Plockmatic BLM 35, BLM 50 Operator's Manual

Plockmatic BLM 35/50 Production Booklet Maker

Operator Manual

Please read this manual carefully before you use this product and keep it handy for future reference. For safety, please follow the instructions in this manual.

Doc no: X04107E Date: 26 June 2017

Electromagnetic compliance

This product complies with EU Standard EN 55032:2015, Class A. Operation of this equipment in a residential environment could cause radio interference.

NOTE: The domestic environment is an environment where the use of broadcast radio and television receivers may be expected within a distance of 10m of the apparatus concerned.

Introduction

This manual contains instructions on the operation and maintenance of this machine. To get maximum versatility from this machine all operators should carefully read and follow the instructions in this manual. Keep this manual in a handy place near the machine.

Please read the Safety Information before using this machine. 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 misoperation

• 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.

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 off the power and disconnect the power plug (by pulling the plug, not the cable) if any of the following conditions exists:

• 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).

• 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 required to take adequate measures.

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

General safety

WARNING

• Always connect the equipment to a properly grounded power source (wall outlet). 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 machine 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.

• Always locate the equipment on a solid support surface with adequate strength tor the weight of the machine.

General safety, continued

CAUTION

• The machine and its peripherals must be installed and maintained by a customer service representative who has completed the training course on those models.

• Always follow all warnings marked on, or supplied with, the equipment.

• When you disconnect the power plug from the wall outlet, always pull the plug (not the cable).

• Disconnect the power cord before you move the machine. While moving the machine, always exercise care and make sure that the power cord will not be damaged under the machine.

• Always contact service if relocating the equipment.

• Do not move the machine while the machine is running.

• Do not open covers while the machine is running.

• Do not switch off the power while the machine is running. Make sure the machine cycle has ended.

• Lay the power cord in a way that nobody will stumble over it. Do not place things on the cord.

• Never attempt any maintenance function that is not specically described in this documentation.

• Always keep magnets and all devices with strong magnetic elds away from the machine.

• If the place of installation is air-conditioned or heated, do not place the machine where it will be:

• Subject to sudden temperature changes.

• Directly exposed to cool air from an air-conditioner.

• Directly exposed to heat from a heater.

• If the machine is not used over an extended period of time it should be unplugged to prevent damage in the case of overload.

NOTE:

• The indications like front and rear, left and right refer to the paper transport direction.

• The operator manual always has to be available at the place of use of the machine.

• In the interest of technical development the company reserves the right to make

alterations to specications without prior notice!

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TABLE OF CONTENTS

What You Can Do With This Machine ............................................................................. 11

Guide to Components ...................................................................................................... 13

Booklet Maker ............................................................................................................................. 13

User Interface ............................................................................................................................. 16

Control Panel.........................................................................................................................................16

Options .............................................................................................................................. 19

Rotate Crease Trim Module ........................................................................................................ 19

Booklet Maker ............................................................................................................................. 24

Alive Logo..............................................................................................................................................24

Cover Feeder ........................................................................................................................................25

BookFold Module ........................................................................................................................ 26

Trimmer ....................................................................................................................................... 28

BST4000-1 Belt Stacker Module ................................................................................................ 30

BST4000-1 Principle of Operation.........................................................................................................31

1. Basics ............................................................................................... 33

Turning On / Off the Main Power ..................................................................................... 33

RCT, Booklet Maker, BookFold Module, Trimmer & BST Module ............................................... 33

Change staple cartridges and Check Stapler ................................................................ 34

Change left/right staple cartridge(s) ............................................................................................ 34

Check left/right stapler ................................................................................................................ 35

Cover Feeder..................................................................................................................... 35

Loading covers ........................................................................................................................... 35

Emptying the trim waste bin ............................................................................................ 36

Belt Stacker ....................................................................................................................... 37

Setting up Belt Stacker for right-angled mode ............................................................................ 37

Setting up Belt Stacker for straight mode ................................................................................... 38

2. Making Booklets .............................................................................. 39

Guided Start ...................................................................................................................... 39

Guided Start, step by step .......................................................................................................... 39

Changing settings ............................................................................................................ 42

General procedure ...................................................................................................................... 42

Basic settings ................................................................................................................... 42

Input Sheet Size ......................................................................................................................... 42

Selecting standard paper sizes ............................................................................................................. 42

AUTO sheet size ...................................................................................................................................43

Custom input sheet size ........................................................................................................................ 43

Finished Booklet Size ................................................................................................................. 43

Auto trimming ........................................................................................................................................ 43

Custom booklet size .............................................................................................................................. 44

Customizing settings ....................................................................................................... 45

Staple .......................................................................................................................................... 45

Selecting stapling On or Off ..................................................................................................................45

Adjusting staple position........................................................................................................................45

Fold position ............................................................................................................................... 46

Adjusting fold position ...........................................................................................................................46

Cover .......................................................................................................................................... 46

General..................................................................................................................................................46

Cover ..................................................................................................................................................... 47

Air Separation........................................................................................................................................47

Double Sheet Detection ........................................................................................................................47

Purge Cover .......................................................................................................................................... 48

BookFold ..................................................................................................................................... 48

General..................................................................................................................................................48

Selecting BookFold pressure setting ..................................................................................................... 49

Crease ........................................................................................................................................ 50

Crease Mode ......................................................................................................................................... 50

Crease position .....................................................................................................................................50

Fine-tuning booklet appearance ..................................................................................... 51

Set registration (ne adjustment) ..........................................................................................................51

Bleed Trimmer - Asymmetric Side Trim ................................................................................................. 52

Bleed Trimmer - Cover Adjust ............................................................................................................... 52

Hand-feeding ..................................................................................................................... 53

Hand feed mode ......................................................................................................................... 53

3. Tools ................................................................................................. 55

The Tools screen ......................................................................................................................... 55

Stacker full detection .................................................................................................................. 55

Units ............................................................................................................................................ 55

Software version ......................................................................................................................... 56

Paper path light ........................................................................................................................... 56

Language .................................................................................................................................... 56

Service mode .............................................................................................................................. 57

Fold delay ................................................................................................................................... 57

Sheet feeder ............................................................................................................................... 57

Auto Rotate ................................................................................................................................. 58

BookFold offset ........................................................................................................................... 58

4. Jobs .................................................................................................. 59

Handling jobs .................................................................................................................... 59

Saving a Job ............................................................................................................................... 59

Opening and handling stored Jobs ............................................................................................. 60

5. Clearing Misfeed(s) ......................................................................... 61

Clearing misfeed(s) .......................................................................................................... 61

General ....................................................................................................................................... 61

RCT Module ....................................................................................................................... 62

Clearing misfeed(s) ..................................................................................................................... 62

Infeed “A” area and exit “D” area...........................................................................................................62

Registration and creaser area ............................................................................................................... 63

Booklet Maker ................................................................................................................... 64

Clearing misfeed(s) ..................................................................................................................... 64

Inside the Booklet Maker ....................................................................................................................... 64

Clearing misfeed in infeed area.............................................................................................................65

Clearing misfeed in folder area .............................................................................................................66

Cover Feeder..................................................................................................................... 67

Clearing misfeed(s) in vertical transport area ............................................................................. 67

BookFold Module ............................................................................................................. 68

Clearing misfeed(s) ..................................................................................................................... 68

Inside the BookFold Module .................................................................................................................. 68

Trimmer .............................................................................................................................69

Clearing misfeed(s) ..................................................................................................................... 69

Clearing misfeed in input area...............................................................................................................69

Clearing misfeed in exit area ................................................................................................................. 70

Belt Stacker ....................................................................................................................... 71

Clearing misfeed(s) ..................................................................................................................... 71

Clearing misfeed on belt stacker ........................................................................................................... 71

6. Troubleshooting .............................................................................. 73

Fault codes........................................................................................................................ 73

General ....................................................................................................................................... 73

RCT fault codes .......................................................................................................................... 73

Booklet Maker fault codes .......................................................................................................... 74

Cover Feeder fault codes ........................................................................................................... 75

BookFold Module fault codes ..................................................................................................... 76

Trimmer fault codes .................................................................................................................... 77

Belt stacker fault codes ............................................................................................................... 77

General fault codes ..................................................................................................................... 78

Clear Misfeed(s) .................................................................................................................................... 78

Close cover(s) ....................................................................................................................................... 78

Empty stacker!.......................................................................................................................................78

7. REMARKS ........................................................................................ 79

Do’s And Don’ts ................................................................................................................ 79

Where to put Your Machine ............................................................................................. 80

Machine environment ................................................................................................................. 80

Power connection ....................................................................................................................... 80

Access to machine ...................................................................................................................... 81

Maintaining Your Machines ............................................................................................. 82

Cover Feeder .............................................................................................................................. 82

Cleaning feed rollers and paper separator pad ..................................................................................... 82

BookFold Module ........................................................................................................................ 83

Cleaning feed belts................................................................................................................................83

Pressure springs ...................................................................................................................................84

RCT Module ................................................................................................................................ 85

Cleaning the paper path transportation nip rollers (12x) ....................................................................... 85

Cleaning the xing rollers (3x) ............................................................................................................... 86

Cleaning the registration cross roller (4x) & friction tires (4X) ............................................................... 87

Cleaning the rotator rollers (2x) ............................................................................................................. 88

Cleaning the paper path sensors (5x) ................................................................................................... 88

Cleaning of creaser tools (2x) ...............................................................................................................90

Adjustment of Bleed Trimmer registration angle (parallel cut)............................................................... 91

Adjustment of Creaser registration angle .............................................................................................. 92

Best practices for the BLM 35/50 system....................................................................... 93

Limitations of the BLM 35/50 system ............................................................................. 94

8. Specication ................................................................................... 97

Machine Specications .................................................................................................... 97

Rotate Crease Trim Module (option) ........................................................................................... 97

Booklet Maker ............................................................................................................................. 98

Cover Feeder Module ................................................................................................................ 99

Trimmer Module .......................................................................................................................... 99

BookFold Module ..................................................................................................................... 100

BST4000-1 Belt Stacker Module .............................................................................................. 100

System Set Size Guide ............................................................................................................. 101

Cables, plugs and jumpers ....................................................................................................... 105

INDEX.................................................................................................. 106

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What You Can Do With This Machine

BF50 BookFold Module (option)

Belt Stacker

FTR50 Trimmer Module (option)

BLM50 upgrade kit (option) incl. Alive Logo

BLM35/50 Production Booklet Maker

CF50 Cover Feeder Module (option)

RCT50 Rotate Crease Trim Module (option)

The Plockmatic BLM50 or the Plockmatic BLM35 Production Booklet Maker System

consists of:

Rotate Crease Trim Module (optional), also referred to as the RCT Module or the RCT Cover Feeder Module (optional), also referred to as the Cover Feeder or the CF BookFold Module (optional), also referred to as the BookFold or the BF

Trimmer Module (optional), also referred to as the Trimmer or the TR

BST4000-1 Belt Stacker Module (optional), also referred to as the BST Module or the BST

Together they form a system that allows full bleed booklet making online with the Printer. A capacity enhancement is the BLM50 upgrade kit. This kit increases the capacity of the

BLM35 Booklet maker from 35 sheets to 50 sheets. This means that instead of 140 page booklets, 200 page booklets are now possible. The BLM50 upgrade kit also includes the Live logo feature. The logo below the user interface will be illuminated, allowing the user to monitor the system status from a distance.

