GBC FusionPunch II User Manual Download Page 10

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Preface vi

FusionPunch II User Guide

remove the machine’s outer covers. ALWAYS refer service requirements to
qualified GBC personnel.

The following ISO and IEC symbols appear on this product. Their meaning
is:

I Means Power ON.

O Means Power OFF.

Means START.

Means you can select a preferred language (also used by Service
Personnel).

Means the machine can run in conjuction with the printer or run
without the printer. Also used to set up the machine in different
configurations.

Means Raise or Lower Stacker.

Means INTERRUPT the job that you are running.

Means STOP.

Means RESET.

IMPORTANT SAFEGUARDS

Use the

FusionPunch II

only for its intended purpose of punching

paper and covers according to the indicated product specifications.

Retain this Operating Instructions manual for later use.

"DIAGNOSTICS"

"ONLINE/OFFLINE"

Summary of Contents for FusionPunch II

Page 1: ...GBC FusionPunch II UserGuide Manuale dell utente Bedienungsanleitung Gebruikershandleiding Guided opération Guía del usuario ...

Page 2: ...ng Corporation Tutti i diritti riservati 2001 General Binding Corporation Alle Rechte vorbehalten 2001 General Binding Corporation Alle rechten voorbehouden 2001 General Binding Corporation Tous droits réservés 2001 General Binding Corporation Todos los derechos reservados ...

Page 3: ...er Guide English Libro 2 GBC FusionPunch II Manuale dell utente Italiano Buch 3 GBC FusionPunch II Bedienungsanleitung Deutsch Boek 4 GBC FusionPunch II Gebruikershandleiding Nederlands Livre 5 GBC FusionPunch II Guide d opération Français Libro 6 GBC FusionPunch II Guía del usuario Español ...

Page 4: ...Table of Contents FusionPunch II User Guide ...

Page 5: ...GBC FusionPunch II User Guide ...

Page 6: ......

Page 7: ...eating 61XX Profiles and Print Queues 1 11 What is a Profile 1 11 What is a Print Queue 1 11 System Access for Setup 1 11 61XX Log On 1 12 61XX Profile Setup 1 14 61XX Print Queue Setup 1 24 GBC Punch Queue Output 1 27 GBC Short Edge Punch Queue Output 1 28 SBM1 SBM2 Queue Output 1 29 Chapter 2 General Procedures Changing Die Sets 2 3 Removing and Replacing Die Pins 2 6 Centering the Punch 2 7 Set...

Page 8: ...om downstream devices 3 13 Chapter 4 Maintenance Cleaning the FusionPunch II 4 3 When to Clean 4 3 What to Use 4 4 What to Clean 4 4 Cleaning the Punch 4 5 Cleaning the Stacker 4 8 Cleaning the Bypass 4 9 Appendix A Personality Profiles Contents A 3 Personality Profiles A 5 Standard Punch Profiles A 5 Other Known Configurations A 8 Glossary Glossary of Common FusionPunch II Terms G 3 ...

Page 9: ... you open the product and expose yourself to hazardous voltage NEVER Riesgo de choque eléctrico No abra Adentro no hay piezas reparables para el usuario Mantenimiento solamente para personal calificado Risque de secousse électrique Ne pas ouvrir Pas de pièces réparables par l utilisateur Entretien par personnel qualifié Electrical shock hazard Do not open No user serviceable parts inside Refer ser...

Page 10: ...ed by Service Personnel Means the machine can run in conjuction with the printer or run without the printer Also used to set up the machine in different configurations Means Raise or Lower Stacker Means INTERRUPT the job that you are running Means STOP Means RESET IMPORTANT SAFEGUARDS n Use the FusionPunch II only for its intended purpose of punching paper and covers according to the indicated pro...

Page 11: ...II It was provided for your safety n Unplug the FusionPunch II before moving the machine or whenever the machine is not in use for an extended period of time n Do not operate the FusionPunch II if the machine has a damaged power supply cord or plug Do not operate the machine after any malfunction if liquid has been spilled into the machine or if the machine has been damaged in any way n Do not ove...

Page 12: ...Preface viii FusionPunch II User Guide CLEANING n You may clean the exterior of the FusionPunch II using a soft damp cloth Do not use detergents or solvents as damage to the machine may occur ...

Page 13: ...Control Functions and Locations Using the Control Panel Creating 61XX Profiles and Print Queues What is a Profile What is a Print Queue System Access for Setup DocuTech 135 Host Enablement refer to Appendix A Xerox 4XXX Host Enablement refer to Appendix A ...

Page 14: ...1 2 Getting Started ...

Page 15: ...e Hole GBC Plastic and TwinLoopTM Custom dies can be built to order Online The FusionPunch II attaches directly to your high speed printer Documents flow directly from the printer to the binding system without the bottleneck associated with traditional offline punching processes The FusionPunch II online punching system not only affords superior turnaround times but also significantly reduces labo...

Page 16: ...ument integrity and allows the operator to set up the machine in offline mode 4 The Output Stacker allows documents to emerge punched and offset stacked for more efficient offline binding operations One or more stackers can be connected for continuous operation 5 An optional Bypass Stacker can be used inline to allow the use of other downline finishers such as a Signature Booklet Maker or BDFX 2 4...

Page 17: ...peed of the printer except for the DT 6180 DT 6180 is slightly slower due to a skip pitch introduced in the printer 11 x 17 A3 All printers run at the rated speed of the printer Denotations Requires a GBC Bypass Stacker and a Xerox High Capacity Stacker Requires a GBC Stacker without the Bypass or a GBC Bypass Stacker and a Xerox High Capacity Stacker Paper Stock 60 gsm Bond to 200 gsm Index Outpu...

