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Plockmatic BF-450e Operator's Manual

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X04144_EN_B BF-450e/435e System Operator Manual
Plockmatic BF-450e/435e
Booklet Maker System
Doc no: x04144_EN_B
Date: 5 November 2024
Read this manual carefully before you use this product and keep it handy for
future reference.
For safety, please follow the instructions in this manual.
System Operator Manual

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Summary of Contents for Plockmatic BF-450e

  • Page 1 X04144_EN_B BF-450e/435e System Operator Manual Plockmatic BF-450e/435e Booklet Maker System System Operator Manual Read this manual carefully before you use this product and keep it handy for future reference. For safety, please follow the instructions in this manual. Doc no: x04144_EN_B...
  • Page 2 X04144_EN_B BF-450e/435e System Operator Manual Scan the QR code to access translated versions of this manual in German, Italian, French, and Spanish. Visit https://plockmaticgroup.com/myfinisher/customer-portal-bf-450e- bf-435e-kyocera/ to view the manual in your preferred language.

  • Page 3: How To Read This Manual

    X04144_EN_B BF-450e/435e System Operator Manual 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 X04144_EN_B BF-450e/435e System Operator Manual Safety Information When using this machine, safety precautions should always be followed. General Safety WARNING • This equipment is not suitable for use in locations where children are likely to be present. • Only connect the machine to a mains power supply of the correct voltage with a good earth- connection;...
  • Page 5 X04144_EN_B BF-450e/435e System Operator Manual Safety during operation, continued WARNING • Turn off the power and disconnect the power plug (by pulling the plug, not the cable) if any of the following conditions exists: • Objects are dropped into the equipment.
  • Page 6 X04144_EN_B BF-450e/435e System Operator Manual Safety Information, continued English Description of Safety/Warning labels in the product Crushing Hazard Cutting Hazard Entanglement Hazard Risk for crushing or Sharp objects inside machine. Risk for loose hanging hair, squeezing body parts. jewelry, or clothes to get caught.

  • Page 7: Table Of Contents

    X04144_EN_B BF-450e/435e System Operator Manual TABLE OF CONTENTS What You Can Do With This Machine ................10 Guide To Components ..................... 12 Booklet Maker ..........................12 User Interface ..........................16 Options ..........................19 Manual Feed Tray ........................19 Finishing Module ......................... 20 Rotate Crease Trim Module ......................
  • Page 8 X04144_EN_B BF-450e/435e System Operator Manual Fold ............................. 58 Adjusting fold position ........................... 58 Staple ............................59 Selecting stapling On or Off ........................59 Saddle staple............................59 Adjusting saddle staple position ......................59 Edge Staple ............................60 Corner Staple ............................60 Crease ............................
  • Page 9 Cleaning of creaser tools (x2) ......................107 Adjustment of Side Trimmer registration angle (parallel cut)............... 108 Adjustment of Creaser registration angle .................... 109 Best practices for the BF-450e/435e system ............... 110 Limitations of the BF-450e/435e system ..............111 8. Specification ................. 115 Machine Specifications ....................

  • Page 10: What You Can Do With This Machine

    Together they form a system that allows full bleed booklet making online with the Upstream Device. The BF-450e upgrade kit raises the capacity of the BF-435e Booklet maker from 35 sheets to 50 sheets. This means that, instead of 140 page booklets, 200 page booklets are now possible.
  • Page 11 X04144_EN_B BF-450e/435e System Operator Manual What You Can Do With This Machine, continued The Booklet Maker jogs, staples and can, depending on the choice of stapling, also fold the set. There are three types of stapling to choose from; Saddle, Edge or Corner stapling.

  • Page 12: Guide To Components

    X04144_EN_B BF-450e/435e System Operator Manual Guide To Components Booklet Maker Parts that are important for setup, adjustments, troubleshooting or maintenance are high- lighted below. 1. Belt Stacker Stop Bracket 4. Top Cover 2. Belt Stacker 5. Top Cover Latch Handle 3.
  • Page 13 X04144_EN_B BF-450e/435e System Operator Manual Booklet Maker, continued 1. Infeed Area 5. Holes for hanging the Manual Feed 2. Document storage compartment Tray (optional) when docked 3. Casters 6. Docking Bracket 4. Connections continued on next page...
  • Page 14 X04144_EN_B BF-450e/435e System Operator Manual Booklet Maker, continued 1. Corner Staple Kit 5. Infeed Drive and Paper Guide/Jam 2. Power Switch Clearance 3. Small paper kit 6. Upper and Lower Fold Roller Paper 4. Counter Guide/Jam Clearance 7. Transport Belt/Jam Clearance...
  • Page 15 X04144_EN_B BF-450e/435e System Operator Manual Booklet Maker, continued 1. Gas Spring 4. Staple Cartridge Ejector Levers 2. Back Jogger Fingers (x4) 5. Staple Cartridges 3. Infeed Drive 6. Spare Staple Cartridges storage slots...

