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Plockmatic BOOKLET MAKER Pro 30, Operating Instruction

The Plockmatic BOOKLET MAKER Pro 30 is a high-quality, reliable machine for creating professional booklets. Ensure optimal performance with the Operating Instruction manual, available for free download at manualshive.com. Maximize productivity and efficiency with this essential tool for any printing operation.

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63

6. 

Troubleshooting

Fault codes

General

If frequent input jams are experienced please check paper curl and decurler adjustments in 

printer operator guide.

When there is a misfeed or fault condition in the booklet maker system, a message will 

be displayed on the Booklet Maker. In case there is a problem that can be rectified by the 

operator, a fault code and an explanation will be displayed.

Fault codes that can be rectified by the operator:

BM30 40-XXXX

TR30 41-XXXX

SQF30 42-XXXX

CF30 43-XXXX

RCT 30 

44-XXXX

 

Note

If procedures in this manual do not rectify the problem an authorized technician will be 

needed.

Summary of Contents for BOOKLET MAKER Pro 30

Page 1: ...his 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 1...

Page 2: ...ich 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 broad...

Page 3: ...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 resul...

Page 4: ...trician 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 specific pur...

Page 5: ...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 runnin...

Page 6: ...Page intentionally blank...

Page 7: ...edure 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 trim...

Page 8: ...al 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 registra...

Page 9: ...tation nip rollers 4x 76 Cleaning the fixing 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 too...

Page 10: ...10 Page intentionally blank...

Page 11: ...oklet 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 o...

Page 12: ...ssing 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 first row shows that the settin...

Page 13: ...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...

Page 14: ...14 8 Connections 9 Fold stop gate Booklet Maker continues Main Power Terminator COM TR30 Terminator Stacker COM Copier POW SQF30 Interlock jumper Interlock jumper POW TR30 9 8...

Page 15: ...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...

Page 16: ...er 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 baffle 5...

Page 17: ...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...

Page 18: ...rts 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...

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

Page 20: ...ower 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 lif...

Page 21: ...21 1 RCT 30 2 3 4 1 Top cover 2 Infeed slot 3 Upstream docking assembly 4 Slide door...

Page 22: ...22 1 Outfeed slot 2 Trim waste transport 3 Waste container 4 Connections 5 Downstream docking assembly RCT 30 continues 3 4 1 5 2...

Page 23: ...23 Connections bracket 1 COM Copier 2 Terminator 3 Terminator COM TR30 4 Main power RCT 30 continues 1 2 3 4...

Page 24: ...24 RCT 30 continues Operator side top cover 1 Infeed Section A 2 Main switch 3 Bleed trimmer circular knives 4 Outfeed section D 3 1 2 4...

Page 25: ...25 RCT 30 continues 1 Latch handle slide 2 Bleed trimmer registration adjustment 3 Creaser registration adjustment 4 Waste chute s 1 2 3 4...

Page 26: ...26 RCT 30 continues 1 Rotator 2 Coarse registration section B 3 Fine registration section C 4 Creaser tools 1 2 3 4...

Page 27: ...from millimeters to inches and more See section 3 Tools for how to get around in the Tools screen Changing settings To change or adjust settings Select an item in the Ready screen with the arrow butt...

Page 28: ...When the printer has cycled down in the middle of a set for any reason load stock refill etc the processing screen will be shown until the printer has completed the set job The Please wait screen Whil...

Page 29: ...r 1 Set main power switch 2 on Booklet Maker to ON position Note The main power switch also controls Cover Feeder optional Trimmer optional and Square Folder optional Close the Top cover Turning On Of...

Page 30: ...stapler head Check staples Staple cartridge and stapler head Open the top cover Remove the set of paper Disconnect the staple indication lead A from the socket Hold the stapler head in place press the...

Page 31: ...the head actuate the Stapler up and down through full travel Perform this operation with staple cartridge Repeat this a few times to ensure that the staples are ejected at each down movement Reinstal...

Page 32: ...1 32 Consumables To reorder staples please use following part numbers XNA 8R3838 XE 8R3839...

Page 33: ...1 33 Emptying the trim bin Remove the trim bin by lifting it and pulling it out trim bin no Square Folder installed trim bin with Square Folder installed...

Page 34: ...1 34 Page intentionally blank...

Page 35: ...changes From the Ready screen select the option you wish to change and press the Change button Confirm changes by pressing the OK button Procedure for permanent changes From the Ready screen press the...

Page 36: ...aper sizes continues If a RCT 30 is installed there is a selection of ready made job setups to facilitate quick and easy setup to process oversizes to nominal sizes These are named with the suffix T l...

Page 37: ...n Trimming Selecting trimming On or Off If trimming was On the first choice will be Off and vice versa Select On or Off with the arrow button and press the OK button From the Ready screen select Trim...

Page 38: ...ect Feed if you want to fold only one sheet in sequence Press the OK button to confirm From the Ready screen select Cover and press the Change button Adjusting the cutting margin Select Trim and press...

Page 39: ...the cover sheets well to achieve a reliable feeding operation and good finishing results Make sure that the ink has completely dried to avoid smearing Press on top of either air nozzle A to lower the...

