Plockmatic BK5030 User manual

BOOKLET MAKER BK5030
Operating Instruction
Stapler Folder Reference
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.
13 August 2015

Part no: 102-106761
Doc no: x04092
13 September 2011
Warning:
This is a Class A product. In a domestic environment this product may cause radio interference
in which case the user may be required to take adequate measures.
The product (System) which is connected to this machine will be class A
Note
The domestic environment is an environment where the use of broadcast radio and television
receivers may be expected within a distance of 10 m of the apparatus concerned.

Introduction
This manual contains instructions on the operation and maintenance of this machine. To
get the maximum versatility from this machine all operators should carefully read and fol-
low 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 re-
lated 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.

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:
• Before disassembling or assembling parts of the System and peripherals.
• You drop objects or spill something into the equipment.
• You suspect that your equipment needs service or repair.
• Your equipment’s covers has been damaged.
• You notice unusual noises or odours when operating the equipment.
• If the power cable or plug becomes worn out or otherwise damaged.
• Before cleaning and care (unless otherwise specically instructed).
• If any adjustment or operation check has to made with exterior covers off or open
while the main switch is turned on, keep hand away from electrical or mechanically
driven components.
• Note that components of the System and peripherals can be supplied with electric
voltage even if the mail power switch is turned off and the power cord is disconnected.
• Electromagnetic compliance:
• This is a Class A product. In a domestic environment this product may cause radio
interference in which case the user may be required to take adequate measures.
• The product (System) which is connected to this machine will be class A.
Safety Information
When using this machine, following safety precautions should always be followed.
Safety during operation
General safety
WARNING:
• Always connect the equipment to a properly grounded power source (wall outlet). Wall
outlet should be located near the system and easily accessible. If in doubt, have the
power source checked by a qualied electrician.
• Improper grounding of the equipment can result in electrical shock. Never connect the
machine to a power source that lacks a ground connection terminal. This machine is
destined for specic purpose only. Any use going beyond this specic purpose is re-
garded 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 result-
ing 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 responsibil-
ities 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.

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!
• Dispose of replaced parts and consumables in accordance with local regulations.
CAUTION:
• The machine and its peripherals must be installed and maintained by a customer service repre-
sentative 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).
• Turn off the power and disconnect the power cord before you move the machine. While mov-
ing 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 documenta-
tion.
• 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.
General safety, continued

Page intentionally blank.

TABLE OF CONTENTS
What You Can Do With This Machine ............................................................................................................ 9
Guide To Components .................................................................................................................................. 11
Booklet Maker................................................................................................................................................................11
Options ...........................................................................................................................................................14
Cover Feeder................................................................................................................................................................ 14
Trimmer......................................................................................................................................................................... 15
Book Folder .................................................................................................................................................................. 17
Control Panel .................................................................................................................................................19
1. Basics ....................................................................................................... 21
Docking / Undocking .....................................................................................................................................21
Docking the Booklet Maker........................................................................................................................................... 21
Undocking the Booklet Maker....................................................................................................................................... 22
Turning On / Off the Main Power ..................................................................................................................23
Booklet Maker, Cover Feeder, Trimmer and Book Folder............................................................................................. 23
Change staple cartridges and Check stapler..............................................................................................24
Change left/right staple cartridge(s).............................................................................................................................. 24
Check left/right stapler .................................................................................................................................................. 25
Cover feeder...................................................................................................................................................25
Loading covers ............................................................................................................................................................. 25
Emptying the trim bin ....................................................................................................................................26
2. Making Booklets ...................................................................................... 27
Changing settings .........................................................................................................................................27
General procedure........................................................................................................................................................ 27
Paper Size .................................................................................................................................................................... 27
Selecting standard paper sizes..........................................................................................................27
Custom paper size .............................................................................................................................. 28
Staple............................................................................................................................................................................ 28
Selecting stapling On or Off ............................................................................................................... 28
Staple position .............................................................................................................................................................. 29
Adjusting staple position ................................................................................................................... 29
Fold position ................................................................................................................................................................. 29
Adjusting fold position .......................................................................................................................29
Cover ............................................................................................................................................................................ 30
Using covers ........................................................................................................................................30
Air Separation ......................................................................................................................................31
Double Sheet Detection ......................................................................................................................31
Trim............................................................................................................................................................................... 31
Select trimming Auto, Manual or Off ................................................................................................ 31
Book fold unit ............................................................................................................................................................... 32
General ................................................................................................................................................. 32
Selecting book folding mode .............................................................................................................32
On-line/Off-line ...............................................................................................................................................33
Off-line mode ................................................................................................................................................................ 33
On-line mode ................................................................................................................................................................ 33
Begin On-line Production .............................................................................................................................34
3. Tools ......................................................................................................... 35
The Tools Screen ...........................................................................................................................................35
The Tools screen........................................................................................................................................................... 35
Stacker full detection .................................................................................................................................................... 35
Auto shrink.................................................................................................................................................................... 35
Units.............................................................................................................................................................................. 35
Language...................................................................................................................................................................... 36
Software version ........................................................................................................................................................... 36
Service access.............................................................................................................................................................. 36
Sheet feeder ................................................................................................................................................................. 36
4. Jobs .......................................................................................................... 37
Handling jobs .................................................................................................................................................37
Saving a Job ................................................................................................................................................................. 37
Handling stored Jobs .................................................................................................................................................... 38