Page 18: ...when the machine requires service The Diagnostics button also has another feature known as User Functions To use this feature perform the following steps a Press the Diagnostics button once Version Control information displays to include the current version level of the machine s software b Press the Diagnostics button again The Punch Count is displayed c Press the Diagnostics button again The cur...

Page 19: ...iagnostics function is for use only by trained service personnel Attempting to use diagnostics without proper training may result in damage to the machine 3 Online Offline The Online Offline button is used to change the operating mode of the FusionPunch II By pressing the Online Offline button once the following flashing messages will appear on the Upper row of the LCD Display Screen 1 Change Run ...

Page 20: ...the FusionPunch II without the host printer In this mode the FusionPunch II must be started manually before the operator inserts pages in the Single Sheet Feeder Online50 used to deliver offsets in stacks of 50 sets Complete Books to the Stackers In this mode the operator must start and stop the FusionPunch II manually Required when connected to the DT 135 if offsets of 50 sets are needed Cycle50 ...

Page 21: ...ver to Stacker 1 when Stacker 2 is full The paper tray in Stacker 1 must be in the up position for this to work S1 Only the FusionPunch II will only stack in Stacker 1 and will stop when it is full S2 Only the FusionPunch II will only stack in Stacker 2 and will stop when it is full Bypass the FusionPunch II will Bypass all sheets to a downstream device To exit this menu press the Stop Reset butto...

Page 22: ...halt all operation of the FusionPunch II if it should become necessary It is also used to reset the machine after an error has been corrected 7 Arrows The arrow controls at the upper right hand corner of the Control panel are used to scroll the information on the LCD display screen up or down or left or right They are also used to change the different run modes and destinations 8 LCD Display Scree...

Page 23: ...r example the profile for a DocuTech 135 is different than the profile for a DocuTech 6100 What is a Print Queue A Print Queue is also a set of values or system configuration parameters that communicates input and output information from the printer to a finishing device The FusionPunch II is a finishing device System Access for Setup Profile and Print Queue configuration is performed at the same ...

Page 24: ... in as System Administrator go to Step 2 If not log on as System Administrator as described below Figure 1 1 61XX Monitor Screen a Go to the DocuSP Print Services screen as shown in Figure 1 1 b Pull down the System menu and select Logon as shown in Figure 1 2 Figure 1 2 The System Option Menu Logon level DocuSP Print Services Screen ...

Page 25: ...and Print Queues 1 13 1 The Logon window will display as shown in Figure 1 3 Figure 1 3 The Logon Window c Click on Trusted User and then select System Administrator d Type Administ in the password field and then click on OK ...

Page 26: ...rinter Manager window as shown already open in Figure 1 4 If it is not open go to the DocuSP Print Services window and click the Printer Manager button Printer Manager window Figure 1 4 61XX Monitor screen and Printer Manager window DocuSP Print Services window Printer Manager button ...

Page 27: ...r Manager Window as shown in Figure 1 5 Figure 1 5 The Finishing Icon in Printer Manager The Finishing Window will display as shown in Figure 1 6 Device Setup Tab Figure 1 6 The Device Setup Tab in the Finishing Window 3 Click on the Device Setup Tab as shown in Figure 1 6 Finishing Icon ...

Page 28: ...1 16 Getting Started The Device Setup Tab screen will display as shown in Figure 1 7 New Figure 1 7 The Device Setup Tab screen 4 Click on the NEW button as shown in Figure 1 7 ...

Page 29: ...mits screen 5 With the Device Profile Window and the Properties and Default Limits screen open you are ready to begin entering Personality Profile values for the FusionPunch II and the printer you are using Perform the following steps a Go to Appendix A of this User Guide and locate the profile sheets for the devices you will be setting up b Begin with the sheet for the Properties and Default Limi...

Page 30: ...all of the entered values conform to those in the profile sheet If they do not enter the values from the profile sheet Note Do not click OK at this point Go on to Step 6 6 Click on the Timings tab in the Device Profile Window The Device Profile Window will display the Timings screen as shown in Figure 1 9 Figure 1 9 The Timings screen ...

Page 31: ...5 this time using the sheet for the Timings values b Verify that all of the entered values conform to those in the profile sheet and click OK This will bring you back to the Finishing Window with the Device Setup Tab screen displayed 8 Click on the Profile Setup tab as shown in Figure 1 10 then click on the NEW button Figure 1 10 The Profile Setup Tab Screen Profile Setup Tab New ...

Page 32: ...ndow Properties and Limits Screen 9 Perform the following steps a Go to Appendix A in this User Guide and locate the profile sheets for the same finishing device as in Step 5 but this time with the sheet for the Finisher Profile Properties and Limits values b Ensure that all of the entered values conform to those in the profile sheet then click on OK ...

Page 33: ...After entering and or checking the default values for the FusionPunch II you will need to repeat Steps 5 through 9 for each additional finishing device installed in the system Figure 1 12 The Finishing Window and Profile Setup screen 10 Highlight GBC and click On Line 11 Select the On Line Finishers tab in the Finishing Window On line button ...

Page 34: ...ne Finishers screen displays as shown in Figure 1 13 Figure 1 13 Finishing Window and On Line Finishers screen 12 Highlight GBC again and then click the Enable button 13 Select the Finishing tab in the Finishing Window Enable Button ...

Page 35: ...nd that the name of the correct device appears in parentheses to the right of External Finisher as shown in Figure 1 14 This completes the Profile setup Go now to the Print Queue setup procedure that follows Note If you have more than one finishing device inline with the printer you must set up a profile for each To do so repeat this profile setup procedure for each finishing device External Finis...

