Pro 35/50 Booklet making system

Operating Instruction
Stapler Folder Reference

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.

Doc no: X04101

Date: 24 September, 2013
 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.
Safety Information
When using this machine, following safety precautions should always be followed.

Safety during operation

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 specified 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 specifically 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.

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 qualified 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 specific purpose only. Any use going beyond this specific 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 modifications to the machine. The manufacturer will
not be liable for modifications 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 fingers 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.
General safety, continued

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 specifically described in this documentation.
• Always keep magnets and all devices with strong magnetic fields 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.

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
specifications without prior notice!
Page intentionally blank.
TABLE OF CONTENTS
What You Can Do With This Machine.............................................................................. 11
Guide To Components...................................................................................................... 13
Booklet Maker.............................................................................................................................. 13
Options............................................................................................................................... 16
Cover Feeder............................................................................................................................... 16
Square Folder.............................................................................................................................. 17
Trimmer........................................................................................................................................ 19
Rotator Creaser Trimmer............................................................................................................. 21
User interface.................................................................................................................... 27
Control panel............................................................................................................................... 27
Alive logo..................................................................................................................................... 28

1. Basics................................................................................................ 29
Turning On / Off the Main Power...................................................................................... 29
RCT module, Booklet Maker, Trimmer and Square Folder.......................................................... 29
Change staple cartridges and Check stapler................................................................. 30
Change left/right staple cartridge(s)............................................................................................. 30
Check left/right stapler................................................................................................................. 31
Cover feeder...................................................................................................................... 31
Loading covers............................................................................................................................ 31
Emptying the trim bin........................................................................................................ 32
2. Making Booklets............................................................................... 33
Changing settings............................................................................................................. 33
General procedure....................................................................................................................... 33
Paper Size................................................................................................................................... 33
Selecting standard paper sizes.............................................................................................................. 33
Custom paper size................................................................................................................................. 34
Staple........................................................................................................................................... 34
Selecting stapling On or Off................................................................................................................... 34
Staple position............................................................................................................................. 35
Adjusting staple position........................................................................................................................ 35
Fold position................................................................................................................................ 35
Adjusting fold position............................................................................................................................ 35
Cover........................................................................................................................................... 36
Using covers.......................................................................................................................................... 36
Air Separation........................................................................................................................................ 37
Double Sheet Detection......................................................................................................................... 37
Trim.............................................................................................................................................. 37
Select trimming Auto, Manual or Off ...................................................................................................... 37
Square Folding............................................................................................................................ 38
General.................................................................................................................................................. 38
Selecting square folding mode............................................................................................................... 39
SQF stop gate offset.............................................................................................................................. 39
Rotator Side Trimmer................................................................................................................... 40
Rotator (Optional) - Selecting On or Off................................................................................................. 40
Rotator (Optional) - Rotator Conflict....................................................................................................... 40
Creaser - Selecting Creaser Mode......................................................................................................... 40
Bleed Trimmer - Selecting ON or OFF................................................................................................... 41
Bleed Trimmer - Selecting Bleed Trim Mode.......................................................................................... 42
Bleed Trimmer - Bleed Trim Conflict...................................................................................................... 43
Hand-feeding...................................................................................................................... 44
On-line/Off-line................................................................................................................... 45
Off-line mode............................................................................................................................... 45
Side Adjustment................................................................................................................ 46
Booklet Maker Adjustment........................................................................................................... 46
3. Tools.................................................................................................. 47
The Tools Screen............................................................................................................... 47
The Tools screen.......................................................................................................................... 47
Stacker full detection................................................................................................................... 47
Auto shrink................................................................................................................................... 47
Language..................................................................................................................................... 48
Units............................................................................................................................................. 48
SQF stop gate offset.................................................................................................................... 48
Software version.......................................................................................................................... 48
Sheet feeder................................................................................................................................ 49
Service access............................................................................................................................. 49

4. Jobs................................................................................................... 51
Handling jobs..................................................................................................................... 51
Saving a Job................................................................................................................................ 51
Handling stored Jobs................................................................................................................... 52
Recalling a Job............................................................................................................................ 52

5. Clearing Misfeed(s).......................................................................... 53
Clearing misfeed(s)........................................................................................................... 53
General........................................................................................................................................ 53
RCT module....................................................................................................................... 54
Clearing misfeed(s) in the paper path.......................................................................................... 54
Infeed “A” area and exit “D” area........................................................................................................... 54
Rotator, registration and creaser area.................................................................................................... 55
Booklet Maker.................................................................................................................... 56
Clearing misfeed(s)...................................................................................................................... 56
Inside the Booklet Maker........................................................................................................................ 56
Clearing misfeed in input area with infeeder (no deburster).................................................................. 57
Clearing misfeed in input area with deburster........................................................................................ 58
Clearing misfeed in folder area.............................................................................................................. 59
Cover Feeder..................................................................................................................... 60
Clearing misfeed(s) in vertical transport area.............................................................................. 60
Square Folder.................................................................................................................... 61
Clearing misfeed(s)...................................................................................................................... 61
Inside the Square Folder........................................................................................................................ 61
Trimmer.............................................................................................................................. 62
Clearing misfeed(s)...................................................................................................................... 62
Clearing misfeed in input area............................................................................................................... 62
Clearing misfeed in exit area.................................................................................................................. 63
Belt stacker........................................................................................................................ 64
Clearing misfeed(s)...................................................................................................................... 64
Clearing misfeed on belt stacker............................................................................................................ 64

6. Troubleshooting............................................................................... 65
Fault codes........................................................................................................................ 65
General........................................................................................................................................ 65
General fault codes...................................................................................................................... 67
Clear Misfeed(s)..................................................................................................................................... 67
Close cover(s)........................................................................................................................................ 67
Empty stacker!....................................................................................................................................... 67
Illegal feed mode.................................................................................................................................... 67
Rotator Creaser Trimmer fault codes........................................................................................... 68
Bleed Trim Conflict................................................................................................................................. 68
Rotator Conflict...................................................................................................................................... 68
 Waste bin full.......................................................................................................................................... 68
Booklet maker fault codes........................................................................................................... 69
Check stapler or Change staple cartridge.............................................................................................. 69
Set too thick, remove set........................................................................................................................ 69
Remove purged set................................................................................................................................ 69
No vacant deburster............................................................................................................................... 69
Too many sheets.................................................................................................................................... 69
Cover feeder fault codes.............................................................................................................. 69
Misfeed................................................................................................................................................... 69
Remove double feed.............................................................................................................................. 69
Few covers left, add covers................................................................................................................... 70
Load covers............................................................................................................................................ 70
Out of covers.......................................................................................................................................... 70
Remove double feed.............................................................................................................................. 70
Change cover size................................................................................................................................. 70
Trimmer fault codes..................................................................................................................... 71
Empty trim bin........................................................................................................................................ 71
Close trimmer belts................................................................................................................................ 71
Square folder fault codes............................................................................................................. 71
Feed errors............................................................................................................................................. 71

7. REMARKS......................................................................................... 73
Do’s And Don’ts................................................................................................................. 73
Where to put Your Machine.............................................................................................. 74
Machine environment.................................................................................................................. 74
Power connection........................................................................................................................ 74
Access to machine....................................................................................................................... 75
Maintaining Your Machines.............................................................................................. 76
Cover Feeder............................................................................................................................... 76
Cleaning feed rollers and paper separator pad...................................................................................... 76
Square folder............................................................................................................................... 77
Cleaning feed belts................................................................................................................................ 77
RCT module................................................................................................................................. 78
Cleaning the paper path transportation nip rollers (4x).......................................................................... 78
Cleaning the fixing rollers (3x)................................................................................................................ 79
Cleaning the registration cross roller (4x).............................................................................................. 80
Cleaning the rotator rollers (2x).............................................................................................................. 81
Cleaning the paper path sensors (5x).................................................................................................... 81
Cleaning of creaser tools (2x)................................................................................................................ 83
Adjustment of Bleed Trimmer registration angle (parallell cut)............................................................... 84
Adjustment of Creaser registration angle............................................................................................... 85
Limitations in the Pro 35 / 50 system.............................................................................. 86
Best practice for the Pro 35 / 50 system......................................................................... 87
8. Specification .................................................................................... 89
Machine Specifications..................................................................................................... 89
Booklet Maker BM 35 / 50........................................................................................................... 89
Cover Feeder CF 50 ................................................................................................................... 90
Trimmer TR 50 ............................................................................................................................ 90
Square folder SQF 50 ................................................................................................................. 91
Rotator Creaser Trimmer module RCT (option)........................................................................... 92
System Certifications................................................................................................................... 93
BM 35 / 50 System Set Size Guide............................................................................................. 94

INDEX.................................................................................................... 97
10
What You Can Do With This Machine
CF 50 Cover Feeder (option) Pro 50 kit (option)
incl. alive logo
Deburster (option)
SQF 50 Square Folder (option)

Belt Stacker

BM 35 / 50 Booklet Maker

RCT Rotator Creaser Trimmer (option) TR 50 Trimmer (option)

The Booklet Maker BM 35/50, Trimmer TR 50, Square Folder SQF 50, Rotator Creaser
Trimmer module RCT and Cover Feeder CF 50 forms a system that allows full bleed
booklet making online with the Copier. To maintain the full productivty of a high capacity
printer, the Booklet maker can be equipped with a deburster kit (option). The deburster
buffers the high speed burst of sheets delivered from the printer. Another productivity
enhancement is the Pro 50 kit. This kit raises the capacity ot the Booklet maker from 35
sheets to 50 sheets. That means that instead of 140 page booklets, 200 page booklets are
now possible. The Pro 50 kit also includes the Alive logo feature. The logo below the user
interface will be illuminated, allowing the user to monitor the system status from a distance.

