Oce BLM 500 Owner's manual

BLM 500 / Bookletmaker 50
User manual
Operating information

Edition 2008-08 US
Copyright
Copyright
2008 Océ
All rights reserved. No part of this work may be reproduced, copied, adapted, or
transmitted in any form or by any means without written permission from Océ.
Océ makes no representation or warranties with respect to the contents hereof and
specifically disclaims any implied warranties of merchantability or fitness for any
particular purpose.
Further, Océ reserves the right to revise this publication and to make changes from
time to time in the content hereof without obligation to notify any person of such
revision or changes.
Note: The contents of this document are subject to copyright
protection by third parties.

3
Table of Contents
Table of Contents
Chapter 1
Introduction to the Booklet maker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Description of the Booklet maker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Right-Hand Side of the Booklet maker. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
The Rear Panel of the Booklet maker . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chapter 2
How to run the Booklet maker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Turn ON the Booklet maker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Enter the Job Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Stacker adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Run the Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Chapter 3
The User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
The Touch Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
The Job Mimic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
The BASIC Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
The LOAD & SAVE Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
The ADVANCED Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
The CONFIGURE Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
The MENU Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Chapter 4
Standard Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Load and Save the Job Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Adjust the Stitch Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Open the Connecting Bridge Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Open and Close the Folder Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Lift and Lower the Clincher Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Open the Gathering Area Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Lift the Booklet maker Main Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Empty the Trim Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Open the Stitch Wire Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Adjust the Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Operate the Booklet maker offline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4
Table of Contents
Chapter 5
Error Conditions, Problems, and Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Clear a Printer Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Clear a Booklet maker error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
General Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Book Quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Clear Paper Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Stitch Timeout Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Stitch Head Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Clear a Stitch Wire Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Clear a Stitch Head Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Calibrate the Touch Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Change the Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Manually park the Shuttle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Chapter 6
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
About Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Booklet maker cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Clean the Static Elimination Bars. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Clean the Former Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Clean the Polyurethane Strips in the Form Clamp. . . . . . . . . . . . . . . . . . 96
Clean the Trimmings Removal Fingers . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Clean excess grease from the Stitch Head . . . . . . . . . . . . . . . . . . . . . . 101
Lubricate the Stitch Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Lubricate the Wire-feed Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Install New Stitch Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Appendix A
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Appendix B
Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

5
Chapter 1
Introduction to the Booklet
maker

6 Chapter 1 Introduction to the Booklet maker
Introduction
Introduction
Introduction
Thank you for choosing the Booklet maker.
Your Manual
The User Manual for the Booklet maker describes how to perform these tasks:
■Operate the Booklet maker
■Find and correct error conditions
■Perform normal maintenance tasks
Operator training is given when the Booklet maker is installed. To make sure you use
your Booklet maker correctly, read your manual.
The User Manual for the Booklet maker does not describe the operation of the
printer. If needed, refer to your printer user manual.
Safety Information
Safety information is included in the separate “Safety Information Manual.” Read
the safety information before you use your Booklet maker.
Caution: A CAUTION message tells you that a procedure or operation can
be dangerous. To prevent injury, you must follow the instructions.
Attention: An ATTENTION message tells you that a procedure or operation can
damage the machine or the product. To prevent damage, you must follow the
instructions.
Installation
Your Booklet maker must be installed by a service engineer. Special knowledge is
needed to install the machine.
Attention:
Connect the machine only to a power supply of the correct voltage with a good
ground connection. The correct machine voltage is shown on the label at the power
supply input on the rear of the machine. If the machine is connected to the wrong
supply, the warranty is voided.

7
Introduction
How to Get Help
If you have any questions or problems, refer to the problem-solving section in this
manual (see the chapter “Error Conditions, Problems, and Solutions”). Contact your
Booklet maker supplier for further help.

