Plockmatic LCT3500 Operator's Manual
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Plockmatic LCT3500 Operator's Manual

Large capacity tray for ricoh
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CIP Training
Plockmatic
LCT3500
Large Capacity Tray
Operators Guide
LCT3500 Large Capacity Tray
for Ricoh

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Summary of Contents for Plockmatic LCT3500

  • Page 1 CIP Training Plockmatic LCT3500 Large Capacity Tray Operators Guide LCT3500 Large Capacity Tray for Ricoh...
  • Page 3 CIP Training Plockmatic LCT3500 Large Capacity Tray Introduction Introduction This manual contains instructions on the operation and maintenance of this machine. To get maximum versatility from this machine all operators should carefully read and follow the instructions in this manual. Keep this manual in a handy place near the machine.

  • Page 4: Safety Information

    CIP Training Plockmatic LCT3500 Large Capacity Tray Introduction Safety Information When using this machine, following safety precautions should always be followed. Safety During Operation WARNING: • To avoid hazardous situations like for instance electric shock or danger while exposed to moving, rotating or cutting devices, do not remove any covers, guards or screws other than those specified in this manual.
  • Page 5 CIP Training Plockmatic LCT3500 Large Capacity Tray Introduction CAUTION: • The machine and its peripherals must be installed and maintained by a customer service representative who has completed the training course on those models. • Always follow all warnings marked on, or supplied with, the equipment.

  • Page 6: What You Can Do With This Machine

    Ricoh Finishing Printers Devices The Plockmatic LCT3500 Large Capacity Tray is a newly engineered option for Ricoh Pro- duction printers. The LCT attaches inline and is compatible with multiple Ricoh printers and downstream modules. The design of the Plockmatic LCT is tailored specifically to complement Ricoh printing sys-tems and provides features that set Ricoh systems apart from their competitors.
  • Page 7 CIP Training Plockmatic LCT3500 Large Capacity Tray Guide To Components Exterior 1. Exit Area 2. Docking Pin 3. Top hatch 4. Long Sheet Module (LSM) 5. User Interface (UI) 6. Upper Tray / Tray 3 (Tray 1 in Printer) 7. Lower Tray / Tray 4 (Tray 2 in Printer)
  • Page 8 CIP Training Plockmatic LCT3500 Large Capacity Tray Vertical Paper Path and Exit 9. Jam Clearance Baffles (8x blue handles) 10. Power Switch...

  • Page 9: Tray Assembly

    CIP Training Plockmatic LCT3500 Large Capacity Tray Tray Assembly 11. Paper Guide Lock Release 12. Paper Guide Fans (2x on each side) 13. Vacuum Feed Belts 14. Optical Double Sheet Detection (DSD) Sensor (Q101/201) 15. Ultrasonic Double Sheet Detection (Q102/202) 16.
  • Page 10 CIP Training Plockmatic LCT3500 Large Capacity Tray Long Sheet Module (LSM) 24. Handle, tray 25. Fans 26. Side guides, tray 27. Tray extension 28. Side guides, tray extension 29. Sensor, tray empty (Q505) 30. Sensor, paper path (Q521) 31. Sensor exit (Q522) 32.

  • Page 11: User Interface

    CIP Training Plockmatic LCT3500 Large Capacity Tray User Interface The Plockmatic LCT has a User Interface (UI) / Control Panel which allows for viewing or adjusting local machine settings and properties. In other configurations where the LCT is connected to a downstream printer or device, setting up a job will be handled via the UI of the downstream device.
  • Page 12 CIP Training Plockmatic LCT3500 Large Capacity Tray User Interface Media Pressing the [Media] button from the Main Menu opens the Media sub- menu. From this sub-menu the user can specify the type of media loaded in the machine (trays and Long Sheet Module).

  • Page 13: Status Leds

    CIP Training Plockmatic LCT3500 Large Capacity Tray Status LEDs The LCT trays and the optional LSM module are equipped with status LEDs. Below is a short explanation of the state colors. Tray LED Blue LEDs: Yellow LEDs: Tray Loaded paper level: low on paper.

