Find and correct error conditions Do normal maintenance tasks Operator training is given when the Océ BLM500 is installed. To make sure you use your Océ BLM500 correctly, read your manual. The Océ BLM500 User Manual does not describe the operation of the printer. If needed, refer to your printer user manual.
Page 7
Introduction How to Get Help If you have any questions or problems, refer to the problem solving section in this manual (see chapter 'Error Conditions, Problems and Solutions”'). Contact your Océ BLM500 supplier for further help.
Description of the Océ BLM500 Description of the Océ BLM500 Introduction The Océ BLM500 operates online with digital printers to process sets of printed pages into stitched books. The main parts are shown below. Illustration [1] Operator Side of the Océ BLM500 Component - function table [1] Operator Side of the Océ...
Right Hand Side of the Océ BLM500 Right Hand Side of the Océ BLM500 Illustration [2] Right hand side of the Océ BLM500 Component - function table [2] Right hand side of the Océ BLM500 Component Function The stitch wire The stitch wire cabinet holds the spool of stitch wire.
Mains power The mains power ON/OFF switch turns the Océ ON/OFF switch BLM500 ON or OFF. When you turn OFF the Océ BLM500, the current settings are stored. Voltage advisory The voltage advisory label tells the installer to refer label to the installation instructions before the Océ...
Chapter 2 How to run the Océ BLM500 This chapter gives information on how to run a job on the Océ BLM500. For information on how to operate the printer, refer to the printer documentation. Information about the user interface is included in chapter 'The User Interface'.
Enter accurate dimensions via the touch screen. If the book is made from several different types of paper, make sure the different paper types are all the same size. See Book Quality on page 56 for further information. Chapter 2 How to run the Océ BLM500...
Turn On the Océ BLM500 Procedure Connect the Océ BLM500 to the mains power supply. Use the mains ON/OFF switch to turn ON the Océ BLM500 Result The machine makes this sequence of beeps: 'beep__beep beep beep beep_____ beep beep'.
The PAPER SIZE and PAGE DIRECTION settings are entered via the touch screen. These dimensions refer to the format of the paper when it enters the Océ BLM500 Attention: Do not operate the touch screen with a sharp object or with too much force.
Page 15
Enter the Job Settings Job Setting for a Standard Paper Size Step Action Information Touch BASIC Enter the paper size Touch PAPER SIZE > PRESETS > A3 or A4. and page direction (USA: 11x17, 8.5x11 or 8.5x14) The PAGE DIRECTION is PORTRAIT. If needed, touch PAGE DIRECTION >...
Page 16
Job Setting for a Saved Job Touch LOAD & SAVE Touch the job name or use the Up arrow and the Down arrow to select the job. Touch LOAD. Wait until theOcé BLM500 is ready Chapter 2 How to run the Océ BLM500...
Stacker adjustment Stacker adjustment Adjust the Stacker Adjust the collection table on the stacker according to the size of the finished book. (see ‘Adjust the Gate in the Gathering Area’ on page 44).
Adjust the gate in the gathering area into the 'up' position for jobs of 1 to 3 sheets or the 'down' position for jobs of more than 3 sheets. Adjust the Gate in the Gathering Area on page Chapter 2 How to run the Océ BLM500...
Unload books from the stacker before the stacker is full. The Océ BLM500 stops and displays a message if the stacker is full. Empty the trim bin from time to time. The Océ BLM500 displays a message if the trim bin is full.
Page 20
Run the Job Chapter 2 How to run the Océ BLM500...
The Touch Screen The Touch Screen Introduction [4] The User Interface ON Button OFF Button Touch Screen The user interface includes a color touch screen and ON/OFF buttons Operate the touch screen with a fingertip. You can touch the screen with a blunt item, for example a palm-top 'wand' or the blunt end of a pen.
Page 23
The Touch Screen Illustration [5] The Touch Screen Component - function table Component Function Window Tabs The touch screen buttons are divided into groups that have connected functions. Each group of buttons has a separate window. Touch the correct tab to select the window. LOAD &...
Page 24
ATTENTION - the Océ BLM500 needs an action by the operator. - RED The Océ BLM500 is in an ERROR condition. Help Help text is available on the touch screen. Touch HELP then touch any button or tab on the screen.