The print-outs rst enter the Rotate Crease Trim Module. The RCT Module is able to

rotate small(er) sheets from long edge feed to short edge feed to maintain high printer productivity. In order to avoid toner cracking at the spine when folded, the RCT can be programmed to crease the cover sheet. The RCT can also trim the long sides of the booklet sheets to deliver booklets in the desired size. To enable full bleed booklets, a

Trimmer Module must be installed after the Booklet Maker, see below.

From the RCT, the printed sheets are transported into the BLM50 or BLM35 Production Booklet Maker where they are compiled in the stapler area.

If a Cover Feeder Module is installed in the Booklet Maker, it can add any type of cover, in colour or black and white, to the printed set. The Booklet Maker jogs and staples the set.

continued on next page

continued from previous page

The set is then transported further into the Booklet Maker to the folding area where the set

is folded into a booklet and delivered out to the belt stacker or a downstream module.

After the Booklet Maker, an optional BookFold Module can be attached. The stapled and folded books will be fed into the BookFold Module where the spine of the booklets are

attened square. The booklets will now have the look of a perfect bound book. Finally, the

booklets are fed out to the optional Trimmer or directly to a Belt Stacker.

When a larger number of sheets are folded, an effect called creeping occurs. In order to eliminate creep, an optional Trimmer Module can be attached after the Booklet Maker or BookFold Module. The booklets are transported from the Booklet Maker or BookFold Module into the Trimmer where the front edge will be cut off. The Trimmer combined with an RCT Module in front of the Booklet Maker creates the possibility to create full bleed booklets.

To allow longer, unattended runs there is an optional high capacity belt stacker available. The BST4000-1 Belt Stacker Module will stack up to 1000 A4 or 8,5 × 11” booklets of 4

pages.

In addition to producing booklets inline, it is possible to use the Booklet Maker System for hand-feeding.

The user interface/control panel is of

touch screen type. Point at the screen and press the button or function you wish to make changes to. In this sample screen shot, the Staple button is pressed.

A sub screen is shown.

Make your changes and conrm by

pressing the green check mark or exit without making any changes by pressing the red X. Pressing the home symbol takes you back to the main or home screen.

Guide to Components

Booklet Maker

1. Top cover

2. Cover for Hand Feed

3. Latch handle

4. Live Logo, only on 50 sheet option

5. Belt Stacker

6. Belt Stacker Cover

7. Slot for optional Cover Feeder

Booklet Maker, continued

2 3

1. Belt Stacker Connector

2. Upstreams Communication

3. Downstreams Communication

4. Power Connection

5. Printer interface

NOTE:

How to connect cables, plugs and jumpers is described at the end of this manual.

Booklet Maker, continued

Parts that are important for setup, adjustments, troubleshooting or maintenance are highlighted below.

1. Hand feeding paper guides

2. Compiler area

3. Staple cartridges (incl. stapler heads)

4. Main power switch

5. Set thickness sensor

6. Control panel

7. Fold roller guide

8. Staple cartridge ejection lever

23456

User Interface

The Plockmatic BLM50 or BLM35 Production Booklet Maker System is controlled from a panel

located on the Booklet Maker. The control panel will allow you to set up, adjust and operate the complete system. An optional “Alive logo” makes the state of system visible from a distance.

NOTE: Depending on modules and features installed, the screen may look different from what you see here. Some functions are greyed out or not visible at all and remaining buttons may

stretch to t the screen. This manual will most often show a fully congured system.

Control Panel

The control panel is of touch screen type. Point at the screen and press the “button” to

reach the desired function or change the desired setting.

The Start Screen

When the system power is switched on, the Start screen will be shown. From here you can choose to set up Booklet Production, perform a Guided Start, retrieve stored jobs or access the General System Settings.

Settings for Booklet Production

Pressing the [Booklet Production] button in the Start Screen opens the Settings for Booklet Production screen. From here you can reach all detailed settings for setting up the job.

A counter shows the number of

booklets produced. Clear will reset.

Detailed Settings

Pressing, for example, the [Staple] button in the Settings for Booklet Production screen opens the Staple settings screen. Here you can perform detailed settings concerning stapling. Explore this and other settings more thoroughly in section 2,

“Making Booklets.”

Guided Start

Guided Start is a function that takes you through all the basic settings the Booklet Maker System needs for booklet production in eight easy steps. See “Guided Start” in section 2

“Making Booklets” for details.

The Jobs Screen

Pressing the [Open Jobs] button in the Start screen opens the Open saved Job screen. From here you can open a saved job. Jobs can be stored, deleted, customized etc. Handling jobs is described in section

4, “Jobs”.

General System Settings

Pressing the [Tools] button opens the General Systems Settings screen. From here you can change basic settings like the display language, setting units from millimeters to inches and more. See section 3,

”Tools” for how to work with the Tools

screen.

The Please wait screen

While the machine sometimes needs time to perform changes in settings, the Please wait screen will be shown.

Power save mode

When the Booklet Maker System is in a ready state, it will enter power save mode after 20 minutes of inactivity.

To recover from Power save mode,

touch the screen or send a print job to the Booklet Maker System.

The Booklet Maker System can also

be forced into Power save mode by pressing the [Power save mode] button.

When the Booklet Maker system is processing or when there is a jam state it will not enter power save mode.

Information on screen

Depending on how the system is

congured, the information on the

screen changes and the size of the

buttons will adapt to t the screen.

This sample screen shows a fully

congured Booklet Maker system

with RCT, Cover Feeder, BookFold Module and Trimmer.

This sample screen shows exactly the same screen as above but this

time the system is congured only

with a Trimmer.

Options

Rotate Crease Trim Module

1. Top cover

2. Side door

Rotate Crease Trim Module, continued

Connections bracket

1. Exit slot

2. Trim waste transport

3. Waste container

4. Cable protector

NOTE

How to connect cables, plugs and jumpers is described at the end of this manual.

Rotate Crease Trim Module, continued

Parts that are important for setup, adjustments, troubleshooting or maintenance are highlighted below.

1. Exit section “D”

2. Bleed trimmer circular knives

3. Infeed Section “A”

4. Main switch

5. Counter

31 4

Rotate Crease Trim Module, continued

2 3 4

1 Waste chute(s) 2 Creaser registration adjustment 3 Bleed trimmer registration adjustment 4 Latch handle, slide

Rotate Crease Trim Module, continued

1 Creaser tools 2 Jam clearance bafe, ne registra-

tion, section “C”

3 Jam clearance bafe, coarse regis-

tration, section “B”

4 Rotator

Booklet Maker

Alive Logo

With a BLM50 upgrade kit installed, the three

stripes below the user interface will signal status

as follows:

Not illuminated - System in power save mode or

switched off.

Steady blue - System is on and ready.

Alternating blue/yellow - Soft stop (staples low,

cover low, stacker full, waste bin full).

Alternating blue/red - Jam or malfunction

Cover Feeder

Parts that are important for setup, adjustments, troubleshooting or maintenance are highlighted below.

1 Loading capacity mark 2 Rear side guide 3 Feed roller assembly 4 Paper separator pad

5 Front side guide 6 Paper orientation indicator 7 Air nozzle (2x)

8 Jam clearance bafe

BookFold Module

1. Top cover

2. Base

3. Connections

4. Cable protector

NOTE:

How to connect cables, plugs and jumpers is described at the end of this manual.

BookFold Module, continued

Parts that are important for setup, adjustments, troubleshooting or maintenance are highlighted below.

NOTE:

Upper feed belt on operator side cannot be lifted fully

BookFold Module, top view, non operator side upper feed belts lifted up

1 Upper feed belt release latch 2 Lower feed belts 3 Upper feed belts

Trimmer

1. Top cover

2. Trim bin

3. Base

4. Connections

5. Cable protector

NOTE:

How to connect cables, plugs and jumpers is described at the end of this manual.

Trimmer, continued

Parts that are important for setup, adjustments, troubleshooting or maintenance are highlighted below.

Trimmer, top view

1 Set counter 2 Exit drive lifting lever 3 Trimmer stop 4 Exit drive release 5 Exit compressing brackets

6 Infeed roller shaft 7 Trimmer fan 8 Transport belt 9 Upper trim knife

BST4000-1 Belt Stacker Module

The BST4000-1 High Capacity Belt Stacker Module is an option available for the Plockmatic BLM50 or BLM35 Production Booklet Maker System. The stacker can be

congured in a straight line after the booklet maker system or at a 90 degree angle.

Parts that are important for setup, adjustments, troubleshooting or maintenance are highlighted below.

