Canon Plockmatic BLM5035 Operator's Manual
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Canon Plockmatic BLM5035 Operator's Manual

Canon Plockmatic BLM5035 Operator's Manual

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x04138_EN_E BLM5000
Plockmatic BLM5035/5050
Production Booklet Maker
Doc no: X04138_EN_E
Date: 31 March 2025
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.
Operator Manual

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  • Page 1 BLM5000 Plockmatic BLM5035/5050 Production Booklet Maker 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: X04138_EN_E Date: 31 March 2025...
  • Page 2 BLM5000 Scan the QR code to access translated versions of this manual in German, Italian, French, and Spanish. Visit https://plockmaticgroup.com/myfinisher/blm5000-series-for-canon/ to view the manual in your preferred language.

  • Page 3: How To Read This Manual

    x04138_EN_E BLM5000 Introduction This manual contains instructions on the operation and maintenance of this machine. To get maximum versatility from this machine all operators should carefully read and follow the instructions in this manual. Keep this manual in a handy place near the machine. Please read the Safety Information before using this machine.

  • Page 4: Safety During Operation

    x04138_EN_E BLM5000 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 x04138_EN_E BLM5000 Safety during operation, continued • 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. • Liquids are spilled inside the equipment. •...
  • Page 6 x04138_EN_E BLM5000 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. Hazardous Voltage Do Not Step Hot Surface...

  • Page 7: Table Of Contents

    x04138_EN_E BLM5000 TABLE OF CONTENTS What You Can Do With This Machine ................11 Guide To Components ..................... 13 Booklet Maker ..........................13 Alive logo ............................... 16 User Interface ..........................17 User Interface ............................17 Finishing Module ......................... 20 Options ..........................23 Waste Transport to Finishing Module ..................
  • Page 8 x04138_EN_E BLM5000 2. Making Booklets, continued SquareBack ..........................59 General..............................59 Selecting SquareBack pressure setting ....................60 Fold ............................. 61 Adjusting fold position ........................... 61 Staple ............................62 Selecting stapling On or Off ........................62 Adjusting staple position........................62 Crease ............................63 Crease Mode ............................
  • Page 9 x04138_EN_E BLM5000 5. Clearing Misfeed(s), continued Booklet Maker ........................84 Clearing misfeed(s) inside the Booklet Maker ................84 Clearing misfeed in the Infeed area - BM1 .................... 84 Clearing misfeed in Stapler area - BM2 ....................85 Clearing misfeed in Folder area - BM3....................86 Clearing misfeed in the Fold Stop area - BM3 ..................
  • Page 10 x04138_EN_E BLM5000 7. REMARKS, continued Finishing Module ........................122 Cleaning SquareBack Feed Belts ....................... 122 SquareBack Pressure springs ......................123 Cleaning SquareBack Clamps and Roller ................... 124 Cleaning Trimmer Infeed Transport Belts .................... 125 Cleaning Trimmer Exit Transport Belts ....................126 Cleaning the Waste Transport ......................

  • Page 11: What You Can Do With This Machine

    x04138_EN_E BLM5000 What You Can Do With This Machine Waste Transport FM5000 Finishing BLM5035s/5050s (option) Module Booklet Maker Trim Waste Conveyor (option) Belt Stacker Convenience Feeder RCT 3.0 Rotate Crease (option) Trim Module (option) The Plockmatic BLM5050 or BLM5035 Production Booklet Maker System consists of: RCT 3.0 Rotate Crease Trim Module (optional), also referred to as the RCT Module or the BLM5050 or BLM5035 Booklet Maker, also referred to as the BLM5050/BLM5035, the Booklet Maker or the BM...
  • Page 12 x04138_EN_E BLM5000 From the RCT, the printed sheets are transported into the BLM5050 or BLM5035 Production Booklet Maker where they are compiled in the stapler area. If a Convenience Feeder is installed in the Booklet Maker, it can add any type of cover, sheet or centerfold, in colour or black and white, to the printed set.

  • Page 13: Guide To Components

    x04138_EN_E BLM5000 Guide To Components Booklet Maker Parts that are important for setup, adjustments, troubleshooting or maintenance are high- lighted below. Right angle (90°) checker Small storage area Scale User Interface Top Cover Top Cover Latch Handle Manual Feed Cover Top Cover Glass Document Storage Compartment Front Door...
  • Page 14 x04138_EN_E BLM5000 Booklet Maker, continued Parts that are important for setup, adjustments, troubleshooting or maintenance are high- lighted below. NOTE: Picture shows the Booklet Maker setup for docking towards an RCT. Transparent parts (6 & 8) will be installed if the Booklet Maker should be setup for docking directly towards the Finisher.
  • Page 15 x04138_EN_E BLM5000 Booklet Maker, continued Parts that are important for setup, adjustments, troubleshooting or maintenance are high- lighted below. Storage for spare Staple Car- tridges Staple cartridge ejection levers Fold Roller Paper Guide Paper Transport Set thickness sensor Staple cartridges (incl. stapler heads) Clinchers Back Jogger Beam...

  • Page 16: Alive Logo

    x04138_EN_E BLM5000 Booklet Maker, continued Alive logo Alive logo The three stripes below the user interface makes the state of the system visible from a distance. They will signal status as follows: Not illuminated - System is in power save mode or is switched off. Steady blue - System is on and ready or is cycling down.