The Job Mimic The Job Mimic Introduction The job mimic shows the current machine status. Illustration [6] The Job Mimic Component - function table Icon Information The following items are shown the size of paper the format of the paper in the gathering area the broken line shows the fold line the small thick lines show the stitches...
The BASIC Window The BASIC Window Introduction The BASIC window gives you access to frequently-changed machine settings. Button overview [10] [10] The BASIC Window Buttons (1 – 2) Button Information PAPER SIZE Touch PAPER SIZE to enter the paper size. When the machine is in operation, you can adjust the PAPER SIZE by a maximum of +/- 1mm.
Page 27
The BASIC Window [10] The BASIC Window Buttons (2 – 2) Button Information - NUMBER Touch NUMBER to select how many times the form roller processes the spine. The available options are 1, 2, 3 or 4. The form function can be turned off. An increase in NUMBER increases the time taken to form the spine and can decrease the production rate for thin books.
The LOAD & SAVE Window The LOAD & SAVE Window Introduction The LOAD & SAVE window lets you save and reload job settings. Each job is given a name. The jobs are displayed in a list on the screen. Touch the job name or use the Up arrow or Down arrow to make the selection.
Page 29
The LOAD & SAVE Window [11] The LOAD & SAVE Window Buttons (2 – 2) Button Information PADLOCK The padlock symbol shows when a saved job is locked or SYMBOL unlocked. There is a small padlock symbol next to each locked job.
The ADVANCED Window The ADVANCED Window Introduction The ADVANCED window gives you access to special machine functions. [12] [12] Button overview Button Information RE-REF If the machine calibration appears incorrect, touch RE-REF to re-reference the adjustment axes. The adjustment axes return to the current settings. At intervals, the machine will re-reference the axes during the set-up procedure.
The CONFIGURE Window The CONFIGURE Window Introduction The CONFIGURE window lets you make changes to the configuration of the machine. Some of the settings can be changed, depending on the current access level. CONFIGURE Window Buttons [13] [13] Button overview Button Information MACHINE...
The MENU Window The MENU Window Introduction MENU shows the settings that are not changed during day-to-day operation. These settings include Change the Access Level Change the display language Advanced machine settings that are accessed by a person who has the correct access-code.
Load and Save the Job Settings Introduction The current job settings can be saved to the memory and reloaded for use again at a later date. Load the 'Default Job Template' to reset the Océ BLM500 to normal settings. Save a job Touch LOAD &...
Open the Connecting Bridge Cover Open the Connecting Bridge Cover Introduction The Océ BLM500 will not stop if you open the connecting bridge cover. [11] [11] Connecting Bridge Cover in the open position. [15] Connecting Bridge Cover When to do If a machine error occurs, or for maintenance.
If a machine error occurs, or for maintenance. To access the stitch area To access the folder area Note: The folder cover has an interlock switch. The Océ BLM500 stops if you open the folder cover. [12] [12] Unlock the Folder Cover.
Clincher Frame [14] [14] Clincher Frame Components [17] Clincher Locking Handle Clincher Frame When to do If a machine error occurs, or for maintenance. To clear a paper jam in the stitch area To unlock the Océ BLM500 main deck...
Page 38
Lift and Lower the Clincher Frame Lift the Clincher Frame Open the folder cover. Turn the locking handle to the left , until the thread is disengaged. Lift the clincher frame to the vertical position. Lower the Clincher Frame Attention: You must hold the weight of the clincher frame. Do not let the clincher frame fall on your hand.
If a machine error occurs, or for maintenance. To access the gathering area To access the static elimination bar in the gathering area The Océ BLM500 will stop if you open the gathering area cover. Procedure Open the connecting bridge cover.
Lift the Océ BLM500 Main Deck Lift the Océ BLM500 Main Deck Introduction [16] [16] Lift the Océ BLM500 Main Deck [19] Folder Cover open Connecting Bridge Cover open Clincher Frame lifted When to do If a machine error occurs, or for maintenance.
