Canon BLM550+_Operation Guide Océ BLM550+ Operation BLM550Plus

User Manual: Canon Océ BLM550+ Operation Guide Production Printing User Manuals

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Operation guide
Océ BLM550⁺
Copyright
© 2013 - 2014, Océ
All rights reserved. No part of this work may be reproduced, copied, adapted, or transmitted in
any form or by any means without written permission from Océ.
Océ makes no representation or warranties with respect to the contents hereof and specifically
disclaims any implied warranties of merchantability or fitness for any particular purpose.
Furthermore, Océ reserves the right to revise this publication and to make changes from time to
time in the content hereof without obligation to notify any person of such revision or changes.
Edition 2014-06 US
Contents
Chapter 1
Preface................................................................................................................................. 5
Notes for the reader......................................................................................................................................... 6
Chapter 2
Introduction to the Booklet maker....................................................................................9
Introduction.....................................................................................................................................................10
Description of the Booklet maker..................................................................................................................11
Right-Hand Side of the Booklet maker......................................................................................................... 13
The Rear Panel of the Booklet maker............................................................................................................14
The mains input panel of the optional Book Stacker.................................................................................. 15
Chapter 3
How to run the Booklet maker........................................................................................ 17
Quality instructions........................................................................................................................................ 18
Turn ON the Booklet maker........................................................................................................................... 20
Enter the Job Settings....................................................................................................................................21
Procedure for a New Job.........................................................................................................................21
Procedure for a Saved Job......................................................................................................................23
Adjust the Stacker and the optional Book Stacker...................................................................................... 24
Run the job......................................................................................................................................................25
Chapter 4
The User Interface.............................................................................................................27
The Touch Screen...........................................................................................................................................28
The Job Mimic................................................................................................................................................ 31
The BASIC Window........................................................................................................................................ 33
The LOAD & SAVE Window.......................................................................................................................... 35
The ADVANCED Window...............................................................................................................................37
The CONFIGURE Window..............................................................................................................................38
The MENU Window........................................................................................................................................39
Chapter 5
Standard Tasks................................................................................................................. 41
Load and Save the Job Settings................................................................................................................... 42
Adjust the Stitch Pitch....................................................................................................................................43
Open the Connecting Bridge Cover.............................................................................................................. 44
Open and Close the Folder Cover................................................................................................................. 45
Lift and Lower the Clincher Frame................................................................................................................46
Open the Gathering Area Cover....................................................................................................................48
Lift the Booklet maker Main Deck................................................................................................................. 49
Empty the Trim Bin........................................................................................................................................ 51
Open the Stitch Wire Cabinet........................................................................................................................ 52
Adjust the Stacker.......................................................................................................................................... 53
Operate the Booklet maker offline................................................................................................................ 55
Standard Tasks of the optional Book Stacker.............................................................................................. 56
Adjust the Book Stacker.......................................................................................................................... 56
Unload the Book Stacker......................................................................................................................... 57
Contents
3
Move the Book Stacker............................................................................................................................58
Chapter 6
Error Conditions, Problems and Solutions.....................................................................59
Clear a Printer Error........................................................................................................................................60
Clear a Booklet maker error...........................................................................................................................61
General Problems...........................................................................................................................................62
Book Quality....................................................................................................................................................64
Error Messages...............................................................................................................................................76
Clear Paper Jams............................................................................................................................................85
Jam in the Bridge Infeed......................................................................................................................... 85
Jam in the Connecting Bridge................................................................................................................ 87
Jam in the Gathering Area...................................................................................................................... 88
Jam in the Stitch Area............................................................................................................................. 89
Jam in the Folder or Former Area.......................................................................................................... 90
Jam before the Trimmer......................................................................................................................... 91
Jam in the Trim Area............................................................................................................................... 93
Clear a Stitch-wire Jam..................................................................................................................................95
Clear a Stitch Head Jam.................................................................................................................................97
Procedure 1...............................................................................................................................................97
Procedure 2...............................................................................................................................................98
Calibrate the Touch Screen......................................................................................................................... 100
Change the fuses of the Booklet Maker......................................................................................................101
Manually park the Shuttle............................................................................................................................102
Clear Paper Jams of the optional Book Stacker.........................................................................................104
Jam at Book Stacker infeed...................................................................................................................104
Jam at Book Stacker outfeed................................................................................................................ 105
Change the fuses of the optional Book Stacker......................................................................................... 107
Chapter 7
Maintenance....................................................................................................................109
About Maintenance...................................................................................................................................... 110
Booklet maker cleaning................................................................................................................................111
Clean the Former Roller............................................................................................................................... 112
Clean the Polyurethane Strips in the Form Clamp.................................................................................... 113
Clean the Trimmings Removal Fingers...................................................................................................... 115
Clean excess grease from the Stitch Head.................................................................................................117
Lubricate the Stitch Head.............................................................................................................................118
Apply Grease to the Driver Bar............................................................................................................. 120
Lubricate the wire-feed cam..................................................................................................................121
Reset the Operator Maintenance Counter........................................................................................... 122
Install New Stitch Wire.................................................................................................................................123
Remove the Stitch-wire from the Stitch Head..................................................................................... 123
Fit a New Stitch-wire Spool...................................................................................................................125
Install the Stitch Wire into the Stitch Head.......................................................................................... 126
Close the Booklet maker........................................................................................................................127
Feed the Stitch-wire............................................................................................................................... 128
Clear paper from the trim stop....................................................................................................................129
Appendix A
Specifications.................................................................................................................. 131
Specifications................................................................................................................................................132
Appendix B
Declaration of Conformity..............................................................................................135
Declaration of Conformity........................................................................................................................... 136
Contents
4
Chapter 1
Preface
Notes for the reader
Introduction
This manual helps you to use the Océ BLM550+. The manual contains a description of the product
and guidelines to use and operate the Océ BLM550+.
Definition
Attention-Getters
Parts of this manual require your special attention. These parts can provide the following:
• Additional general information, for example, information that is useful when you perform a
task.
• Information to prevent personal injuries or property damage.
Symbols used in this manual
The following symbols are used in this manual to explain procedures, restrictions, handling
precautions, and instructions that must be observed for safety.
Overview of the attention getters
Word Icon Indicates
WARNING Indicates a warning concerning operations that may
lead to death or injury to persons if not performed
correctly. To use the machine safely, always pay at-
tention to these warnings.
CAUTION General hazard
Indicates a caution concerning operations that may
lead to injury to persons if not performed correctly.
To use the machine safely, always pay attention to
these cautions.
This indication has several icons that warn against
various hazards. The icons are shown below.
Hot surface
Electric shock
Moving parts
Laser beam
IMPORTANT Indicates operational requirements and restrictions.
Be sure to read these items carefully to operate the
machine correctly and to avoid damaging the ma-
chine or property. 4
Notes for the reader
6Chapter 1 - Preface
Word Icon Indicates
NOTE Indicates a clarification of an operation or contains
additional explanations for a procedure. Reading
these notes is highly recommended.
Indicates an operation that must not be performed.
Read these items carefully and make sure not to
perform the described operations.
The use of heat-resistant gloves is mandatory when
you carry out the actions concerned.
Safety information
Before using this Océ product, make sure that you read and understand the safety information
which is part of the user documentation. You can download the safety information via
"http://
downloads.oce.com"
or, if applicable, find it on the user documentation CD/DVD that is delivered
together with the machine or obtain the safety information from your local Océ representative. To
avoid potential hazards, maintenance is strictly preserved to properly qualified and trained
service technicians.
Notes for the reader
Chapter 1 - Preface 7
Notes for the reader
8Chapter 1 - Preface
Chapter 2
Introduction to the Booklet
maker
Introduction
Introduction
This User Manual is applicable to all model Océ BLM550+ booklet makers from serial number
0800 onwards with software version 4.x. You can attach the optional Book Stacker to the Océ
BLM550+ booklet maker. It is possible to retrofit the optional Book Stacker to the Océ BLM550+
models.
CAUTION
A CAUTION message tells you that a procedure or operation can be dangerous. To prevent
injury, you must follow the instructions.
IMPORTANT
An IMPORTANT message tells you that a procedure or operation can damage the machine or the
product. To prevent damage, you must follow the instructions.
Documentation
Your Manual
The User Manual for the Booklet maker describes how to perform these tasks:
• Operate the Booklet maker
• Find and correct error conditions
• Perform normal maintenance tasks
Operator training is given when the Booklet maker is installed. To make sure you use your
Booklet maker correctly, read your manual.
The User Manual for the Booklet maker does not describe the operation of the printer. If needed,
refer to your printer user manual.
Safety Information
Safety information is included in the separate “Safety Information Manual.” Read the safety
information before you use your Booklet maker.
Installation
Your Booklet maker must be installed by a service engineer. Special knowledge is needed to
install the machine.
IMPORTANT
Only connect the machine to a mains power supply of the correct voltage with a good earth
connection. The correct machine voltage is shown on the label at the power supply input on the
rear of the machine. If the machine is connected to the wrong supply, the warranty is voided.
How to Get Help
If you have any questions or problems, refer to the problem solving section in this manual (
Error
Conditions, Problems and Solutions
on page 59). Contact your Booklet maker supplier for
further help.
Introduction
10 Chapter 2 - Introduction to the Booklet maker
Description of the Booklet maker
Introduction
The Booklet maker operates online with digital printers to process sets of printed pages into
stitched books. The main parts are shown below.
Illustration
A
B
C
D
[1] Operator Side of the Booklet maker
E
[2] Book Stacker (optional)
Component - function table
Operator Side of the Booklet maker
Component Function
A The connecting bridge The connecting bridge moves the printed sheets from the
printer to the Booklet maker. If needed, the sheets are rotated
into the correct direction. Rotation lets the printer operate at
optimum print speed. Adjustment for the size of the paper
and sheet rotation is automatic, according to the settings en-
tered on the touch screen.
B The user interface The user interface has a color touch screen, a start button
and a stop button . 4
Description of the Booklet maker
Chapter 2 - Introduction to the Booklet maker 11
Component Function
C The Booklet maker The Booklet maker stitches, folds, spine-forms, and trims the
sheets to make a finished book.
D The Stacker The Stacker collects the finished books.
E The Book Stacker The optional Book Stacker is a high-capacity stacker for the
finished books.
Description of the Booklet maker
12 Chapter 2 - Introduction to the Booklet maker
Right-Hand Side of the Booklet maker
Illustration
A
B
[3] Right-hand side of the Booklet maker
Component - function table
Right-hand side of the Booklet maker
Component Function
A The stitch-wire cabinet The stitch-wire cabinet holds the spool of stitch-wire.
B Trim Bin The trim bin collects the paper that is trimmed from the edge
of the book
Right-Hand Side of the Booklet maker
Chapter 2 - Introduction to the Booklet maker 13
The Rear Panel of the Booklet maker
Illustration
B
C
E
D
A
[4] The Rear Panel of the Booklet maker
Component - function table
The Rear Panel of the Booklet maker
Component Function
A Rating and serial label The rating label displays the type of machine, serial num-
ber, power use, and fuse information.
B Power ON/OFF switch The mains power ON/OFF switch turns the Booklet maker
ON or OFF. When you turn OFF the Booklet maker, the cur-
rent settings are stored.
C Fuses The fuses make sure the operator and the machine are pro-
tected if there is an electrical problem or short circuit.
D Voltage label The voltage label is fitted to the Booklet maker during the
installation procedure. The voltage label displays the selec-
ted voltage.
E Power input connector The power input connector is used to connect the Booklet
maker to the electrical power supply.
The Rear Panel of the Booklet maker
14 Chapter 2 - Introduction to the Booklet maker
The mains input panel of the optional Book Stacker
Illustration
A
B
C
D
E
[5] The mains input panel of the Book Stacker
Component - function table
The mains input panel of the Book Stacker
Component Function
A Rating and serial label The rating label displays the type of machine, serial
number, power use, and fuse information.
B Voltage advisory label The voltage advisory label shows that the input voltage
is 230 V AC. The 230 V power is supplied by the Océ
BLM550+.
C Power input connector The power input connector is used to connect the power
supply from the Océ BLM550+ to the Book Stacker.
D Power ON/OFF switch The mains power ON/OFF switch turns the Book Stacker
ON or OFF.
E Fuses The fuses make sure the operator and the machine are
protected if there is an electrical problem or short circuit.
The mains input panel of the optional Book Stacker
Chapter 2 - Introduction to the Booklet maker 15
The mains input panel of the optional Book Stacker
16 Chapter 2 - Introduction to the Booklet maker
Chapter 3
How to run the Booklet maker
Introduction
This chapter gives information on how to run a job on the Booklet maker. For information on how
to operate the printer, refer to the printer documentation.
Information about the user interface is included in the chapter “The User Interface.”
Information about standard procedures, for example opening covers to clear a paper jam, is
included in the chapter “Standard Tasks.”
Quality instructions
Introduction
The size of the paper and the thickness of the set must be measured to ensure good book quality.
The paper size must be measured with an accuracy of 0.5 mm. To do so, a ruler and a magnifying
glass have been added to the bridge cover. The ruler has a scale of 0.5 mm to allow accurate
measurements. Use the magnifying glass to read the values easily.
The measured value must be entered in the paper size setting on the touch screen with an
accuracy of 0.5 mm. Because the paper size changes during the printing process, you have to
measure the size immediately after the paper exits the printer. Otherwise, book quality issues can
occur.
Paper and Book Quality Instructions
• Measure the size of the printed paper. The paper size changes during the printing process.
• Measure the set thickness as accurately as possible. Use the ruler and the magnifying glass on
the bridge cover.