  • Page 16: User Interface

    X04144_EN_B BF-450e/435e System Operator Manual User Interface The Plockmatic BF-450e/435e Production Booklet Maker System is controlled from a panel located on the Booklet Maker. The User Interface will allow you to set up, adjust and operate the complete system. NOTE: Depending on features installed, the screen may look different from what you see here. Some...
  • Page 17 X04144_EN_B BF-450e/435e System Operator Manual User Interface, continued This screenshot shows a system without an RCT and FM. In this case, the possibility to set the face trim, square form and crease is not available. The shape of the buttons will adapt to fit the screen.
  • Page 18 X04144_EN_B BF-450e/435e System Operator Manual User Interface, continued The Counter Screen Pressing the [Counters] button in the Settings Screen opens the Counters screen. The Tools Screen Pressing the [Tools] button opens the Tools screen. From here you can change basic settings like the display language, setting units from millimetres to inches and more.

  • Page 19: Options

    X04144_EN_B BF-450e/435e System Operator Manual Options Manual Feed Tray The optional Manual Feed Tray facilitates manual feeding of sets to the Booklet Maker when the system also contains an RCT. The Tray can be attached when the Booklet Maker system is undocked. When not in use, the Manual Feed Tray can be stored hanging on the Booklet Maker Rear Cover.

  • Page 20: Finishing Module

    X04144_EN_B BF-450e/435e System Operator Manual Finishing Module 1. Exit Area 4. Cover to Trim Waste Bin 2. Top Cover 5. Casters 3. Top Cover Latch Handle continued on next page...
  • Page 21 X04144_EN_B BF-450e/435e System Operator Manual Finishing Module, continued 1. Gas Spring 2. Infeed Area 3. Trim Waste Bin...

  • Page 22: Rotate Crease Trim Module

    X04144_EN_B BF-450e/435e System Operator Manual Rotate Crease Trim Module Parts that are important for setup, adjustments, troubleshooting or maintenance are high- lighted below. 1. Top Cover 4. Docking Latch 2. Slide Door 5. Casters 3. Upstream Docking assembly 6. Infeed Bracket...
  • Page 23 X04144_EN_B BF-450e/435e System Operator Manual Rotate Crease Trim Module, continued 1. Exit slot 5. Connections 2. Downstream Docking assembly 6. Cable Protector 3. Trim Waste Transport 7. Waste Bin 4. Waste Bin full Detection continued on next page...
  • Page 24 X04144_EN_B BF-450e/435e System Operator Manual Rotate Crease Trim Module, continued 1. Counter 4. Main switch 2. Top Cover Latch 5. Side trimmer circular knives 3. Infeed area “A” 6. Exit area “D” continued on next page...
  • Page 25 X04144_EN_B BF-450e/435e System Operator Manual Rotate Crease Trim Module, continued 1. Waste chute(s) 2. Creaser registration adjustment 3. Bleed trimmer registration adjustment 4. Latch handle, slide continued on next page...
  • Page 26 X04144_EN_B BF-450e/435e System Operator Manual Rotate Crease Trim Module, continued 1. Rotator 3. Creaser tools 2. Jam Clearance Baffle, coarse registra- 4. Jam Clearance Baffle, fine registra- tion, area “B” tion, area “C”...

  • Page 27: Bst4000-1 Belt Stacker Module

    BST4000-1 Belt Stacker Module The BST4000-1 High Capacity Belt Stacker Module is an option available for the Plockmatic BF-450e/435e Production Booklet Maker System. The stacker can be configured in a straight line after the Booklet Maker system or at a 90 degree angle.

  • Page 28: Bst4000-1 Principle Of Operation

    X04144_EN_B BF-450e/435e System Operator Manual BST4000-1 Belt Stacker Module, continued 1. Power switch (on/off) 2. Belt speed selector 3. Run-out button (full speed) BST4000-1 Principle of Operation The belt is triggered by a signal from the Booklet Maker and will run for a set time.

  • Page 29: Trim Waste Conveyor

    X04144_EN_B BF-450e/435e System Operator Manual Trim Waste Conveyor The Trim Waste Conveyor attaches to and is powered from the RCT. It transports trim waste upwards which enables the use of a larger waste bin. This makes long, unattended runs easier than ever before.
  • Page 30 X04144_EN_B BF-450e/435e System Operator Manual Page intentionally blank.

  • Page 31: Basics

    X04144_EN_B BF-450e/435e System Operator Manual 1. Basics Turning On / Off the Main Power RCT and Booklet Maker Make sure that the power cords to the RCT module (optional), Booklet Maker and BST (optional) are plugged into a live wall outlet.