Trim Bin Side Handle Trim Bin open Note: The Océ BLM500 operates with the trim bin removed for a short time. The printer waits while the trim bin is removed, then continues when the trim bin is replaced. To prevent lost production, you must remove, empty and return the trim bin to the Océ...
Open the Stitch Wire Cabinet Open the Stitch Wire Cabinet Introduction [18] [18] Stitch Wire Cabinet. [22] Stitch wire cabinet open When to do To see if the stitch wire is jammed or finished. An error message is displayed on the touch screen when the stitch wire is jammed or finished.
Adjust the Stacker Collection Table Adjust the Stacker Collection Table Introduction The collection table must be in the correct position for the stacker to operate. The position of the collection table depends on the finished size of the job. [19] [19] Collection Table Positions [23] Insert the collection table into one of the three pairs of slots.
Adjust the Gate in the Gathering Area Adjust the Gate in the Gathering Area Introduction The gate in the gathering area must be in the 'up' position for jobs of 1 to 3 sheets and in the 'down' position for jobs of more than 3 sheets. If the gate is left 'down' for thin jobs, then the sheets of paper can be damaged or jam in the machine.
Operate the Océ BLM500 offline Operate the Océ BLM500 offline Introduction You can hand feed sets into the Océ BLM500 if offline operation is needed. The machine operates when you push the two buttons. When to do To check the settings are correct...
Page 46
Operate the Océ BLM500 offline Chapter 4 Standard Tasks...
Chapter 5 Error Conditions, Problems and Solutions This chapter describes how to correct problems that can occur on your Océ BLM500. If a problem continues, contact your service engineer.
Clear a Printer Error Clear a Printer Error Introduction If a paper jam or other error occurs in the printer, the printer and the Océ BLM500 stop. Procedure Clear the printer error. Follow the instructions on the printer. If the printer tells you to remove paper from the Océ...
Clear a Océ BLM500 Error Clear a Océ BLM500 Error Introduction If a paper jam or other error occurs in the Océ BLM500, the printer and the Océ BLM500 stop. The type of Océ BLM500 error is displayed on the touch screen. (see ‘Error Messages’...
General Problems General Problems [26] Problem Cause Solution The Océ BLM500 does The Océ BLM500 is not Turn ON the Océ not start turned on. BLM500 (see ‘Turn On the Océ BLM500’ on page 13). The printer has not sent a Correct the problem at the job to the Océ...
Error Messages Error Messages [27] Problem Cause Solution AXES MOVING Some of the machine axes are moving. This message clears when the adjustment is complete. BOOK CYCLE TIME The printer has delivered the sets TOO LONG faster than the books can be made.
Page 52
Error Messages Problem Cause Solution ERROR IN TRIM There is an error at the trimmer. AREA Check the machine for a paper or book jam. FLOW ERROR - There is an error at the (see ‘Clear Paper BRIDGE connecting bridge. Open the Jams’...
Page 53
Error Messages Problem Cause Solution JAM AT FORM The form roller is jammed. Open (see ‘Jam in the Trim ROLLER the folder cover and remove the Area’ on page 64). jam. JAM BEFORE There is a book jammed before (see ‘Jam before the TRIMMER the trimmer.
Page 54
Error Messages Problem Cause Solution MOTOR The drive motor controller has OVERLOAD reached its power limit. Check for a paper jam and clear if necessary. If the problem continues, contact your service engineer. REMOVE SET Open the folder cover and FROM FOLD AREA remove the set.
Page 55
Error Messages Problem Cause Solution Stitch position The stitch position is adjusting. adjusting This message clears when the adjustment is complete. STITCH TIMEOUT There is an internal error. If the problem continues, then call your service engineer. TOO MANY PAGES The printer has delivered more (see ‘Open the than 55 sheets into the gathering...
56). The Océ BLM500 Touch RE-REF in the adjustment system is ADVANCED window to not calibrated calibrate the Océ BLM500 correctly. adjustment axes. (see table 12 on page The static elimination Clean the static elimination bars bars are dirty.
Page 57
Book Quality Book Quality Cause Solution Problem The spine is not formed The SET Measure the set thickness and correctly THICKNESS is enter the correct dimension (see incorrect. ‘Enter the Job Settings’ on page 14). The settings for (see ‘Spine Form Problems’ on FORM or page PRESSURE are...