5. Clearing Misfeed(s) ................................................................................. 39
Clearing misfeed(s) .......................................................................................................................................39
General ......................................................................................................................................................................... 39
Booklet Maker ................................................................................................................................................40
Clearing misfeed(s)....................................................................................................................................................... 40
Inside the Booklet Maker .................................................................................................................... 40
Trimmer ..........................................................................................................................................................41
Clearing misfeed(s)....................................................................................................................................................... 41
Clearing misfeed in input area ........................................................................................................... 41
Clearing misfeed in exit area..............................................................................................................42
Cover Feeder..................................................................................................................................................43
Clearing misfeed(s) in vertical transport area ............................................................................................................... 43
Book Folder ....................................................................................................................................................44
Clearing misfeed(s)....................................................................................................................................................... 44
Inside the Book Folder........................................................................................................................44
Exit area ...............................................................................................................................................44
6. Troubleshooting ...................................................................................... 45
Fault codes.....................................................................................................................................................45
General ......................................................................................................................................................................... 45
General fault codes....................................................................................................................................................... 46
Clear Misfeed(s)...................................................................................................................................46
Close cover(s)......................................................................................................................................46
Booklet maker fault codes ............................................................................................................................................ 47
Check stapler or Change staple cartridge ........................................................................................47
Set too thick .........................................................................................................................................47
Remove purged sets ........................................................................................................................... 47
Illegal feed mode .................................................................................................................................47
Stacker full ........................................................................................................................................... 47
Cover feeder fault codes............................................................................................................................................... 47
Misfeed ................................................................................................................................................. 47
Double feed ..........................................................................................................................................47
Load covers .........................................................................................................................................48
Trimmer fault codes ...................................................................................................................................................... 49
Trim bin full ..........................................................................................................................................49
Close trimmer belts .............................................................................................................................49
Book Folder fault codes ................................................................................................................................................ 49
Feed errors...........................................................................................................................................49
7. REMARKS ................................................................................................ 51
Do’s And Don’ts .............................................................................................................................................51
Where to put Your Machine ..........................................................................................................................52
Machine environment ................................................................................................................................................... 52
Power connection ......................................................................................................................................................... 52
Access to machine........................................................................................................................................................ 53
Maintaining Your Machines .......................................................................................................................... 54
Book Folder .................................................................................................................................................................. 54
Cleaning feed belts ............................................................................................................................. 54
Limitations in the BK5030 system ...............................................................................................................55
Best practice for the BK5030 system ..........................................................................................................56
8. Specication ........................................................................................... 57
Machine Specications .................................................................................................................................57
Booklet Maker BK5030 ................................................................................................................................................. 57
Cover Feeder CF5030 (option)..................................................................................................................................... 58
Trimmer TR5030 (option).............................................................................................................................................. 58
Book Folder BF5030 (option)........................................................................................................................................ 59
BK5030 System Set Size Guide ................................................................................................................................... 60
INDEX............................................................................................................ 63