  • Page 32: Change Staple Cartridges And Check Stapler

    X04144_EN_B BF-450e/435e System Operator Manual Change staple cartridges and Check stapler The staple cartridges contain approximately 5000 staples each. Each cartridge includes all wearable parts. The cartridges may need to be removed either for replacement or for jam clearance. Out of Staple The Booklet Maker will indicate “Out of Staple”...

  • Page 33: Stapler Miss

    X04144_EN_B BF-450e/435e System Operator Manual Stapler miss If the Booklet Maker indicates “...stapler miss”, it means that there is a jam in the indicated stapler. Remove the stapler cartridge as described in “Replacing staple cartridge(s)”. Open the Booklet Maker top cover.

  • Page 34: Installing/Removing The Small Paper Kit

    X04144_EN_B BF-450e/435e System Operator Manual Installing/Removing the Small Paper Kit The small paper kit consists of two side jogger extensions that are stored on the inside of the top cover. Using paper widths less than 206 mm (8.111”) requires that they are installed in the booklet maker.
  • Page 35 X04144_EN_B BF-450e/435e System Operator Manual Installing the small paper kit, continued Fit the keyhole shaped cut-out [E] around the upper knob [A]. Slide the slotted holes on the left side jogger extension under knobs [A] and [B]. Tighten knobs [A] and [B] on the left side jogger.

  • Page 36: Removing The Small Paper Kit

    X04144_EN_B BF-450e/435e System Operator Manual Removing the small paper kit Loosen the knobs [C] on the inside of the top cover. Loosen the knobs [A] and [B] on the left side jogger. Slide the left side jogger extension [D] towards the infeed area and lift when the keyhole shaped cut-out [E] fits around the upper knob [A].
  • Page 37 X04144_EN_B BF-450e/435e System Operator Manual Removing the small paper kit, continued Slide the slotted holes on the left side jogger extension [D] into the gaps [F] between the right spacers, knob and lock nut on the inside of the top cover.

  • Page 38: Installing/Removing The Corner Staple Kit

    X04144_EN_B BF-450e/435e System Operator Manual Installing/Removing the corner staple kit The corner staple kit enables repositioning of the compiled sheets so that a staple can be put in the corner. The kit is stored on the rear machine frame. Selecting corner stapling will start a step-by- step guide in the UI to help installing the corner staple kit.
  • Page 39 X04144_EN_B BF-450e/435e System Operator Manual Installing the corner staple kit, continued Slide the slotted holes on the corner staple kit [D] under knobs [A] and [B]. Tighten the knobs [A] and [B] on the left side jogger. Insert the cable [E] in to the jack [F] in the front frame.

  • Page 40: Removing The Corner Staple Kit

    X04144_EN_B BF-450e/435e System Operator Manual Removing the corner staple kit Disconnect the cable [E] from the jack [F] in the front frame. Loosen the knobs [A] and [B] on the left side jogger. Slide the the corner staple kit [D] towards the infeed and lift to remove.
  • Page 41 X04144_EN_B BF-450e/435e System Operator Manual Removing the corner staple kit, continued Hang the corner staple kit [D] on the screw [G] on the rear frame. Secure the cable [E] to the rear frame using the cable fastener [C]. Tighten knobs [A] and [B].

  • Page 42: Emptying Waste Bins

    X04144_EN_B BF-450e/435e System Operator Manual Emptying waste bins Side Trim Waste Bin The Side Trim Waste Bin is located behind the RCT. The message “Empty Side Trim Waste Bin” will be shown on the User Interface when the Side Trim Waste Bin is full. Proceed as follows: Empty the Side Trim Waste Bin.

  • Page 43: Face Trim Waste Bin

    X04144_EN_B BF-450e/435e System Operator Manual Face Trim Waste Bin The Face Trim Waste Bin is located inside the Finishing Module behind the Trim Waste Bin Cover. The message “Empty Face Trim Waste Bin” will be shown on the User Interface when the Face Trim Waste Bin is full.

  • Page 44: Belt Stacker Bst4000-1

    X04144_EN_B BF-450e/435e System Operator Manual Belt Stacker BST4000-1 Setting up Belt Stacker for right-angled mode Follow these steps to correctly set up the Stacker Move the inner Side Guide [A] as far as possible towards the Booklet Maker. Adjust the outer Side Guide [B] to give at least 5 mm (1/4″) play.

  • Page 45: Setting Up Belt Stacker For Straight Mode

    X04144_EN_B BF-450e/435e System Operator Manual Setting up Belt Stacker for straight mode Adjust Side Guides to their outermost position by loosening knobs [A]. Adjust the stacking with belt speed selector [B].

  • Page 46: Detaching / Attaching The Trim Waste Conveyor

    X04144_EN_B BF-450e/435e System Operator Manual Detaching / Attaching the Trim Waste Conveyor Detaching the Trim Waste Conveyor Remove screws [A] (x3) and remove the Belt safety cover [B]. Unhook the O-ring [C] from the upper Pulley [D] Loosen Knob [E]. The TWC is now detached from the RCT and can be moved away.