Page 36: ... for the FusionPunch II and one for each additional finishing device down the line such as a Signature Booklet Maker SBM 1 From the 61XX Monitor screen go to the Queue Manager window as shown already open in Figure 1 15 If it is not open go to the DocuSP Print Services window and click the Queue Manager button Figure 1 15 61XX Monitor screen and Queue Manager window DocuSP Print Services window Qu...

Page 37: ...anager screen is not open click on the Queue Manager icon as shown in Figure 1 16 Figure 1 16 Queue Manager Icon 2 Pull down the Queue menu from the toolbar and select New as shown in Figure 1 17 Figure 1 17 The Queue Menu in Queue Manager Queue Manager Icon New ...

Page 38: ...nisher Profile sheet 4 Go to the Extended Options field and select Output as shown in Figure 1 18 The Output Window will display as shown in the information that follows This information consists of Print Queue Setup procedures for the following finishing devices n GBC Punch Queue Output for the FusionPunch II n GBC Short Edge Punch Queue Output for the FusionPunch II and Xerox High Capacity Stack...

Page 39: ...nd fill in or choose the fields as specified in the table below for a GBC Punch Queue output Item Entry a 2 Sided Do not check the override option b System Specified c Check the Override option d System Specified e Check the Override option f GBC g Check the Override option h Click OK then OK again in new Queue Setup window a d e f g b c h ...

Page 40: ...elow for a GBC Short Edge Punch Queue Output Item Entry a System Specified b System Specified c Check the Override option d System Specified e Check the Override option f GBCSE Note if the GBCSE Personality Profile is not Online and Enabled this option will not show up in the drop down list g Check the Override option h Click OK then OK again in new Queue Setup window a d e f g b c h ...

Page 41: ...he fields as specified in the table below for a SBM Punch Queue output Item Entry a 2 Sided Do not check the override option b System Specified c Check the Override option d System Specified e Check the Override option f Same as the name of the Finisher Profile for the SBM1 SBM2 g Check the Override option h Click OK then OK again in new Queue Setup window a d e f g b c h ...

Page 42: ...rted This completes the Print Queue setup and Chapter 1 of this User Guide Go now to Chapter 2 General Procedures to become familiar with basic operator level mechanical adjustments and operation of the FusionPunch II ...

Page 43: ...ging Die Sets Removing and Replacing Die Pins Centering the Punch Setting the Side Guide Setting Backgauge for Punch Depth from End of Page Starting a Job Punching and Stacking Bypassing to a Downstream device Using the Stacker Stackers ...

Page 44: ...2 2 General Procedures ...

Page 45: ...WARNING Switch OFF O the main power switch before beginning this procedure 1 Open the Right Punch Door as shown in Figure 2 1 2 Open the Punch Cover as shown in Figure 2 1 Figure 2 1 Opening the Punch Door and Cover Right Punch Door Punch Cover ...

Page 46: ...ning levers down and to the side as shown in Figure 2 2 Figure 2 2 Unlocking the Die Assembly 5 Unlock the Die turn the Die Lock knob clockwise until a click is felt as shown in Figure 2 2 Do not turn past that point or you will lock the Die again Sheet Eject Strap Assembly Punch Arm Retaining Levers Die Lock Knob ...

Page 47: ... base of the Die and lift straight up as shown in Figure 2 3 Figure 2 3 Removing and replacing the Die Assembly 7 To replace the Die repeat Steps 1 through 6 in reverse order Note The Die assembly is keyed and will reinstall only one way ...

Page 48: ...Bar release levers to the side and lift the Pressure Bar off of the Die as shown in Figure 2 4 You may now remove and replace individual die pins Figure 2 4 Accessing the Die Pins 2 Reverse this procedure to reinstall the Punch Arm Pressure Bar Release Die Pins Die Base Pressure Bar Lift Pressure Bar in this direction ...

Page 49: ...2 button either once or twice until the Stacker moves up to its TOP position The Punch will not start with the Stacker Tray down 3 Press START 4 Into the Single Sheet Feeder feed a sheet of paper of the size required for the job 5 Press the STOP RESET button 6 Press the RAISE LOWER STACKER 1 or 2 button to lower the Stacker 7 Open the Stacker Door and remove the punched sheet of paper 8 Check the ...

Page 50: ...or 11 Loosen the Locking Wing Nut as shown in Figure 2 6 12 Use the Edge Guide Adjustment Knob to make small 1 8 to 1 4 turn adjustments as shown in Figure 2 6 Test after each adjustment until the punched hole sets are centered Figure 2 6 Edge Guide Adjustment 13 Tighten the Locking Wing Nut after you have completed the adjustments Locking Wing Nut Edge Guide Adjustment Knob ...

Page 51: ...sionPunch II Note Use tab stock or cover stock when performing these procedures 1 Press the STOP RESET button 2 Open the Punch Cover 3 Open the Document Transport Ball Track assembly as shown in Figure 2 7 4 Open the Sheet Eject assembly as shown in Figure 2 7 Figure 2 7 Preparing to Adjust the Side Guide Document Transport Ball Track Assembly Sheet Eject Strap Assembly ...

Page 52: ... the Side Guide 7 If punching the 11 edge of the sheet loosen the Side Guide Retaining Screw If punching the 8 5 edge of the sheet add the additional Short Edge Side Guide to the Sheet Eject Strap assembly with the adjustment screws finger tight Remove the stock and close the Sheet Eject Strap assembly Now slide the stock under the Sheet Eject Straps and partially through the Die again Note When u...

Page 53: ...se to the stock as possible without actually touching the stock 9 Tighten the Side Guide Retaining Screw s 10 When you have completed this procedure close the Sheet Eject Strap assembly Document Transport Ball Track assembly and the Punch Cover if they are not already closed ...

