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Plockmatic PL450e Operator's Manual

Booklet maker system
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X04147_EN_A PL450e/435e System Operator Manual
Plockmatic PL450e/435e
Booklet Maker System
Doc no: X04147_EN_A
Date: 30 May 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.
System Operator Manual

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  • Page 1 X04147_EN_A PL450e/435e System Operator Manual Plockmatic PL450e/435e Booklet Maker System System Operator Manual Read this manual carefully before you use this product and keep it handy for future reference. For safety, please follow the instructions in this manual. Doc no: X04147_EN_A...
  • Page 2 X04147_EN_A PL450e/435e System Operator Manual Scan the QR code to access translated versions of this manual in German, Italian, French, and Spanish. Visit https://plockmaticgroup.com/myfinisher/pl450e-pl435e-riso/ to view the manual in your preferred language.
  • Page 3 X04147_EN_A PL450e/435e System Operator Manual Introduction This manual contains instructions on the operation and maintenance of this machine. To get maximum versatility from this machine all operators should carefully read and follow the instructions in this manual. Keep this manual in a handy place near the machine.
  • Page 4 X04147_EN_A PL450e/435e System Operator Manual Safety Information When using this machine, safety precautions should always be followed. General Safety WARNING • This equipment is not suitable for use in locations where children are likely to be present. • Only connect the machine to a mains power supply of the correct voltage with a good earth- connection;...
  • Page 5 X04147_EN_A PL450e/435e System Operator Manual Safety during operation, continued WARNING • Turn off the power and disconnect the power plug (by pulling the plug, not the cable) if any of the following conditions exists: • Objects are dropped into the equipment.
  • Page 6 X04147_EN_A PL450e/435e System Operator Manual Safety Information, continued English Description of Safety/Warning labels in the product Crushing Hazard Cutting Hazard Entanglement Hazard Risk for crushing or Sharp objects inside machine. Risk for loose hanging hair, squeezing body parts. jewelry, or clothes to get caught.

  • Page 7: Table Of Contents

    X04147_EN_A PL450e/435e System Operator Manual TABLE OF CONTENTS What You Can Do With This Machine ................10 Guide To Components ..................... 12 Booklet Maker ..........................12 User Interface ..........................16 Options ..........................19 Finishing Module ......................... 19 BST4000-1 Belt Stacker Module ....................21 BST4000-1 Principle of Operation......................
  • Page 8 X04147_EN_A PL450e/435e System Operator Manual Fine-tuning the booklet appearance ................52 Set registration, Fine Adjustment ......................52 Skew Compensation ..........................54 Manual Feed ........................55 Using the built-in Manual Feed Slot .................... 55 3. Tools ....................57 The Tools screen ......................... 57 Production Priority ........................
  • Page 9 Cleaning SquareBack Clamp ........................ 86 Cleaning the sensors..........................88 Sensors’ location ........................... 88 Cleaning Infeed Module Foam Rollers ....................90 Best practices for the PL450e/435e system ..............91 Limitations of the PL450e/435e system................92 8. Specification ................... 95 Machine Specifications ....................95 PL450e/435e Booklet Maker ......................

  • Page 10: What You Can Do With This Machine

    Together they form a system that allows full bleed booklet making online with the Upstream Device. The PL450e upgrade kit raises the capacity of the PL435e Booklet maker from 35 sheets to 50 sheets. This means that, instead of 140 page booklets, 200 page booklets are now possible.
  • Page 11 X04147_EN_A PL450e/435e System Operator Manual What You Can Do With This Machine, continued Edge and Corner Staple After the sets have been edge or corner stapled in the Booklet Maker, they will bypass the folding action and be delivered to the Belt Stacker. Either directly from the Booklet Maker or after passing through the attached optional Finishing Module.

