Read this manual carefully before you use this product and keep it handy for future reference.
For safety, please follow the instructions in this manual.
BOOKLET MAKER Pro 30 and RCT 30
Operating Instruction
Stapler Folder Reference
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
The domestic environment is an environment where the use of broadcast radio and television Note recievers may be expected within a distance of 10 m of the apparatus concerned.
Introduction
This manual contains instructions on the operation and maintenance of this machine. To get maximum versatility from this machine all operators should carefully read and follow the instructions in this manual. Keep this manual in a handy place near the machine.
Please read the Safety Information before using this machine. It contains information re- lated to USER SAFETY and PREVENTING EQUIPMENT PROBLEMS.
How to read this manual
Notation conventions
Whenever necessary, the following points for attention are indicated in this manual.
WARNING:
Indicates a potentially hazardous situation which, if instructions are not followed, could result in death or serious injury.
CAUTION:
Indicates a potentiality hazardous situation which, if instructions are not followed, may result in minor or moderate injury or damage to machine or property.
Note
This sign refers to:
• Remarks for making the operation much easier. You get practical hints or knowledge to assist you in the machine operation such as:
• Preparations required before operating
• How to prevent papers from being misfed or damaged
• Precautions required or actions to take after misoperation
• Limitations like numerical limits, functions that cannot be used together or conditions, under which a particular function cannot be used or obtained.
• Information.
[ ]
Keys that appear on the machine’s display panel.
WARNING:
• To avoid hazardous situations like for instance electric shock or danger while exposed to moving, rotating or cutting devices, do not remove any covers, guards or screws other than those 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.
Safety Information
When using this machine, following safety precautions should always be followed.
Safety during operation
General safety WARNING:
• Always connect the equipment to a properly grounded power source (wall outlet). If in doubt, have the power source checked by a 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.
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!
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.
General safety, continued
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TABLE OF CONTENTS
What You Can Do With This Machine ... 11
Guide To Components ... 13
Booklet Maker ...13
Options ... 16
Cover Feeder ...16
Trimmer ...17
Square Folder ...19
Control Panel ... 27
1. Basics ... 29
Turning On / Off the Main Power ... 29
Booklet Maker, Cover Feeder, Trimmer and Square Folder ...29
RCT 30 ...29
Check staples, Staple cartridge and stapler head... 30
Removing stapler head ...30
Removing staple cartridge ...30
Installing stapler head, staple cartridge / clearing staple jam ...31
Consumables ... 32
Emptying the trim bin ... 33
2. Making Booklets ... 35
Changing settings ... 35
General procedure ...35
Setting Paper Size ...35
Selecting standard paper sizes ... 35
Selecting standard paper sizes, continues ... 36
Custom paper size ... 36
Stapling ...37
Selecting stapling On or Off ... 37
Trimming ...37
Selecting trimming On or Off ... 37
Adjusting the cutting margin ... 38
Covers ...38
Selecting Cover Feeder Mode ... 38
Loading covers ... 39
Air separation ... 39
Double Sheet Detection ... 39
Square Folding ...40
General ... 40
Setting Mode ...40
Procedure ... 40
RCT 30 ...41
Rotator - Selecting On or Off ... 41
Creaser - Selecting Creaser Mode ... 41
Creaser - Selecting On or Off ... 43
Bleed Trimmer - Selecting On or Off ... 43
Bleed Trimmer - Selecting Bleed Trim Mode ... 43
Bleed Trimmer - Bleed Trim Conflict ... 46
On-line/Off-line ... 46
Off-line mode ...46
3. Tools ... 47
The Tools Screen ... 47
Air Separation ...49
Double Sheet Detection ...49
Stacker Full Detection ...50
Service access ...50
4. Jobs ... 51
Storing and deleting jobs ... 51
Storing a new Job ...51
Recalling a Job ...52
5. Clearing Misfeed(s) ... 53
Clearing misfeed(s) ... 53