Page 58
The Océ BLM500 Touch RE-REF in the adjustment system is ADVANCED window to not calibrated calibrate the Océ BLM500 correctly. adjustment axes. (see table 12 on page The books do not stack The collection table is...
Page 59
Book Quality Spine Form Condition Solution [22] Incorrect The spine needs more form. If the spine needs more Change NUMBER to 2 form at one end or 4. See "FORM" in table 10 on page 26 If the spine needs more Increase NUMBER or form at each end increase PRESSURE.
Clear Paper Jams Clear Paper Jams Introduction [24] [24] Paper Jam Locations [30] Connecting Bridge Gathering Area Stitch Area Fold and Forming Areas Trim Area [25] [25] Paper Jam Location - Bridge Infeed [31] Bridge Infeed Cover Chapter 5 Error Conditions, Problems and Solutions...
Page 61
Clear Paper Jams [26] [26] Trimmer Infeed Conveyor viewed from above. [32] Trimmer Infeed Conveyor [27] [27] Trim Stop Assembly [33] Orange Plastic Hand Screw Locking Plate Trim Stop Guard...
Page 62
Remove the jammed paper. Close the bridge infeed cover. If there is paper in the gathering area, touch PURGE SET. This action clears paper from the Océ BLM500. Continue the print job. Jam in the Connecting Bridge Open the connecting bridge cover.
Page 63
Remove the jammed paper. If you cannot see the paper in the former area. (see ‘Jam in the Trim Area’ on page Close the folder cover. If there is paper in the gathering area, touch PURGE SET. This action clears paper from the Océ BLM500. Continue the print job.
Page 64
Clear Paper Jams Jam before the Trimmer [35] Step Action Information Open the Océ BLM500 main deck Remove the trim bin. Remove the trimmer infeed The procedure can be seen from the conveyor. top of the machine. Access to the parts is through the trim bin opening.
Page 65
Push the trim stop guard into position. Hold the locking plates in position and tighten the orange hand screws. Attach the trim bin Touch PURGE SET. This action clears any other paper from the Océ BLM500. Continue the print job.
Stitch Head Problems Stitch Head Problems [37] Problem Cause Solution The stitch head does not The STITCH function is Make sure STITCH is set to 1 or operate not selected. more (see ‘The BASIC Window’ on page 26). The stitch wire is Load a new spool of stitch-wire (see finished.
Clear a Stitch Wire Jam Clear a Stitch Wire Jam Introduction Before you begin: Lift the Océ BLM500 main deck. See Lift the Océ BLM500 Main Deck on page 40 [31] [31] Stitch Head. [38] Top location of Middle Wire Tube...
Page 68
Information Turn off the BLM500 Use the mains ON/OFF switch. Disconnect the BLM500 from the mains power supply. Lift the BLM500 main deck (see ‘Lift the Océ BLM500 Main Deck’ on page Clear the Jammed Wire [40] Step Action Information...
Clear a Stitch Head Jam Introduction Problem: A loud and repeated banging noise from the fold area of the Océ BLM500 or the Océ BLM500 will not start. Action: Press the stop button. The banging noise does not indicate damage has occurred, but can cause alarm.
Page 70
Clear a Stitch Head Jam [36] [36] Inspect for stitch-wire [42] Inspect this area for pieces of stitch-wire Tools and Materials: Klüber Isoflex NBU 15 Grease, 50g. Article number 1060060886 Air duster. Supplied with the machine. Wire cutters. Supplied with the machine. Flat blade screwdriver.
Page 71
Clear a Stitch Head Jam [43] Step Action Information "Lift the Océ BLM500 Lift the Océ BLM500 Main Deck main deck. page 40 Remove the wire-holder Move the wire-holder retaining from the stitch head. spring to the right. figure 35 on...
Calibrate the Touch Screen Calibrate the Touch Screen When to do Calibrate the touch screen if the buttons do not operate or the buttons do not operate correctly. Attention: Use a pencil, the blunt end of a pen or a palm top wand for this procedure.