  • Page 12: Guide To Components

    X04147_EN_A PL450e/435e System Operator Manual Guide To Components Booklet Maker Parts that are important for setup, adjustments, troubleshooting or maintenance are high- lighted below. 1. Top Cover Latch Handle 5. Belt Stacker Stop Bracket 2. Top Cover 6. Casters with brake 3.
  • Page 13 X04147_EN_A PL450e/435e System Operator Manual Booklet Maker, continued 1. Operator manual tray 5. Outer Docking Bracket 2. Connections 6. Infeed area 3. Casters w/o brake 7. Manual Feed Cover 4. Inner Docking Bracket 8. Manual Feed Side Guides continued on next page...
  • Page 14 X04147_EN_A PL450e/435e System Operator Manual Booklet Maker, continued 1. Counter 4. Small paper kit 2. Infeed Drive and Paper Guide/ 5. Upper and Lower Fold Roller Paper Jam Clearance Guide/Jam Clearance 3. Power Switch 6. Transport Belt/Jam Clearance 7. Corner Stapler Kit...
  • Page 15 X04147_EN_A PL450e/435e System Operator Manual Booklet Maker, continued 1. Back Jogger Fingers (x4) 4. Staple Cartridge Ejector Levers 2. Infeed Drive 5. Staple Cartridges 3. Gas Spring 6. Spare Staple Cartridges Storage...

  • Page 16: User Interface

    X04147_EN_A PL450e/435e System Operator Manual User Interface The Plockmatic PL450e/435e Production Booklet Maker System is controlled from a panel located on the Booklet Maker. The User Interface will allow you to set up, adjust and operate the complete system. NOTE: Depending on features installed, the screen may look different from what you see here.
  • Page 17 X04147_EN_A PL450e/435e System Operator Manual User Interface, continued The Manual Feed Screen Pressing the [Manual Feed] button in the Settings screen opens the Manual Feed screen. From here you can start the manual feed procedure. See section 2 of this manual, “manual feed”...
  • Page 18 X04147_EN_A PL450e/435e System Operator Manual User Interface, continued The Tools Screen Pressing the [Tools] button opens the Tools screen. From here you can change basic settings like the display language, setting units from millimetres to inches and more. See section 3, ”Tools” for how to work with the Tools screen.

  • Page 19: Options

    X04147_EN_A PL450e/435e System Operator Manual Options Finishing Module 1. Top Cover Latch Handle 4. Cover to Trim Waste Bin 2. Top Cover 5. Caster w\o brake 3. Exit Area 6. Caster with brake...
  • Page 20 X04147_EN_A PL450e/435e System Operator Manual Finishing Module, continued 1. Gas Spring 2. Infeed Area 3. Trim Waste Bin...

  • Page 21: Bst4000-1 Belt Stacker Module

    BST4000-1 Belt Stacker Module The BST4000-1 High Capacity Belt Stacker Module is an option available for the Plockmatic PL450e/435e Production Booklet Maker System. The stacker can be configured in a straight line after the Booklet Maker system or at a 90 degree angle.

  • Page 22: Bst4000-1 Principle Of Operation

    X04147_EN_A PL450e/435e System Operator Manual BST4000-1 Belt Stacker Module, continued 1. Power switch (on/off) 2. Belt speed selector 3. Run-out button (full speed) BST4000-1 Principle of Operation The belt is triggered by a signal from the Booklet Maker and will run for a set time.

  • Page 23: Basics

    X04147_EN_A PL450e/435e System Operator Manual 1. Basics Turning On / Off the Main Power Booklet Maker 1 1 Make sure that the power cords to the, Booklet Maker and BST (optional) are plugged into a live wall outlet. 2 2 Open the Booklet Maker top cover.

  • Page 24: Change Staple Cartridges And Check Stapler

    X04147_EN_A PL450e/435e System Operator Manual Change staple cartridges and Check stapler The staple cartridges contain approximately 5000 staples each. Each cartridge includes all wearable parts. The cartridges may need to be removed either for replacement or for jam clearance. Out of Staple The Booklet Maker will indicate “Out of Staple”...