General ...53
Booklet Maker ... 54
Clearing misfeed(s) ...54
Inside the Booklet Maker ... 54
Clearing misfeed in input area ... 55
Trimmer ... 56
Clearing misfeed(s) ...56
Clearing misfeed in input area ... 56
Clearing misfeed in exit area ... 57
Cover Feeder... 58
Clearing misfeed(s) in vertical transport area ...58
Square Folder ... 59
Clearing misfeed(s) ...59
Inside the Square Folder ... 59
Exit area ... 59
RCT 30 ... 60
Clearing misfeed(s) in the paper path ...60
Infeed “A” area and exit “D” area ... 60
Rotator, registration and creaser area ... 61
6. Troubleshooting ... 63
Fault codes... 63
General ...63
General fault codes ...64
Clear Misfeed(s) ... 64
Close cover(s) ... 64
Booklet maker fault codes ...65
Check staples ... 65
Oil clinchers ... 65
Remove purged sets ... 65
Illegal feed mode ... 65
Stacker full ... 65
Trimmer fault codes ...65
Trim bin full ... 66
Close trimmer belts ... 66
Cover feeder fault codes ...66
Misfeed ... 66
Double feed ... 66
Load covers ... 66
Square Folder fault codes ...67
Feed errors ... 67
RCT 30 fault codes ...68
Adjustment errors ... 68
7. REMARKS ... 69
Do’s And Don’ts ... 69
Where to put Your Machine ... 70
Machine environment ...70
Power connection ...70
Access to machine ...71
Maintaining Your Machines ... 72
Booklet Maker ...72
Oil Clinchers and Stapler Heads ... 72
Cover Feeder ...74
Cleaning feed rollers and paper separator pad ... 74
Square Folder ...75
Cleaning feed belts ... 75
RCT 30 ...76
Cleaning the paper path transportation nip rollers (4x) ... 76
Cleaning the fixing rollers (3x) ... 77
Cleaning the registration cross roller (4x) ... 78
Cleaning the rotator rollers (2x) ... 79
Cleaning the paper path sensors (5x) ... 79
Cleaning of creaser tools (2x) ... 81
Adjustment of Bleed Trimmer registration angle (parallell cut) ... 82
Adjustment of Creaser registration angle ... 83
8. Specification ... 85
Machine Specifications ... 85
Booklet Maker BM30 ...85
Cover Feeder CF30 (optional) ...86
Trimmer TR30 (optional) ...86
Square Folder SQF30 (optional) ...87
RCT 30 (optional) ...88
System Certifications ...89
PRO30 System Set Size Guide ...90
INDEX... 91
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What You Can Do With This Machine
The RCT 30, Booklet Maker BM30, Trimmer TR30, Square Folder SQF30 and Cover Feeder (CF300) forms a booklet making system that works online with the Printer.
The print-outs are transported through the RCT 30 (optional) prior to entering the Booklet Maker. The RCT 30 is able to rotate small(er) sheets from long edge feed to short edge feed, to increase printer productivity. In order to avoid color prints to break or dissolve at the spine after folding, the Creaser can prepare the cover sheet for that.The Bleed Trimmer trims the long sides of the sheets to shape the print-outs to the desired format. After that, the print-outs are transported into the stapler area and compiled. From the CF30 Cover Feeder (optional), if present, any type of covers, colored or black and whites, can be added to the printed set.
The Booklet Maker now jogs and then staples the set. The set is then transported further to the folding area where the set is folded into a booklet and then fed out to the belt stacker.
When a larger number of sheets are folded an effect called creeping occurs. In order to rectify creep, the TR30 Trimmer (optional) can be attached after the Booklet Maker. The booklets are then transported from the Booklet Maker into the Trimmer where the trail edge will be cut off. If a TR30 Trimmer is installed to the BM30 Booklet Maker, you can attach the SQF30 Square Folder (optional). The printouts, which have been stapled, folded and trimmed will be fed into the SQF30. The SQF30 will flatten the spine of the booklet square. The booklets will, after passing the SQF30, have the look of a perfect bound book. The booklets are then fed out to the Belt Stacker. Undocked or off-line, the Booklet Maker can be used as a stand- CF30 Cover Feeder (optional) TR30 Trimmer (optional)
BM30 Booklet Maker
SQF30 Square Folder (optional)
Belt Stacker RCT 30
The buttons are multi functional, meaning that the function of each button depends on the information displayed.
For example: Pressing button 3 from the Ready screen takes you to the Tools screen.
Example 2: In this screen, button 3 has no function.