The print-outs first enters the RCT module (optional). The RCT is able to rotate (rotator is
optional) small(er) sheets from long edge feed to short edge feed to maintain high printer
productivity. In order to avoid color prints to break or dissolve at the spine when folded,
the RCT can crease the cover sheet. The RCT can also trim the long sides of the sheets
to shape the print-outs to the desired format. Combined with a TR 50 Trimmer (optional)
this enables full bleed booklets. From the RCT, the print-outs are transported into the BM
35/50 where they are compiled in the stapler area.
If installed in the Booklet Maker, the CF 50 Cover Feeder (optional) can add any type of
covers, colored or black and whites to the printed set. The Booklet Maker jogs and staples
the set. The set is then transported further to the folding area where the set is folded into a
booklet and fed out to the belt stacker or device attached after the Booklet Maker.

continued on next page

11
continued from previous page

When a larger number of sheets are folded, an effect called creeping occurs. In order to
rectify creep, the TR 50 Trimmer (optional) can be attached after the Booklet Maker. If so,
the booklets are transported from the Booklet Maker into the Trimmer where the trail edge
will be cut off.

After the Bookler Maker, but before an optional Trimmer, the SQF 50 Square Folder
(optional) can be attached. The printouts, which have been stapled and folded, will be fed
into the SQF 50 where the spine of the booklets will be flattened square. The booklets will
have the look of a perfect bound book. Finally, the booklets are then fed out to the Belt
Stacker or to an optional Trimmer.

The Booklet making system can also be used as a stand-alone unit for hand-feeding.

12
Guide To Components

Booklet Maker

1 2 3 4 5 6

10

1 Infeed safety cover 6 Alive logo, only on Pro 50 (optional)

2 Hand feed cover 7 Cover feeder (optional)
3 Top cover 8 Belt Stacker outfeed cover
4 Latch handle 9 Belt Stacker
5 Control panel 10 Base

13
Booklet Maker, continued

9
8 10

8 Fold stop gate

9 Connections, see below
10 Cable protector

Terminator (or
Stacker Terminator (or COM SQF 50 / Main Power
COM RCT) TR 50)

Booklet maker,
stand alone

COM Copier Interlock jumper (or

POW SQF 50 / TR 50)
14
Booklet Maker, continued
Terminator (or COM SQF 50 / Main Power
COM RCT) TR 50

Booklet maker,
with Square
folder and/or
Trimmer

COM Copier POW SQF 50 / TR 50

1 2 3

6 5 4

1 Staple cartridges (incl. stapler heads)

2 Staple cartridge ejector lever
3 Fold roller guide
4 Main power switch
5 Set thickness sensor
6 Compiler area
7 Hand feeding paper guides. Hand feed assy can be lifted for jam clearance
15
Options

Cover Feeder

2
3

7 6 5

1 Air nozzle (2x) 5 Feed roller assembly

2 Loading capacity mark 6 Paper separator pad (also see page 74)
3 Rear side guide 7 Front side guide
4 Paper orientation indicator 8 Jam clearance baffle

16
Square Folder

2
3

1 Top cover
2 Connections, see below
3 Cable protector
4 Base

Square folder, no Trimmer Square folder, with Trimmer

Terminator Terminator

Stacker POW from COM from POW to TR 50 COM to TR 50

BM 35 / 50 BM 35 / 50
17
Square Folder, continued

The Square Folder interior has parts that you will come in contact with if a misfeed occur.

2 3

Square folder, top view,

Upper feed belts in lifted up

1 Lower feed belts

2 Upper feed belts
3 Upper feed belt release latch

18
Trimmer

1 Top cover
2 Trim bin
3 Connections, see below
4 Cable protector
5 Base

Stacker COM from Power from Terminator

BM 35 / 50 or BM 35 / 50 or
SQF 50 SQF 50

19
Trimmer, continued

The Trimmer interior has parts that you will come in contact with if a misfeed occurs.

4
3

2 7

1
8

Trimmer, top view

1 Infeed roller shaft 5 Trimmer stop

2 Upper knife (not visible) 6 Transport belt
3 Trimmer fan 7 Outfeed drive release (not visible)
4 Pre-cut compressing brackets 8 Set counter

20
Rotator Creaser Trimmer

2
4

1 Top cover
2 Infeed slot
3 Upstream docking assembly
4 Slide door

21
Rotator Creaser Trimmer, continued

4
5

1 Outfeed slot
2 Trim waste transport
3 Waste container
4 Connections
5 Downstream docking assembly

22
Rotator Creaser Trimmer, continued

Connections bracket

1 DFA / Communication to Copier

2 CAN termination plug
3 CAN / Communication to BM 35 / 50
4 Main power

23
Rotator Creaser Trimmer, continued

3
Operator, side top cover

1 Infeed Section “A”

2 Main switch
3 Bleed trimmer circular knives
4 Outfeed section “D”

24
Rotator Creaser Trimmer, continued

2 3

4
1

1 Latch handle, slide

2 Bleed trimmer registration adjustment
3 Creaser registration adjustment
4 Waste chute(s)

25
Rotator Creaser Trimmer, continued

4
1

1 Rotator
2 Coarse registration, section “B”
3 Fine registration, section “C”
4 Creaser tools

26
User interface
The BM 35 / 50 Booklet making system is controlled from a control panel located on the
Booklet Maker. The control panel will allow you to easily set up, adjust and operate the
complete system. An optional “Alive logo” makes state of system visible from a distance.

Control panel
The control panel is of touch screen type. Point at the screen and press the “button” to
reach the desired function or change the desired setting.

The Ready screen

When the system power is switched on, the
Ready screen will be shown. Here you will find
information showing the actual set up. From this
screen you can also access other screens that will
help you operate the complete BM 35 / 50 Booklet
making system.

Changing settings
To change or adjust settings just point at an item
in the Ready screen. For example you can fine
adjust the trimming, turn off the cover feeder, set
the Square folder to the correct mode or adjust
the staple or fold position during run. Explore all
settings more thoroughly in section 2. Making
Booklets.

The Jobs screen

Pressing the [Jobs] button in the Ready screen
opens the Jobs screen. From here you can
load, customize and save job settings. These
procedures are described in section 4. Jobs.

27
 The Tools screen
Pressing the [Tools] button in the Ready screen takes
you to the tools screen. This screen looks different
depending of how the system is configured. From
here you can change the display language, set units
from millimetres to inches and more. See section
3. Tools. for how to get around in the Tools screen.

The Processing screen

This screen is shown when the machine is busy
working. If the machine is used in off-line mode
you do not have to wait for the Ready screen
before hand-feeding the next set.

The Please wait screen

While the machine sometimes needs time
to perform changes in settings, the Please
wait screen will be shown. The machine will
automatically return to the Ready screen after
changes have been implemented.

The Power save mode screen

The machine will go into a power saving mode
if it is left unused for more than app. 10 minutes.
Touch the control panel, send a job from the printer
or open a cover to reinstate the Ready mode.

Alive logo
Alive logo
With a Pro 50 kit installed, the three stripes below
the user interface will signal status as follows:
Steady blue - when system is on and ready,
processing with or without paper flow
Alternating blue/yellow - Soft stop (staples low,
cover low, stacker full, waste bin full).
Alternating blue/red - Jam or malfunction
Not illuminated - System in power save mode or
switched of.
28
1. Basics

Turning On / Off the Main Power

RCT module, Booklet Maker, Trimmer and Square Folder

A Make sure that the Booklet maker and RCT

module (optional) power cords are plugged into
the wall outlet.
Note
Trimmer (optional) and Square Folder (optional) are
powered from the Booklet Maker.

Open the Booklet maker top cover (A).

Set main power switch (B) on Booklet Maker to

ON position. If a Square Folder and Trimmer are
attached, they will be powered on via the Booklet
B Maker main power switch.

Close the Booklet Maker top cover.

Open the top cover of the RCT (C).

C

Set the main power switch (D) to ON position.

D Close the RCT top cover.