9
What You Can Do With This Machine
The Booklet Maker BK5030, Trimmer TR5030, Book Folder BF5030 and Cover Feeder CF5030
forms a booklet making system that works online with the Copier.
The print-outs from the Copier are collected in the nisher and then transported into the BK5030
Booklet Maker to the staple area. From the CF5030 Cover Feeder (optional), if present, any
type of covers, colored or black and whites, can be added to the printed set. The Booklet
Maker now jogs and then staples the set. The set is then transported further to the folding
area where the set is folded into a booklet and then fed out to the belt stacker. When a larger
number of sheets are folded an effect called creeping occurs. In order to rectify creep, the
TR5030 Trimmer (optional) can be attached after the Booklet Maker. The booklets are then
transported from the Booklet Maker into the Trimmer where the trail edge will be cut off. If a
TR5030 Trimmer is installed to the BK5030 Booklet Maker, you can attach the BF5030 Book
Folder (optional). The printouts, which have been stapled, folded and trimmed will be fed
into the BF5030. The BF5030 will atten the spine of the booklet square. The booklets will,
after passing the BF5030, have the look of a perfect bound book. The booklets are then fed
out to the Belt Stacker.
To facilitate undocking, a BK5030 Rail unit (optional) can be installed under the Booklet Maker.
Undocked or off-line, the Booklet Maker can be used as a stand-alone unit for hand feeding.
CF5030 Cover Feeder (option)TR5030 Trimmer (option)
BK5030 Booklet MakerBK5030 Rail unit(option)
BF5030 Book Folder (option)
Belt Stacker

10
The BK5030 Booklet making system is controlled from a user interface/control panel located
on the Booklet Maker. The control panel will allow you to easily set up, adjust and operate
the complete system.
The user interface/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.

11
Guide To Components
2
3
6
7
1
1 Top cover
2 Control panel
3 Main power switch
4 Infeed assembly
5 Exit tray storing shelf
4
Booklet Maker
6 Base
7 Docking assembly
8 Belt Stacker
9 Belt Stacker Cover
5
89

12
89
8 Connections
9 Fold stop gate
Booklet Maker, continues
Main Power
Terminator/
COM TR5030TerminatorStacker
COM Copier POW BF5030
Interlock jumper/
POW TR5030

13
2
1 Staple cartridges (incl. stapler heads)
2 Hand feeding paper guides
Booklet Maker, continues
1

14
4
3
2
6
1
5
7
Options
Cover Feeder
1 Loading capacity mark
2 Rear side guide
3 Feed roller assembly
4 Paper separator pad (also see
page 52)
8
5 Front side guide
6 Paper orientation indicator
7 Air nozzle (2x)
8 Jam clearance bafe

15
Trimmer
1
2
4
1 Top cover
2 Trim bin
3 Base
4 Connections
3
Stacker COM BK5030 Terminator/
Com BF5030
Power from
BK5030

16
Trimmer, continues
5
1
2
3
4
6
7
8
9
The Trimmer interior has parts that you will come in contact with if a misfeed occurs.
1 Set counter
2 Trimmer stop
3 Outfeed drive release
4 Pre-trimming compressing
brackets
5 Transport belt
6 Infeed roller shaft
7 Trimmer fan
8 Upper knife
9 Infeed drive release
Trimmer, top view

17
1
1 Top cover
2 Trim bin location
3 Base
4 Connections
3
StackerCOM BF5030
Terminator
POW BF5030
2
Book Folder
4

18
1 Lower feed belts
2 Upper feed belt release latch
3 Upper feed belts
1
23
Book Folder, top view,
Upper feed belts in lifted up
Book Folder, continues
The Book Folder interior has parts that you will come in contact with if a misfeed occur.

19
Control Panel
The Ready screen
When the system power is switched on, the Ready
screen will be shown. Here you will nd information
showing the actual set up. From this screen you can
also access other screens that will help you operate
the complete BK5030 Booklet making system.
The Jobs screen
Pressing the [Jobs] button in the Ready screen
opens the Jobs screen. From here you can load,
customize and save job settings. These procedures
are described in section 4. Jobs.
The Tools screen
Pressing the [Tools] button in the Ready screen
takes you to the tools screen. This screen looks
different depending of how the system is congured.
From here you can change the display language,
set units from millimetres to inches and more. See
section 3. Tools. for how to get around in the Tools
screen.
Changing settings
To change or adjust settings just point at an item in
the Ready screen. For example you can ne adjust
the trimming, turn off the cover feeder, set the Book
Folder to the correct mode or adjust the staple or
fold position during run. Explore all settings more
thoroughly in section 2. Making Booklets.

20
The Processing screen
This screen is shown when the machine is busy
working. If the machine is used in off-line mode you
do not have to wait for the Ready screen before
handfeeding the next set.
The Please wait screen
While the machine sometimes needs time to perform
changes in settings, the Please wait screen will be
shown. The machine will automatically return to the
Ready screen after changes have been implemented.
The Power save mode screen
The machine will go into a power saving mode if it
is left unused for more than app. 10 minutes. Touch
the control panel, send a job from the printer or open
a cover to reinstate the Ready mode.