Related Manuals for Plockmatic BM3000
Summary of Contents for Plockmatic BM3000
- Page 1 Plockmatic BM3000 Installation Instruction This Installation Instruction is an excerpt from the Service Manual T09343A 1 July 2019...
- Page 2 Page Intentionally Blank...
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Page 3: Table Of Contents
1.6.1 Accessory check ................... 1-35 1.14.3 Example of a complete system ............1-62 1.6.2 Installation procedure ................1-36 1.14.4 Connecting BST4000-1 Belt Stacker ........... 1-63 1.6.3 Docking CST with AF602 ..............1-38 Plockmatic BM3050 system 1 July 2019 1. Installation Procedure... - Page 4 1.16.3 Checking the CST crease ..............1-72 1.16.4 Checking the CR..................1-73 1.17.1 Checking the Booklet Maker ..............1-73 1.16.5 Checking the Square Fold ..............1-74 1.16.6 Checking the Trimmer................1-74 Plockmatic BM3050 system 1 July 2019 1. Installation Procedure...
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Page 5: Unpacking Instruction
UNPACKING INSTRUCTION Remove packaging foam and plastic wrap 1.1.1 AF602/VF602 FEEDER Remove packaging foam Plockmatic BM3050 system 1 July 2019 1. Installation Procedure... - Page 6 Remove electronics Remove rear cover Rear Cover Front Cover 1. Loosen screw [A] 2. Lift up cover [B] 3. Tilt out top [C] 4. Remove cover Plockmatic BM3050 system 1 July 2019 1. Installation Procedure...
- Page 7 2. Cut red tie wrap [D] (transport protection) 3. Lift the latch [E] and push in the bin 4. Repeat on second bin 5. Open the door [F] 6. Lift and remove front cover Plockmatic BM3050 system 1 July 2019 1. Installation Procedure...
- Page 8 [7a] Lower wheels (x4) Stand on edge of ramp to stabilize; carefully roll unit down ramp [7b] Remove packaging supports Plockmatic BM3050 system 1 July 2019 1. Installation Procedure...
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Page 9: Cst Module
Ensure that the waste box is saved. 1. Remove the straps [A] 3. Remove the Waste Box and ensure it is saved [C]. 2. Remove the lid [B]. 4. Remove the Ramp Support [D] . Plockmatic BM3050 system 1 July 2019 1. Installation Procedure... - Page 10 5. Remove the Protection Foam Blocks (x2) [E]. 7. Remove from the Corners the Protection Foam Blocks (x4) [G]. 6. Remove Ramp Support Foam (x2) [F]. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure...
- Page 11 8. Remove the Paper Box [H]. 11. Open the bottom corners of the box [K]. 9. Remove the Plastic Cover [I]. 12. Remove the Protection Foam [L]. 10. Remove Accessories Box [J] Plockmatic BM3050 system 1 July 2019 1. Installation Procedure...
- Page 12 13. Open Top Cover and remove two screws securing Front Cover [M]. 15. Remove two screws securing the Rear Cover [N]. 14. Lift Front Cover and remove. 16. Lift Rear Cover and remove. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-10...
- Page 13 Two persons are required to remove the foam blocks. 18. Adjust the height of the casters on the CST to 44mm (1.75”). 19. Pull out the foam blocks (x2) underneath the CST. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure...
- Page 14 20. Mount Ramp Support Foam according to picture [P]. 21. Place Ramp [D] as illustrated. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-12...
- Page 15 WARNING: Two persons are required to carefully roll the CST off the pallet. 22. Carefully roll CST off the pallet. 23. Remove material packed inside the CST [Q]. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-13...
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Page 16: Cr3050 Creaser
1.1.3 CR3050 CREASER 1. Remove straps [A] 3. Remove instructions [C] and ramp board [D]. 2. Remove lid [B]. 4. Remove protective foam block (x1) [E]. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-14... - Page 17 4. Remove accessories box [I] and protective card board boxes (x2) [J]. 2. Remove ramp support foam (x2) [G]. 5. Remove protective foam blocks (x2) [K] . 3. Remove card board sleeve [H]. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-15...