Page 54: ... it stops If your die set is a GBC Cerlox die set go to Step 2 2 Check the margin between the leading edge and the punched holes of copies that have been run through the Punch or from paper you have run through the Manual Feed Tray If the margin is correct go to Starting a Job in this chapter to familiarize yourself with the operation of the FusionPunch II If the margin is not correct go to Step 3...

Page 55: ...t up the FusionPunch II in the following modes and destination Offline Punch Stack 1 or Stack 2 b Ensure that the Stacker Tray is in the TOP position If it is not press the RAISE LOWER STACKER 1 or 2 button either once or twice until the Stacker moves up to its TOP position The Punch will not start with the Stacker Tray down c Press START d Into the Single Sheet Feeder feed a sheet of paper of the...

Page 56: ...e Page 2 20 n For punching and stacking the 8 5 edge go to Starting a Job for Bypassing to a Dowstream device Page 2 20 To prepare for starting a printing job and sending it to the FusionPunch II perform the following procedures 1 Set up the FusionPunch II according to the job requirements For FusionPunch II setup refer to the Getting Started section On line Off line 2 From the DocuSP Print Servic...

Page 57: ...ll display as shown below Figure 2 11 On line Finishers tab 4 Verify that the GBC FusionPunch II profile is Enabled If this profile is not visible in this window go to step 8 If this profile is visible but not Enabled green check mark in the Enabled column highlight the profile and click Enable and then click Close On line Finishers Tab ...

Page 58: ...ocedures 5 Go to the Job Manager window and highlight the job to run Click the Move Icon Figure 2 12 Job Manager window 6 Highlight the GBC Punch Queue and then click Apply Figure 2 13 GBC Punch Queue window Move Icon ...

Page 59: ...ob sets from the job before may be left in the Stacker Stackers 8 Highlight any External Profile shown in the On line Finishers tab window and click Disable The green check mark in the Enabled column of the highlighted profile should now have switched to a red X as shown in the figure below Figure 2 15 On line Finishers tab Release Icon Enabled column ...

Page 60: ...abled profile not the GBC FusionPunch II profile and then click Off line Now highlight the GBC FusionPunch II profile and click On line The GBC FusionPunch II profile should now have a green check mark in the On line column as shown in the figure below Figure 2 16 Profile Setup tab Profile Setup Tab ...

Page 61: ...nd highlite the GBC FusionPunch II profile then click Enable The GBC FusionPunch II profile should now have a green check mark in the Enabled column Figure 2 17 On line Finishers tab 11 Click Close to close this window Now go back and follow steps 4 7 Enable Close ...

Page 62: ...s Destination as well as the correct Punch mode For FusionPunch II setup refer to the Getting Started section On line Off line Once the FusionPunch II is setup for the application go to the Downstream device and enable it for On line operation 2 From the DocuSP Print Services screen open the Printer Manager window and click on the Finishing Icon The Finishing Window will display defaulted to the F...

Page 63: ...is Enabled l For punching and stacking the 8 5 edge ensure the GBCSE profile is Enabled l For all other applications ensure the profile that associates with the Downstream device to be run is Enabled In the figure above is an example of a job being sent to a Signature Booklet Maker If this profile is not visible in this window go to step 8 If this profile is visible but not Enabled green check mar...

Page 64: ...ger window and highlight the job to run Click the Move Icon Figure 2 20 Job Manager window 6 Highlight the appropriate Queue for your job in the figure below is an example of a SBM Queue and then click Apply Figure 2 21 SBM Queue window Move Icon ...

Page 65: ...ob Manager window 8 Highlight any External Profile shown in the On line Finishers tab window and click Disable The green check mark in the Enabled column of the highlighted profile should now have switched to a red X as shown in the figure below Figure 2 23 On line Finishers tab Release Icon Enabled column ...

Page 66: ... below Highlight any enabled profile not the SBM profile and then click Off line Now highlight the SBM profile and click On line The SBM profile should now have a green check mark in the On line column as shown in the figure below Figure 2 24 Profile Setup tab Profile Setup Tab ...

Page 67: ...Finishers tab and highlight the SBM profile then click Enable The SBM profile should now have a green check mark in the Enabled column Figure 2 25 On line Finishers tab 11 Click Close to close this window Now go back and follow steps 4 7 Enable Close ...

Page 68: ...h under control of the Printer The Stacker requires minimal operator intervention with the exception of unloading the Stacker Tray Although the internal Stacker Tray has an extension that is adjustable you will seldom have to change this adjustment except in the case of job runs with unique paper sizes See Figure 2 26 below for locations of Stacker components Figure 2 26 The GBC Stacker with Front...

Page 69: ...f the first 1 Stacker in the system Press the Raise Lower Stacker 2 button to lower the tray of the second stacker in the system if a second Stacker is installed 3 Open the Stacker Door and remove the punched copy 4 Close the Stacker Door 5 Press the Raise Lower Stacker button s to raise the Stacker tray or trays back up to the top position The Punch will not start with the Stacker tray s down The...

Page 70: ...2 28 General Procedures ...

Page 71: ...3 Chapter 3 Troubleshooting Clearing Jams Error Messages from the Printer from the FusionPunch II from downstream devices ...

Page 72: ...3 2 Troubleshooting ...

Page 73: ...follows 1 Press the Stop Reset button on the Punch Control Panel 2 Open both Top Covers on the Punch as shown in Figure 3 1 3 Open lift the Input Ball Tracks as shown in Figure 3 1 and clear any paper that may be jammed in that area Also check the printer Finisher and output tray for any paper jams Figure 3 1 The Top Covers and Input Ball Tracks Input Ball Tracks Assembly Top Covers ...