29
 Change staple cartridges and Check stapler
The staple cartridges contains approximately 5000 staples each. Each cartridge includes
all wear-out and service parts (i.e. the stapler head). The cartridges may be removed ei-
1 ther for renewal or for jam clearance.
To reorder staple cartridges, please use EDP code: 404461 (box of three cartridges).

Change left/right staple cartridge(s)

The Booklet Maker will indicate “Change left/right/

left and right staple cartridges” when there is app.
20 staples left in the stapler cartridge. Replace the
indicated staple cartridge by doing the following:

Open the Booklet Maker top cover.

Press the staple cartridge ejector lever (A) and

pull out the staple cartridge (B) using the grip (C)
at both sides at the top of the staple cartridge.

Renew by pushing a new staple cartridge into

stapler until it snaps in position.
A
Close booklet maker top cover and restart the job.

30
Check left/right stapler

If the Booklet Maker indicates “Check left/right/left

and right stapler”, it means that there is a jam in
the indicated stapler. Remove the stapler cartridge 1
as described above.

Open the Booklet Maker top cover.

Press the staple cartridge ejector lever (A) and

B pull out the staple cartridge (B).

Remove any sheets left in the Booklet Maker

and look for jammed staples stuck in the sheets.

Look inside the staple cartridge for jammed

staples and remove them if any.
A
Look at the clinchers (C) and remove any
jammed staples.

Push the staple cartridge into stapler until it

snaps in position.

Close Booklet Maker top cover and restart the job.

Note
C If the error message persists for no reason or if
staple jam reoccurs, renew the staple cartridge as
Cover feeder described above.

Loading covers
A Make sure that the cover sheets are well fanned to
avoid misfeeds or double-feeds.

Align 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

paper bin. Load the covers facing downwards into
the paper bin.
B Move the adjustable side guides (B) up against the
cover sheets until there is no clearance.
31
 Emptying the trim bin
Remove the trim bin by lifting it and pulling it out.

trim bin

32
2. Making Booklets

Changing settings
General procedure

Changing of settings can be performed in two ways. Temporary, which means that the
changes will remain until a new job is loaded or permanent, which means that the changes
will be stored as a job. This job can later be recalled.

Procedure for temporary 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 [Jobs] button to reach the Jobs screen. Select the Job
you want to change by pressing the [Next] button and then press the [Change] button.

Note
Choose either of the above mentioned procedures when changing size, stapling, trimming,
covers or square folding as follows.

Paper Size
Selecting standard paper sizes

From the Ready screen, press the [Paper Size]

button.

Select any standard paper size by pressing the

corresponding button.
For other paper sizes, follow “Custom paper size”
as described on the next page.

33
 Custom paper size

From the Paper size screen, select any of the

present custom size formats and press the [Edit]
button.

Note
2 The asterisk (star) indicates that the Auto shrink
function is activated. See section 3. Tools.

Select Length or Width and key in the desired

value. Save the custom size format by pressing
the [OK] button.

Four different custom paper sizes can be stored.

Note
Also decimal(s) must be entered before [OK] button
appears.

Staple

Selecting stapling On or Off

From the Ready screen, press the [Staple] button.

Select On or Off by pressing the corresponding

button and save setting by pressing the [OK]
button.

34
Staple position

Adjusting staple position

From the Ready screen, press the [Staple

position] button.

Set to Manual, the staple position can be altered

2
up to 3 mm (0.12”) on either side of the fold. Press
the [+] button move position closer to the lead edge
and press the [-] button move position closer to the
trail edge. Save setting by pressing the [OK] button.

Note
This change can be performed during run.

Set to Auto, the Booklet Maker uses the set

thickness sensor to adjust the staple position.
Press the [Auto] button and save setting by
pressing the [OK] button.

Fold position

Adjusting fold position

From the Ready screen, press the [Fold position]

button.

The position of the fold can be changed up to 3 mm

(0.12”) on either side of the centre of the set. Press
the [+] button move position closer to the lead edge
and press the [-] button move position closer to the
trail edge. Save setting by pressing the [OK] button.

Note
This change can be performed during run.
You may want to turn off trimming to see the result
more clearly when you move the fold position.

Set to Auto, the Booklet Maker uses the set

thickness sensor to adjust the fold position.
Press the [Auto] button and save setting by
pressing the [OK] button.
35
 Cover

If a Cover Feeder is present, the [Cover] button will be visible in the control panel. Set to
On, the cover feeder will automatically feed one cover to each set from the copier, or if
you are manually feeding a set. The cover feeder can be used in either for feeding regular
covers or for feeding protection sheets.
In the first case, higher paper weight, pre-printed covers are fed to the set waiting in the
2 compiler. The set and the cover are then stapled and folded together.
In the latter case the sheets in the set are jogged and stapled before the protection sheet
is fed. The set and the cover sheet are then folded together.
Depending of the system setup, the booklet is then fed to the belt stacker, Square Folder
or to the Trimmer.

Using covers

From the Ready screen, press the [Cover] button

to go to the Cover screen.

Select [Cover On], [Protection sheet] or [Off]

by pressing the corresponding button and save
setting by pressing the [OK] button.
Note
To avoid that fault code “54-9003 Load covers” will
be shown, load covers before selecting [Cover On]
or [Protection sheet on]. See section 1. Basics

The Purge mode is used when you want to

completely empty the Cover Feeder from covers.

Remove all cover sheets from the bin.

Select Purge and press the [OK] button. The
prefed cover sheet will now be fed into the
Booklet Maker to the stapling area, but without
being stapled.

Open the Top Cover and remove the cover sheet.

Note
If you open and close the Top Cover without removing
the cover sheet, the cover sheet will be stapled and
folded and then fed to the stacker.
36
Air Separation

You might want to increase the Air flow when

running thick, heavy covers. From the Cover
screen, press the [Air separation] button to go to
the Air separation screen.
Set the desired amount of air flow by pressing the
corresponding button and save setting by pressing
the [OK] button. Default) setting is 40%.
2

Double Sheet Detection

From the Cover screen, press the [Double sheet

detection] button to go to the Double sheet
detection screen.
Set the detection to On or Off by pressing the
corresponding button and save setting by pressing
the [OK] button.
Normally double sheet detection should be set
to On when you are feeding covers. However, if
you experience “false double sheet feeds”, for
example when running covers that are thick, with
dark print or with mixed prints on the covers, the
double sheet detection can be set to Off.

Note
Misfeed detection will work regardlessly.

Trim

Select trimming Auto, Manual or Off

From the Ready screen, press the [Trim] button.

Trimming can be set to on, off or auto. When
trimming is set to auto, a minimum trim, based
on the information from set thickness sensor, is
calculated. To set the trim manually, press the
[On Manual] button and use the [+] or [-] buttons
to set the desired value. Save setting or trim state
by pressing the [OK] button.

37
 Square Folding

General

The Square folder has ten different settings - Auto, Off and Mode 1 up to Mode 8.

Set to Auto, information from the set thickness sensor in the Booklet maker is used to
2 calculate the most appropriate mode between 1 to 7. See guidance table below.

Select Off to bypass the Square Folder without any square forming action.

Note
When the Square folder is set to Auto and the booklet has less than approximately 6 sheets/
booklet, the Square Folder will bypass the Square folding action.
Mode 8 is a heavy duty setting in case of extra demanding media. Mode 8 is not included
in the Auto setting and therefore have to be selected manually.

Use the manual modes to override the auto function. There are eight different manual modes
to select from.

Table below is approximate numbers and is based on 80 gsm / 20 lb Bond sheets.

Mode Number of sheets in the set Notes
1 Approximately 6 to 10
2 Approximately 11 to 16
3 Approximately 17 to 22
4 Approximately 23 to 29
5 Approximately 30 to 35
6 Approximately 36 to 43
7 Approximately 44 to 50
8 Heavy duty setting in case of
extra demanding media.
Square folding guidance table

Note
When Square Folding thick booklets with a thin cover, the cover sheet may be spaced away
from the body of the book and/or it may be crushed in the Square Folding process.
This phenomenon is eliminated/reduced by using a heavier media as the cover. If using a
heavier cover is not an option using a lower MODE in the Square Folding process might help.

38
Selecting square folding mode

From the Ready screen, press the [Square fold]

button.

Select the desired mode and save setting by

pressing the [OK] button.
2

SQF stop gate offset

The Square folding action is set to a standard that should suit most applications.
Operators have the option of sharpening or softening the Square fold based on application
or preference. Customising this setting will affect modes 1 to 7 but not mode 8.
From the Ready screen, press the [Tools] button.
Then press the [SQF offset] button

Select sharper Square fold by pressing the [+]

button or softer Square fold by pressing the [-]
button. Save setting by pressing the [OK] button.

Note
SQF stop gate offset affects modes 1 -7 only.

39
 Rotator Side Trimmer

Rotator (Optional) - Selecting On or Off

From the Ready screen, press the [RCT] button.

Then press the [Rotation] button.
2
Note
If your RCT module is not epuipped with Rotator,
the selection will not be available (grayed out).