  • Page 17: User Interface

    x04138_EN_E BLM5000 User Interface The Plockmatic 5050 or 5035 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 functions are disabled (grayed out or not visible at all) and remaining buttons may stretch to fit the screen. This manual will most often show a fully configured system.
  • Page 18 x04138_EN_E BLM5000 User Interface, continued The Jobs Screen Pressing the [Jobs] button in the Start screen opens the Jobs screen. From here you can open a saved job. Jobs can be stored, deleted, customized etc. Handling jobs is described in section 4, “Jobs”. The Counter Screen Pressing the [Counters] button in the Start screen opens the Counters...
  • Page 19 x04138_EN_E BLM5000 User Interface, continued Power save mode When the Booklet Maker System is in a ready state, it will enter power save mode after 20 minutes of inactivity. To recover from Power save mode, touch the screen or send a print job to the Booklet Maker System.

  • Page 20: Finishing Module

    x04138_EN_E BLM5000 Finishing Module Belt Stacker Chassis Belt Stacker Table Belt Stacker Stop Gate Belt Stacker Table Re- lease Button Trim Waste Bin Door to Trim Waste Bin Top Cover Top Cover Glass Top Cover Latch Handle Door for jam clearance Operator Side Casters, no brakes Rail Guides...
  • Page 21 x04138_EN_E BLM5000 Finishing Module, continued Parts that are important for setup, adjustments, troubleshooting or maintenance are high- lighted below. NOTE: Picture shows the Short Booklet Feed Enhancement assembly in its home position. Pressure Roller Upper Transport Belt assembly Short Booklet Feed Enhancement assembly Upper and Lower Clamp Beam Upper Feed Belt Release Latch Upper Feed Belts...
  • Page 22 x04138_EN_E BLM5000 Finishing Module, continued Parts that are important for setup, adjustments, troubleshooting or maintenance are high- lighted below. Set Counter Top Cover Opener Limiting device Exit Compressing Brackets Upper Exit Transport Belts Lift Lever, Upper Exit Transport assembly Finishing Module, Upper Exit Transport lifted up...

  • Page 23: Options

    x04138_EN_E BLM5000 Options Waste Transport to Finishing Module The Waste Transport installs to the Finishing Module. Instead of using the Trim Waste Bin in the Finishing Module, trim waste is now transported upwards which enables the use of a larger waste bin. This makes long, unattended runs easier than ever before. Parts that are important for setup, adjustments, troubleshooting or maintenance are high- lighted below.

  • Page 24: Rotate Crease Trim Module

    x04138_EN_E BLM5000 Rotate Crease Trim Module Top Cover Docking Latch Slide Door Star shaped knob Infeed Slot Front Waste Cover Upstream Docking assembly continued on next page...
  • Page 25 x04138_EN_E BLM5000 Rotate Crease Trim Module, continued Exit slot Waste Bin full Detection Waste Bin Trim Waste Transport Cable Protector / TWC Downstream Docking assembly docking bracket* Foam Roller* Star shaped knob* Rear Waste Cover* Connections * Installed to the RCT when an optional TWC (Trim Waste Conveyor) is installed continued on next page...
  • Page 26 x04138_EN_E BLM5000 Rotate Crease Trim Module, continued Parts that are important for setup, adjustments, troubleshooting or maintenance are high- lighted below. Top Cover Glass Interlock switch Counter Main switch Top Cover Latch Infeed area “A” Exit area “D” Trim waste guides Side trimmer circular knives continued on next page...
  • Page 27 x04138_EN_E BLM5000 Rotate Crease Trim Module, continued Waste chute(s) Latch handle, slide Creaser registration adjustment Interlock switch Bleed trimmer registration adjustment continued on next page...
  • Page 28 x04138_EN_E BLM5000 Rotate Crease Trim Module, continued Rotator Creaser tools Jam Clearance Baffle, coarse regis- Jam Clearance Baffle, fine regis- tration, area “B” tration, area “C”...

  • Page 29: Booklet Maker

    x04138_EN_E BLM5000 Booklet Maker Convenience Feeder The optional Convenience Feeder has a loading capacity of 80 mm (3.15″) which equals 800 sheet of 80 gsm (20 lb Bond). It will often be used as a cover feeder but due to its capacity it can also be used as a regular feeder.
  • Page 30 x04138_EN_E BLM5000 Convenience Feeder, continued Parts that are important for setup, adjustments, troubleshooting or maintenance are high- lighted below. Separation Fans (×2) Feed Roller assembly Loading capacity marks Jam Clearance Baffle Air Nozzle (×2) Rear Paper Guide Side Guides Release Lever Operator Side guide None Operator Side guide DSD sensors (behind cover)
  • Page 31 x04138_EN_E BLM5000 Convenience Feeder, continued Parts that are important for setup, adjustments, troubleshooting or maintenance are high- lighted below. Drive Shaft Feed Roller Pressure adjustment Paper Separator Pad Paper Separator Pad Pressure adjustment...

  • Page 32: Bst4000-1 Belt Stacker Module

    x04138_EN_E BLM5000 BST4000-1 Belt Stacker Module The BST4000-1 High Capacity Belt Stacker Module is an option available for the Plockmatic 5050 or 5035 Production Booklet Maker System. The stacker can be configured in a straight line after the Booklet Maker system or at a 90 degree angle. Parts that are important for setup, adjustments, troubleshooting or maintenance are high- lighted below.

  • Page 33: Bst4000-1 Principle Of Operation

    x04138_EN_E BLM5000 BST4000-1 Belt Stacker Module, continued Power switch (on/off) Belt speed selector 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. The belt speed can be adjusted in order to optimize the stacking function for various materials.

