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Plockmatic PBM5035s Operator's Manual

Production booklet maker
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x04116_EN_J PBM5000s
Plockmatic PBM5035s/5050s
Production Booklet Maker
Doc no: X04116_EN_J
Date: 13 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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Ann
July 23, 2025

HOw do you correct skew on a single sheet. It is not correcting anything when the adjustment is made in the fold tab.

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Summary of Contents for Plockmatic PBM5035s

  • Page 1 PBM5000s Plockmatic PBM5035s/5050s 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: X04116_EN_J Date: 13 March 2025...
  • Page 2 x04116_EN_J PBM5000s Scan the QR code to access translated versions of this manual in German, Italian, French, and Spanish. Visit https://plockmaticgroup.com/myfinisher/customer-portal-pbm5000/ to view the manual in your preferred language.
  • Page 3 x04116_EN_J PBM5000s 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 x04116_EN_J PBM5000s 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 x04116_EN_J PBM5000s 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 x04116_EN_J PBM5000s 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

    x04116_EN_J PBM5000s TABLE OF CONTENTS What You Can Do With This Machine ................11 Guide To Components ..................... 13 Booklet Maker ..........................13 Alive logo ............................... 18 User Interface ..........................19 User Interface ............................19 Finishing Module ......................... 24 Options ..........................27 Waste Transport to Finishing Module ..................
  • Page 8 x04116_EN_J PBM5000s 2. Making Booklets or Stapled Sets ........... 69 Changing settings ......................69 General procedure ........................69 Paper Size ..........................69 Selecting standard paper sizes ......................69 AUTO Paper Size ..........................70 Custom Paper size ..........................70 Booklet Size ..........................70 General..............................
  • Page 9 x04116_EN_J PBM5000s 3. Tools, continued SquareBack Offset ........................96 Waste Transport Fan ........................96 Stacker Settings .......................... 97 View On Demand ........................97 Stitch Reminder .......................... 98 Units ............................98 Language ............................ 98 Software version ......................... 99 Service mode ..........................99 4.
  • Page 10 Cleaning Trimmer Infeed Transport Belts .................... 147 Cleaning Trimmer Exit Transport Belts ....................148 Cleaning the Waste Transport ......................149 Best practices for the PBM5035s/PBM5050s system ..........151 Limitations of the PBM5035s/PBM5050s system ............152 8. Specifications ................157 Machine Specifications ....................157 PBM Rotate Crease Trim Module (option) ................

  • Page 11: What You Can Do With This Machine

    Feeder (option) Trim Module (option) The Plockmatic PBM5050s or PBM5035s Production Booklet Maker System consists of: PBM Rotate Crease Trim Module 3.0 (optional), also referred to as the RCT Module or the PBM5050s or PBM5035s Booklet Maker, also referred to as the PBM5050s/PBM5035s,...
  • Page 12 PBM5000s From the RCT, the printed sheets are transported into the PBM5050s or PBM5035s Production Booklet Maker where they are compiled in the stapler area. If a PBM 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

    x04116_EN_J PBM5000s 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 Top Cover Manual Feed Cover Top Cover Glass Document Storage Compartment Front Door holding tools 9 - 12 Stitching Wire Cutters Stitching Head Alignment tools...
  • Page 14 x04116_EN_J PBM5000s 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 x04116_EN_J PBM5000s Booklet Maker, continued Parts that are important for setup, adjustments, troubleshooting or maintenance are high- lighted below. Paper Transport Latch Wire Spools Fold Roller Paper Guide Paper Transport Stitching Heads Set thickness sensor Side Joggers Back Jogger Beam Compiler area (red color) Main power switch Upper Infeed Paper Path...
  • Page 16 x04116_EN_J PBM5000s Booklet Maker, continued Parts that are important for setup, adjustments, troubleshooting or maintenance are high- lighted below. Wire Guide Spring assy Check Pawl Collar Wire Spool Spring Rotator Operator Spring Wire Spool Face Plate assy Stitching Head positioning scale Magnetic Rotator Cutter Clincher...
  • Page 17 x04116_EN_J PBM5000s Booklet Maker, continued Parts that are important for setup, adjustments, troubleshooting or maintenance are high- lighted below. Threading Lever Thread Guide Block Wire Draw Adjuster Lever Set Collar Gripper Star Knob Hole in Face Plate assy Stitching Head Clutch Wire Guide Spring Rollers Bonnet Clamp Block Felt Pads...

