Storing and deleting jobs
Select an already stored job by pressing the [Next]
button. Then press the [Change] button.
Select the option you want to change with the [arrow]
button and then press the [Change] button. See section 2. Making Booklets for how to set up each separate option.
After changing the options press the [OK] button to accept the changes you just made.
Continued on next page.
The Booklet Maker has a maximum storage capacity of 10 different jobs. It is not possible to delete jobs, therefore when you need to store a new job, an old job must be overwritten.
To make temporary changes in the actual job settings or temporary changes of a stored job, see section 2. Making Booklets.
Storing a new Job
To store a new job or add new settings to an existing job you need to start from the Jobs screen. From the Ready screen press the [Jobs] button to enter the Jobs screen.
4
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 by pressing the [Next] button.
Then press the [Load] button. The booklet maker will then automatically setup that specific job and return to the Ready screen.
Storing a new Job, continues
To store the job, press the [Save] button.
If you want to run the actual job, press the [Load] button.
The booklet maker will then automatically setup that specific job and return to the Ready screen.
5. Clearing Misfeed(s)
Clearing misfeed(s)
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.
General
Misfeeds in the Booklet Maker are indicated as area A, B or C and by the error code 40-XXXX.
Misfeeds in the Square Folder are indicated as area E and by the error code 42-XXXX.
Misfeeds in the RCT 30 are indicated as area G and by the error code 44-XXXX.
5
To clear a misfeed indicated in Area A or B Open the top cover.
Remove misfed sheets.
Close the top cover.
To clear a misfeed indicated in Area C 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.
Clearing misfeed(s)
Booklet Maker
Inside the Booklet Maker
5
Clearing misfeed(s), continues
Open Top Cover.
Manually pull the spring supported paper guides apart.
Remove the misfed sheets.
Close Top Cover.
Clearing misfeed in input area
5
Trimmer
Clearing misfeed(s)
Raise the infeed roller shaft (A) by lifting latch (B).
Remove the misfed sheets in the infeed area.
After the misfed sheets are removed, lower the latch (B) and place the infeed roller shaft into operating position.
Clearing misfeed in input area
The upper trimmer blade on the trimmer is protected by a knife protection plate that moves away during the cutting stroke. Jams can occur in the input area or the exit area.
WARNING:
Never put fingers or other parts of the body between the upper and lower trimmer knives.
A
B
5
Clearing misfeed(s), continues
Lift the exit compressing brackets (A).
Secure them under the latch (B).
Remove the misfed sheets from the exit area.
After the misfed sheets are removed, lift up the latch (B) and place the compressing brackets in operating position.
Clearing misfeed in exit area
A
B
5
Open the Hand Feed Cover.
Lift the jam clearance baffle (A).
Remove the misfed cover.
Put the jam clearance baffle back in normal position.
Clearing misfeed(s) in vertical transport area
Cover Feeder
8
5
Open the top cover.
Lift up both upper feed belts (A).
Press the green dots (B) on the latches to release.Note
Remove the misfeeds.
Place the upper feed belts in normal position.
Close the top cover.
Inside the Square Folder
Exit area
Open the top cover.
Remove the misfeeds through the jam clearance area (A).
Close the top cover.
Clearing misfeed(s)
Square Folder
A
B B
A
5
RCT 30
Clearing misfeed(s) in the paper path
Infeed “A” area and exit “D” area
Open the top cover.
Lift up “A” (A) and “D” (B) baffles if needed.
Remove any misfeed(s).
Lower “A” and “D” baffles to normal position
Misfeed(s) in the trimmer area are rolled out by rotating the rubber surfaced pinch roller (C).
Close the top cover.
WARNING!
Do not put your fingers within knife protections (D).
Doing so may result in injury.
5
Open the slide door (A).
Unlatch and pull out the slide (B).
Open “B” (C) and “C” (D) baffles 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.
