 September 2024 Pro XL / Ultra 1-51 Unpacking & Installation Instruction...
Page 60 31. Install Deflect Bracket [AJ] using the Nut Caps No 5 [AK] (4x). NOTE This is the end of assembling the TWC placed left to the DigiFold Ultra. 24 September 2024 Pro XL / Ultra 1-52 Unpacking & Installation Instruction...
Page 61 2. Route the Belt No 22 [A] on the Pulleys [B] and [C] and ensure it is twisted the right way to make the Belt go in the desired transport direction. Parts hidden for clarity. Continued on next page... 24 September 2024 Pro XL / Ultra 1-53 Unpacking & Installation Instruction...
Page 62 5. Install Conveyor OB Belt Cover No 27 [G] using screws No 30 [H] (2x). NOTE Pulley Cover and screws were removed while preparing the DigiFold Ultra. NOTE This is the end of TWC installation straight to the DigiFold Ultra. 24 September 2024 Pro XL / Ultra 1-54 Unpacking & Installation Instruction...
Page 63 9. Reinstall Pulley Cover [E] using screws [F] (3x). transport direction. NOTE Docking plate transparent for clarity. Pulley Cover and screws were removed while preparing the DigiFold Ultra. Continued on next page... 24 September 2024 Pro XL / Ultra 1-55 Unpacking & Installation Instruction...
Page 64 12. Hook up the Round belt No 22 [A] on the Pulleys [B] and [C] and ensure it is twisted the right way to make the Belt go in the desired transport direction. Continued on next page... 24 September 2024 Pro XL / Ultra 1-56 Unpacking & Installation Instruction...
Page 65 14. Install Conveyor OB Belt Cover No 27 [G] using screws No 30 [H] (2x). NOTE This is the end of TWC installation left to the DigiFold Ultra. 24 September 2024 Pro XL / Ultra 1-57 Unpacking & Installation Instruction...
Page 66 4. If the Pulley [B] is rotating, but the Belt [C] is not rotating, the belt is not tensioned enough. NOTE Pulley and belt covers transparent for clarity. 24 September 2024 Pro XL / Ultra 1-58 Unpacking & Installation Instruction...
Page 67 Tension of the Conveyor belt is correct when the Conveyor belt can trans- port the load without the Conveyor belt slipping on the TWC Drive shaft [B]. NOTE Make sure that upper and lower rollers are level. 24 September 2024 Pro XL / Ultra 1-59 Unpacking & Installation Instruction...
Page 68 For example, if the Conveyor belt tends to move to the picture left, the Belt tensioner on that side can be moved outwards. 24 September 2024 Pro XL / Ultra 1-60 Unpacking & Installation Instruction...
Page 69 5. To adjust skewness, rotate Excenter [C] until Conveyor Belt travels centered on the Idler roller. NOTE NOTE Make sure that upper and lower rollers are level. This is the end of the Trim waste conveyor installation. 24 September 2024 Pro XL / Ultra 1-61 Unpacking & Installation Instruction...
Page 70: Power On And Calibration Check - Pro Xl
This section is for customers who only have AutoCreaser Pro XL or Digi- 2. Plug in the CAN termination plug [B]. Fold Pro XL. If you have DigiFold Ultra, please skip forward to section 1.5 3. Turn on the main power switch [C].
Page 71: Module Alignment Check
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 “1.4.1 Feeder alignment to AutoCreaser/DigiFold Pro XL”. Center in cut-out Continued on next page...
Page 72 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. 24 September 2024 Pro XL / Ultra 1-64 Unpacking & Installation Instruction...
Page 73: Creaser Calibration Check
Feed direction 3. If the measurement is not within the machine tolerance (± 0.4 mm / ± 0.016”) continue to “1.4 Calibration Procedures - Pro XL”. 4. If the measurement is not within the machine tolerance (± 0.4 mm / ±...
Page 74: Checking For Software Updates
3. If an update is available, follow “1.4.4 Updating software” or the techni- cal bulletin supplied with the software. Page intentionally blank. 24 September 2024 Pro XL / Ultra 1-66 Unpacking & Installation Instruction...
Page 75: Calibration Procedures - Pro Xl
This section is for customers who only have AutoCreaser Pro XL or Digi- trapped into the rollers and cause injuries. Fold Pro XL. If you have DigiFold Ultra, please skip forward to section 1.5 6. Release nuts on brackets [G] using a 13 mm wrench.