Select if you want the Rotator to be On or Off and

press the [OK] button to confirm.

When turned on, the Rotator enables more sheets

being run through in a shorter time.
Press the [OK] button to confirm.

Rotator (Optional) - Rotator Conflict

*Rotator Conflict*

If the warning “Rotator Conflict” is displayed on

the UI it means that you have tried to rotate an
unsupported paper size.

Remedy

Turn off rotation or check paper size in the Booklet

maker.

Creaser - Selecting Creaser Mode

From the Ready screen, press the [RCT] button.

Then press the [Creasing] button.

The Creaser gives you the option to crease the

cover sheet of the booklet in order to avoid image
cracking or toner flaking at the fold.

40
Creaser - Selecting Creaser Mode continued

Press the corresponding button to choose [On

Fine], [On Coarse] or [Off] and press the [OK]
button to confirm.

Normally Fine is selected for cover sheets less

than 120 gsm / 32 lb Bond. For sheets heavier
than that, select Coarse. Press the [OK] button to
2
confirm.

When you want to turn the Creaser off, select Off

and press [Ok] to confirm.

The crease is initially set to the center of the sheet.

Operators have the option to offset the position of
the crease using the [+] or [-] buttons. Press the
[+] button move position closer to the lead edge
and press the [-] button move position closer to
the trail edge. Regardless if you chose Fine or
Coarse creasing, each press of a button will move
the crease 0.1 mm / 0.004”.

When ready press the [OK] button to confirm.

Sample screen shows that the Coarse crease is

offset 1,5 mm towards the lead edge.

Bleed Trimmer - Selecting ON or OFF

From the Ready screen, press the [RCT] button.

Then press the [Bleed Trim] button.

Select if you want the Bleed Trim to be On or Off

and press the [OK] button to confirm.

When turned on, the Bleed Trimmer trims the long

sides of the sheets to shape the print-outs into
the 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 *Bleedtrim Conflict*.

41
 Bleed Trimmer - Selecting Bleed Trim Mode

Width in collects its value from the Booklet Maker

and stands for the width the sheet has before it
enters the RCT module. Width in will most likely
need to be changed if a new size is entered in the
Booklet Maker.
2 If you want to change the value, press the [Width
in] button.

Type in the desired value and press the [OK]

button to confirm.

Note
Also decimal(s) must be entered before [OK] button
appears.

Width adjust shows the difference between the

Booklet Maker’s understanding of width and the
RCT’s understanding of the format’s width that
comes from the Bleed Trimmer. This parameter
only needs to be changed in order to compensate
for poor side registration in the Booklet Maker.

If you want to adjust the Width adjust value, press

the [Width adjust] button.

Change the Width adjust offset with the [+] or [-]

buttons and press the [OK] button to confirm.

A decrease of the value in the Width Adjust

parameter, will make the side registration in the
Booklet Maker tighter.

Press the [Image Offset] if you want to move the

offset for where the image will be cut from.

42
Bleed Trimmer - Selecting Bleed Trim Mode continued

Change the Image offset value with the [+] or [-]

buttons and press the [OK] button to confirm.

IB
When pressing the [+] button the
image will be closer to IB. When
pressing the [-] button the image will
be closer to OB.

OB

Bleed Trimmer - Bleed Trim Conflict

*Bleed Trim Conflict*

The trimmer of cut must be in-between 5 – 30mm.

This is determined by the settings of 3 parameters:
-The Width of the Booklet makers “Size”
parameter
-The “Width In” parameter.
-The “Image Offset” parameter.

Every time any one of these parameters is

changed, the resulting of cut is re-calculated.

Should any of 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
43
 Hand-feeding

Set up the Booklet making system according to

section “Changing settings” above.
Note
RCT features will not be available.

Open the hand-feed cover (A) and adjust the

hand feeding paper guides (B) to the correct
paper size.
3

B A

Start hand-feeding sets.

Close hand-feed cover when you are finished

hand-feeding.

Note
When the hand-feed cover is open, the printer
may be halted and signal “Check Third Party
Finishing Device”. If so, in-line run is not possible.
Remember to close the hand-feed cover when not
in use.

sample screen shot from a Xerox Nuvera

44
On-line/Off-line
The Booklet making system is designed to work on-line but can also be operated off-line,
working as a stand-alone unit.

Off-line mode

If the system is attached to a printer and you want to use it off-line, consult a service
technician to have the system prepared for off-line use.
3
Operate the system as described in section “Hand-feeding” above.

WARNING!
Make sure that the infeed cover plate (A) is mounted in the upper position when using the
Booklet maker in off-line mode.

45
 Side Adjustment
The Booklet Maker is designed so the operator can easily adjust the alignment of the
system if required to correct for possible registration problems caused by the upstream
interface device.

2
Booklet Maker Adjustment

Under the Booklet Maker front cover, down by the floor there is a small crank. Pull the
crank out and turn to adjust the system sideways. One revolution of the crank moves the
Booklet Maker 1.0mm (0.04”) sideways. Total adjustment range is ±14.0mm (± 0.55”).

Position the crank horizontally when pulling it out or pushing it back.

Note
If problem with side adjustment remains call Service for a proper adjustment of the
installation.

46
3. Tools

The Tools Screen

The Tools screen.
From the Ready screen, press the [Tools] button
to get to the Settings screen. Select the setting
you want to change and press the corresponding
button.

Stacker full detection

Select if you want the Stacker full detection to be
On or Off. Press the [OK] button to confirm.

When turned On the Stacker full detection can

keep count of how many booklets are on the
stacker and notifies when it’s full and stops the
printer. After emptying the stacker, reset the
Stacker full det.

Note
The Stacker full detection feature uses the set
thickness sensor to calculate when to empty the
stacker. If you change from very thick booklets to
thinner ones, you might want to turn Stacker full
detection on again.

Auto shrink
The booklet maker system is able to compensate
for the shrinkage that occurs when the sheets are
sent from the printer. The compensation factor is
calculated based on the information about paper
weight and paper size. Turn the function on or off
by pressing the corresponding button and save
setting by pressing the [OK] button. An asterisk
(star) in front of the paper format indicates that
Auto shrink is on.
Note
Compensation for shrinkage will not be activated if
the cover feeder is on or when sets are hand fed.
47
 Language

Select desired language by pressing the

corresponding button and save by pressing the
[OK] button.

3
Units
Select millimetres or inch by pressing the
corresponding button and then save setting by
pressing the [OK] button.

SQF stop gate offset

See section 2. Making Booklets under the heading
“Square Folding”.

Software version
Select machine by pressing the corresponding
button to display the software version. Press [Exit]
button to go back to the Settings screen.

48
Sheet feeder
This function allows you to individually fold the
sheets loaded in the cover feeder in a sequence.
Load the cover feeder and press the [Start] button
to begin folding. Press the [Stop] button to stop.
See section 2. Making Booklets, for how to load
the cover feeder.

3
Service access
This function is for authorized service personnel
only and is password protected.

49
3

50
4. Jobs

Handling jobs
The Booklet Maker has a maximum storage capacity of 20 different jobs. To make
temporary changes in the actual job settings or temporary changes of a stored job, see
section 2. Making Booklets.
From the Ready screen, press the [Jobs] button to be able to store, change or delete jobs.

Saving a Job
To store a new job, press the [Save as new job]
button.

Enter a job name and save by pressing the [OK]

button.

If you already have a job active, you can choose

either to save your new settings as a new job or
to save to the active job. Press the corresponding
button to continue.

Continued on next page.

51
 Handling stored Jobs

To access already stored jobs, press the [Saved

jobs] button.

Rename, open (load) or delete any stored job by

4 pressing the job button and choose action.

Recalling a Job
To recall a stored job press the [Jobs] button from the
Ready screen to enter the Jobs screen.

Select the desired job. Then press the [Open] button.

The booklet maker will then automatically setup that
specific job and return to the Ready screen.

The booklet maker will then automatically setup that

specific job and return to the Ready screen.

52
5. Clearing Misfeed(s)

Clearing misfeed(s)
General

If a misfeed condition should occur, it is indicated on the Booklet Maker display. The
message “Clear Misfeed(s)”, an error code and the location of the misfeed is displayed.
See examples below.

Misfeeds in the Rotator Creaser Trimmer are

indicated by the error code 50-XXXX.

Misfeeds in the Booklet Maker are indicated by

the error code 51-XXXX or 54-XXXX. Warning
sign shows where in Booklet maker error occured -
leftmost area, middle or rightmost area.
Picture shows leftmost area.

Misfeeds in the Square folder are indicated by the

error code 52-XXXX.

Misfeeds in the Trimmer are indicated by the error

code 53-XXXX.

53
 RCT module

Clearing misfeed(s) in the paper path

Infeed “A” area and exit “D” area

Open the top cover.

Lift up baffles marked “A” and “D” if needed.

Remove any misfeed(s).