  • Page 25: Stapler Miss

    X04147_EN_A PL450e/435e System Operator Manual Stapler miss If the Booklet Maker indicates “...stapler miss”, it means that there is a jam in the indicated stapler. Remove the stapler cartridge as described in “Replacing staple cartridge(s)”. 1 1 Open the Booklet Maker top cover.

  • Page 26: Installing/Removing The Small Paper Kit

    X04147_EN_A PL450e/435e System Operator Manual Installing/Removing the Small Paper Kit The small paper kit consists of two side jogger extensions that are stored on the inside of the top cover. Using paper widths less than 206 mm (8.111”) requires that they are installed in the booklet maker.
  • Page 27 X04147_EN_A PL450e/435e System Operator Manual Installing the small paper kit, continued 4 4 Fit the keyhole shaped cut-out [E] around the upper knob [A]. 5 5 Slide the slotted holes on the right side jogger extension under knob [B]. 6 6 Tighten knobs [A] and [B] on the right side jogger.

  • Page 28: Removing The Small Paper Kit

    X04147_EN_A PL450e/435e System Operator Manual Removing the small paper kit 1 1 Loosen the knobs [C] on the inside of the top cover. 2 2 Loosen the knobs [A] and [B] on the left side jogger. 3 3 Slide the left side jogger extension [D] towards the infeed area and lift when the keyhole shaped cut-out [E] fits around the upper knob [A].
  • Page 29 X04147_EN_A PL450e/435e System Operator Manual Removing the small paper kit, continued 4 4 Slide the slotted holes on the left side jogger extension [D] into the gaps [F] between the right spacers, knob and lock nut on the inside of the top cover.

  • Page 30: Installing/Removing The Corner Staple Kit

    X04147_EN_A PL450e/435e System Operator Manual Installing/Removing the corner staple kit The corner staple kit enables repositioning of the compiled sheets so that a staple can be put in the corner. The kit is stored on the front machine frame. Selecting corner stapling will start a step-by- step guide in the UI to help installing the corner staple kit.
  • Page 31 X04147_EN_A PL450e/435e System Operator Manual Installing the corner staple kit, continued Slide the slotted holes on the corner staple kit [D] under knobs [A] and [B]. 5 5 Tighten the knobs [A] and [B] on the left side jogger. 6 6...

  • Page 32: Removing The Corner Staple Kit

    X04147_EN_A PL450e/435e System Operator Manual Removing the corner staple kit 1 1 Disconnect the cable [E] from the jack [F] in the rear frame. 2 2 Loosen the knobs [A] and [B] on the left side jogger. 3 3 Slide the the corner staple kit [D] towards the infeed and lift to remove.
  • Page 33 X04147_EN_A PL450e/435e System Operator Manual Removing the corner staple kit, continued 4 4 Hang the corner staple kit [D] on the screw [G] on the rear frame. 5 5 Secure the cable [E] to the rear frame using the cable fastener [C].

  • Page 34: Emptying Waste Bins

    X04147_EN_A PL450e/435e System Operator Manual Emptying waste bins Face Trim Waste Bin The Face Trim Waste Bin is located inside the Finishing Module behind the Trim Waste Bin Cover. The message “Empty Face Trim Waste Bin” will be shown on the User Interface when the Face Trim Waste Bin is full.

  • Page 35: Belt Stacker Bst4000-1

    X04147_EN_A PL450e/435e System Operator Manual Belt Stacker BST4000-1 Setting up Belt Stacker for right-angled mode Follow these steps to correctly set up the Stacker Move the inner Side Guide [A] as far as possible towards the Booklet Maker. 2 2 Adjust the outer Side Guide [B] to give at least 5 mm (1/4″) play.