1 Control panel 2 Conveyor belt

1 Stacking tray 2 Conveyor belt 3 COM-cable 4 Side guides 5 Front end side guide adjustment knobs 6 Leg assembly 7 Control panel box 8 Height adjustment knobs (two on each leg) 9 Rear end side guide adjustment knobs (underneath)

BST4000-1 Control Panel

BST4000-1 Belt Stacker Module, continued

(1)

1 Power switch (on/off) 2 Belt speed selector 3 Run-out button (full speed)

BST4000-1 Principle of Operation

The belt is triggered by a signal from the Booklet Maker and will run for a set time.

The belt speed can be adjusted in order to optimize the stacking function for various materials.

The Run-out button is used to gather the material after a job is nished.

The belt then moves at the highest speed, independent of the speed setting.

The power switch is also used to reset the unit after an overload situation.

(3)

(2)

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1. Basics

Turning On / Off the Main Power

RCT, Booklet Maker, BookFold Module, Trimmer & BST Module

1

Make sure that the Booklet Maker, RCT module (optional) and BST power cords are plugged into the wall outlet.

NOTE: BookFold (optional) and/or Trim (optional) Modules are both powered from the Booklet Maker.

2

Open the Booklet Maker top cover [A].

[A] [B]

[C] [D]

3

Set main power switch [B] on Booklet Maker to ON position. If a BookFold Module and Trimmer are attached, they will be powered on via the Booklet Maker main power switch.

4

Close the Booklet Maker top cover.

5

Open the top cover of the RCT [C].

6

Set the main power switch [D] to ON position.

7

Close the RCT top cover.

[E]

8

Set main power switch [E] on the BST Module to ON position.

Change staple cartridges and Check Stapler

The staple cartridges contains approximately 5000 staples each. Each cartridge includes all wearable parts. The cartridges may need to be removed either for replacement or for jam clearance.

Change left/right staple cartridge(s)

The Booklet Maker will indicate “Replace left/ right/left and right staple cartridges” when there are approximately 20 staples left in the stapler cartridge. Replace the indicated staple cartridge by doing the following:

1

Open the Booklet Maker top cover.

2

Remove one or both staple cartridges by lifting the lever [A], pressing either or both levers [B] and pulling either or both staple

[B]

cartridges [C] out using the grip [E] at both sides of the staple cartridge.

NOTE:

Lever [A] controls the stapler guides [D]. It is kept in place by a magnet and can be hard to release. Pressing either lever [B] makes it a bit easier to

overcome the force of the magnet.

[A]

[C]

[D]

3

Replace by pushing a new staple cartridge into stapler until it snaps into position.

4

Put the stapler guides [D] back in position so that lever is locked by the magnet.

5

Close booklet maker top cover and restart the job.

[E]

Check left/right stapler

If the Booklet Maker indicates “Check right/left/ right and left stapler”, it means that there is a jam in the indicated stapler. Remove the stapler cartridge as described above.

1

Open the Booklet Maker top cover.

2

Remove either or both staple cartridge(s) as described above.

3

Remove any sheets left in the Booklet Maker and look for jammed staples stuck in the sheets.

4

Look inside the staple cartridge for jammed staples and remove them if any.

5

Look at the clinchers [A] and remove any jammed staples.

6

Push the staple cartridge(s) into stapler until it snaps into position and lock stapler guides in position as described above.

Cover Feeder

Loading covers

[A]

7

Close Booklet Maker top cover and restart job.

NOTE: If the error message persists for no reason or if staple jam reoccurs, replace the staple cartridge as described above.

1

Make sure the cover sheets are well fanned to avoid misfeeds or double-feeds.

2

Align the cover sheets well to achieve a

reliable feeding operation and good nishing

results.

3

Make sure that the ink has completely dried, to avoid smearing.

4

Press on top of either air nozzle [A] to lower the paper bin. Load the covers facing downwards into the paper bin.

[B]

5

Adjust side guides [B] up against the cover sheets until there is no clearance.

NOTE: Make sure covers are same size as sheets fed to booklet maker. When using an RCT, see Note under “Changing settings, Finished Booklet Size, Custom booklet size”.

Emptying the trim waste bin

Remove the trim waste bin by lifting it and pulling it out.

Trim bin

The Stacker can be used in either right-angled or in-line conguration with the Booklet

Maker. In-line mode is preferred if running heavy and large booklets.

Setting up Belt Stacker for Right-Angled Mode

Tighten the Side Guides at both

Move the inner Side Guide [A] as far as possible towards the

Setting up Belt Stacker BST4000-1

Belt Stacker

Setting up Belt Stacker for right-angled mode

Follow these steps to correctly set up the Stacker

1

[B]

[A]

Move the inner Side Guide [A] as far as possible towards the Booklet Maker.

Booklet Maker.

2

Adjust the outer Side Guide [B] to give at least 5mm (1/4”) play.

Adjust the outer Side Guide [B]

Tighten the Side Guides at both

to give at least 5 mm play.

ends.

3

Adjust the stacking with belt speed

ends.

selector.

Adjust the stacking with belt

speed selector. See page

11.

5 mm

Setting up Belt Stacker for Straight Mode

Adjust the stacking with belt speed

Adjust Side Guides to their outermost position by loosening

Setting up Belt Stacker for straight mode

1 Adjust Side Guides to their

outermost position by loosening knobs [A].

knobs [A].

2 Adjust the stacking with belt speed

selector [B].

selector.

[A]

[B]

2. Making Booklets

Guided Start

Guided Start is a function that takes you through all the basic settings the Booklet Maker System needs to start booklet production in a few easy steps. Customizing settings and

ne adjustments are described later in this chapter.

Guided Start, step by step

Guided Start

Press the [Guided Start] button to enter the Guided Start procedure.

Guided Start 1/8

This is the rst of up to 8 screens.

Depending on how the system is

congured and your selections

during this procedure, the number of screens may be less than 8.

Conguration of the system also

affects the information shown and

button size will adapt to t screen.

To proceed from one screen to

another, press the [Next] button.

Guided Start 2/8

Select the sheet size loaded for the job by pressing the corresponding button.

For other sizes, follow “Custom sheet size” described in section “Basic Settings” below.

Guided Start 3/8

Choose either of two suggested formats (except for B4 which only has one suggested format).

When Face Trim is set to Auto, a minimum trim, based on the information from Set Thickness Sensor, is calculated.

To set the trim manually, follow

“Finished Booklet size” described in

section “Basic Settings” below.

Guided Start 4/8

Select whether the Cover Feeder is to be used or not and press the corresponding button.

Guided Start 5/8

Load the covers face down.

NOTE: Make sure covers are same size as sheets fed to the Booklet Maker.

When using the bleed trim function

and feeding covers at the same time, make sure covers loaded in Cover

Feeder are same size as sheets fed

from RCT to the Booklet Maker.

Guided Start 6/8

Select whether or not the booklet should have a square formed spine and press the corresponding button.

NOTE:

If the job includes a small number

of lighter weight sheets, the square forming action will be switched off and the BookFold Module will be bypassed.

Guided Start 7/8

Select whether the booklets should have a creased cover or not. This feature is used to avoid high area coverage toner cracking on the spine on booklets containing less than 6 sheets. Press the corresponding button.

After you are done, press the [Finish]

button to conclude the Guided Start.

Guided Start 8/8

All settings needed to begin

producing booklets are now set.

Start production by sending the print job from the printer.

After the job has been sent to the

Booklet Maker System, the “Settings for Booklet Production” screen is shown.

From here you can customize and

ne-tune settings, save the job and

access the Tools screen.

Customizing and ne-tuning settings

is described below in this section. How to save jobs is described in section 4, “Jobs.”

Tools are described in section 3,

“Tools.”

Press Home to return to the “Start Screen”.

Changing settings

General procedure

Settings can changed in one of two ways. “Temporary”, which means that the changes will remain until a new job is loaded or “Permanent”, which means that the changes will be stored as a job.

This job can later be recalled.

Procedure for temporary changes:

From the Settings for Booklet Production screen, select the option you wish to alter and make your

selection. Conrm by pressing the green [check] button. You will be returned to the Settings for

Booklet Production screen

Procedure for permanent changes:

To keep your new settings, press the [Save current settings] button. Follow on screen instructions

to save your current settings as a new job or to an existing job.

NOTE: Choose either of the above mentioned procedures when changing size, stapling, trimming, covers or square forming as follows.

Depending on how the system is congured, the number of settings that can be selected varies.

The information on the screen and the size of the buttons will adapt to t the screen. Examples

below shows a fully congured system.

Basic settings

Input Sheet Size

Selecting standard paper sizes

From the Settings for Booklet Production screen, press the [Input Sheet Size] button.

Select any standard paper size by pressing the corresponding button and save choice by pressing the green [check] button.

Depending on conguration, available

standard paper sizes may differ. The LEF paper sizes are only available if

there is a RCT installed.

For other paper sizes, follow “Custom input sheet size” as described on the next page.

NOTE:

Change of paper size will set Staple

position, Fold position, BookFold and Crease to Auto and Cover to Off. Any Fine-tuning (see section below) and

the “Booklets produced” counter will

also be reset.

AUTO sheet size

AUTO means that the Booklet Maker will adjust to the paper size information sent from the printer.

Auto Rotate will be turned on and a nished booklet size will be chosen from a predened list i.e.

the [Finished Booklet Size] button will be greyed out. No other settings will be affected.

Custom input sheet size

From the Input sheet size screen, press any of the Custom size buttons and then press the [Edit] button.

NOTE: Changing to a Custom input sheet size will NOT change Staple position, Fold position, Cover, BookFold, Crease or Fine adjustment settings.

The “Booklets produced” counter will still be

reset.

Select Length and/or Width and key in the desired value. Save the custom size format by pressing the [check] button.

Finished Booklet Size

Auto trimming

Three different custom paper sizes can be stored.

NOTE: A full number (incl. decimal point and fractions

of an inch/mm) must be entered before the green [check] button appears.

Save setting by pressing the green [check] button.

From the Settings for Booklet Production screen, press [Finished Booklet Size].

Trimming can now be set to either of two

suggested formats (except for B4 which only has one suggested format) or Custom Booklet Size.