Lower baffles “A” and “D” to normal position

Misfeed(s) in the trimmer area are rolled out by rotating the rubber surfaced pinch roller (A).
5
Close the top cover.

WARNING!
Do not put your fingers within knife protections (B).
Doing so may result in injury.

Baffle A B A Baffle D

54
Rotator, registration and creaser area

Open the slide door (A).

Unlatch and pull out the slide (B).

Open baffles “B” and “C” if needed.

Remove any misfeed(s).

Push in and latch the slide.

Always remove any residual waste from waste channel and waste belt before closing the
slide door.

Close the slide door.

Clearing jams in the waste transport

5
The waste transport is easily accessible through the slide door. Shreds jammed in or wrapped
around the knife assembly are also accessible through the slide door.

Caution!
Under no circumstances should jams around the trimmer blades be cleared using metallic
tools. The edges are very fragile and easily damaged.

Baffle C

Baffle B

55
 Booklet Maker

Clearing misfeed(s)

Inside the Booklet Maker

To clear a misfeed in the leftmost or middle

area

Open the top cover.

Remove misfed sheets.

Close the top cover.

To clear a misfeed in the rightmost area

Open the top cover.

Close top cover.

If misfeed condition 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 stop. By hand, pull down
the fold stop (page 8, item 9).

Remove misfed sheets.

Push the fold stop back into the upper position.

Switch on the main power.

56
Clearing misfeed(s), continues

Clearing misfeed in input area with infeeder (no deburster)

Open Top Cover.

Lift the spring loaded infeed paper guide (A) to access and remove misfed sheets.

Lift the handfeed assy (B).

Lift the spring loaded paper guide (C) to access and remove misfed sheets.

Lower handfeed assy (B) to operating position and close Top Cover.
5

57
 Clearing misfeed(s), continues

Clearing misfeed in input area with deburster

Open Top Cover.

Lift the spring loaded infeed paper guide (A) to access and remove misfed sheets.

Lift the handfeed assy (A).

Move the spring loaded paper guides (C) to the front, to the rear or apart to access
and remove misfed sheets.

Lower handfeed assy (B) to operating position and close Top Cover.
5 A

58
Clearing misfeed(s), continues

Clearing misfeed in folder area

Open Top Cover.

Open the fold roller paper guide (A) by lifting (arrow 1) and pivoting (arrow 2) to access
any misfed or jammed sheets/booklets between the lower and upper pair of fold rollers.

Remove sheets/booklets in folder area between fold rollers.

In reversed manner, place the fold roller paper guide back in operating position.
Note
Make sure the fold roller paper guide is locked in operating position (B) at both sides.
5
Close Top Cover.

2
1

B
59
 Cover Feeder

Clearing misfeed(s) in vertical transport area

Open the Top Cover (A).

Lift the jam clearance baffle (B).

Remove the misfed cover.

Release the spring loaded jam clearance baffle and close the Top Cover.

B A

60
Square Folder

Clearing misfeed(s)
Inside the Square Folder

Open the top cover.

Lift up upper feed belts (A) to access jammed/misfed booklets.

Note
Press the green dots (B) (only one visible in picture) on the latches to release.

Remove the jammed/misfed booklets.

Place the upper feed belts in normal position.

Close the top cover.

5

61
 Trimmer
Clearing misfeed(s)

The upper trimmer blade on the trimmer is protected by a knife protection plate that moves
away during the cutting stroke.

WARNING:
Never put fingers or other parts of the body between the upper and lower trimmer knives.

Clearing misfeed in input area

Raise the rightmost side of the infeed roller shaft assembly (A).

5 Remove the misfed sheets in the infeed area.

After the misfed sheets are removed, place the infeed roller shaft assembly into operating
position.

[A]

infeed roller shaft assy in normal position infeed roller shaft assy lifted

62
Clearing misfeed(s), continued

Clearing misfeed in exit area

Lift the exit compressing brackets and transport belts (B).

Secure using the latch (C). Not clearly visible in picture

Remove the misfed sheets from the exit area.

After the misfed sheets are removed, release the latch (C) and place the exit compressing
brackets in operating position.

Exit compressing brackets in normal position Exit compressing brackets lifted

63
 Belt stacker
Clearing misfeed(s)

Clearing misfeed on belt stacker

Lift the belt stacker outfeed cover (A).

Remove jammed/misfed booklets.

Place belt stacker outfeed cover back in operating position.

5 A

64
6. Troubleshooting

Fault codes
General
When there is a misfeed or fault condition in the Booklet Maker system, a code and/or
a message will be displayed on the UI. In case there is a problem that can be rectified
by the operator, a fault code and an explanation will be displayed. Table and fault code
descriptions below will guide you troubleshooting.

If frequent input jams are experienced please check paper curl and decurler adjustments
in printer operator guide.

For fault codes other than specified below - remove any paper in the paper path and
power Off and On the system.

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

Rotator Creaser Trimmer

Code / message Explanation
50-1001 - 50-1012 Clear misfeed A misfeed has occured in the RCT module
50-2XXX Fault in area, power off and on Indicates that there might be an internal communication
error. Power off and on the system. If problem persists,
contact customer support.
Bleed trim conflict Indicate that shreds are outside the interval 5 - 30 mm.
Rotator conflict Indicates trying to rotate an unsupported paper size.
Waste Bin full Check / Empty Waste container and check Waste
Transport.

Booklet Maker, Deburster and Bypass Unit

Code / message Explanation
51-1001 - 51-1008 Clear misfeed A misfeed has occured in the Booklet maker.
51-1009 - 51-1011 Clear misfeed A misfeed has occured in the Deburster (Booklet maker).
51-1012 - 51-1013 Clear misfeed A misfeed has occured in the Bypass unit (Booklet
maker).
51-2XXX Fault in area, power off and on Indicates that there might be an internal communication
error. Power off and on the system. If problem persists,
contact customer support.
Check right stapler Indicates jam in either or both staplers.
Check left stapler
Check right and left stapler

Continued on next page.

65
 Booklet Maker, Deburster and Bypass Unit, continues
Code / message Explanation
Change right staple cartridge Indicates almost out of staples in either or both staplers
Change left staple cartridge
Change right and left staple cartridges
Set too thick, remove set Indicates that the set is too thick to be folded. Remove set.
Remove purged set There is an incomplete set in the Booklet Maker in the
infeed area. Remove set.
No vacant deburster Make sure you are not running simplex printed sheets
from the printer in-line.
Too many sheets Indicating there are too many sheets in the Booklet
Maker. Remove set.

Cover Feeder
Code / message Explanation
54-2XXX Fault in area, power off and on Indicates that there might be an internal communication
error. Power off and on the system. If problem persists,
contact customer support.
54-1001 Out of covers Indicates “Out of covers” in the Cover Feeder.

6 54-1002 - 54-1006 Clear misfeed

54-1005 Remove double feed
A misfeed has occured in the Cover Feeder.
A double feed has occured in the Cover Feeder.
Few covers left, add covers Indicates that the Cover Feeder is almost out of Covers.
How to clear, see Cover Feeder fault codes.
Change cover size Indicates that there is a format mismatch between the
cover sheets and the sheets sent from the copier. Change
either.
Load covers Indicates there is no more cover sheets in the Cover
feeder. How to clear, see Cover feeder fault codes.

Square folder
Code / message Explanation
52-1001 - 52-1006 Clear misfeed A misfeed has occured in the Square folder.
52-2XXX Fault in area, power off and on Indicates that there might be an internal communication
error. Power off and on the system. If problem persists,
contact customer support.

Trimmer
Code / message Explanation
53-1001 - 53-1006 Clear misfeed A misfeed has occured in the Trimmer.
53-2XXX Fault in area, power off and on Indicates that there might be an internal communication
error. Power off and on the system. If problem persists,
contact customer support.
Empty trim bin! Indicates that the trim bin is full. Empty it.
Close trimmer belts Indicates that either the infeed roller shaft assy or the exit
compressing brackets are lifted. Close them.

66
General fault codes

Clear Misfeed(s)

In general, fault codes indicate a misfeed

condition. When a misfeed occurs, a code, the
message “Clear misfeed(s)” and 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 6

any of the interlock switches are actuated.

Check that the top cover is in down position.

Make sure that the cover of the Belt Stacker

is in normal position, see section 5, Clearing
Misfeeds, Exit area.

Make sure power cables between Booklet Maker,

Square Folder and Trimmer are connected

Empty stacker!

This message will be displayed when the Stacker

is full. Empty the belt stacker and press the [Done]
button to continue operation.

Illegal feed mode

If this message is displayed, contact customer support.

67
 Rotator Creaser Trimmer fault codes

Bleed Trim Conflict

Shreds outside the interval 5 - 30 mm.

The trimmer of cut must be in-between 5 - 30 mm.

This is determined by the combined settings of 3 parameters:
- The Width of the Booklet makers “Size” parameter
- The “Width In” parameter.
- The “Image Offset” parameter.