• To get the best accuracy, use millimeters to measure the set (see
Enter the Job Settings
on
page 21).
• Enter accurate dimensions into the touchscreen.
• If the book is made from several different types of paper, make sure the different paper types
are all the same size.
See
Book Quality
on page 64 for further information.
Set thickness and Sheet thickness
To make a high quality finished book, the machine adjusts the length of the stich and the amount
of spine-form. The adjustment is done according to the set thickness. There are two operating
modes.
• Sheet thickness and page count
Default operating mode
• Measure the thickness of a single sheet.
Use the measuring tool supplied with the machine.
• Enter the value into the touch screen.
• The sheets are counted when they enter the machine. The settings are adjusted
automatically.
NOTE
Measure 10 sheets of paper. Divide the value by 10. If you use the same type of paper frequently,
record the value.
• Set thickness
• Measure the thickness of a complete set.
• Measure the set thickness as accurately as possible.
Quality instructions
18 Chapter 3 - How to run the Booklet maker
Use the measuring tool supplied with the machine.
• Enter the value into the touch screen.
Quality instructions
Chapter 3 - How to run the Booklet maker 19
Turn ON the Booklet maker
Procedure
1. Connect the Booklet maker to the power supply.
2. Use the ON/OFF switch to turn ON the Booklet maker.
Result
The machine makes this sequence of beeps:
'beep __ beep beep beep beep _____ beep __ beep'.
The touchscreen illuminates and the machine calibrates.
When READY is displayed on the screen, the machine is ready for use.
Turn ON the Booklet maker
20 Chapter 3 - How to run the Booklet maker
Enter the Job Settings
Introduction
Make the settings for a new job in the BASIC window on the touch screen. See the chapter
“The User Interface” for more information.
The PAPER SIZE and PAGE DIRECTION settings are entered on the touch screen. These
dimensions refer to the format of the paper when it enters the Booklet maker.
IMPORTANT
Do not operate the touch screen with a sharp object or with too much force. These actions can
damage the touch screen.
NOTE
The paper size must be measured with an accuracy of 0.5 mm.
Step Action Information
1 Print a set to the stack-
er.
2 Measure the sheet
size.
Measure the sheet
thickness or the set
thickness.
Measure the set accurately. To make an accurate book you
must enter accurate paper dimensions into the touch screen.
To get the best accuracy, use millimeters to measure the set.
If needed, set the Booklet maker to use millimeters:
• Touch MENU.
• Select Supervisor access level.
• Touch MENU > CONFIGURE > MACHINE OPTIONS.
• Touch mm > CLOSE.
3 Use these dimensions
for the job setting.
Procedure for a New Job
Step Action Information
1 Touch BASIC
2 Enter the paper size Touch PAPER SIZE. Enter the dimensions of the paper.
The job setting is easier if you first select a preset paper size,
then adjust the settings as necessary
Touch PAPER SIZE > PRESETS > A3 or A4. (USA: 11x17,
8.5x11 or 8.5x14)
3 Enter the page direc-
tion
Touch PAGE DIRECTION > LANDSCAPE or PORTRAIT.
If the PAGE DIRECTION option is not available, the PAGE DI-
RECTION cannot be changed.
4 Enter the page rota-
tion setting
For A4 paper size, the normal setting for ROTATE is ON. Rota-
tion lets the printer operate at optimum speed.
Touch ROTATE to turn the sheet rotation ON or OFF. Always
select the page direction before you change the rotate set-
ting. 4
Enter the Job Settings
Chapter 3 - How to run the Booklet maker 21
Step Action Information
5 Enter the sheet thick-
ness.
Or
Touch SET THICKNESS. Set AUTO to ON. Use '+' or '-' to en-
ter the SHEET THICKNESS.
Enter the set thick-
ness. See
Quality in-
structions
on page 18.
Touch SET THICKNESS. Set AUTO to OFF. Use '+' or '-' to en-
ter the SET THICKNESS.
6 Enter the number of
stitches.
Touch STITCHES and enter the number of stitches. If needed,
the stitch pitch can be changed. See "STITCH PITCH,"
Button
overview
on page 33
7 Enter the spine form
setting
The spine form setting is automatic, according to the SET
THICKNESS setting. If needed, the setting can be changed.
See "FORM" in
Button overview
on page 33
8 Enter the trim setting. The trim setting is automatic, according to the PAGE SIZE
and SET THICKNESS settings. To change the setting, touch
TRIM. See “TRIM” in
Button overview
on page 35
9 Touch CLOSE
If needed, save the job
settings to memory.
If the same job settings are used frequently, then save the job
settings to memory.
See
Load and Save the Job Settings
on page 42.
Procedure for a New Job
22 Chapter 3 - How to run the Booklet maker
Procedure for a Saved Job
Procedure
1. Touch LOAD & SAVE
2. Touch the job name or use the Up arrow or the Down arrow to select the job.
3. Touch LOAD.
4. Wait until the Booklet maker is ready.
Procedure for a Saved Job
Chapter 3 - How to run the Booklet maker 23
Adjust the Stacker and the optional Book Stacker
Adjust the Stacker
Adjust the stacker according to the size and thickness of the finished book (see
Adjust the Stacker
on page 53).
Adjust the optional Book Stacker
Check if the Book Stacker is ready to accept books (see
Adjust the Book Stacker
on page 56).
Adjust the Stacker and the optional Book Stacker
24 Chapter 3 - How to run the Booklet maker
Run the job
Procedure
1. Make sure the adjustments on the Booklet maker are complete before you release the print job
from the print queue.
2. Start the print job. The Booklet maker starts automatically.
3. Check the quality of the first book.
4. If the quality is not acceptable, make adjustments (see
Book Quality
on page 64).
Result
During the job
• Unload books from the Stacker before the Stacker is full. The Booklet maker displays no
message when the Stacker is full.
• Unload books from the optional Book Stacker (see
Unload the Book Stacker
on page 57). The
Booklet maker displays a message when the Stacker is full. The Booklet maker stops.
• Empty the trim bin from time to time. The Booklet maker displays a message when the trim bin
is full
Empty the Trim Bin
on page 51.
Run the job
Chapter 3 - How to run the Booklet maker 25
Run the job
26 Chapter 3 - How to run the Booklet maker
Chapter 4
The User Interface
The Touch Screen
Introduction
A
B
C
[6] The User Interface
ASTART Button
B STOP Button
C Touch Screen
The user interface includes a color touch screen and START/STOP buttons.
Operate the touch screen with your fingertip. You can touch the screen with a blunt item, for
example a palm-top 'wand' or the blunt end of a pen. Do not use too much force. A light touch is
all that is needed.
Power save
The touch screen has a power-save function. After several minutes without use, the brightness of
the touch screen decreases. After several hours, the touch screen turns off. Touch the screen to
restore the normal brightness. The touch screen takes two or three minutes to reach full
brightness.
If you hear a 'beep' when you operate the touch screen, the selected function is not available.
Some functions are not available when the machine is in operation.
Some functions and buttons are only available at certain access levels. See "ACCESS LEVEL"
The
MENU Window
on page 39.
IMPORTANT
Do not operate the touch screen with a sharp object or with too much force. These actions can
damage the touch screen.
The Touch Screen
28 Chapter 4 - The User Interface
Illustration
[7] The Touch Screen
Component - function table
No. Component Function
1 Window Tabs The touch screen buttons are divided into groups that
have related functions. Each group of buttons has a sep-
arate window. Touch the correct tab to select the win-
dow.
LOAD & SAVE
BASIC
ADVANCED
CONFIGURE
MENU
2 Window Buttons Each window contains a group of buttons. Touch the
button to select the function.
3 Message List Information and error messages are shown in the MES‐
SAGE LIST.
To display the information about a message, touch HELP
then touch the message list. Use the right-arrow and
left-arrow to see the help text for each message.
4 Job Mimic The job mimic shows the current machine settings.
5 Status The STATUS line shows the machine status.
- GREEN The Booklet maker is READY or RUNNING.
- ORANGE PLEASE WAIT - wait until the Booklet maker is ready.
ATTENTION - the Booklet maker needs intervention by
the operator.
- RED The Booklet maker is in an ERROR condition. 4
The Touch Screen
Chapter 4 - The User Interface 29
No. Component Function
6 Help Help text is available on the touch screen.
•Touch HELP then touch any button or tab on the
screen. Information about that button or tab is dis-
played.
• To display the information about a message, touch
HELP then touch the message list.
• Use the Up arrow and the Down arrow to scroll up
and down the screen.
• Some text has more than one screen. Use the right ar-
row and left arrow to see the other screens.
To leave the help text, touch HELP or touch X.
7Sheet Counter The sheet counter shows the number of sheets in the
gathering area. The counter starts again with each book.
8 Book Counter The book counter shows the number of books made.
The counter is reset to zero when the Booklet maker is
turned off.
The Touch Screen
30 Chapter 4 - The User Interface
The Job Mimic
Introduction
The job mimic shows the current machine status.
Illustration
[8] The Job Mimic
Component - function table
No. Icon Information
1 The following items are shown
• the size of paper
• the format of the paper in the gathering
area
• the broken line shows the fold line
• the small thick lines show the stitches
• the arrow shows the original feed edge
in the printer
2 Stitch Pitch The stitch pitch is shown only when a
non-standard setting is selected.
3 Sheet thickness
Or
The sheet thickness, in mm, is shown.
NOTE
The arrows show a single sheet.
Set thickness The set thickness, in mm, is shown.
NOTE
The arrows show the complete
set. 4
The Job Mimic
Chapter 4 - The User Interface 31
No. Icon Information
4 The number of forms is shown. If the
pressure is adjusted, the setting is shown
in brackets. A red X shows that the form
function is not active.
5 The trim setting is displayed. A red X
shows that the trim function is not active.
The Job Mimic
32 Chapter 4 - The User Interface
The BASIC Window
Introduction
The BASIC window gives you access to frequently-changed machine settings.
Button overview
The BASIC Window Buttons
Button Information
PAPER SIZE Measure the accurate size of the printed paper before you make a
book.
Touch PAPER SIZE to enter the paper size. When the machine is in
operation, you can adjust the PAPER SIZE by a maximum of +/- 1
mm.
- PAGE DIRECTION Touch PAGE DIRECTION to change the direction of the paper to
Landscape or Portrait.
- ROTATE Touch ROTATE to set the sheet rotation ON or OFF. If you select
A4 portrait (USA: 8.5x11), ROTATE is set to ON automatically.
- PRESETS Touch PRESET to select a standard paper size.
SET THICKNESS Use the SET THICKNESS window to define the thickness of the
set.
Measure the thickness of the set before you make a book. Touch
SET THICKNESS and enter the value.
Or
Use AUTO and SHEET THICKNESS to automatically calculate the
SET THICKNESS.
- AUTO Touch SET THICKNESS > AUTO to select automatic adjustment of
SET THICKNESS. Enter the SHEET THICKNESS.
The sheets are counted when they enter the machine. The SET
THICKNESS is calculated from the SHEET THICKNESS and the
sheet count.
- SHEET THICKNESS Use SHEET THICKNESS to enter the measured thickness of one
sheet of paper.
SHEET THICKNESS determines the maximum number of sheets
that is allowed. The maximum number is displayed on the screen.
STITCHES Touch STITCHES to select the number of stitches. Available op-
tions are 1 - 6. The machine automatically calculates the position
of the stitches according to the size of the paper. Select 0 to turn
off the stitch function.
-STITCH PITCH The stitch pitch is the space between the stitches. The machine au-
tomatically calculates the stitch pitch according to the size of the
paper.
If a non-standard stitch pitch is needed, use STITCH PITCH to
make the adjustment.
- AUTO Touch AUTO to select the default stitch pitch. 4
The BASIC Window
Chapter 4 - The User Interface 33
Button Information
FORM To make the square spine of the book, pressure is applied to the
spine. This process is called forming.
Touch FORM to specify the amount of spine form.
To make a good spine on different paper types, the amount of
spine form can be changed.
To change the amount of spine form:
•Touch NUMBER to change how many times the spine is pro-
cessed
•Touch PRESSURE to change the pressure
- AUTO Touch AUTO to select the optimum amount of spine form, accord-
ing to the set thickness.
- NUMBER Touch NUMBER to select how many times the form roller process-
es the spine. The available options are 1, 2, 3 or 4. An increase in
NUMBER increases the time taken to form the spine and can de-
crease the production rate for thin books. Alternatively, increase
the PRESSURE.
- PRESSURE Touch PRESSURE to increase or decrease the pressure used to
form the spine.
Touch + to increase the amount of spine form. Touch - to decrease
the amount of spine form. The range is -9 to +9. The default set-
ting is 0.
- THRESHOLD Use THRESHOLD to choose whether a square spine is formed.
If the SET THICKNESS value is thinner than the THRESHOLD val-
ue, a square spine is not formed.
If the SET THICKNESS value is thicker than the THRESHOLD value,
a square spine is formed.
If the SET THICKNESS value is 1.5 mm or thicker, a square spine is
always formed.
The default value is 0.8 mm. The allowed range is 0.1 mm to 1.5
mm
TRIM The trim dimension is calculated automatically according to the
PAPER SIZE and SET THICKNESS.
If needed, the trim dimension can be changed. Touch TRIM to ad-
just the size of the finished book after the fore-edge is trimmed.
The maximum trim is 28 mm. The trim function can be turned off.
- AUTO Touch AUTO to select the default trim position.
The BASIC Window
34 Chapter 4 - The User Interface
The LOAD & SAVE Window
Introduction
The LOAD & SAVE window lets you save and reload job settings. Each job is given a name.
