Konica Minolta GP-502 Operation Manual

KONICA MINOLTA

GP-502

OPERATION MANUAL

Rev 1.0

February 2012

Table of Contents

1. Safety

2. Overview

2.1 Features & Benefits of GP-502

2.2 Ellipse Binding Elements

2.3 User Interface & Feature Locations

3. Installation

4. Unit Operation - Bypass

5. Unit Operation -Binding

5.1 Getting To Know The GP-502

5.2 Installing Elements

6. Creating Bind Job

6.1 Setting Front & Back Cover

6.2 Enabling Bind Function

6.3 Folding Book Over

7. Media

7.1 Bypass

7.2 Binding

8. Jam Clearance

8.1 Bypass Path Jam Clearance

8.2 Bind Path Jam Clearance

8.3 Element Jam Clearance

8.4 Book Jam Clearance

8.5 Jam Due To Opening Front Door

9. Language Selection

10. Specification

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1. Safety

THE SAFETY OF YOU AND OTHERS IS VERY IMPORT ANT T O
GBC. IMPORTANT SAFETY MESSAGES AND INFORMATION
ARE CONTAINED IN THIS MANUAL AS WELL AS ON THE
MACHINE ITSELF. PLEASE MAKE SURE YOU CAREFULLY
READ AND UNDERSTAND ALL OF THESE BEFORE
OPERATING THE MACHINE.

THE SAFETY ALERT SYMBOL PRECEDES EACH
SAFETY MESSAGE IN THIS OPERATION
INSTRUCTIONS MANUAL. THIS SYMBOL
INDICATES A POTENTIAL PERSONAL SAFETY
HAZARD THAT COULD HURT YOU OR OTHERS

THE FOLLOWING PICTORIAL IS FOUND ON THE GP-502.

This safety message means you could
get an electrical shock because
disconnecting power from this section
does not cut off power from adjacent
sections of the machine.

This safety message means that you
might get seriously hurt or killed if you
open the product and expose yourself to
hazardous voltage. NEVER remove the
screwed on covers.

ALWAYS refer service

• Use the GP-502 only for its intended purpose of punching
and binding books using paper and covers according to the
indicated specifications.

• Retain this Operation Instructions manual for future use.

CAUTION: THE PRINTER ON/OFF SWITCH DOES
NOT CUT OFF POWER FROM THE BINDER.

CAUTION: THE PUNCH ON/OFF SWITCH DOES
NOT CUT OFF POWER FROM THE BINDER.

• The GP-502 must be connected to a supply voltage
corresponding to the electrical rating of the machine
operation instructions (also listed on the serial number label).

• The grounding plug is a safety feature and will only fit into
the proper grounding-type power outlet. If you are unable to
insert the plug into an outlet, contact a qualified electrician to
have a suitable outlet installed.

• Do not alter the plug on the end of the cordset of the GP-502.
It is provided for your safety.

• Unplug the GP-502 before moving the machine or whenever
the machine is not in use for an extended period of time.

• Do not operate the GP-502 if the machine has a damaged

power supply cord or plug. Do not operate the machine after
any malfunction. Do not operate the machine in case of
liquid spills, or if the machine has been damaged in any
other way.

• Do not overload electrical outlets.

FCC NOTE

(THE FOLLOWING NOTE ONLY APPLIES TO THE UNITS
RATED 115V 60HZ.)

This equipment has been tested and found to comply with the
limits for a Class A digital device, pursuant to Part 15 of the FCC
Rules. These limits are designed to provide reasonable protection
against harmful interference when the equipment is operated in a
commercial environment.

This equipment generates, uses, and can radiate radio frequency
energy and, if not installed and used in accordance with the
Operation Manual, may cause harmful interference with radio
communications.

Operation of this equipment in a residential area is likely to cause
harmful interference in which case the user will be required to
correct the interference at his/her own expense.