  • Page 36: Setting Up Belt Stacker For Straight Mode

    X04147_EN_A PL450e/435e System Operator Manual 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 37: Docking / Undocking

    X04147_EN_A PL450e/435e System Operator Manual Docking / Undocking Docking the Booklet Maker System 1 1 Move the Booklet Maker System with uplifter up to the Upstream device and dock it. CAUTION To avoid damaging the communication cable connecting the Uplifter and the Upstream device do not separate them too far.
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  • Page 39: Making Booklets

    X04147_EN_A PL450e/435e System Operator Manual 2. Making Booklets General procedure Settings can be changed temporarily or permanently. Temporarily means that the changes will not be possible to restore if changed again or when a saved job is loaded. Permanently means that the changes are saved as a job with the possibility of later being restored.
  • Page 40 X04147_EN_A PL450e/435e System Operator Manual General, continued Using paper widths less than 206 mm (8.111”) requires that the small paper kit is installed. The installation is described above (see section 1, Installing/Removing the Small Paper Kit). Changing from a larger paper size to such a small paper size will start a step-by-step guide to help installing this small paper kit.

  • Page 41: Selecting Standard Paper Sizes

    X04147_EN_A PL450e/435e System Operator Manual Selecting standard paper sizes From the Settings Screen, press the [Paper Size] button. Select any available standard paper size by pressing the corresponding button and save choice by pressing the green [check] button. For other paper sizes, see “Custom Paper Size”...
  • Page 42 X04147_EN_A PL450e/435e System Operator Manual Custom Paper size, continued Pressing the width or length numbers will dis- play a number pad. Enter the desired width and/ or length. Confirm your changes to the custom paper size by pressing the green check mark or exit with- out making any changes by pressing the red X mark.

  • Page 43: Booklet Size

    X04147_EN_A PL450e/435e System Operator Manual Booklet Size General From the Settings Screen, press the [Booklet Size] button. Booklet Size can be set to either of two suggested formats or to a Custom Booklet Size. The amount of Bleed trim as well as the size of the finished booklet as a result of the actual Booklet Size choices, is displayed.

  • Page 44: Custom Booklet Size

    X04147_EN_A PL450e/435e System Operator Manual Custom Booklet Size To set the trim manually, press the [Custom Booklet Size] button and then the [Edit] button. Set the desired length either by pressing the [plus] and [minus] buttons or by pressing the length number.

  • Page 45: Squareback

    X04147_EN_A PL450e/435e System Operator Manual SquareBack General The SquareBack in the Finishing Module has three different settings - AUTO, Manual and OFF. Information on the [SquareBack] button shows the actual Status of the SquareBack and what mode is selected. Set to AUTO, the Booklet Maker uses informa-...
  • Page 46 X04147_EN_A PL450e/435e System Operator Manual General, continued The table below shows highest supported SquareBack pressure settings during normal operation. Precision Mode turned OFF No of A3 SRA3 8.5x11 8.5x11 11x17 12x18 210x490 225x610 225x660 sheets Off Off 6-10 11-15 For certain media requiring more SquareBack pressure, “Precision Mode” can be enabled to allow more time in the SquareBack process.

  • Page 47: Selecting Squareback Pressure Setting

    X04147_EN_A PL450e/435e System Operator Manual Selecting SquareBack pressure setting The default status for the SquareBack is ON and the default mode is AUTO. After one booklet has been produced, the Mode info in the [SquareBack] button will change from “AUTO” to show the mode that was calculated to be the most appropriate mode setting.

  • Page 48: Fold

    X04147_EN_A PL450e/435e System Operator Manual Fold Adjusting fold position Information on the [Fold] button shows the ac- tual Fold status and position. To alter the Fold settings, press the [Fold] button from the Set- tings Screen. The Booklet Maker uses information from the set thickness sensor to calculate and adjust the correct fold position.