When Face Trim is set to Auto, a minimum trim, based on the information from Set Thickness Sensor, is calculated.

For custom sized booklets, see below.

Custom booklet size

To set the trim manually, press [Custom Booklet Size] and then [Edit].

To adjust the amount of face trim, press the number on the [Length] button and type in the desired length of the booklet, decimals included. Also, the [plus] and [minus] buttons can be used to change the numbers. The amount of face trim is displayed in the box.

Press the green [check] button to conrm or

continue adjusting the amount of bleed trim.

To also adjust the amount of bleed trim, press the number on the [Width] button and type in the desired width of the booklet, decimals included. Also the [plus] and [minus] buttons can be used to change the numbers. The amount of bleed trim is displayed in the box.

Press the green [check] button to conrm.

Back in the Finished Booklet size screen, the

size of the nished booklet and the amount of

face and bleed trim is displayed.

Press the green [check] button to conrm.

NOTE: When using the bleed trim function and feeding covers at the same time, make sure covers loaded in Cover Feeder are the same size as sheets fed from the RCT. According to the example on the left, covers must be 300x450mm.

Customizing settings

Staple

Selecting stapling On or Off

From the Settings for Booklet Production

screen, press the [Staple] button.

Select On or Off by pressing the corresponding

button and save setting by pressing the green [check] button.

Adjusting staple position

From the Settings for Booklet Production

screen, press the [Staple] button.

Set to Manual, the staple position can be altered

up to 3 mm (0.12”) on either side of the fold.

Press the [+] button move position closer to the

lead edge and press the [-] button move position

closer to the trail edge. Save setting by pressing

the green [check] button.

NOTE:

This change can be performed during run.

Set to Auto, the Booklet Maker uses the set

thickness sensor to adjust the staple position.

Press the [Auto] button and save setting by

pressing the green [check] button.

Fold position

Adjusting fold position

From the Settings for Booklet Production

screen, press the [Fold position] button.

The position of the fold can be changed up to 3

mm (0.12”) on either side of the center of the set.

Press the [+] button move position closer to the lead edge and press the [-] button move position closer to the trail edge. Save setting by pressing

the green [check] button.

NOTE: This change can be performed during run. You may want to turn off trimming to see the

result more clearly when you move the fold

position.

Set to Auto, the Booklet Maker uses the set

thickness sensor to adjust the fold position. Press the [Auto] button and save setting by pressing the green [check] button.

Cover

General

If the optional Cover Feeder is installed, the [Cover] button will be visible in the control panel. If enabled, the cover feeder will automatically feed one sheet to each set from the printer, or one sheet to each manually, hand-fed set.

A higher paper weight, pre-printed cover is fed to the set waiting in the compiler. The set and the cover are then stapled and folded together.

Depending of system conguration, the booklet is then fed to the Belt Stacker, BookFold Module or

Trimmer.

NOTE: Make sure sheets fed from Cover Feeder are the same size as sheets fed to booklet maker from printer or by hand. When using an RCT, see Note under “Changing settings, Finished Booklet Size, Custom booklet size”.

NOTE:

After selecting Cover [Yes], when the green [check] button is pressed, the Cover Feeder will try to

move the rst sheet into feeding postion. Therefore, load covers before pressing the green [check]

button to avoid the error message “Load covers” from being shown. See section 1, “Basics” for how to load covers.

The Cover Feeder can also be used as a regular feeder. See section 3, “Tools”.

NOTE:

In case of a cover feeding jam/error, it is difcult to remove a stuck cover due to the very strong

separation nip. Removing the stack of sheets and then using the purge button on the stuck sheet is the easiest way to remove a cover that is stuck.

Cover

Air Separation

From the Settings for Booklet Production screen, press the [Cover] button. Press the

[Yes] button and conrm by pressing the green

[check] button.

You may want to increase the Air ow when

running thick, heavy covers. From the Cover screen, press the [Air separation] button.

Set the desired amount of air ow by pressing

the corresponding button and save setting by pressing the green [check] button. Default setting is 40%.

Double Sheet Detection

From the Cover screen, press the [Double sheet detection] button. Set the detection to On or Off by pressing the corresponding button and save setting by pressing the green [check] button.

Normally, double sheet detection should be set to “On” when you are feeding covers. However, if you experience “false double sheet feeds”, for example when running covers that are thick, with dark print or with mixed prints on the covers, the double sheet detection can be set to Off.

NOTE: Misfeed detection will work regardless of how Double Sheet detection is set.

Purge Cover

The Purge mode is used when you want to

completely empty the Cover Feeder from covers.

1 Remove all cover sheets from the bin.

2 Press the [Purge Cover] button and conrm

by pressing the green [check] button. The

NOTE: If you open and close the top cover without removing the cover sheet, the cover sheet will be stapled and folded and then fed to the stacker.

pre-fed cover sheet will now be fed into the Booklet Maker to the stapling area, but will not be stapled.

3 Open top cover and remove the cover sheet.

BookFold

General

The BookFold Module has three different settings - Manual, Auto and Off.

In Manual mode, there are eight different modes of BookFold pressure to choose from. Set to Auto, information from the set thickness sensor in the Booklet Maker is used to calculate the most appropriate mode between 1 and 7. See guidance table below. Select Off to bypass the BookFold Module without any square forming action.

NOTE: When the BookFold Module is set to Auto and the booklet has less than approximately 6 sheets/ booklet, the BookFold Module will bypass the square forming action.

For some jobs, Auto mode may not provide the optimum result. In this case, ne tune by selecting

a mode in Manual mode - see the table below.

Mode 8 is a heavy duty setting in case of extra demanding media. Mode 8 is not included in the

Auto setting and therefore must be selected manually.

Use the manual modes to override the auto function. There are eight different manual modes to select from.

Table below is approximate numbers and is based on 80 gsm / 20 lb Bond sheets.

Mode Number of sheets in the set Notes

1 Approximately 6 to 10 2 Approximately 11 to 16 3 Approximately 17 to 22 4 Approximately 23 to 29 5 Approximately 30 to 35 6 Approximately 36 to 43 7 Approximately 44 to 50 8 Heavy duty setting in case of

extra demanding media.

BookFold pressure settings guidance table

continued on next page

The table below shows highest supported BookFold pressure settings on BLM35 and BLM50 Production Booklet Maker systems.

NOTE: The following table indicates maximum BookFold pressure setting that can be used on the Production Booklet Maker systems without slowing the printer down.

Number of sheets A4 A3 SRA3 8.5x11" 11x17" 12x18"

1-5 2 4 7 1 4 7 6-10 4 7 8 4 7 8 11-15 7 8 8 7 8 8 16-20 7 8 8 7 8 8 21-30 8 8 8 8 8 8 31-50 8 8 8 8 8 8

NOTE: When square forming thick booklets with a thin cover, the cover sheet may be spaced away from the body of the book and/or it may be crushed in the square forming process. This phenomenon is eliminated/reduced by using a heavier media as the cover. If using a heavier cover is not an option, using a lower BookFold pressure setting in the square forming process may improve booklet appearance.

Selecting BookFold pressure setting

From the Settings for Booklet Production

screen, press the [BookFold] button.

Press the [Manual] button and select the desired amount of pressure using the [+] and [-]

buttons. Save setting by pressing the green

[check] button.

Crease

The Crease function makes it possible to crease the cover sheet of the booklet in order to avoid

toner cracking or aking at the fold.

Crease Mode

Crease position

From the Settings for Booklet Production screen, press the [Crease] button.

Press the corresponding button to choose [On Fine], [On Coarse] or [OFF].

Fine is recommended for cover sheets less than 120 gsm / 32 lb Bond. For sheets heavier than that, select Coarse.

When you want to turn the Creaser off, select Off.

Press the green [check] button to conrm.

The crease is initially set to the center of the

sheet. Operators have the option to offset the position of the crease using the [+] or [-] buttons.

Press the [+] button move position closer to the

lead edge and press the [-] button move position closer to the trail edge. Regardless if you

chose Fine or Coarse creasing, each press of a

button will move the crease 0.1 mm / 0.004”.

When done, press the green [check] button to

conrm.

The illustration shows that the crease is offset

0.5 mm towards the trail edge.

Fine-tuning booklet appearance

Set registration (ne adjustment)

You can ne-tune the booklet quality by adjust-

ing the joggers in the booklet maker.

From the Settings for Booklet Production

screen, press the [Finished Booklet Size] button.

From the Finished Booklet size screen, press

the [Set registration (ne adjustment)] button.

Press the [-] and [+] buttons to alter either or both registration values. Negative value means a tighter registration.

NOTE:

Too tight of a setting may worsen the result.

After setting registration value, press the [Check

set registration] button and follow the instructions on screen.

If you are satised with the registration, conrm

by pressing the green [check] button. If not, press the [-] and [+] buttons to enter new value. Check out the new value by pressing the

[Verify adjustments] button.

Press the green [check] button when you are

satised.

Bleed Trimmer - Asymmetric Side Trim

From the Finished Booklet size screen, press the [Asymetric Side Trim] button.

Choose Asymmetric Side Trim if you want to

offset the bleed trim. Move using the [+] and [-]

buttons and press the green [check] button to

save setting.

Settings as in the example above would result

in a booklet with trim settings shown in the im-

age to the left.

Bleed Trimmer - Cover Adjust

From the Finished Booklet size screen, press the [Cover Adjust] button.

Choose Cover Adjust to compensate for different

shrinkage of body- and booklet cover stock. This

can occur under some conditions and can be

caused by different paper stocks shrinking due to

the heat and pressure of the fusing process.

Adjusting these settings can improve booklet

appearance, especially if the cover is dark and

the body sheets are bright.

The shown example will make the cover sheet

0.7mm bigger than the body stock.

Hand-feeding

The Booklet maker can be operated in two modes. On-line mode, when used together with

the printer, or off-line mode, working as a stand-alone unit.

Hand feed mode

[A] [C][B]

1

Setup the Booklet Maker to the correct paper size.

2

Open the Hand Feed Cover [B].

3

Adjust the hand feeding paper guides [A] to the correct paper size.