Button: 1 2 3 4
Example 3: Pressing button 3 here will load the stored Job (4).
Button: 1 2 3 4
Example 4: In this screen pressing button 3 will save the current settings for job No 1. The asterisk on the first row shows that the settings for Job (1) has been changed, but not yet saved.
The BM30 Booklet making system is controlled from a single control panel on the Booklet Maker. The control panel has only four buttons which will allow you to easily set up, adjust and operate the complete system.
Guide To Components
1 Infeed assembly 2 Docking assembly 3 Hand feed cover 4 Top cover
Booklet Maker
6 Main power switch 7 Belt Stacker
8 Belt Stacker cover 7
8
5 6
2 1 4
3
8 Connections 9 Fold stop gate
Booklet Maker, continues
Main Power Terminator/
COM TR30 Terminator
Stacker
COM Copier POW SQF30
Interlock jumper
Interlock jumper/
POW TR30
9 8
1 Stapler heads 4 Stapler release latches
Booklet Maker, continues
6
1
5
3
4 5
2
Options
Cover Feeder
1 Paper orientation label
2 Paper separator pad (also see page 60)
3 Feed roller assembly 4 Rear side guide
5 Loading capacity mark 6 Front side guide 7 Air nozzle (2x)
8 Jam clearance baffle 5
43 2 1
6
7
8
Trimmer
1 Top cover 2 Trim bin 3 Base
4 Connections
4 1
2
3
Stacker COM BM30 Terminator/
Com SQF30 Power from
BM30
Trimmer, continues
The Trimmer interior has parts that you will come in contact with if a misfeed occurs.
1 Set counter 2 Trimmer stop 3 Outfeed latch
4 Exit compressing brackets 5 Transport belt
6 Infeed roller shaft 7 Trimmer fan 8 Upper knife 9 Infeed latch 8
5 1
2
3 4 6
7
9 Trimmer, top view
1 Top cover 2 Trim bin 3 Base
4 Connections
Square Folder
1
3 2
4
Stacker
COM SQF30 Terminator
POW SQF30
1 Lower feed belts 2 Upper feed belts
Square Folder, continues
The Square Folder interior has parts that you will come in contact with if a misfeed occur.
2 1
Square Folder, top view, Upper feed belts in lifted up
1
RCT 30
2
3
4
1 Top cover 2 Infeed slot
3 Upstream docking assembly 4 Slide door
1 Outfeed slot
2 Trim waste transport 3 Waste container 4 Connections
5 Downstream docking assembly
RCT 30, continues
3 4 1
5
2
Connections bracket
1 COM Copier 2 Terminator
3 Terminator / COM TR30 4 Main power
RCT 30, continues
1 2
3
4
RCT 30, continues
Operator, side top cover
1 Infeed Section “A”
2 Main switch
3 Bleed trimmer circular knives 4 Outfeed section “D”
3 1
2
4
RCT 30, continues
1 Latch handle, slide
2 Bleed trimmer registration adjustment 3 Creaser registration adjustment 4 Waste chute(s)
1
2 3
4
RCT 30, continues
1 Rotator
2 Coarse registration, section “B”
3 Fine registration, section “C”
4 Creaser tools 1
2
3 4
Control Panel
arrow button
change button
tools button
jobs button
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.
The Tools screen.
Pressing the [Tools] button in the Ready screen takes you to the tools screen. Here you will find all the necessary tools for a troublefree operation. From here you can change the display language, set units from millimeters to inches and more. See section 3. Tools.
for how to get around in the Tools screen.
Changing settings.
To change or adjust settings; Select an item in the Ready screen with the [arrow] button and press the [Change] button. For example you can fine adjust the trimming, turn off the cover feeder or set the Square Folder to the correct mode. Explore all settings more thoroughly in section 2. Making Booklets.
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 Pro 30 Booklet making system.
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 handfeeding the next set.
When the printer has cycled down in the middle of a set for any reason (load stock, refill etc.) the processing screen will be shown until the printer has completed the set/job.
The Please wait screen.
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.
Plug the Booklet Maker and RCT 30 (optional) Power cords into the wall outlet.
Cover Feeder (optional), Trimmer (optional) and Square Folder (optional) are powered from the Booklet Maker.
Open the Top cover (1).