  • Page 34: Trim Waste Conveyor

    x04138_EN_E BLM5000 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. Parts that are important for setup, adjustments, troubleshooting or maintenance are high- lighted below.

  • Page 35: Basics

    x04138_EN_E BLM5000 1. Basics Turning On / Off the Main Power RCT, Booklet Maker, Finishing Module & BST Module 1 1 Make sure that the power cords to the RCT module (optional), Booklet Maker and BST (optional) are plugged into a live wall outlet. 2 2 Open the top cover of the RCT.

  • Page 36: Change Staple Cartridges And Check Stapler

    x04138_EN_E BLM5000 Change staple cartridges and Check stapler The staple cartridges contains 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” and “Replace left, right, or left and right staple cartridges”...

  • Page 37: Stapler Miss

    x04138_EN_E BLM5000 Stapler miss If the Booklet Maker indicates “...stapler miss”, it means that there is a jam in the indicated sta- pler. Remove the stapler cartridge as described above. 1 1 Open the Booklet Maker top cover. 2 2 Press the staple cartridge ejector lever and pull out the staple cartridge as described above.

  • Page 38: Paper Stack Preparation

    x04138_EN_E BLM5000 Paper Stack Preparation General 1 1 Make sure that the ink has completely dried to avoid smearing. 2 2 Hold the paper stack on a flat surface as shown. 3 3 Bend the paper stack. 4 4 Use your fingers and thumbs to pinch the paper stack.

  • Page 39: Measuring Paper Curl On A Single Sheet

    x04138_EN_E BLM5000 General, continued Flex the paper back and forth a couple of times to break surface tension and preseparate the sheets. 7 7 Realign the sheets well into a stack before putting them into the tray in order to achieve a reliable feeding operation and good finishing results.

  • Page 40: Emptying The Trim Waste Bins

    x04138_EN_E BLM5000 Emptying the trim waste bins The Trim Waste Bin is located in the Finishing Module behind the left door on the front side. The message “Empty Face Trim Waste Bin” will be shown on the User Interface when the Trim Waste Bin is full.

  • Page 41: Removing Trim Waste From Trimmer Blade Area

    x04138_EN_E BLM5000 Removing trim waste from trimmer blade area The purpose of the Trim waste guides [A] is to guide waste material towards the waste chutes. The Trim waste guides are fastened using magnets and can be moved aside or removed completely, should waste material get caught in the trimmer blade area.

  • Page 42: Convenience Feeder

    x04138_EN_E BLM5000 Convenience Feeder Loading sheets 1 1 Before loading, make sure to follow the General Stack Preparation Procedure described earlier in this section. 2 2 Lift Release Lever [A] and move Side Guides [B] apart and move Rear Guide [C] outwards. 3 3 Mind how the sheets travel and are fed on top of the collated set [D] and load the sheets accordingly...

  • Page 43: Convenience Feeder Settings

    x04138_EN_E BLM5000 Convenience Feeder settings Feeder settings may vary depending on thickness and friction of the media. Start from these sug- gested settings below and make adjustments until you get a good feed. According to media run, see table below for approximate settings of Feed Roller pressure and Separation.

  • Page 44: Using The Belt Stacker

    x04138_EN_E BLM5000 Using the Belt Stacker The Belt Stacker on the Finishing Module features a load sensor and it can be placed in three different positions to suit any stacking needs. Auto position (raised), High Capacity/Box position (lowered) or External Device position (folded). Belt Stacker Belt Stacker Release...
  • Page 45 x04138_EN_E BLM5000 Using the Belt Stacker, continued 1 1 Auto position. This basic setting suits most types of stacking situations. Except from unloading booklets it needs no action by the operator. Make sure that the Belt Stacker Stop Gate is placed in its correct resting position not past the plastic Bulge in the Belt Stacker Table.
  • Page 46 x04138_EN_E BLM5000 Using the Belt Stacker, continued 2 2 High Capacity position. This position is also suitable for the majority of stacking situations but compared to the Auto position it enables a higher stacking capacity. Note: In order to achieve correct stacker full function and detection in High Capacity mode, make sure to position the Belt Stacker Stop Gate correctly.
  • Page 47 x04138_EN_E BLM5000 Using the Belt Stacker, continued 3 3 Box position. Position the Belt Stacker Table in the High Capacity position but keep the Belt Stacker Stop Gate in a flat position. This allows the booklets to slide off the Belt Stacker Table into a box.

  • Page 48: Belt Stacker Bst4000-1

    x04138_EN_E BLM5000 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. 2 2 Adjust the outer Side Guide [B] to give at least 5 mm (1/4″) play.

  • Page 49: Setting Up Belt Stacker For Straight Mode

    x04138_EN_E BLM5000 Setting up Belt Stacker for straight mode Adjust Side Guides to their outermost position by loosening knobs [A]. 2 2 Adjust the stacking with belt speed selector [B].

  • Page 50: Detaching / Attaching The Trim Waste Conveyor

    x04138_EN_E BLM5000 Detaching / Attaching the Trim Waste Conveyor Detaching the Trim Waste Conveyor Lift the Rear Waste Cover [A] and hang it on the upper two of the four hangers [B] on the back side of the RCT rear cover. Lift and remove the Belt Protection plate [C] from the RCT.