- Page 18 1. Plastic bag [L] is secured with tape at top of machine. 4. Note position (inside front and rear cover) of board reinforced foam 2. Pull down plastic bag and remove silica gel (desiccant) bags [M]. blocks under machine (x2) [O]. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-16...
- Page 19 3. Tilt machine and move plastic bag [L] in under machine. 2. Tilt machine other way and remove second board reinforced foam block (x1) [O]. 4. Tilt machine other way and remove and remove plastic bag [L]. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-17...
- Page 20 1. Install ramp support foam (x2) [G] 3. Roll machine off of pallet. 2. Install ramp board [D]. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-18...
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Page 21: Bm3035 / Bm3050 Booklet Maker
1.1.4 BM3035 / BM3050 BOOKLET MAKER 3. Remove Ramp. Remove lid. Remove box containing accessories. Remove remove Ramp support (x2). Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-19... - Page 22 5. Remove card board tubes (x2). 7. Remove card board tubes (x2), foam (x2) and plastic cover. 6. Remove box sides. 8. Remove bubble wrap from stacker. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-20...
- Page 23 11. Place Ramp on Ramp support according to picture. WARNING: 12. Carefully roll Booklet Maker off the pallet. Two persons are required to remove the foam blocks. 10. Mount Ramp Support according to picture. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-21...
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Page 24: Squarefold Module
1.1.5 SQUAREFOLD MODULE Remove straps. 3. Remove foam. Remove lid. Remove box sides. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-22... - Page 25 Remove plastic cover. Remove accessories. Tilt the unit to upright position. WARNING: Two persons are required to tilt the unit to the upright position. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-23...
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Page 26: Trimmer Module
1.1.6 TRIMMER MODULE Remove straps. 3. Remove foam. Remove lid. Remove box sides. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-24... - Page 27 Remove plastic cover. 7. Remove accessories from inside the trim bin. Tilt the unit to upright position. WARNING: Two persons are required to tilt the Trimmer to the upright position. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-25...
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Page 28: Bst 4000-1 Belt Stacker Module
1.1.7 BST 4000-1 BELT STACKER MODULE Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-26... - Page 29 Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-27...
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Page 30: Installation Requirements
The optional high capacity Belt Stacker BST4000-1 can be placed either in-line or angled to the Booklet Making system. The BST4000-1 measures 1730x440mm / 68x17”. NOTE: BM3050 Upgrade kit and Plockmatic Cover Feeder does not impact floor space requirements. 400 mm 16” 420-630 mm... -
Page 31: Power Requirements
Check the Booklet Maker installation section for how to remove the rear tions are present and ensure that all packaging material, strech film etc. is cover in order to obtain the supplied tools. removed from the modules. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-29... -
Page 32: Installation Precautions
Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-30... -
Page 33: Af602/Vf602 Installation
Wide paper support 131-110182 Female Docking Bracket 122-109998 (for docking to BM) Screws M6S M6x12 washer o18x1,6 99400 *Part numbers are subject to change. For part number information, see AF602/VF602 Parts Catalog Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-31... -
Page 34: Removal Of Covers
1. Lift the latch [D] (x2) and push in the bins 3. Tilt out top [C] 2. Open the front door [E] 4. Remove cover 3. Lift and remove front cover Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-32... -
Page 35: Height Adjustment
3. Keep the height of the left front wheel and adjust the other three to level the machine, using a water level. 4. Lock the jam nuts [B] (x4) against the chassis. 100 mm Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-33... -
Page 36: Connectors
1.4.7 CALIBRATION After system integration, use accessory items 10 and 12 to calibrate the AF602/VF602. For detailed calibration procedures, refer to the AF602/VF602 Feeder Settings sections of the Operators Manual. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-34... -
Page 37: Cst Installation
Female Docking Bracket 122-109998 (for docking to BM) Screws M6S M6x12 washer o18x1,6 99400 * Part numbers are subject to change. Please refer to Spare Part Manual for correct numbers. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-35... -
Page 38: Installation Procedure
CST (see picture below). 2. Remove front cover by loosening screws 3. Open Slide Door slightly and lift/remove front cover 4. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-36... - Page 39 4. Install female Docking Bracket on the downstream side of the CST. Position it sideways as shown in picture below. Intentionally blank. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-37...