Every time any one of these parameters is changed, the resulting shreds are recalculated.
Should any of the cuts (on any side) be outside the 5 - 30 mm. interval, the warning for “Bleed
Trim Conflict” is displayed on the UI.

Check settings according to specification section 2. Making Booklets.

6 Rotator Conflict

Rotation is only allowed for media dimension (before rotation) within a certain interval.
Width (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”)

Check settings according to specification and section 2. Making Booklets.

Waste bin full

Empty Waste Box and check Waste Transport Channel and Waste Transport Belt for build
up of Waste Strips.

It is highly recommended to empty the waste box whenever the system stops to keep up
productivity.

50-2050 Fault in area, power off and on

Indicates that the communication between the RCT module and the Booklet Maker is
interrupted. Check that the CT 30 is powered up and that the communication cable to the
RCT module is OK.

50-1001 - 50-1012 and 50-2009 Clear misfeed

If feed errors occurs in the paper path or in the waste transport system, check for obstructions.
If no obvious obstructions are found, see section 7, REMARKS Maintaning Your Machine.

68
Booklet maker fault codes

Check stapler or Change staple cartridge

These messages will be displayed when a staple cartridge is empty or when stapling could
not be performed. Check in the following order:
– If a staple cartridge is empty, replace according to section 1. Basics.
– If staple cartridges are OK; remove the set and check that the number of sheets is within
specifications.
– If staple cartridges are OK and set is within specifications; remove and check stapler
head according to section 1. Basics.

Set too thick, remove set

This message will be displayed when the set sent from the copier is outside Booklet Maker
specifications. Open the top cover, remove the set and close the top cover.

Remove purged set

This message will be displayed when the purged set is in the infeed area. Open the top
cover, remove the set and close the top cover.
6
No vacant deburster
If this message is displayed, make sure you are not running simplex printed sheets from the
printer in-line.

Too many sheets

The Booklet Maker has recieved too many sheets from the printer. Open the top cover,
remove the set and close the top cover.

Cover feeder fault codes

Misfeed
This message will be displayed when the Cover feeder could not feed a cover from the
paper bin. Check cover loading according to section 2. Making Booklets. If problem
persists, clean separator pad according to section 7. REMARKS.

Remove double feed

This message will be displayed when the Cover Feeder detects that more than one cover
was fed from the cover bin. If more than one cover was fed, check cover loading according
to section 2. Making Booklets. If the covers that are fed are thick, with dark print or with
mixed prints on the covers, double feeding may be displayed even if that is not the case.
Turn off double sheet detection according to section 3. Tools.

Continued on next page.

69
 Cover feeder fault codes, continued

Few covers left, add covers

Message “Few covers left, add covers” is displayed when covers run low.
There are two ways to continue operation.

Loading more cover sheets:

Load more cover sheets according to section 2. Making Booklets and press the [Done]
button. The message will extinguish and copier will start.

Using up the remaining cover sheets that are loaded:

Press the [Exit] button. The message will extinguish and copier will start.

Note
Be aware that if you use this method, the system will hard stop i.e. without completing the
cycle when there is no covers left.

Load covers
6 Message “Load covers” is displayed when covers are empty. There are two ways to
continue operation.

If you wish to continue production:

Load cover sheets according to section 2. Making Booklets and press the [Done] button.
The message will extinguish and copier will start.

If cover job is finished and you wish to run a new job without covers:
Select Cover Off in the Cover menu.

Out of covers
This message will be displayed when the Cover feeder is empty. Load cover according to
section 2. Making Booklets.

Remove double feed

This message will be displayed when double feed is detect. Remove cover(s) fed to
check. If there is a true double, increase air flow according to section 2. Making Booklets,
Air separtion and/or clean feed belts according to section 7. REMARKS, Maintaining
your machines. It there is a false double, check that covers are whithin specification or
temporary turn double sheet detection off. See section 2. Making Booklets, Double sheet
detection.

Change cover size

This message will be displayed when the sheet size in the Cover feeder does not match
the paper size set in the Booklet Maker. Check formats according to section 2. Making
Booklets.
70
Trimmer fault codes
Note
During poor environmental conditions waste from the trimming operation may be transported
through the system.

To improve the situation the trim margin may be increased and thereby ensuring that
The waste is transported into the waste bin.

Empty trim bin

This message will be displayed when the trim bin is full or when a trim strip, due to static
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 trimmer belts

Indicates that either the infeed roller shaft assy or the exit compressing brackets are lifted.
Close them. Open cover and set Trimmer belts to their lower position. Close cover.
6
Square folder fault codes
Feed errors

If feed errors occur, the feed belts need to be cleaned (according to section 7. REMARKS,
Maintaining your machines) or the pressure on the upper feed belts need to be set to the
default position. The pressure springs should always be at its upper position where the
pressure is equal to its highest value.

OB spring in upper position IB spring in upper position

(default position.) (default position.)

71
6

72
7. REMARKS

Do’s And Don’ts

• Always follow all warnings marked on, or supplied with, the equipment.

• Always exercise care in moving or relocating the equipment.

Caution:
• Unplug the power cord from the wall outlet and machine before you move or relocate
the equipment.

• Do not remove the covers or guards that are fastened with screws.

• Do not override or bypass electrical or mechanical interlock devices.

• Do not operate the equipment if you notice unusual noises or odors. Disconnect the
power cord from the power source and call your authorized technician to
correct the problem.

Warning:
• Do not put fingers or other parts of the body between the upper and lower trimmer
knives.

• Do not switch off the main power switch while machine is running. Make sure machine
cycle has ended.

• Do not open covers while machine is running.

• Do not move machine while machine is running.

73
 Where to put Your Machine

Machine environment

• Always locate the equipment on a solid support surface with adequate strength for the
weight of the machine.

• Always keep magnets and all devices with strong magnetic fields away from the
machine.

If the place of installation is air-conditioned or heated, do not place the machine where it
will be:

• Subjected to sudden temperature changes.

• Directly exposed to cool air from air-conditioner.

• Directly exposed to heat from heater.

7 Power connection

• Always connect the equipment to a properly grounded power source. If in

doubt, have the power source checked by a qualified electrician.

• WARNING: Improper grounding of the equipment can result in electrical shock.

• Never connect the machine to a power source that lacks a ground connection
terminal.

74
Access to machine

Place the machine near the power source, providing clearance as shown.

4 2

3
1

1. Left: more than 400 mm / 15 3/4” (off-line use).

2. Rear: more than 700 mm / 27 1/2”
3. Right: more than 400 mm / 15 3/4”.
4. Rear: more than 700 mm / 27 1/2” (on-line use).

75
 Maintaining Your Machines
Never attempt any maintenance function that is not specifically described in this documentation.

Cover Feeder

Cleaning feed rollers and paper separator pad

The Feed rollers need to be cleaned regularly when in use, and if the unit has not been
used for a period of time. How often this should be done, depends on the paper type and
print quality.
An increasing number of misfeeds, or double 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 (1). The left end of the
feed roller assembly will now be released (2) and the assembly can be removed.

Clean the Feed rollers and the Paper separator pad with water and a clean lint free cloth.

7
Press toward front. Paper separator pad Lift out this side

Feed rollers
76
Square folder

Cleaning feed belts

The Feed belts need to be cleaned regularly when in use, and if the unit has not been
used for a period of time. How often this should be done, depends on the paper type and
print quality.
An increasing number of misfeeds is one indication of the need to clean the feed belts.
Clean the 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.

Press the release latch and lift up the upper feed belts to access the lower feed belts.

Clean the lower feed belts (B). Rotate the lower feed belts towards the outfeed side for
complete cleaning.

Place the upper feed belts in normal position.

Close the top cover.

7

Upper feed belts in normal position. Upper feed outer belt lifted up.

77
 RCT module
The feed rollers and paper path need to be cleaned regularly when in use, and if the unit
has not been used for a period of time. How often this should be done depends on the paper
type and print quality.

An increasing number of 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 free cloth. Sensors are wiped clean with a lint free cloth.

A problem with registration accuracy is often related to build up residual toner and paper dust.

Caution!
Never use any cleaning fluids on sensors.

Cleaning the paper path transportation nip rollers (4x)

Also clean the idler rollers

7 WARNING!
Do not put your fingers within knife protections.
Doing so may result in injury.

Knife protections

Nip rollers

78
Cleaning the paper path transportation nip rollers (4x) continues

Nip rollers

7
Cleaning the fixing rollers (3x)
WARNING!
Do not put your fingers within knife protections.
Doing so may result in injury.
Also clean the idler rollers

Fixing rollers

Knife protections
79
 Cleaning the the fixing rollers (3x) continues

Fixing rollers

Cleaning the registration cross roller (4x)

7
Cleaning of the friction tires is done from within the registration sub-frame.

Registration
cross rollers

Cleaning friction
tires

80
Cleaning the rotator rollers (2x)
Also clean the idler rollers

Rotator rollers

Cleaning the paper path sensors (5x)

WARNING! 7
Do not put your fingers within knife protections.
Doing so may result in injury.