Safety messages
CAUTION: CHANGES OR MODIFICATIONS NOT
EXPRESSLY APPROVED BY GENERAL BINDING
CORPORATION COULD VOID YOUR AUTHORITY TO
OPERATE THE EQUIPMENT.

Canada Class A Notice - Avis Canada, Classe A
This Class A digital apparatus complies with Canadian ICES-3.
Cet appareil numérique de la classe A est conforme à la norme
NMB-003 du Canada.

MAIN CORDSET SELECTION

(THE FOLLOWING NOTE ONLY AP PLIES ONLY TO THE UNITS
RATED 230V 50HZ, AND LOCATED IN THE EUROPEAN

UNION)

CAUTION: WHEN CHOOSING A DETACHABLE LINE
CORD FOR USE WITH YOUR GP-502,
ALWAYS FOLLOW THE FOLLOWING PRECAUTIONS

The cordset consists of three parts: the attachment plug, the cord
and the appliance inlet. Each of these components must have
European regulatory safety approvals.

The following minimum electrical ratings for the specific cordset
are published for safety purposes.

DO NOT USE CORDSETS THAT DO NOT MEET THE
FOLLOWING MINIMUM ELECTRICAL REQUIREMENTS.

PLUG: 3 amperes, 250 volts, 50/60 Hz, Class 1, 3 conductor,

European safety approved.
CORD: Type H05VV-F3G0.75, Harmonized (< HAR>). The "< >"

symbols indicate cord approved according to appropriate
European standard (NOTE: "HAR" may be substituted for
approval mark of European safety agency that approved the cord.
An example would be "< VDE >").

APPLIANCE CONNECTOR: 3 amperes, 250 volts, 50/60 Hz,
European safety approved, Type IEC 320. The cordset shall not
exceed 3 meters in length. A cordset with component electrical
ratings

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2. Overview

2.1 FEATURES & BENEFITS OF THE GP-502

The GBC GP-502 attaches directly to your high-speed Konica Minolta printer. Documents flow directly from
the printer to the binding system without the bottleneck associated with traditional offline punching processes.
The GBC GP-502 online binding system not only affords superior turnaround times, but also significantly
reduces labor costs. Only one operator is required to print, punch and bind documents.

The GP-502 is an automated binder system capable of binding small and large books by simply making a
selection on the printers screen. The GP-502 reduces downtime by not requiring the Ellipse binding element
to be changed when different size books are produced. By use of internal automation, all books whether large
or small are all created with only one common Ellipse element.

Some customer benefits noted for this system include:

• Docks to the Konica Minolta printer to combine printing, punching, collating, and binding into one
convenient step.

• Increases throughput of finishing applications with a completely automated process.

• Creates books that lie-flat and wrap around for easy note taking.

• Operates seamlessly with no supply changeovers required for different size books.

• Utilizes an attractive new element to bind all document sizes.

• Compared to other styles of binding, the unique elliptical shape of the GBC GP-502 element creates a
more stable document that takes up less space when shipping, stacking and storing.

• Easily operable with limited user training.

• Saves costs by bringing out-sourced jobs in-house.

• Outputs printed, punched, bound and neatly stacked documents in the convenient document stacker.

2.2 Ellipse Binding Elements

The Ellipse binding element is available in four colors.

•Black, Qty 200: .......... Type#: Ring Binder RB-101 Black

•Clear, .Qty 200: ......... Type#: Ring Binder RB-101 Clear

•White, Qty 200:.......... .Type#: Ring Binder RB-101 White

•Navy Blue, Qty 200: . .Type#: Ring Binder RB-101 Navy Blue

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2.3 User Interface & Feature Locations

PAPER PATH

See Fig. 1 for an illustration of the GP-502 bind paper path.

FEATURE LOCATIONS:

A. GP-502 screen/display:

Shows operational status of GP-502

B. Paper Tray:

Holds sheets until book is bound and dropped into book drawer.

C. Element Feeder:

Holds Ellipse binding element and feeds element for binding.

D. Paper Punch:

Paper is punched before being delivered to the paper tray.

