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Plockmatic CT XL Operator's Manual

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X04132_EN_C CT XL
Plockmatic CT XL
Creaser Trimmer
Doc no: X04132_EN_C
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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  • Page 1 X04132_EN_C CT XL Plockmatic CT XL Creaser Trimmer 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: X04132_EN_C Date: 13 March 2025...
  • Page 2 X04132_EN_C CT XL Scan the QR code to access translated versions of this manual in German, Italian, French, and Spanish. Visit https://plockmaticgroup.com/myfinisher/customer-portal-ct-xl-for- ricoh/ to view the manual in your preferred language.

  • Page 3: How To Read This Manual

    X04132_EN_C CT XL Introduction This manual contains instructions on the operation and maintenance of this machine. To get maximum versatility from this machine all operators should carefully read and follow the instructions in this manual. Keep this manual in a handy place near the machine.
  • Page 4 X04132_EN_C CT XL 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: Electromagnetic Compliance

    X04132_EN_C CT XL 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 X04132_EN_C CT XL Safety Information, continued English Description of Safety/Warning labels in the product Crushing Hazard Cutting Hazard Entanglement Hazard Risk for crushing or Sharp objects inside machine. Risk for loose hanging hair, squeezing body parts. jewelry, or clothes to get caught.

  • Page 7: Table Of Contents

    Loading Jobs ..........................42 Deleting Jobs ..........................42 5. Clearing Misfeed(s) ................. 43 Clearing misfeed(s) ......................43 General ............................43 CT XL Creaser Side Trimmer ................... 44 Clearing sequence for misfeed(s) in the CT XL and CT BU paper path ........44...
  • Page 8 General ............................51 General fault codes ........................51 Clear Misfeed(s) ............................ 51 Close cover(s) ............................51 Crease Trimmer (CT XL) fault codes ..................52 7. REMARKS ..................55 Do’s And Don’ts ........................ 55 Where to put Your Machine ..................... 56 Machine environment .........................

  • Page 9: What You Can Do With This Machine

    The CT Bridge Unit (optional), also referred to as the Bridge Unit or CT BU, is only needed in configurations including the Ricoh Interposer. It is a device used to space the CT XL away from the Interposer so that the Top Cover on the CT XL will not interfere with the delivery trays on the Interposer.
  • Page 10 X04132_EN_C CT XL The User Interface is of resistive touch screen type. Point at the screen and press the button or function you wish to make changes to. In this sample screen shot, the Fine Adjust button is pressed. Pressing the [Fine Adjust] button above, takes you to this sub screen.

  • Page 11: Guide To Components

    X04132_EN_C CT XL Guide To Components Creaser Side Trimmer Parts that are important for setup, adjustments, troubleshooting or maintenance are high- lighted below. User Interface (UI) Slide Door Handle Top Cover Slide Door Top Cover Handle Casters Downstream Docking assembly...
  • Page 12 Power connection and Termination Cable Protector plug jacks (ECAN) Exit Slot TWC Docking Bracket* Downstream communication jack * Installed to the CT XL when an optional TWC Rear Waste Cover* (Trim Waste Conveyor) is installed Foam Roller* continued on next page...
  • Page 13 X04132_EN_C CT XL Creaser Side Trimmer, continued Counter Side Trimmer Upper Knives Bridge Unit connections Upper Gratings Infeed area, Baffle “A” Exit area, Baffle “D” Main switch Optional Antistatic Bars Interlock switch continued on next page...
  • Page 14 X04132_EN_C CT XL Creaser Side Trimmer, continued Parts that are important for setup, adjustments, troubleshooting or maintenance are high- lighted below. Waste Chute(s) Slide Slide Latch Handle Interlock Switch Actuator Interlock Switch Waste Chute Cover, removed Slide Door Magnet Waste Chute Cover, installed...
  • Page 15 X04132_EN_C CT XL Creaser Side Trimmer, continued Slide pulled out. Slide door made transparent for clarity. Jam Clearance Baffle, area “B” Creaser Roller Mylar Guides Creaser tools...

  • Page 16: User Interface

    X04132_EN_C CT XL User Interface The Plockmatic CT XL is controlled from a resistive touch screen type panel. The User Interface will allow you to set up and adjust the CT by pointing at the screen and pressing buttons and objects to reach the desired functions or change the desired settings.
  • Page 17 X04132_EN_C CT XL User Interface, continued The Paper Size Screen Pressing the [Paper Size] button in the Home screen opens the Paper Size screen. From here you can select any standard paper size or edit and save a custom paper size.
  • Page 18 X04132_EN_C CT XL User Interface, continued Power save mode When the CT 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.