The jobs are displayed in a list on the screen. Touch the job name or use the Up arrow or Down
arrow to make the selection.
Button overview
The LOAD & SAVE Window Buttons
Button Information
SAVE Touch SAVE to save the current settings. An on-screen keyboard
is displayed. Enter the job name. Touch OK or CLOSE. The new
job appears in the list of saved jobs. You can reload a saved job to
decrease set-up time in the future.
- REPLACE If you change the settings of a saved job, touch REPLACE to save
the new settings.
- CANCEL Touch CANCEL if you do not need to save a job that you have
changed.
- SAVE NEW If you change the settings of a saved job, touch SAVE NEW to
save the new settings as a new job. An on-screen keyboard is dis-
played. Enter the new job name. Touch OK or CLOSE. The original
job is not changed. If the job name is not changed before OK or
CLOSE is touched, the job will be saved with the current name fol-
lowed by an asterisk *.
JOB DETAILS JOB DETAILS shows the settings for each saved job. Select the job
that you need to view from the job list. Touch JOB DETAILS to see
a summary of the job settings.
LOAD Touch the job name or use the Up arrow or the Down arrow to
make the selection. Touch the LOAD button
PADLOCK SYMBOL The padlock symbol shows when a saved job is locked or un-
locked. There is a small padlock symbol next to each locked job.
To lock or unlock a job.
1. select the job from the job list
2. touch the large key symbol.
A padlock symbol displayed in light grey shows that a job has
been locked by a supervisor to prevent changes to the settings
DELETE To delete a particular job it must be unlocked. Touch the job name
or use the Up arrow or Down arrow to make the selection from the
job list. Touch and hold DELETE. A red line appears. The red line
fills from left to right. Hold DELETE until the red line reaches the
right-hand side.
VIEW OF JOB LIST VIEW OF JOB LIST changes the order that saved jobs are listed.
There is a line between Factory Template jobs and jobs saved by
the operator. The Factory Template jobs are at the top of the list
- A->Z Touch A->Z to list the jobs in alphabetical order. 4
The LOAD & SAVE Window
Chapter 4 - The User Interface 35
Button Information
- BY USE Touch BY USE to list jobs in the order they were last used. The
most recently-run job is at the top of the list.
- BY INDEX Touch BY INDEX to list jobs in numerical order. the machine gives
a number to all jobs that are saved.
The LOAD & SAVE Window
36 Chapter 4 - The User Interface
The ADVANCED Window
Introduction
The ADVANCED window gives you access to special machine functions.
Button overview
Button Information
RE-REF If the machine calibration appears incorrect or if an 'axis moving'
error message remains on the screen, touch RE-REF to re-refer-
ence the adjustment axes. The adjustment axes return to the cur-
rent settings. At intervals, the machine will re-reference the axes
during the set-up procedure.
STITCHER UP Touch STITCHER UP before you lubricate the stitch head. This ac-
tion moves the stitch head to the correct position for lubrication.
PURGE SET If the print job has been canceled, a set or part of a set can remain
in the gathering area. Touch START , then touch PURGE SET to
clear the set from the machine. The book is not stitched or trim-
med
According to the type of error that occurred, there can be a pause
of 7 seconds before the PURGE SET button will operate.
For safety reasons, this function is disabled when the gathering
area cover is open.
- MAKE BOOK If there is a set in the gathering area, you can make the set into a
book.
NOTE
Do not use this option if SET THICKNESS is set to AUTO.
Touch START then touch MAKE BOOK to clear the set from the
machine. The book is not stitched or trimmed.
According to the type of error that occurred, there can be a pause
of 7 seconds before the MAKE BOOK button will operate.
For safety reasons, this function is disabled when the gathering
area cover is open.
The ADVANCED Window
Chapter 4 - The User Interface 37
The CONFIGURE Window
Introduction
The CONFIGURE window lets you make changes to the configuration of the machine.
Some functions and buttons are only available at certain access levels, see 'ACCESS LEVEL'
Button overview
on page 39.
CONFIGURE Window Buttons
Button overview
Button Information Operator Supervisor
MACHINE OP‐
TIONS
Touch MACHINE OPTIONS to view
the general machine setup. Some of
the settings can be changed, depend-
ing on the current access level.
Hidden Active
- MEASURE-
MENT
Select 'mm' or 'inch' as the unit of
measurement.
Hidden Active
- STITCH SEN-
SOR
There is a sensor that checks for
stitches. Touch STITCH SENSOR to
turn the stitch sensor on or off. The
default setting is ON.
Hidden Active
- PRESET PAPER
SIZES
The preset paper sizes can be either
ISO A sizes or US paper sizes. To se-
lect which preset paper sizes are
available, touch the relevant button.
Hidden Active
- PBS INSTALLED Touch BOOK STACKER to switch off
communication to the Book Stacker.
Only if the Book Stacker is discon-
nected.
Hidden Active
SHUTTLE Touch SHUTTLE to make adjust-
ments to the tamper.
Hidden Active
-TAMPER DELAY This button is used by the service en-
gineer.
Hidden Visible
- TAMPER TIME TAMPER TIME adjusts the time that
the tamper touches the set.
An increase in TAMPER TIME causes
a decrease in the production rate for
thin books.
Hidden Active
FORM SETUP This button is used by the service en-
gineer.
Visible Visible
The CONFIGURE Window
38 Chapter 4 - The User Interface
The MENU Window
Introduction
MENU shows the settings that are not changed during day-to-day operation.
These settings include
• Change the Access Level
• Change the display language
• Advanced machine settings that are accessed by a person who has the correct access-code.
Button overview
The MENU Window Buttons
Button Information
ACCESS LEVEL The Touch Screen has five different access levels
• Operator
• Supervisor
• Service
• Distributor
• Factory
Touch ACCESS LEVEL and select the correct level from the list.
The last three levels are protected by access codes. To protect the
job settings, the supervisor level allows jobs to be locked.
CURRENT LANGUAGE Touch one of the flags to select the language you need.
AXES Touch AXES to re-reference individual axes. Supervisor access
level is needed for this function.
Other functions on this button are used by the service engineer.
BRIDGE Touch BRIDGE to re-reference the bridge axes. Supervisor access
level is needed for this function.
Other functions on this button are used by the service engineer.
SERVICE OPTIONS This button is used by the service engineer.
TEST This button is used by the service engineer.
COUNTERS The counters display the
• number of books that have been made
• number of sheets that have been processed
• number of stitches that have been used
-RESET Touch RESET to reset the book, sheet and stitch counter. Use RE‐
SET after operator maintenance to the stitch head.
Touch and hold RESET. A red line appears. The red line fills from
left to right. Hold RESET until the red line reaches the right-hand
side.
The MENU Window
Chapter 4 - The User Interface 39
The MENU Window
40 Chapter 4 - The User Interface
Chapter 5
Standard Tasks
Introduction
This chapter describes the standard tasks that are needed in the day-to-day operation of your
Booklet maker.
Load and Save the Job Settings
Introduction
The current job settings can be saved to memory and reloaded for use again at a later date. Load
the 'Default Job Template' to reset the Booklet maker to normal settings.
Save a job
1. Touch LOAD & SAVE > SAVE.
2. If these options appear, select one.
•REPLACE to over-write the previous job with the current job settings.
•SAVE NEW to save the current job with a new name.
•CANCEL to cancel the job save.
3. Enter the name for the job on the keyboard.
4. Touch OK or CLOSE.
Load a job
1. Touch LOAD & SAVE .
2. Touch the job name or use the Up arrow or the Down arrow to select the job.
3. Touch LOAD.
4. Wait until the Booklet maker has made the adjustments.
Reset the Booklet maker to default settings
1. Touch LOAD & SAVE .
2. Select the Default Job Template from the list of jobs.
3. Touch LOAD.
4. Touch YES.
Load and Save the Job Settings
42 Chapter 5 - Standard Tasks
Adjust the Stitch Pitch
Introduction
The stitch pitch is the space between the stitches. The machine automatically calculates the stitch
pitch according to the size of the paper and the number of stitches. The stitches are inserted
symmetrically on the spine of the book.
If a non-standard stitch pitch is needed, use STITCH PITCH to make the adjustment.
AA B
A = Stitch Pitch
[9] Stitch Pitch
Limitations:
• The minimum stitch pitch 'A' is 25 mm.
• The minimum distance from the center of the stitch to the edge of the sheet 'B' is 15 mm.
When to do
If you need the Booklet maker to insert the stitches in a non-standard position. For example, to
keep the stitches away from the text on the spine of the book.
Select a non-standard stitch pitch
1. Touch BASIC > STITCHES.
2. Touch AUTO. The STITCH PITCH value becomes green.
3. Change the stitch pitch value. Either use the "+" and "-" or touch the green stitch pitch value to
open a numeric keypad.
4. Touch STITCHES to close the window.
The stitch pitch value is displayed in the job mimic and on the STITCHES button.
Select a standard stitch pitch
1. Touch BASIC > STITCHES.
2. Touch AUTO to select ON.
3. Touch STITCHES to close the window.
The stitch pitch value is not displayed in the job mimic or on the STITCHES button.
Adjust the Stitch Pitch
Chapter 5 - Standard Tasks 43
Open the Connecting Bridge Cover
Introduction
The Booklet maker will not stop if you open the connecting bridge cover.
A
[10] Connecting Bridge Cover in the open position.
AConnecting Bridge Cover
When to do
If a machine error occurs, or for maintenance.
• To clear a paper jam
CAUTION
Keep your hands, clothing and hair away from the belts.
Procedure
1. Lift the connecting bridge cover.
Open the Connecting Bridge Cover
44 Chapter 5 - Standard Tasks
Open and Close the Folder Cover
Introduction
[11] Unlock and lock the Folder Cover.
Open the Folder Cover
If a machine error occurs, or for maintenance.
• To access the stitch area
• To access the folder area
NOTE
The folder cover has an interlock switch. The Booklet maker stops if you open the folder cover.
1. Lift the black locking handle against the spring pressure.
2. Turn the handle through 90° to unlock.
3. Lift the folder cover carefully to the vertical position.
Close the Folder Cover
CAUTION
Check that the folder cover will not hit the clincher frame locking handle when you close the
folder cover. If necessary, lift and rotate the clincher frame locking-handle to a new position
Lift
and Lower the Clincher Frame
on page 46.
1. Lower the folder cover.
2. Turn the handle through 90° to lock.
3. Close the locking handle to lock the folder cover.
Open and Close the Folder Cover
Chapter 5 - Standard Tasks 45
Lift and Lower the Clincher Frame
Introduction
A
B
[12] Folder Cover in the vertical position.
AFolder Cover
B Clincher Frame
A
B
C
[13] Clincher Frame Components
AClincher
B Locking Handle
C Clincher Frame
When to do
If a machine error occurs, or for maintenance.
• To clear a paper jam in the stitch area
• To unlock the Booklet maker main deck
Lift the Clincher Frame
1. Open the folder cover.
2. Turn the locking handle to the left , until the thread is disengaged.
Lift and Lower the Clincher Frame
46 Chapter 5 - Standard Tasks
3. Lift the clincher frame to the vertical position.
Lower the Clincher Frame
1. Lower the clincher frame.
2. Turn the locking handle to the right , until the handle is tight.
3. Check that the locking handle will not be hit by the folder cover when you close the folder
cover. The locking handle should point towards the middle of the machine. If necessary, lift
and rotate the locking handle to a new position.
Lift and Lower the Clincher Frame
Chapter 5 - Standard Tasks 47
Open the Gathering Area Cover
Introduction
A
B
C
[14] Gathering Area Cover.
AConnecting Bridge Cover open
B Gathering Area Cover
C Gathering Area Cover Handle
When to do
If a machine error occurs, or for maintenance.
• To access the gathering area
The Booklet maker will stop if you open the gathering area cover.
Procedure
1. Open the connecting bridge cover.
2. Use the gathering area cover handle to lift the gathering area cover.
Open the Gathering Area Cover
48 Chapter 5 - Standard Tasks
Lift the Booklet maker Main Deck
Introduction
A
B
C
E
D
[15] Lift the Booklet maker Main Deck
AFolder Cover open
B Connecting Bridge Cover open
C Clincher Frame lifted
D Gathering Area Cover
E Main Deck
When to do
If a machine error occurs, or for maintenance.
• To access the stitch head
• To access the former area
• To access the trim area
Check the touchscreen for the error message FOLD BLADE NOT PARKED.
If the error message is displayed: Open the folder cover, remove any paper, close the fold-
er cover. Touch START , then follow the instructions on
the screen.
Wait for the message to clear. Then continue with the
procedure below.
If the error message is not displayed: Continue with the procedure below.
CAUTION
Keep your hands and fingers clear when you lift the main deck.
IMPORTANT
Do not lift the main deck if the error message FOLD BLADE NOT PARKED is shown on the
screen.
Lift the Booklet maker Main Deck
Chapter 5 - Standard Tasks 49
Step Action Information
1 Open the connecting bridge cover.
Open the Connecting Bridge Cover
on
page 44
2 Open the folder cover.
Open the Connecting Bridge Cover
on
page 44
3 Lift the clincher frame.
Lift the Clincher Frame
on page 46
4 Open the gathering area cover.
Lift the Clincher Frame
on page 46
5 Lift the Booklet maker main deck. The main deck lifts to approximately 60.
The weight of the main deck is suppor-
ted by a gas strut. Let the gas strut con-
trol the movement of the main deck.
Lift the Booklet maker Main Deck
50 Chapter 5 - Standard Tasks
Empty the Trim Bin
Introduction
A
B
[16] Trim Bin Open.