  • Page 18: Alive Logo

    x04116_EN_J PBM5000s 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 19: User Interface

    PBM5000s User Interface The Plockmatic 5050s or 5035s 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 20 x04116_EN_J PBM5000s 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 21 x04116_EN_J PBM5000s 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 millimeters to inches and more. See section 3, ”Tools” for how to work with the Tools screen.
  • Page 22 x04116_EN_J PBM5000s Information on screen Depending on how the system is configured, the information on the screen changes and the size of the buttons will adapt to fit the screen. This sample screen shows a fully configured Booklet Maker system with RCT and internal Convenience Feeder.
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  • Page 24: Finishing Module

    x04116_EN_J PBM5000s 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 Glas Top Cover Latch Handle Fold Stop Pocket adjust- ment instruction Edge and Corner Stapling Stacker...
  • Page 25 x04116_EN_J PBM5000s 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 26 x04116_EN_J PBM5000s 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 27: Options

    x04116_EN_J PBM5000s 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 28: Rotate Crease Trim Module

    x04116_EN_J PBM5000s Rotate Crease Trim Module Top Cover Slide Door Infeed Slot Upstream Docking assembly Docking Latch...
  • Page 29 x04116_EN_J PBM5000s Rotate Crease Trim Module, continued Exit slot Waste Bin full Detection Waste Bin Trim Waste Transport Cable Protector Downstream Docking assembly Connections continued on next page...
  • Page 30 x04116_EN_J PBM5000s 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...
  • Page 31 x04116_EN_J PBM5000s Rotate Crease Trim Module, continued Waste chute(s) Creaser registration adjustment Bleed trimmer registration adjustment Latch handle, slide continued on next page...
  • Page 32 x04116_EN_J PBM5000s 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 33: Booklet Maker

    x04116_EN_J PBM5000s 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 34 x04116_EN_J PBM5000s 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 Front Side guide Rear Side guide DSD sensors...
  • Page 35 x04116_EN_J PBM5000s 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 36: Manual Feed Tray

    x04116_EN_J PBM5000s Manual Feed Tray The optional Manual Feed Tray facilitates manual feeding of sets to the Booklet Maker. It can be attached when the Booklet Maker system is undocked. When not in use, the Man- ual Feed Tray can be stored hanging on the Booklet Maker Rear Cover. Insert the tabs of the Manual Feed Tray into the holes on the upper left of the Booklet Maker Rear Cover.

  • Page 37: Bst4000-1 Belt Stacker Module

    The BST4000-1 High Capacity Belt Stacker Module is an option available for the Plockmatic 5050s or 5035s 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 38: Bst4000-1 Principle Of Operation

    x04116_EN_J PBM5000s 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 39: Trim Waste Conveyor

    x04116_EN_J PBM5000s 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.
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  • Page 41: Basics

    x04116_EN_J PBM5000s 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 42: Emptying The Edge And Corner Staple Stacker

    x04116_EN_J PBM5000s Emptying the Edge and Corner Staple Stacker The Edge and Corner Staple Stacker is located in the Finishing Module behind the right door on the front side. The message “Stacker Full” will be shown on the User Interface when the Edge and Corner Staple Stacker is full.

  • Page 43: Emptying The Trim Waste Bins

    x04116_EN_J PBM5000s 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 44 x04116_EN_J PBM5000s 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. WARNING: Do not put your fingers within knife protections [B].

  • Page 45: Stitching Heads

    x04116_EN_J PBM5000s Stitching heads The Booklet Maker can be equipped with two or four stitching heads. To match different stapling scenarios, the stitching heads can be moved to different positions and also be disengaged for example when corner stapling. Out of Wire The User Interface will indicate “Out of Wire”...