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Page 40: Docking Cst With Af602
3.Use a spirit level (included in Booklet Maker) to make sure that both AF602 and CST are fully leveled in both directions. 4.Connect the Communication Cable be- tween Feeder and CST. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-38... -
Page 41: Cr3050 Installation
Screws M6S M6x12 washer o18x1,6 99400 * Part numbers are subject to change. Please refer to Spare Part Manual for correct numbers. ** Configuration with ACF510 is not yet launched (may 2016) Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-39... -
Page 42: Removal Of Front Cover
B < C NOTE: Do not turn each nut more than 2 full revolutions before adjusting the other nuts. Each turn of a nut equals to a 1,5 mm (1/16”) travel. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-40... - Page 43 3. Pull and lift at [D] to unlock docking device on AF602/VF602. 4. Roll CR3050 up to AF602/VF602, dock and lock docking device. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-41...
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Page 44: Cables And Cable Protector
Position it sideways as shown in picture below. 2. Connect communication cable [C] to upstream device i.e. AF602/ VF602 3. Connect communication cable [D] to downstream device i.e. BM3050. 4. Connect power cable [E] to outlet. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-42... -
Page 45: Bm3050 Upgrade Kit
Check the quantity and condition of the accessories in the box against the following list: Description Q’ty Machine logo, Plockmatic Machine logo, Morgana 4. Plug in connector [F]. Active logo hardware 5. Install and fasten the PCB with screws [G]. -
Page 46: Bm3050 Installation
Termination Plug, male 140227 Interlock Jumper 770224 USB to Serial Converter (inside machine) 93536 Software Download Cable (inside machine) 770010 Spirit Level 101-102792 Logotype Plockmatic BM3035 102-114347 Logotype Morgana BM3035 102-114346 Safety Instruction N0001641 Operator Manual T10200 Cable protector with screws 890700... -
Page 47: Bm3050 Installation Procedure
When not in use, place it in the holder underneath the inlet. Adjust the lenght of bolts [Q] to protrude about 21mm for docking to upstream device. Tighten the jam nuts [R] after a successful and straight docking is achieved. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-45... - Page 48 Install the Cable Protector [T] and Cable Holders [U] This is the end of the Booklet Maker installation procedure. Installing con- nectors and cables and checking of installation will be done later on. Continue with next section. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-46...
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Page 49: Square Fold Module Installation
4. Tighten screws [A]. Check the quantity and condition of the accessories against the following list: Description Q’ty 1. Communication cable 2. Power cord 3. Cable protector with 2 screws 4. Cable holder Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-47... - Page 50 Do not turn each nut more than 2 full revolutions before adjusting the other nuts. Each turn of a nut equals to a 1,5 mm (1/16”) travel. Continued on next page Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-48...
- Page 51 Square Fold. This is the end of the SquareFold Module installation procedure. Installing connectors and cables and checking of installation will be done later on. Continue with next section below. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-49...
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Page 52: Trimmer Module Installation
4. Cable holder Two on the front side and two on the back side. Adjust alignment by turning only two of the nuts on either the infeed or exit side. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-50... - Page 53 8. Install the cable protector [H] (two screws) to the Trimmer and the Installing connectors and cables and checking of installation will be done cable holder [I] to the Trimmer base. later on. Continue with section 1.11 to install Belt Stacker Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-51...
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Page 54: Installation Procedure, Trimmer To Booklet Maker
In order to dock a Trimmer to the Booklet Maker, the docking studs [C] on the Booklet Maker have to be relocated to the lower holes [D] in the exit cover. 6. Relocate docking studs to the lower holes [D] and tighten the screws. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-52... - Page 55 Do not turn each nut more than 2 full revolutions before adjusting the other nuts. Each turn of a nut equals to a 1,5 mm (1/16”) travel. If adjustment is necessary, begin with adjusting alignment and con- tinue with adjusting height. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-53...
