Plockmatic BOOKLET MAKER Pro 30 User manual

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.
BOOKLET MAKER Pro 30
and RCT 30
Operating Instruction
Stapler Folder Reference
Part no: 122-106738
Doc no: x04093
Date: 28 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
recievers 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 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 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:
• 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 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).
• 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maintenace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 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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7
TABLE OF CONTENTS
What You Can Do With This Machine.......................................................................................... 11
Guide To Components.................................................................................................................. 13
Booklet Maker ............................................................................................................................................13
Options........................................................................................................................................... 16
Cover Feeder .............................................................................................................................................16
Trimmer ......................................................................................................................................................17
Square Folder.............................................................................................................................................19
Control Panel................................................................................................................................. 27
1.Basics............................................................................................... 29
Turning On / Off the Main Power.................................................................................................. 29
Booklet Maker, Cover Feeder, Trimmer and Square Folder....................................................................... 29
RCT 30 .......................................................................................................................................................29
Check staples, Staple cartridge and stapler head...................................................................... 30
Removing stapler head .............................................................................................................................. 30
Removing staple cartridge..........................................................................................................................30
Installing stapler head, staple cartridge / clearing staple jam..................................................................... 31
Consumables................................................................................................................................. 32
Emptying the trim bin.................................................................................................................... 33
2.MakingBooklets.............................................................................. 35
Changing settings......................................................................................................................... 35
General procedure .....................................................................................................................................35
Setting Paper Size......................................................................................................................................35
Selecting standard paper sizes.......................................................................................... 35
Selecting standard paper sizes, continues....................................................................... 36
Custom paper size............................................................................................................... 36
Stapling ......................................................................................................................................................37
Selecting stapling On or Off................................................................................................ 37
Trimming..................................................................................................................................................... 37
Selecting trimming On or Off.............................................................................................. 37
Adjusting the cutting margin.............................................................................................. 38
Covers ........................................................................................................................................................38
Selecting Cover Feeder Mode............................................................................................. 38
Loading covers..................................................................................................................... 39
Air separation....................................................................................................................... 39
Double Sheet Detection....................................................................................................... 39
Square Folding ...........................................................................................................................................40
General.................................................................................................................................. 40
Setting Mode ..............................................................................................................................................40
Procedure............................................................................................................................. 40
RCT 30 .......................................................................................................................................................41
Rotator - Selecting On or Off.............................................................................................. 41
Creaser - Selecting Creaser Mode...................................................................................... 41
Creaser - Selecting On or Off.............................................................................................. 43
Bleed Trimmer - Selecting On or Off.................................................................................. 43
Bleed Trimmer - Selecting Bleed Trim Mode..................................................................... 43
BleedTrimmer-BleedTrimConict.................................................................................. 46
On-line/Off-line............................................................................................................................... 46
Off-line mode..............................................................................................................................................46
3.Tools................................................................................................. 47
The Tools Screen........................................................................................................................... 47
Units ...........................................................................................................................................................47
Software version.........................................................................................................................................47
Language ...................................................................................................................................................48

8
Air Separation.............................................................................................................................................49
Double Sheet Detection ............................................................................................................................. 49
Stacker Full Detection ................................................................................................................................ 50
Service access ...........................................................................................................................................50
4.Jobs.................................................................................................. 51
Storing and deleting jobs............................................................................................................. 51
Storing a new Job.......................................................................................................................................51
Recalling a Job...........................................................................................................................................52
5.ClearingMisfeed(s)......................................................................... 53
Clearing misfeed(s)....................................................................................................................... 53
General.......................................................................................................................................................53
Booklet Maker................................................................................................................................ 54
Clearing misfeed(s) ....................................................................................................................................54
Inside the Booklet Maker..................................................................................................... 54
Clearing misfeed in input area............................................................................................ 55
Trimmer.......................................................................................................................................... 56
Clearing misfeed(s) ....................................................................................................................................56
Clearing misfeed in input area............................................................................................ 56
Clearing misfeed in exit area.............................................................................................. 57
Cover Feeder.................................................................................................................................. 58
Clearing misfeed(s) in vertical transport area............................................................................................. 58
Square Folder................................................................................................................................ 59
Clearing misfeed(s) ....................................................................................................................................59
Inside the Square Folder..................................................................................................... 59
Exit area................................................................................................................................ 59
RCT 30............................................................................................................................................ 60
Clearing misfeed(s) in the paper path ........................................................................................................ 60
Infeed “A” area and exit “D” area....................................................................................... 60
Rotator, registration and creaser area............................................................................... 61
6.Troubleshooting.............................................................................. 63
Fault codes..................................................................................................................................... 63
General.......................................................................................................................................................63
General fault codes .................................................................................................................................... 64
Clear Misfeed(s)................................................................................................................... 64
Close cover(s)...................................................................................................................... 64
Booklet maker fault codes ..........................................................................................................................65
Check staples....................................................................................................................... 65
Oil clinchers.......................................................................................................................... 65
Remove purged sets............................................................................................................ 65
Illegal feed mode.................................................................................................................. 65
Stacker full............................................................................................................................ 65
Trimmer fault codes....................................................................................................................................65
Trim bin full........................................................................................................................... 66
Close trimmer belts.............................................................................................................. 66
Cover feeder fault codes ............................................................................................................................ 66
Misfeed.................................................................................................................................. 66
Double feed........................................................................................................................... 66
Load covers.......................................................................................................................... 66
Square Folder fault codes .......................................................................................................................... 67
Feed errors........................................................................................................................... 67
RCT 30 fault codes.....................................................................................................................................68
Adjustment errors................................................................................................................ 68