  • Page 49: Staple

    X04147_EN_A PL450e/435e System Operator Manual Staple Selecting stapling On or Off Information on the [Staple] button shows the actual Staple status and position. To alter the Staple settings, press the [Staple] button from the Settings Screen. Staple status can be set to either Saddle Sta- pling, Edge Stapling, Corner Stapling or being disabled by pressing the corresponding button.

  • Page 50: Edge Staple

    X04147_EN_A PL450e/435e System Operator Manual Edge Staple In the Staple Settings screen, enable edge sta- pling by pressing the [Edge Staple] button. Confirm by pressing the green [check] button. NOTE: Edge stapling is possible on following paper sizes: • A4 LEF (long edge feed) and SEF (short edge feed) •...

  • Page 51: Corner Staple

    X04147_EN_A PL450e/435e System Operator Manual Corner Staple In the Staple Settings screen, enable corner sta- pling by pressing the [Corner Staple] button. Confirm by pressing the green [check] button. Enabling corner stapling starts a step-by-step guide in the user interface showing how to in- stall the corner staple kit that is needed.

  • Page 52: Fine-Tuning The Booklet Appearance

    X04147_EN_A PL450e/435e System Operator Manual Fine-tuning the booklet appearance There are a number of adjustments you can perform to fine-tune the appearance of the booklets and compensate for variations in paper or print. NOTE: All these adjustments are specific and will be reset to zero if the Paper Size is changed. For all adjustments on this spread, start by...
  • Page 53 X04147_EN_A PL450e/435e System Operator Manual Set registration, Fine Adjustment, continued Send one set of the job from the Upstream De- vice and follow instructions on screen. When using the Booklet Maker system in hand feeding mode, the screen shown will be slightly different, as shown to the side on the left.

  • Page 54: Skew Compensation

    X04147_EN_A PL450e/435e System Operator Manual Skew Compensation There is a number of reasons why finished book- lets could come out skewed. One being that the sheets might not have been cut in perfect angle. The folder can be set up to compensate for that.

  • Page 55: Manual Feed

    X04147_EN_A PL450e/435e System Operator Manual Manual Feed Manual feed function can be used by simply opening the Manual Feed Cover on the Uplift Module. Using the built-in Manual Feed Slot The built-in Manual Feed Slot is used to hand feed sets when the system is not installed to...
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  • Page 57: Tools

    X04147_EN_A PL450e/435e System Operator Manual 3. Tools The Tools screen Press the [Tools] button to get to the Tools screen. Select the setting you want to change by pressing the corresponding button. After changing setting in the sub screen, press the green [check] button to save your changes and return to the Tools screen.

  • Page 58: Squareback Offset

    X04147_EN_A PL450e/435e System Operator Manual SquareBack Offset The SquareBack pressure setting is set to a standard that should suit most applications. Operators have the option of sharpening or softening the square edges based on application or preference. Select sharper edges by pressing the [+] button or softer edges by pressing the [-] button.

  • Page 59: Units

    X04147_EN_A PL450e/435e System Operator Manual 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 Settings Screen.

  • Page 60: Software Version

    X04147_EN_A PL450e/435e System Operator Manual Software version Shows the software version of all modules in the booklet making system. Press the red [X] button to go back to the Tools screen. Press [Third Party Licences] to read it. Service mode This function is for authorized service personnel only and is password protected.

  • Page 61: Jobs

    X04147_EN_A PL450e/435e System Operator Manual 4. Jobs Handling jobs The Booklet Maker has a maximum storage capacity of 100 different jobs. To make temporary changes in the actual job settings or temporary changes of a stored job, see section 2, “Making Booklets”.

  • Page 62: Loading Jobs

    X04147_EN_A PL450e/435e System Operator Manual Loading Jobs Open (load) any stored job by selecting the job and confirm by pressing the [Load] button. Deleting Jobs Delete any stored job by selecting the job from the list and confirm by pressing the [Delete] but- ton.