ATrim Bin Side Handle
B Trim Bin open
NOTE
The Booklet maker operates with the trim bin removed for a short period of time. The printer
waits while the trim bin is removed, then continues when the trim bin is replaced. To prevent
lost production, you must remove, empty, and return the trim bin to the Booklet maker as
quickly as possible.
When to do
• An error message is displayed on the touch screen when the trim bin is full.
• You can empty the trim bin when you choose. For example, before you start a print job.
Procedure
1. Use the handle to open the trim bin.
2. Use the side handles to lift and remove the trim bin.
3. Empty the trim bin
4. Fit the bottom of the trim bin over the mounting rail.
5. Push the trim bin closed at the top.
Empty the Trim Bin
Chapter 5 - Standard Tasks 51
Open the Stitch Wire Cabinet
Introduction
A
[17] Stitch Wire Cabinet.
AStitch wire cabinet open
When to do
• To see if the stitch wire is jammed or finished. An error message is displayed on the touch
screen when the stitch wire is jammed or finished.
• To install a new stitch wire spool.
Install New Stitch Wire
on page 123.
Procedure
1. Open the stitch wire cabinet cover. The cover is held closed by a magnetic catch.
Open the Stitch Wire Cabinet
52 Chapter 5 - Standard Tasks
Adjust the Stacker
Introduction
The collection table must be in the correct position for the stacker to operate. The position of the
collection table depends on the finished size of the job.
• When you start a new job
• If the books do not stack correctly
C
B
A
2
1
[18] The Stacker
ACatch tray adjustment
B Collection table
C Catch tray
A
C
D
B
[19] Collection table position
ABook size in window
B Collection table
C Orange plastic hand screw 4
Adjust the Stacker
Chapter 5 - Standard Tasks 53
D Catch tray
Step Action Information
1 Set the catch tray angle according to the
thickness of the book.
For books that are 1.5 mm thick or less,
use position 1.
For books that are more than 1.5 mm
thick, use position 2.
2 Set the collection table position accord-
ing to the size of the book.
Read the settings through the window.
These settings are recommendations. The settings can change with the size, thickness, and
material of book. Make further adjustments if necessary.
Adjust the Stacker
54 Chapter 5 - Standard Tasks
Operate the Booklet maker offline
Introduction
You can hand feed sets into the Booklet maker if offline operation is needed. The machine
operates when you push the two buttons.
When to do
• To check the settings are correct
• To make a small number of books offline
IMPORTANT
Do not put your hands in the gathering area while the machine is in operation. Use two hands to
push the buttons. For safety reasons, this task is for a single operator. Do not allow another
person to help you.
NOTE
Do not use this function when SET THICKNESS is set to AUTO. The SET THICKNESS must be the
correct setting for the book.
Procedure
1. Enter the correct settings on the touch screen, according to the size and thickness of the job.
2. Touch START
3. Open the connecting bridge cover.
4. Open the gathering area cover.
5. Put the set in the gathering area with the middle pages of the book face up.
6. Press the two buttons and hold for 9 seconds or until you hear the folder operate. The time
interval changes according to the number of stitches.
Operate the Booklet maker offline
Chapter 5 - Standard Tasks 55
Standard Tasks of the optional Book Stacker
This section describes the standard tasks that are needed in the day-to-day operation of your
Book Stacker.
Adjust the Book Stacker
[20] Push the book support to the left
A
[21] The magnetic paper guide for thin books
AMagnetic paper guide
Procedure
1. Before you use the Book Stacker, make sure the book support is pushed completely to the left.
There is no need to empty the Book Stacker until the stacker is full.
2. If you are making thin books, attach the magnetic paper guide above the book outfeed on the Océ
BLM550+. Insert the loose end of the magnetic paper guide into the slot opposite.
Standard Tasks of the optional Book Stacker
56 Chapter 5 - Standard Tasks
Unload the Book Stacker
Introduction
A
B
[22] The book divider
AGuide rail
B Book divider
Procedure
1. If required, insert the book divider so that the stack does not slip while you unload the books.
2. Remove the books.
3. Push the book support completely to the left (see
Adjust the Book Stacker
on page 56).
4. Remove the book divider until it is needed. Store the book divider on the right-hand end of the
guide rail of the stacker.
Unload the Book Stacker
Chapter 5 - Standard Tasks 57
Move the Book Stacker
Introduction
The Book Stacker locks in position onto the Booklet Maker. A foot pedal releases the docking
latch.
[23] Docking latch of the Book Stacker
When to do
• Access the mains ON/OFF switch.
• Replace the mains input fuses.
Procedure
1. Use your foot to release the docking latch.
2. Rotate the Book Stacker away from the Booklet Maker as far as the safety chain allows.
The safety chain prevents damage to the power and communication cables.
3. When you completed your action, rotate the Bock Stacker to the docked position. The latch clicks
when closed.
Move the Book Stacker
58 Chapter 5 - Standard Tasks
Chapter 6
Error Conditions, Problems and
Solutions
Introduction
This chapter describes how to correct problems that can occur with your Booklet maker. If a
problem persists, contact your service engineer.
Clear a Printer Error
Introduction
If a paper jam or other error occurs in the printer, the printer and the Booklet maker stop.
Procedure
1. Clear the printer error.
2. Follow the instructions on the printer. If the printer tells you to remove paper from the Booklet
maker, press START to start the machine.
3. Then touch ADVANCED > PURGE SET > PURGE SET.
4. The partial book is delivered to the stacker.
5. Discard the book.
6. Check the Océ BLM550+ screen. If an error message is displayed, take the corresponding action
(see
Error Messages
on page 76).
Clear a Printer Error
60 Chapter 6 - Error Conditions, Problems and Solutions
Clear a Booklet maker error
Introduction
If a paper jam or other error occurs in the Booklet maker, the printer and the Booklet maker stop.
The type of error is displayed on the touch screen
Error Messages
on page 76.
Procedure
1. Clear the error. The error message on the touch screen tells you about the error.
2. Remove all sheets from the Booklet maker.
3. Follow the instructions on the printer.
Clear a Booklet maker error
Chapter 6 - Error Conditions, Problems and Solutions 61
General Problems
The Booklet maker does not start
Is the touchscreen illuminated?
No Yes
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
V
Are error messages displayed on the touchscreen?
No Yes
¦
¦
V
See
Error Messages
on
page 76
Is there an error message on the printer?
No Yes
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
V
Correct the printer error. If the
printer error message is
‘Check Third Party Finishing
Device’ or ‘check custom’,
then check for an error mes-
sage on the Booklet maker
touchscreen. If the problem
continues, then call your serv-
ice engineer.
Turn OFF and turn ON the PSQ.
If the problem continues, then call your service engineer.
Is the touchscreen in power-save mode (see
The Touch Screen
on page 28)?
Touch the screen to restore the normal brightness.
No Yes
¦
V
Go back to the start of this fault-finding table.
Is the mains power ON/OFF switch illuminated?
No Yes
¦
V
Call your service engineer.
Is the Booklet maker turned ON and connected to the mains power supply of the correct type
and voltage?
No Yes
¦
¦
¦
V
Replace the fuse at the mains input (see
Change the Fuses
on
page 101). If the problem continues, then call your service en-
gineer.
Connect the Booklet maker to the mains supply of the correct type and voltage and then turn
the machine ON.
General Problems
62 Chapter 6 - Error Conditions, Problems and Solutions
The touchscreen does not work
Is the touchscreen in power-save mode (see
The Touch Screen
on page 28)?
Touch the screen to restore the normal brightness.
No Yes
¦
V
No further action is needed.
Calibrate the touchscreen (see
Calibrate the Touch Screen
on page 100).
General Problems
Chapter 6 - Error Conditions, Problems and Solutions 63
Book Quality
Paper Size and Book Quality Instructions
• Careful measurement of the paper size and the set or sheet thickness is important.
• To make an accurate book you must enter accurate paper dimensions into the touch screen.
• To get best accuracy, use millimeters to measure the set (see
Enter the Job Settings
on
page 21).
• Measure the size of the printed paper. The paper dimension changes when the paper is
printed.
• If the book is made from several different types of paper, make sure the different paper types
are all the same size. If the size of the paper is different, an accurate book cannot be made.
• The paper must be cut accurately. If the sheets are not cut squarely, an accurate book cannot
be made.
•Adjustments to the FORM settings can be necessary for some types of paper.
Machine Adjustments
Machine adjustments can be made while the machine is in operation.
The PAPER SIZE adjustment is limited to a maximum of +/- 1 mm when the machine is in
operation.
Untidy book problem
• The finished book is not tidy.
• The sheets are not aligned.
• The book is not folded squarely.
Are the covers of the books and the insides of the books made from the same paper weight and
paper type?
Yes No
¦
¦
¦
¦
¦
¦
¦
V
Accurately measure the different papers. Are the different
types of paper exactly the same size?
Yes No
¦
¦
¦
V
You must use paper that is the
same size.
Is the paper within specification (see
Specifications
on page 132)?
Yes No
¦
¦
V
Do not use paper that is outside the specification.
Have you accurately measured the paper-size after printing?
Yes No 4
Book Quality
64 Chapter 6 - Error Conditions, Problems and Solutions
¦
¦
¦
¦
V
Print a sample to the stacker and measure the printed paper.
Accurate measurement will improve book quality.
Have you entered the measured PAPER SIZE into the touchscreen?
Yes No
¦
¦
¦
V
Enter the correct, measured PAPER SIZE into the touchscreen.
Have you accurately measured the set thickness or the sheet thickness?
Yes No
¦
¦
¦
V
Measure the set thickness or the sheet thickness and enter the
correct SET THICKNESS or SHEET THICKNESS into the touch
screen.
Have you entered the measured set thickness or sheet thickness into the touch screen?
Yes No
¦
¦
V
Enter the correct SET THICKNESS or SHEET THICKNESS into
the touch screen.
Touch ADVANCED > RE-REF > RE-REF to re-reference the machine.
Does the problem persist?
Yes No
¦
¦
V
No further action is required.
Is the paper thin and/or curly?
Yes No
¦
¦
V
Call your service engineer.
Increase the TAMPER TIME to give the paper more time to settle. Supervisor access level is nee-
ded (see
The MENU Window
on page 39). This may reduce the production speed for thin books.
Press CONFIGURE > SHUTTLE. Increase the TAMPER TIME in increments of 200.
Does the problem persist?
Yes No
¦
¦
V
No further action is required.
Call your service engineer.
Book Quality
Chapter 6 - Error Conditions, Problems and Solutions 65
Spine form problems
Correct spine form Incorrect spine form.
The square spine is part
formed or not formed.
Incorrect spine form.
The spine is over-formed and
the book is damaged.
Is the spine form different at each end of the spine?
Yes No
¦
¦
¦
¦
¦
¦
¦
V
The spine is incorrect along the full length. Is the folder cover closed
fully?
Yes No
¦
¦
¦
V
Lock the folder cover (see
Close the Folder
Cover
on page 45).
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
V
Is the SET THICKNESS or the SHEET THICKNESS correct?
Yes No
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
V
Measure the SET THICKNESS or the SHEET
THICKNESS and enter the value in the touch
screen. Does the problem persist?
Yes No
¦
¦
V
No further action is re-
quired.
Check the THRESHOLD setting. If the SET
THICKNESS is less than the THRESHOLD, a
square spine is not formed (see
The BASIC
Window
on page 33). Adjust THRESHOLD if
needed.
Does the problem persist?
Yes No
¦
¦
V
No further action is re-
quired.
¦
¦
¦
¦
¦
¦
¦
V
Adjust the PRESSURE setting. Increase the PRESSURE to give more
spine form and decrease the PRESSURE to give less spine form. Does
the problem persist?
Yes No
¦
¦
V
No further action is required.
4
Book Quality
66 Chapter 6 - Error Conditions, Problems and Solutions
¦
¦
¦
¦
¦
¦
¦
¦
V
Adjust the NUMBER of forms setting. Increase the NUMBER of forms to
create more spine form and decrease the NUMBER of forms to create
less spine form.
Does the problem persist?
Yes No
¦
¦
V
No further action is required.
¦
¦
¦
¦
¦
¦
¦
¦
V
Load a Default Job. This will reset the FORM settings, including PRES‐
SURE, NUMBER and THRESHOLD (see
Reset the Booklet maker to de-
fault settings
on page 42).
Does the problem persist?
Yes No
¦
¦
V
No further action is required.
¦
¦
¦
¦
¦
¦
¦
¦
¦
V
Run a standard job using paper of 80 g/m² (20 lb bond).
Does the problem persist?
Yes No
¦
¦
¦
¦
¦
V
The problem is caused by the cover material or
the finish on the cover. Change the cover ma-
terial.
¦
¦
¦
¦
¦
¦
¦
V
Re-reference the machine. Touch ADVANCED > RE-REF > RE-REF to re-
reference the machine.
Does the problem persist?
Yes No
¦
¦
V
No further action is required.
Call your service engineer.
Book Quality
Chapter 6 - Error Conditions, Problems and Solutions 67
Stitching problems - the book is not stitched
C
A
B
[24] Pulling stitch-wire
AStitch-wire cabinet
B Stitch-wire
C Accessory bag
B
D
C
A
[25] Stitch-wire jam
AMiddle wire-tube
B Large feed gear
C Stitch-wire jam
D Small feed gear
Is the number of STITCHES set between 1 and 6?
Yes No
¦
¦
V
Select STITCHES 1 - 6 (see
The BASIC Window
on page 33).
Check the stitch-wire spool. Is there stitch-wire present?
Yes No 4
Book Quality
68 Chapter 6 - Error Conditions, Problems and Solutions
¦
¦
V
Load a new stitch-wire spool (see
Install New
Stitch Wire
on page 123).