Page 76: Autocreaser/Digifold Pro Xl Adjustments
4. [DigiFold Pro XL only] Fold roller adjustment bration 200-300 gsm / 0.25 mm thick 5. [DigiFold Pro XL only] Delivery roller home position 350-400 gsm / 0.4 mm thick 6. [DigiFold Pro XL only] Transport roller calibration Crease position cali- 200-300 gsm / 0.25 mm...
Page 77 DigiFold Pro XL/AutoCreaser Pro XL Input roller adjustment NOTE: Complete “1.3.2 Module alignment to check” before continuing with this 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.
Page 78 NOTE: 5. If crease skew (difference between registered side and operator side) If calibrating AutoCreaser Pro XL complete “1.3.2 Module alignment to is > 0.4 mm mechanical adjustment is necessary. Use a 6 mm hex key check” and “Input roller adjustment” before continuing with this procedure.
Page 79 It is possible to carry out the calibration with other weights and sizes of the All job parameters are set automatically, the operator only has to press paper. However, resulting accuracy may be affected. [Proof], measure and enter values. 24 September 2024 Pro XL / Ultra 1-71 Unpacking & Installation Instruction...
Page 80 3. Enter service mode: go to [Tools], enter [Service mode]. 4. When prompted enter password 1974 and click the tick mark. Click the [Calibration] button. Select [Roller gaps]. Continued on next page... 24 September 2024 Pro XL / Ultra 1-72 Unpacking & Installation Instruction...
Page 81 (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. Continued on next page... 24 September 2024 Pro XL / Ultra 1-73 Unpacking & Installation Instruction...
Page 82 Ideally, the slips will be difficult to obstruct the paper path press the [Move fold knives] button this cycles pull out, but not stuck in place. the knives to the second position. 24 September 2024 Pro XL / Ultra 1-74 Unpacking & Installation Instruction...
Page 83 (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. 24 September 2024 Pro XL / Ultra 1-75 Unpacking & Installation Instruction...
Page 84 20. Adjust Roller Gaps if they are either too loose or too tight. To do this change the Roller Gap 3 value using the [+] or [-] buttons for the relevant roller gap. Press [Calibrate] for changes to take effect. 24 September 2024 Pro XL / Ultra 1-76 Unpacking & Installation Instruction...
Page 85 2. Go to Tools, enter Service mode. 3. When prompted enter password 1974 and click the tick mark. 4. Select Calibration. 5. Push Calibrate (the value is saved and adjustment is complete). 24 September 2024 Pro XL / Ultra 1-77 Unpacking & Installation Instruction...
Page 86 Transport Roller Calibration NOTE: This procedure applies only for DigiFold Pro XL. Complete in sequence “1.3.2 Module alignment to check”, “Input roller adjustment”, “Fold roller adjustment” and “Delivery roller home position” before continuing with this procedure. Transport roller calibration replaces “stretch” on previous Morgana prod- ucts.
Page 87: Feed Direction
4. Measure the distance between creases 2 and 3. (SRA 3 should be in the top right corner. Or return to Service Home. 200 mm). Continued on next page... 24 September 2024 Pro XL / Ultra 1-79 Unpacking & Installation Instruction...
Page 88 6. Click [Calibrate]. The NVM value shown at the bottom center of the screen will update. 2. In Calibration sub-menu choose [5. Speed offset] to open calibration 7. Repeat steps 4 to 6 until correct. screen. 24 September 2024 Pro XL / Ultra 1-80 Unpacking & Installation Instruction...
Page 89 NOTE: 5. If crease skew (difference between registered side and operator side) If calibrating DigiFold Pro XL complete “1.3.2 Module alignment to check”, is > 0.4 mm mechanical adjustment is necessary. Use a 6 mm hex key “Input roller adjustment”, “Fold roller adjustment”, “Delivery roller home to loosen 4x screws [A] to calibrate the static creaser.
Page 90 All job parameters are set automatically, the operator only has to press It is possible to carry out the calibration with other weights and sizes of the [Proof], measure and enter values. paper. However, resulting accuracy may be affected. 24 September 2024 Pro XL / Ultra 1-82 Unpacking & Installation Instruction...
