1. Manuals
  2. Brands
  3. Plockmatic Manuals
  4. Booklet makers
  5. PBM5035
  6. Operator's manual

Plockmatic PBM5035 Operator's Manual

Production booklet maker
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
x04113_EN_J PBM5000
Plockmatic PBM5035/5050
Production Booklet Maker
Doc no: X04113_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

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the PBM5035 and is the answer not in the manual?

Questions and answers

Related Manuals for Plockmatic PBM5035

Summary of Contents for Plockmatic PBM5035

  • Page 1 PBM5000 Plockmatic PBM5035/5050 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: X04113_EN_J Date: 13 March 2025...
  • Page 2 x04113_EN_J PBM5000 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 x04113_EN_J PBM5000 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

    x04113_EN_J PBM5000 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 x04113_EN_J PBM5000 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 x04113_EN_J PBM5000 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

    x04113_EN_J PBM5000 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 x04113_EN_J PBM5000 2. Making Booklets, continued Booklet Size ..........................58 General..............................58 AUTO trimming ............................59 Custom Booklet Size ..........................59 Face Trim ............................59 Side Trim (Head and Foot) ....................... 60 SquareBack ..........................61 General..............................61 Selecting SquareBack pressure setting ....................62 Fold .............................
  • Page 9 x04113_EN_J PBM5000 4. Jobs ....................83 Handling jobs ........................83 Saving a Job ..........................83 Loading Jobs ..........................84 Deleting Jobs ..........................84 5. Clearing Misfeed(s) ................. 85 Clearing misfeed(s) ......................85 General ............................85 RCT module ........................86 Clearing misfeed(s) in the paper path ..................86 Infeed “A”...
  • Page 10 Cleaning Trimmer Infeed Transport Belts .................... 127 Cleaning Trimmer Exit Transport Belts ....................128 Cleaning the Waste Transport ......................129 Best practices for the PBM5035/PBM5050 system ............. 132 Limitations of the PBM5035/PBM5050 system ............133 8. Specification ................. 137 Machine Specifications ....................137 PBM Rotate Crease Trim Module (option) ................

  • Page 11: What You Can Do With This Machine

    The Plockmatic PBM5050 or PBM5035 Production Booklet Maker System consists of: PBM Rotate Crease Trim Module 3.0 (optional), also referred to as the RCT Module or the PBM5050 or PBM5035 Booklet Maker, also referred to as the PBM5050/PBM5035, the Booklet Maker or the BM...
  • Page 12 PBM5000 From the RCT, the printed sheets are transported into the PBM5050 or PBM5035 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

    x04113_EN_J PBM5000 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 Front Door Document Storage Com-...
  • Page 14 x04113_EN_J PBM5000 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 x04113_EN_J PBM5000 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 Set thickness sensor Staple cartridges (incl. stapler heads) Clinchers Compiler area...

  • Page 16: Alive Logo

    x04113_EN_J PBM5000 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

    PBM5000 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.
  • Page 18 x04113_EN_J PBM5000 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 x04113_EN_J PBM5000 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

    x04113_EN_J PBM5000 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 Door for jam clearance Operator Side Casters, no brakes Rail Guides...
  • Page 21 x04113_EN_J PBM5000 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 x04113_EN_J PBM5000 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

    x04113_EN_J PBM5000 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

    x04113_EN_J PBM5000 Rotate Crease Trim Module Top Cover Slide Door Infeed Slot Upstream Docking assembly Docking Latch...
  • Page 25 x04113_EN_J PBM5000 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 26 x04113_EN_J PBM5000 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 27 x04113_EN_J PBM5000 Rotate Crease Trim Module, continued Waste chute(s) Creaser registration adjustment Bleed trimmer registration adjustment Latch handle, slide continued on next page...
  • Page 28 x04113_EN_J PBM5000 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

    x04113_EN_J PBM5000 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 x04113_EN_J PBM5000 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 31 x04113_EN_J PBM5000 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: Manual Feed Tray

    x04113_EN_J PBM5000 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 33: 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.

  • Page 34: Bst4000-1 Principle Of Operation

    x04113_EN_J PBM5000 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 35: Trim Waste Conveyor

    x04113_EN_J PBM5000 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 36 x04113_EN_J PBM5000 Page intentionally blank.