  • Page 14: Turning On/Off The Power

    CIP Training Plockmatic LCT3500 Large Capacity Tray Basics Turning On / Off the Power Main Power Switch 1 1 Ensure that the main power cord is plugged into the wall and to the back of the LCT; 2 2 Make sure the two termination plugs are plugged in, as shown in the picture;...

  • Page 15: Sensor Calibration

    CIP Training Plockmatic LCT3500 Large Capacity Tray Basics Calibration Sensor Calibration The LCTvacuum trays and the optional LSM module have two types of double sheet de- tection (DSD): optical and ultrasonic. If feed errors begin occurring more frequently, these sensors may need to be calibrated. Refer to Section 6 for full calibration details and in- structions.
  • Page 16 CIP Training Plockmatic LCT3500 Large Capacity Tray Basics Sensor Calibration The LCT vacuum trays are also equipped with two linear sensors which are used to detect the size of the type of paper loaded in the trays. Should these sensors need to be calibrated, refer to section 6.

  • Page 17: Job Preparation

    CIP Training Plockmatic LCT3500 Large Capacity Tray Basics Job Preparation Paper stack preparation 1 1 Hold the paper stack on a flat surface as shown 2 2 Bend the paper stack 3 3 Use your fingers and thumbs to pinch the paper stack...
  • Page 18 CIP Training Plockmatic LCT3500 Large Capacity Tray Basics Paper stack preparation 5 5 Flex the paper back and forth a couple of times to break surface tension and preseparate the sheets 6 6 Realign the sheets into a stack before...

  • Page 19: Measuring The Paper Curl

    CIP Training Plockmatic LCT3500 Large Capacity Tray Basics Measuring the paper curl Take a sample of the stack (about 15 mm / 0.59” high) and place it on a flat surface 1 1 Take the midpoint as reference and do all the measurements within the...
  • Page 20 CIP Training Plockmatic LCT3500 Large Capacity Tray Basics Loading Paper 1 1 From the Main Menu, select Load tray 3 or Load tray 4 depending on which tray you intend to open and load. Tray 3 is the upper tray;...

  • Page 21: Loading Paper

    CIP Training Plockmatic LCT3500 Large Capacity Tray Basics Loading Paper 6 6 The Vacuum Size Valve controls the size of the vacuum suction area on the bottom of the vacuum chamber. The Vacuum Size Valve needs to be manually shifted to the correct position, which depends on paper width.
  • Page 22 CIP Training Plockmatic LCT3500 Large Capacity Tray Basics Loading Paper 1 1 Pull the paper guides [A] and [B] outwards to gain space to insert the stack of sheets; 2 2 If the paper sheets require a long tray base, pull the LSM extension [C] out;...
  • Page 23 CIP Training Plockmatic LCT3500 Large Capacity Tray Basics Printer settings It is extremely important to program the sheets size/type both in the LCT and on the printer: there is no communication among the printer and the LCT about paper properties.

  • Page 24: Setting Up A Job

    LCT and on the printer: there is no communication among the printer and the LCT about paper properties. Plockmatic always recommends to use all auto/default settings. Media The main menu on the User Interface will show a summary of the main info for each of the three trays.

  • Page 25: Setting The Paper Type

    CIP Training Plockmatic LCT3500 Large Capacity Tray Setting Up a Job Setting the Paper Type Select [Paper Size] to enter the size of the media loaded. Select [Paper Weight] to enter the correct paper weight range of the media loaded.
  • Page 26 CIP Training Plockmatic LCT3500 Large Capacity Tray Setting Up a Job Setting the Paper Type Paper weight: Select the paper weight by choosing one of the listed options. Push the green check mark to confirm the changes or the red cross to discard them and to go back to the main menu.