  • Page 47: Attaching The Trim Waste Conveyor

    X04144_EN_B BF-450e/435e System Operator Manual Attaching the Trim Waste Conveyor NOTE: If already attached, remove the Cable protector on RCT, before attaching the TWC unit Attaching the Trim Waste Conveyor is an exact reversal of detaching as described above. NOTE:...

  • Page 48: Docking / Undocking

    X04144_EN_B BF-450e/435e System Operator Manual Docking / Undocking Docking the Booklet Maker System If installed, remove the Manual Feed Tray from the Booklet Maker. The Manual Feed Tray can be stored hanging on the top left of the rear cover of the Booklet Maker.

  • Page 49: Making Booklets

    X04144_EN_B BF-450e/435e System Operator Manual 2. Making Booklets General procedure Settings can be changed temporarily or permanently. Temporarily means that the changes will not be possible to restore if changed again or when a saved job is loaded. Permanently means that the changes are saved as a job with the possibility of later being restored.
  • Page 50 X04144_EN_B BF-450e/435e System Operator Manual General, continued Using paper widths less than 206 mm (8.111”) requires that the small paper kit is installed. The installation is described above (see section 1, Installing/Removing the Small Paper Kit). Changing from a larger paper size to such a small paper size will start a step-by-step guide to help installing this small paper kit.

  • Page 51: Selecting Standard Paper Sizes

    X04144_EN_B BF-450e/435e System Operator Manual Selecting standard paper sizes From the Settings Screen, press the [Paper Size] button. Select any available standard paper size by pressing the corresponding button and save choice by pressing the green [check] button. For other paper sizes, see “Custom Paper Size”...
  • Page 52 X04144_EN_B BF-450e/435e System Operator Manual Custom Paper size, continued Pressing the width or length numbers will dis- play a number pad. Enter the desired width and/ or length. Confirm your changes to the custom paper size by pressing the green check mark or exit with- out making any changes by pressing the red X mark.

  • Page 53: Booklet Size

    X04144_EN_B BF-450e/435e System Operator Manual Booklet Size General From the Settings Screen, press the [Booklet Size] button. Booklet Size can be set to either of two suggested formats or to a Custom Booklet Size. The amount of Bleed trim as well as the size of the finished booklet as a result of the actual Booklet Size choices, is displayed.

  • Page 54: Custom Booklet Size

    X04144_EN_B BF-450e/435e System Operator Manual Custom Booklet Size To set the trim manually, press the [Custom Booklet Size] button and then the [Edit] button. Set the desired width and/or length either by pressing the [plus] and [minus] buttons or by pressing the width or length numbers.

  • Page 55: Squareback

    X04144_EN_B BF-450e/435e System Operator Manual SquareBack General The SquareBack in the Finishing Module has three different settings - AUTO, Manual and OFF. Information on the [SquareBack] button shows the actual Status of the SquareBack and what mode is selected. Set to AUTO, the Booklet Maker uses informa-...
  • Page 56 X04144_EN_B BF-450e/435e System Operator Manual General, continued The table below shows highest supported SquareBack pressure settings during normal operation. Precision Mode turned OFF No of A3 SRA3 8.5x11 8.5x11 11x17 12x18 210x490 225x610 225x660 sheets Off Off 6-10 11-15 For certain media requiring more SquareBack pressure, “Precision Mode” can be enabled to allow more time in the SquareBack process.

  • Page 57: Selecting Squareback Pressure Setting

    X04144_EN_B BF-450e/435e System Operator Manual Selecting SquareBack pressure setting The default status for the SquareBack is ON and the default mode is AUTO. After one booklet has been produced, the Mode info in the [SquareBack] button will change from “AUTO” to show the mode that was calculated to be the most appropriate mode setting.

  • Page 58: Fold

    X04144_EN_B BF-450e/435e System Operator Manual Fold Adjusting fold position Information on the [Fold] button shows the ac- tual Fold status and position. To alter the Fold settings, press the [Fold] button from the Set- tings Screen. The Booklet Maker uses information from the set thickness sensor to calculate and adjust the correct fold position.

  • Page 59: Staple

    X04144_EN_B BF-450e/435e System Operator Manual Staple Selecting stapling On or Off Information on the [Staple] button shows the actual Staple status and position. To alter the Staple settings, press the [Staple] button from the Settings Screen. Staple status can be set to either Saddle Sta- pling, Edge Stapling, Corner Stapling or being disabled by pressing the corresponding button.

  • Page 60: Edge Staple

    X04144_EN_B BF-450e/435e System Operator Manual Edge Staple In the Staple Settings screen, enable edge sta- pling by pressing the [Edge Staple] button. Confirm by pressing the green [check] button. NOTE: Edge stapling is possible on following paper sizes: • A4 LEF (long edge feed) and SEF (short edge feed) •...