E. Book Chute:

After the book is bound it is fed through the book chute.

F. Vertical Paper Path:

Sheets are fed along vertical paper path to paper punch.

G. Bypass Path:

Bypassed sheets are fed along this paper path.

H. Front Door:

I. Top Cover & Handle:

J. Book Drawer:

Completed books are stacked in the book drawer.

K. Chip Tray:

Contains punch chips/waste.

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Fig. 1

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3. Installation

The GP-502 should only be installed by a Customer Engineer (CE). Please contact service representative for
installation of this finisher with the host printer.

1. Power Inlet:

The power inlet is located on the rear of the GP-502. Attach the included power cord to the GP-502 at
this location. Only use power that meets the voltage and frequency as listed on the rating label located
on the GP-502.

2. Power Switch:

The power switch is located on the rear of the GP-502.

NOTE: Setting the power switch to the off position will not turn off all power within
the GP-502. Power is passed through the GP-502 by and other finishers.

4. Unit Operation - Bypass

Whenever binding is not selected for the GP-502 bypass will be enabled. For bypass operation no
consideration needs to be made for media weight or size, all acceptable printer paper sizes and weights
can be bypassed.

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5. Unit Operation - Binding

5.1 GETTING TO KNOW THE GP-502

To improve the appearance of the bound
book, flip the rear cover over after the book is
bound. This will cause the spine of the bound
book to be hidden between the rear cover and
the last page of the book body.

When removing the finished books from the
book drawer, do not grasp the book by the
binding loop. Grasping or holding the binding
loop can cause the element loop shape to
change.

The GP-502 will temporarily stop in the process of

creating a book if the main body's (printer) paper feed
drawer runs out of paper; opening and closing the top cover
when in this condition will cause the GP-502 to display a
JAM. Because of this, the top cover should never be
opened while the GP-502 is operating.

To operate the GP-502 three areas of the machine require
regular attention from the operator.

1.Book Drawer:

After the GP-502 completes the binding of a book it is
dropped into the book drawer. The book drawer will
hold up to 35 books before it declares to the printer that
it is full. The number of books held in the drawer is
dependent upon the size of the book created. Larger
books will fill the drawer much sooner than small
books.

The book drawer should never be opened while the
GP-502 is operating. Opening the book drawer while
the GP-502 or printer is operating will result in a paper
jam. After the printer and finishers within the system
have stopped operating it is safe to open the book
drawer.

The GP-502 will alert the operator when the book drawer
requires emptying or when it is open. See the two illustrations to the right.

The GP-502 may temporarily stop during operation. Opening the book drawer of the GP-502 when in this
state will cause a paper jam. Always wait to open the book drawer until the GP-502 operation has completely
stopped.

HIDING SPINE OF BINDING ELEMENT

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2. Punch Chip Tray:

The punch waste tray contains the paper chips/waste that result
from punching holes in the paper. The tray will hold a maximum
of roughly 5,000 punches.

Before emptying the chip tray, wait until the printer and finishers
have finished operating, then open the front door and remove the
chip tray.

The GP-502 will alert the operator when the chip tray requires
emptying or when it is missing. The two illustrations on the right
show the images that the GP-502 screen will display when the
chip tray needs attention.

To empty the chip tray first open the front door, then remove the
chip tray in a waste basket as shown in the illustration. Before
replacing the chip tray in the GP-502, remove any spilled paper
chips by using a vacuum cleaner. The emptied chip tray can now
be inserted into the GP-502 and the front door closed.

3. Element Feeder Drawer:

Before operating the GP-502 binding elements

must be installed into the element feeder drawer. For

detailed instructions on this process see section 5.2.

The GP-502 will alert the operator when the element

feeder drawer is empty or when it is open. See the two

illustrations below.

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5.2 INSTALLING ELEMENTS INTO THE GP-502

1. Open the front door of the GP-502. Then locate the
element drawer, which can be identified by the label
shown below.

Open the element drawer by squeezing the two blue
handles together.

