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Plockmatic BM500 Service Manual

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Table of Contents

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Plockmatic BM500
Booklet Maker Service Manual
T08134A
1 July 2019

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Summary of Contents for Plockmatic BM500

  • Page 1 Plockmatic BM500 Booklet Maker Service Manual T08134A 1 July 2019...
  • Page 2 WARNING: This is a Class A product. In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures. The product (System) which is connected to this machine will be class A NOTE The domestic environment is an environment where the use of broadcast radio and television receivers may be expected within a distance of 10 m of the apparatus concerned.
  • Page 3 Introduction This manual contains instructions on the operation and maintenance of this machine. To get the maximum versatility from this machine all operators should carefully read and follow the instructions in this manual. Keep this manual in a handy place near the machine. Please read the Safety Information before using this machine.
  • Page 4 Safety Information When using this machine, following safety precautions should always be followed. Safety during operation WARNING: • To avoid hazardous situations such as electric shock or danger while exposed to moving, rotating or cutting devices, do not remove any covers, guards or screws other than those specified in this manual.
  • Page 5 General Safety WARNING: • Always connect the equipment to a properly grounded power source (wall outlet). Wall outlet should be located near the system and eas- ily accessible. If in doubt, have the power source checked by a qualified electrician. •...
  • Page 6 TABLE OF CONTENTS 1 Installation procedure............ 1-1 2 Preventive Maintenance (PM) ........2-1 3 Repairs and Adjustments (REP and ADJ) ....3-1 4 Troubleshooting (RAP) ..........4-1 5 Service tables (GP) ............5-1 6 Detailed Description ............6-1 7 Specifications ..............7-1 8 Wiring ................

  • Page 7: Table Of Contents

    1.12.7 main power cord, BST4000-1 Belt Stacker Module ......1-56 CST installation 1.13 After switching on the power 1.5.1 Accessory check ................... 1-30 1.5.2 Installation procedure ................1-31 1.5.3 Docking CST with AF602 ..............1-33 Plockmatic BM3050 system 27 August 2019 1. Installation Procedure...
  • Page 8 1.14.2 Adjusting/checking the CST bleed trim ..........1-62 1.14.3 Checking the CST crease ..............1-63 1.14.4 Checking the Booklet Maker ..............1-64 1.14.5 Checking the Square Fold ..............1-65 1.14.6 Checking the Trimmer................1-65 Plockmatic BM3050 system 27 August 2019 1. Installation Procedure...

  • Page 9: Unpacking Instruction

    UNPACKING INSTRUCTION Remove packaging foam and plastic wrap 1.1.1 AF602/VF602 FEEDER Remove packaging foam Plockmatic BM3050 system 27 August 2019 1. Installation Procedure...
  • Page 10 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 27 August 2019 1. Installation Procedure...
  • Page 11 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 27 August 2019 1. Installation Procedure...
  • Page 12 [7a] Lower wheels (x4) Stand on edge of ramp to stabilize; carefully roll unit down ramp [7b] Remove packaging supports Plockmatic BM3050 system 27 August 2019 1. Installation Procedure...

  • Page 13: 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 27 August 2019 1. Installation Procedure...
  • Page 14 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 27 August 2019 1. Installation Procedure...
  • Page 15 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 27 August 2019 1. Installation Procedure...
  • Page 16 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 27 August 2019 1. Installation Procedure 1-10...
  • Page 17 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 27 August 2019 1. Installation Procedure...
  • Page 18 20. Mount Ramp Support Foam according to picture [P]. 21. Place Ramp [D] as illustrated. Plockmatic BM3050 system 27 August 2019 1. Installation Procedure 1-12...
  • Page 19 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 27 August 2019 1. Installation Procedure 1-13...

  • Page 20: Bm3035 / Bm3050 Booklet Maker

    1.1.3 BM3035 / BM3050 BOOKLET MAKER 3. Remove Ramp. Remove lid. Remove box containing accessories. Remove remove Ramp support (x2). Plockmatic BM3050 system 27 August 2019 1. Installation Procedure 1-14...
  • Page 21 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 27 August 2019 1. Installation Procedure 1-15...
  • Page 22 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 27 August 2019 1. Installation Procedure 1-16...