  • Page 61: Crease

    X04144_EN_B BF-450e/435e System Operator Manual Crease The Crease function makes it possible to crease the cover sheet and/or the centre sheet of the booklet in order to avoid toner cracking or flaking at the fold. Crease Mode Information on the [Crease] button shows the actual Crease status and position.

  • Page 62: Fine-Tuning The Booklet Appearance

    X04144_EN_B BF-450e/435e System Operator Manual Fine-tuning the booklet appearance There are a number of adjustments you can perform to fine-tune the appearance of the booklets and compensate for variations in paper or print. NOTE: All these adjustments are specific and will be reset to zero if the Paper Size is changed. For all adjustments on this spread, start by...
  • Page 63 X04144_EN_B BF-450e/435e System Operator Manual Set registration, Fine Adjustment, continued Send one set of the job from the Upstream De- vice and follow instructions on screen. When using the Booklet Maker system in hand feeding mode, the screen shown will be slightly different, as shown to the side on the left.

  • Page 64: Side Trimmer - Asymmetric Side Trim

    X04144_EN_B BF-450e/435e System Operator Manual Side Trimmer - Asymmetric Side Trim Change value of the Asymmetric Side Trim if you want to offset the Side Trim from the center. From the Booklet size screen, press the [Asym- metric Side Trim] button.

  • Page 65: Skew Compensation

    X04144_EN_B BF-450e/435e System Operator Manual Skew Compensation There is a number of reasons why finished book- lets could come out skewed. One being that the sheets might not have been cut in perfect angle. The folder can be set up to compensate for that.

  • Page 66: Manual Feed

    X04144_EN_B BF-450e/435e System Operator Manual Manual Feed Sets can be manually fed to the Booklet Maker in two different ways, depending on whether the RCT module is installed to the system or not. If the RCT is installed to the system, the manual feed function can be used by installing the optional Manual Feed Tray.

  • Page 67: Tools

    X04144_EN_B BF-450e/435e System Operator Manual 3. Tools The Tools screen Press the [Tools] button to get to the Tools screen. Select the setting you want to change by pressing the corresponding button. After changing setting in the sub screen, press the green [check] button to save your changes and return to the Tools screen.

  • Page 68: Squareback Offset

    X04144_EN_B BF-450e/435e System Operator Manual SquareBack Offset The SquareBack pressure setting is set to a standard that should suit most applications. Operators have the option of sharpening or softening the square edges based on application or preference. Select sharper edges by pressing the [+] button or softer edges by pressing the [-] button.

  • Page 69: Guides

    X04144_EN_B BF-450e/435e System Operator Manual Guides Tap the Training button to go to the welcome screen. Tap [X] on the bottom right side to re- turn to Tools screen. Units Select the desired units by pressing the [millim- eter] or [inch] button.

  • Page 70: Software Version

    X04144_EN_B BF-450e/435e System Operator Manual Software version Shows the software version of all modules in the booklet making system. Press the red [X] button to go back to the Tools screen. Service mode This function is for authorized service personnel...

  • Page 71: Jobs

    X04144_EN_B BF-450e/435e System Operator Manual 4. Jobs Handling jobs The Booklet Maker has a maximum storage capacity of 100 different jobs. To make temporary changes in the actual job settings or temporary changes of a stored job, see section 2, “Making Booklets”.

  • Page 72: Loading Jobs

    X04144_EN_B BF-450e/435e System Operator Manual Loading Jobs Open (load) any stored job by selecting the job and confirm by pressing the [Load] button. Deleting Jobs Delete any stored job by selecting the job from the list and confirm by pressing the [Delete] but- ton.

  • Page 73: Clearing Misfeed(S)

    X04144_EN_B BF-450e/435e System Operator Manual 5. Clearing Misfeed(s) Clearing misfeed(s) General If a misfeed condition occurs, it is indicated on the Booklet Maker User Interface. See examples below. The User Interface provides a visual indication of where the misfeed has...

  • Page 74: Rct Module

    X04144_EN_B BF-450e/435e System Operator Manual RCT module Clearing misfeed(s) in the paper path Infeed “A” area and exit “D” area - RCT1 Open the top cover. Lift up the baffles marked “A” and “D” if needed. Remove any jammed/misfed sheets.

  • Page 75: Registration And Creaser Area - Rct2

    X04144_EN_B BF-450e/435e System Operator Manual Registration and creaser area - RCT2 Open the slide door [A]. Unlatch and pull out the slide [B]. Open the baffles marked “B” and “C” if needed. Remove any jammed/misfed sheets. Push in and latch the slide.

  • Page 76: Booklet Maker

    X04144_EN_B BF-450e/435e System Operator Manual Booklet Maker Clearing misfeed(s) inside the Booklet Maker Clearing misfeed in the Infeed area - BM1 To clear a misfeed indicated in Area BM1 Follow the procedure below. NOTE: See also “Clearing misfeed(s)” in areas BM2 / BM3 if other misfed sheets are present in other areas of the Booklet Maker. Open the Booklet Maker Top Cover.