  • Page 37: Basics

    x04113_EN_J PBM5000 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 38: Change Staple Cartridges And Check Stapler

    x04113_EN_J PBM5000 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 39: Stapler Miss

    x04113_EN_J PBM5000 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 40: Paper Stack Preparation

    x04113_EN_J PBM5000 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 41: Measuring Paper Curl On A Single Sheet

    x04113_EN_J PBM5000 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 42: Emptying Trim Waste Bins

    x04113_EN_J PBM5000 Emptying 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 43: Removing Trim Waste From Trimmer Blade Area

    x04113_EN_J PBM5000 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 44: Convenience Feeder

    x04113_EN_J PBM5000 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 45: Convenience Feeder Settings

    x04113_EN_J PBM5000 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 46: Using The Belt Stacker

    x04113_EN_J PBM5000 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 47 x04113_EN_J PBM5000 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 48 x04113_EN_J PBM5000 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 49 x04113_EN_J PBM5000 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 50: Belt Stacker Bst4000-1

    x04113_EN_J PBM5000 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 51: Setting Up Belt Stacker For Straight Mode

    x04113_EN_J PBM5000 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 52: Detaching / Attaching The Trim Waste Conveyor

    x04113_EN_J PBM5000 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 53: Attaching The Trim Waste Conveyor

    x04113_EN_J PBM5000 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 54: Docking / Undocking

    x04113_EN_J PBM5000 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 55: Undocking The Booklet Maker

    x04113_EN_J PBM5000 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.
  • Page 56 x04113_EN_J PBM5000...

  • Page 57: Making Booklets

    x04113_EN_J PBM5000 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 58: Auto Paper Size

    x04113_EN_J PBM5000 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 59: Auto Trimming

    x04113_EN_J PBM5000 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 60: Side Trim (Head And Foot)

    x04113_EN_J PBM5000 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 61: Squareback

    x04113_EN_J PBM5000 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 62: Selecting Squareback Pressure Setting

    PBM5000 General, continued The table below shows highest supported SquareBack pressure settings on PBM5050 and PBM5035 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 63: Fold

    x04113_EN_J PBM5000 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 64: Staple

    x04113_EN_J PBM5000 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 65: Crease

    x04113_EN_J PBM5000 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 66: Convenience Feeder

    x04113_EN_J PBM5000 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 67: Add Cover And/Or Add Centerfold

    x04113_EN_J PBM5000 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 68: Advanced Feeder Settings

    x04113_EN_J PBM5000 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 69: Sheet Feeder

    x04113_EN_J PBM5000 Sheet Feeder To set up the Convenience Feeder as a regu- lar Feeder, press the [Feeder] button from the Start screen. NOTE: Both saddle stapling and folding or just folding (saddle stapling disabled) are possible. From the Feeder Settings screen, press the [Sheet Feeder] button.

  • Page 70: Fine-Tuning The Booklet Appearance

    x04113_EN_J PBM5000 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 71 x04113_EN_J PBM5000 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 72: Side Trimmer - Asymmetric Side Trim

    x04113_EN_J PBM5000 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 73: Skew Compensation

    x04113_EN_J PBM5000 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 74: Manual Feed

    x04113_EN_J PBM5000 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 75: Using The Built-In Manual Feed Slot

    x04113_EN_J PBM5000 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 76: Begin On-Line Production

    x04113_EN_J PBM5000 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 77: Tools

    x04113_EN_J PBM5000 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 78: Precision Fold Mode

    x04113_EN_J PBM5000 Precision Fold Mode 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 79: Squareback Offset

    x04113_EN_J PBM5000 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 80: View On Demand

    x04113_EN_J PBM5000 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 81: Units

    x04113_EN_J PBM5000 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 82: Service Mode

    x04113_EN_J PBM5000 Service mode This function is for authorized service personnel only and is password protected.

  • Page 83: Jobs

    x04113_EN_J PBM5000 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 84: Loading Jobs

    x04113_EN_J PBM5000 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 85: Clearing Misfeed(S)

    x04113_EN_J PBM5000 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 86: Rct Module

    x04113_EN_J PBM5000 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 87: Registration And Creaser Area - Rct2

    x04113_EN_J PBM5000 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 88: Booklet Maker

    x04113_EN_J PBM5000 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 89: Clearing Misfeed In Stapler Area - Bm2

    x04113_EN_J PBM5000 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 90: Clearing Misfeed In Folder Area - Bm3

    x04113_EN_J PBM5000 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 91: Clearing Misfeed In The Fold Stop Area - Bm3

    x04113_EN_J PBM5000 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 92: Clearing Misfeed In Convenience Feeder Area - Bm4

    x04113_EN_J PBM5000 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 93: Clearing Misfeed In Convenience Feeder Area - Bm5

    x04113_EN_J PBM5000 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 94: Finishing Module

    x04113_EN_J PBM5000 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 95: Clearing Misfeed In The Trimmer Infeed Area - Fm2

    x04113_EN_J PBM5000 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 96: Clearing Misfeed In The Trimmer Exit Area - Fm2

    x04113_EN_J PBM5000 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 97: Clearing Misfeed In The Waste Transport

    x04113_EN_J PBM5000 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 98 x04113_EN_J PBM5000 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 99 x04113_EN_J PBM5000 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 100: Belt Stacker

    x04113_EN_J PBM5000 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 intentionally blank.