Set main power switch (2) on Booklet Maker to ON position.
The main power switch also controls Cover Feeder Note (optional), Trimmer (optional) and Square Folder (optional).
Close the Top cover.
Turning On / Off the Main Power
Booklet Maker, Cover Feeder, Trimmer and Square Folder
2 1
1. Basics
Open the Top cover of the RCT 30 (3).
Set the main power switch (4) to ON.
Close the Top Cover of the RCT 30.
3
4
RCT 30
1
The staple cartridge contain approximately 5000 staples per cartridge. Cartridge may be removed either for replacement or for clearing jams.
Raise the handle (C) on the staple cartridge locking lever.
Remove the staple cartridge from the stapler head by sliding it away from the stapler head.
Check staples, Staple cartridge and stapler head
Open the top cover.
Remove the set of paper.
Disconnect the staple indication lead (A) from the socket.
Hold the stapler head in place, press the release latch (B) to release the rear end of the stapler head and lift up this end.
Lift out the head, allowing it to rotate around the front end. The stapler assembly is spring loaded and will follow the rotation of the stapler.
Removing stapler head
A B
C
Removing staple cartridge
1
Look inside stapler head for jammed staples in the area of the staple actuator. Remove staples if any.
Position the stapler head on the edge of a firm surface (for example the top of a table).
While securely holding the head, actuate the Stapler up and down through full travel. Perform this operation without staple cartridge
When replacing or reinstalling the staple cartridge, pull 25 mm (1 inch) of staples out of the cartridge and tear the staples downward starting at one side pulling away from you. The staple tear line is indicated by an arrow on the side of the cartridge.
Insert the cartridge into the stapler head with the end of the staples facing toward the head of the stapler mechanism. Push it firmly ahead.
Hold the staple cartridge firmly in place and push down the cartridge locking lever.
IMPORTANT
Keep holding (pushing) the staple cartridge into place while pushing down the cartridge locking lever.
While securely holding the head, actuate the Stapler up and down through full travel. Perform this operation with staple cartridge. Repeat this a few times to ensure that the staples are ejected at each down movement.
Reinstall the stapler head by inserting the pin at the top of the stapler head into the stapler retraction swing arm (D).
While rotating the stapler head, insert the pin located at the rear end of the stapler head into the slots in the frame of the stapler head assembly. Press down the rear end of the stapler head until the release lever snaps into place, locking the stapler head in position.
Press down the front end of the stapler head until it snaps in position under the frame assembly.
Reconnect the staple indication lead (A), see previous page.
Close the top cover and press the [Esc] button. The booklet maker will automatically go to Ready mode. If not and/or error message persists, hand feed a four sheet set of paper. The booklet maker will automatically cycle and advance staples until both stapler heads are
Installing stapler head, staple cartridge / clearing staple jam
1
Consumables
To reorder staples, please use following part numbers
XNA 8R3838
XE 8R3839
1 Emptying the trim bin
Remove the trim bin by lifting it and pulling it out.
trim bin, no Square Folder installed
trim bin, with Square Folder installed
1
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2. Making Booklets
Setting Paper Size
Selecting standard paper sizes
Changing settings
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.
Choose either of the above mentioned procedures when changing size, stapling, trimming, Note covers or book folding as follows.
From the Ready screen, select Size and press the [Change] button.
General procedure
2
The paper size can now be changed in increments of 0.1 mm or approx.. 0.01 inches. Press the [OK] button to confirm.
Four different custom paper sizes can be stored.
Custom paper size
Select Size and press the [Change] button to display the preprogrammed paper sizes.
Scroll down to Custom sizes, by pressing the [arrow]
button, and press the [OK] button. Select the custom paper size you want to use and press the [OK]
button.
If you want to adjust, select the custom paper size you want to change and press the [Change] button. Select Width or Length with the [arrow] button and press the [Change] button.
Selecting standard paper sizes, continues
If a RCT 30 is installed there is a selection of ready made job setups to facilitate quick and easy setup to process oversizes to nominal sizes. These are named with the suffix T like in SRA3T, SRA4T, 12”x18”T and 9”x12”T. The assumption for 12”x18T is that 12”x18” is printed and that it should be cut down to 11x17 which in turn results in a finished booklet of 8.5” x 11”. The assumption for 9”x12T is that 9”x12” is printed LEF and that it should be cut down to 8.5” x 11 which in turn results in a finished booklet of 4.25” x 5.5”.