2. Install the elements by aligning the locating hole on
the elements with the rod on the element drawer.

Install the elements after flipping the rear side of the
elements to remove any dust that may be present.

3. Press the elements firmly into place to secure the
adhesive to the element drawer. Failure to perform this
task could lead to element feeding trouble within the
GP-502.

4. A maximum of 115 elements can be installed into the
element drawer. To install additional elements place
them on top of the elements that are already in the
drawer. Always press the elements firmly in the drawer
to properly secure them. Do not overfill the element
drawer; doing so will cause the elements to be
damaged when the drawer is closed.

Elements should be installed into the drawer not to
exceed the Max label.

Continued on next page

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5.2 INSTALLING ELEMENTS INTO THE GP-502

5. When installing additional elements into the
element drawer ensure that each set of
elements is aligned with the previous set.
Precise alignment is not required, yet severe
misalignment should be corrected.

The photo on the right shows an acceptable
amount of misalignment within the element sets.

6. Squeeze the handles of the element drawer
together and then push the drawer into the GP-

502. Always make sure to continue squeezing
the handles of the element drawer until after the
drawer is fully inserted into the machine. Failure
to squeeze the handles while inserting the
element drawer may cause element feeding
errors.

The illustrations below are shown on the GP-502 to aid in the installation of elements

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6. Creating Bind Job

6.1 SETTING FRONT & BACK COVER

The GP-502 requires that a front and back cover be used. Refer
to the media section of this manual for a list of approved cover
weights.

Refer to the printers display, then perform the

following:

1. Check the GP-502 screen and ensure that is

states ready. See Fig. 1

2. Navigate to the (Copy) menu. Select

(Application). See Fig. 2

3. Select (Insert Sheet). See Fig. 3

4. Select an approved cover type for
both the front and back cover. See Fig. 4

6.2 ENABLING BIND FUNCTION

Refer to the media section of this manual for a list of
approved paper weights for the book body.

Refer to the printers display, then perform the following:

1. Navigate to the (Copy) menu. Then select

(Output Setting). See Fig. 4

2. Select the (Ring Bind) function. See Fig. 5

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Fig. 1

Fig. 2

Fig. 3

Fig. 4

Fig. 4

Fig. 5

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7. Media

7.1 Bypass

For bypass operation no consideration needs to be made for media weight or size, all acceptable printer paper
sizes and weights can be bypassed.

7.2 Binding

When binding a book with the GP-502, be certain to only use the approved paper sizes and weights. Using the
incorrect media weight or size will result in poor performance or no operation at all.

Book Size:

The GP-502 is limited to the size of book to which can bound. The number of sheets that can be bound in one
book is dependent upon the weight and thickness of the media. See the below book size restriction based
upon 75 gsm.

Paper Size:

Two GP-502 models exist, one for binding Letter paper (216x279mm) and another for binding A4 paper
(210x297mm). Each GP-502 can only accept one paper size through the bind paper path (A4 or Letter
respectively).

Book Covers:

Covers are required to ensure proper machine operation and book stacking. Not using covers can result in
jams and damage to the books as they are ejected and stacked. See the below list of approved cover types.

Book Body:

The book body is referring to sheets that are not the out covers and are not inserted tabs. The acceptable
media weight of the body of the book is given below.

Tabs:

The GP-502 is capable of binding books containing tabbed inserts that meet the specification given below. No
adjustment or input is required prior to operating a print job containing tabs. Acceptable tabs must have a
shoulder as shown in the illustration below. When feeding tabs they must be fed such that they leave the
printer with the tab on the trailing edge. Failure to comply with either of these requirements will cause a jam
and will prevent binding of the book.

Book Cover, Media Weight

163gsm - 216gsm [90lb Index to 80lb Cover]

Book Body, Media Weight

75gsm - 120gsm [20lb bond to 32lb bond]

Tabs

Not to exceed 163gs m [90lb Index]

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Book Size (Sheets)

Smallest = (5shts+2covers) Largest = (100shts+2covers)

[Assumes 75gsm body and 216gsm covers]

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8. Jam Clearance

The red dotted line parts or rectangular parts in the figures below show the place of the paper jam.