  • Page 51: Attaching The Trim Waste Conveyor

    x04138_EN_E BLM5000 Detaching the Trim Waste Conveyor, continued 6 6 When the Finishing Module is equipped with a Waste Transport [H], make sure the TWC Support [I] exits the slot in the bracket [J] on the back side of the Waste Transport Rear Cover.
  • Page 52 x04138_EN_E BLM5000 Attaching the Trim Waste Conveyor, continued WARNING The Trim Waste Conveyor must be prevented from falling over. This can be done either by placing the TWC support [I] in the slot in the bracket [J] on the back side of the Rear Cover of the Waste Transport [J] or, when no Waste Transport is installed, by installing a safety wire [L] between the Conveyor support and the rear caster spindle on the Booklet Maker on the exit side.

  • Page 53: Docking / Undocking

    x04138_EN_E BLM5000 Docking / Undocking Undocking the Booklet Making system 1 1 Turn the Printer off. For a Booklet Making system without an RCT, push in the latch on the docking as- sembly and move the Booklet Maker System away from the Printer. When the Booklet Making system includes also an RCT module, it is advisable to un- dock the Booklet Maker alone first (A) and...

  • Page 54: Docking The Booklet Making System

    x04138_EN_E BLM5000 Docking the Booklet Making System 1 1 Turn the Printer off. For a Booklet Making system without an RCT, move the Booklet Maker System up to the Printer and dock it. When the Booklet Making system includes also an RCT module, it is advisable to first separate the RCT module from the Booklet Maker and dock the RCT module alone (A).

  • Page 55: Making Booklets

    x04138_EN_E BLM5000 2. Making Booklets Changing settings General procedure Settings can be changed in one of two ways. “Temporary”, which means that the changes will remain until a new job is loaded or “Permanent”, which means that the changes will be stored as a job.

  • Page 56: Custom Paper Size

    x04138_EN_E BLM5000 Custom Paper size Three different custom paper sizes can be stored. From the Paper Size screen, press any of the [Custom size] buttons and then press 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 57: Booklet Size

    x04138_EN_E BLM5000 Booklet Size General From the Start 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 58 x04138_EN_E BLM5000 Custom Booklet 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 booklet size by pressing the green check mark or exit without making any changes by pressing the red X mark.

  • Page 59: Squareback

    x04138_EN_E BLM5000 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- tion from the set thickness sensor to calculate the most appropriate mode from 1 to 7 or if the SquareBack should be by-passed.

  • Page 60: Selecting Squareback Pressure Setting

    x04138_EN_E BLM5000 General, continued The table below shows highest supported SquareBack pressure settings on BLM5050 and BLM5035 Production Booklet Maker systems. These are the maximum settings that can be used without slowing the printer down. Number of sheets SRA3 8.5x11" 11x17"...

  • Page 61: Fold

    x04138_EN_E BLM5000 Selecting SquareBack pressure setting, continued For Manual mode, with the AUTO mode switch in the Off position, select the desired amount of square forming pressure or set to off to by-pass the square forming action. Use the [+] and [-] buttons or just point/drag at the scale .

  • Page 62: Staple

    x04138_EN_E BLM5000 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 Start screen. Enable or disable saddle stapling by pressing the [Saddle Staple] button and save setting by pressing the green [check] button.

  • Page 63: Crease

    x04138_EN_E BLM5000 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 64: Convenience Feeder

    x04138_EN_E BLM5000 Convenience Feeder General If the optional Convenience Feeder is installed, a [Feeder] button will be displayed on the Start Screen in the User Interface. The Convenience Feeder can be used as an interposer, inserting a centerfold and/or a cover to the set, a protec- tion sheet or as a regular feeder.

  • Page 65: Add Cover And/Or Add Centerfold

    x04138_EN_E BLM5000 Interposer, continued From the Interposer screen, activate Add Cover and/or Add Centerfold by setting either or both switches to On and confirm by pressing the green [check] button. Add Cover and/or Add Centerfold Used as a Cover Feeder, a pre-printed possibly higher paper weight cover is fed from the Con- venience Feeder to a set already waiting in the compiler in the Booklet Maker.

  • Page 66: Add Protection Sheet

    x04138_EN_E BLM5000 Add Protection Sheet In case you are running sensitive media you can use the Convenience Feeder to feed a protection sheet. From the Interposer screen, activate Add Pro- tection Sheet by setting the switch to On and confirm by pressing the green [check] button. The sheets in the set will be jogged and stapled before the Protection Sheet is fed.

  • Page 67: Separation Air

    x04138_EN_E BLM5000 Separation Air You may want to increase the Air flow when running thick, heavy sheets. From the Ad- vanced Feeder Settings screen, press the [Separation Air] button. Set the desired amount of air flow by pressing the corresponding button and save setting by pressing the green [check] button.

  • Page 68: Fine-Tuning The Booklet Appearance

    x04138_EN_E BLM5000 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 pressing the [Booklet Size] button from the Start screen in order to reach the Booklet Size screen.
  • Page 69 x04138_EN_E BLM5000 Set registration, Fine Adjustment, continued Send one set of the job from the printer or press the proof button to feed a job from the Conveni- ence Feeder and follow instructions on screen. When the set has stopped in the compiler area, follow instructions on screen to check the regis- tration of the set.

  • Page 70: Side Trimmer - Asymmetric Side Trim

    x04138_EN_E BLM5000 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. Move the Side Trim to either side, Head or Foot, by using the [-] buttons and then press...

  • Page 71: Skew Compensation

    x04138_EN_E BLM5000 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. From the Start screen, press the [Fold Settings] button.