Page 74: ...t may be jammed in that area 6 Reinstall the Output Guide Roller assembly and ensure that all assemblies are locked down Then close the Top Covers 7 Open the Bypass Stacker Top Cover and clear any paper that might be jammed in that area 8 IftheFusionPunchIIissetupinCycleUpmode presstheStop Reset button and the job will restart automatically 9 If the FusionPunch II isset up in Online mode press the...

Page 75: ... is not Online 1 Click on the Printer icon If there is a reset option select Reset 2 Press Stop Reset at the Punch and then press ONLINE OFFLINE Ensure that the Punch is in the Online mode and then press Start DocuTech 135 External Finisher Full The Punch has filled the Stacker and is waiting to be emptied Unload the Stacker and then restart the Punch Online DocuTech 61XX Clear ExternalFinisher to...

Page 76: ...sher 1 The Profile has not been set up correctly 2 The Profile has not been loaded into the Printer correctly or has not been loaded at all 1 Check the Profile at the Printer to ensure proper Host Enablement Call your System Administrator and refer to the setup procedures in Appendix A of this User Guide 2 Call the Xerox Service Representative to verify proper Host Enablement Xerox 4xxx DT 135 61X...

Page 77: ...pen Punch Right Door open The Interlock Switch behind the Punch Door that corresponds to the error message is not actuated Open and close the appropriate door corresponding to the error message and ensure that it is securely closed If the problem persists call your GBC or Xerox Service Representative Stacker Cover open The Interlock Switch under the Stacker s Top Cover is not actuated Open and clo...

Page 78: ...he paper 2 Clean the Entrance Sensor and reflector using Isopropyl alcohol and a clean lint free cloth If the problem persists call your GBC or Xerox Service Representative 3 Ensure that the Side Guide is not too tight Perform the adjustment in Chapter 2 Setting the Side Guide If the problem persists call your GBC or Xerox Service Representative 4 Press Stop Reset button to clear error message Fol...

Page 79: ...nd remove the paper 2 Clean the Document Transport Sensor 1 and reflector using Isopropyl alcohol and a clean lint free cloth If the problem persists call your GBC or Xerox Service Representative 3 Ensure that the Side Guide is not too tight Perform the adjustment in Chapter 2 Setting the Side Guide If the problem persists call your GBC or Xerox Service Representative 4 Press Stop Reset button to ...

Page 80: ...nd remove the paper 2 Clean the Document Transport Sensor 2 and reflector using Isopropyl alcohol and a clean lint free cloth If the problem persists call your GBC or Xerox Service Representative 3 Ensure that the Side Guide is not too tight Perform the adjustment in Chapter 2 Setting the Side Guide If the problem persists call your GBC or Xerox Service Representative 4 Press Stop Reset button to ...

Page 81: ...persists call your GBC or Xerox Service Representative 4 Press Stop Reset button to clear error message Follow printer jam clearance procedure and resume the job Jam Punch Exit Sensor 1 There is a sheet of paper blocking the Punch Exit Sensor at the Stacker s input 2 The Punch Exit Sensor and or its Reflector may be dirty 1 Lift up the Stacker Top Cover and remove the paper 2 Clean the Punch Exit ...

Page 82: ...onPunch II is turned ON this message will appear It will also appear after 100 000 completed punches Open the Punch Right Door and leave it open for at least 5 seconds before closing it The total count will not be affected by opening the Punch Right Door Stacker Upper Switch The Stacker s Upper Switch did not release during an emptying operation Lower and raise the Stacker Tray several times using...

Page 83: ...d on and that the communications cable DFA Cable is properly connected Figure 3 5 Downstream device Generated Error Messages Error Message Possible Cause Resolution Next Device Not Ready The downstream device from the FusionPunch II is not ready to receive paper Check the downstream device for further information Next Device Faulted The downstream device from the FusionPunch II is in a Fault condi...

Page 84: ...3 14 Troubleshooting ...

Page 85: ...4 Chapter 4 Maintenance Cleaning the FusionPunch II ...

Page 86: ...4 2 Maintenance ...

Page 87: ... the following operator maintenance practices When to Clean The following is based on a printing house that operates one to three shifts a day Usage Cleaning Intervals Heavy usage continuous 8 hours per shift after each shift Medium Usage intermittent 4 hours per shift after every 2 shifts Light usage intermittent 2 to 3 hours per shift after every 3 shifts In effect the FusionPunch II should be c...

Page 88: ...ssible damage to the machine use only 90 Isopropyl alcohol Do not use film remover or any other type of cleaning solvent What to Clean A good rule for cleaning that is easy to remember is to follow the paper path through the Punch and Bypass Stacker from left to right The cleaning procedures are as follows WARNING Switch OFF O the Main Power Switch before performing this procedure ...

Page 89: ... shown in Figure 4 1 Clean the green belt under the three ball tracks the Sensor Reflector and the Sensor under the hole in the base plate with Isopropyl alcohol and a clean lint free cloth Check also for accumulations of paper dust or toner under the base plate Figure 4 1 The Top Covers and Input Ball Tracks Input Ball Tracks Assembly Top Covers ...

Page 90: ...he base plate with Isopropyl alcohol and a clean lint free cloth Check also for accumulations of paper dust or toner on the base plate Figure 4 2 The Internal Paper Path Components 5 Open lift the Sheet Eject Strap assembly Clean the green belts under the straps the Sensor Reflector and the Sensor under the hole in the base plate with Isopropyl alcohol and a clean lint free cloth Clean the Side Gu...