  • Page 23: Squarefold Module

    1.1.4 SQUAREFOLD MODULE Remove straps. 3. Remove foam. Remove lid. Remove box sides. Plockmatic BM3050 system 27 August 2019 1. Installation Procedure 1-17...
  • Page 24 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 27 August 2019 1. Installation Procedure 1-18...

  • Page 25: Trimmer Module

    1.1.5 TRIMMER MODULE Remove straps. 3. Remove foam. Remove lid. Remove box sides. Plockmatic BM3050 system 27 August 2019 1. Installation Procedure 1-19...
  • Page 26 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 27 August 2019 1. Installation Procedure 1-20...

  • Page 27: Bst 4000-1 Belt Stacker Module

    1.1.6 BST 4000-1 BELT STACKER MODULE Plockmatic BM3050 system 27 August 2019 1. Installation Procedure 1-21...
  • Page 28 Plockmatic BM3050 system 27 August 2019 1. Installation Procedure 1-22...

  • Page 29: 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 30: 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 27 August 2019 1. Installation Procedure 1-24...

  • Page 31: Installation Precautions

    Plockmatic BM3050 system 27 August 2019 1. Installation Procedure 1-25...

  • Page 32: 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 27 August 2019 1. Installation Procedure 1-26...

  • Page 33: 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 27 August 2019 1. Installation Procedure 1-27...

  • Page 34: 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 27 August 2019 1. Installation Procedure 1-28...

  • Page 35: 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 27 August 2019 1. Installation Procedure 1-29...

  • Page 36: 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 27 August 2019 1. Installation Procedure 1-30...
  • Page 37 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 27 August 2019 1. Installation Procedure 1-31...
  • Page 38 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 27 August 2019 1. Installation Procedure 1-32...

  • Page 39: 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 27 August 2019 1. Installation Procedure 1-33...

  • Page 40: 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 41: 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 42: Manual Feed

    Install docking bracket [N] on BM with nuts [O] (4x) and [P] (2x). 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 27 August 2019 1. Installation Procedure 1-36...
  • Page 43 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 27 August 2019 1. Installation Procedure 1-37...

  • Page 44: 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 27 August 2019 1. Installation Procedure 1-38...
  • Page 45 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 27 August 2019 1. Installation Procedure 1-39...
  • Page 46 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 27 August 2019 1. Installation Procedure 1-40...

  • Page 47: 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 27 August 2019 1. Installation Procedure 1-41...
  • Page 48 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 27 August 2019 1. Installation Procedure 1-42...

  • Page 49: 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 27 August 2019 1. Installation Procedure 1-43...
  • 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. If adjustment is necessary, begin with adjusting alignment and con- tinue with adjusting height. Plockmatic BM3050 system 27 August 2019 1. Installation Procedure 1-44...

  • Page 51: 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 27 August 2019 1. Installation Procedure 1-45...

  • Page 52: 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. 1.11.1 INSTALLATION PROCEDURE 1. Locate the orange cable inside the frame, plug in and secure connec- tor. Plockmatic BM3050 system 27 August 2019 1. Installation Procedure 1-46...
  • Page 53 Plockmatic BM3050 system 27 August 2019 1. Installation Procedure 1-47...
  • Page 54 Measure height [A] Adjust distance [B] to match height [A] Plockmatic BM3050 system 27 August 2019 1. Installation Procedure 1-48...
  • Page 55 Plockmatic BM3050 system 27 August 2019 1. Installation Procedure 1-49...
  • Page 56 Plockmatic BM3050 system 27 August 2019 1. Installation Procedure 1-50...
  • Page 57 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 27 August 2019 1. Installation Procedure 1-51...

  • Page 58: 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 27 August 2019 1. Installation Procedure 1-52...