  • Page 63: Clearing Misfeed(S)

    X04147_EN_A PL450e/435e System Operator Manual 5. Clearing Misfeed(s) Clearing misfeed(s) General If a misfeed condition occurs, it is indicated on the Booklet Maker User Interface. See examples below. The User Interface provides a visual indication of where the misfeed has...

  • Page 64: Uplift

    X04147_EN_A PL450e/435e System Operator Manual Uplift Clearing misfeed(s) Clearing misfeed in the Uplift - BM1 Area BM1 can either refer to the infeed area of the Booklet Maker module or to the Uplift Module. If the misfeed is in the Uplit Module, follow the procedure below to clean it, otherwise, refer to the BM misfeed clearing procedures.

  • Page 65: Booklet Maker

    X04147_EN_A PL450e/435e System Operator Manual Booklet Maker Clearing misfeed(s) inside the Booklet Maker Clearing misfeed in the Infeed area - BM1 To clear a misfeed indicated in Area BM1 Follow the procedure below. NOTE: See also “Clearing misfeed(s)” in areas BM2 / BM3 if other misfed sheets are present in other areas of the Booklet Maker.

  • Page 66: Clearing Misfeed In Folder Infeed Area - Bm2 (A)

    X04147_EN_A PL450e/435e System Operator Manual Clearing misfeed in Folder Infeed area - BM2 (A) To clear a misfeed indicated in Area BM2 (A) Open and then close the top cover. If system does not purge, remove misfed sheets manually following the procedure below.

  • Page 67: Clearing Misfeed In Folder Outfeed Area - Bm2 (B)

    X04147_EN_A PL450e/435e System Operator Manual Clearing misfeed in Folder Outfeed area - BM2 (B) To clear a misfeed indicated in Area BM2 (B) Open and then close the top cover. If system does not purge, remove misfed sheets manually following the procedure below.
  • Page 68 X04147_EN_A PL450e/435e System Operator Manual Clearing misfeed in Folder Outfeed area - BM2 (B), continued 4 4 Pull the Levers [H] (x2) towards the centre of the machine. 5 5 Lift and remove the Lower Fold Roller Paper Guide [J].

  • Page 69: Clearing Misfeed In Lower Folder Area - Bm3

    X04147_EN_A PL450e/435e System Operator Manual Clearing misfeed in Lower Folder area - BM3 To clear a misfeed indicated in Area BM3 Open and then close the top cover. If system does not purge, remove misfed sheets manually following the procedure below.
  • Page 70 X04147_EN_A PL450e/435e System Operator Manual Clearing misfeed in Lower Folder area - BM3, continued 4 4 Removing the two Transport Belts [K] from the pulleys and sliding them aside is not required but can make jam clearance easier. 5 5 Lift Paper Guide [L].

  • Page 71: Finishing Module

    X04147_EN_A PL450e/435e System Operator Manual Finishing Module To clear a misfeed indicated in Areas FM1 and/or FM2 Open and then close the top cover. If system does not purge, remove misfed sheets manually following the procedure below. WARNING: The trim unit (A) has two sharp knives for trimming booklets: do not touch them for any reason and at any time.

  • Page 72: Belt Stacker

    X04147_EN_A PL450e/435e System Operator Manual Belt Stacker Clearing misfeed(s) Clearing misfeed in the belt stacker - BM4/FM3 To clear a misfeed indicated in Area BM4/ Follow procedure below. 1 1 Look for any jammed/misfed sets/booklets and remove them. NOTE: Cover [A] is fixed and CANNOT be lifted for safety reasons.

  • Page 73: Troubleshooting

    X04147_EN_A PL450e/435e System Operator Manual 6. Troubleshooting Fault codes General Procedure When there is a misfeed or a fault condition in the Booklet Maker system, a code and/or a message will be displayed on the User Interface. Follow this general procedure to clear a jam condition: •...