Rotator, registration and creaser area
Clearing jams in the waste transport
The waste transport is easily accessible through the slide door. Shreds jammed in or 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.
A
B
C
D
Page intentionally blank.
6. Troubleshooting
Fault codes
General
If frequent input jams are experienced please check paper curl and decurler adjustments in printer operator guide.
When there is a misfeed or fault condition in the booklet maker system, a message will be displayed on the Booklet Maker. In case there is a problem that can be rectified by the operator, a fault code and an explanation will be displayed.
Fault codes that can be rectified by the operator:
BM30 40-XXXX TR30 41-XXXX SQF30 42-XXXX CF30 43-XXXX
RCT 30 44-XXXX
If procedures in this manual do not rectify the problem an authorized technician will be Note needed.
6
General fault codes
Clear Misfeed(s)
In general, fault codes indicate a misfeed condition.
When a misfeed occurs, the message “Clear Misfeed(s)”, a code 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 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.
6
Booklet maker fault codes
Check staples
Trimmer fault codes
This message 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.
Oil clinchers
This message will be displayed every 20 000 stapling cycles. The purpose is to remind the operator to maintain stapler head and clinchers. If not doing that every 20 000 there is a great risk of a costly mechanical breakdown. See section Maintaining Your Machines on page 72 for procedure.
Remove purged sets
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.
Illegal feed mode
If this message is displayed, contact customer support.
Stacker full
This message will be displayed when the Stacker is full. Empty Stacker.
During poor environmental conditions waste from the trimming operation may be transported Note 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.
6
Load covers 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.
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.
Cover feeder fault codes
Trim bin full
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
This message will be displayed when the belts at the outfeed area of the Trimmer is not in correct position. Open cover and set Trimmer belts to their lower position. Close cover.
Code 43-9001 is displayed when covers run low.
If you wish to continue production:
Load more cover sheets according to section 2. Making Booklets.
Code 43-9001 will extinguish and copier will start.
If you wish to continue production, using up the cover sheets that are loaded:
Press ESC. Code 43-9001 will extinguish and copier will start.
Code 43-1001 is displayed when covers are empty.
If you wish to continue production:
Load more cover sheets according to section 2. Making Booklets.
If cover job is finished and you wish to run a new job without covers:
Select Cover Off in the Cover menu.
6
If feed errors occur, the feed belts needs to be cleaned or the pressure on the upper feed belts needs to be increased. To clean the feed belts, see section 7, REMARKS Maintaining Your Machine. To increase the pressure on the upper feed belts follow this procedure.
Open the top cover.
Place both springs in the upper position.
Close the top cover.
Square Folder fault codes
Feed errors
Spring in upper position Spring in normal position
6
RCT 30 fault codes
44-9001, 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 Maker “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.
44-9002, Out of rotator limits
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”) 44-9003, 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.
44-2150, Communication lost
Indicates that the communication between the RCT 30 and the Booklet Maker is interrupted.
Check that the RCT 30 is powered up and that the communication cable to the RCT 30 is OK.
44-1XXX, Feed errors
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.
Adjustment errors
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 powercord 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 put fingers within knife protections in the RCT 30 module.
• Do not turn 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.
7
Where to put Your Machine
Machine environment
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.
• 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
Access to machine
Place the machine near the power source, providing clearance as shown.
1. Left: more than 400 mm / 15 3/4” (off-line use).
2. Rear: more than 555 mm / 21 7/8”
3. Right: more than 400 mm / 15 3/4”.
4. Rear: more than 700 mm / 27 1/2” (on-line use).
1
2
3 4
7
Maintaining Your Machines
Never attempt any maintenance function that is not specifically described in this documentation.
Booklet Maker
Oil Clinchers and Stapler Heads
Stapling area, view from infeed
close-up of clincher
lever close-up of clincher
lever close-up of
clincher
A
B B
The clinchers must be oiled every 20 000 stapling cycles to avoid mechanical breakdown.
7
Open the top cover.