Change the Fuses Change the Fuses Introduction The Océ BLM500 has two fuses at the mains power input. If either fuse is broken, the Océ BLM500 will not operate. Attention: Turn OFF the machine and remove the mains power supply cable before you change the fuses.
Manually park the Shuttle Manually park the Shuttle When to do The error messages ‘MANUALLY PARK SHUTTLE’ and ‘SHUTTLE NOT PARKED’ are displayed. Illustration [38] [38] Shuttle Assembly Position - CORRECT [39] [39] Shuttle Assembly Position - NOT CORRECT [40] [40] Detail A: Pick-up fingers Chapter 5 Error Conditions, Problems and Solutions...
Page 75
Manually park the Shuttle [44] Step Open the folder cover. Open the Folder Cover on page 36 Push the shuttle-assembly to figure 38 on page 74 shows the the right. correct position for the shuttle assembly. If the shuttle assembly does not move to the correct position, push the pick-up fingers away from each other by 2-3mm and try again.
Page 76
Manually park the Shuttle Chapter 5 Error Conditions, Problems and Solutions...
The Océ BLM500 needs service every four months. After every one-million stitches, the stitch head needs service. This interval is every 3rd spool of stitch wire. Only a service engineer can service the Océ BLM500. Contact your supplier for further information. Operator Maintenance...
Do not use other chemicals or abrasive material. Outside of the Océ BLM500 Use a moist cloth to clean the outside of the Océ BLM500. Touch screen Clean the touch screen with a clean, dry cloth. Never use an abrasive material or chemical to clean the touch screen.
Clean the static elimination bars every week. This action extends the performance and service life of the static elimination bars The Océ BLM500 is supplied with a small brush. Use the brush to clean the static elimination bars. There are three static elimination bars.
Page 81
Clean the static elimination bar Open the gathering area cover. in the gathering area. Clean the pins on the bottom of the static elimination bar with a small brush Close the Océ BLM500 Close the gathering area cover Close the connecting bridge cover.
Clean the Former Roller Clean the Former Roller When to do Clean the former roller if the spines of the books are dirty. Ink and toner can collect on the former roller. Required tool Clean, plain paper that is not printed. A3 size (USA: 11 x 17”) is recommended. 4mm thickness is needed for each cycle.
Clean the Polyurethane Strips in the Form Clamp Clean the Polyurethane Strips in the Form Clamp When to do Follow this procedure if there are dirty marks near the spine on the front and back cover of the book. Ink and toner can collect on these parts, especially when you make thin books.
Page 84
Clean the Polyurethane Strips in the Form Clamp Step Action Information Reach into the form clamp and clean There is a polyurethane strip on each of the polyurethane strips. the face of each side of the clamp. Repeat this step until the polyurethane strips are clean.
Lubricate the Stitch Head Lubricate the Stitch Head Introduction [44] [44] Trim the nozzle of the tube of grease [45] [45] Stitch Head Wire Holder [50] Stitch Head Wire Holder Wire Holder Retaining Spring...
Page 86
Driver, in upper position Driver Bar Required tools Klüber Isoflex NBU15 Grease, 50g - Oce article number 1060060886 Air duster - is supplied with the machine. Attention: - Only use the grease shown in this manual. Correct lubrication extends the performance and service life of the stitch head. Other types of grease do not protect the stitch head - Only apply the grease as shown.
Page 87
ADVANCED > STITCHER UP > closed. This action moves the STITCHER UP stitch head to the correct position for lubrication. Lift the BLM500 main deck See Lift the Océ BLM500 Main Deck on page 40 Apply the Grease to the Driver Bar [53] Step...
Page 88
Lubricate the Stitch Head Step Action Information Lower theOcé BLM500 main deck. Lower the clincher frame. (see ‘Lower the Clincher Frame’ on page 38). Close all of the covers. Chapter 6 Maintenance...
Apply 10mm of grease from the tube figure 49 between the bearing surface of the [50] wire-feed cam and the feed lever. 10mm Lower theOcé BLM500 main deck Lower the clincher frame. Lower the Clincher Frame page 38 Close all of the covers...