4

Start hand feeding sets [C] when the text [Ready to feed!] is shown in the user interface.

5

To stop hand feeding, close the Hand

Feed Cover.

NOTE:

RCT features will not be available.

Page intentionally blank.

3. Tools

The Tools screen

From the Start screen or the Settings

for Booklet Production screen, press the [Tools] button to get to the General System Settings screen. Select the setting you want to change by pressing the corresponding button.

Press the green [check] button to save your changes.

Stacker full detection

Units

Set Stacker Full Detection to ON if you want

the system to stop and cycle down when the stacker is full.

Select millimeters or inches by pressing the cor-

responding button.

Software version

Paper path light

Select module by pressing the corresponding button to display the software version. Press [Exit] button to go back to the Settings screen.

This function is for service purposes. To turn the paper path light on, press [ON 5 min]

button and save by pressing the [OK] button.

Language

Select desired language by pressing the corresponding button.

Service mode

Fold delay

This function is for authorized service personnel

only and is password protected.

With this feature, the set will stay under pressure between the fold rollers for an extended

time to provide a atter fold. This only applies

to sheet sizes shorter than 400mm or 15.8” and for applications over 10 sheets. In hand feed mode and feeder mode from the CF, the fold delay will automatically switch off.

Sheet feeder

This function allows you to use the Cover Feed-

er as a regular Feeder. Load the Cover Feeder, enter the desired number of sheets in each set and press the [Start] button to begin folding. Press the [Stop] button to stop.

See section 1, “Basics”, for how to load the

cover feeder.

See section 2, “Making Booklets” for how to ad-

just Air Separation and Double sheet detection.

NOTE:

To avoid the error message “Load covers”, load

covers before pressing the [START] button.

Auto Rotate

If your system includes the optional RCT mod-

ule, you can select whether you want Auto

Rotate function to be ON or OFF by pressing

the corresponding button.

It is recommended to keep this ON. When turned on, the Rotator will automatically

rotate all sheet sizes sent from the printer in long edge feed, enabling higher printer productivity.

Selecting OFF will prevent sheets from being

rotated when possible. Sheet length has to

exceed 275mm / 10.6”. Otherwise Auto Rotate

will automatically be changed to ON and sheets will be rotated.

BookFold offset

The BookFold pressure setting is set to a standard that should suit most applications. Operators have the option of sharpening or softening the square edges based on application or preference. Customizing this setting will affect modes 1 to 7 but not mode 8.

Select sharper edges by pressing the [+] button or softer edges by pressing the [-] button.

NOTE:

BookFold Offset affects modes 1 -7 only.

4. Jobs

Handling jobs

The Booklet Maker has a maximum storage capacity of 20 different jobs. To make

temporary changes in the actual job settings or temporary changes of a stored job, see section 2, “Making Booklets.” From the Start screen, press the [Jobs] button to be able to store, change or delete jobs.

Saving a Job

To store a job, press from the Settings for Booklet Production screen.

Press the [Save as a NEW job] button and then press the green [check] button to continue.

The [Save to existing job] button is only available if a job is currently loaded.

Enter a job name and save by pressing the green [check] button.

To delete last character, press the [←] button

Opening and handling stored Jobs

To access already stored jobs,

press from the Start Screen.

Open (load) any stored job by pressing the job

and conrm by pressing the green [check] mark.

Delete any stored job by pressing the job but-

ton, the waste bin symbol and then conrm by

pressing the [Yes] button.

NOTE:

The currently loaded job cannot be deleted.

The button [Save to existing job] is only available if a saved job is currently loaded. Press the [Save to existing job] button to overwrite the currently loaded job.

Press the green [check] button to conrm.

The name of the currently loaded job is shown

in the upper right corner. An asterisk next to the name shows that changes to the job have been made and that the changes have not yet been saved.

5. Clearing Misfeed(s)

Clearing misfeed(s)

General

If a misfeed condition should occur, it is indicated on the Booklet Maker display. The message “Clear Misfeed(s)”, an error code and the location of the misfeed is displayed. See examples below.

Misfeeds in the Rotate Crease Trim Module are indicated by the error code RCT-XXX.

Misfeeds in the Booklet Maker are indicated by the error code BM-XXX and visually where in the Booklet Maker (B1, B2 or B3) the misfeed occurred.

Misfeeds in the BookFold Module are indicated by the error code BF-XXX.

Misfeeds in the Trimmer are indicated by the error code TR-XXX.

RCT Module

Clearing misfeed(s)

Infeed “A” area and exit “D” area

1

Open the RCT top cover.

2

Lift up bafes “A” and “D” if needed.

3

Remove any misfeed(s).

4

Lower bafes “A” and “D” to normal position

5

Misfeed(s) in the trimmer area are rolled out by rotating the rubber surfaced pinch roller [A].

6

Close the top cover.

WARNING

Do not put your ngers within knife protections (B).

Doing so may result in injury.

Bafe D

[A]

[B]

Bafe A

Registration and creaser area

1

Open the slide door [A].

2

Unlatch and pull out the slide [B].

3

Open bafes “B” and “C” if needed.

4

Remove any misfeed(s).

5

Close bafes “B” and “C”.

6

Push in and latch the slide.

7

Always remove any residual waste from waste channel and waste [C] belt before closing the slide door.

8

Close the slide door.

Clearing jams in the waste transport

The waste transport is easily accessible through the slide door. Shreds jammed in or wrapped around the knife assembly are also accessible through the slide door.

CAUTION

Under no circumstances should jams around the trimmer blades be cleared using metallic tools. The edges are very fragile and easily damaged.

[A] [C] [B]Bafe C Bafe B

Booklet Maker

Clearing misfeed(s)

Inside the Booklet Maker

To clear a misfeed indicated in Area B1

1 Open the top cover.

2 Remove misfed sheets.

3 Close the top cover.

To clear a misfeed indicated in Area B2

1 Open the top cover.

2 Close top cover.

If system does not purge, open top cover and remove misfed sheets manually.

To clear a misfeed indicated in Area B3

1 Open the top cover.

2 Close top cover.

If misfeed condition remains:

1 Switch off the main power.

2 Switch on the main power.

Clearing misfeed(s), continued

Clearing misfeed in infeed area

1

Open the top cover.

2

Lift the paper guide [A] as shown in picture.

3

Remove misfed sheets.

4

Close top cover.

[A]

Clearing misfeed(s), continued

Clearing misfeed in folder area

1

Open the top cover.

2

Open the fold roller paper guide [A] by pushing (arrow 1), lifting (arrow 2) and pivoting (arrow 3) to access any misfed or jammed sheets/booklets between the lower and upper pair of fold rollers.

3

Remove sheets/booklets in folder area between fold rollers.

4

In reversed manner, place the fold roller paper guide back in operating position.

NOTE:

Make sure the fold roller paper guide is locked in operating position [B] at both sides.

5

Close top cover.

[A]

Fold roller paper guide locks here

[B]

Cover Feeder

Clearing misfeed(s) in vertical transport area

1

Open the top cover [A].

2

Lift the jam clearance bafe [B].

3

Remove the misfed sheet.

4

Put the jam clearance bafe back in normal position.

NOTE:

In case of a cover feeding jam/error, it is difcult to remove a stuck cover due to the very strong separation nip. Removing the stack of sheets and then lifting the jam clearance bafe is the

easiest way to remove a cover that is stuck.

[A]

[B]

BookFold Module

Clearing misfeed(s)

Inside the BookFold Module

1

Open the top cover.

2

Lift up upper feed belts (A) to access jammed/misfed booklets.

NOTE:

Press the green dots (B) (only one visible in picture) on the latches to release.

3

Remove the jammed/misfed booklets.

4

Place the upper feed belts in normal position.

5

Close the top cover.

NOTE: The upper feed belt on the operator side cannot be lifted fully.

Trimmer

Clearing misfeed(s)

The upper trimmer blade on the trimmer is protected by a knife protection plate that moves

away during the cutting stroke.

WARNING

Never put ngers or other body parts between the upper and lower trimmer knives.

Clearing misfeed in input area

1

Raise the rightmost side of the infeed roller shaft assembly (A).

2

Remove the misfed sheets in the infeed area.

3

After the misfed sheets are removed, place the infeed roller shaft assembly into operating position.

[A]

infeed roller shaft assy. in normal position infeed roller shaft assy. lifted

Clearing misfeed(s), continued

Clearing misfeed in exit area

1

Lift the exit compressing brackets and transport belts [B] at the green dot.

2

Secure using the latch [C]. Not clearly visible in picture

3

Remove the misfed sheets from the exit area.

4

After the misfed sheets are removed, release the latch [C] and place the exit compressing brackets in operating position.

[B]

[C]

Exit compressing brackets in normal position Exit compressing brackets lifted

Belt Stacker

Clearing misfeed(s)

Clearing misfeed on belt stacker

1

Lift the belt stacker exit cover (A).

2

Remove jammed/misfed booklets.

3

Place belt stacker exit cover back in operating position.

Page intentionally blank.

6. Troubleshooting

Fault codes

General

When there is a misfeed or fault condition in the Booklet Maker system, a code and/or a message will be displayed on the UI. Table and fault code descriptions below will guide you troubleshooting.

If frequent input jams are experienced please check paper curl and de-curler adjustments in printer operator guide.

For fault codes other than specied below - remove any paper in the paper path and

power Off and On the system.

NOTE: If procedures in this manual do not rectify the problem an authorized technician will be needed.

RCT fault codes

RCT Module

Code / message Explanation / action RCT-001 - RCT-171 Possible fault in

area, please power off and power on to recover!

RCT201 - RCT212 and RCT230 Clear misfeed!

Empty trim bin from RCT module and check waste belt!

Indicates that there might be an internal communication error between the RCT module and the Booklet Maker. Check that the RCT is powered up and that the communication cable between the RCT module and the Booklet Maker is OK. Power off and on the system. If problem persists, contact customer support.

A misfeed has occurred in the RCT module. See section 5, “Clearing Misfeed(s)” for how to clear misfeed(s).