  • Page 59: Example Of A Complete System

    1.12.3 EXAMPLE OF A COMPLETE SYSTEM Plockmatic BM3050 system 27 August 2019 1. Installation Procedure 1-53...

  • Page 60: Connecting Bst4000-1 Belt Stacker

    1.12.4 CONNECTING BST4000-1 BELT STACKER Plockmatic BM3050 system 27 August 2019 1. Installation Procedure 1-54...
  • Page 61 Plockmatic BM3050 system 27 August 2019 1. Installation Procedure 1-55...

  • Page 62: Main Power Cord, Bm3050 Booklet Maker

    1.12.5 MAIN POWER CORD, BM3050 BOOKLET MAKER 1.12.7 MAIN POWER CORD, BST4000-1 BELT STACKER MODULE 1.12.6 MAIN POWER CORD, ROTATE CREASE TRIM MODULE Plockmatic BM3050 system 27 August 2019 1. Installation Procedure 1-56...

  • Page 63: 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 27 August 2019 1. Installation Procedure 1-57...
  • Page 64 11. Exit diagnostic mode by powering off the system. 12. Reinstall the two staple cartridges and close the top cover. Plockmatic BM3050 system 27 August 2019 1. Installation Procedure 1-58...

  • Page 65: 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 27 August 2019 1. Installation Procedure 1-59...
  • Page 66 [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 27 August 2019 1. Installation Procedure 1-60...
  • Page 67 • 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 27 August 2019 1. Installation Procedure 1-61...

  • Page 68: 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 27 August 2019 1. Installation Procedure 1-62...

  • Page 69: 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 27 August 2019 1. Installation Procedure 1-63...

  • Page 70: Checking The Booklet Maker

    7. Using 80 gsm/20 lb Bond sheets, send five sets of 20 sheet A4/8.5x11” (20 sheets of A4/8.5x11” equals a booklet containing 80 pages) to the Booklet Maker system. 8. Check that the booklets are stapled and folded at the middle of the Plockmatic BM3050 system 27 August 2019 1. Installation Procedure 1-64...

  • Page 71: 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 27 August 2019 1. Installation Procedure...
  • Page 73 PREVENTIVE MAINTENANCE (PM) Contents Booklet Maker Square Folder Trimmer Crease Side Trimmer AF602 VF602 Plockmatic BM3050 system 27 August 2019 2. Preventive Maintenance (PM)

  • Page 74: Preventive Maintenance (Pm)

    (x2) grease Fold transmission Cou- Lubricate metal to metal surfaces with MoS2 REP 6.4 125K pling assemblies grease Drive chain, fold trans- Lubricate chain with Oil ADJ 6.4 125K mission Plockmatic BM3050 system 27 August 2019 2. Preventive Maintenance (PM)
  • Page 75 Tyre, drive wheel set Replace Tyre 30/38x6 102- REP 4.3 PL 5.0, It. 4 transport 104204 Set transport motor BM- Replace Motor 24V 10:1 781022 REP 4.3 PL 5.0, It. 6 Plockmatic BM3050 system 27 August 2019 2. Preventive Maintenance (PM)

  • Page 76: Square Folder

    Use film remover to clean belts REP 10.22 125K Upper Exit belts (x2) Use film remover to clean belts REP 10.23 125K Trim Knife Inspect trim result; 2 and 50 sheets REP 10.16, 125K 10.17 Plockmatic BM3050 system 27 August 2019 2. Preventive Maintenance (PM)
  • Page 77 Transport and knife mo- Replace Motor Wevin with con- 782044 REP 10.12 PL 11.2, It. 4 tor TR-M1 nector Length adjustment motor Replace Motor 24V 30:1 762042 REP 10.22 PL 11.9, It.1 TR-M3 Plockmatic BM3050 system 27 August 2019 2. Preventive Maintenance (PM)

  • Page 78: Crease Side Trimmer

    REP 12.47 PL 12.22, It. 1 2M istration cross roller 109691 Upper and Lower knife Replace Upper and Lower knife 531019 REP 13.1, 13.2 PL 12.42, It. 1 2M replacement kit Plockmatic BM3050 system 27 August 2019 2. Preventive Maintenance (PM)