  • Page 46: Replacing Wire Spool(S)

    x04116_EN_J PBM5000s Out of Wire, continued Replacing Wire Spool(s) 1 1 Select a large paper size (SRA3 or 11x17”) in order to move the rear jogger assembly away from the stitching heads. 2 2 Turn off the Booklet Maker. 3 3 Turn the Wire Threading Lever [A] clockwise to the “Off”...
  • Page 47 x04116_EN_J PBM5000s Out of Wire, continued Replacing Wire Spool(s), continued Install the Set Collar [I] on the Wire Spool Shaft. Push in the Set Collar and the Wire Spool so that the Spring compresses approximately 2 mm (5/64 ). This to exert the smallest amount force ″...

  • Page 48: Engage/Disengage Stitching Heads

    x04116_EN_J PBM5000s Engage/disengage Stitching Heads Disengaging Stitching Head(s) 1 1 Loosen the Knob [A] 2 2 Move the Knob and the Stitching Head Clutch [B] away from the Stitching Head Driver [C]. 3 3 Tighten the Knob [A] to prevent Stitching Head from being engaged by mistake.

  • Page 49: Engaging Stitching Head(S)

    x04116_EN_J PBM5000s Engage/disengage Stitching Heads, continued Engaging Stitching Head(s) 1 1 Loosen the Knob [A] 2 2 Move the Knob and the Stitching Head Clutch [B] towards the Stitching Head Driver [C]. 3 3 Lift the Stitching Head Driver [C] and mate with the Stitching Head Clutch [B].

  • Page 50: Changing Staple Position

    x04116_EN_J PBM5000s Changing Staple position Moving Stitching Head(s) Looking along the left side of any Stitching Head, the actual staple position, center to center, can be read on the scale behind. The purpose of the scales is to show Stitching Head positions where to avoid skew folding and damaging of the sheets especially when running booklet with few sheets in the set.

  • Page 51: Moving Clincher(S)

    x04116_EN_J PBM5000s Changing Staple position, continued Moving Clincher(s) The Booklet Maker is delivered with four Clinchers as standard, this in preparation for four stitch head option. This simplifies the clincher positioning. To move the Clinchers, obtain the 3 mm hex key from the Stitching Tools compartment in the Front Door.

  • Page 52: Aligning Clincher(S)

    x04116_EN_J PBM5000s Aligning Clincher(s) The clinchers must be properly aligned with the stitch- ing heads to operate without malfunction or damage. To align a clincher to a stitching head, first obtain the Clincher Alignment Tools from the Stitching Tools com- partment in the Front Door.

  • Page 53: Wire Draw Adjustment

    x04116_EN_J PBM5000s Wire Draw Adjustment The Stitching head is equipped with a 5 position ec- centric Adjuster Lever Assembly.This lever changes the length of wire used to staple the booklet. 31 – 50 The down position results in the shortest length of wire 23 –...

  • Page 54: Paper Stack Preparation

    x04116_EN_J PBM5000s 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 55: Measuring Paper Curl On A Single Sheet

    x04116_EN_J PBM5000s 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 into a stack before putting them into the tray. Measuring Paper Curl on a single sheet 1 1 Place the sheet on a flat surface.

  • Page 56: Convenience Feeder

    x04116_EN_J PBM5000s 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 57: Convenience Feeder Settings

    x04116_EN_J PBM5000s 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 58: Using The Belt Stacker

    x04116_EN_J PBM5000s 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, High Capacity/Box postion or External Device position. Belt Stacker Belt Stacker Release...
  • Page 59 x04116_EN_J PBM5000s 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 60 x04116_EN_J PBM5000s 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 61 x04116_EN_J PBM5000s 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. 4 4 External Device position.

  • Page 62: Belt Stacker Bst4000-1

    x04116_EN_J PBM5000s 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 63: Setting Up Belt Stacker For Straight Mode

    x04116_EN_J PBM5000s 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 64: Detaching / Attaching The Trim Waste Conveyor

    x04116_EN_J PBM5000s Detaching / Attaching the Trim Waste Conveyor Detaching the Trim Waste Conveyor Loosen the Knobs [A] (x2) and remove the Cable Protection Extension [B]. Unhook the O-ring [C] from the upper Pulley [D] 3 3 Loosen Knob [E]. The TWC is now detached from the RCT and can be moved away.