If feed errors occurs in the paper path or in the waste transport system, check for obstructions. If no obvious obstructions are found, see section 7, “REMARKS” Maintaining Your Machine.

Check / Empty Waste container and check Waste Transport for buildup of trim waste strips. It is highly recommended to empty the waste box whenever the system stops to keep up productivity.

Booklet Maker fault codes

Booklet Maker

Code / message Explanation / action BM-001 - BM-169 Possible fault in

area, please power off and power on to recover!

BM-170, Incompatible RCT software! Software in the RCT is reported to be of an incompatible

BM-201 - BM-208 Clear misfeed! A misfeed has occurred in the Booklet maker.

BM-401, Check right stapler! BM-402, Check left stapler! BM-403, Check right and left stapler!

BM-404, Set too thick, remove set from booklet maker!

BM-407 Too many sheets, remove set

and reduce number of sheets in the job!

BM-408 CF empty, remove incomplete set from Booklet Maker!

BM-600 - BM-617 File error! Indicates that there might be an internal communication

Replace right staple cartridge! Replace left staple cartridge! Replace right and left staple cartridges!

Remove purged cover from inside booklet maker!

Size mismatch! Hold the job in the printer and check paper size settings.

Indicates that there might be an internal communication error. Power off and on the system. If problem persists, contact customer support.

version. Power off and on the system. If problem persists, contact customer support.

See section 5, “Clearing Misfeed(s)” for how to clear misfeed(s).

Indicates jam in either or both staplers. Check staple cartridge(s) according to procedure in section 1, “Basics.”

Indicates that the set from the copier is outside Booklet

Maker specications and is too thick to be folded. Open

top cover and remove set. Close top cover. Indicating there are too many sheets in the Booklet

Maker. Open top cover and remove set. Close top cover. Reduce the number of sheets in the job.

Using the Cover Feeder as a regular feeder, the bin has run out of sheets before a set was completed. Open top cover and remove the incomplete set from the Booklet Maker.

error. Power off and on the system. If problem persists, contact customer support.

Indicates almost out of staples in either or both staplers. Change staple cartridge(s) according to procedure in section 1, “Basics.”

There is a purged cover inside the Booket Maker. Open top cover and remove set. Close top cover.

There is a mismatch between paper size in the printer and the Booklet Maker. Input sheet size in the Booklet Maker is automatically set to AUTO. Press the [Done] button to continue with the Booklet Maker in AUTO mode or hold the printer and a check paper size settings.

Cover Feeder fault codes

Cover Feeder

Code / message Explanation / action

CF-001 - CF-012 Possible fault in area, please power off and power on to recover!

CF-201 Out of covers, remove sheets from Booklet Maker!

CF-202 - CF205 and CF-207 Clear misfeed!

Double feed from CF, remove double from inside the booklet maker.

Indicates that there might be an internal communication error. Power off and on the system. If problem persists, contact customer support.

Indicates “Out of covers” in the Cover Feeder. Load covers according to section 1, “Basics.”

A misfeed has occurred in the Cover Feeder. Check cover loading according to section 1, “Basics”, Cover Feeder. If problem persists, clean separator pad according to section 7, “REMARKS.”

A double feed has occurred in the Cover Feeder. If there was a true double:

1. Check for proper loading of covers according to section 1, “Basics”, Cover Feeder.

2. Increase air ow according to section 2, “Making Booklets.”

3. Clean feed belts according to section 7, “REMARKS”, Maintaining your machines.

Cover size not equal to paper size. Change cover size!

If there is a false double:

1. Check that covers are within specication.

2. Temporary turn double sheet detection off. See section 2, “Making Booklets”, Customizing settings.

If the covers fed are thick, with dark print or with mixed prints on the covers, double feeding may be displayed even if that is not the case.

Indicates that there is a format mismatch between the sheets loaded in the Cover Feeder and the sheets in the Booklet Maker. There are two options:

1. Correct either mismatch and press the [Done] button.

2. Turn the Cover Feeder off by pressing the [Turn cover off] button to continue booklet making but without feeding covers.

Cover Feeder fault codes, continued

Cover Feeder, continued

Code / message Explanation / action

Cover stack is low, please add covers! Indicates that the Cover Feeder is almost out of Covers.

There are two ways to continue operation.

1. Loading more cover sheets:

2. Using up the remaining cover sheets that are

Be aware that if you use alternative 2, the system will hard stop i.e. without completing the cycle when there is no covers left.

Load covers! Message is displayed when covers are empty. Message

will also be displayed if the green [check] button was pressed after deciding to use Covers but before the bin was loaded. There are two ways to continue operation.

1. If you wish to continue production:

2. If cover job is nished and you wish to run a new job

Load more cover sheets according to section 2, “Making Booklets” and press the [Done] button. The message will extinguish and copier will start.

loaded: Press the [Dismiss] button. The message will extinguish and copier will start.

NOTE:

Load cover sheets according to section 2, “Making Booklets” and press the [Done] button. The message will extinguish and copier will start.

without covers: Select Cover Off in the Cover menu.

BookFold Module fault codes

BookFold Module

Code / message Explanation / action BF-001 - BF-151 Possible fault in area,

please power off and power on to recover!

BF-201 - BF-206 Clear misfeed A misfeed has occurred in the BookFold Module.

Indicates that there might be an internal communication error. Power off and on the system. If problem persists, contact customer support.

If problem persists, clean feed belts according to section 7, “REMARKS.” Check that the pressure on the upper feed belts is set to the default position. The pressure springs should always be at its upper position where the pressure is equal to its highest value. See section 7, “REMARKS.”

Trimmer fault codes

Trimmer

Code / message Explanation / action TR-001 - TR-153 Possible fault in

area, please power off and power on to recover!

TR-201 - TR-206 Clear misfeed A misfeed has occurred in the Trimmer.

Empty trim waste bin from Face Trimmer!

Close infeed belts! Indicates that the infeed roller shaft assy. is lifted. Close

Close exit belts! Indicates that the exit compressing brackets are lifted.

Close infeed and exit belts! Indicates that the infeed roller shaft assy. and the exit

Indicates that there might be an internal communication error. Power off and on the system. If problem persists, contact customer support.

See section 5, “Clearing Misfeed(s)” for how to clear misfeed(s).

Indicates that the trim bin is full or that a trim strip, due to static electricity, is prevented from falling down into the trim bin. Empty the trim bin and remove loose trim strips from inside the Trimmer. See section 1, “Basics.” for how to remove the trim bin.

it. See section 5, “Clearing Misfeed(s).”

Close them. See section 5, “Clearing Misfeed(s).”

compressing brackets are lifted. Close them. See section 5, “Clearing Misfeed(s).”

NOTE: During poor environmental conditions waste from the trimming operation may be transported through the system.

To improve the situation, the trim margin may be increased and thereby ensuring that the waste is transported into the waste bin.

Belt stacker fault codes

Belt stacker

Code / message Explanation / action Stacker full, please empty stacker! Stacker is full. Empty stacker.

General fault codes

Clear Misfeed(s)

Close cover(s)

In general, fault codes indicate a misfeed condition. When a misfeed occurs, a code, the message “Clear misfeed(s)” and the jam area will be displayed. See section 5, “Clearing Misfeeds”, for how to clear a misfeed.

When the message “Close Cover(s)” is displayed any of the interlock switches are actuated.

1 Check that the top cover is in down

position.

Empty stacker!

2 Make sure that the cover of the Belt

Stacker is in normal position, see section 5, “Clearing Misfeeds”, Belt stacker.

3 Make sure power cables between

Booklet Maker, BookFold and Trimmer are connected

This message will be displayed when the stacker is full. Empty the belt stacker and press the [Done] button to continue operation.

7. REMARKS

Do’s And Don’ts

• Always follow all warnings marked on, or supplied with, the equipment.

• Always exercise care in moving or relocating the equipment.

• CAUTION

Unplug the power cord from the wall outlet and machine before you move or relocate the equipment.

• Do not remove the covers or guards that are fastened with screws.

• Do not override or bypass electrical or mechanical interlock devices.

• Do not operate the equipment if you notice unusual noises or odors. Disconnect the

power cord from the power source and call your authorized technician to correct the problem.

WARNING

Do not put ngers or other parts of the body between the upper and lower trimmer knives.

• Do not switch off the main power switch while machine is running. Make sure machine cycle has ended.

• Do not open covers while machine is running.

• Do not move machine while machine is running.

Where to put Your Machine

Machine environment

• Always locate the equipment on a solid support surface with adequate strength for the weight of the machine.

• Always keep magnets and all devices with strong magnetic elds away from the

machine.

If the place of installation is air-conditioned or heated, do not place the machine where it will be:

• Subjected to sudden temperature changes.

• Directly exposed to cool air from air-conditioner.

• Directly exposed to heat from heater.

• Directly exposed to sunlight.

Power connection

• Always connect the equipment to a properly grounded power source. If in

doubt, have the power source checked by a qualied electrician.

• WARNING

Improper grounding of the equipment can result in electrical shock.

• Never connect the machine to a power source that lacks a ground connection terminal.

Access to machine

Place the machine near the power source, providing clearance as shown.

550 mm

22”

90 mm

3.5”

105 mm

4”

400 mm 16”

420-630 mm 17-26”

660 mm

360 mm 14”

26”

360 mm 14”

850 mm

33.5”

2700-2910 mm

106.7-114.6”

750 mm

29.5”

700 mm

27.5”

530 mm

710 mm 28”

21”

860 mm

33.8”

1835 mm

72.2”

Ensure that the minimum required oor space is available for the system that you are

about to install (Figure 1). The optional high capacity Belt Stacker BST4000-1 can be placed either in-line or angled to the Booklet Making system. The BST4000-1 measures 1730x440 mm / 68x17”.

Approximate oor space requirements / conguration;

• BLM 35/50 + Stacker ~1480 mm / 58.2”.

• BLM 35/50 +FTR50 + Stacker ~ 1840 mm / 72.4”.

• BLM 35/50 + BF50 + FTR50 + Stacker ~ 2200 mm / 86.6”.

• RCT + BLM 35/50 + BF50 + FTR50 + Stacker = 2910 mm / 114.6”.