Infeed sensor Outfeed sensor

Knife protections
81
 Cleaning the paper path sensors (5x) continues

Rotator sensor

Registration sensor

82
Cleaning the paper path sensors (5x) continues

Creaser sensor

Cleaning of creaser tools (2x)

7
After a period of time toner and paper dust may leave residuals in the grooves of the tool.
These grooves need to be cleaned periodically to restore creasing performance.

Grooves on both sides of the tool

83
 Adjustment of Bleed 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 screw

Reference scale

84
Adjustment of Creaser 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.

Knurled eccentric

Alignment marks

Star shaped knob

85
 Limitations in the Pro 35 / 50 system
• T
­ he BM 35 / 50 Production Booklet Maker system is suited for customers whose book-
let making needs will not exceed an yearly average of 30,000 booklets per month.

• If sheets entering the Booklet maker BM 35 / 50 is not uniform and square the booklet
quality will vary accordingly.

• The maximum recommended number of sheets that can be folded without stapling is 5
sheets of 80 gsm. If there is very low friction between the sheets, running non stapled
sets may be difficult.

• Staple position may vary on the spine when being square folded with the Square folder
SQF 50 module, especially on thicker booklets. Moving staple position so staple is cen-
tered on the spine will reduce this phenomenon.

• Staple may be radius shaped (bent) when running with Square folder SQF 50 module.
Moving staple position so staple is centered on the spine will reduce this phenomenon.

• Covers may show marking along the spine of the booklet from the clamp in the Square
folder SQF 50 module. The more pages in the booklet, the more evident the marking.
The use of “protection sheet” eliminates this marking.

7 • F
­ or some white coated stock, such as “Silk type” two sided coated paper, occasional
fold roller marks may be observed on the “top side” of the book. . The use of “protection
sheet” eliminates this marking.

• The double feed sensor should be turned off when feeding cover 200 gsm or more from
the Cover feeder CF 50 module. You may also have to turn off this function if you have
heavy dark area coverage or covers with different images on them.

• F
­ or jobs with multiple sheets of 200 gsm or heavier, the Square folder SQF 50 module
is recommended for an acceptable output. If a Square folder SQF 50 module is present
in the configuration the Square fold shall be turned ON or feed problem at output may
occur.

• T
­ he protection sheet function may not function correctly with thicker booklets. If there is
very low friction between the protection sheet and the set, functionality may be poor.

• ­Heavy weight media will show image crack in the spine, pre-crease the cover to avoid cracking.

• T
­ hick books made from coated stock with high friction between each sheet may show
permanent “wave like” deformation of the sheets.

• Marks from the fold knife may appear on sensitive media on the inner sheet.

• M
­ arks from side guide motion may appear on sensitive media, the use of protection
sheet eliminates this.

• Never run simplex printed sheets from the printer in-line.

86
Best practice for the Pro 35 / 50 system
• If the set is not properly registered (side jogged and back jogged) changing to a smaller
custom size of paper in the Booklet maker BM 35 / 50 may improve the situation.

• If staples have problems penetrating thicker sets of heavy media changing staple car-
tridge may improve the situation.

• If the booklets show markings or scratches the use of the “protection sheet” will im-
prove the situation.

• Square folder SQF 50 module may wrinkle the cover at the spine when light weight
media is used for cover sheet. Changing to heavier stock or turning square fold module
off usually fixes the problem.

• Staple may be radius shaped (bent) when running with Square fold module. Moving
staple position so staple is centered on the spine will reduce this phenomenon.

• Covers may show marking along the spine of the booklet from the clamp in the Square
folder SQF 50 module. The more pages in the booklet, the more evident the marking.
The use of “protection sheet” eliminates this marking.

• For jobs with multiple sheets of 200 gsm or heavier the Square folder SQF 50 module
is recommended for an acceptable output. If a Square folder SQF 50 module is present
in the configuration the Square fold shall be turned ON or feed problem at output may
7
occur.

87
7

88
8. Specification

Machine Specifications
Booklet Maker BM 35 / 50

Major Specifications
Specifications Remarks
Speed (Online usage) Maintains engine speed (actual depends Actual speed in number of book-
of engine speed). lets (per min / hour) depends on
number of sheets per booklet.
Standard Paper Sizes A4, A3, B4, 8.5x11”, 8.5x14”, 11x17”, Custom sizes are available
12x18”, SRA3
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 / 110 lb Cover
Belt stacker capacity 2 sheets: 200 sets 80 gsm / 20 lb. Bond
8 sheets: 70 sets
15 sheets: 35 sets Figures are based on rough
20 sheets: 25 sets estimates and founded on pure
30 sheets: 15 sets observation
35 sheets: 15
40 sheets: 10
45 sheets: 10
50 sheets: 10
Input / Output Sheets 1 – 35/50 Sheets (80 gsm / 20 lb Bond) Stapled (see Set size Guide on
page 64)
Input / Output Sheets Not more than 5 sheets recommended Non Stapled Folding
Off-line Use Possible Stitch / Fold (2 staples)
Weight 148,5 kg / 327.4 lb
Dimensions (L x H x D) 860 x 1070 x 700 mm / 33.8 x 42.1 x 27.6” Excluding belt stacker *
Power Source 100 - 230 V, 50-60Hz + 6%, - 10%
Power consumption 250 W or less Continuous Operations
Noise emission 62 dB Complete system
* A Belt stacker, installed after a booklet maker, square folder or trimmer, adds 420 - 635 mm / 16.5 - 25”

89
 Cover Feeder CF 50

Specifications Remarks
Maximum Speed Same as BM 35 / 50 A3/11x17” or bigger paper
sizes, need two sheet sets as
inlet at least
Standard Paper Sizes Same as BM 35 / 50
Paper Weight (Minimum) 70 gsm / 18 lb Bond
Paper Weight (Maximum) 250 gsm / 67 lb Bond
Cover Feeder Capacity 20 mm (app. 200 sheets of 80 gsm paper)
13/16” (app. 200 sheets of 20 lb Bond paper)
Off-line Use Possible (Together with Booklet maker)
Weight 7 kg / 15.4 lb or less
Dimensions (L x H x D) 310 x 190 x 530 mm / 12.2 x 7.5 x 20.9” The Cover Feeder dimensions
are included in the Booklet
Maker diversions and will not
add anything more to the space.
Power Source From BM 35 / 50

Trimmer TR 50
8 Specifications Remarks
Speed 1800 sets per hour
Standard Paper Sizes Same as BM 35 / 50 Custom sizes are available
Default trim length 4.5 mm / (11/64”) Adjustable in 0.5 mm steps
Minimum trimming 1 mm / (0.0394 in)* Adjustable in 0.5 mm steps
Maximum trimming 16 mm (0.63”) Adjustable in 0.5 mm steps
Paper Weight (Minimum) Same as BM 35 / 50
Paper Weight (Maximum) Same as BM 35 / 50 Engine Duplex: 216 gsm
Input / Output Sheets Same as BM 35 / 50
Off-line Use Possible (Together with Booklet maker)
Weight 77 kg / 169.8 lb or less
Dimensions (L x H x D) 360 x 1010 x 620 mm / 14.2 x 39.8 x 24.4”
Power Source From BM 35 / 50
* When trimming SRA3 (450 mm) Booklets minimum trimming is 5 mm, when trimming 18” Booklets mini-
mum trimming is 9 mm.

90
Square folder SQF 50

Specifications Remarks
Speed Same as BM 35 / 50 Appr. 6 - 30 sheet booklet (80 gsm
/ 20 lb Bond)
Standard Paper Sizes Same as BM 35 / 50 Custom sizes are available
Paper Weight (Minimum) Same as BM 35 / 50
Paper Weight (Maximum) Same as BM 35 / 50
Input / Output Sheets Same as BM 35 / 50
Off-line Use Possible (Together with Booklet maker &
Trimmer)
Weight 64,9 kg / 143 lb
Dimensions 360 x 1010 x 620 mm / 14.2 x 39.8 x 24.4”
Power Source From BM 35 / 50

91
 Rotator Creaser Trimmer module RCT (option)

Specifications Remarks
Speed Same as BM 35 / 50
Standard Paper Sizes Same as BM 35 / 50
Paper Size Minimum (Out) Same as BM 35 / 50
Paper Size Maximum (Out) Same as BM 35 / 50
Paper Width Maximum (In) Same as BM 35 / 50
Paper Weight (Minimum) Same as BM 35 / 50
Paper Weight (Maximum) Same as BM 35 / 50
Rotator (optional)
Width (cross process direction) min. 275
Rotation is only possible within mm. (10.9”).
the interval Width (cross process direction) 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 Stock < 120 gsm
8 Coarse tool Stock > 120 gsm
(gsm =grams per sq. meter)
Bleed Trimmer