Page 91: ...the rollers with Isopropyl alcohol and a clean lint free cloth Check also for accumulations of paper dust or toner on the base plate 7 Close lower all assemblies and reinstall the Output Guide Roller assembly when finished Close the Top Covers and resume normal operation Teflon is a registered trademark of E I du Pont de Nemours and Company Infeed Guide Teflon Plastic Piece Side Guide ...

Page 92: ... Clean the two orange O rings on the Roller Assembly as shown in Figure 4 4 using only 90 Isopropyl alcohol and a clean lint free cloth 3 Clean the large O rings that transfer the drive to the rollers using only 90 Isopropyl alcohol and a clean lint free cloth Figure 4 4 Cleaning the Stacker ...

Page 93: ... three red feed rollers and the green Flat Belt as shown in Figure 4 5 using only 90 Isopropyl alcohol and a clean lint free cloth 3 Clean the Sensor as shown in Figure 4 5 using only 90 Isopropyl alcohol and a clean lint free cloth Figure 4 5 Cleaning the Bypass ROLLERS FLAT BELT SENSOR ...

Page 94: ...4 10 Maintenance ...

Page 95: ...A Appendix A Personality Profiles Standard Punch Profiles Other Known Configurations ...

Page 96: ...A 2 Appendix A ...

Page 97: ...ourg products Finisher Profile A 14 With the Xerox SBM2 downstream 61XX to FusionPunch II to SBM2 Device Profile without CIM A 17 6155 6180 to FusionPunch II to SBM2 Device Profile without CIM Timings A 19 61XX to FusionPunch II to SBM2 Finisher Profile without CIM A 21 61XX to FusionPunch II to SBM2 Device Profile with CIM A 23 61XX to FusionPunch II to SBM2 Device Profile with CIM Timings A 24 6...

Page 98: ...y n High Capacity Stacker software must be 3 5 2 DFA Input Driver to support Cycle up and T E Signals from printer n BPRF BBF2005 control of milling motor by BPRF requires Cycle up from printer BPRF ready in perf mode if connected on a 61xx printer PLC input X17 ON BPRF ready in perf mode if connected BBF2005 PLC inputs X17 18 19 OFF n Delivery End Adjust to allow the BPRF to determine if C0 C1 ar...

Page 99: ...FusionPunch II FusionPunch II PunchSE Type External External External Function 1 Line Off Line Off Line Off Function 2 Line Off Line Off Line Off Sheet Sequence 1 N and N 1 1 N and N 1 1 N and N 1 Side 1 Direction Face Up and Face Down Face Up and Face Down Face Up and Face Down Rotate Never Never Always Minimum Sheet Length 254 254 254 Maximum Sheet Length 364 364 364 Minimum Sheet Width 203 203 ...

Page 100: ...0 2200 3250 Set Compiler Processing Time 0 0 0 Time Between Sets 0 0 0 Set Jam Time 2600 2600 3750 Time to Cycle Up 0 0 0 S0 Enabled Enabled Enabled S1 Enabled Enabled Enabled S2 Enabled Enabled Enabled S3 Enabled Enabled Enabled S4 Disabled Disabled Disabled Delivery Signal Type Lead Edge Lead Edge Lead Edge Delivery Start Adjust 0 0 120 Delivery End Adjust 100 100 50 End of Set Offset 0 0 30 Rec...

Page 101: ...onPunch II FusionPunch II PunchSE Function 1 Line Off Line Off Line Off Function 2 Line Off Line Off Line Off Sheet Sequence 1 N and N 1 1 N and N 1 1 N and N 1 Side 1 Direction Face Up and Face Down Face Up and Face Down Face Up and Face Down Rotate Never Never Always Minimum Sheet Length 254 254 254 Maximum Sheet Length 364 364 364 Minimum Sheet Width 203 203 203 Maximum Sheet Width 432 432 432 ...

Page 102: ...et Maker External Function 1 Line Off Line Off Function 2 Line Off Line Off Sheet Sequence 1 N and N 1 1 N and N 1 Side 1 Direction Face Up and Face Down Face Up and Face Down Rotate System Specified Never NB Rotation needed if glue must be applied on short edge Minimum Sheet Length 254 254 Maximum Sheet Length 364 364 Minimum Sheet Width 203 203 Maximum Sheet Width 432 432 Maximum Sheet Weight 20...

Page 103: ...on 2 Line Off Line Off Sheet Sequence 1 N and N 1 1 N and N 1 Side 1 Direction Face Up and Face Down Face Up and Face Down Rotate Never NB Rotation needed if glue must be applied on short edge Never NB Rotation needed if glue must be applied on short edge Minimum Sheet Length 254 254 Maximum Sheet Length 364 364 Minimum Sheet Width 203 203 Maximum Sheet Width 432 432 Maximum Sheet Weight 200 200 M...

Page 104: ...Function 2 Line Off Line Off Sheet Sequence 1 N and N 1 1 N and N 1 Side 1 Direction Face Up and Face Down Face Up and Face Down Rotate Never NB Rotation needed if glue must be applied on short edge Never or Always depending on job Minimum Sheet Length 254 254 Maximum Sheet Length 364 364 Minimum Sheet Width 203 203 Maximum Sheet Width 432 432 Maximum Sheet Weight 200 200 Minimum Sheet Weight 60 6...

Page 105: ...ime Between Sheets 250 0 Sheet Jam Time 1000 1 1000 1 Set Compiler Processing Time 1300 2000 Maximum Set Processing Time 1300 15000 Set Jam Time 8000 32760 Time to Cycle Up 0 0 S0 Enabled Enabled S1 Enabled Enabled S2 Enabled Enabled S3 Disabled Disabled on request S4 Disabled Disabled on request Delivery Signal Type Lead Edge Trial Edge 2 Delivery Start Adjust 0 60 Delivery End Adjust 30 60 End o...