  • Page 65: Attaching The Trim Waste Conveyor

    x04116_EN_J PBM5000s Attaching the Trim Waste Conveyor Attaching the Trim Waste Conveyor is an exact reversal of detaching as described above. NOTE: In order to make the conveyor belt travel in the correct direction, make sure to route the O-ring [C] on the Pulleys [D] and [F] as illustrated.

  • Page 66: Docking / Undocking

    x04116_EN_J PBM5000s Docking / Undocking Docking the Booklet Maker System 1 1 Turn the Printer off. 2 2 Lift up the Exit arm catcher on the Printer Finisher and set the Exit paper arm in the upper position. 3 3 Remove the Exit tray from the Printer’s Finisher.

  • Page 67: Undocking The Booklet Maker

    x04116_EN_J PBM5000s Undocking the Booklet Maker 1 1 Turn the Printer off. 2 2 Push in the latch on the docking assembly and move the Booklet Maker System away from the Printer. If the system includes an RCT module, it is advisable to undock the Booklet Maker alone first and then the RCT.
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  • Page 69: Making Booklets Or Stapled Sets

    x04116_EN_J PBM5000s 2. Making Booklets or Stapled Sets 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 70: Auto Paper Size

    x04116_EN_J PBM5000s AUTO Paper Size AUTO means that the Booklet Maker will adjust to the paper size information sent from the printer. Auto Rotate will be turned on and a finished booklet size will be chosen from a predefined list i.e. the [Finished Booklet Size] button will be greyed out.

  • Page 71: Auto Trimming

    x04116_EN_J PBM5000s AUTO trimming When Booklet Size is set to a format that includes AUTO Face Trim, a minimum trim, based on the information from Set Thickness Sensor, is calculated. After one booklet have been produced, the amount of Face Trim is displayed within parentheses.

  • Page 72: Side Trim (Head And Foot)

    x04116_EN_J PBM5000s Custom Booklet Size, continued Side Trim (Head and Foot) To adjust the amount of Side Trim, press the Width number and enter the desired width of the booklet. Also, the [plus] and [minus] buttons can be used to change the numbers. The amount of Head and Foot Trim is displayed in the box.

  • Page 73: Squareback

    x04116_EN_J PBM5000s 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 74: Selecting Squareback Pressure Setting

    PBM5000s General, continued The table below shows highest supported SquareBack pressure settings on PBM5050s and PBM5035s Production Booklet Maker systems. These are the maximum settings that can be used without slowing the printer down. Number of sheets SRA3 8.5x11"...

  • Page 75: Fold

    x04116_EN_J PBM5000s 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 76: Staple

    x04116_EN_J PBM5000s Staple General 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. Staple status can be set to either Saddle Sta- pling, Edge Stapling, Corner Stapling or being disabled by pressing the corresponding button.

  • Page 77: Saddle Staple

    x04116_EN_J PBM5000s General, continued Staple icon Later, when beginning on-line production, select the [Staple icon] for all types of stapling; saddle, edge and corner stapling. Saddle Staple In the Staple Settings screen, enable saddle stapling by pressing the [Saddle Staple] button. Confirm by pressing the green [check] button.

  • Page 78: Edge Staple

    x04116_EN_J PBM5000s 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 Staple is only possible on paper sizes A4 or 8.5x11”. The [Staple] button will show that the Booklet Maker is set to Edge Staple.

  • Page 79: Crease

    x04116_EN_J PBM5000s 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 80: Convenience Feeder

    x04116_EN_J PBM5000s 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, or as a regular feeder.

  • Page 81: Add Cover And/Or Add Centerfold

    x04116_EN_J PBM5000s 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. When [Add Cover] is enabled, the next cover will be pre-fed to maximize productivity.