  • Page 79: Af602

    Timing belt 8T5/100 Replace PL 2.3a/b Solenoid Bin Lock Replace PL 2.0 (SOL102/SOL202) Interlock switch x3 Replace PL 2.0 / 3.0 Blower Fan x8 Replace PL 2.1a/b Coupling shaft Replace PL 4.0 Plockmatic BM3050 system 27 August 2019 2. Preventive Maintenance (PM)
  • Page 80 Timing belt 8T5/100 Replace PL 2.3a/b Solenoid Bin Lock Replace PL 2.0 (SOL102/SOL202) Interlock switch x3 Replace PL 2.0 / 3.0 Blower Fan x8 Replace PL 2.1a/b Coupling shaft Replace PL 4.0 Plockmatic BM3050 system 27 August 2019 2. Preventive Maintenance (PM)

  • Page 81: Vf602

    Coupling shaft x2 Replace PL 4.0 Solenoid Vacuum Release Replace PL2.3 (SOL103/203) Suction Belts (Feeder Use rubber reactivator alcohol fluid to clean suction belts. PL 2.3 Assembly) Replace if worn. Plockmatic BM3050 system 27 August 2019 2. Preventive Maintenance (PM)
  • Page 82 Coupling shaft x2 Replace PL 4.0 Solenoid Vacuum Release Replace PL2.3 (SOL103/203) Suction Belts (Feeder Use rubber reactivator alcohol fluid to clean suction belts. PL 2.3 Assembly) Replace if worn. Plockmatic BM3050 system 27 August 2019 2. Preventive Maintenance (PM) 2-10...
  • Page 83 General Check point Instruction Part Name Spare Qty Service Spare Parts Maintenance Part No. manual manual Interval Check Booklet Quality Section 9 BQ 125K Plockmatic BM3050 system 27 August 2019 2. Preventive Maintenance (PM) 2-11...
  • Page 84 REP 7.5 Expansion PCB ”J” 4 In 4 Out ..............3-60 REP 4.0 Stapler Heads, Stapler Assy and Clincher ..........3-33 REP 7.6 User Interface assembly ................3-60 REP 4.1 Staple Quality (forming) ................3-37 Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)
  • Page 85 REP 10.18 TR-Q14 Paper Path & TR-Q6 Exit Sensor ..........3-81 REP 11.13 SQF-Q5 Infeed Sensors ..............3-108 REP 10.19 Stop Gate Carriage ................3-82 REP 11.14 SQF-Q7 Exit Sensors ................3-108 Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)
  • Page 86 REP 12.49 Creaser Assembly ................3-162 REP 12.17 Pre Trimmer Fixing Roller ..............3-136 REP 12.50 Creaser Trigger Sensor (CT-Q4) LED ..........3-164 REP 12.18 Post Trimmer Fixing Roller ..............3-137 Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)
  • Page 87 REP 13.24 Solenoid Driver PCB “B” ..............3-189 REP 14.12 Lead Screw Assembly ................3-214 REP 13.25 Stepper Motor Driver (M7) PCB “C” ..........3-190 REP 14.13 Stepper Motor M101 / M201 ...............3-216 Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)
  • Page 88 REP 15.33 Idler Shaft, Exit ...................3-258 REP 15.1 Cover, Front ..................3-235 REP 15.34 Baffle Hardware ..................3-259 REP 15.2 Cover, Bin ....................3-236 REP 15.35 SP Sensor ....................3-260 REP 15.3 Door .......................3-236 Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)
  • Page 89 ADJ 12.44 Registration Cross Rollers Drive Shaft ..........3-305 ADJ 4.1 Staple Quality ..................3-280 ADJ 12.47 Registration Cross Rollers Idler Roller ..........3-306 ADJ 4.2 Set Transport Calibration ...............3-284 Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)
  • Page 90 ADJ 13.21 Slide R/H Lower Baffle ...............3-318 ADJ 13.36 12V Power Supply Unit ...............3-318 ADJ 13.37 24V Power Supply Unit (1) ..............3-318 ADJ 13.38 24V (48V) Power Supply Unit (2) ............3-318 Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 91: General Cautions

