Plockmatic BK5030 User manual

INSTALLATION MANUAL
BK5030 SYSTEM
including CT5010e and CT5030
Part no:122-106962
Doc no: X17138
Date: November 2012

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 installaion manual contains instructions how to install this machine. To make sure that
this machine is properly installed, carefully read and follow the instructions in this manual.
Keep this manual in a handy place near the machine while installing.
Please read the Safety Information before installing 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.

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

TABLE OF CONTENTS
1 INSTALLATION PROCEDURE ........................... 1-1
1.1 INSTALLATION REQUIREMENTS ...........................................1-1
1.1.1 MINIMUM SPACE REQUIREMENTS.............................................1-1
1.1.2 POWER REQUIREMENTS ............................................................1-2
1.2 INSTALLATION FLOW CHART.................................................1-3
1.3 BOOKLET MAKER INSTALLATION..........................................1-5
1.3.1 ACCESSORY CHECK ....................................................................1-5
1.3.2 INSTALLATION PROCEDURE .......................................................1-6
1.3.3 ADJUSTMENTS ...........................................................................1-14
1.3.4 CONNECTORS.............................................................................1-18
1.3.5 CHECK THE INSTALLATION .......................................................1-19
1.4 COVER FEEDER INSTALLATION..........................................1-21
1.4.1 ACCESSORY CHECK ..................................................................1-21
1.4.2 INSTALLATION PROCEDURE .....................................................1-22
1.4.3 ENABLING THE COVER FEEDER ..............................................1-28
1.4.4 CHECK THE INSTALLATION .......................................................1-29
1.5 TRIMMER INSTALLATION .....................................................1-33
1.5.1 ACCESSORY CHECK ..................................................................1-33
1.5.2 INSTALLATION PROCEDURE .....................................................1-34
1.5.3 ADJUSTMENTS ...........................................................................1-37
1.5.4 DOCKING .....................................................................................1-40
1.5.5 CONNECTORS.............................................................................1-42
1.5.6 CHECK THE INSTALLATION .......................................................1-44

1.6 BOOK FOLDER INSTALLATION ............................................1-49
1.6.1 ACCESSORY CHECK ..................................................................1-49
1.6.2 INSTALLATION PROCEDURE .....................................................1-50
1.6.3 ADJUSTMENTS ...........................................................................1-54
1.6.4 DOCKING .....................................................................................1-57
1.6.5 INSTALLING STACKER SAFETY BRACKET...............................1-59
1.6.6 CONNECTORS.............................................................................1-60
1.6.7 CHECK THE INSTALLATION .......................................................1-62
1.7 CREASER TRIMMER INSTALLATION ...................................1-66
1.7.1 ACCESSORY CHECK ..................................................................1-66
1.7.2 INSTALLATION PROCEDURE .....................................................1-67
1.7.3 DOCKING .....................................................................................1-91
1.7.4 CONNECTORS.............................................................................1-93
1.7.5 ADJUSTMENT..............................................................................1-95
1.7.6 CHECK THE INSTALLATION .......................................................1-96

1-1
November 2012
Installation
requirements
INSTALLATION REQUIREMENTS
1 INSTALLATION PROCEDURE
1.1 INSTALLATION REQUIREMENTS
1.1.1 MINIMUM SPACE REQUIREMENTS
420-630 mm
16.5-24.8”
360 mm
14.2”
360 mm
14.2”
810 mm
31.9”
400 mm
15.8”
700 mm
27.6”
500 mm 21.8”
760 mm 29.9”

1-2
November 2012
INSTALLATION REQUIREMENTS
1.1.2 POWER REQUIREMENTS
1. Input voltage level:
100 - 240 V AC, 50 - 60 Hz, 4 - 2 A.
2. Never place anything on the power cord.
WARNING
1. Make sure that the wall outlet is near the main machine and easily
accessible.Makesuretheplugisrmlyinsertedintheoutlet.
2. Avoid multi-wiring.
3. Be sure to ground the machine.

1-3
November 2012
Installation
requirements
INSTALLATION REQUIREMENTS
1.2 INSTALLATION FLOW CHART
Thefollowingowchartshowshowtoinstalltheoptionalunitsmoreefciently.
Yes No
Yes No
Install the Booklet maker BK5030
Does the user require a Cover Feeder?
Install the Cover Feeder CF5030
Does the user require a Trimmer?
Install the Trimmer TR5030
Does the user require a Book Folder?
Is a Trimmer installed?
Yes No
Install the Book Folder BF5030
Install the Belt Stacker
Yes
Install Trimmer
No
Install CT5030/ CT5010 if applicable
Check the Installation