  • Page 82: Advanced Feeder Settings

    x04116_EN_J PBM5000s Advanced Feeder Settings From the Interposer screen (or the Sheet Feeder screen), press the [Advanced Settings] button. Press the appropriate button to change settings of either Double Sheet Detection or Separation Air. Double Sheet Detection From the Advanced Feeder Settings screen, press the [Double Sheet Detection] button.

  • Page 83: Sheet Feeder

    x04116_EN_J PBM5000s Sheet Feeder To set up the Convenience Feeder as a regu- lar Feeder, press the [Feeder] button from the Start screen. NOTE: All staple modes or just folding (saddle stapling disabled) are possible. From the Feeder Settings screen, press the [Sheet Feeder] button.

  • Page 84: Fine-Tuning The Booklet Appearance

    x04116_EN_J PBM5000s 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 UI 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 85 x04116_EN_J PBM5000s Send one set of the job from the printer and fol- low instructions on screen. When the set has stopped in the compiler area, follow instructions on screen to check the regis- tration of the set. After the Top Cover is closed, press the [-] and [+] buttons from the [Set Registration Fine Adjustment] screen to change either or both registration values.

  • Page 86: Side Trimmer - Asymmetric Side Trim

    x04116_EN_J PBM5000s 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 87: Skew Compensation

    x04116_EN_J PBM5000s 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 88: Fold Stop Pocket Adjustment

    x04116_EN_J PBM5000s Fold Stop Pocket adjustment Normally, setting the Fold Stop Pocket adjustment knob so that the indicator is pointing to the number one position (leftmost position) should be suitable for most combinations of paper weights, sheet lengths and set sizes within the specifications. However, if the fold line is consistently not aligned with the staple line, tightening the Fold Stop Pocket might help to correct this phenomenon.
  • Page 89 x04116_EN_J PBM5000s Normal setting is position 1 where the Fold Stop Pocket is fully opened. This setting is suitable for corner, edge and saddle stapling. Increasing the setting will tighten the Fold Stop Pocket and is used when saddle stapling sets of various thickness and length and when a misalignment between the staple line and the fold line is experienced.

  • Page 90: Manual Feed

    x04116_EN_J PBM5000s Manual Feed There are two ways you can feed sets into the Booklet Maker manually. Either by opening the Manual Feed Cover in the Top Cover or by using the more convenient and ergonomic optional Manual Feed Tray when the Booklet maker is undocked. General Manual Feed Mode is initiated by opening the Manual Feed Cover in the Top Cover.

  • Page 91: Using The Built-In Manual Feed Slot

    x04116_EN_J PBM5000s Using the built-in Manual Feed Slot 1 1 Open the Manual Feed Cover [A] in the Booklet Maker Top Cover to initiate Manual Feed Mode. The User Interface will display a green hand when the Booklet Maker is ready to receive manually fed sets.

  • Page 92: Begin On-Line Production

    x04116_EN_J PBM5000s Begin On-line Production 1 1 Make sure that the staple icon [B] is present on the Printer User Interface. If not, power off the Printer and Booklet Maker. First power on the Booklet Maker and then power on the Printer.

  • Page 93: Tools

    x04116_EN_J PBM5000s 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 94: Stitching Head Configuration

    x04116_EN_J PBM5000s Stitching Head Configuration The Stitching Head Configuration screen must reflect wether stitching heads are engaged and where they are positioned. CAUTION: Make sure that the information about the position of the stitching heads and whether they are engaged is correct. Severe permanent damage to the stitching heads, clinchers and/or the side guides might occur otherwise.

  • Page 95: Production Priority

    x04116_EN_J PBM5000s The purpose of the scales is to show Stitching Head positions where to avoid skew folding and damaging of the sheets especially when running booklet with few sheets in the set. When two Stitching Heads are installed - use any positions marked with green lines, two or four.

  • Page 96: Adjust Trimmer Registration

    x04116_EN_J PBM5000s Adjust Trimmer registration Adjust the time the trimmer tries to register the booklet before trimming. Select a negative val- ue to decrease the risk of “over registering” the top cover when a thin media is used for cover. A negative value can also decrease the number of marks caused by the registration belts in the Trimmer.