Stitch Wire Description Model name stitcher wire S33 Article number 29701412 Before you begin Lift the Océ BLM500 main deck. (see ‘Lift the Océ BLM500 Main Deck’ on page Illustration [51] [51] Stitch Wire Guide Block [56] Stitch Wire Guide Block...
Page 91
Install New Stitch Wire Remove the Stitch Wire from the Stitch Head [57] Step Action Information [52] Cut the stitch wire to the right of the stitch wire guide block. Detail A: Cut here Pull the stitch wire from the stitch wire guide block.
Page 92
Install New Stitch Wire Step Action Information [54] Feed the stitch wire through the stitch wire guide. Install the stitch wire. (see ‘Install the Stitch Wire into the Stitch Head’ on page Chapter 6 Maintenance...
Page 93
[58] Push the stitch wire as far as possible. Detail A:Make sure the stitch wire runs between the wire feed rollers and into the middle wire tube. Close the Océ BLM500 [60] Step Action Information Close the stitch wire cabinet.
Page 94
Install New Stitch Wire Step Action Information Close the folder cover.. Close the connecting bridge cover. Feed the Stitch Wire [61] Step Action Information Touch START Set the number of stitches to 6 (see ‘Job Setting for a Standard Paper Size’...
Specifications Specifications [62] Operating 10-35°C at 35-85% relative humidity Conditions Production Cycle time: Printer dependent Interset gap: 2 seconds Minimum set time: 6 seconds Stock Sizes Minimum input size: 203 x 203mm Maximum input size: 320 x 488mm [59] 203 x 203mm 320 x 488mm A = Stitch &...
Page 97
Book quality is dependent upon quality of input sheets. Dimensions Footprint: 1870 x 1675mm Height - 1330mm maximum Weight Océ BLM500 including stitching wire: 542kg As above, plus bridge and bridge covers: 702kg Power Supply Adjustable to 200, 208, 220, 230 and 240V 50/60Hz, single phase...
Page 98
Specifications Appendix A Specifications...
Blaydon Road Sandy, Bedfordshire SG19 1RZ United Kingdom Declares that the product: Name of Product: Océ BLM500 serial Number: WA/PSQ/---/010 onwards Conforms to the following Product Specifications: Safety: 290/95/EEC & 98/37/EC Council Directive 'on the approximation of laws of Member States relating to machinery'.
Reader's comment sheet Reader's comment sheet Questions Have you found this manual to be accurate? O Yes O No Were you able to operate the product, after reading this manual? O Yes O No Does this manual provide sufficient background information? O Yes O No Is the format of this manual convenient in size, readability and arrangement (page...
Page 103
City: Country: Please return this sheet to: Océ-Technologies B.V. For the attention of ITC User Documentation. P.O. Box 101, 5900 MA Venlo The Netherlands Send your comments by E-mail to: itc-userdoc@oce.com For the addresses of local Océ organisations see: http://www.oce.com...
Océ-Australia Ltd. Océ-Österreich GmbH P.O. Box 363 Postfach 95 Ferntree Gully MDC 1233 Vienna Vic 3165 Austria Australia http://www.oce.at/ http://www.oce.com.au/ Océ-Belgium N.V./S.A. Océ-Brasil Comércio e Indústria Ltda. J. Bordetlaan 32 Av. das Nações Unidas, 11.857 1140 Brussel Brooklin Novo Belgium São Paulo-SP 04578-000...
Page 105
Addresses of local Océ organisations Océ-Hungaria Kft. Océ-Ireland Ltd. 1241 Budapest 3006 Lake Drive Pf.: 237 Citywest Business Campus Hungary Saggart http://www.oce.hu/ Co. Dublin Ireland http://www.oce.ie/ Océ-Italia S.p.A. Océ Japan Corporation Strada Padana Superiore 2/B 3-25-1, Nishi Shinbashi 20063 Cernusco sul Naviglio (MI)
Page 106
5450 North Cumberland Avenue Chicago, IL 60656 http://www.oceusa.com/ Note: The web site http://www.oce.com gives the current addresses of the local Océ organizations and distributors. Note: The addresses of local Océ organizations for information about the Wide Format Printing Systems and the Production Printing Systems can be different from the addresses above.