  • Page 74: Booklet Maker Fault Codes

    X04147_EN_A PL450e/435e System Operator Manual Booklet Maker fault codes Code # Area Cause Explanation / Action Q1 (infeed sensor) covered BM-101 too long Check that paper sizes match between upstream Q1 (infeed sensor) not cov- device and the Booklet Maker system. Check that...
  • Page 75 X04147_EN_A PL450e/435e System Operator Manual Booklet Maker fault codes, continued Code # Area Cause Explanation / Action Check that no obstructions are in paper path. Clean pa- M3 (side jogger motor) per path. Set registration’s value might be too high. See...

  • Page 76: Finishing Module Fault Codes

    X04147_EN_A PL450e/435e System Operator Manual Finishing Module fault codes WARNING: The trim unit has two sharp knives for trimming booklets: do not touch them for any reason and at any time. If service is needed, call a technician. Code # Area...
  • Page 77 X04147_EN_A PL450e/435e System Operator Manual Finishing Module fault codes, continued Code # Area Cause Explanation / Action Q17 (paper path sensor) not reached FM-607 in time. Q17 (paper path sensor) covered too FM-608 Exit long. Q17 (paper path sensor) covered after FM-609 purge.

  • Page 78: General Fault Codes

    X04147_EN_A PL450e/435e System Operator Manual General fault codes Clear Misfeed(s) In general, fault codes indicate a misfeed condition. When a misfeed occurs, it is indicated visually where the misfeed occurred, by an error code and by a component description. See section 5, “Clearing Misfeeds”, for how to clear a...

  • Page 79: Process Speed Too High

    X04147_EN_A PL450e/435e System Operator Manual Process Speed Too High This message will be displayed when the process speed is too high. System will cycle down. Incomplete sets were delivered to the stacker. Press the [Enable] button to change Production Priority from “Productivity” to “Precision”.
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  • Page 81: Remarks

    X04147_EN_A PL450e/435e System Operator Manual 7. REMARKS Do’s And Don’ts • Always follow all warnings marked on, or supplied with, the equipment. • Always exercise care in moving or relocating the equipment. • CAUTION: Power off and unplug the power cord from the wall outlet and machine before you move or relocate the equipment.

  • Page 82: Where To Put Your Machine

    X04147_EN_A PL450e/435e System Operator Manual Where to put Your Machine Machine environment • Always locate the equipment on a solid support surface with adequate strength for the weight of the machine. • Always keep magnets and all devices with strong magnetic fields away from the machine.

  • Page 83: Access To Machine

    X04147_EN_A PL450e/435e System Operator Manual Access to machine Place the machine near the power source, providing clearance as shown. NOTE: Ensure at least 800 mm / 31.5” clearance around the system for servicing. Service Access - 4000 mm / 157.5″...

  • Page 84: Maintaining Your Machines

    X04147_EN_A PL450e/435e System Operator Manual Maintaining Your Machines Never attempt any maintenance function that is not specifically described in this documentation. Booklet Maker Cleaning Booklet Maker Transport Belts, rollers and sensors The Booklet Maker Transport belts, rollers and sensors need to be cleaned regularly when in use.

  • Page 85: Cleaning Clincher Area

    X04147_EN_A PL450e/435e System Operator Manual Cleaning Clincher area Grey marks around the staple area in the center of the booklet may be caused by metal dust from the staple. If the marks are caused by dirt deposits or metal dust on the clinchers, these marks can be reduced by operator cleaning or wiping clinch area with a clean rag.

  • Page 86: Finishing Module

    X04147_EN_A PL450e/435e System Operator Manual Finishing Module Cleaning SquareBack Clamp The Upper and Lower Clamp Beam need to be cleaned regularly when in use. How often this should be done depends on the paper type and print quality. Color smeared off on the spine of the booklets is one indication of the need to clean the Upper and Lower Clamp Beam.
  • Page 87 X04147_EN_A PL450e/435e System Operator Manual Trimmer Unit made transparent for clarity Clean the Upper and Lower Clamp Beam [D]. Close the Finishing Module top cover. continued on next page...