Minimum bleed trimming 5 mm

Maximum bleed trimming 30 mm
Max assymetric bleed trimming +/-5 mm
Input / Output Sheets Same as BM 35 / 50
Input / Output Sheets Same as BM 35 / 50
Off-line Use Not possible
Weight 200 kg/441 lb
Dimensions (L x H x D) 720 x 1115 x 755 (incl. 100 mm. waste
transport) 38,4” x 43.9” x 29.7”
Power Source 100/110/115/ 127/ 220/ 230 / 50-60 Hz ±10%
Power Consumption 400 W or less Continous operations

92
System Certifications

The system complies with the following directives:

EU Directive 2006/95/EC Low Voltage Directive

EU Directive 2004/108/EC EMC Directive, Class A equipment
EU Directive 2002/95/EC RoHS Directive
EU Directive 2002/96/EC WEEE Directive

Turkey RoHS Regulation of May 30, 2008

China RoHS, Standards SJ/T 11363-2006 and SJ/T 11364-2006

Certification Description Certifica-

tion Body
EN 60950-1:2006 + A11:2009 Information Technology UL (Un-
IEC 60950-1:2005, 2nd Edition Equipment Safety – Part 1: Gen- derwriters
UL 60950-1:2003, 2nd Edition, 2007-03-27 eral Requirements Laborato-
CSA C22.2 No. 60950-1-07: 2nd Edition,2007-03 ries, Inc.)
(E70243-
A20)
EN 55022:2006 + A1:2007, Class A EMC – emission Intertek ETL
EN 61000-3-2:2006 + A1:2009 + A2:2009 SEMKO
EN 61000-3-3:2008
FCC Part 15 (2009) Subpart B, Class A equipment 8
EN 55024:1998 + A1:2001 + A2:2003 EMC – immunity Intertek ETL
SEMKO

93
 BM 35 / 50 System Set Size Guide
Paper size
<A3/11x17” (small sizes) >A3/11x17” (large sizes)

Grain direction Grain direction

Short Long Short Long

Area coverage Area coverage Area coverage Area coverage

Paper weight Low High Full Low High Full Low High Full Low High Full
Bond Offset Cover Tag Index Gsm
50

D
48
46

B
44

T
42
40
38
36
34
32
20 50 28 46 42 80 30 25 22 27 22 20 27 22 20 24 17 14
24 60 33 56 50 90 26 23 21 24 20 18 24 20 18 21 17 14
28 70 39 64 58 100 24 21 19 21 19 17 21 19 17 19 16 14
29 73 40 62 60 110 17 17 17 17 17 16 17 17 16 17 16 13
31 81 45 73 66 120 17 17 17 17 16 15 17 16 15 15 15 13
8 35 90 48 80 74 130 17 17 16 16 15 14 16 15 14 14 13 12
36 90 50 82 75 140 17 16 14 15 14 13 15 14 13 13 12 11
39 100 54 90 81 150 15 15 13 14 13 12 14 13 12 12 11 10
43 110 60 100 90 160 12 12 12 12 12 11 12 12 11 11 11 9
44 110 61 102 92 170 12 12 12 12 11 10 12 11 10 10 10 9
47 120 65 108 97 180 12 12 11 11 10 10 11 10 10 10 9 8
190 12 11 10 10 10 9 10 10 9 9 9 8
53 135 74 122 110 200 11 10 10 10 9 8 10 9 8 9 8 7
54 137 75 125 113 210 10 10 9 9 9 8 9 9 8 8 8 7
58 146 80 134 120 220 9 9 9 9 8 8 9 8 8 8 7 6
230 9 9 8 8 8 7 8 8 7 7 7 6
65 165 90 150 135 240 9 8 8 8 7 7 8 7 7 7 7 6
67 170 93 156 140 250 8 8 7 7 7 6 7 7 6 7 6 5
260 6 6 6 6 6 6 6 6 6 6 6 5
72 183 100 166 150 270 6 6 6 6 6 6 6 6 6 6 6 5
76 192 105 175 158 280 6 6 6 6 6 5 6 6 6 6 5 5
290 6 6 5 5 5 4 6 6 5 5 5 4
300 6 5 4 5 4 4 6 5 4 5 4 4

Note
1. For cover jobs , deduct 2 sheets
2. Paper size: large = A3/11x17”> , Small = <A3/11x17”
3. Area coverage: Low = text only, High = Pictures, Full = Maximum coverage
4. For jobs with multiple sheets of 200 gsm or higher paper weight the SQF 50 module is recommended for an acceptable
output
94
Declaration of Conformity
Title Doc no.

Declaration of Conformity
D0001499
Date (ISO 8601) & time

2012-02-15
Plockmatic PDM Document 09:57
Process owner Signature Revision Status Page

Quality Department BOL A.3 Released 1(1)

Manufacturer:................................ PLOCKMATIC International AB

Product description: ...................... Booklet Maker System

Model/Type number(s): F122-001, F122-002

Brand name(s) RCT 30, CT5010, CT5030
Description Rotator Creaser Bleed Trimmer

The described product(s) conform(s) to the requirements of the following EU Directives:

Low Voltage Directive (LVD) .......... 2006/95/EC as amended

EMC Directive.................................. 2004/108/EC as amended
RoHS Directive ................................ 2002/95/EC
WEEE Directive ............................... 2002/96/EC
First year of CE-Marking................. 2011

Conformity of the product(s) with the requirements of EU and other directives is established
through full compliance with the following standards.

Certifications Description Certification Body

IEC 60950-1:2005, 2nd Edition Information Technology UL (Underwriters
Equipment Safety – Part 1: Laboratories, Inc.)
EN 60950-1:2006 + A11:2009
General Requirements (E70243-A20)
UL 60950-1, 2nd Edition, 2007-03-27
CSA C22.2 No. 60950-1-07, 2nd Edition, 2007-03
EN 55022:2006 + A1:2007, Class A EMC – emission Intertek ETL SEMKO
EN 61000-3-2:2006 + A1:2009 + A2:2009
EN 61000-3-3:2008
FCC Part 15 (2009) Subpart B, Class A equipment
EN 55024:1998 + A1:2001 + A2:2003 EMC – immunity Intertek ETL SEMKO

As manufacturer established within the EU, we declare under our sole responsibility that the
equipment follows the provisions of Directives stated above.

Name:

Bengt Olenfalk
Quality & Compliance Manager

Date: See top of page

PLOCKMATIC International AB – Box 10025, SE-121 26 Stockholm-Globen – Phone +46 8 602 50 00 – Fax +46 8 722 99 70
INDEX Maintaining Your Machines 76
Making Booklets 33

A O
Access to machine 75 Off-line mode 45
Air Separation 37 On-line/Off-line 45
Alive logo 28 Options 16
Auto shrink 47
P
B
Turning On / Off the Main Power 29
Basics 29 Paper Size
Best practice for the Pr0 35/50 system 87 custom 34
Bleed Trimmer 41 setting 33
BM 35 / 50 System Set Size Guide 94 Power connection 74
Booklet Maker 13
Booklet Maker Adjustment 46 R
Booklets, making 33
RCT module 54
C Clearing misfeed(s) 54
Ready screen, The 27
Change staple cartridges 30 REMARKS 73
Changing settings 33 Rotator 40
Check staplers 30 Rotator Creaser Trimmer 21
Clearing Misfeed(s) 53 Rotator Side Trimmer 40
Control panel 27
Cover, covers S
loading 31
using 36 Safety Information 4
Cover Feeder 16 Saving a Job 51
Loading covers 31 Service access 49
Creaser 40 Setting Paper Size 33
Custom paper size 34 Settings, changing 33
Sheet feeder 49
D Side Adjustment 46
Software version 48
Do’s And Don’ts 73 Specification 89
Double Sheet Detection 37 Square Folder 17
Square Folding 38
E selecting square folding mode 39
stop gate offset 39
Emptying the trim bin 32 Stacker full detection 47
Staple position 35
F Staple, stapling 34
Stored jobs 52
Fault codes 65
System Set Size Guide 94
Fold position 35

G T
Turning On / Off the Main Power 29
General safety 4
Table of Contents 7
Guide To Components 13
Tools 28,?47
Trim bin
H emptying 32
Hand-feeding 44 Trimmer 19
How to read this manual 3 Trim, trimming
auto / manual / off 37
I Troubleshooting 65
Booklet maker fault codes 69
Introduction 3 Cover feeder fault codes 69
Fault codes, General 65
J General fault codes 67
Rotator Creaser Trimmer fault codes 68
Jobs screen, The 27 Square folder fault codes 71
Jobs 51 Trimmer fault codes 71
storing, recalling & deleting 51 Turning Off the Main Power 29
Turning On the Main Power 29
L
Language 48
U
Limitations in the Pro 35/50 system 86 Units 48
Loading covers 31 User interface 27

M W
Machine What You Can Do with This Machine 11
environment 74 Where to put Your Machine 74
specifications 89