8 Chapter 1 Introduction to the Booklet maker
Description of the Booklet maker
Description of the Booklet maker
Introduction
The Booklet maker operates online with digital printers to process sets of printed
pages into stitched books. The main parts are shown below.
Illustration
[1]
[1] Operator Side of the Booklet maker
Component - function table
[1]
A
B
C
D
[1] Operator Side of the Booklet maker
Component Function
A The connecting
bridge
The connecting bridge moves the printed sheets from
the printer to the Booklet maker. If needed, the sheets
are rotated into the correct direction. Rotation lets the
printer operate at optimum print speed. Adjustment
for the size of the paper and sheet rotation is
automatic, according to the settings entered on the
touch screen.
B The user interface The user interface has a color touch screen, a start
button, and a stop button.
C The Booklet
maker
The Booklet maker stitches, folds, spine-forms, and
trims the sheets to make a finished book.
D The stacker The stacker collects the finished books.

9
Right-Hand Side of the Booklet maker
Right-Hand Side of the Booklet maker
Illustration
[2]
[2] Right-hand side of the Booklet maker
Component - function table
[2]
A
B
[2] Right-hand side of the Booklet maker
Component Function
A The stitch-wire
cabinet
The stitch-wire cabinet holds the spool of
stitch-wire.
B Trim Bin The trim bin collects the paper that is trimmed from
the edge of the book

10 Chapter 1 Introduction to the Booklet maker
The Rear Panel of the Booklet maker
The Rear Panel of the Booklet maker
Illustration
[3]
[3] The Rear Panel of the Booklet maker
Component - function table
[3]
B
C
E
D
F
A
[3] The Rear Panel of the Booklet maker
Component Function
A Rating and serial
label
The rating label displays the type of machine, serial
number, power use, and fuse information.
B Power ON/OFF
switch
The power ON/OFF switch turns the Booklet
maker ON or OFF. When you turn OFF the Booklet
maker, the current settings are stored.
C Voltage advisory
label
The voltage advisory label tells the installer to refer
to the installation instructions before the Booklet
maker is connected to the electrical power supply.
The Booklet maker can be adjusted for one of
several different input voltages.
D Fuses The fuses make sure the operator and the machine
are protected if there is an electrical problem or
short circuit.
E Voltage label The voltage label is fitted to the Booklet maker
during the installation procedure. The voltage label
displays the selected voltage.
F Power input
connector
The power input connector is used to connect the
Booklet maker to the electrical power supply.

11
Chapter 2
How to run the Booklet maker
This chapter gives information on how to run a job on the Booklet maker. For
information on how to operate the printer, refer to the printer documentation.
Information about the user interface is included in the chapter “The User Interface.”
Information about standard procedures, for example opening covers to clear a paper
jam, is included in the chapter “Standard Tasks.”

12 Chapter 2 How to run the Booklet maker
Before You Begin
Before You Begin
Paper and Book Quality Instructions
■The size of paper and the thickness of the set must be measured. These
measurements are entered via the touch screen before you begin a print job.
■Measure the size of the printed paper. The paper dimension changes when the
paper is printed.
■Measure the set thickness as accurately as possible. Use the measuring tool
supplied with the machine.
■Enter accurate dimensions via the touch screen.
■If the book is made from several different types of paper, make sure the different
paper types are all the same size.
See Book Quality on page 63 for further information.

13
Turn ON the Booklet maker
Turn ON the Booklet maker
Procedure
1. Connect the Booklet maker to the power supply.
2. Use the ON/OFF switch to turn ON the Booklet maker.
Result
The machine makes this sequence of beeps:
'beep__beep beep beep beep_____ beep beep'.
The touch screen illuminates and the machine is ready for use.

14 Chapter 2 How to run the Booklet maker
Enter the Job Settings
Enter the Job Settings
Introduction
Enter the settings for a new job in the BASIC window on the touch screen. See the
chapter “The User Interface” for more information.
The PAPER SIZE and PAGE DIRECTION settings are entered on the touch screen.
These dimensions refer to the format of the paper when it enters the Booklet maker.
Attention: Do not operate the touch screen with a sharp object or with too much
force. These actions can damage the touch screen.
Before You Begin
[4]
Note: This set can be made into a book (see Operate the Booklet maker offline on
page 47).
Step Action Information
1 Print a set to the
stacker.
2 Measure the sheet
size and the set
thickness.
Measure the set accurately. To make an accurate
book you must enter accurate paper dimensions via
the touch screen.
3Usethese
dimensions for the
job setting.