    Place the adjustable wrist strap securely on the wrist. Wait for one minute to let the electrostatic be discharged from your body. ESD sensitive components can now be handled without causing any ESD related damage. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 92: Recommended Tools

    1.5, 2, 2.5, 3, 4, 5mm allen keys • Flat blade screwdriver size 4 or 5 • Circlip pliers • Metric feeler gauge set • Metric sliding caliper Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 93: Rep 1.0 Undocking Bm / Tr / Sqf

    Open the docking mechanism according to the arrows in figure. Undock the Booklet Maker (system). NOTE: Ensure cables on the rear of the machine are not interfering when moving the system. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-10...
  • Page 94 Push Locking Bracket down [B]. NOTE: Ensure cables on the rear of the machine are not interfering when moving the SQF / TR. Continued on next page Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-11...
  • Page 95 Push Locking Bracket down [B]. Move Trimmer aside. NOTE: Ensure cables on the rear of the machine are not interfering when moving the TR / SQF. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-12...

  • Page 96: Rep 1.1 Front And Rear Cover

    Remove screws (x2) [B]. Pull out the lower part and unhook the rear cover. Remove the front cover. Replacement Replacement Reverse removal procedure. Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-13...

  • Page 97: Rep 1.2 Lower Infeed Cover And Infeeder

    Lift up and remove the Lower Infeed Cover Lower Infeed Cover is very heavy and could cause injury if it falls down. continued on next page Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-14...
  • Page 98 Replacement Disconnect connectors from motor [A]. Reverse removal procedure. Loosen screws [B] (x4) and remove Cover lower, infeed (x2) [C]. Loosen screws [D] (x4). Remove Infeeder. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-15...

  • Page 99: Rep 1.3 Upper And Lower Exit Cover

    10. Pull out lower end of the Exit Cover, lift it up enough to clear the Exit Sensor [D]. 11. Pull out upper end of the Exit Cover and lower it until it touches the Fold Gate. Replacement Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-16...

  • Page 100: Rep 1.4 Top Cover And Hand Feed Cover

    Turn off the main power and disconnect the power cord. Open the Top Cover. Remove nuts [A] (x6). Remove top cover Replacement Reverse removal procedure. Check adjustment according to (ADJ 1.4 Top Cover Height) Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-17...

  • Page 101: Rep 1.5 Top Cover Assembly

    1. Adjustment After all covers are mounted. check the gap all the way arund the top cover and adjkust to same gap by adjusting height of hinges [C] Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 102: Rep 1.6 Interlock Switch Assembly

    Remove screws [B] to remove interlock box (x4). SW1.2 SW1.4 SW1.3 SW1.1 Replacement 1 Reverse removal procedure. 2 Check adjustment according to (ADJ 1.6 Interlock Switch Assembly). Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-19...

  • Page 103: Rep 1.7 Sensor Q53 Handfeed Unit Infeed Sensor

    Disconnect the Sensor [C] reach in from under side. Remove sensor by removing screw and nut [D]. (Picture from inside of infeeder) Replacement 1 Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-20...

  • Page 104: Rep 3.0 Infeed Module

    Remove screws [E] on the Rear side of the Booklet Maker (x2). 10. Pull out the Infeeder carefully. NOTE: Make sure that the Side jogger motor M3 is not catching the frame of the Booklet Maker. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-21...

  • Page 105: Rep 3.1 Bm-Q1 Paper Infeed Sensor

    If you are using longer screws, you may damage the side guide shaft. Replacement Reverse removal procedure. Perform BQ 4 Paper / Side Guide Parallelism (staple skew). Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-22...