Page 91 10 until correct. NOTE: 12. This is the final step in DigiFold Pro XL calibration. Return to Service It is possible to carry out the calibration with other weights and sizes of the Home.
Page 92: Updating Software - Single Point Download
6. Press [Yes] in the dialog box that comes up. 7. Follow instructions on screen. Note: This is the end of calibration procedures for DigiFold Pro XL and AutoCreaser Pro XL. 24 September 2024 Pro XL / Ultra 1-84...
Page 93: Power On And Calibration Check/Procedures - Digifold Ultra
Plug DK2-1a. When using a non-polarized plug, touch current may reach 4.5 mA but does not exceed 5 mA. 24 September 2024 Pro XL / Ultra 1-85 Unpacking & Installation Instruction...
Page 94: Software Update Check
3. If an update is available, follow “Updating software” or the technical bulletin supplied with the software. (Follow procedure 1.5.15) Note: Make sure that Slit/Cut, Crease and Fold functions are active in UI Continued on next page... 24 September 2024 Pro XL / Ultra 1-86 Unpacking & Installation Instruction...
Page 95 0.016”) continue to “1.5 Calibration Procedures - DigiFold Ultra”. Crease Measure Feed direction Note: If the folded paper is straight and the measurement is within the machine tolerance, this is the end of procedure. 24 September 2024 Pro XL / Ultra 1-87 Unpacking & Installation Instruction...
Page 96: Digifold Ultra Adjustments
All paper should be at least A3/SRA3 in length or longer. Alternative paper weights and thicknesses can be used, but the closer they are to recom- mended values, the better the calibration result. 24 September 2024 Pro XL / Ultra 1-88 Unpacking & Installation Instruction...
Page 97 90° clockwise to lock into position. 4. If the measurement is not within the machine tolerance (± 0.4 mm / ± 0.016”) continue with Fold Roller adjustment. Continued on next page... 24 September 2024 Pro XL / Ultra 1-89 Unpacking & Installation Instruction...
Page 98 (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. Continued on next page... 24 September 2024 Pro XL / Ultra 1-90 Unpacking & Installation Instruction...
Page 99 (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. Continued on next page... 24 September 2024 Pro XL / Ultra 1-91 Unpacking & Installation Instruction...
Page 100 (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. Continued on next page... 24 September 2024 Pro XL / Ultra 1-92 Unpacking & Installation Instruction...
Page 101 3.0+/-0.5N). For adjustment continue to step 20. If Fold knives obstruct the paper path press the [Move fold knives] button this cycles the knives to the second position. 24 September 2024 Pro XL / Ultra 1-93 Unpacking & Installation Instruction...
Page 102 6. Re-dock and replace covers. Check creaser accuracy and re-cali- brate if necessary (section “Crease position calibration’’). NOTE: This adjustment should be carried out with the input roller drive belt ten- sioned. 24 September 2024 Pro XL / Ultra 1-94 Unpacking & Installation Instruction...
Page 103 2. Go to Tools, enter Service mode. 3. When prompted enter password 1974 and click the tick mark. 4. Select Calibration. 5. Push Calibrate (the value is saved and adjustment is complete). 24 September 2024 Pro XL / Ultra 1-95 Unpacking & Installation Instruction...
Page 104 16-21 for Slitter / Cutter section alignment to Feeder. 3. Remove Slitter Cassette [A]. 4. Center in the cutout to straighten the registration wall. Cutout Continued on next page... 24 September 2024 Pro XL / Ultra 1-96 Unpacking & Installation Instruction...
Page 105 15. Measure both sides of cutout margin [E]. If they are not the same size, carry out machine alignment in the next steps. If they are the same size, this is the end of the procedure. Continued on next page... 24 September 2024 Pro XL / Ultra 1-97 Unpacking & Installation Instruction...
Page 106 Nominal value of the distance between the modules is 18.8 mm (0.74″). 17. Release nuts on Brackets [F] (2x) and on Bracket [G]. Use Bracket [G] to adjust the angle between the modules. 24 September 2024 Pro XL / Ultra 1-98 Unpacking & Installation Instruction...
Page 107 14-20 for Slitter / 3. Remove Slitter Cassette [A]. Cutter section alignment to Folder. 4. Center in the cutout to straighten the registration wall. Cutout Continued on next page... 24 September 2024 Pro XL / Ultra 1-99 Unpacking & Installation Instruction...