  • Page 72: Manual Feed

    x04138_EN_E BLM5000 Manual Feed 1 1 Open the Manual Feed Cover [A] in the Booklet Maker Top Cover to initiate Manual Feed Mode. 2 2 The User Interface will display a green hand when the Booklet Maker is ready to receive manually fed sets. 3 3 Adjust the Manual Feed Side Guides [B] to the correct paper size.

  • Page 73: Tools

    x04138_EN_E BLM5000 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 74: Production Priority

    x04138_EN_E BLM5000 Production Priority Use the default Productivity mode if the applica- tion allows for it. The productivity will be higher, but the system will get more demanding for high quality media. Thin media (below 120 gsm for coated media) or media that has a slight curl will generally run better in Precision mode.

  • Page 75: Squareback Offset

    x04138_EN_E BLM5000 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 76: View On Demand

    x04138_EN_E BLM5000 Stacker Settings, continues Turn Stacker Booklet Size Warning off if you do not want to have this warning. The Stacker Full Max Limit default setting should suit most types of stacking situations. However, the limit can be adjusted ± 20 % to better suit the actual situation.

  • Page 77: Units

    x04138_EN_E BLM5000 Units Select the desired units by pressing the [millim- eter] or [inch] button. By selecting Metric, Inch or Japan Series, the corresponding common paper sizes will be shown when pressing the [Paper Size] button on the Start Screen. By selecting millimeter [mm] and Inch Series, common inch formats are shown and will also be expressed in millmeters.

  • Page 78: Service Mode

    x04138_EN_E BLM5000 Service mode This function is for authorized service personnel only and is password protected.

  • Page 79: Jobs

    x04138_EN_E BLM5000 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”. From the Start screen, press the [Jobs] button to be able to store, change or delete jobs. Saving a Job From the Start Screen, press [Jobs] button.

  • Page 80: Loading Jobs

    x04138_EN_E BLM5000 Loading Jobs Open (load) any stored job by selecting the job and confirm by pressing the [Load] button. The name of the currently loaded job is shown in the upper left corner. When there is an aster- isk next to the name, it indicates that changes to the job have been made after the job was loaded and that the changes have not yet been saved.

  • Page 81: Clearing Misfeed(S)

    x04138_EN_E BLM5000 5. Clearing Misfeed(s) Clearing misfeed(s) General If a misfeed condition should occur, it is indicated on the Booklet Maker User Interface. See examples below. Misfeeds in the Rotate Crease Trim Module are indicated visually where in the RCT the misfeed occurred (area RCT1 or RCT2), by an error code RCT-XXX and by a component description.

  • Page 82: Rct Module

    x04138_EN_E BLM5000 RCT module Clearing misfeed(s) in the paper path Infeed “A” area and exit “D” area - RCT1 1 1 Open the top cover. 2 2 Lift up the baffles marked “A” and “D” if needed. 3 3 Remove any jammed/misfeed sheets. 4 4 Lower the baffles “A”...

  • Page 83: Registration And Creaser Area - Rct2

    x04138_EN_E BLM5000 Registration and creaser area - RCT2 1 1 Open the slide door [A]. 2 2 Unlatch and pull out the slide [B]. 3 3 Open the baffles marked “B” and “C” if needed. 4 4 Remove any jammed/misfeed sheets. 5 5 Push in and latch the slide.

  • Page 84: Booklet Maker

    x04138_EN_E BLM5000 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. 1 1 Open the Booklet Maker Top Cover. 2 2 Lift the Back Jogger Beam [A], lift the Infeed Roller assembly [B] and the Upper and Lower Infeed Paper paths [C].

  • Page 85: Clearing Misfeed In Stapler Area - Bm2

    x04138_EN_E BLM5000 Clearing misfeed in Stapler area - BM2 To clear a misfeed indicated in Area BM2 Open and then close the top cover. If system does not purge, remove misfed sheets manually following the procedure below. 1 1 Open the Booklet Maker Top Cover. 2 2 Lift the Paper Transport [D].

  • Page 86: Clearing Misfeed In Folder Area - Bm3

    x04138_EN_E BLM5000 Clearing misfeed in Folder area - BM3 To clear a misfeed indicated in Area BM3 Open and then close the top cover. If system does not purge or if misfeed condition persists, power off and then power on the system.

  • Page 87: Clearing Misfeed In The Fold Stop Area - Bm3

    x04138_EN_E BLM5000 Clearing misfeed in the Fold Stop area - BM3 To clear a misfeed indicated in Area BM3 Follow the procedure below. 1 1 Open the Jam Clearance Door [G]. 2 2 Lift the Fold Stop Paper Guide [H] 3 3 Remove any jammed/misfed sets/booklets.

  • Page 88: Clearing Misfeed In Convenience Feeder Area - Bm4

    x04138_EN_E BLM5000 Clearing misfeed in Convenience Feeder area - BM4 To clear a misfeed indicated in Area BM4 Follow the procedure below. 1 1 Open the Convenience Feeder Cover. 2 2 Remove any jammed/misfeed sheets. 3 3 Close the Convenience Feeder Cover.

  • Page 89: Clearing Misfeed In Convenience Feeder Area - Bm5

    x04138_EN_E BLM5000 Clearing misfeed in Convenience Feeder area - BM5 To clear a misfeed indicated in Area BM5 Follow the procedure below. 1 1 Open the Convenience Feeder Front Cover and the Front Door. 2 2 Open the Jam Clearance Baffle [I]. 3 3 Remove any jammed/misfeed sheets.