9
7.REMARKS........................................................................................ 69
Do’s And Don’ts............................................................................................................................. 69
Where to put Your Machine.......................................................................................................... 70
Machine environment .................................................................................................................................70
Power connection.......................................................................................................................................70
Access to machine ..................................................................................................................................... 71
Maintaining Your Machines.......................................................................................................... 72
Booklet Maker ............................................................................................................................................72
Oil Clinchers and Stapler Heads......................................................................................... 72
Cover Feeder .............................................................................................................................................74
Cleaning feed rollers and paper separator pad................................................................. 74
Square Folder.............................................................................................................................................75
Cleaning feed belts.............................................................................................................. 75
RCT 30 .......................................................................................................................................................76
Cleaning the paper path transportation nip rollers (4x)................................................... 76
Cleaningthexingrollers(3x)............................................................................................ 77
Cleaning the registration cross roller (4x)......................................................................... 78
Cleaning the rotator rollers (2x).......................................................................................... 79
Cleaning the paper path sensors (5x)................................................................................ 79
Cleaning of creaser tools (2x)............................................................................................. 81
Adjustment of Bleed Trimmer registration angle (parallell cut)...................................... 82
Adjustment of Creaser registration angle......................................................................... 83
8.Specication................................................................................... 85
MachineSpecications................................................................................................................. 85
Booklet Maker BM30 ..................................................................................................................................85
Cover Feeder CF30 (optional)....................................................................................................................86
Trimmer TR30 (optional) ............................................................................................................................ 86
Square Folder SQF30 (optional) ................................................................................................................ 87
RCT 30 (optional) .......................................................................................................................................88
SystemCertications..................................................................................................................................89
PRO30 System Set Size Guide..................................................................................................................90
INDEX.................................................................................................... 91

10
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11
What You Can Do With This Machine
The RCT 30, Booklet Maker BM30, Trimmer TR30, Square Folder SQF30 and Cover
Feeder (CF300) forms a booklet making system that works online with the Printer.
The print-outs are transported through the RCT 30 (optional) prior to entering the Booklet
Maker. The RCT 30 is able to rotate small(er) sheets from long edge feed to short edge feed,
to increase printer productivity. In order to avoid color prints to break or dissolve at the spine
after folding, the Creaser can prepare the cover sheet for that.The Bleed Trimmer trims the
long sides of the sheets to shape the print-outs to the desired format. After that, the print-outs
are transported into the stapler area and compiled. From the CF30 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 TR30 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 TR30 Trimmer is installed to the BM30 Booklet Maker, you can attach the SQF30
Square Folder (optional). The printouts, which have been stapled, folded and trimmed will
befedintotheSQF30.TheSQF30willattenthespineofthebookletsquare.Thebooklets
will, after passing the SQF30, have the look of a perfect bound book. The booklets are then
fed out to the Belt Stacker. Undocked or off-line, the Booklet Maker can be used as a stand-
alone unit for hand feeding.
CF30 Cover Feeder (optional) TR30 Trimmer (optional)
BM30 Booklet Maker
SQF30 Square Folder (optional)
Belt Stacker
RCT 30

12
The buttons are multi functional, meaning that the
function of each button depends on the information
displayed.
For example: Pressing button 3 from the Ready screen
takes you to the Tools screen.
Example 2: In this screen, button 3 has no function.
Button: 1 2 3 4
Example 3: Pressing button 3 here will load the stored
Job (4).
Button: 1 2 3 4
Example 4: In this screen pressing button 3 will save
the current settings for job No 1. The asterisk on the
rstrowshowsthatthesettingsforJob(1)hasbeen
changed, but not yet saved.
Button: 1 2 3 4
The BM30 Booklet making system is controlled from a single control panel on the Booklet
Maker. The control panel has only four buttons which will allow you to easily set up, adjust
and operate the complete system.

13
Guide To Components
1 Infeed assembly
2 Docking assembly
3 Hand feed cover
4 Top cover
5 Control panel
Booklet Maker
6 Main power switch
7 Belt Stacker
8 Belt Stacker cover
7
8
5
6
2
4
1
3

14
8 Connections
9 Fold stop gate
Booklet Maker, continues
Main Power
Terminator/
COM TR30TerminatorStacker
COM Copier POW SQF30
Interlock jumper
Interlock jumper/
POW TR30
98

15
1 Stapler heads
2 Staple cartridges
3 Cartridge locking levers
4 Stapler release latches
5 Staple detection leads
6 Hand feeding positioning labels
Booklet Maker, continues
6
1
5
3
4 5
2

16
Options
Cover Feeder
1 Paper orientation label
2 Paper separator pad (also see
page 60)
3 Feed roller assembly
4 Rear side guide
5 Loading capacity mark
6 Front side guide
7 Air nozzle (2x)
8 Jamclearancebafe
5
4
3
2
1
6
7
8

17
Trimmer
1 Top cover
2 Trim bin
3 Base
4 Connections
4
1
2
3
Stacker COM BM30 Terminator/
Com SQF30
Power from
BM30

18
Trimmer, continues
The Trimmer interior has parts that you will come in contact with if a misfeed occurs.
1 Set counter
2 Trimmer stop
3 Outfeed latch
4 Exit compressing brackets
5 Transport belt
6 Infeed roller shaft
7 Trimmer fan
8 Upper knife
9 Infeed latch
8
5
1
2
3
4
6
7
9
Trimmer, top view

19
1 Top cover
2 Trim bin
3 Base
4 Connections
Square Folder
1
3
2
4
Stacker
COM SQF30
Terminator
POW SQF30

20
1 Lower feed belts
2 Upper feed belts
Square Folder, continues
The Square Folder interior has parts that you will come in contact with if a misfeed occur.
1
2
Square Folder, top view,
Upper feed belts in lifted up