Page 106: ...me 1000 1 1000 1 Set Compiler Processing Time 2000 2000 Maximum Set Processing Time 15000 15000 Set Jam Time 32760 32760 Time to Cycle Up 0 0 S0 Enabled Enabled S1 Enabled Enabled S2 Enabled Enabled S3 Disabled on request Disabled on request S4 Disabled on request Disabled on request Delivery Signal Type Trial Edge 2 Trial Edge 2 Delivery Start Adjust 200 60 Delivery End Adjust 60 60 End of Set Of...

Page 107: ...ts 0 0 Sheet Jam Time 1000 1 1000 1 Set Compiler Processing Time 2000 600 Maximum Set Processing Time 15000 600 Set Jam Time 32760 7168 Time to Cycle Up 0 0 S0 Enabled Enabled S1 Enabled Enabled S2 Enabled Enabled S3 Disabled on request Enabled S4 Disabled on request Enabled Delivery Signal Type Trial Edge 2 Lead Edge Delivery Start Adjust 60 120 Delivery End Adjust 60 50 End of Set Offset 30 30 R...

Page 108: ...e Off Line Off Function 2 Line Off Line Off Sheet Sequence 1 N and N 1 1 N and N 1 Side 1 Direction Face Up and Face Down Face Up and Face Down Rotate System Specified Never NB Rotation needed if glue must be applied on short edge Minimum Sheet Length 254 254 Maximum Sheet Length 364 364 Minimum Sheet Width 203 203 Maximum Sheet Width 432 432 Maximum Sheet Weight 200 200 Minimum Sheet Weight 60 60...

Page 109: ...ion 2 Line Off Line Off Sheet Sequence 1 N and N 1 1 N and N 1 Side 1 Direction Face Up and Face Down Face Up and Face Down Rotate Never NB Rotation needed if glue must be applied on short edge Never NB Rotation needed if glue must be applied on short edge Minimum Sheet Length 254 254 Maximum Sheet Length 364 364 Minimum Sheet Width 203 203 Maximum Sheet Width 432 432 Maximum Sheet Weight 200 200 ...

Page 110: ...n 2 Line Off Line Off Sheet Sequence 1 N and N 1 1 N and N 1 Side 1 Direction Face Up and Face Down Face Up and Face Down Rotate Never NB Rotation needed if glue m ust be applied on short edge Never or Always depending on job Minim um Sheet Length 254 254 Maxim um Sheet Length 364 364 Minim um Sheet W idth 203 203 Maxim um Sheet W idth 432 432 Maxim um Sheet W eight 200 200 Minim um Sheet W eight ...

Page 111: ...d Device Name SBM2Bk1to22 SBM2Bk1to22S SBM2Bk23to27 Type External External External Function 1 Line Off Line Off Line Off Function 2 Line Off Line Off Line Off Sheet Sequence 1 N and N 1 1 N and N 1 1 N and N 1 Side 1 Direction Face Up and Face Down Face Up and Face Down Face Up and Face Down Rotate Always Always Always Minimum Sheet Length 254 254 254 Maximum Sheet Length 364 364 364 Minimum Shee...

Page 112: ...m Feed Device Name SBM2Bk23to27S SBM2Ldgr1to27 Type External External Function 1 Line Off Line Off Function 2 Line Off Line Off Sheet Sequence 1 N and N 1 1 N and N 1 Side 1 Direction Face Up and Face Down Face Up and Face Down Rotate Always Never Minimum Sheet Length 254 254 Maximum Sheet Length 364 364 Minimum Sheet W idth 203 203 Maximum Sheet W idth 432 432 Minimum Sheet W eight 60 60 Maximum ...

Page 113: ...heet Set Stream Feed 8 5x11 8 5x14 A4 23 to 27 Sheet Set Non Stream Feed Time Between Sheets 120 120 120 Sheet Jam Time 800 800 800 Set Compiler Processing Time 150 150 400 Maximum Set Processing Time 1200 1800 0 Set Jam Time 7168 7168 7168 Time to Cycle Up 0 0 0 S0 Enabled Enabled Enabled S1 Enabled Enabled Enabled S2 Enabled Enabled Enabled S3 Disabled Disabled Disabled S4 Disabled Disabled Disa...

Page 114: ... A4 23 to 27 Sheet Set Stream Feed 11x17 A3 1 to 27 Sheet Set Non Stream Feed Stream Feed Time Between Sheets 120 120 Sheet Jam Time 800 800 Set Compiler Processing Time 600 150 Maximum Set Processing Time 0 2400 Set Jam Time 7168 7168 Time to Cycle Up 0 0 S0 Enabled Enabled S1 Enabled Enabled S2 Enabled Enabled S3 Disabled Disabled S4 Disabled Disabled Delivery Signal Type Lead Edge Lead Edge Del...

Page 115: ...M2Bk1to22S SBM2Bk23to27 Type SBM2Bk1to22 SBM2Bk1to22S SBM2Bk23to27 Function 1 Line Off Line Off Line Off Function 2 Line Off Line Off Line Off Sheet Sequence 1 N and N 1 1 N and N 1 1 N and N 1 Side 1 Direction Face Up and Face Down Face Up and Face Down Face Up and Face Down Rotate Always Always Always Minimum Sheet Length 254 254 254 Maximum Sheet Length 364 364 364 Minimum Sheet Width 203 203 2...