  • Page 27: Paper Curl

    CIP Training Plockmatic LCT3500 Large Capacity Tray Setting Up a Job Auto Fans / Manual Fans This button allows the user to switch between automatic or manual fan settings. Auto mode sets all the process parameters except for the paper color, which is set in the [Advanced] sub-menu, and the paper curl amount.
  • Page 28 CIP Training Plockmatic LCT3500 Large Capacity Tray Setting Up a Job DSD Sensors Ultrasonic DSD Sensor [A] The LCT is equipped with three (in the vacuum trays and in the optional LSM) independent double sheet detection systems, both optical and ultrasonic.
  • Page 29 CIP Training Plockmatic LCT3500 Large Capacity Tray Setting Up a Job Advanced Press [Advanced] to reach the advanced settings: the advanced settings for the selected tray will be displayed. NOTE: Always push the green checkmark button to save changes. Switching to...

  • Page 30: Status Icons

    CIP Training Plockmatic LCT3500 Large Capacity Tray Setting Up a Job Advanced Pick Up Time The Pick up Time is the amount of time the vacuum is activated to feed each sheet. This value can be adjusted between 75 ms and 500 ms.
  • Page 31 Plockmatic recommends adjusting only one setting at a time. If adjusting that setting does not provide satisfactory results, set it back to auto mode prior to adjusting another setting.
  • Page 32 CIP Training Plockmatic LCT3500 Large Capacity Tray Setting Up a Job Manual Fans Adjustment Vacuum Air This parameter controls the vacuum fan, which pulls paper towards the transportation belt during feeding. Push the green check mark to confirm the changes or the red cross to discard them and to go back to the main menu.
  • Page 33 CIP Training Plockmatic LCT3500 Large Capacity Tray Setting Up a Job Manual Fans Adjustment Rear Float Air This parameter controls the flow of the two rear fans. Float air blows into the paper stack from the sides to create separation between sheets.

  • Page 34: Saving Changes

    Testing the changes Before starting a job, Plockmatic recommends testing the changes made in manual mode with the “test settings” button under the Tools Menu (see section 3 of this manual). This function activates all the fans and moves the elevator to process position according to your settings.
  • Page 35 CIP Training Plockmatic LCT3500 Large Capacity Tray Setting Up a Job Tray A settings (Long Sheet Module - LSM) If the optional Long Sheet Module is installed on the LCT, the [Tray A] button will appear on the User Interface. When [Tray A] is selected, the LSM sub-menu is shown.

  • Page 36: The Tools Menu

    CIP Training Plockmatic LCT3500 Large Capacity Tray Tools The Tools Menu From the Tools sub-menu the user can modify parameters such as Units and Language. This sub-menu also allows the user to test the manual settings, change paper size lists, units and languages, enter...

  • Page 37: Service Mode

    CIP Training Plockmatic LCT3500 Large Capacity Tray Tools Language Select the desired operating language for the machine by pressing the [Language] button. Service Mode This function is for authorized service personnel only and is password pro- tected. Calibration The operator will be able to calibrate...

  • Page 38: Software Version

    CIP Training Plockmatic LCT3500 Large Capacity Tray Tools Units Toggle between millimetres or inches by pressing the [Units] button. Software version This function allows the user to check the Software version installed on the LCT. Counters The Counter sub-menu allows the user...

  • Page 39: Handling Jobs

    CIP Training Plockmatic LCT3500 Large Capacity Tray Jobs Handling jobs Pressing [Jobs] opens the Jobs sub- menu. From here you can open a saved job. Saved jobs can be customized and deleted. Loading a Job The user can load a job by selecting it from the saved jobs list and then pushing the [Load] button.