  • Page 97: Stacker Settings

    x04116_EN_J PBM5000s Stacker Settings Whenever the Paper Size is changed and the Belt Stacker is in High Capacity position, the Stacker Booklet Size Warning will be shown as reminder to set the Belt Stacker Stop Gate to the correct position. See section 1, “Basics”, for how to use the Belt Stacker and position the Belt Stacker Stop Gate.

  • Page 98: Stitch Reminder

    x04116_EN_J PBM5000s Stitch Reminder To minimize the risk of severe permanent damage to the stitching heads and to the side guides, a reminder will be shown at power on and change of paper format. This default setting is called “ON Limited”. To enable this reminder also upon opening and closing of the Booklet Maker Top Cover, set this reminder to “ON”.

  • Page 99: Software Version

    x04116_EN_J PBM5000s 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 only and is password protected.
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  • Page 101: Jobs

    x04116_EN_J PBM5000s 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 102: Loading Jobs

    x04116_EN_J PBM5000s 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 103: Clearing Misfeed(S)

    x04116_EN_J PBM5000s 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 104: Rct Module

    x04116_EN_J PBM5000s 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 105: Registration And Creaser Area - Rct2

    x04116_EN_J PBM5000s 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 106: Booklet Maker

    x04116_EN_J PBM5000s 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 Infeed Paper path [C].

  • Page 107: Clearing Misfeed In Stapler Area - Bm2

    x04116_EN_J PBM5000s 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] until it latches.

  • Page 108: Clearing Misfeed In Folder Area - Bm3

    x04116_EN_J PBM5000s 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 109: Clearing Misfeed In The Fold Stop Area - Bm3

    x04116_EN_J PBM5000s 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 110: Clearing Misfeed In Convenience Feeder Area - Bm4

    x04116_EN_J PBM5000s 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 111: Clearing Misfeed In Convenience Feeder Area - Bm5

    x04116_EN_J PBM5000s 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 112: Finishing Module

    x04116_EN_J PBM5000s 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 113: Clearing Misfeed In The Trimmer Infeed Area - Fm2

    x04116_EN_J PBM5000s 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 114: Clearing Misfeed In The Trimmer Exit Area - Fm2

    x04116_EN_J PBM5000s 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 ModuleTop Cover. 2 2 Lift the exit compressing brackets and transport belts [B]. 3 3 Remove any jammed/misfeed sets/booklets.

  • Page 115: Clearing Misfeed In The Waste Transport

    x04116_EN_J PBM5000s 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 116 x04116_EN_J PBM5000s Clearing misfeed in the Waste Transport, continued 5 5 Open the Waste Transport Top Cover [D]. 6 6 Push down the Lever [E] to release the Jam Clearance Cover [F]. 7 7 Remove any trim waste strips from between the transport belts [G]. 8 8 Lift the Lever [E] to restore the Jam Clearance Cover to operating position.

  • Page 117: Belt Stacker

    x04116_EN_J PBM5000s 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.
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  • Page 119: Troubleshooting

    x04116_EN_J PBM5000s 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 120: Booklet Maker Fault Codes

    x04116_EN_J PBM5000s Booklet Maker 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 121: Booklet Maker Fault Codes

    x04116_EN_J PBM5000s Booklet Maker fault codes 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 122: Finishing Module (Fm) Fault Codes

    x04116_EN_J PBM5000s Booklet Maker (BM) fault codes, continued Code / message Explanation / action BM504 - Wire spool 4 empty Replace spool 4 to continue production or disable stapling. BM505 - Attention! The paper size is not compatible with the stitching heads positions.

  • Page 123: Stacker (St) Fault Codes

    x04116_EN_J PBM5000s 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 124: Communication Box (Rppi) Fault Codes

    x04116_EN_J PBM5000s Communication Box (RPPI) 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 125: General Fault Codes

    x04116_EN_J PBM5000s 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 126: Empty Stacker

    x04116_EN_J PBM5000s General fault codes, continued Lubricate Stitching Heads The message [Lubricate Stitching Heads] will be displayed every 10.000 booklets to inform the operator that the Felt Pads needs to be dampened. See section 7, “REMARKS”, Maintaining Your Machines for how to dampen the Felt Pads.