  • Page 77: Clearing Misfeed In Folder Infeed Area - Bm2 (A)

    X04144_EN_B BF-450e/435e System Operator Manual Clearing misfeed in Folder Infeed area - BM2 (A) To clear a misfeed indicated in Area BM2 (A) Open and then close the top cover. If system does not purge, remove misfed sheets manually following the procedure below.

  • Page 78: Clearing Misfeed In Folder Outfeed Area - Bm2 (B)

    X04144_EN_B BF-450e/435e System Operator Manual Clearing misfeed in Folder Outfeed area - BM2 (B) To clear a misfeed indicated in Area BM2 (B) Open and then close the top cover. If system does not purge, remove misfed sheets manually following the procedure below.
  • Page 79 X04144_EN_B BF-450e/435e System Operator Manual Clearing misfeed in Folder Outfeed area - BM2 (B), continued Pull the Levers [H] (x2) towards the centre of the machine. Lift and remove the Lower Fold Roller Paper Guide [J]. Remove any jammed/misfed sheets/sets.

  • Page 80: Clearing Misfeed In Lower Folder Area - Bm3

    X04144_EN_B BF-450e/435e System Operator Manual Clearing misfeed in Lower Folder area - BM3 To clear a misfeed indicated in Area BM3 Open and then close the top cover. If system does not purge, remove misfed sheets manually following the procedure below.
  • Page 81 X04144_EN_B BF-450e/435e System Operator Manual Clearing misfeed in Lower Folder area - BM3, continued Removing the two Transport Belts [K] from the pulleys and sliding them aside is not required but can make jam clearance easier. Lift Paper Guide [L].

  • Page 82: Finishing Module

    X04144_EN_B BF-450e/435e System Operator Manual Finishing Module To clear a misfeed indicated in Areas FM1 and/or FM2 Open and then close the top cover. If system does not purge, remove misfed sheets manually following the procedure below. WARNING: The trim unit [A] has two sharp knives for trimming booklets: do not touch them for any reason and at any time.

  • Page 83: Belt Stacker

    X04144_EN_B BF-450e/435e System Operator Manual Belt Stacker Clearing misfeed(s) Clearing misfeed in the belt stacker - BM4/FM3 To clear a misfeed indicated in Area BM4/ Follow procedure below. Look for any jammed/misfed sets/booklets and remove them. NOTE: Cover [A] is fixed and CANNOT be lifted for safety reasons.
  • Page 84 X04144_EN_B BF-450e/435e System Operator Manual Page intentionally blank.

  • Page 85: Troubleshooting

    X04144_EN_B BF-450e/435e System Operator Manual 6. Troubleshooting Fault codes General Procedure When there is a misfeed or a fault condition in the Booklet Maker system, a code and/or a message will be displayed on the User Interface. Follow this general procedure to clear a jam condition: •...

  • Page 86: Rotate Crease Trimmer (Rct) Fault Codes

    X04144_EN_B BF-450e/435e System Operator Manual Rotate Crease Trimmer (RCT) fault codes WARNING: The RCT has two sharp round knives for trimming sheets: do not touch them for any reason and at any time. If service is needed, call a technician.
  • Page 87 X04144_EN_B BF-450e/435e System Operator Manual Booklet Maker fault codes, continues Code # Area Cause Explanation / Action Check that no obstructions are in paper path. Clean pa- M3 (side jogger motor) per path. Set registration’s value might be too high. See...

  • Page 88: Finishing Module Fault Codes

    X04144_EN_B BF-450e/435e System Operator Manual Finishing Module fault codes WARNING: The trim unit has two sharp knives for trimming booklets: do not touch them for any reason and at any time. If service is needed, call a technician. Code # Area...
  • Page 89 X04144_EN_B BF-450e/435e System Operator Manual Finishing Module fault codes, continues Code # Area Cause Explanation / Action Q17 (paper path sensor) not reached FM-607 in time. Q17 (paper path sensor) covered too FM-608 Exit long. Q17 (paper path sensor) covered after FM-609 purge.

  • Page 90: General Fault Codes

    X04144_EN_B BF-450e/435e System Operator Manual General fault codes Clear Misfeed(s) In general, fault codes indicate a misfeed condition. When a misfeed occurs, it is indicated visually where the misfeed occurred, by an error code and by a component description. See section 5, “Clearing Misfeeds”, for how to clear a...

  • Page 91: Remarks

    X04144_EN_B BF-450e/435e System Operator Manual 7. REMARKS Do’s And Don’ts • Always follow all warnings marked on, or supplied with, the equipment. • Always exercise care in moving or relocating the equipment. CAUTION: • Power off and unplug the power cord from the wall outlet and machine before you move or relocate the equipment. • Do not remove the covers or guards that are fastened with screws.