  • Page 40: Saving A Job

    CIP Training Plockmatic LCT3500 Large Capacity Tray Solutions Saving a Job After having selected the Job from the job list, push the [Save] button to save changes to it. Push [Yes] to confirm. NOTE: Before saving a Job, make sure to have pressed the green checkmark button on the Settings sub-menu (see “saving...
  • Page 41 CIP Training Plockmatic LCT3500 Large Capacity Tray Clearing Misfeeds Clearing Misfeed(s) Misfeed / Jam in Feeder Tray The affected tray will unlock. 1 1 Pull out the tray; 2 2 If the sheet has been misfed and isn’t damaged, reposition and restart;...

  • Page 42: Clearing Misfeeds

    CIP Training Plockmatic LCT3500 Large Capacity Tray Clearing Misfeeds Misfeed / Jam in Long Sheet Module (LSM) Area (continued) 1 1 Release the Latch handle [A] and open the top hatch with the connected baffle; 2 2 Remove misfed sheet(s) and clear area of any debris or obstructions.
  • Page 43 CIP Training Plockmatic LCT3500 Large Capacity Tray Clearing Misfeeds Misfeed / Jam in Vacuum Trays when feeding thick media If you experience frequent misfeeds when feeding thick media (thicker than 350 gsm) from the vacuum trays, consider using Tray A (the optional LSM tray) instead. If your machine is not equipped with the optional LSM and you are feeding thick media from tray 4 (the lower tray), try using tray 3 (the upper tray).
  • Page 44 CIP Training Plockmatic LCT3500 Large Capacity Tray Clearing Misfeeds Misfeed / Jam in Vacuum Trays when feeding thick media 5 5 Locate the separation pads [B] (2x) and the vacuum belts [C]; 6 6 The separation pads are factory adjusted so that the distance between the top edge of the separation pads and the vacuum belts is equal to 1 mm.
  • Page 45 CIP Training Plockmatic LCT3500 Large Capacity Tray Troubleshooting - Fault codes General When there is a misfeed or fault condition in the LCT, a message and fault code will be displayed on the UI. Some fault codes may be rectified by the operator, but some fault codes may only be rectified by an authorized technician.

