Plockmatic BLM 35 User 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.
Operator Manual
Doc no: X04107E
Date: 26 June 2017
Plockmatic BLM 35/50
Production Booklet Maker

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.

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.
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). 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!
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.
General safety, continued

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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

10
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11
What You Can Do With This Machine
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.
BLM35/50 Production
Booklet Maker
FTR50 Trimmer Module
(option)
BLM50 upgrade kit
(option) incl. Alive Logo
BF50 BookFold
Module (option)
RCT50 Rotate Crease
Trim Module (option)
CF50 Cover Feeder
Module (option)
Belt Stacker
continued on next page

12
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.
continued from previous page
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.

13
Guide to Components
Booklet Maker
4
1
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
2
3
6
7
5

14
1
5
2 3
4
NOTE:
How to connect cables, plugs and jumpers is described at the end of this manual.
1. Belt Stacker Connector
2. Upstreams Communication
3. Downstreams Communication
4. Power Connection
5. Printer interface
Booklet Maker, continued

15
Booklet Maker, continued
1
23456
7
8
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
Parts that are important for setup, adjustments, troubleshooting or maintenance are high-
lighted below.

16
User Interface
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.”
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 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

17
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.

18
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.

19
Options
Rotate Crease Trim Module
1. Top cover
2. Side door
1
2

20
Rotate Crease Trim Module, continued
1. Exit slot
2. Trim waste transport
3. Waste container
4. Cable protector
2
4
3
1
Connections bracket
NOTE
How to connect cables, plugs and jumpers is described at the end of this manual.