For smaller sizes, possible to rotate, the assumption also includes that they are printed LEF. Rotation will be selected by default when these T-sizes are selected.
Selection of Creaser mode is NOT a part of these ready made jobs, and must always be done manually.
2
If stapling was On, the first choice will be Off and vice versa.
Select On or Off with the [arrow] button and press the [OK] button.
Trimming
Selecting trimming On or Off
If trimming was On, the first choice will be Off and vice versa.
Select On or Off with the [arrow] button and press the [OK] button.
From the Ready screen, select Trim and press the [Change] button.
Stapling
Selecting stapling On or Off
From the Ready screen, select Staple and press the [Change] button.
2
Selecting Cover Feeder Mode
Covers
Select On if you want the cover feeder to automatically feed one cover to each set from the copier, or if you are manually feeding a set.
Select Off if no covers are to be fed.
Select Feed if you want to fold only one sheet in sequence.
Press the [OK] button to confirm.
From the Ready screen, select Cover and press the [Change] button.
Adjusting the cutting margin
Select Trim and press the [Change] button. Select Trim length and press the [OK] button. Press the [+]
or [-] buttons to fine adjust in increments of 0.5 mm or 0.02 inches. The trimmed booklet size and waste are displayed. Press the [OK] button to confirm.
2
Selecting Cover Feeder Mode, continues
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 [Run] 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.
If you open and close the Top Cover without removing Note the cover sheet, the cover sheet will be stapled and folded and then fed to the stacker.
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.
Move the adjustable side guides (B) up against the cover sheets until there is no clearance.
Loading covers
B A
Air separation
You might want to increase the Air flow when running thick, heavy covers. See section 3.
Tools for details.
Double Sheet Detection
Normally double sheet detection should be set to On. However, if you experience “false
2
Square Folding
General
The Square Folder has six different settings. It can be set to [Auto], [Mode 1], [Mode 2], [Mode 3], [Mode 4] or [Off].
In [Auto] mode, the Booklet Maker detects how many sheets there are in the booklet, and automatically set the Square Folder to the correct mode.
When the Square Folder is set to [Auto] and the booklet has less than approximately 6 Note sheets/booklet, the Square Folder will bypass the Square folding action, transporting the booklet out to the Belt stacker.
Use the manual modes to override the auto function. There are four different manual modes to select from.
Mode 1: Approximately 6 to 11 sheets. Decreased amount of square forming.
Mode 2: Approximately 12 to 16 sheets. Medium amount of square forming.
Mode 3: Approximately 17 to 23 sheets. Increased amount of square forming.
Mode 4: Approximately 24 to 30 sheets. Maximum amount of square forming.
Select [Off] to bypass the Square Folder.
Always select Square Folder mode manually when hand feeding.
Setting Mode
Procedure
From the Ready screen, scroll down to SQF and press the [Change] button.
Select [Auto], [Mode 1], [Mode 2], [Mode 3], [Mode 4] or [Off] with the [arrow] button and press the [OK]
button.
2
Select if you want the Rotator to be On or Off. If rotator was Off, the first choice will be On and vice versa.
When turned On the Rotator enables more sheets being run through in a shorter time.
Press the [OK] button to confirm.
RCT 30
Rotator - Selecting On or Off
From the Ready screen, select Rotator and press the [Change] button.
Creaser - Selecting Creaser Mode
From the Ready screen, select Creaser and press the [Change] button.
Using the Creaser enables you to crease the cover sheet of the booklet, in order to avoid toner cracking at the fold.
2
If you want to change the Coarse tools offset, select Coarse and press the [Change] button. Then you are able to change the offset with [+] or [-] buttons that changes the crease position from the center with 0.1 mm for each button push. When pressing the [+] button the offset is positioned closer to the lead edge, when positioned the [-] button the offset is placed closer to the If your cover sheet is heavier than 120 gsm, select Coarse and press the [Change] button.