• RCT + BLM 35/50 + BF50 + FTR50 + BST4000-1 Stacker (straight) = 4430 mm / 174.4”.

• RCT + BLM 35/50 + BF50 + FTR50 + BST4000-1 Stacker (angled) = 3140 mm / 123.6”.

NOTE:

BLM 35/50 Upgrade kit and Cover Feeder Module does not impact oor space

requirements.

Maintaining Your Machines

Never attempt any maintenance functi on t hat is not speci cally described in this documentation.

Cover Feeder

Cleaning feed rollers and paper separator pad

The Feed rollers need to be cleaned regularly when in use, and if the unit has not been used for a period of time. How often this should be done, depends on the paper type and print quality. An increasing number of misfeeds, or double feeds, is one indication of the need to clean the Feed Rollers.

1

Remove the feed roller assembly by pressing it to the front of unit (A). The non operator side end of the feed roller assembly will now be released (B) and the assembly can be removed.

2

Clean the Feed rollers and the Paper separator pad with water and a clean lint free cloth.

Press toward front.

Lift out this side

Paper separator pad

Feed rollers

BookFold Module

Cleaning feed belts

The feed belts need to be cleaned regularly when in use, and if the unit has not been used for a period of time. How often this should be done, depends on the paper type and print quality. An increasing number of misfeeds is one indication of the need to clean the feed belts. Clean the feed belts with water and a lint free cloth.

1

Open the top cover.

2

Clean the upper feed belts (A). The upper feed belts can easily be rotated in either direction.

3

Press the release latch (B), one to each and lift up the upper feed belts to access the lower feed belts.

4

Clean the lower feed belts (C). Rotate the lower feed belts towards the exit side for complete cleaning.

5

Place the upper feed belts in normal position.

6

Close the top cover.

Upper non operator side feed belt lifted up.Upper feed belts in normal position.

NOTE: The upper feed belt on the operator side (D) cannot be lifted fully.

BookFold Module, continued

Pressure springs

If feed errors occur, check that the pressure on the upper feed belts is set to the default position. The pressure springs should always be at its upper position where the pressure is equal to its highest value.

Non operator side spring in upper position (default position)

operator side spring in lower position

Pressure Clamps:

Smearing marks from the pressure clamps may appear if the clamps are not clean. If marks occur, run a number of blank booklets to clean the clamps prior to running your next set of booklets.

RCT Module

The feed rollers and paper path need to be cleaned regularly when in use, and if the unit has not been used for a period of time. How often this should be done depends on the paper type and print quality.

An increasing number of misfeeds is one indication of the need to clean the feed roller, paper path and/or the sensors. Feed rollers and paper path are cleaned with the same cleaning agent used to clean the printer and a lint free cloth. Sensors are wiped clean with a lint free cloth.

A problem with registration accuracy is often related to build up residual toner and paper dust.

CAUTION

Never use any cleaning uids on sensors.

Cleaning the paper path transportation nip rollers (12x)

Also clean the idler rollers

WARNING

Do not put your ngers within knife protections.

Doing so may result in injury.

Knife protections

Nip rollers

Cleaning the paper path transportation nip rollers (12x), continued

Nip rollers

Cleaning the xing rollers (3x)

Also clean the idling rollers

WARNING

Do not place your ngers inside the knife guards.

Doing so may result in injury.

Nip rollers (2x)

Nip rollers

Knife guards

Fixing rollers

continued on next page

Cleaning the xing rollers (3x), continued

Fixing rollers

Cleaning the registration cross roller (4x) & friction tires (4X)

Registration cross rollers

Cleaning friction tires

Cleaning the rotator rollers (2x)

Also clean the idler rollers

Rotator rollers

Cleaning the paper path sensors (5x)

WARNING

Do not place your ngers inside the knife guards.

Doing so may result in injury.

Infeed sensor

Knife guardsExit sensor

continued on next page

Cleaning the paper path sensors (5x), continued

Rotator sensor

Registration sensor

Cleaning the paper path sensors (5x), continued

Creaser sensor

Cleaning of creaser tools (2x)

After a period of time toner and paper dust may leave residuals in the grooves of the tool. These grooves must be cleaned periodically to maintain creasing performance.

Grooves on both sides of the tool

Adjustment of Bleed Trimmer registration angle (parallel cut)

Adjustment of Bleed Trimmer registration angle (trimmer cut parallel to registration (operator side) edge)

1

Turn adjustment screw [A] in desired direction. Change in adjustment is reected on

the reference scale [B].

Turn the adjustment

Process direction

screw clockwise to remedy this misalignment

NOTE: Sheets may show wrinkles in the process direction if adjustment is set too tight. Turn adjustment screw counter clockwise until wrinkles disappear.

[A] [B]

Adjustment of Creaser registration angle

1

Loosen the star shaped knob [A].

2

Turn the knurled eccentric adjuster [B] to move reference mark in the desired direction.

3

Tighten the star shaped knob [A] again.

Process direction

Lower the operator side side of the creaser to remedy this misalignment

Reference marks

[A] [B]

Best practices for the BLM 35/50 system

• If the set is not properly registered (side jogged and back jogged), ne adjustment of registra-

tion may improve the situation. See section Fine-tuning booklet appearance for details.

• If staples have problems penetrating thicker sets of heavy media changing staple cartridge may

improve the situation.

• The BookFold Module may wrinkle the cover at the spine when light weight media is used for

cover sheet. Changing to heavier stock or turning BookFold Module off usually resolves the problem.

• Staple back may be radius shaped (bent) when running with BookFold Module. Moving staple

position so staple is centered on the spine will reduce this phenomenon.

• Covers may show marking along the spine of the booklet from the clamp in the BookFold Mod-

ule. The more pages in the booklet, the more evident the marking.

• For jobs with multiple sheets of 200 gsm or heavier the BookFold Module is recommended for

an acceptable output. If a BookFold Module is present in the conguration, it should be turned

ON or feed problem at output may occur.

• If the Adjustment of “Bleed Trimmer registration angle” described in section Maintaining Your Ma-

chines in the OP manual is set too tight, the sheets may show wrinkles in the process direction.

• To prevent this phenomenon, turn the adjustment screw counter clockwise until the wrinkles disappear.

• If a JOB is cancelled on the printer there might be an incomplete set inside the BLM 35/50 system. This set has to be manually removed from the system by opening and closing the top cover of the Booklet Maker. This will purge the set.

Limitations of the BLM 35/50 system

• The BLM 35/50 Production Booklet Maker systems are suited for customers whose booklet making needs will not exceed a yearly average of 30,000 booklets per month.

• If sheets entering the BLM 35/50 is not uniform and square the booklet quality will vary accordingly.

• The maximum recommended number of sheets that can be folded without stapling is 5 sheets of

80 gsm. If there is very low friction between the sheets, running non stapled sets may be difcult.

• Staple position may vary on the spine when being square formed with the BookFold Module, especially on thicker booklets. Moving staple position so staple is centered on the spine will reduce this phenomenon.

• Staple may be radius shaped (bent) when running with the BookFold Module. Moving staple position so staple is centered on the spine will reduce this phenomenon.

• Covers may show marking along the spine of the booklet from the clamp in the BookFold Module. The more pages in the booklet, the more evident the marking.

• For some white coated stock, such as “Silk type” two sided coated paper, occasional fold roller marks may be observed on the “top side” of the book.

• The double feed sensor should be turned off when feeding cover 200 gsm or more from the Cover Feeder. You may also have to turn off this function if you have heavy dark area coverage

or covers with different images on them.

• For jobs with multiple sheets of 200 gsm or heavier, the BookFold Module is recommended for

an acceptable output. If a BookFold Module is present in the conguration it shall be turned ON

or feed problem at output may occur.

• Heavy weight media will show image crack in the spine, pre-crease the cover to avoid cracking.

• Thick books made from coated stock with high friction between each sheet may show permanent “wave like” deformation of the sheets.

• Marks from the fold knife may appear on sensitive media on the inner sheet.

• Marks from side guide motion may appear on sensitive media.

• Never run simplex printed sheets from the printer in-line.

• Covers may show markings from the Cover Feeder separation process.

• Avoid using smear sensitive material in Cover Feeder.

• Small booklets A5/ 5,5 x 8,5” or smaller may stack poorly on the conveyer.

• If corners/edges of sheets by any reason are folded before trimming, result may look as illustrated when corners/edges are unfolded.

Limitations of the BLM 35/50 system, cont.

• Sheets may show marks from the “registration rollers” in the RCT module, as shown in the image below. These marks are more commonly seen on silk/coated paper and on darker images. Changing media will improve the situation.

These marks have been seen consistently on the following media:

• Océ Top Coated Plus Silk

• Océ Top Coated Plus Gloss

• Océ Top Colour Zero

• Neenah Smooth

• On some coated media, staples may not completely penetrate the set resulting in a faulty staple. If problem persists, consider changing media. Staple may not be able to penetrate the number of sheets indicated by the “Set Size Guide”. Some uncoated extra “dense” paper may show the same limitation. The following list shows examples of media where this has been observed:

• Futura Laser Gloss 80c

• Hammermil Laser Print

• OPUS Gloss

• On brand new Booklet Maker units, paper may show trace of oil coming from the fold mechanism. Oil is applied to the mechanism during production. The problem will be eliminated after initial production.

• When trimming small amount (less than 5mm or 0.2”) in the Trimmer Module on books made from more than 2 sheets, the cut may not be clean, leaving trim waste hanging from the book.

• Paper can show markings on the lead edge of the set from the compiler area. If this occurs the use of the Trimmer Module will eliminate this

• For thick booklets, the clinch quality of the staples may show limitations resulting in the staple legs to be spaced away from the sheets.

• Heavy media above 250gsm/14lb Index may show feeding problems in the RCT Module. This issue will be more common on smaller sheet sizes A4 and 8,5” x 11”

Limitations of the BLM 35/50 system, cont.

• Staple leg offset outside the 1,0mm specication can occur on thicker sets. To check if the unit performs within specication produce a book made from 4 sheets of 80 gsm plain paper.