  • Page 92: Where To Put Your Machine

    X04144_EN_B BF-450e/435e System Operator Manual 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 93: Access To Machine

    29.1″ 20.9″ 34.7″ 27.6″ 6.3″ Plockmatic BF-450e/435e Production Booklet Maker floor plan Approximate floor space requirements / configuration NOTE: The 50 Sheet Upgrade Kit does not impact floor space requirements. The optional high capacity Belt Stacker BST4000-1 (not shown) connects to the included belt stacker with the extender folded away and can be placed either in-line or angled to the Booklet Making system.

  • Page 94: Maintaining Your Machines

    X04144_EN_B BF-450e/435e System Operator Manual Maintaining Your Machines Never attempt any maintenance function that is not specifically described in this documentation. Booklet Maker Cleaning Booklet Maker Transport Belts, rollers and sensors The Booklet Maker Transport belts, rollers and sensors need to be cleaned regularly when in use.

  • Page 95: Cleaning Clincher Area

    X04144_EN_B BF-450e/435e System Operator Manual Cleaning Clincher area Grey marks around the staple area in the center of the booklet may be caused by metal dust from the staple. If the marks are caused by dirt deposits or metal dust on the clinchers, these marks can be reduced by operator cleaning or wiping clinch area with a clean rag.

  • Page 96: Finishing Module

    X04144_EN_B BF-450e/435e System Operator Manual Finishing Module Cleaning SquareBack Clamps and Roller The SquareBack Roller, Upper and Lower Clamp Beam need to be cleaned regularly when in use. How often this should be done depends on the paper type and print quality.
  • Page 97 X04144_EN_B BF-450e/435e System Operator Manual Trimmer Unit removed for clarity Clean the Upper and Lower Clamp Beam [D]. Clean the SquareBack Roller [E]. The Roller can easily be rotated by hand. Close the Finishing Module top cover. continued on next page...

  • Page 98: Cleaning The Sensors

    X04144_EN_B BF-450e/435e System Operator Manual Finishing Module, continued Cleaning the sensors The sensors need to be cleaned regularly when in use and if the unit has not been used for a period of time. Sensors must be wiped clean with a lint free cloth.
  • Page 99 X04144_EN_B BF-450e/435e System Operator Manual Sensors’ location (continued) Belt stacker sensor continued on next page...

  • Page 100: Cleaning Infeed Module Foam Rollers

    X04144_EN_B BF-450e/435e System Operator Manual Finishing Module, continued Cleaning Infeed Module Foam Rollers WARNING: The trim unit has two sharp knives for trimming booklets: keep your hands clear of the knives The Foam Rollers in the Infeed Module need to be cleaned regularly when in use. How often this should be done depends on the paper type and print quality.

  • Page 101: Rct Module

    X04144_EN_B BF-450e/435e System Operator Manual RCT Module The feed rollers and paper path need to be cleaned regularly when in use, and if the unit has not been used for a period of time. How often this should be done depends on the paper type and print quality.

  • Page 102: Cleaning The Fixing Rollers (X3)

    X04144_EN_B BF-450e/435e System Operator Manual Cleaning the paper path transportation nip rollers (x12), continued Nip rollers Nip rollers Nip rollers Cleaning the fixing rollers (x3) Also clean the idling rollers WARNING: Do not place your fingers inside the knife guards. Doing so may result in injury.

  • Page 103: Cleaning The Registration Cross Rollers (X6) & Friction Tires (X6)

    X04144_EN_B BF-450e/435e System Operator Manual Cleaning the fixing rollers (x3), continued Fixing roller Cleaning the registration cross rollers (x6) & friction tires (x6) Registration cross rollers continued on next page...
  • Page 104 X04144_EN_B BF-450e/435e System Operator Manual Cleaning the registration cross rollers (x6) & friction tires (x6), continued Friction tires...

  • Page 105: Cleaning The Rotator Rollers (X2)

    X04144_EN_B BF-450e/435e System Operator Manual Cleaning the rotator rollers (x2) Also clean the idler rollers Rotator rollers Cleaning the paper path sensors (x5) WARNING: Do not put your fingers inside the knife guards. Doing so may result in injury. Exit sensor...
  • Page 106 X04144_EN_B BF-450e/435e System Operator Manual Cleaning the paper path sensors (x5), continued Rotator sensor Registration sensor...

  • Page 107: Cleaning Of Creaser Tools (X2)

    X04144_EN_B BF-450e/435e System Operator Manual Cleaning the paper path sensors (x5), continued Creaser sensor Cleaning of creaser tools (x2) After a period of time, toner and paper dust may leave residuals in the grooves of the tool. These grooves must be cleaned periodically to maintain creasing performance.