  • Page 19: Bridge Unit

    X04132_EN_C CT XL Bridge Unit Exit Slot Casters Front Door Handle Downstream Docking Bracket Front Door continued on next page...
  • Page 20 X04132_EN_C CT XL Bridge Unit, continued Jam Clearance Baffle A Docking Latch Infeed Slot Front Door Magnet Interlock Switch Interlock Switch Actuator...

  • Page 21: Options

    Options Trim Waste Conveyor The Trim Waste Conveyor attaches to and is powered from the CT XL. It transports trim waste upwards which enables the use of a larger waste bin. This makes long, unattended runs easier than ever before.
  • Page 22 X04132_EN_C CT XL Page intentionally blank.

  • Page 23: Basics

    Turning On / Off the Main Power CT XL 1 1 Make sure that the power cord to the CT XL is plugged into a live and grounded wall outlet. 2 2 Open the CT XL Top Cover. 3 3 Set the main power switch [A] to ON position.

  • Page 24: Measuring Paper Curl

    Measuring Paper Curl 1 1 Obtain a stack of 5 sheets of the media that is fed from the printer to the CT XL. 2 2 Pinch hold the stack with two fingers at the center of the edge of interest, long edge or short edge.
  • Page 25 X04132_EN_C CT XL...
  • Page 26 X04132_EN_C CT XL Page intentionally blank.

  • Page 27: Creasing And/Or Trimming Sheets

    X04132_EN_C CT XL 2. Creasing and/or Trimming sheets Changing settings General procedure Settings can be changed either temporarily or permanently. Temporary changes will remain until they are changed again or when a job is loaded. To keep your new settings, see section 4, “Jobs” for how to save your current settings as a new job or to an existing job.

  • Page 28: Paper Size

    Bypass and Registration Hardstop will be reset to off. AUTO Paper Size AUTO means that the CT XL will adjust to the paper size information sent from the Upstream Device. NOTE: When AUTO paper size is selected, there is no possibility to Fine Adjust the selected crease setting or to create a Custom crease setting.

  • Page 29: Custom Paper Size

    X04132_EN_C CT XL Paper Size, continued Custom Paper size One custom paper size can be stored. To create a new custom paper size, press the [Custom Size] button from the Paper Size screen and then press the [Edit] button. Change the Width and/or Length either by using the [+] / [-] buttons or by pressing on the actual numbers.

  • Page 30: Crease

    X04132_EN_C CT XL Crease General Information on the [Crease] button shows the actual crease setting. To alter the crease set- ting, press the [Crease] button from the Home screen. Select from ten preset crease settings or create a Custom crease setting.

  • Page 31: Fine Adjustment Of Preset Settings

    X04132_EN_C CT XL Crease, continued Fine Adjustment of preset settings To Fine Adjust position of a crease Line, select a preset crease setting from the Crease menu and then press the [Fine Adjust] button. In this example SRA3 was chosen as Paper Size and Accordion as crease setting.

  • Page 32: Creating A Custom Crease Setting

    X04132_EN_C CT XL Crease, continued Creating a Custom Crease setting To create a Custom crease setting, press the [Custom] button from the Crease menu and then press the [Fine Adjust] button. In this ex- ample SRA3 was chosen as Paper Size.
  • Page 33 X04132_EN_C CT XL Crease, continued Creating a Custom Crease setting, continued Back at the Crease screen, choose between: 1. Pressing the red X mark to keep using the Crease setting that was used when the [Crease] button was pressed from the Home screen.
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  • Page 35: Tools

    X04132_EN_C CT XL 3. Tools The Tools Screen From the Home Screen, press the [Tools] but- ton to get to the Tools screen. Select the setting you want to change by press- ing the corresponding button. After changing setting in the subscreen, press the green check mark to save your changes and return to the Tools screen.
  • Page 36 X04132_EN_C CT XL The Tools Screen, continued Skew Compensation, continued The following examples indicate that there is need for Skew Compensation: 1 Using only side trimming. Process direction If the operator side trim strip is nonparallel. In this specific example, looking at the operator...

  • Page 37: Cover Adjust

    0.7 mm wider than the body stock. Booklet Crease Mode When producing booklets, press the [Booklet Crease Mode] button on the CT XL user inter- face to choose whether to crease the cover sheet, the center sheet or to crease both the cover and the center sheet.