  • Page 90: Finishing Module

    x04138_EN_E BLM5000 Finishing Module Clearing misfeed(s) in the Finishing Module Inside the SquareBack area - FM1 To clear a misfeed indicated in Area FM1 Follow the procedure below. 1 1 Open the Finishing ModuleTop Cover. 2 2 Press the Green Dots [A] on the Release Latches and lift up Upper Feed Belts (B). NOTE: The upper feed belt on the operator side cannot be lifted fully.

  • Page 91: Clearing Misfeed In The Trimmer Infeed Area - Fm2

    x04138_EN_E BLM5000 The upper trimmer blade on the trimmer is protected by a knife protection plate that moves away during the cutting stroke. WARNING: Never put fingers or other parts of the body between the upper and lower trimmer knives. Clearing misfeed in the Trimmer infeed area - FM2 To clear a misfeed indicated in Area FM2 Follow the procedure below.

  • Page 92: Clearing Misfeed In The Trimmer Exit Area - Fm2

    x04138_EN_E BLM5000 Clearing misfeed in the Trimmer exit area - FM2 To clear a misfeed indicated in Area FM2 Follow the procedure below. 1 1 Open the Finishing Module Top Cover. 2 2 Lift the exit compressing brackets and transport belts [B]. 3 3 Remove any jammed/misfeed sets/booklets.

  • Page 93: Clearing Misfeed In The Waste Transport

    x04138_EN_E BLM5000 Clearing misfeed in the Waste Transport The message “Empty Waste Transport” will be shown on the User Interface when trim strips are getting stuck in the waste transport areas. Proceed as follows: 1 1 Open the Left Door [A] on the Finishing Module.
  • Page 94 x04138_EN_E BLM5000 Clearing misfeed in the Waste Transport, continued 5 5 Open the Right Door [D]. 6 6 Pull the upper part of the Transport Belt [B] downwards and remove any trim waste strips. 7 7 Also remove any trim waste strips from the bottom area [E] inside the Finishing Module. 8 8 Close the Right Door [D] on the Finishing Module.
  • Page 95 x04138_EN_E BLM5000 Clearing misfeed in the Waste Transport, continued 9 9 Open the Waste Transport Top Cover [F]. Push down the Lever [G] to release the Jam Clearance Cover [H]. Remove any trim waste strips from between the transport belts [J]. Lift the Lever [G] to restore the Jam Clearance Cover to operating position.

  • Page 96: Belt Stacker

    x04138_EN_E BLM5000 Belt stacker Clearing misfeed(s) Clearing misfeed in the belt stacker To clear a misfeed indicated in Area FM4 Follow the procedure below. 1 1 Lift the upper belt unit [A]. 2 2 Remove any jammed/misfed sets/booklets.

  • Page 97: Troubleshooting

    x04138_EN_E BLM5000 6. Troubleshooting Fault codes General • When there is a misfeed or fault condition in the Booklet Maker system, a code and/ or a message will be displayed on the User Interface. Remove any paper in the paper path and power Off and On the system.

  • Page 98: Booklet Maker (Bm) Fault Codes

    x04138_EN_E BLM5000 Booklet Maker (BM) fault codes Code / message Explanation / action BM101 - Tray empty (Convenience Load paper in the Convenience Feeder. Feeder) BM102 - Misfeed (Convenience • Open the Convenience Feeder; Feeder) • Clean the feed rollers (see “Cleaning Convenience Feeder Feed Rollers and Paper Separator Pad”...
  • Page 99 x04138_EN_E BLM5000 Booklet Maker (BM) fault codes (continued) Code / message Explanation / action BM201 - BM204 Misfeed • Open the front door of the Booklet Maker; • Open the Feeder Transport; • Remove misfed sheet(s); • See section 7, “REMARKS”, Maintaining Your Machine and clean the paper path;...

  • Page 100: Finishing Module (Fm) Fault Codes

    x04138_EN_E BLM5000 Booklet Maker (BM) fault codes (continued) Code / message Explanation / action BM406 - Paper set too thick Paper stack is too thick and it is not within specifications. This can depend either on the thickness of the loaded media or on the number of sheets loaded in the machine.

  • Page 101: Stacker (St) Fault Codes

    x04138_EN_E BLM5000 Finishing Module (FM) fault codes (continued) Code / message Explanation / action FM1008 Attention! The operator has shortened the finished booklet length while running, therefore the Booklet Maker System cannot handle the cut process while keeping the same processing speed.

  • Page 102: Communication Box (Dfd) Fault Codes

    x04138_EN_E BLM5000 Communication Box (DFD) fault codes Code / message Explanation / action COMBOX20 Attention! The printer is loaded with sheets outside the Bookletmaker’s size or paper weight specifications. • Load printer with sheets within specifications. COMBOX21 Attention! Enter button confirming the last page in the set was pressed too late when scanning manually.

  • Page 103: General Fault Codes

    x04138_EN_E BLM5000 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 misfeed.

  • Page 104: Job Settings Not Supported

    x04138_EN_E BLM5000 Job Settings Not Supported General This message is shown when the Booklet Maker System is not able to process a job with the combination of finishing settings chosen. One or more finishing settings will need to be modified to allow the job to be processed.