  • Page 46: Troubleshooting - Fault Codes

    CIP Training Plockmatic LCT3500 Large Capacity Tray Troubleshooting - Fault codes List of fault codes that can be rectified by the operator Fault Code Description LCT-551 "Paper late to exit position" LCT-560 "Paper flow error Q321 - LCT" LCT-561 "Paper flow error Q322 - LCT"...
  • Page 47 CIP Training Plockmatic LCT3500 Large Capacity Tray Troubleshooting - Fault codes Fault Codes NOTE: For components locations, refer to the Guide to Components section. LCT-100/200 Misfeed Tray 3/4 Misfeed is a paper flow error detection. Misfeed checks if a sheet is moved correctly from paper pile to optical DSD sensor.
  • Page 48 CIP Training Plockmatic LCT3500 Large Capacity Tray Troubleshooting - Fault codes Fault Codes NOTE: For components locations, refer to the Guide to Components section. LCT-104/204 Too Thick, Tray 3/4 Too Thick is a paper thickness error detection. Too Thick checks if a sheet is too thick when it passes the optical DSD sensor Q101/201.
  • Page 49 CIP Training Plockmatic LCT3500 Large Capacity Tray Troubleshooting - Fault codes Fault Codes NOTE: For components locations, refer to the Guide to Components section. LCT-108/208 Too Thin, Tray 3/4 Too Thin is a paper thickness error detection. Too Thin checks if a sheet is too thin when it passes the optical DSD sensor Q101/201.
  • Page 50 CIP Training Plockmatic LCT3500 Large Capacity Tray Troubleshooting - Fault codes Fault Codes NOTE: For components locations, refer to the Guide to Components section. LCT-301 Jam Tray A (LSM) Jam is a paper flow error detection. Jam checks if a sheet is moved past the DSD sensor correctly.
  • Page 51 CIP Training Plockmatic LCT3500 Large Capacity Tray Troubleshooting - Fault codes Fault Codes NOTE: For components locations, refer to the Guide to Components section. LCT-305 DSD Functionality Uncertain, Tray A (LSM) DSD functionality uncertain is a warning that can be generated at calibration. DSD func- tionality uncertain checks if the sheet thickness is within reading range for the optical DSD sensor Q501.
  • Page 52 CIP Training Plockmatic LCT3500 Large Capacity Tray Troubleshooting - Fault codes Fault Codes NOTE: For components locations, refer to the Guide to Components section. LCT-309 Tray A not in process position, Tray A (LSM) Tray A not in process position is a tray position error detection. Tray A not in process posi- tion checks if the load lock handle is released and that the tray is in the process position.
  • Page 53 CIP Training Plockmatic LCT3500 Large Capacity Tray Troubleshooting - Fault codes Fault Codes NOTE: For components locations, refer to the Guide to Components section. LCT-461 Paper flow error Q522 Paper flow error Q522 is a paper flow error detection. Paper flow error checks sensor sta-tus during running, both previous and following sensors in transport direction are checked when paper leading/trailing edge is detected by a paper path sensor.
  • Page 54 CIP Training Plockmatic LCT3500 Large Capacity Tray Troubleshooting - Fault codes Fault Codes (Continued) NOTE: For components locations, refer to the Guide to Components section. LCT-560 Paper flow error Q321 Paper flow error Q321 is a paper flow error detection. Paper flow error checks sensor sta-tus during running, both previous and following sensors in transport direction is checked when paper leading/trailing edge is detected by a paper path sensor.
  • Page 55 CIP Training Plockmatic LCT3500 Large Capacity Tray Troubleshooting - Fault codes Fault Codes NOTE: For components locations, refer to the Guide to Components section. LCT-564 Paper flow error Q325 Paper flow error Q325 is a paper flow error detection. Paper flow error checks sensor sta- tus during running, both previous and following sensors in transport direction are checked when paper leading/trailing edge is detected by a paper path sensor.
  • Page 56 CIP Training Plockmatic LCT3500 Large Capacity Tray Troubleshooting - Jam recovery Jam recovery manual setting Miss error When the message “miss” is displayed, the paper is not being fed from the trays. Procedure Does paper have cross process direction curl? Measure paper curl: if paper curl is negative, decrease process position by that amount, if paper curl is positive, increase process position by that amount.
  • Page 57 CIP Training Plockmatic LCT3500 Large Capacity Tray Troubleshooting - Jam recovery Jam recovery manual setting Jam, Too long, Too thick errors When one of these messages is displayed, there might be jam or a double sheet detection in the trays.

  • Page 58: Troubleshooting

    CIP Training Plockmatic LCT3500 Large Capacity Tray Troubleshooting Optical Sensor Calibration Sensors should be calibrated if the machine noticeably increases in frequency of misfeeds. Calibration sub-menus for Optical DSD Sensor, Ultrasonic DSD Sensor may be selected from the Tools Menu.
  • Page 59 CIP Training Plockmatic LCT3500 Large Capacity Tray Troubleshooting Ultrasonic Sensor Calibration Procedure - Calibration of Ultrasonic DSD: • Select Ultrasonic DSD Tray 3 to calibrate the upper tray’s sensor; • Select Ultrasonic DSD Tray 4 to calibrate the lower tray’s sensor;...
  • Page 60 CIP Training Plockmatic LCT3500 Large Capacity Tray Troubleshooting Paper Sensors Calibration Tray 3/4 Sensors should be calibrated if the LCT does not recognise correctly the paper loaded into the trays. Calibration sub-menus may be selected from the Tools Menu. Procedure - Paper Sensors Calibration Tray: •...

  • Page 61: Do's And Don'ts

    CIP Training Plockmatic LCT3500 Large Capacity Tray Do’s And Don’ts • Always follow all warnings marked on, or supplied with, the equipment. • Always exercise care in moving or relocating the equipment. Caution Unplug the power cord from the wall outlet and machine before you move or relocate the equipment.