Open the PSQ main deck (see
Lift the Booklet maker Main Deck
on page 49).
Pull approximately 100 mm -150 mm of stitch-wire from the stitch wire spool.
Does the wire move freely?
Yes No
¦
¦
¦
¦
V
Open the stitch-wire cabinet. Discard any tan-
gled wire and reload the stitch-wire spool (see
Install New Stitch Wire
on page 123).
Check the stitch head for stitch-wire jams.
Is the stitch head clear of stitch-wire jams?
Yes No
¦
¦
V
Clear the stitch-wire jam (see
Clear a Stitch-
wire Jam
on page 95).
Lubricate the stitch head (see
Lubricate the Stitch Head
on page 118).
Does the problem persist?
Yes No
¦
¦
V
No further action is required.
Call your service engineer
Stitching problems - the book is badly stitched
A correctly formed stitch:
• has equal leg length
• has straight legs
• the distance between the ends of the stitch legs is approximately 1 mm, the distance can vary
by +/- 0.5 mm
• has a flat crown.
Is the stitch formed correctly?
Yes No
¦
¦
V
Call your service engineer
The stitches should be aligned centrally on the spine.
Are the stitches positioned correctly?
Yes No 4
Book Quality
Chapter 6 - Error Conditions, Problems and Solutions 69
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
V
Are the covers of the books and the insides of the books made from the
same paper weight and paper type?
Yes No
¦
¦
¦
¦
¦
¦
¦
¦
V
Accurately measure the different papers. Are
the different types of paper exactly the same
size?
Yes No
¦
¦
¦
V
You must use paper
that is the same size.
¦
¦
¦
¦
¦
¦
V
Is the paper within specification (see
Specifications
on page 132)?
Yes No
¦
¦
V
Do not use paper that is outside the specifica-
tion.
¦
¦
¦
¦
¦
¦
V
Have you accurately measured the paper size after printing?
Yes No
¦
¦
¦
V
Print a sample to the stacker and measure the
printed paper. Accurate measurement will im-
prove the book quality.
¦
¦
¦
¦
¦
¦
V
Have you entered the measured PAPER SIZE into the touchscreen?
Yes No
¦
¦
V
Enter the correct, measured PAPER SIZE into
the touchscreen.
¦
¦
¦
¦
¦
¦
¦
¦
¦
V
Touch ADVANCED > RE-REF > RE-REF to re-reference the machine.
Does the problem persist?
Yes No
¦
¦
V
No further action is required.
Call your service engineer
No further action is required.
Trimming problem - the book is not trimmed
Is the TRIM option turned off?
No Yes 4
Book Quality
70 Chapter 6 - Error Conditions, Problems and Solutions
¦
¦
V
Turn on the TRIM option.
Is AUTO turned off in the TRIM window?
No Yes
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
V
Set TRIM to AUTO.
Does the problem persist?
Yes No
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
V
No further action is required.
If you need to use a custom
trim size, enter the trim di-
mension in the TRIM window.
Make sure the size is not larg-
er than the book size, or the
book will not be trimmed.
Touch ADVANCED > RE-REF > RE-REF to re-reference the machine.
Does the problem persist?
Yes No
¦
¦
V
No further action is required.
Call your service engineer.
Trimming problem - the book is not trimmed to the correct size
Is TRIM turned on?
Yes No
¦
¦
V
Turn on the TRIM.
Make sure the size is not larger than the book size, or the book will not be trimmed.
Is the correct trim size entered in the touchscreen?
Yes No
¦
¦
V
Enter the correct size in the touchscreen.
Re-reference the machine.
Touch ADVANCED > RE-REF > RE-REF to re-reference the machine.
Does the problem persist?
Yes No 4
Book Quality
Chapter 6 - Error Conditions, Problems and Solutions 71
¦
¦
V
No further action is required.
Call your service engineer.
Trimming problem - the book is not trimmed square
Open the trim stop guard and check for paper trimmings (see
Clear paper from the trim stop
on
page 129).
Is the trim stop clear of paper trimmings?
Yes No
¦
¦
¦
¦
¦
¦
V
Clear paper from the trim stop.
Does the problem persist?
Yes No
¦
¦
V
No further action is needed.
Call your service engineer.
Trimming problem - poor trim quality
The trim process uses a double-edge blade to cut thick books. This can leave a small mark in the
center of the trimmed edge. The visibility of this mark will depend on the paper quality and
characteristics.
[26] Blade witness mark in the center of the book
[27] Blade damage mark
Are there marks on the trimmed edge other than the blade witness mark? 4
Book Quality
72 Chapter 6 - Error Conditions, Problems and Solutions
No Yes
¦
¦
V
Call your service engineer.
No further action is needed.
Dirty marks on book
Are there dirty marks on the spine?
Marks on the spine
No Yes
¦
¦
¦
¦
V
Clean the former roller (see
Clean the Former
Roller
on page 112).
Are there grease or oil spots on the spine of
the book?
Grease marks near the stitches
No Yes
¦
¦
¦
¦
V
Clean grease from the top of the stitch head
(see
Clean excess grease from the Stitch Head
on page 117).
Are there dirty marks on the cover of the book
near to the spine?
Marks beside the spine
No Yes
¦
¦
¦
¦
V
Clean the polyurethane form strips (see
Clean
the Polyurethane Strips in the Form Clamp
on
page 113).
4
Book Quality
Chapter 6 - Error Conditions, Problems and Solutions 73
Are there curved dirty marks on either the
front or rear cover of the book?
Curved marks on the book
No Yes
¦
¦
¦
¦
V
Clean the trimmings removal fingers (see
Clean the Trimmings Removal Fingers
on
page 115).
Print a sample to the printer stacker. Is the printer the cause of the dirty marks?
No Yes
¦
V
Printer service is required.
Call your service engineer.
Damaged book
A
[28] Normal witness mark (A) left by the form clamp during spine forming
Are there damage marks on the cover of the book near to the spine, from the form clamp, that
are worse than the normal witness mark?
No Yes
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
V
Run a standard job using paper of 80 g/m² (20 lb bond).
Does the problem persist?
Yes No
¦
¦
¦
¦
V
The problem is caused by the
cover material or the finish.
Change the cover material.
Call your service engineer.
Is the spine torn or creased?
No Yes
¦
¦
V
The spine is over-formed (see
Spine form problems
on
page 66).
4
Book Quality
74 Chapter 6 - Error Conditions, Problems and Solutions
Is there damage to the spine at the stitch positions or is the cover falling off?
No Yes
¦
¦
¦
¦
¦
¦
¦
¦
¦
¦
V
Run a standard job using paper of 80 g/m² (20 lb bond).
Does the problem persist?
Yes No
¦
¦
¦
¦
V
The problem is caused by the
cover material or the finish.
Change the cover material.
Call your service engineer.
Print a sample to the printer stacker and inspect the pages.
Is the printer the cause of the damage?
No Yes
¦
¦
V
Printer service is required.
Call your service engineer.
Book Quality
Chapter 6 - Error Conditions, Problems and Solutions 75
Error Messages
Message list
Information and error messages are shown in the message list.
The error messages are shown in order of priority.
Follow the action needed for the messages, starting with the message at the top of the list.
To display the information about a message:
•Touch HELP then touch the message list.
• Use the right-arrow and left-arrow to see the help text for each message.
Problem Cause Solution
AXES MOVING Some of the machine axes are
moving. This message clears
when the adjustment is com-
plete.
If the message does not clear,
touch ADVANCED > RE REF
BOOK CYCLE TIME TOO
LONG
The printer has delivered the
sets faster than the books can
be made. To decrease the
book cycle time, adjust the
machine settings:
• decrease the number of
FORMS
• decrease the number of
STITCHES
• decrease the TAMPER TIME
• touch STOP to clear the
message from the screen
BOOK DELIVERY TOO FAST Books are being delivered to
the stacker too quickly. This
error can occur when you in-
sert books into the stacker by
hand. Press the reset button
on the stacker. If the problem
continues, then call your serv-
ice engineer.
Bridge axis moving The bridge axis is moving.
This message clears when the
adjustment is complete.
If the message does not clear,
touch ADVANCED > RE REF.
BRIDGE INFEED COVER OPEN The bridge infeed cover is
open.
The machine will not operate
until the cover is closed.
See
Clear Paper Jams
on
page 85
4
Error Messages
76 Chapter 6 - Error Conditions, Problems and Solutions
Problem Cause Solution
BRIDGE MOTOR STALL Check for a paper jam in the
connecting bridge.
• Touch STOP to stop the
Booklet maker.
• Clear the paper jam.
• Touch STOP to clear the
message from the screen.
• Continue the print job.
See
Clear Paper Jams
on
page 85
BRIDGE - No comms Use the mains ON/OFF switch.
Turn the machine OFF, then
turn the machine ON.
If the problem continues, then
call your service engineer.
CHECK PAPER SIZE Remember to check the paper
size.
To make an accurate book you
must enter accurate paper di-
mensions into the touch
screen.
Measure the size of the prin-
ted paper. The paper dimen-
sion changes when the paper
is printed.
CHECK THE TRIM BIN The trim bin is either open or
full. Check the trim bin. Empty
the trim bin if necessary.
COVER OPEN A safety cover is open. The
machine will not operate until
the cover is closed.
DFA INTERFACE - No comms Use the mains ON/OFF switch.
Turn the machine OFF, then
turn the machine ON. If the
problem continues, then call
your service engineer.
DRIVE MOTOR STALL There is a paper jam. Check
the machine and correct the
error.
Touch STOP to clear the
message from the screen.
Endlay axis moving The endlay axis (size adjust-
ment) is moving. This mes-
sage clears when the adjust-
ment is complete.
If the message does not clear,
touch ADVANCED > RE REF.
4
Error Messages
Chapter 6 - Error Conditions, Problems and Solutions 77
Problem Cause Solution
ENDLAY - No comms Use the mains ON/OFF switch.
Turn the machine OFF, then
turn the machine ON. If the
problem continues, then call
your service engineer.
ERROR IN TRIM AREA There is an error at the trim-
mer.
Check the trimmer for a paper
or book jam.
Touch STOP to clear the
message from the screen.
ERROR - No comms Use the mains ON/OFF switch.
Turn the machine OFF, then
turn the machine ON. If the
problem continues, then call
your service engineer.
FLOW ERROR - BRIDGE There is an error at the con-
necting bridge. Open the con-
necting bridge cover and
check for a paper jam.
Touch STOP to clear the
message from the screen.
See
Clear Paper Jams
on
page 85
FLOW ERROR - FORMER There is an error at the former.
Open the folder cover and re-
move the book. If necessary,
open the main deck to remove
the book.
See
Jam in the Folder or For-
mer Area
on page 90
FLOW ERROR - GATHER AREA There is a paper jam in the
gathering area. Open the con-
necting bridge cover, lift the
gathering area and remove
the paper jam.
See
Jam in the Gathering Area
on page 88
FLOW ERROR - OUTFEED There is an error at the out-
feed. Remove the trim bin and
open the trim stop guard to re-
move the book.
If necessary, open the main
deck to remove the book.
See
Jam in the Trim Area
on
page 93
FLOW ERROR - STITCHER There is an error at the stitch-
er. Open the folder cover and
remove the book.
If the problem continues, then
call your service engineer.
See
Jam in the Stitch Area
on
page 89
4
Error Messages
78 Chapter 6 - Error Conditions, Problems and Solutions
Problem Cause Solution
Fold blade axis moving The fold blade axis (book
thickness adjustment) is mov-
ing. This message clears when
the adjustment is complete.
If the message does not clear,
touch ADVANCED > RE REF
FOLD BLADE NOT PARKED Open the folder cover, remove
the paper, close the folder
cover. Touch START , then
follow the instructions on the
screen.
FOLD - No comms Use the mains ON/OFF switch.
Turn the machine OFF, then
turn the machine ON. If the
problem continues, then call
your service engineer.
FORM CLAMP CLOSED The form clamp is in the
wrong position. Touch START
to reset the position. Follow
the instructions on the screen.
FORM ROLLER ERROR Open the folder cover, remove
the paper, close the folder
cover.
See
Jam in the Folder or For-
mer Area
on page 90
FORM ROLLER NOT PARKED The form roller is in the wrong
position. Touch START to
reset the position. Follow the
instructions on the screen.
FORM CLAMP ERROR There is an error at the former.
Open the folder cover and re-
move the book. If necessary,
open the main deck to remove
the book.
See
Jam in the Folder or For-
mer Area
on page 90
GATHERING AREA COVER
OPEN
Close the gathering area cover
if you need to operate the ma-
chine online.
INVERTER ERROR Check for a paper jam and
clear if necessary.
Touch STOP to clear the
message from the screen. If
the problem continues, con-
tact your service engineer.
JAM AT BRIDGE INFEED There is a paper jam at the in-
feed to the connecting bridge.
Clear the jam and continue.
See
Clear Paper Jams
on
page 85
JAM AT FORM ROLLER Open the folder cover, remove
the paper, close the folder
cover.
See
Jam in the Trim Area
on
page 93
4
Error Messages
Chapter 6 - Error Conditions, Problems and Solutions 79
Problem Cause Solution
JAM AT STACKER INFEED There is a jam in the stacker
infeed. Remove the books
from the stacker infeed. Press
the reset button on the stack-
er.
See
Jam at Book Stacker in-
feed
on page 104
JAM AT STACKER OUTFEED There is a jam in the stacker
outfeed or there are paper
trimmings in the stacker out-
feed. Remove the books from
the stacker outfeed. Check for
paper trimmings and remove
them if present. Press the re-
set button on the stacker.