  • Page 101: Troubleshooting

    x04113_EN_J PBM5000 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 102: Booklet Maker (Bm) Fault Codes

    x04113_EN_J PBM5000 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 103 x04113_EN_J PBM5000 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 104: Finishing Module (Fm) Fault Codes

    x04113_EN_J PBM5000 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 105: Stacker (St) Fault Codes

    x04113_EN_J PBM5000 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 106: Communication Box (Rppi) Fault Codes

    x04113_EN_J PBM5000 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 107: General Fault Codes

    x04113_EN_J PBM5000 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 108 x04113_EN_J PBM5000 Page intentionally blank.

  • Page 109: Remarks

    x04113_EN_J PBM5000 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 110: Where To Put Your Machine

    x04113_EN_J PBM5000 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 111: Access To Machine

    x04113_EN_J PBM5000 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 112: Maintaining Your Machines

    x04113_EN_J PBM5000 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 113: Cleaning The Fixing Rollers (X3)

    x04113_EN_J PBM5000 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 114: Cleaning The Registration Cross Rollers (X6) & Friction Tires (X6)

    x04113_EN_J PBM5000 Cleaning the fixing rollers (x3) continued Fixing roller Cleaning the registration cross rollers (x6) & friction tires (x6) Registration cross rollers...
  • Page 115 x04113_EN_J PBM5000 Cleaning the registration cross rollers (x6) & friction tires (x6) continued Friction tires continued on next page...

  • Page 116: Cleaning The Rotator Rollers (X2)

    x04113_EN_J PBM5000 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 117 x04113_EN_J PBM5000 Cleaning the paper path sensors (x5) continued Rotator sensor Registration sensor continued on next page...

  • Page 118: Cleaning Of Creaser Tools (X2)

    x04113_EN_J PBM5000 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 119: Adjustment Of Side Trimmer Registration Angle (Parallel Cut)

    x04113_EN_J PBM5000 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 120: Adjustment Of Creaser Registration Angle

    x04113_EN_J PBM5000 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 121: Booklet Maker

    x04113_EN_J PBM5000 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 122: Cleaning Clincher Area

    x04113_EN_J PBM5000 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 123: Cleaning Convenience Feeder Feed Rollers And Paper Separator Pad

    x04113_EN_J PBM5000 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 124: Finishing Module

    x04113_EN_J PBM5000 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 125: Squareback Pressure Springs

    x04113_EN_J PBM5000 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 126: Cleaning Squareback Clamps And Roller

    x04113_EN_J PBM5000 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 127: Cleaning Trimmer Infeed Transport Belts

    x04113_EN_J PBM5000 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 128: Cleaning Trimmer Exit Transport Belts

    x04113_EN_J PBM5000 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 129: Cleaning The Waste Transport

    x04113_EN_J PBM5000 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 130 x04113_EN_J PBM5000 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 131 x04113_EN_J PBM5000 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 132: Best Practices For The Pbm5035/Pbm5050 System

    PBM5000 Best practices for the PBM5035/PBM5050 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 133: Limitations Of The Pbm5035/Pbm5050 System

    PBM5000 Limitations of the PBM5035/PBM5050 system • If sheets entering the PBM5035/PBM5050 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 134 PBM5000 Limitations of the PBM5035/PBM5050 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 135 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 136 400 mm that are also thin below 80gsm. Workaround is to use heavier paper above 80gsm. • The PBM5035/5050 Production Booklet Maker systems are suited for customers whose book- let making needs will not exceed a yearly average of 40,000 booklets per month. •...

  • Page 137: Specification

    8. Specification Machine Specifications PBM Rotate Crease Trim Module (option) Specifications Remarks Speed Same as PBM5035/PBM5050 Booklet Maker Input Paper Width Min 216 mm / 8.5″ Input Paper Width Max 330 mm / 13″ 5 mm / 0.2″ Head and...

  • Page 138: Pbm5035/Pbm5050 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 139: Pbm Convenience Feeder (Option)

    PBM5000 PBM5035/PBM5050 Booklet Maker, continued Specifications, Stapler version (Isaberg) Specifications Remarks Paper Size, Min W×L: 206x210 mm / 8.1x8.3″ For sheets under 209 mm/8.23″ in width registration quality could show larger variance Paper Size, Max W×L: 320x620 mm / 12.6x24.4″...

  • Page 140: Pbm Finishing Module

    For footprint, see section 7, Access to ma- chine Power Source From PBM5035/PBM5050 Booklet Maker Environmental Require- For environmental requirements of the ments system refer to PBM5035/PBM5050 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 141: Waste Transport (Option)

    x04113_EN_J PBM5000 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 30 kg / 66.2 lb Dimensions (L ×...

  • Page 142: 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. PBM5035 Paper Size Longer than 450 mm / 18" A3 or 11 x 17"...
  • Page 143 x04113_EN_J PBM5000 Page intentionally blank.

  • Page 144: 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 145 PBM5000 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 146 PBM5000 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...

This manual is also suitable for:

Pbm5050

Table of Contents