  • Page 62: Power Connection

    CIP Training Plockmatic LCT3500 Large Capacity Tray Where to Put Your Machine Machine Environment • Always locate the equipment on a solid support surface with adequate strength for the weight of the machine • Always keep magnets and all devices with strong magnetic fields away from the machine...

  • Page 63: Maintaining Your Machines

    CIP Training Plockmatic LCT3500 Large Capacity Tray Maintaining Your Machines Never attempt any maintenance function that is not specifically described in this documentation. Maintenance Cleaning An increasing number of misfeeds may indicate a need to clean the LCT. Clean every 50 000 cycles or when the number of misfeeds increases.
  • Page 64 CIP Training Plockmatic LCT3500 Large Capacity Tray Maintaining Your Machines Cleaning 4. Open the front door. 5. Toggle the blue handles to the baffles and clean surfaces from toner smearings. 6. Clean, if needed, the feed rollers inside the baffles with rubber...
  • Page 65 CIP Training Plockmatic LCT3500 Large Capacity Tray Maintaining Your Machines Cleaning The LSM Feed Rollers need to be cleaned regularly when in use or if the unit has not been used for a period of time. How often this has to be done, depends on the paper type and print quality.
  • Page 66 CIP Training Plockmatic LCT3500 Large Capacity Tray Maintaining Your Machines Cleaning An increasing number of misfeeds may indicate a need to clean the LSM. Clean every 50 000 cycles or when the number of misfeeds increases. Use a vacuum cleaner, towels and brushes for general purpose cleaning of the paper path. In addition, follow the detailed cleaning instructions below: Clean, if needed, the feed and idler rollers inside the LSM with rubber reactivator alcohol.
  • Page 67 • When loading paper in the trays of the LCT3500 make sure that it has the same direction of pa-per curl: paper with different curl directions cannot be mixed, doing so would result in a misfeed or a jam.

  • Page 68: Specifications

    Safety and EMC according to lat- est standard Plockmatic uses open source code in parts of this product. Plockmatic uses QT open source license (LGPL) to develop the software used in this machine (https:// www.qt.io/qt-licensing-terms). Print Engine Compatibility Pro C9200 series...
  • Page 69 CIP Training Plockmatic LCT3500 Large Capacity Tray Specifications Vacuum Trays Specifications Specifications Remarks Maximum loading capacity, 175 mm each tray 6.88 in Maximum loading weight, 62 kg each tray 136.67 lb Minimum - Maximum paper size 120 x 210 mm / 4.73 x 8.27 in...
  • Page 70 CIP Training Plockmatic LCT3500 Large Capacity Tray Specifications LSM (Long Sheet Module - tray A) Specifications Specifications Remarks Plain media Loading Capacity LSM Note! Feeding performance on • 70mm 80-105gsm thicker media (300-400gsm) • 50mm 105.1-256gsm might be limited in below length •...
  • Page 71 CIP Training Plockmatic LCT3500 Large Capacity Tray Specifications Integrity Factors Specifications Remarks UMR (Unscheduled Maintenance 1 visit per 1.2 million sheets Rate) SDR, Shut Down Rate Vacuum Tray 1 per 3000 sheets A3 (11 x 17”) 120 gsm Xerox Colour Impression...
  • Page 72 Specifications Auto Paper Size Detection Although being able to process several types of standard paper formats, the LCT3500 is able to detect only some of those standard paper formats. The detection of the paper formats is carried out by using several sensors, which include the sensors mounted on the side guides. Therefore, it is important to set the side guides correctly.

  • Page 73: Eu Declaration Of Conformity

    CIP Training Plockmatic LCT3500 Large Capacity Tray Specifications EU DECLARATION OF CONFORMITY ......N0007386 (A.1) Manufacturer ..Plockmatic International AB, Telefonvägen 30, S-126 26 Hägersten, Sweden This Declaration of Conformity is issued under the sole responsibility of the manufacturer Object of the Declaration Model/Type F140-001...
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