15
Enter the Job Settings
Procedure for a New Job
[5]
Procedure for a Saved Job
1. Touch LOAD & SAVE
Step Action Information
1TouchBASIC
2 Enter the paper
size
Touch PAPER SIZE. Enter the dimensions of the
paper.
The job setting is easier if you first select a preset
paper size, then adjust the settings as necessary
Touch PAPER SIZE > PRESETS > A3 or A4. (USA:
11x17, 8.5x11 or 8.5x14)
3 Enter the page
direction
Touch PAGE DIRECTION > LANDSCAPE or
PORTRAIT.
If the PAGE DIRECTION option is not available, the
PAGE DIRECTION cannot be changed.
4 Enter the page
rotation setting
For A4 paper size, the normal setting for ROTATE is
ON. Rotation lets the printer operate at optimum
speed.
Touch ROTATE to turn the sheet rotation ON or OFF.
Always select the page direction before you change
the rotate setting.
5 Enter the set
thickness.
Touch SET THICKNESS. Enter the measured value.
6 Enter the number
of stitches.
Touch STITCHES and enter the number of stitches.
If needed, the stitch pitch can be changed. See
"STITCH PITCH," table 9on page 25
7 Enter the spine
form setting
The spine form setting is automatic, according to the
SET THICKNESS setting. If needed, the setting can
be changed. See "FORM" in table 9on page 25
8 Enter the trim
setting.
The trim setting is automatic, according to the PAGE
SIZE and SET THICKNESS settings. To change the
setting, touch TRIM. See “TRIM” in table 10 on
page 27
9TouchCLOSE
If needed, save the
job settings to
memory.
If the same job settings are used frequently, then save
the job settings to memory.
See "Save a job."Load and Save the Job Settings on
page 34

16 Chapter 2 How to run the Booklet maker
Enter the Job Settings
2. Touch the job name or use the Up arrow or the Down arrow to select the job.
3. Touch LOAD.
4. Wait until the Booklet maker is ready

17
Stacker adjustment
Stacker adjustment
Adjust the Stacker
Adjust the stacker according to the size and thickness of the finished bookAdjust the
Stacker on page 45.

18 Chapter 2 How to run the Booklet maker
Run the Job
Run the Job
1. Make sure the adjustments on the Booklet maker are complete before you release the
print job from the print queue.
2. Start the print job. The Booklet maker starts automatically.
3. Check the quality of the first book.
4. If the quality is not acceptable, make adjustments (see ‘Book Quality’ on page 63).
Result
During the job
■Unload books from the stacker before the stacker is full. The Booklet maker stops
and displays a message if the stacker is full.
■Empty the trim bin from time to time. The Booklet maker displays a message if
the trim bin is full (see ‘Empty the Trim Bin’ on page 43).

19
Chapter 3
The User Interface

20 Chapter 3 The User Interface
The Touch Screen
The Touch Screen
Introduction
[4]
[4] The User Interface
[6]
The user interface includes a color touch screen and START/STOP buttons.
Operate the touch screen with your fingertip. You can touch the screen with a blunt
item, for example a palm-top 'wand' or the blunt end of a pen. Do not use too much
force. A light touch is all that is needed.
Power save
The touch screen has a power-save function. After several minutes without use, the
brightness of the touch screen decreases. After several hours, the touch screen turns
off. Touch the screen to restore the normal brightness. The touch screen takes two or
three minutes to reach full brightness.
If you hear a 'beep' when you operate the touch screen, the selected function is not
available. Some functions are not available when the machine is in operation.
Some functions and buttons are only available at certain access levels. See "ACCESS
LEVEL" The MENU Window on page 31.
Attention: Do not operate the touch screen with a sharp object or with too much
force. These actions can damage the touch screen.
A
B
C
ASTARTButton
B STOP Button
CTouchScreen