  • Page 88: Cleaning The Sensors

    X04147_EN_A PL450e/435e System Operator Manual Finishing Module, continued Cleaning the sensors The sensors need to be cleaned regularly when in use and if the unit has not been used for a period of time. Sensors must be wiped clean with a lint free cloth.
  • Page 89 X04147_EN_A PL450e/435e System Operator Manual Sensors’ location (continued) Belt stacker sensor continued on next page...

  • Page 90: Cleaning Infeed Module Foam Rollers

    X04147_EN_A PL450e/435e System Operator Manual Finishing Module, continued Cleaning Infeed Module Foam Rollers WARNING: The trim unit has two sharp knives for trimming booklets: keep your hands clear of the knives The Foam Rollers in the Infeed Module need to be cleaned regularly when in use. How often this should be done depends on the paper type and print quality.

  • Page 91: Best Practices For The Pl450E/435E System

    X04147_EN_A PL450e/435e System Operator Manual Best practices for the PL450e/435e system • Use the side guides on the Uplift Module / optional hand feeding table to make sure the set enters centred into the machine; • If average bool fold result is not satisfying, please see section 3 of this manual: “SquareBack Offset”;...

  • Page 92: Limitations Of The Pl450E/435E System

    The PL450e/435e system is suited for customers whose booklet making needs will not exceed an average of 30,000 booklets per month; • If sheets entering the PL450e/435e system are not uniform or if they are skewed, the booklet quality will vary accordingly; •...
  • Page 93 • 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. • Books made from 1-3 sheets of thin media longer than 420 mm may show fold quality variation.
  • Page 94 X04147_EN_A PL450e/435e System Operator Manual Limitations of the PL450e/435e system, continued • On thin books (2-4 sheets) that do not have the staple position centred in the fold line paper tear or paper damage may occur around the staple legs as the book passes through the fold rollers.

  • Page 95: Specification

    X04147_EN_A PL450e/435e System Operator Manual 8. Specification Machine Specifications NOTE: Plockmatic uses QT open source license (LGPL) to develop the software used in this machine (https://www.qt.io/qt-licensing). PL450e/435e Booklet Maker Specifications Remarks Speed (Inline usage) Maintains engine speed while collating Actual speed in number of sheets (actual depends on engine speed).
  • Page 96 Offline Use Possible. PL450e/435e can be hand fed Dimensions (L x H x D) 880 x 1120 x 720 mm / 34.6” x 44” x 28.3” Length with Belt stacker and Uplift –...

  • Page 97: Fm400 Finishing Module (Option)

    400W = 1365 BTU/hr Power Source From PL450e/435e Weight 110 kg / 242 lb Environmental Require- For environment requirements of the sys- ments tem refer to PL450e/435e Booklet Maker specifications BST4000-1 Belt Stacker Module (option) Specifications Remarks Speed Variable Overlap...

  • Page 98: System Set Size Guide

    X04147_EN_A PL450e/435e System Operator Manual System Set Size Guide NOTE: The following tables are guidelines designed to give an indication on how many sheet a specific application can have for a given media weight. Exact number of sheets is depending on media type and image. PL435e A3 or 11 x 17" A4 or 8,5 x 11"...

  • Page 99: Declaration Of Conformity, Bm And Fm

    EU & UK DECLARATION OF CONFORMITY ......N0007571 (B.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 (including all accessories and consumables)

  • Page 100: Declaration Of Conformity, Bst

    X04147_EN_A PL450e/435e System Operator Manual EU & UK DECLARATION OF CONFORMITY ......D0000356 (K.5) Manufacturer ..Plockmatic International AB, Telefonvägen 30, S-126 26 Hägersten, Sweden This declaration of conformity is issued under the sole responsibility of the manufacturer Object of the Declaration Type/Model...

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