Put a couple of drops of oil in each clincher (A).
To get rid of excessive oil:
Push down clincher (B) lever a couple of times.
Push down clincher lever (B) while wiping of excessive oil with a dry cloth.
Run a few blank booklets.
When clinchers have beed lubricated, the error message must be reset:
Turn off the main power switch on the machine.
Press and hold the two innermost buttons on the UI, buttons 2 and 3.
Turn on the main power switch and release the buttons after 2 seconds.
Remove the Stapler heads according to section 1, BASICS Check staples, Staple cartridge and Stapler head.
Put a couple of drops of oil on each side of the drive post (C).
Cycle the Stapler head a couple of times before installing it again.
The stapler heads must be oiled every 20 000 stapling cycles to avoid mechanical breakdown.
C
7
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 (A). The left end of the feed roller assembly will now be released (B) and the assembly can be removed.
Clean the feed rollers and the paper separator pad with water and a clean lint free cloth.
Cleaning feed rollers and paper separator pad
Cover Feeder
Feed rollers
Press toward front.
Lift out this side
A
B
7
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.
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.
Square Folder
Cleaning feed belts
B A
7
Cleaning the paper path transportation nip rollers (4x) Also clean the idler rollers
RCT 30
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.
WARNING!
Do not put your fingers within knife protections.
Doing so may result in injury.
Knife protections
7
Cleaning the paper path transportation nip rollers (4x) continues
Nip rollers
Cleaning the fixing rollers (3x)
Fixing rollers
Also clean the idler rollers
WARNING!
Do not put your fingers within knife protections.
Doing so may result in injury.
7
Cleaning the the fixing rollers (3x) continues
Fixing rollers
Cleaning the registration cross roller (4x)
Cleaning friction tires
Registration cross rollers
Cleaning of the friction tires is done from within the registration sub-frame.
7
Cleaning the paper path sensors (5x) Cleaning the rotator rollers (2x)
Rotator rollers Also clean the idler rollers
WARNING!
Do not put your fingers within knife protections.
Doing so may result in injury.
Infeed sensor Outfeed sensor
7
Cleaning the paper path sensors (5x) continues
Rotator sensor
7
Creaser sensor
Cleaning the paper path sensors (5x) continues
Cleaning of creaser tools (2x)
Grooves on both sides of the tool
After a period of time toner and paper dust may leave residuals in the grooves of the tool.
These grooves need to be cleaned periodically to restore creasing performance.
7
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
7
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.
Star shaped knob Knurled eccentric
Alignment marks
7
Page intentionally blank.8. Specification
Machine Specifications
Major Specifications
Specifications Remarks
Speed (Online usage) Maintains engine speed Actual speed in number of
book-lets (per min / hour) depends on number of sheets per booklet.
Maximum Speed 1440 booklets / hour (A4 / 8.5x11”)
720 booklets / hour (A3 / 11x17”)
Standard Paper Sizes A4, A3, 8.5x11”, 8.5x14”, 11x17”, SRA3,
12x18” Custom sizes are available
Paper Size (Minimum) Width 206mm / 8.1”
Length 275mm / 10.8”
Paper Size (Maximum) Width 320mm / 12.6”
Length 457.2mm / 18”
Paper Weight (Minimum) 64gsm/16 lb. Bond
Paper Weight (Maximum) 300gsm / 172 lb. Index / 115 lb Cover
Input / Output Sheets 1 – 30 Sheets (80 gsm / 20 lb Bond) Stapled
Input / Output Sheets 1 – 2 Sheets Non Stapled Folding
Off-line Use Possible
Weight 130 kg / 286.6 lb
Dimensions (L x H x D) 1455 x 1085 x 606 mm / 57.3 x 42.7 x 23.9” Incl. Stacker
Power Source 100 / 110 / 120 / 127 / 220 V+6 % /
-10%, 230 V, 50-60Hz
Power consumption 300 W or less Continuous Operations