See
Jam at Book Stacker out-
feed
on page 105
JAM BEFORE TRIMMER There is a book jammed be-
fore the trimmer. Open the
main deck to remove the
book.
See
Jam before the Trimmer
on page 91
JAM IN CONNECTING BRIDGE There is a paper jam in the
connecting bridge. Clear the
jam and continue.
See
Jam in the Connecting
Bridge
on page 87
JAM IN GATHERING AREA There is a paper jam in the
gathering area. Open the con-
necting bridge cover, lift the
connecting bridge and remove
the paper jam.
See
Jam in the Gathering Area
on page 88
JAM IN STACKER AREA There is a paper jam at the
outfeed of the machine. Re-
move the jammed books and
continue.
JAM IN STITCHER AREA There is a paper jam in the
stitch area. Open the folder
cover, remove the paper jam
and continue.
See
Jam in the Stitch Area
on
page 89
JAM IN STITCH HEAD There is a jam in the stitch
head.
See
Clear a Stitch Head Jam
on page 97
JAM IN TRIMMER There is a book jammed in the
trimmer. Clear the jam and
continue.
See
Jam in the Trim Area
on
page 93
MAIN CONTROL - No comms Use the mains ON/OFF switch.
Turn the machine OFF, then
turn the machine ON. If the
problem continues, then call
your service engineer.
4
Error Messages
80 Chapter 6 - Error Conditions, Problems and Solutions
Problem Cause Solution
MANUALLY PARK SHUTTLE The shuttle is not parked cor-
rectly. Open the folder cover
and move the shuttle to the
park position. Close the folder
cover. The shuttle will reset.
When the message list is
clear, continue operation.
See
Manually park the Shuttle
on page 102
MISSING STITCHES The machine has detected
missed stitches. Check if the
stitch wire is jammed or if the
stitch wire spool is empty.
See
Clear a Stitch-wire Jam
on
page 95
See
Install New Stitch Wire
on
page 123
MOTOR CONTROLLER NOT
READY
The drive motor controller is
not ready. If the problem con-
tinues, contact your service
engineer.
OPERATOR MAINTENANCE The machine needs routine
maintenance by the operator.
See
Operator Maintenance
on
page 110
REBOOT THE MACHINE Use the mains ON/OFF switch.
Turn the machine OFF, then
turn the machine ON. If the
problem continues, then call
your service engineer.
REMOVE SET FROM FOLD
AREA
Open the folder cover and re-
move the set.
REMOVE SET - GATHERING
AREA
Open the gathering area and
remove the sheets.
REMOVE SET - STITCH AREA Open the folder cover and re-
move the set.
See
Jam in the Stitch Area
on
page 89
Rotate axis moving The rotate axis is moving. This
message clears when the ad-
justment is complete.
If the message does not clear,
touch ADVANCED > RE REF.
ROTATE - No comms Use the mains ON/OFF switch.
Turn the machine OFF, then
turn the machine ON. If the
problem continues, then call
your service engineer.
4
Error Messages
Chapter 6 - Error Conditions, Problems and Solutions 81
Problem Cause Solution
SET IN GATHERING AREA There is a set or partial set in
the gathering area.
Open the gathering area and
remove the sheets.
If the print job has been can-
celed, open the gathering area
and remove the sheets. Or
touch START , then touch
ADVANCED > PURGE SET >
PURGE SET to clear the set
from the machine.
Shuttle axis moving The shuttle axis is moving.
This message clears when the
adjustment is complete.
If the message does not clear,
touch ADVANCED > RE REF.
SHUTTLE MOTOR COMMS
FAIL
Use the mains ON/OFF switch.
Turn the machine OFF, then
turn the machine ON. If the
problem continues, then call
your service engineer.
SHUTTLE MOTOR ERROR Use the mains ON/OFF switch.
Turn the machine OFF, then
turn the machine ON. If the
problem continues, then call
your service engineer.
SHUTTLE - No comms Use the mains ON/OFF switch.
Turn the machine OFF, then
turn the machine ON. If the
problem continues, then call
your service engineer.
SHUTTLE NOT PARKED The shuttle is in the wrong po-
sition. Touch START , then
follow the instructions on the
screen to reset the position.
Sidelay axis moving The sidelay axis (size adjust-
ment) is adjusting. This mes-
sage clears when the adjust-
ment is complete.
If the message does not clear,
touch ADVANCED > RE REF.
SIDELAY - No comms Use the mains ON/OFF switch.
Turn the machine OFF, then
turn the machine ON. If the
problem continues, then call
your service engineer.
STACKER FULL The stacker is full. Unload the
books from the stacker.
4
Error Messages
82 Chapter 6 - Error Conditions, Problems and Solutions
Problem Cause Solution
Stitch axis moving The stitch axis is moving. This
message clears when the ad-
justment is complete.
If the message does not clear,
touch ADVANCED > RE REF.
Stitch length will change soon The stitch length cannot adjust
at the moment. The stitch leg
length will adjust after the
next book.
STITCH - No comms Use the mains ON/OFF switch.
Turn the machine OFF, then
turn the machine ON. If the
problem continues, then call
your service engineer.
Stitch position adjusting The stitch position is adjust-
ing. This message clears when
the adjustment is complete.
If the message does not clear,
touch ADVANCED > RE REF.
STITCH TIMEOUT Press STOP . Open the folder
cover, remove the paper, close
the folder cover.
SYSTEM ERROR
00.20
40.21
40.22
Touch STOP to clear the mes-
sage from the screen. If the
message is not cleared, use
the mains ON/OFF switch.
Turn the machine OFF, then
turn the machine ON. If the
problem continues, then call
your service engineer.
SYSTEM ERROR 39.xx Press the reset button on the
stacker. If the message is not
cleared, use the stacker mains
ON/OFF switch. Turn the
stacker OFF, then turn the
stacker ON. If the problem
continues, then call your serv-
ice engineer.
TOO MANY PAGES The printer has delivered too
many sheets into the gather-
ing area. Remove the incorrect
set. Correct the printer setting.
Touch STOP to clear the
message from the screen.
Check the settings for SET
THICKNESS or SHEET THICK‐
NESS.
See
Open the Gathering Area
Cover
on page 48
4
Error Messages
Chapter 6 - Error Conditions, Problems and Solutions 83
Problem Cause Solution
TOUCH PAD ERROR There is a fault with the
START and STOP touch pads.
If the problem continues, then
call your service engineer.
Touch START to clear ma-
chine
There may be some paper in
the machine. Touch START
to clear the machine before
you start a new job.
Trim axis moving The trim axis (size adjustment)
is moving. This message
clears when the adjustment is
complete.
If the message does not clear,
touch ADVANCED > RE REF.
TRIM BIN OPEN The trim bin is not fitted or is
not contacting the safety
switch. Fit the trim bin.
TRIM BLADE NOT PARKED The trim blade is in the wrong
position. Touch START to
reset the position.
Follow the instructions on the
screen.
TRIM - No comms Use the mains ON/OFF switch.
Turn the machine OFF, then
turn the machine ON. If the
problem continues, then call
your service engineer.
USER STOP The user has touched the
STOP button while the ma-
chine is in operation. Touch
START to restart the ma-
chine.
Error Messages
84 Chapter 6 - Error Conditions, Problems and Solutions
Clear Paper Jams
Introduction
A
B
D
C
E
[29] Paper Jam Locations
AConnecting Bridge
B Gathering Area
C Stitch Area
D Fold and Forming Areas
E Trim Area
Jam in the Bridge Infeed
Illustration
A
[30] Paper Jam Location - Bridge Infeed
ABridge Infeed Cover
Procedure
1. Open the connecting bridge cover.
Clear Paper Jams
Chapter 6 - Error Conditions, Problems and Solutions 85
2. Open the bridge infeed cover.
3. Remove the jammed paper.
4. Close the bridge infeed cover.
5. Close the connecting bridge cover.
Jam in the Bridge Infeed
86 Chapter 6 - Error Conditions, Problems and Solutions
Jam in the Connecting Bridge
Procedure
1. Open the connecting bridge cover.
2. Remove the jammed paper.
3. Close the connecting bridge cover.
Jam in the Connecting Bridge
Chapter 6 - Error Conditions, Problems and Solutions 87
Jam in the Gathering Area
Illustration
ü
û
û
û
ü ü
[31] Gathering Area Belt Positions
Procedure
1. Open the connecting bridge cover.
2. Lift the gathering area cover.
3. Remove the jammed paper.
4. Check the belts are in the correct position. Adjust the position of the belts if necessary (see
illustration 'Gathering Area Belt Positions').
5. Close the gathering area cover.
6. Close the connecting bridge cover.
Jam in the Gathering Area
88 Chapter 6 - Error Conditions, Problems and Solutions
Jam in the Stitch Area
Step Action Information
1 Open the folder cover. See
Open the Folder Cover
on page 45
2 Lift the clincher frame. See
Lift and Lower the Clincher Frame
on page 46.
3 Remove the jammed paper.
4 Check for broken or damaged stitch-
es in the clincher area. Manually op-
erate the clincher to clear any stitch-
es that are jammed.
A
A: Press to manually operate the clinch-
er.
5 Lower the clincher frame. See
Lift and Lower the Clincher Frame
on page 46
6 Close the folder cover.
Jam in the Stitch Area
Chapter 6 - Error Conditions, Problems and Solutions 89
Jam in the Folder or Former Area
Procedure
1. Open the folder cover.
2. Remove the jammed paper. See
Jam in the Trim Area
on page 93 if you cannot see the paper in
the former area.
3. Close the folder cover.
Jam in the Folder or Former Area
90 Chapter 6 - Error Conditions, Problems and Solutions
Jam before the Trimmer
The error message JAM BEFORE TRIMMER is displayed. This error can be
1. a book jammed before the trimmer.
2. a piece of paper trimming covered the jam sensor.
Illustration
A
B
[32] Trimmer Infeed Conveyor viewed from above.
ATrimmer Infeed Conveyor
B Former clamp mechanism
A
C
B
[33] Access to the Trimmer Infeed Conveyor
AReach in here to access the trim-infeed conveyor
B Former clamp - look in here for paper trimmings
C Former clamp mechanism.
Step Action Information
1 Open the Booklet maker main deck See
Lift the Booklet maker Main Deck
on
page 49
2 Remove the trim bin. 4
Jam before the Trimmer
Chapter 6 - Error Conditions, Problems and Solutions 91
Step Action Information
3 Loosen the trimmer infeed convey-
or.
The procedure can be seen from the top
of the machine.
Access to the parts is through the for-
mer-clamp mechanism.
Hold the shaft and push to the right,
against spring pressure to disengage the
shaft from the drive pin.
Lift the left hand end clear.
4Remove the book, if one is found.
5 Remove any paper offcuts from the
trimmer infeed conveyor.
Look down through the former clamp.
Small pieces of paper trimmings can
cover the jam sensor and cause an error
message.
6 Fit the trimmer infeed conveyor.
Look down through the former clamp.
• Insert the right hand end of the shaft
into the bearing, against the spring
pressure.
• Rotate the trimmer infeed conveyor,
so that the green belts are vertical.
• Insert the left-hand end, so that the
shaft engages with the drive pin.
7Fit the trim bin.
8 Close the Booklet maker main deck
and covers.
Jam before the Trimmer
92 Chapter 6 - Error Conditions, Problems and Solutions
Jam in the Trim Area
Illustration
A
C
B
[34] Trim Stop Guard
AOrange Plastic Hand Screw
B Locking Plate
C Trim Stop Guard
A
[35] Location of the sensor
ACheck under here for paper trimmings
Step Action Information
1 Remove the trim bin.
2 Open the trim stop guard. See illustration 'Trim Stop Guard'.
Loosen the 2 orange plastic hand screws
to release the locking plates.
The locking plates can rotate to release
the trim stop guard.
Pull the trim stop guard towards you.
3 Remove the jammed book. 4
Jam in the Trim Area
Chapter 6 - Error Conditions, Problems and Solutions 93
Step Action Information
4 Check the trim stop and remove any
pieces of trimmed paper.
In particular, check around the sensor.
The sensor is where you can see a red
and a green light (see illustration 'Loca-
tion of the sensor').
Small pieces of paper trimmings can
cover the sensor and cause an error
message.
5 Close the trim stop guard. Push the trim stop guard into position.
Hold the locking plates in position and
tighten the orange hand screws.
6 Attach the trim bin.
Jam in the Trim Area
94 Chapter 6 - Error Conditions, Problems and Solutions
Clear a Stitch-wire Jam
Introduction
Before you begin:
Lift the Booklet maker main deck. See
Lift the Booklet maker Main Deck
on page 49
A
B
C
D
[36] Stitch Head.
ATop location of Middle Wire Tube
B Middle Wire Tube
C Metal Spring Clip
D Feed Gears
Step Action Information
1 Cut the stitch-wire at position 'A'
approximately 50 mm (2-inches)
from where the stitch-wire leaves
the stitch-wire guide.
A
Detail A: Cut stitch wire here. 4
Clear a Stitch-wire Jam
Chapter 6 - Error Conditions, Problems and Solutions 95
Step Action Information
2 Cut the stitch wire at position 'B'
between the feed gears and the
middle wire tube.
B
Detail B: Cut stitch wire here.
3Pull the stitch wire from the stitch
wire guide block.
Pull stitch wire in direction of arrow
4 Remove the middle wire tube.
5 Pull the wire from the stitch head.
6 Install the stitch wire into the
stitch head.
See
Install the Stitch Wire into the Stitch
Head
on page 126
Clear a Stitch-wire Jam
96 Chapter 6 - Error Conditions, Problems and Solutions
Clear a Stitch Head Jam
Introduction
The error message JAM IN STITCH HEAD is displayed.