Max 1,0mm

• For thick books with a thin cover, the cover can be “pulled back” during the registration process in the Face Trimmer. This can result in the cover sheet not being trimmed. Recommendation is to use a heavier cover for thick books (over approx. 15 sheets).

• For some media, the legs of the staples may not be properly clinched causing the legs of the staple to be spaced away from the inner sheet. This phenomenon occurs on extra thick books over 40 sheets made from “soft” paper (recycled and some non-coated media mostly).

• The BookFold roller can pick up “colour” from the rst staple during the BookFold process. After one full revolution of the BookFold roller, the colour is smeared off on the spine of the booklet. This phenomenon occurs more for some coated media and for higher BookFold modes.

• The “pressure foot” in the BookFold Module can cause a shiny mark on sensitive media. This phenomenon has been observed on Glossy media.

• Thick booklets that are not square folded may have a higher tendency to be scratched.

• Sensitive media may pick up toner or residue while being transported through the paper path. Cleaning the paper path and conducting some preventative maintenance may help improve the situation.

8. Specication

Machine Specications

Rotate Crease Trim Module (option)

Specications Remarks

Speed Same as BLM35/50 Booklet Maker

Standard Paper Sizes Same as BLM35/50 Booklet Maker

Paper Size Minimum (Out) Same as BLM35/50 Booklet Maker

Paper Size Maximum (Out) Same as BLM35/50 Booklet Maker

Paper Width Maximum (In) 330mm 5mm bleed trim will auto-

matically be turned on

Paper Weight (Minimum) Same as BLM35/50 Booklet Maker

Paper Weight (Maximum) Same as BLM35/50 Booklet Maker Above 300gsm limited

performance with some media

Rotator (optional)

Width (cross process direction) Rotation is only possible within the interval

Creaser

Tools Fine tool Coarse tool

Bleed Trimmer

Minimum bleed trimming Maximum bleed trimming Max asymmetric bleed trimming

Input / Output Sheets Same as BLM35/50 Booklet Maker

min. 275mm. (10.9”).

Width (cross process direction)

max. 325mm. (12.7”).

Length (process direction)

min. 205mm. (8.1”).

Length (process direction)

max. 232mm. (9.1”).

Stock < 120 gsm

Stock > 120 gsm

(gsm =grams per sq. meter)

5 mm

30 mm

±5 mm

On each side of the sheet

Off-line Use Not possible

Weight 210kg/463lb

Dimensions (W x D x H) 710 x 860 x 1080 / 28 x 33.8 x 42.5”

(incl. 105mm / 4” waste transport)

Power Source 100 - 230V ±10% 50-60Hz

Power Consumption 300W Continuous operation

400W Max

Booklet Maker

Major Specications

Specications Remarks

Speed (Online usage) Maintains engine speed. Actual speed in number of book-

lets (per min / hour) depends on number of sheets per booklet.

Standard Paper Sizes A4, SRA4, B4, A3, SRA3,

8.5x11”, 8.5x14”, 9x12”, 11x17”, 12x18”

Paper Size (Minimum) Width 206mm / 8.1”

Length 275mm / 10.8”

Paper Size (Maximum) Width 320mm / 12.6”

Length 457.2mm / 18”

Paper Weight (Minimum) 64gsm/16lb Bond uncoated

105gsm coated

Paper Weight (Maximum) 300gsm / 172lb Index / 115lb Cover 350gsm / 130lb Cover

Belt stacker capacity 2 sheets: 200 sets

8 sheets: 70 sets 15 sheets: 35 sets 20 sheets: 25 sets 30 sheets: 15 sets 35 sheets: 15 sets 40 sheets: 10 sets 45 sheets: 10 sets 50 sheets: 10 sets

Folding/stapling capability

Folding capability only 1 to 2 sheets

2 – 35 or 50 Sheets (80gsm / 20lb Bond) See Set Size Guide for more

Custom sizes are available

80gsm / 20lb Bond

Figures are based on rough estimates and founded on pure observation

information

Off-line use Possible Staple / Fold (2 staples)

Weight 155 kg / 341.7 lb

Dimensions (W x D x H) 1420 x 730 x 1050mm / 55.9 x 28.8 x 41.4” Incl. belt stacker*

Incl. cable protector**

Power Source 100 - 230V, 50-60Hz + 6%, - 10%

Power consumption 250 or less Continuous Operations

Noise emission 62dB Complete system

Plockmatic use open source code in parts of this product

*The Belt Stacker, installed after Booklet Maker, BookFold Module or Trimmer, adds 420 - 630mm / 16.5” -

24.8” to system length. **Cable protector adds 50mm / 2” to depth.

Cover Feeder Module

Specications Remarks

Maximum Speed Same as BLM35/50 Booklet Maker A3/11x17” or bigger paper

sizes, need two sheet sets as inlet at least

Standard Paper Sizes Same as BLM35/50 Booklet Maker

Paper Weight (Minimum) 64gsm / 16lb Bond

Paper Weight (Maximum) 250gsm / 67lb Bond

Cover Feeder Capacity 20mm (app. 200 sheets of 80gsm paper)

13/16” (app. 200 sheets of 20lb Bond paper)

Off-line Use Possible (Together with Booklet maker)

Weight 8kg / 17.6lb or less

Dimensions (W x D x H) 310 x 190 x 530mm / 12.2 x 7.5 x 20.9” The Cover Feeder dimensions

are included in the Booklet Maker dimensions and will not add anything more to the space.

Power Source From BLM35/50 Booklet Maker

Trimmer Module

Specications Remarks

Speed 1800 sets per hour

Standard Paper Sizes Same as BLM35/50 Booklet Maker Custom sizes are available

Default trim length 4.5mm / (11/64”) Adjustable in 0.5mm (0.004”) steps

Minimum trimming 1mm / (0.0394”)* Rec. min trim is 2,5mm (0.098”)

Maximum trimming 16mm (5/8”) per cut Possible to trim down to 105mm

(49/64”). Trim larger than 16mm (5/8”) will cause trimmer to make multiple cycles. This reduces system speed in some applications. Multiple cuts also affect lifetime.

Paper Weight (Min / Max) Same as BLM35/50 Booklet Maker

Paper Weight (Max) Same as BLM35/50 Booklet Maker

Input / Output Sheets Same as BLM35/50 Booklet Maker

Off-line Use Possible (Together with Booklet maker)

Weight 73kg / 160.8lb or less

Dimensions (W x D x H) 360 x 1100 x 730mm / 14.2 x 43.3 x 28.8” Incl. cable protector**

Power Source From BLM35/50 Booklet Maker

* When trimming SRA3 (450mm) Booklets minimum trimming is 5mm, when trimming 18” Booklets minimum trimming is 9mm / 0.35”. **Cable protector adds 90mm / 3.5” to depth.

BookFold Module

Specications Remarks

Speed Same as BLM35/50 Booklet Maker Appr. 6 - 30 sheet booklet

(80gsm / 20lb Bond)

Standard Paper Sizes Same as BLM35/50 Booklet Maker Custom sizes are available

Paper Weight (Minimum) Same as BLM35/50 Booklet Maker

Paper Weight (Maximum) Same as BLM35/50 Booklet Maker

Input / Output Sheets Same as BLM35/50 Booklet Maker

Off-line Use Possible (Together with Booklet maker &

Trimmer)

Weight 53kg / 116.7lb

Dimensions (W x H x D) 360 x 1100 x 730mm / 14.2 x 43.3 x 28.8” Incl. cable protector*

Power Source From BLM35/50 Booklet Maker

*Cable protector adds 90mm / 3.5” to depth.

BST4000-1 Belt Stacker Module

Speed Variable

Overlap Adjustable

Capacity A4 / 8,3”x11,7” ....≥ 1,000

Side guides Adjustable 0-357mm / 14”

Weight 70kg/1541lb

Dimensions Table height Width Length

Power Source 100 - 240V, 50-60Hz, 1A + 6%, - 10%

Power Consumption 70W or less

Specications Remarks

A3 / 11,7”x16,5” .....≥ 500

575 - 1000mm / 22.6” - 39.4” 440mm / 17” 1380mm / 54”

Booklet of 2 sheets 80gsm / 20lb Bond Booklet of 2 sheets 80gsm / 20lb Bond

Input height = Table height + 60mm / 2.4” + Control unit + 350mm / 14” for end stacking tray

100

Plockmatic BLM 35, BLM 50 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

What You Can Do With This Machine

Guide to Components

Booklet Maker

User Interface

Control Panel

Options

Rotate Crease Trim Module

Booklet Maker

Alive Logo

Cover Feeder

BookFold Module

Trimmer

BST4000-1 Belt Stacker Module

BST4000-1 Principle of Operation

1. Basics

Turning On / Off the Main Power

RCT, Booklet Maker, BookFold Module, Trimmer & BST Module

Change staple cartridges and Check Stapler

Change left/right staple cartridge(s)

Check left/right stapler

Cover Feeder

Loading covers

Emptying the trim waste bin

Setting up Belt Stacker for Right-Angled Mode

Belt Stacker

Setting up Belt Stacker for Straight Mode

2. Making Booklets

Guided Start

Guided Start, step by step

Changing settings

General procedure

Basic settings

Input Sheet Size

Selecting standard paper sizes

AUTO sheet size

Custom input sheet size

Finished Booklet Size

Auto trimming

Custom booklet size

Customizing settings

Staple

Selecting stapling On or Off

Adjusting staple position

Fold position

Adjusting fold position

Cover

General

Cover

Air Separation

Double Sheet Detection

Purge Cover

BookFold

General

Selecting BookFold pressure setting

Crease

Crease Mode

Crease position

Fine-tuning booklet appearance

Bleed Trimmer - Asymmetric Side Trim

Bleed Trimmer - Cover Adjust

Hand-feeding

Hand feed mode

3. Tools

The Tools screen

Stacker full detection

Units

Software version

Paper path light

Language

Service mode

Fold delay

Sheet feeder

Auto Rotate

BookFold offset

4. Jobs

Handling jobs