  • Page 38: Registration Hardstop

    X04132_EN_C CT XL The Tools Screen, continued Registration Hardstop Sheets skewed and/or offset out of range for what can be compensated by the CT will render a misfeed condition and cause the CT to stop production. The default setting is “OFF” (red colored) which...

  • Page 39: Language

    Select desired language by pressing the corre- sponding button. Software version Shows the software version of the CT XL. 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.

  • Page 40: Crease Emergency Mode

    To enable Crease Emergency mode, use the key pad at the Service Mode menu to enter 1224. Confirm by pressing the green check mark. Power off and power on the CT XL to put the Crease Emergency mode into effect.

  • Page 41: Jobs

    Save current settings or handle saved jobs from the [Jobs] screen. Access the [Jobs] screen by pressing the [Jobs] button from the Home screen. The CT XL has a maximum storage capacity of 100 different jobs. To make temporary changes see section 2, “Creasing and/or Trimming sheets”.

  • Page 42: Loading Jobs

    X04132_EN_C CT XL 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-...

  • Page 43: Clearing Misfeed(S)

    X04132_EN_C CT XL 5. Clearing Misfeed(s) Clearing misfeed(s) General If a misfeed condition occurs, it is indicated on the CT User Interface. See examples below. Misfeeds in the Crease Side Trim Module will be indicated by an error code (CT-XXX), a localization (area CT1 or CT2) and an error description.

  • Page 44: Ct Xl Creaser Side Trimmer

    X04132_EN_C CT XL CT XL Creaser Side Trimmer Clearing sequence for misfeed(s) in the CT XL and CT BU paper path WARNING: Do not put your fingers within knife protections [A]. Doing so may result in injury. CAUTION: Under no circumstances should jams around the trimmer blades be cleared using metallic tools.
  • Page 45 X04132_EN_C CT XL Clearing sequence for misfeed(s) in the CT XL and CT BU paper path, continued 5 5 Lift up the Baffle marked “D” and remove any jammed/misfed sheets. 6 6 Remove any jammed/misfed sheets stuck the Gratings area [B], in and in-between the Trimmer Blades [C].
  • Page 46 X04132_EN_C CT XL Clearing sequence for misfeed(s) in the CT XL and CT BU paper path, continued 9 9 Remove the Waste Chute Cover [E] and remove any visible trim strips from the Waste Chute [F] Refit the Waste Chute Cover [F].
  • Page 47 X04132_EN_C CT XL Clearing sequence for misfeed(s) in the CT XL and CT BU paper path, continued Open the Baffle marked “B” and remove any jammed/misfed sheets. Close baffle “B” to operating position. Baffle B continued on next page...
  • Page 48 X04132_EN_C CT XL Clearing sequence for misfeed(s) in the CT XL and CT BU paper path, continued At the lower end and at the left side of slide jammed/misfed sheets have to be rolled out. Make sure the rulers of the creaser rollers are open [I] so that sheets can pass between the rollers.
  • Page 49 X04132_EN_C CT XL Clearing sequence for misfeed(s) in the CT XL and CT BU paper path, continued Open the CT BU Front Door [N]. Open the CT BU Baffle marked “A” and remove any jammed/misfed sheets. Lower the CT BU Baffle “A” to operating position.
  • Page 50 X04132_EN_C CT XL Page intentionally blank.

  • Page 51: Troubleshooting

    General • When there is a misfeed or fault condition in the CT XL or CT BU, a code and/or a message will be displayed on the User Interface. Follow suggested instruction to remove any paper or obstruction in the paper path.

  • Page 52: Crease Trimmer (Ct Xl) Fault Codes

    Continue button at the CT XL UI. • Interrupt the active printing job. Press the Continue button on the CT XL UI. Set the correct paper size in the CT XL UI. Restart the printing job. Invalid trim offset (out of spec)
  • Page 53 X04132_EN_C CT XL Crease Trimmer (CT XL) fault codes, continued Code / message Explanation / action Attention Occurs when machine initiates (after closing covers). M6 (creaser tools motor) position not See section 5, “Clearing Misfeed(s)” for how to clear reached misfeed(s).
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  • Page 55: Remarks

    X04132_EN_C CT XL 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 56: Where To Put Your Machine

    X04132_EN_C CT XL 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 57: Access To Machine

    X04132_EN_C CT XL Access to machine 2310 mm / 90.9″ 1950 mm 76.7″ 710 mm 410 mm 28″ 16.1″ CT XL and CT Bridge Unit floor plan...