Page 116: ...ofile Name SBM2Bk23to27S SBM2Ldgr1to27 Type SBM2Bk23to27S SBM2Ldgr1to27 Function 1 Line Off Line Off Function 2 Line Off Line Off Sheet Sequence 1 N and N 1 1 N and N 1 Side 1 Direction Face Up and Face Down Face Up and Face Down Rotate Always Never Minimum Sheet Length 254 254 Maximum Sheet Length 364 364 Minimum Sheet Width 203 203 Maximum Sheet Width 432 432 Minimum Sheet Weight 60 60 Maximum S...

Page 117: ... Set Non Stream Feed Stream Feed Device Name SBM2Bk1to27C SBM2Ldgr1to27C Type External External Function 1 Line Off Line Off Function 2 Line Off Line Off Sheet Sequence 1 N and N 1 1 N and N 1 Side 1 Direction Face Up and Face Down Face Up and Face Down Rotate Always Never Minimum Sheet Length 254 254 Maximum Sheet Length 364 364 Minimum Sheet Width 203 203 Maximum Sheet Width 432 432 Minimum Shee...

Page 118: ...ream Feed Stream Feed DT 6155 6180 8 5x11 8 5x14 A4 1 to 27 Sheet Set Stream Feed DT 6155 6180 11x17 A3 1 to 27 Sheet Set Non Stream Feed Stream Feed Time Between Sheets 120 120 Sheet Jam Time 800 800 Set Compiler Processing Time 400 600 Maximum Set Processing Time 1200 2400 Set Jam Time 7168 7168 Time to Cycle Up 0 0 S0 Enabled Enabled S1 Enabled Enabled S2 Enabled Enabled S3 Disabled Disabled S4...

Page 119: ...eam Feed Stream Feed Profile Name SBM2Bk1to27C SBM2Ldgr1to27C Type SBM2Bk1to27C SBM2Ldgr1to27C Function 1 Line Off Line Off Function 2 Line Off Line Off Sheet Sequence 1 N and N 1 1 N and N 1 Side 1 Direction Face Up and Face Down Face Up and Face Down Rotate Always Never Minimum Sheet Length 254 254 Maximum Sheet Length 364 364 Minimum Sheet W idth 203 203 Maximum Sheet W idth 432 432 Maximum She...

Page 120: ...s listed below FBN settings for DocuTech 135 FBN 186 0 This is the End of Set Offset Time FBN 188 100 This is the End of Set Pulse Width FBN 191 0 This is the lead edge and trail edge trigger Lead edge 0 and Trail edge 1 After you have entered the values you must close the call To do this 1 Select SCP found in the top left corner of the screen 2 Go to the bottom left corner of the screen and click...

Page 121: ...mpt displays again 8 Type SCE and press Enter The system will prompt you to name the file so it can save it 9 Type FCG LIB and press Enter 10 If the system asks you to overwrite the file press Y for yes The system will save the GBC Punch Profile to the printer You must now load the profile Use the following procedure to load the profile 1 Press Enter to exit the EDIT mode 2 Type FCG GBCPUNCH and p...

Page 122: ...is Online 2 At the Sun NPS Workstation point the cursor to a blank part of the screen right click the mouse and select Restart The system will reboot 3 Type Priv admin space and press Enter The system will prompt you for a password 4 Type administrator as your password The prompt Ps Admin displays You are now at the System Administrator logon level 5 Type Create Output Profile and press Enter The ...

Page 123: ...pe Priv admin space and press Enter The system will prompt you for a password 2 Type administrator as your password The prompt Ps Admin displays You are now at the System Administrator logon level 3 Type Create Virtual Printer and press Enter The system prompts you to enter a name 4 Type GBCPunch and press Enter 5 Type Change Virtual Printer and press Enter 6 Type Output Bin and press Enter The sy...

Page 124: ...A 30 Appendix A ...

Page 125: ...G Glossary Glossary of Common FusionPunch II Terms ...

Page 126: ...G 2 Glossary ...

Page 127: ...o its extreme minimum position Backgauge Adjustment Knob a knob that is used to adjust the Backgauge assembly described above Centering the Punch an adjustment procedure that is used to ensure that the punched holes are centered side to side on the paper Control Panel the central control area for the FusionPunch II and any stackers that may be inline with the Punch It consists of all control butto...

Page 128: ...so contains reflectors for the two sensors installed in that area of the paper path DocuPrint a high speed printer that feeds the actual documents to the FusionPunch II and stackers DocuTech same as DocuPrint above except it is larger more configurable and has a wider range of capabilities Edge Guide Adjustment Knob the knob that is used in centering the Punch to ensure that the holes are centered...

Page 129: ...ethod of stacking documents in a staggered side to side fashion so that each individual document e g book or manual is separated from the next One Sided a printing job that uses only one side of the paper also called Single Sided Online the opposite of Offline when the finishing devices are being fed and controlled automatically by the printer in a live production run Operator the person responsib...

Page 130: ...t communicates input and output information from the printer to a finishing device such as the FusionPunch II Each model of printer has its own unique profile Punch a finishing device such as the FusionPunch II that is used to punch binding holes in printed documents Punch Arm Retaining Levers two levers that are used to lock or release the Die Set assembly from the machine You would release these...

Page 131: ...embly consisting of a steel rail and three spring steel straps that is used to tension the paper just before it enters the Die Set The Sheet Eject Strap assembly is hinged and can be opened to clear paper jams Side Guide a small contoured paper guide made of sheet metal and located under the Sheet Eject Strap Assembly to the right of the Infeed Guide The Side Guide is adjustable and is used in Set...

Page 132: ...e System Administrator the person who is responsible for setting up and maintaining the printer s operating system The System Administrator also installs new software when necessary Two Sided a printing job that uses both sides of the paper also called Double Sided or Duplex ...

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