This may be caused by
•the SET THICKNESS setting is incorrect
• the stitch head is jammed by broken wire
• the stitch head needs lubrication
Do Procedure 1. If the error message continues, do Procedure 2.
Procedure 1
Step Action Information
1 Open the folder cover. See
Open and Close the Folder Cover
on
page 45
2 Lift the clincher frame. See
Lift and Lower the Clincher Frame
on page 46.
3 Remove the jammed paper.
4 Check for broken or damaged stitch-
es in the clincher area. Manually op-
erate the clincher to clear any stitch-
es that are jammed.
A
A: Press to manually operate the clinch-
er.
5 Lower the clincher frame. See
Lift and Lower the Clincher Frame
on page 46
6 Close the folder cover.
7 Press the START button . Follow
the on-screen instructions.
Clear a Stitch Head Jam
Chapter 6 - Error Conditions, Problems and Solutions 97
Procedure 2
A
B
C
[37] Remove the stitch head wire holder
AStitch head
B Wire holder
C Wire holder retaining spring
IMPORTANT
Do not apply force to the wire guide bars or the pivot block when you do this procedure. Force
on these parts will damage the stitch head.
A
B
C
[38] Inspect for stitch wire
AInspect this area for pieces of stitch wire
B Wire guide bars
C Pivot block
Tools and Materials
• Klüber Isoflex NBU 15 Grease, 50g.
• Air duster. Supplied with the machine.
• Wire cutters. Supplied with the machine.
Procedure 2
98 Chapter 6 - Error Conditions, Problems and Solutions
• Flat blade screwdriver.
Step Action Information
1 Lift the Booklet maker main deck. See
Lift the Booklet maker Main Deck
on
page 49
2 Remove the wire-holder from the
stitch head.
• Move the wire-holder retaining spring to
the right.
• Remove the wire-holder
If the wire-holder is held in position, use a
screwdriver to help remove the wire-holder
from the stitch head.
IMPORTANT
Attention: Do not apply force to
the wire guide bars or the pivot
block.
3 Inspect the area behind the wire-
holder for stitch-wire.
4 Remove any stitches or pieces of
stitch-wire and clean the area with
the air duster.
Use wire cutters to remove any jammed
stitches or pieces of stitch-wire.
5 Lubricate the stitch-head.
Lubricate the Stitch Head
on page 118
6 Fit the wire-holder. Remember to put the wire-holder retaining
spring in position.
7 Close the Booklet maker.
8 Start the Booklet maker. If the head operates normally and returns to
the parked position, then further action is
not needed.
If the stitch-head remains jammed, then re-
peat the procedure again.
If the problem continues, contact your serv-
ice engineer.
Procedure 2
Chapter 6 - Error Conditions, Problems and Solutions 99
Calibrate the Touch Screen
When to do
Calibrate the touch screen if the buttons do not operate or the buttons do not operate correctly.
IMPORTANT
Use a pencil, the blunt end of a pen or a palm top wand for this procedure. Do not use a sharp
object. Sharp objects damage the screen.
Procedure
1. Touch the STOP button 5 times.
2. Follow the instructions on the touchscreen.
You must touch the screen, where shown, as accurately as possible.
3. Touch DONE in the center of the screen.
Calibrate the Touch Screen
100 Chapter 6 - Error Conditions, Problems and Solutions
Change the fuses of the Booklet Maker
Introduction
The Booklet Maker has 2 fuses located at the mains power input (see
The Rear Panel of the
Booklet maker
on page 14). If either fuse is blown, the Booklet maker will not operate.
Required tools
Fuse description: 7A, HRC Quick Acting, F
IMPORTANT
Turn OFF the machine and remove the mains power supply cable before you change the fuses.
This machine uses two fuses in parallel. To avoid the risk of fire, replace fuses using only the
same type and rating.
Procedure
1. Turn OFF the Booklet maker.
2. Disconnect the Booklet maker from the power supply.
3. Turn one fuse-holder to the left and remove the fuse-holder from the Booklet maker.
4. Check the fuse.
5. If the fuse is blown, then replace with a fuse of the correct specification.
6. Repeat the procedure for the other fuse.
NOTE
If the fuse blows again, call your service engineer.
Change the fuses of the Booklet Maker
Chapter 6 - Error Conditions, Problems and Solutions 101
Manually park the Shuttle
When to do
The error messages ‘MANUALLY PARK SHUTTLE’ and ‘SHUTTLE NOT PARKED’ are displayed.
Illustration
B
A
[39] Shuttle Assembly Position - CORRECT
1
[40] Pick-up fingers
1Pick-up fingers
Step
1 Open the folder cover. See
Open and Close the Folder Cover
on
page 45
2 Push the shuttle-assembly to the
end.
The illustration above shows the correct
position for the shuttle assembly. Screw
‘A’ must be aligned with white gear ‘B’.
If the shuttle assembly does not move to
the correct position, push the pick-up fin-
gers away from each other by 2-3 mm
and try again. Repeat if necessary.
See illustration above.
3Wait until the error message SHUT‐
TLE NOT PARKED is cleared from the
screen.
If the message does not clear, check that
the shuttle assembly is in the correct posi-
tion. Repeat Step 2 if necessary.
4 Close the folder cover.
Manually park the Shuttle
102 Chapter 6 - Error Conditions, Problems and Solutions
Result
The error message ‘MANUALLY PARK SHUTTLE’ is cleared from the screen. The shuttle axis re-
references and the message Shuttle axis moving is displayed.
When the message list is clear, you can continue operation
Manually park the Shuttle
Chapter 6 - Error Conditions, Problems and Solutions 103
Clear Paper Jams of the optional Book Stacker
Jam at Book Stacker infeed
When to do
The error message JAM AT STACKER INFEED is displayed. This means a book covers the sensor
at the Book Stacker infeed.
Illustration
A
B
[41] Book Stacker infeed
ABook Stacker infeed
B Book Stacker reset button
Procedure
1. Remove the book.
2. If you are making thin books, attach the magnetic paper guide (see
Adjust the Book Stacker
on
page 56).
3. Press the reset button on the Book Stacker.
Clear Paper Jams of the optional Book Stacker
104 Chapter 6 - Error Conditions, Problems and Solutions
Jam at Book Stacker outfeed
Illustration
C
A
B
[42] Book Stacker outfeed - 1
D
E
[43] Book Stacker outfeed - 2
ABook Stacker outfeed
B Book Stacker reset button
C Pusher
D Book Stacker outfeed is visible.
E The pusher is in forward position. The Book Stacker outfeed is not visible.
The error message JAM AT STACKER OUTFEED is displayed. This means a book or some paper
trimmings cover the sensor at the Book Stacker outfeed.
If the Book Stacker outfeed is visible:
Step Action Information
1 Remove the book, if present.
2 Check for paper trimmings and re-
move them, if present.
4
Jam at Book Stacker outfeed
Chapter 6 - Error Conditions, Problems and Solutions 105
Step Action Information
3 Press the reset button on the Book
Stacker.
If the pusher is in the forward position so that the Book Stacker outfeed is not visible:
Step Action Information
1 Use your hand to move the pusher
to the left, against the spring pres-
sure.
2 Remove the book, if present.
3 Check for paper trimmings and re-
move them, if present.
4 Press the reset button on the Book
Stacker.
Jam at Book Stacker outfeed
106 Chapter 6 - Error Conditions, Problems and Solutions
Change the fuses of the optional Book Stacker
Introduction
The Book Stacker has 2 fuses at the power input connector (see
The mains input panel of the
optional Book Stacker
on page 15).
If either fuse has blown, the Book Stacker will not operate.
Required tools
Fuse description: 3A, HRC Quick Acting, F
IMPORTANT
Turn OFF the machine and remove the mains power supply cable before you change the fuses.
This machine uses two fuses in parallel.
IMPORTANT
To avoid the risk of fire, replace fuses using only the same type and rating.
Procedure
1. Turn OFF the Book Stacker.
2. Disconnect the Book Stacker from the power supply.
3. Check each fuse.
4. If the fuse is blown, then replace with a fuse of the correct specification.
NOTE
If the fuse blows again, call your service engineer.
Change the fuses of the optional Book Stacker
Chapter 6 - Error Conditions, Problems and Solutions 107
Change the fuses of the optional Book Stacker
108 Chapter 6 - Error Conditions, Problems and Solutions
Chapter 7
Maintenance
About Maintenance
Service Interval
• The Booklet maker needs service every six months.
• After every one million stitches, the stitch head needs service. This interval is every third spool
of stitch-wire.
Only a service engineer can service the Booklet maker. Contact your supplier for further
information.
Operator Maintenance
Correct maintenance by the operator makes sure that
• The machine operates correctly
• The machine makes high-quality books
• The machine is safe to use
• Small problems can be identified early
Operator Maintenance Plan
Interval Task Reference
• Every week Clean the machine. See
Booklet maker cleaning
on
page 111
When the message OPERA‐
TOR MAINTENANCE is dis-
played on the screen.
Lubricate the stitch head. See
Lubricate the Stitch Head
on page 118
Clean the former roller. See
Clean the Former Roller
on
page 112
Clean the polyurethane strips in
the form clamp.
See
Clean the Polyurethane
Strips in the Form Clamp
on
page 113
Clean the trimmings-removal
fingers.
See
Clean the Trimmings Re-
moval Fingers
on page 115
Clean excess grease from the
stitch head.
See
Clean excess grease from
the Stitch Head
on page 117
About Maintenance
110 Chapter 7 - Maintenance
Booklet maker cleaning
Introduction
Clean the Booklet maker every week to remove surface dust.
IMPORTANT
Only clean the machine with materials that are recommended in this manual. Do not use other
chemicals or abrasive material.
Outside of the Booklet maker
Use a moist cloth to clean the outside of the Booklet maker.
Touch screen
Clean the touch screen with a clean, dry cloth. Never use an abrasive material or chemical to
clean the touch screen. Light pressure with a clean, dry cloth is enough to remove fingerprints.
Do not use too much force.
Booklet maker cleaning
Chapter 7 - Maintenance 111
Clean the Former Roller
Introduction
Clean the former roller:
• Every month, as part of the operator maintenance plan.
• If the spines of the books are dirty. Ink and toner can collect on the former roller.
[44] Dirty marks on the spine
Required tools
Clean, plain paper that is not printed. A3 size (USA: 11 x 17”) is recommended. 4mm thickness is
needed for each cycle. More than one cycle can be needed
Step Action Information
1 Enter the correct settings on the
touch screen.
•Set the touch screen to the correct PA‐
PER SIZE
•Set the SET THICKNESS to 4.0
•Set the number of STITCHES to 0.
•Set the number of FORMS to 4.
2 Touch START
3 Open the connecting bridge cover.
4 Lift the gathering area cover.
5 Put 4mm of clean paper in the gath-
ering area.
6 Press the two orange buttons and
hold for 9 seconds, or until you hear
the folder operate.
Result
The book is delivered to the stacker. Check the book. Repeat the procedure until the book spine is
clean.
Clean the Former Roller
112 Chapter 7 - Maintenance
Clean the Polyurethane Strips in the Form Clamp
Introduction
Clean the polyurethane strips in the form clamp:
• Every month, as part of the operator maintenance plan.
• If there are dirty marks near the spine on the front and back cover of the book. Ink and toner
can collect on these parts, especially when you make thin books.
[45] Dirty marks beside the spine
Required tools
Alcohol wipe or
A lint free cloth and alcohol (isopropanol)
IMPORTANT
Only use alcohol to clean this part of the machine. Other chemicals can damage the machine.
CAUTION
Wear protective gloves when you use the alcohol wipe.
NOTE
If you push the eject rollers, the rollers can move together against your hand. This movement
can alarm you, but is not dangerous.
Illustration
A
[46] Polyurethane strips
APolyurethane strip
Step Action Information
1 Open the folder cover 4
Clean the Polyurethane Strips in the Form Clamp
Chapter 7 - Maintenance 113
Step Action Information
2 Use an alcohol wipe, or apply a small
amount of alcohol to a lint free cloth.
Wear protective gloves when you use the
alcohol wipe.
3 Reach into the form clamp and clean
each of the polyurethane strips.
There is a polyurethane strip on the face
of each side of the clamp.
Repeat this step until the polyurethane
strips are clean.
4 Close the folder cover
Clean the Polyurethane Strips in the Form Clamp
114 Chapter 7 - Maintenance
Clean the Trimmings Removal Fingers
Introduction
Clean the trimming removal fingers:
• Every month, as part of the operator maintenance plan.
• If there are small, dirty marks on the book. Ink and toner can collect on the trimmings removal
fingers and cause marks on the book.
[47] Curved marks on the book
Required tools
Alcohol wipe
CAUTION
Wear protective gloves when you use the alcohol wipe.
Illustration
A
B
C
[48] Trimmer infeed conveyor viewed from above 1
ATrimmer infeed conveyor
B Former clamp mechanism
C Reach in here to access the trim-infeed conveyor
Clean the Trimmings Removal Fingers
Chapter 7 - Maintenance 115
C
B
A
[49] Trimmer infeed conveyor viewed from above 2
ATrimmer infeed conveyor
B Trimmings removal fingers
C Former clamp mechanism
Step Action Information
1 Lift the Booklet maker main deck. See
Lift the Booklet maker Main Deck
on
page 49.
2 Remove the trim bin.
3 Clean the four visible trimmings-re-
moval fingers with an alcohol wipe.
The procedure can be seen from the top
of the machine.