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Page 56: Belt Stacker Installation
This is the end of the Trimmer Module to BM Booklet Maker installation procedure. Installing connectors and cables and checking of installation will be done later on. Continue with next section below. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-54... -
Page 57: Bst4000-1 Belt Stacker Installation
This section describes how to install a BST4000-1 Belt Stacker Module. • If you don’t have this option, go to next section. 1.13.1 INSTALLATION PROCEDURE 1. Locate the orange cable inside the frame, plug in and secure connec- tor. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-55... - Page 58 Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-56...
- Page 59 Measure height [A] Adjust distance [B] to match height [A] Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-57...
- Page 60 Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-58...
- Page 61 Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-59...
- Page 62 Alt. 2 This is the end of the BST4000-1 Belt Stacker installation procedure. Installing connectors and cables will be done later on. Continue with next section below. Alt. 1 Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-60...
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Page 63: Cables, Plugs And Jumpers
The Interlock Jumper must be installed on a Booklet Maker without Square Fold or Trimmer connected. The Square Fold and Trimmer modules are powered from the booklet maker. The black cables are used for this purpose. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-61... -
Page 64: Example Of A Complete System
1.14.3 EXAMPLE OF A COMPLETE SYSTEM Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-62... -
Page 65: Connecting Bst4000-1 Belt Stacker
1.14.4 CONNECTING BST4000-1 BELT STACKER Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-63... - Page 66 Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-64...
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Page 67: Main Power Cord, Bm3050 Booklet Maker
1.14.5 MAIN POWER CORD, BM3050 BOOKLET MAKER 1.14.7 MAIN POWER CORD, BST4000-1 BELT STACKER MODULE 1.14.6 MAIN POWER CORD, ROTATE CREASE TRIM MODULE Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-65... -
Page 68: After Switching On The Power
7. Press the [+] or [-] buttons to enter the value retrieved from the Trim- mer. 8. Press the [OK] button. 9. Press [Home] button once to go back to Service mode. 10. Press [Exit Service] button to leave Service mode. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-66... -
Page 69: Performing A Self Diagnostic
11. Exit diagnostic mode by powering off the system. 12. Reinstall the two staple cartridges and close the top cover. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-67... -
Page 70: Checking The Installation
Use of smaller paper sizes during alignment can cause SRA3/12x18” to have infeed issues. 1. Open the CST top cover and install an interlock cheater [A] to be able to run the CST with the top cover open. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-68... - Page 71 [G]. If not, the position of the Booklet Maker must be adjusted. 6. Loosen screws [E] and adjust Infeed Docking Bracket on the CST to achieve tolerance. Repeat step 3 to 6 until alignment is correct. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-69...
- Page 72 • Undock the Booklet Maker from the upstreams device • Adjust the docking bracket by loosening the two nuts [H] and sliding the alignment pin in desired direction. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-70...
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Page 73: Adjusting/Checking The Cst Bleed Trim
If not, repeat step 1, 8 - 10. tight. 11. Turn adjustment screw [B] clockwise and send five more sets of 2 Turn adjustment screw counter clockwise until wrinkles disappear. sheet SRA3/12x18”. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-71... -
Page 74: Checking The Cst Crease
If not, this is a Booklet Quality issue. Not an Installation issue. To correct this, a trained service technician and a service manual is needed. Make a note of this issue and pass it on to a trained service technician. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-72... -
Page 75: Checking The Cr
Booklet maker with the top cover open. 5. Set up the Booklet maker to: Input Sheet Size: SRA3 or 12x18” Face Trim: 0,0mm or 0.000” Bleed Trim: 0,0mm or 0.000” Plockmatic BM3050 system 1 July 2019 1. Installation Procedure 1-73... -
Page 76: Checking The Square Fold
40 pages) to the Booklet Maker system. 10. Check that the booklet cover does not have a crease and that the booklets have a Book Folded spine. Plockmatic BM3050 system 1 July 2019 1. Installation Procedure...