Page 40: ...cker Use the manual modes to override the auto function There are four different manual modes to select from Mode 1 Approximately 6 to 11 sheets Decreased amount of square forming Mode 2 Approximately...

Page 41: ...through in a shorter time Press the OK button to confirm RCT 30 Rotator Selecting On or Off From the Ready screen select Rotator and press the Change button Creaser Selecting Creaser Mode From the Re...

Page 42: ...select Coarse and press the Change button The Crease Offset whether Fine or Coarse is initially set to the center 0 0 mm You can change the offset with or buttons that change the crease position from...

Page 43: ...e desired format You can adjust three different parameters and in all three parameters you have to make sure that the inboard IB and outboard OB shreds are within the interval of 5 30 mm to avoid Blee...

Page 44: ...If you want to adjust the width select Width Adjust and press the Change button Change the WidthAdjust offset with the or buttons and press the OK button to confirm A decrease of the value in the Widt...

Page 45: ...ff and vice versa Select On or Off with the arrow button and press the OK button Change the Image Offset value with the or buttons and press the OK button to confirm When pressing the button the image...

Page 46: ...the of cuts on any side be outside the 5 30 mm interval the warning for Bleed Trim Conflict is displayed on the UI Remedy Adjust any of these parameters to get the of cut within the 5 30mm Bleed Trim...

Page 47: ...From this screen you can change units between millimeters and inches Select Units with the arrow button and press the OK button Select the millimeters or inch units and then press the OK button Selec...

Page 48: ...e arrow button and press the OK button Select desired language with the arrow button and press the OK button Select the module in the system for which you want to check the software version and press...

Page 49: ...in increments of 10 with the or buttons and press the OK button Normal user default setting is 60 Double Sheet Detection From this screen you can turn the double sheet detection On or Off Select Doub...

Page 50: ...On or Off Press the OK button to confirm When turned On the Stacker full det can keep count of how many booklets are on the stacker and notifies when it s full and stops the printer After emptying th...

Page 51: ...cept the changes you just made Continued on next page The Booklet Maker has a maximum storage capacity of 10 different jobs It is not possible to delete jobs therefore when you need to store a new job...

Page 52: ...xt button Then press the Load button The booklet maker will then automatically setup that specific job and return to the Ready screen Storing a new Job continues To store the job press the Save button...

Page 53: ...feed s an error code and the location of the misfeed is displayed See examples below General Misfeeds in the Booklet Maker are indicated as area A B or C and by the error code 40 XXXX Misfeeds in the...

Page 54: ...tion remains Switch off the main power Switch on the main power If misfeed condition remains Switch off the main power If a Trimmer is installed first remove the trim bin to get access to the fold sto...

Page 55: ...5 55 Clearing misfeed s continues Open Top Cover Manually pull the spring supported paper guides apart Remove the misfed sheets Close Top Cover Clearing misfeed in input area...

Page 56: ...e latch B and place the infeed roller shaft into operating position Clearing misfeed in input area The upper trimmer blade on the trimmer is protected by a knife protection plate that moves away durin...

Page 57: ...t compressing brackets A Secure them under the latch B Remove the misfed sheets from the exit area After the misfed sheets are removed lift up the latch B and place the compressing brackets in operati...

Page 58: ...5 58 Open the Hand Feed Cover Lift the jam clearance baffle A Remove the misfed cover Put the jam clearance baffle back in normal position Clearing misfeed s in vertical transport area Cover Feeder 8...

Page 59: ...B on the latches to release Remove the misfeeds Place the upper feed belts in normal position Close the top cover Inside the Square Folder Exit area Open the top cover Remove the misfeeds through the...

Page 60: ...up A A and D B baffles if needed Remove any misfeed s Lower A and D baffles to normal position Misfeed s in the trimmer area are rolled out by rotating the rubber surfaced pinch roller C Close the top...

Page 61: ...the slide door Close the slide door Rotator registration and creaser area Clearing jams in the waste transport The waste transport is easily accessible through the slide door Shreds jammed in or wrapp...

Page 62: ...62 Page intentionally blank...

Page 63: ...booklet maker system a message will be displayed on the Booklet Maker In case there is a problem that can be rectified by the operator a fault code and an explanation will be displayed Fault codes th...

Page 64: ...d the jam area will be displayed See section 5 Clearing Misfeeds for how to clear a misfeed Close cover s When the message Close Cover s is displayed any of the interlock switches are actuated Check t...

Page 65: ...purpose is to remind the operator to maintain stapler head and clinchers If not doing that every 20 000 there is a great risk of a costly mechanical breakdown See section Maintaining Your Machines on...

Page 66: ...tatic electricity is prevented from falling down into the trim bin Empty the trim bin and remove loose trim strips from inside the Trimmer See section 1 Basics for how to remove the trim bin Close tri...

Page 67: ...eased To clean the feed belts see section 7 REMARKS Maintaining Your Machine To increase the pressure on the upper feed belts follow this procedure Open the top cover Place both springs in the upper p...