1-4
November 2012
INSTALLATION
TR5030 Trimmer: Enables On-line trimming. Especially thicker sets
( > 4 sheets) look unprofessional because of ”creep”.
TR5030 will trim those edges ( up to 16 mm / 5/8”).
CF5030 Cover Feeder: Enables the possibility to add colour covers to the book-
lets.
BF5030 Book Folder: Enables the possibility to give the booklets the perfect
bound look.
CT5030 Creaser trimmer
Enables Creasing to avoid toner cracking at the Spine of
the Booklet.
Enables Bleed Trimming for for state of the art looking
Booklets.
Enables Rotation of small media to enhance Productivity.
(Optional)

1-5
November 2012
Booklet Maker
Installation
BOOKLET MAKER INSTALLATION
1.3 BOOKLET MAKER INSTALLATION
1.3.1 ACCESSORY CHECK
Check the quantity and condition of the accessories in the box against the following list:
Description Q’ty
A. Exit arm Catcher .................................................................. 1
B. CommunicationCabletoSR5030nisher ........................... 1
C. Docking assembly (incl. 4 M4 nuts and 4 washers) ............. 1
D. Shift tray plate ...................................................................... 1
E. Exit tray plate ....................................................................... 1
F. Powercords ......................................................................... 3
G. Terminator plug, will always be installed onto BK5030 ........ 1
H. Terminator plug TR5030....................................................... 1
I. Interlock Jumper TR5030 ..................................................... 1
J. Cable protector..................................................................... 1
K. Cable holder......................................................................... 2
L. Cable ties, 100 mm .............................................................. 3
[A] [D]
[C]
[B] [E]
[F] [H]
[G] [I]
[J] [K] [L]

1-6
November 2012
BOOKLET MAKER INSTALLATION
1.3.2 INSTALLATION PROCEDURE
Unpacking
1. Remove all packaging material.
2. Carefully pull out the foam blocks [A] (x2) from underneath the BK5030.
WARNING
Two persons are required to remove the foam blocks.
[A]

1-7
November 2012
Booklet Maker
Installation
BOOKLET MAKER INSTALLATION
3. Mount Ramp Support [B] according to top picture.
4. Place Ramp [C] according to lower picture.
5. Carefully roll BK5030 off the pallet.
[B]
[C]

1-8
November 2012
BOOKLET MAKER INSTALLATION
Exit arm catcher
1. Remove the adhesive backing from the Exit Arm Catcher [A].
2. InstalltheExitarmcatcheronthenisherasshowninpicture.
The nut on the Exit arm catcher should be centered over the Exit paper arm,
according to lower picture.
3. Lift up the Exit paper arm, and set it onto the Exit Arm Catcher [B].
[B]
[A]

1-9
November 2012
Booklet Maker
Installation
BOOKLET MAKER INSTALLATION
[A]
Printer exit tray
1. Make sure that the Exit Paper Arm [A] is in the upper position.
2. Removethenisherexittraybyremovingscrews[B]( x 4).
3. Removetheplasticdeector[C],onthenisherexittray.
[B]
[C]

1-10
November 2012
BOOKLET MAKER INSTALLATION
4. InstalltheShiftTrayPlate[E]ontothenisher(use x 4 counter screws
from installation kit).
5. InstalltheExitTrayPlate[F]ontothenisherexittray(use x 4 from instal-
lation kit).
[E]
[F]

1-11
November 2012
Booklet Maker
Installation
BOOKLET MAKER INSTALLATION
1. Remove the four screws on Finisher Rear Cover [A].
2. Using the screws Install the Docking Assembly [B] as shown in second picture.
Docking assembly
[B]
DS5030 Finisher
[A] ( x 4)

1-12
November 2012
BOOKLET MAKER INSTALLATION
Rail Unit
[B]
CAUTION
Before docking, make sure the Jogger Fence [B] is in the upper position.
Ifnot,withprinterpoweredon-openandclosenisherdoor.
1. If installing a Rail Unit [A], install it according to picture.
Select correct rail hole[C].
NOTE: If the Rail unit is installed at a later time the height adjustment of the
Booklet maker has to be redone.
2. Hook up the Exit arm catcher to it’s upper position.
3. PushtheBookletmakerontotherailbutleaveitundockedwiththenisherat
this time.
[A]
[C]
Select this hole if CT5010 /CT5030
is NOT installed
Select this hole if CT5010 /CT5030
is installed

1-13
November 2012
Booklet Maker
Installation
BOOKLET MAKER INSTALLATION
Interface to SR5030 Finisher
1. Remove Finisher Back Cover [A] ( x 5).
2. Guide the communication cable through opening [B] on back cover (The cable
is part of the installation kit).
3. Make a loop on the cable [C] and attach a Cable tie.
4. Install the communication cable, to connector CN2 [D] ( x1)onthenisher
main board.
[C]
[A]
Finisher Main PCB
[D]
[B]