  • Page 105: Troubleshooting

    x04138_EN_E BLM5000 Troubleshooting Booklet Making The Booklet Maker System is not able to process the job using the current combination of settings chosen. Below list shows probable causes. Work your way through the list changing settings when possible. 1. Set Fold Roller Release function to “OFF”. See section 3, “Tools”. 2.
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  • Page 107: Remarks

    x04138_EN_E BLM5000 7. REMARKS Do’s And Don’ts • Always follow all warnings marked on, or supplied with, the equipment. • Always exercise care in moving or relocating the equipment. CAUTION: • Unplug the power cord from the wall outlet and machine before you move or relocate the equipment.

  • Page 108: Where To Put Your Machine

    x04138_EN_E BLM5000 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 109: Access To Machine

    x04138_EN_E BLM5000 Access to machine Place the machine near the power source, providing clearance as shown. 2310 mm / 90.9″ 380 mm 15″ 400 mm 15.8″ 400 mm 15.8″ 540 mm 21.2″ 115 mm 890 mm 760 mm 1010 mm 720 mm 35″...

  • Page 110: Maintaining Your Machines

    x04138_EN_E BLM5000 Maintaining Your Machines Never attempt any maintenance function that is not specifically described in this documentation. 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 111: Cleaning The Fixing Rollers (X3)

    x04138_EN_E BLM5000 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. Knife guards Fixing rollers continued on next page...

  • Page 112: Cleaning The Registration Cross Rollers (X6) & Friction Tires (X6)

    x04138_EN_E BLM5000 Cleaning the fixing rollers (x3) continued Fixing roller Cleaning the registration cross rollers (x6) & friction tires (x6) Registration cross rollers...
  • Page 113 x04138_EN_E BLM5000 Cleaning the registration cross rollers (x6) & friction tires (x6) continued Friction tires continued on next page...

  • Page 114: Cleaning The Rotator Rollers (X2)

    x04138_EN_E BLM5000 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 Knife guards Infeed sensor...
  • Page 115 x04138_EN_E BLM5000 Cleaning the paper path sensors (x5) continued Rotator sensor Registration sensor continued on next page...

  • Page 116: Cleaning Of Creaser Tools (X2)

    x04138_EN_E BLM5000 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. Grooves on both sides of the tool...

  • Page 117: Adjustment Of Side Trimmer Registration Angle (Parallel Cut)

    x04138_EN_E BLM5000 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]. Process direction Turn the adjustment screw clockwise to...

  • Page 118: Adjustment Of Creaser Registration Angle

    x04138_EN_E BLM5000 Adjustment of Creaser registration angle Adjustment of Creaser registration angle Loosen the star shaped knob [A]. 2 2 Turn the knurled eccentric adjuster [B] to move reference mark in the desired direction. 3 3 Tighten the star shaped knob [A] again. Process direc- Lower the opera- tion...

  • Page 119: Booklet Maker

    x04138_EN_E BLM5000 Booklet Maker Cleaning Booklet Maker Transport Belt The Booklet Maker Transport belt need to be cleaned regularly when in use. How often this should be done depends on the paper type and print quality. An increasing number of misfeeds is an indication of the need to clean the Transport belt. Clean the Transport belt with water and a lint free cloth.

  • Page 120: Cleaning Clincher Area

    x04138_EN_E BLM5000 Booklet Maker, continued 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 121: Cleaning Convenience Feeder Feed Rollers And Paper Separator Pad

    x04138_EN_E BLM5000 Cleaning Convenience Feeder Feed Rollers and Paper Separator Pad The Feed rollers and the paper separator pad needs 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 122: Finishing Module

    x04138_EN_E BLM5000 Finishing Module Cleaning SquareBack Feed Belts The SquareBack Feed belts need to be cleaned regularly when in use. How often this should be done depends on the paper type and print quality. An increasing number of misfeeds is an indication of the need to clean the feed belts. Clean the feed belts with water and a lint free cloth.

  • Page 123: Squareback Pressure Springs

    x04138_EN_E BLM5000 SquareBack Pressure springs If feed errors occur, check that the pressure on the upper feed belts is set to the default position. The pressure springs should always be at its upper position where the pressure is equal to its highest value. continued on next page...

  • Page 124: Cleaning Squareback Clamps And Roller

    x04138_EN_E BLM5000 Finishing Module, continued Cleaning SquareBack Clamps and Roller The SquareBack Roller, Upper and Lower Clamp Beam needs to be cleaned regularly when in use. How often this should be done depends on the paper type and print quality. Color smeared off on the spine of the booklets is one indication of the need to clean the SquareBack Roller, Upper and Lower Clamp Beam.

  • Page 125: Cleaning Trimmer Infeed Transport Belts

    x04138_EN_E BLM5000 Cleaning Trimmer Infeed Transport Belts The Trimmer Infeed Transport Feed Belts need to be cleaned regularly when in use. How often this should be done depends on the paper type and print quality. An increasing number of misfeeds is an indication of the need to clean the feed belts. Clean the feed belts with water and a lint free cloth.

  • Page 126: Cleaning Trimmer Exit Transport Belts

    x04138_EN_E BLM5000 Finishing Module, continued Cleaning Trimmer Exit Transport Belts The Trimmer Exit Transport Feed Belts needs to be cleaned regularly when in use. How often this should be done depends on the paper type and print quality. An increasing number of misfeeds is an indication of the need to clean the feed belts. Clean the feed belts with water and a lint free cloth.