Access to the parts is through the former-
clamp mechanism (see illustration 'Trim-
mer infeed conveyor viewed from above
1').
Wear protective gloves when you use the
alcohol wipe.
4 Rotate the conveyor shaft by half a
turn.
1. Hold the shaft and push to the right,
against spring pressure to disengage the
shaft from the drive pin.
1
2
3
2. Rotate the shaft by half a turn.
3. Align the shaft with the drive pin and
release.
5Clean the four visible trimmings-re-
moval fingers with an alcohol wipe.
Wear protective gloves when you use the
alcohol wipe.
6 Fit the trim bin.
7 Close the Booklet maker.
Clean the Trimmings Removal Fingers
116 Chapter 7 - Maintenance
Clean excess grease from the Stitch Head
Introduction
Clean excess grease from the stitch head:
• Every month, as part of the operator maintenance plan.
• If there are grease marks around the stitches on the book.
[50] Grease marks around the stitches
Required tools
Lint free cloth
Step Action Information
1On the user interface, touch AD‐
VANCED > STITCHER UP > STITCH‐
ER UP
The folder cover must be closed. This ac-
tion moves the stitch head to the correct
position for lubrication.
2 Open the folder cover.
Open and Close the Folder Cover
on
page 45
3 Lift the clincher frame.
Lift and Lower the Clincher Frame
on
page 46
4 Clean grease from the sides of the
stitch head.
5 Lower the clincher frame.
6 Close the folder cover.
Clean excess grease from the Stitch Head
Chapter 7 - Maintenance 117
Lubricate the Stitch Head
Introduction
Lubricate the stitch head:
• Every month, as part of the operator maintenance plan.
• When a new stitch-wire is installed if this interval is shorter.
Required tools
Klüber Isoflex NBU15 Grease, 50g
Air duster
IMPORTANT
Only use the grease shown in this manual. Correct lubrication extends the performance and
service life of the stitch head. Other types of grease do not protect the stitch head.
IMPORTANT
Only apply the grease as shown. If you apply additional grease, the paper will become stained.
Step Action Information
1 Trim the first 2.5 mm from the noz-
zle.
[51] Tip of the nozzle
[52] Trim the nozzle of the tube of grease
2Remove the cap from the tube of
grease.
3 Fit the nozzle to the tube of grease.
4On the user interface, touch AD‐
VANCED > STITCHER UP > STITCH‐
ER UP
The folder cover must be closed.
This action moves the stitch head to
the correct position for lubrication. 4
Lubricate the Stitch Head
118 Chapter 7 - Maintenance
Step Action Information
5 Lift the Booklet maker main deck See
Lift the Booklet maker Main Deck
on page 49
You will see that the stitch head is in
the 'STITCHER UP' position.
6 Use the supplied air duster to re-
move dust from the stitch head.
7 Remove the wire holder from the
stitch head:
• Move the wire holder retaining
spring 'A' to the right.
• Remove the wire holder 'B'.
Lubricate the Stitch Head
Chapter 7 - Maintenance 119
Apply Grease to the Driver Bar
Step Action Information
1 Apply a thin line of grease from the
tube (20 mm long and maximum
0.5 mm thick) to the visible surface
of the driver bar.
1.2"
[53] Maximum dimensions of the line of grease
NOTE
Make sure that you apply
the grease in an upward
direction, from the bot-
tom of the driver bar.
[54] Driver bar
A = Driver
B = Apply grease here
C = Driver bar
NOTE
Only apply the grease as
shown. If you apply addi-
tional grease, the paper
will become stained.
[55] Apply the grease to the driver bar
A = Start
B = Stop
2Fit the wire holder.
Apply Grease to the Driver Bar
120 Chapter 7 - Maintenance
Lubricate the wire-feed cam
Illustration
A
B
C
[56] Lubricate the wire-feed cam
ANozzle of the tube of grease
B Wire-feed cam
C Feed lever
Step Action Information
1 Apply 10 mm of grease from the
tube between the bearing surface of
the wire-feed cam and the feed lever.
See the 'Lubricate the wire-feed cam'
illustration above.
0.4"
2 Lower the Booklet maker main deck.
3 Lower the clincher frame. See
Lower the Clincher Frame
on
page 47
4 Close all of the covers.
5 Make some test books.
6 Clean excess grease from the top of
the stitch head.
See
Clean excess grease from the
Stitch Head
on page 117
Lubricate the wire-feed cam
Chapter 7 - Maintenance 121
Reset the Operator Maintenance Counter
Procedure
1. Touch MENU.
2. Touch and hold RESET. A red line appears. The red line fills from left to right. Hold RESET until
the red line reaches the right-hand side.
3. Touch MENU.
Reset the Operator Maintenance Counter
122 Chapter 7 - Maintenance
Install New Stitch Wire
Introduction
Only use stitch-wire that is approved by your supplier. Stitch-wire that is not approved by your
supplier can cause poor performance and voids the warranty.
Stitch-wire Description: Stitcher wire S33.
Before you begin
Lift the Booklet maker main deck.
See
Lift the Main Deck
on page 49
Remove the Stitch-wire from the Stitch Head
Illustration
A
B
C
[57] Stitch-wire Guide Block
AStitch-wire Guide Block
B Stitch-wire
C Felt wire-cleaning pads
Step Action Information
1 Cut the stitch-wire to the right of
the stitch-wire guide block.
A
Detail A: Cut here
2 Pull the stitch wire from the stitch
wire guide block.
4
Install New Stitch Wire
Chapter 7 - Maintenance 123
Step Action Information
3 Fit a new stitch-wire spool.
Fit a New Stitch-wire Spool
on page 125
Remove the Stitch-wire from the Stitch Head
124 Chapter 7 - Maintenance
Fit a New Stitch-wire Spool
Step Action Information
1 Open the stitch-wire cabinet
2 Remove the stitch-wire cap and fin-
ished stitch-wire spool.
3 Fit a new stitch-wire spool.
4 Fit the stitch-wire cap
5 Loosen the end of the stitch-wire
from the edge of the stitch-wire
spool.
6 Use wire-cutters to remove the
damaged end of the stitch-wire.
Remove enough stitch-wire to leave the end
of the stitch-wire clean and straight.
7 Feed the stitch-wire through the
stitch-wire guide.
8 Install the stitch-wire.
Install the Stitch Wire into the Stitch Head
on
page 126
Fit a New Stitch-wire Spool
Chapter 7 - Maintenance 125
Install the Stitch Wire into the Stitch Head
Step Action Information
1 Pull the stitch-wire from the end of
the stitch-wire guide.
2 Make sure the stitch-wire runs be-
hind the gas-strut.
3 Feed the end of the stitch-wire be-
tween the felt wire-cleaning pads.
A
Detail A: Felt Wire-Cleaning Pads
4 Push the stitch-wire into the stitch-
wire guide block.
Push stitch-wire in direction of arrow
5 Push the stitch-wire as far as possi-
ble.
A
Detail A:Make sure the stitch-wire runs be-
tween the wire feed rollers and into the mid-
dle wire tube.
Install the Stitch Wire into the Stitch Head
126 Chapter 7 - Maintenance
Close the Booklet maker
Step Action Information
1 Close the stitch-wire cabinet.
2 Lower the Booklet maker main
deck.
Lower the Clincher Frame
on page 47.
3 Lower the clincher frame.
4 Close the folder cover.
5 Close the connecting bridge cover.
Close the Booklet maker
Chapter 7 - Maintenance 127
Feed the Stitch-wire
Step Action Information
1 Touch START .
2 Set the number of stitches to 6. Touch BASIC > STITCHES.
3 Hand-feed or print an A4 or larger
size test job.
Enter the correct settings on the touch
screen according to the size and thickness of
the job.
The stitch-wire loads automatically during
the stitch head cycle.
4 Check that the stitch-wire is loa-
ded.
Check that a stitch is made. If needed, repeat
the previous step.
If a stitch is still not made, repeat the proce-
dure. Install the Stitch-wire into the Stitch
Head.
Install the Stitch Wire into the Stitch Head
on
page 126.
5 Reset the number of stitches on
the touch screen.
Feed the Stitch-wire
128 Chapter 7 - Maintenance
Clear paper from the trim stop
Introduction
Clear paper from the trim stop if the books are not trimmed square. If paper trimmings collect on
the trim stop, the books are not trimmed square.
Illustration
B
C
A
[58] Trim Stop Guard
AOrange Plastic Hand Screw
B Locking Plate
C Trim Stop Guard
A
[59] Trim Stop
ATrim Stop
Step Action Information
1 Remove the trim bin. 4
Clear paper from the trim stop
Chapter 7 - Maintenance 129
Step Action Information
2 Open the trim stop guard. Loosen the 2 orange plastic hand
screws to release the locking plates.
The locking plates can rotate to re-
lease the trim stop guard.
Pull the trim stop guard towards you.
3 Check the trim stop and remove any
pieces of trimmed paper.
4 Close the trim stop guard. Push the trim stop guard into posi-
tion.
Hold the locking plates in position
and tighten the orange hand screws.
5 Attach the trim bin.
Clear paper from the trim stop
130 Chapter 7 - Maintenance
Appendix A
Specifications
Specifications
Operating Conditions 10-35 °C
35-85% relative humidity
Up to 2,000 m above mean sea level
Production Cycle time: Printer dependent
Interset gap: 1 second (if printer has DFD2, then 1 or 2 seconds,
depending on job settings)
Minimum set time: 4.2 seconds (if printer has DFD2, then 4.5 or 7.8
seconds, depending on job settings)
Maximum set time: 12.5 seconds
Stock Sizes Minimum input size: 203 mm x 203 mm
Maximum input size: 350 mm x 500 mm
A
350 x 500mm B
203 x 203mm
A = Stitch & fold line
B = indicates original lead edge from the printer
Sheet Rotation Integrated rotator ensures maximum printer productivity.
Maximum rotation sheet size: 320 mm x 227 mm
Minimum rotation sheet size: 210 mm x 203 mm
The cross-track dimension of the sheet (before rotation) must be at
least 7 mm greater than the in-track dimension.
A
12.6" x 8.9" B
8"
8.3"
A = Stitch & fold line
B = indicates original lead edge from the printer
Stock Range 80 - 160 g/m² normal paper types
60 - 250 g/m² dependent on paper type and quality
Book Thickness Maximum finished book thickness: 10.4 mm (208 pages of 80 g/m²;
224 pages of 70 g/m² dependent on paper type and paper quality)
Maximum set thickness: 5.2 mm (52 sheets of 80 g/m²; 56 sheets
of 70 g/m²; dependent on paper type and paper quality)
Stitching 1 - 6 stitches, evenly spaced on the spine of the book
Stitches/spool: up to 291,500
Books*/spool: approximately 127,000 4
Specifications
132 Appendix A - Specifications
Trimming Maximum fore-edge trim: 28 mm
Minimum trimmed book size: 80 mm
min. 80mm max. 28mm
Stacker Capacity Standard Stacker: 35 books*
Book Stacker (optional): 930 mm
Paper Input Requirements Input sheets must be of consistent size and cut square.
Machine setting must match paper size at the input to the Océ
BLM550+
Book quality is dependent upon quality of input sheets.
Dimensions Footprint
With Standard Stacker: 1870 mm x 1675 mm
With Book Stacker: 2420 mm x 1770 mm
Height
1330 mm maximum
Weight Booklet maker including stitching wire: 542 kg
As above, plus bridge and bridge covers: 702 kg/1548 lbs.
Book Stacker: 150 kg/330 lbs.
Power Supply Adjustable to 200, 208, 220, 230 and 240V
50/60Hz, single phase
Power Consumption Océ BLM550+
Stand-by: 92VA (75W)
In operation: 700VA (500W)
Book Stacker
Stand-by: 35VA (16W)
In operation: 75VA (53W)
Noise Emission Stand-by: ambient
In operation: 66 dB (A), peak 87 dB (A)
Approvals Complies with CE and UL. Conforms to FCC rules Part 15 Class A
and VCCI Class A.
* Standard book is made from 20 sheets of 80 g/m² paper, with 2 stitches.
Production may vary according to operating conditions. In line with a policy of continual prod-
uct improvement, the manufacturer reserves the right to alter the materials or specification of
this product at any time without notice.
Specifications
Appendix A - Specifications 133
Specifications
134 Appendix A - Specifications
Appendix B
Declaration of Conformity
Declaration of Conformity
According to ISO/IEC 17050-1
Name of Manufacturer: Watkiss Automation Limited
Address of Manufacturer: Watkiss House
Blaydon Road
Sandy, Bedfordshire
SG19 1RZ
United Kingdom
Declares that the product:
Name of Product: •Océ BLM550+
Serial Number: WA/PSQ/---/0800 onwards
• Book Stacker
Serial Number: WA/PBS/---/0001 onwards
Conforms to the following Directives:
Safety: 2006/95/EC Council Directive 'on the approximation of laws of
Member States relating to electrical equipment designed for use
within certain voltage limits'.
EN 60950-1:2006 (ed.2) + A11:2009 + A1:2010 + A12:2011
EMC: 2004/108/EC Council Directive 'on the approximation of laws of
Member States relating to electromagnetic compatibility'.
EN55022:2010 Class A
EN55024:2010
EN61000-3-2:2006 + A1:2009 + A2:2009
EN61000-3-3:2008
RoHS: 2006/65/EC Council Directive
WEEE: 2002/96/EC Council Directive amended by 2008/34/EC and
2008/35/EC
Reach: REGULATION (EC) No. 1907/2006
M C Watkiss
Technical Director, Watkiss Automation Ltd.
May 21, 2013
Declaration of Conformity
136 Appendix B - Declaration of Conformity
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