The Crease Offset (whether Fine or Coarse) is initially set to the center (0.0 mm). You can change the offset with [+] or [-] buttons that change the crease position from the center with 0.1 mm for each button push. When pressing the [+] button the offset is positioned closer to the lead edge, when pushing the [-] button the offset is positioned closer to the trail edge. When done press the [OK] button to confirm. This is the Fine tools Offset.
Choose either Fine or Coarse tool depending on how heavy the stock is. Normally Fine is selected for cover sheets less than 120 gsm (gsm= grams per square meter).
Creaser - Selecting Creaser Mode continues
2
If you want to turn the Creaser off select Off and press [Ok] to confirm.
If Creaser was Off, the first choice will be Off and vice versa. Select On or Off with the [arrow] button and press the [OK] button.
From the Ready screen, select Bleedt Trim and press the [Change] button.
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*.
Bleed Trimmer - Selecting On or Off Creaser - Selecting On or Off
Bleed Trimmer - Selecting Bleed Trim Mode
The Width In Parameter collects its value from the Booklet Maker. If you want to change the value, select Width in and press the [Change] button. Width in stands for the width the sheet has before it enters the RCT 30 unit (or the Booklet Maker).
2
Select Image Offset if you want to move the offset for where the image will be cut from and press the [Change]
button.
Width Adjust shows the difference between the Booklet Maker’s understanding of width and the RCT 30’s understanding of the sheet 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, select Width Adjust and press the [Change] 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.
Width In collects its default value from the width of the Booklet Maker. Width In will most likely need to be changed if a new size is entered in the Booklet Maker.
If you want to change the Width In value simply use the [+] or [-] buttons. When done press the [OK] button to confirm.
Bleed Trimmer - Selecting Bleed Trim Mode continues
2
If you want to turn the Bleed Trimmer off select Off and press [Ok] to confirm.
If Bleed Trimmer was Off, the first choice will be Off and vice versa. Select On or Off with the [arrow] button and press the [OK] button.
Change the Image Offset value with the [+] or [-] buttons and press the [OK] button to confirm.
When pressing the [+] button the image will be closer to IB. When pressing the [-] button the image will be closer to OB.
IB
OB
Bleed Trimmer - Selecting Bleed Trim Mode continues
2
*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
Bleed Trimmer - Bleed Trim Conflict
On-line/Off-line
The Booklet maker can be operated in two modes. On-line mode, when used together with the copier, or off-line mode, working as a stand-alone unit.
Off-line mode
Select correct paper size.
Open the Hand Feed Cover.
Insert the set and make sure to position the set within the two arrows.
3. Tools
The Tools screen.
From the Ready screen, press the [Tools] button to get to the Tools screen. Here you will find all the necessary tools for troublefree operation.
The Tools Screen
Units
From this screen you can change units, between millimeters and inches. Select Units with the [arrow]
button and press the [OK] button.
Select the millimeters or inch units and then press the [OK] button.
Select Software version with the [arrow] button and press the [OK] button. This screen, and sub screens show the software version for the different modules in the booklet making system.
Software version
3
Language
From this screen you can change the language in the user interface.
Select Language with the [arrow] button and press the [OK] button.
Select desired language with the [arrow] button and press the [OK] button.
Select the module in the system for which you want to check the software version and press the [OK]
button.
This screen will show software version(s) in the selected module.
Software version, continues
3
Air Separation
From this screen you can increase or decrease the Air separation. This screen will only be shown if a Cover Feeder is present. Select Air separation with the [arrow]
button and press the [OK] button.
You might want to increase the Air flow when running thick, heavy covers.
Set the desired speed in increments of 10% with the [+]
or [-] buttons and press the [OK] button. Normal user (default) setting is 60%.
Double Sheet Detection
From this screen you can turn the double sheet detection On or Off. Select Double sheet det. with the [arrow] button and press the [OK] button.
Normally double sheet detection should be set to On.
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.
3
Stacker Full Detection
Service access
This screen is for authorized service personnel only and is password protected.
Select if you want the Stacker full det. to be On or Off.
Press the [OK] button to confirm.
When turned On the Stacker full det. can keep count of how many booklets are on the stacker and notifies when it’s full and stops the printer. After emptying the stacker, reset the Stacker full det.
From this screen you can turn the Stacker full det. On or Off. Select Stacker full det. with the [arrow] button and press the [OK] button.
4. Jobs
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