  • Page 108: Adjustment Of Side Trimmer Registration Angle (Parallel Cut)

    X04144_EN_B BF-450e/435e System Operator Manual Adjustment of Side Trimmer registration angle (parallel cut) Adjustment of Side Trimmer registration angle (trimmer cut parallel to registration (operator side) edge) Turn adjustment screw [A] in desired direction. Change in adjustment is reflected on the reference scale [B].

  • Page 109: Adjustment Of Creaser Registration Angle

    X04144_EN_B BF-450e/435e System Operator Manual Adjustment of Creaser registration angle Adjustment of Creaser registration angle Loosen the star shaped knob [A]. Turn the knurled eccentric adjuster [B] to move reference mark in the desired direction. Tighten the star shaped knob [A] again.

  • Page 110: Best Practices For The Bf-450E/435E System

    X04144_EN_B BF-450e/435e System Operator Manual Best practices for the BF-450e/435e system • Use the side guides on the optional hand feeding table to make sure the set enters centred into the machine; • If average squarefold result is not satisfying, please see section 3 of this manual: “SquareBack Offset”;...

  • Page 111: Limitations Of The Bf-450E/435E System

    The BF-450e/435e system is suited for customers whose booklet making needs will not exceed an average of 30,000 booklets per month; • If sheets entering the BF-450e/435e system are not uniform or if they are skewed, the booklet quality will vary accordingly; •...
  • Page 112 X04144_EN_B BF-450e/435e System Operator Manual Limitations of the BF-450e/435e system, continued • Sheets may show marks from the “registration rollers” in the RCT module. Changing media will improve the situation. This phenomenon has been seen on the following media: •...
  • Page 113 Limitations of the BF-450e/435e system, continued • For booklets without Face Trim, the trailing edge of the booklet may be damaged by the drive belts on the stacker. Plockmatic recommends using Face Trim or thicker sheets to minimize damage. •...
  • Page 114 X04144_EN_B BF-450e/435e System Operator Manual Page intentionally blank.

  • Page 115: Specification

    X04144_EN_B BF-450e/435e System Operator Manual 8. Specification Machine Specifications NOTE: Plockmatic uses QT open source license (LGPL) to develop the software used in this machine (https://www.qt.io/qt-licensing). RCT Rotate Crease Trim Module (option) Specifications Remarks Speed Same as BF-450e/435e Width 145 mm / 5.71”...

  • Page 116: Bf-450E/435E Booklet Maker

    X04144_EN_B BF-450e/435e System Operator Manual RCT Rotate Crease Trim Module (option), continued Specifications Remarks Power Consumption / Heat Sleep mode: 25W 25 W = 85 BTU/hr emissions Standby: 90W 90 W = 307 BTU/hr Normal operation: 300W 300W = 1024 BTU/hr...
  • Page 117 Offline Use Possible. BF-450e/435e can be hand fed Length with Belt stacker 1600 mm Dimensions (L x H x D) 880 x 1120 x 720 mm / 34.6” x 44” x 28.3”...

  • Page 118: Finishing Module (Option)

    Normal operation: 200W 200W = 682 BTU/hr Maximum load: 400W 400W = 1365 BTU/hr Power Source From BF-450e/435e Weight 110 kg / 242 lb Environmental Require- For environment requirements of the sys- ments tem refer to BF-450e/435e Booklet Maker specifications...

  • Page 119: Bst4000-1 Belt Stacker Module (Option)

    X04144_EN_B BF-450e/435e System Operator Manual BST4000-1 Belt Stacker Module (option) Specifications Remarks Speed Variable Overlap Adjustable Capacity A4 / 8,3″x11,7″ ..≥ 1,000 Booklet of 2 sheets 80gsm / 20lb Bond A3 / 11,7″x16,5″ ..≥ 500 Booklet of 2 sheets 80gsm / 20lb Bond Side guides Adjustable 0-357 mm / 14″...

  • Page 120: System Set Size Guide

    X04144_EN_B BF-450e/435e System Operator Manual System Set Size Guide NOTE: The following tables are guidelines designed to give an indication on how many sheet a specific application can have for a given media weight. Exact number of sheets is depending on media type and image. BF-435e A3 or 11 x 17" A4 or 8,5 x 11"...

  • Page 121: Declaration Of Conformity, Rct

    X04144_EN_B BF-450e/435e System Operator Manual EU & UK DECLARATION OF CONFORMITY ......D0001499 (I.9) 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 F136-001,...

  • Page 122: Declaration Of Conformity, Bm And Fm

    X04144_EN_B BF-450e/435e System Operator Manual EU & UK DECLARATION OF CONFORMITY ......N0007571 (A.8) 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...

  • Page 123: Declaration Of Conformity, Bst

    X04144_EN_B BF-450e/435e System Operator Manual EU & UK DECLARATION OF CONFORMITY ......D0000356 (K.5) 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 Type/Model...

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