  • Page 127: Remarks

    x04116_EN_J PBM5000s 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 128: Where To Put Your Machine

    x04116_EN_J PBM5000s 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 129: Access To Machine

    x04116_EN_J PBM5000s Access to machine Place the machine near the power source, providing clearance as shown. 2220 mm / 87.4″ 380 mm 15″ 400 mm 15.8″ 400 mm 15.8″ 540 mm 21.2″ 160 mm 890 mm 760 mm 1010 mm 720 mm 35″...

  • Page 130: Maintaining Your Machines

    x04116_EN_J PBM5000s 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 131: Cleaning The Fixing Rollers (X3)

    x04116_EN_J PBM5000s 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 132: Cleaning The Registration Cross Rollers (X6) & Friction Tires (X6)

    x04116_EN_J PBM5000s Cleaning the fixing rollers (x3) continued Fixing roller Cleaning the registration cross rollers (x6) & friction tires (x6) Registration cross rollers...
  • Page 133 x04116_EN_J PBM5000s Cleaning the registration cross rollers (x6) & friction tires (x6) continued Friction tires continued on next page...

  • Page 134: Cleaning The Rotator Rollers (X2)

    x04116_EN_J PBM5000s 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 135 x04116_EN_J PBM5000s Cleaning the paper path sensors (x5) continued Rotator sensor Registration sensor continued on next page...

  • Page 136: Cleaning Of Creaser Tools (X2)

    x04116_EN_J PBM5000s 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 137: Adjustment Of Side Trimmer Registration Angle (Parallel Cut)

    x04116_EN_J PBM5000s 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 138: Adjustment Of Creaser Registration Angle

    x04116_EN_J PBM5000s 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 139: Booklet Maker

    x04116_EN_J PBM5000s Booklet Maker Cleaning the 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 140: Dampening The Felt Pads

    x04116_EN_J PBM5000s Booklet Maker, continued Dampening the Felt Pads The Felt Pads [A] should be dampened with oil so that the Stitching Wire can pick up oil when it is pulled throught the Pads before the Wire enters the Stitching Heads. Dampen the Felt Pads [A] with a couple of drops of SAE 20W oil every 10 000 staples.

  • Page 141: Cleaning Clincher Area

    x04116_EN_J PBM5000s 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 142: Stitching Heads

    x04116_EN_J PBM5000s Booklet Maker, continued Stitching Heads The Stitching heads have to be serviced every 500k stitches or 12 months of use: make sure to request service when necessary. NOTE: Oil stains in the form of 2 or 4 small dots (where the 2 or 4 stitching heads are) might be seen on the first booklets after oiling/replacing the stitching heads.

  • Page 143: Cleaning Convenience Feeder

    x04116_EN_J PBM5000s Cleaning Convenience Feeder 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 144: Finishing Module

    x04116_EN_J PBM5000s 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 145: Squareback Pressure Springs

    x04116_EN_J PBM5000s 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 146: Cleaning Squareback Clamps And Roller

    x04116_EN_J PBM5000s 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 147: Cleaning Trimmer Infeed Transport Belts

    x04116_EN_J PBM5000s 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 148: Cleaning Trimmer Exit Transport Belts

    x04116_EN_J PBM5000s Finishing Module, continued Cleaning Trimmer Exit Transport Belts The Trimmer Exit 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 149: Cleaning The Waste Transport

    x04116_EN_J PBM5000s 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 150 x04116_EN_J PBM5000s Finishing Module, continued Cleaning the Waste Transport, continued 5 5 Open the Waste Transport Top Cover [D]. 6 6 Push down the Lever [E] to release the Jam Clearance Cover [F]. 7 7 Remove any trim waste strips from between the transport belts [G]. 8 8 Lift the Lever [E] to restore the Jam Clearance Cover to operating position.