Page 68: ...dth cross process direction min 275 mm 10 9 Width cross process direction max 325 mm 12 7 Length in process direction min 205 mm 8 1 Length in process direction max 232 mm 9 1 44 9003 Waste bin full E...

Page 69: ...ical or mechanical interlock devices Do not operate the equipment if you notice unusual noises or odors Disconnect the powercord from the power source and call your authorized technician to correct th...

Page 70: ...the machine to a power source that lacks a ground connection terminal Always locate the equipment on a solid support surface with adequate strength for the weight of the machine Always keep magnets an...

Page 71: ...ace the machine near the power source providing clearance as shown 1 Left more than 400 mm 15 3 4 off line use 2 Rear more than 555 mm 21 7 8 3 Right more than 400 mm 15 3 4 4 Rear more than 700 mm 27...

Page 72: ...ifically described in this documentation Booklet Maker Oil Clinchers and Stapler Heads Stapling area view from infeed close up of clincher lever close up of clincher lever close up of clincher A B B T...

Page 73: ...t Turn off the main power switch on the machine Press and hold the two innermost buttons on the UI buttons 2 and 3 Turn on the main power switch and release the buttons after 2 seconds Remove the Stap...

Page 74: ...e feeds is one indication of the need to clean the Feed Rollers Remove the feed roller assembly by pressing it to the front of unit A The left end of the feed roller assembly will now be released B an...

Page 75: ...feed belts with water and a lint free cloth Open the top cover Clean the upper feed belts A The upper feed belts can easily be rotated in either direction Lift up the upper feed belts to access the l...

Page 76: ...misfeeds is one indication of the need to clean the feed roller paper path and or the sensors Feed rollers and paper path are cleaned with the same cleaning agent used to clean the printer and a lint...

Page 77: ...ransportation nip rollers 4x continues Nip rollers Cleaning the fixing rollers 3x Fixing rollers Also clean the idler rollers WARNING Do not put your fingers within knife protections Doing so may resu...

Page 78: ...the fixing rollers 3x continues Fixing rollers Cleaning the registration cross roller 4x Cleaning friction tires Registration cross rollers Cleaning of the friction tires is done from within the regis...

Page 79: ...ath sensors 5x Cleaning the rotator rollers 2x Rotator rollers Also clean the idler rollers WARNING Do not put your fingers within knife protections Doing so may result in injury Infeed sensor Outfeed...

Page 80: ...7 80 Cleaning the paper path sensors 5x continues Rotator sensor Registration sensor...

Page 81: ...ors 5x continues Cleaning of creaser tools 2x Grooves on both sides of the tool After a period of time toner and paper dust may leave residuals in the grooves of the tool These grooves need to be clea...

Page 82: ...ed Trimmer registration angle parallell cut Adjustment of Bleed Trimmer registration angle trimmer cut parallel to registration OB edge Turn the knurled screw in desired direction Counter nut and set...

Page 83: ...registration angle Adjustment of Creaser registration angle Loosen the star shaped knob Turn the knurled eccentric in the desired direction Tighten the star shaped knob again Star shaped knob Knurled...

Page 84: ...7 84 Page intentionally blank...

Page 85: ...vailable Paper Size Minimum Width 206mm 8 1 Length 275mm 10 8 Paper Size Maximum Width 320mm 12 6 Length 457 2mm 18 Paper Weight Minimum 64gsm 16 lb Bond Paper Weight Maximum 300gsm 172 lb Index 115 l...

Page 86: ...rom BM30 Specifications Remarks Speed Same as BM30 Standard Paper Sizes Same as BM30 Default trim length 3 mm Adjustable in 0 1 mm steps Minimum trimming 1 mm 0 0394 in Adjustable in 0 1 mm steps Maxi...

Page 87: ...ame as BM30 Paper Weight Minimum Same as BM30 Paper Weight Maximum Same as BM30 Input Output Sheets Same as BM30 Input Output Sheets Same as BM30 Off line Use Possible Together with Booklet maker Trim...

Page 88: ...ion max 325 mm 12 7 Length cross process direction min 205 mm 8 1 Length cross process direction max 232 mm 9 1 Creaser Tools Fine tool Coarse tool Stock 120 gsm Stock 120 gsm gsm grams per sq meter B...

Page 89: ...EN 61000 3 2 2006 A1 2009 A2 2009 EN 61000 3 3 2008 FCC Part 15 2009 Subpart B Class A equipment EMC emission Intertek ETLSEMKO EN 55024 1998 A1 2001 A2 2003 EMC immunity Intertek ETL SEM KO The syst...

Page 90: ...5 4 7 6 5 6 5 5 6 6 5 5 5 4 Paper weight Bond Offset Cover Tag Index Gsm 20 50 28 46 42 80 24 60 33 56 50 90 28 70 39 64 58 100 29 73 40 62 60 110 31 81 45 73 66 120 35 90 48 80 74 130 36 90 50 82 75...

Page 91: ...85 Maintaining Your Machines 72 Making Booklets 35 Misfeed s clearing 53 O Options 16 P The Please wait screen 28 The Processing screen 28 Turning On Off the Main Power 29 Paper Size setting 35 Paper...

Page 92: ......

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