8.1 Bypass Path Jam Clearance

Jam Area A

When the GP-502 is operating in bypass mode and a jam

occurs paper may be left in the GP-502 bypass path. If a sheet

remains in the bypass path the machine will show a jam

screen like that in (Fig.1).

To clear a bypass jam first open the top cover, and then

remove any jammed sheets. See (Fig. 2).

8.2 Bind Path Jam Clearance

When the GP-502 is operating in bind mode and a jam occurs paper sheets may be jammed in multiple
locations. After a jam occurs, view the GP-502 screen for the location of the jammed sheets.

Jam Area B

When the GP-502 displays the screen as shown in (Fig. 3),

follow the steps given below.

Open the top cover, bypass path and the front door as

shown in (Fig. 4). Locate any sheets in the vertical paper

path and then remove them.

Fig. 2

Fig. 1

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Fig. 3

Fig. 4

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Jam Area C

When the GP-502 displays the screen as shown in
(Fig. 1), follow the steps given below.

Open the front door, then rotate the knob marked
(GP3) counter-clockwise to drive the sheet into the
paper tray. (Fig.2)

It is also acceptable to rotate the (GP3) roller
clockwise. This will cause the jammed sheet to be
moved towards the punch, which in some
instances may allow for easier removal of the
jammed sheet. (Fig.3)

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Fig. 1

Fig. 2

Fig. 3

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8.3 Element Jam Clearance

If while binding, the GP-502 jams, then the
binding element that jammed and the sheets will
need to be removed by the operator. When this
type of jam occurs the GP-502 will display the
screen shown in (Fig. 1).

Begin by opening the top cover and the front door.
Remove the sheets from the paper tray (Fig. 2)
Next remove the jammed element as shown in
(Fig. 3). Now inspect the bind paper path of the
machine for any jammed paper.

8.4 Book Jam Clearance

If while ejecting a finished book the GP-502 jams, then
the completed book may need to be removed from the
bind path. (Fig.4)

To clear the jam first open the front door, then rotate the
knob GP4 to full exit the book into the drawer. Once the
book has cleared the book chute the book drawer can be
opened. (Fig.5)

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Fig. 1

Fig. 2

Fig. 3

Fig. 5

Fig. 4

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9. Language Selection

The display located on the GP-502 is capable of displaying
text in five different languages, of which are list below:

•...English

•...French

•...German

•...Italian

•...Spanish

To change the languages follow the below instructions.

1. Select the [INFO] button on the GP-502 home
screen. See (Fig. 1).

2. The screen shown in (Fig. 2) should now be
displayed.

3. Press the blue circle next to the desired language.
The selected language will then show a black circle
within the blue circle.

4. When finished making the language selection press
[SET].

NOTE: If no change in the language is desired, press

the arrow on the left side of the screen to return to

the home screen.

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Fig. 1

Fig. 2

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10. Specifications

115VAC, LTR SIZE

(U.S. Market)

230VAC, A4 Size

Speed
Bind Sheet Size

LTR, 216x279mm (8.5"x11") A4, 210x297mm

Bind Media W eight, Covers
Bind Media W eight, Body
Bind, Clear Covers
Bind, Tabs
Bypass Sheet Size
Bypass W eight
Electrical

115VAC 60Hz, 2.2A 230VAC, 50Hz, 0.98A

Safety

TUV/GS TUV/GS, CE

Dimensions
Weight
Shipping W eight
Manufactured

Assembled in Taiwan

Up to 125 sheets per minute

Same As Host Printer
Same As Host Printer

75gsm to 120gsm

163gsm to 216gsm

7mil, 178µm

1050x655x944 (HxWxL)

533lbs (242Kg)

421lbs (191Kg)

163gsm Max

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