  • Page 151: Best Practices For The Pbm5035S/Pbm5050S System

    PBM5000s Best practices for the PBM5035s/PBM5050s 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 152: Limitations Of The Pbm5035S/Pbm5050S System

    PBM5000s Limitations of the PBM5035s/PBM5050s system • If sheets entering the PBM5035s/PBM5050s 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 153 PBM5000s Limitations of the PBM5035s/PBM5050s system, cont. • On some coated media, staples may not completely penetrate the set resulting in a faulty staple. If problem persists, consider changing media. Staple may not be able to penetrate the number of sheets indicated by the “Set Size Guide”.
  • Page 154 Selecting a lower SquareBack setting will reduce this phenomenon. • 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 155 400 mm that are also thin below 80gsm. Workaround is to use heavier paper above 80gsm. • The PBM5035s/5050s Production Booklet Maker systems are suited for customers whose booklet making needs will not exceed a yearly average of 40,000 booklets per month. •...
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  • Page 157: Specifications

    8. Specifications Machine Specifications PBM Rotate Crease Trim Module (option) Specifications Remarks Speed Same as PBM5035s/PBM5050s Booklet Maker Input Paper Width, Min 120 mm / 4.7” (bypass only) 158.5 mm / 6.2″ Input Paper Width, Max 330 mm / 13″...

  • Page 158: Pbm5035S/Pbm5050S Booklet Maker

    50% RH and room tempera- ture should be within 18 - 26 °C / 64 - 78 °F NOTE: Plockmatic uses QT open source license (LGPL) to develop the software used in this machine (https:// www.qt.io/qt-licensing-terms). continued on next page...
  • Page 159 PBM5000s PBM5035s/PBM5050s Booklet Maker, continued Specifications, Stitching version (ISP) Specifications Remarks Paper Size, Min Booklet making W×L: 120x210 mm / 4.7x8.3″ Smallest paper size an RCT can cut down to is 148,5 mm / 5.85”. For paper sizes narrower...

  • Page 160: Pbm Convenience Feeder (Option)

    PBM5000s Machine Specifications, continued PBM5035s/PBM5050s Booklet Maker, continued Specifications, Stitching version (ISP) Specifications Remarks Internal Stacking capacity, It is recommended to unload Edge or corner stapling 50 mm / 2″ the stacker often when stack- ing thinner sets. Thinner sets might trigger a stacker full message too early.

  • Page 161: Pbm Finishing Module

    For footprint, see section 7, Access to ma- chine Power Source From PBM5035s/PBM5050s Booklet Maker Environmental Require- For environmental requirements of the sys- ments tem refer to PBM5035s/PBM5050s Booklet Maker specifications. Belt Stacker Capacity Paper size Sheets per set Square forming on/off Belt Stacker mode Booklets on Stacker A4/8.5x11″...

  • Page 162: Waste Transport (Option)

    x04116_EN_J PBM5000s Machine Specifications, continued 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 PBM Finishing Module Trim Waste Conveyor (option) Specifications Remarks Weight...

  • Page 163: System Set Size Guide

    When the optional four head kit is installed, the maximum amount of sheets in a set is limited to 30. For paper sizes narrower than 148,5 mm / 5.85”, max set thickness is reduced to 30 sheets 80 gsm / 20lb Bond or 3,0 mm / 0.12”. Saddle Stapling, PBM5035s Paper Size Longer than 450 mm / 18"...

  • Page 164: Recommended Staple Positions

    x04116_EN_J PBM5000s Recommended Staple Positions Making booklets using two Stitching Heads...

  • Page 165: Making Booklets Using Four Stitching Heads

    x04116_EN_J PBM5000s Making booklets using four Stitching Heads...

  • Page 166: Staple Position When Using Corner Stapling

    x04116_EN_J PBM5000s Recommended Staple Positions, continued Staple Position when using Corner Stapling...

  • Page 167: Declaration Of Conformity

    Declaration of Conformity EU & UK DECLARATION OF CONFORMITY ......N0007333 (A.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 Model/Type...
  • Page 168 PBM5000s EU & UK DECLARATION OF CONFORMITY ......D0001499 (I.3) 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...
  • Page 169 PBM5000s EU & UK DECLARATION OF CONFORMITY ......D0000356 (K.4) 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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