  • Page 58: Maintaining Your Machines

    X04132_EN_C CT XL Maintaining Your Machines 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 59 X04132_EN_C CT XL Cleaning the paper path transportation nip rollers (x20), continued Baffle B Nip rollers Nip rollers Baffle can be opened slightly parts of the slide made Nip rollers transparent for clarity Nip rollers slide door made transparent for clarity...

  • Page 60: Cleaning The Fixing Rollers (X3)

    X04132_EN_C CT XL Cleaning the fixing rollers (x3) Also clean the opposing idling rollers. WARNING: Do not place your fingers inside the knife guards. Doing so may result in injury. Knife guards Fixing rollers top cover made transparent for clarity...

  • Page 61: Cleaning The Paper Path Sensors (X5)

    X04132_EN_C CT XL Cleaning the paper path sensors (x5) WARNING: Do not put your fingers inside the knife guards. Doing so may result in injury. Exit sensor Q7 Knife guards Infeed sensor Q1 Paper path sensor Q2 continued on next page...
  • Page 62 X04132_EN_C CT XL Cleaning the paper path sensors (x5), continued Creaser sensor Q4 Paper path sensor Q10...

  • Page 63: Cleaning Of Creaser Tool Grooves (X4)

    X04132_EN_C CT XL Cleaning of creaser tool grooves (x4) 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. 3 grooves 1 groove...

  • Page 64: Cleaning The Paper Path Transportation Feed Rollers (X8)

    X04132_EN_C CT XL Bridge Unit, continued Cleaning the paper path transportation feed rollers (x8) Nip rollers Cleaning the paper path sensors (x2) Exit sensor Q42 Infeed sensor Q41...

  • Page 65: Best Practices For The Ct Xl

    When trimming cut sheets longer than 650 mm / 25.6”, remove the cardboard Waste Bin from behind the CT XL and let the trim strips pile up on the floor to prevent long trim strips being caugth by the Waste Bin and jamming the Trim Waste Transport. See section 2, “Creasing and/ or Trimming sheets”.

  • Page 66: Limitations Of The Ct Xl

    Ricoh My paper (65-80 gsm). • For some media trim waste from the CT XL can get stuck in the waste chute causing a jam. This phenomenon is worse in dry environments without climate control when the risk for static output is higher.
  • Page 67 For some special coated media above 300 gsm that is extra “dense”, crease operation may not be possible and CT XL may trigger a crease error. Dense media may generate Error code: CT- 2002 area CT2. This is caused by the Creaser motor stalling trying to crease the media.
  • Page 68 X04132_EN_C CT XL Page intentionally blank.

  • Page 69: Specification

    X04132_EN_C CT XL 8. Specification Machine Specifications CT XL Creaser Side Trimmer Specifications Remarks Minimum paper size, WxL 100x148 mm / 3.9x5.8″ When bypassed 120x200 mm / 4.7x7.9” When trimming Maximum paper size, WxL 330x1260 mm / 13x49.6″ Minimum trimming 5 mm / 0.2”...

  • Page 70: Ct Bridge Unit

    Weight 50 kg / 110 lb Dimensions For footprint, see Operator Manual, section 7, Access to machine Power Source Powered from the CT XL Waste Transport (option) Specifications Remarks Weight 25 kg / 55.1 lb Dimensions (L × H × D)

  • Page 71: Declaration Of Conformity

    Declaration of Conformity EU & UK DECLARATION OF CONFORMITY ......D0001499 (I.8) Manufacturer ..Plockmatic International AB, Telefonvägen 30, S-126 26 Hägersten, Sweden This Declaration of Conformity is issued under the sole responsibility of the manufacturer Object of the Declaration F136-001,...

  • Page 72: Application Limitations Guide

    Application Limitations Guide The tables, for shorter or longer paper, on next page provides guidelines to users on what media characteristics could be extra challenging for the CT XL. How to use the tables: Find what column applies to your current application.
  • Page 73 X04132_EN_C CT XL Application Limitations Guide, continued SHORT PAPER Less than 279,3 mm or 10.9” long Media characteristic Paper from 60,0 gsm Paper from 80,1 gsm Paper from 120,1 gsm Paper over up to 80,0 gsm up to 120,0 gsm...
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