Page 108 11. Press [Pattern], choose Half fold and run a proof sheet. installed. Do not wear ties, lanyards or other things that might get trapped into the rollers and cause injuries. 15. Insert Interlock Cheater. Continued on next page... 24 September 2024 Pro XL / Ultra 1-100 Unpacking & Installation Instruction...
Page 109 20. Remove Interlock Cheater, reinstall Slitter Cassette and Front Cover. NOTE: Nominal value of the distance between the modules is 7.45 mm (0.29″). 24 September 2024 Pro XL / Ultra 1-101 Unpacking & Installation Instruction...
Page 110: Slitter Cassette Calibration
7. Check if the cutout margins are straight by folding them in half. 8. If cutout margins are not straight, perform machine alignment ADJ 1.5.6 Slitter / Cutter section alignment to Feeder. Continued on next page... 24 September 2024 Pro XL / Ultra 1-102 Unpacking & Installation Instruction...
Page 111 For example, if cutout piece is 1 mm too narrow - increase position R (NVM002 Slit 1 blade R pos offset mm*10) by 10. Accept changed value and run a proof sheet. 24 September 2024 Pro XL / Ultra 1-103 Unpacking & Installation Instruction...
Page 112: Transport Roller Calibration
1.5.11 Transport Roller calibration 5. Choose [3. Thickness 0.1 mm] to open calibration screen. Transport roller calibration replaces “stretch” on previous Morgana prod- ucts. There are three distinct steps to this procedure which must be fol- lowed in order. Step “3. Thickness 0.1 mm” recommended paper: 0.1 mm, A3 / SRA3 or longer.
Page 113: Feed Direction
11. Once complete, move to the next step by pressing the forward arrow Crease positions Cr.1Cr.2 Cr.3 in the top right corner. Or return to Service Home. Measure Feed direction Continued on next page... 24 September 2024 Pro XL / Ultra 1-105 Unpacking & Installation Instruction...
Page 114 2. In Calibration sub-menu choose [5. Speed offset] to open calibration buttons. screen. 6. Press [Calibrate]. The NVM value shown at the bottom center of the screen will update. 7. Repeat steps 4 to 6 until correct. 24 September 2024 Pro XL / Ultra 1-106 Unpacking & Installation Instruction...
Page 115: Cross Cutter Calibration
5. Set the Cross Cutter at 30.0 mm. Run a proof sheet and collect the 3. Press [Media] to chose paper sizes and weight, select 200-300 gsm, cutout margin from the waste bin. SRA3 sheet of paper. Continued on next page... 24 September 2024 Pro XL / Ultra 1-107 Unpacking & Installation Instruction...
Page 116 7. If cutout margin is not straight, perform machine alignment ADJ 1.5.6 Slitter / Cutter section alignment to Feeder. 8. If the cutout margin is straight, proceed to measuring it. 30 mm ± 0.4 mm (1.18″ ± 0.016″) 24 September 2024 Pro XL / Ultra 1-108 Unpacking & Installation Instruction...
Page 117: Crease Position Calibration
Feed direction Feed direction Measure 3. If the measurement is not within the machine tolerance (± 0.25 mm / ± 0.001”) continue with adjustment. Continued on next page... 24 September 2024 Pro XL / Ultra 1-109 Unpacking & Installation Instruction...
Page 118 NOTE: It is possible to carry out the calibration with other weights and sizes of the paper. However, resulting accuracy may be affected. Continued on next page... 24 September 2024 Pro XL / Ultra 1-110 Unpacking & Installation Instruction...
Page 119 18. The following steps work the same way, just calibrate different NVMs. All job parameters are set automatically, the operator only has to press [Proof], measure and enter values. 24 September 2024 Pro XL / Ultra 1-111 Unpacking & Installation Instruction...
Page 120: Knife Position Calibration
NOTE: It is possible to carry out the calibration with other weights and sizes of the paper. However, resulting accuracy may be affected. 24 September 2024 Pro XL / Ultra 1-112 Unpacking & Installation Instruction...
Page 121: Software Updates
5. Select the file “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. 24 September 2024 Pro XL / Ultra 1-113 Unpacking & Installation Instruction...

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