  • Page 127: Cleaning The Waste Transport

    x04138_EN_E BLM5000 Cleaning the Waste Transport The Waste Transport needs to be cleaned from trim waste strips regularly when in use. How often this should be done depends on how frequently the Trimmer is used. Proceed as follows: 1 1 Open the Finishing Module Left Door [A].
  • Page 128 x04138_EN_E BLM5000 Finishing Module, continued Cleaning the Waste Transport, continued 5 5 Open the Right Door [D]. 6 6 Pull the upper part of the Transport Belt [B] downwards and remove any trim waste strips. 7 7 Also remove any trim waste strips from the bottom area [E] inside the Finishing Module. 8 8 Close the Right Door [D] on the Finishing Module.
  • Page 129 x04138_EN_E BLM5000 Cleaning the Waste Transport, continued 9 9 Open the Waste Transport Top Cover [F]. Push down the Lever [G] to release the Jam Clearance Cover [H]. Remove any trim waste strips from between the transport belts [J]. Lift the Lever [G] to restore the Jam Clearance Cover to operating position. Close the Top Cover [F].

  • Page 130: Best Practices For The Blm5035/Blm5050 System

    x04138_EN_E BLM5000 Best practices for the BLM5035/BLM5050 system • If the set is not properly registered (side jogged and back jogged), fine adjustment of registra- tion may improve the situation. See section 2 “Making Booklets”, Fine-tuning booklet appear- ance for details. •...

  • Page 131: Limitations Of The Blm5035/Blm5050 System

    x04138_EN_E BLM5000 Limitations of the BLM5035/BLM5050 system • If sheets entering the BLM5035/BLM5050 is not uniform and square the booklet quality will vary accordingly. • The maximum recommended number of sheets that can be folded without stapling is 2 sheets of 80 gsm.
  • Page 132 x04138_EN_E BLM5000 Limitations of the BLM5035/BLM5050 system, cont. • For thick booklets, the clinch quality of the staples may show limitations resulting in the staple legs to be spaced away from the sheets. • For thick booklets with a thin cover, the cover can be “pulled back” during the registration pro- cess in the Face Trimmer.
  • Page 133 x04138_EN_E BLM5000 Limitations of the BLM5035/BLM5050 system, cont. • Books made from 1-3 sheets of thin media longer than 420 mm may show fold quality variation. If this occurs, change media to improve quality. • Curled sheets coming out of the printer will result in increased JAM rate. Flat Curl amount above 10 mm is outside specification.
  • Page 134 x04138_EN_E BLM5000 Limitations of the BLM5035/BLM5050 system, cont. Limitations related to options • Covers may show markings from the Convenience Feeder separation process. • Extra heavy media 300-350gsm may not rotate correctly in the RCT module. As a workaround operator can try to run media in SEF mode. This may help. This phenomenon has been seen on the following media: Reina (A4 348.8 gsm) .

  • Page 135: Specification

    x04138_EN_E BLM5000 8. Specification Machine Specifications RCT Rotate Crease Trim Module (option) Specifications Remarks Speed Same as BLM5035/BLM5050 Booklet Maker Input Paper Width Min 216 mm / 8.5″ Input Paper Width Max 330 mm / 13″ 5 mm / 0.2″ Head and Foot Trim will automati- cally be turned on Output Paper Size Min...

  • Page 136: Blm5035/Blm5050 Booklet Maker

    BLM5000 BLM5035/BLM5050 Booklet Maker General Specifications Specifications Remarks Speed (Online usage) Ask your local Canon representative for details. Paper Weight Min 64 gsm / 16 lb Bond uncoated Limited performance with 105 gsm / 28 lb Bond coated some media below 80 gsm...

  • Page 137: Convenience Feeder (Option)

    Using Min trimming H×W: 206x100 mm / 8.1x4″ Convenience Feeder (option) Specifications Remarks Maximum Speed used as Ask your local Canon representative for an internal feeder details. Paper Size Min 120x210 mm / 4.7x8.3″ Paper Size Max 320x620 mm / 12.6x24.4″...

  • Page 138: Fm5000 Finishing Module

    x04138_EN_E BLM5000 FM5000 Finishing Module Specifications Remarks Auto trim length Starting at 5 mm / 0.2″ at 2 sheets per set Adjustable in 0.1 mm (0.004″) and increasing steps Minimum recommended 5 mm / 0.2″ * Bypass of Trimmer is possible trimming Maximum trimming 16 mm / 0.63″...

  • Page 139: Waste Transport (Option)

    x04138_EN_E BLM5000 Waste Transport (option) Specifications Remarks Weight 25 kg / 55.1 lb Dimensions (L × H × D) For footprint, see section 7, Access to machine Power Source From FM5000 Finishing Module Trim Waste Conveyor (option) Specifications Remarks Weight 30 kg / 66.2 lb Dimensions (L ×...

  • Page 140: System Set Size Guide

    x04138_EN_E BLM5000 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. BLM5035 Paper Size Longer than 450 mm / 18" A3 or 11 x 17"...
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  • Page 142: Declaration Of Conformity

    x04138_EN_E BLM5000 Declaration of Conformity EU & UK DECLARATION OF CONFORMITY ......N0007333 (A.6) 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 F137-001, F137-002, F137-011, F137-012 F138-001, F138-002...
  • Page 143 x04138_EN_E BLM5000 EU & UK DECLARATION OF CONFORMITY ......D0001499 (I.11) 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, Type/Model F122- F122-...
  • Page 144 x04138_EN_E BLM5000 EU & UK DECLARATION OF CONFORMITY ......D0000356 (K.6) 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 PL4700, F680 Name BST4000, BST4000-1, F680, Y980, BST6200, F656, PLBS...
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