  • Page 106: Rep 3.3 Bm-M3 Side Jogger Motor & Bm-Q12 Side Jogger Motor Sensor

    Push Pulley down while re-installing the motor. Ensure that the Allen screw is tightened on the flat spot on the Motor shaft [A]. Reverse the rest of the removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 107: Rep 3.4 Side Guide Transmission & Bm-Q13 Side Jogger Home Position Sensor

    Back jogger module by hand, to easier gain access to the sensor. Pinch the barbs on sensor BM-Q13 [B] to remove sensor. [ I ] Replacement Reverse the rest of the removal procedure. continued on next page Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-24...
  • Page 108 Verify the centering by moving the side guides and check against, for example, the cut-outs [L]. Reverse removal procedure starting from step 6. [ I ] Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-25...

  • Page 109: Rep 3.5 Side Guide Transmission Belt

    (with a screwdriver) [B]. Tighten nuts (x2) [A] and remove screw driver. 10. Loosen screws (x4) [C]. 11. Remove Pulley and Belt [D] continued on next page Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-26...

  • Page 110: Rep 3.6 Back Jogger Module & Bm-Q3 Back Jogger Home Position Sensor

    It is not necessary to remove Infeed module to replace Sensor BM-Q3. Disconnect connector [A] to Sensor BM-Q3 (x1). Remove sensor by pinching the plastic locks in the back [B]. Replacement Sensor Q3 Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-27...

  • Page 111: Rep 3.7 Back Jogger Assembly

    Remove the Back Jogger Assembly. Replacement Reverse removal procedure Make sure to fit hte side guides into the slots on the outer finger assemblies. continued on next page Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-28...

  • Page 112: Rep 3.8 Back Jogger Fingers And Cam

    Adjust the two set collar [G] so they are as close against the cam as possible, and tighten the set screws (x2) [D]. Reverse removal procedure. NOTE: Make sure to position the middle finger tabs fully into the slots [H] Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-29...

  • Page 113: Rep 3.9 Bm-M2 Back Jogger Motor & Bm-Q45 Back Jogger Motor Sensor

    Remove the crank [C] from the motor shaft. Reverse the rest of the removal procedure. Remove connector [D] (x1). Remove screws [E] to the motor (x3). Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-30...

  • Page 114: Rep 3.10 Infeed Transport Module

    Cut cable ties (x2) [C]. Remove connectors [D] (x2). Remove Infeed transport module. Replacement Reverse removal procedure. NOTE: Mount the pin [A] in the lower holes. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-31...

  • Page 115: Rep 3.11 Infeed Transport Wheel

    Removing the Infeed transport module (REP 3.10 Infeed Transport Module) facilitates replacement of the Infeed transport wheel. Figure shows infeed module removed for clarity Replacement Replacement Reverse removal procedure. Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-32...

  • Page 116: Rep 4.0 Stapler Heads, Stapler Assy And Clincher

    Replace by pushing a new staple cartridge into the staple head, until it snaps in position. [D, right stapler] [D, left stapler] Continued on next page. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-33...
  • Page 117 The left stapler is tighten with 4 cables retainer [B]. Check adjustment according to (ADJ 4.1 Staple Quality). [left stapler] [right stapler] [right stapler] [left stapler] Viewed from bottom Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-34...
  • Page 118 Disconnect connectors to staplers [B] (x2) and connector P47 [C]. Disconnect connectors to both clinchers [D] (x2). Remove screws [E] on both sides (x4). Remove stapler/ clincher assembly [F]. continued on next page Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-35...
  • Page 119 Replacement of stapler head bracket assembly Check adjustment according to ( ADJ 4.1 Staple Quality). Reverse the removal procedure. Check adjustment according to (ADJ 4.1 Staple Quality). Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-36...

  • Page 120: Rep 4.1 Staple Quality (Forming)

    If not centered, proceed to adjustment described in ADJ 4.1 Staple Quality. Check the staple quality. If staples are correctly formed, no adjustment is needed. Else proceed with adjustment described in ADJ 4.1 Staple Quality. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-37...

  • Page 121: Rep 4.3 Bm-M5 Set Transport Motor & Bm-Q40 Set Transport Motor Sensor

    Check that the timing belt do not have too much tension. (Too much belt tension will affect the motor speed negatively) Reverse Removal procedure. Check adjustment according to (ADJ 4.3 Set Transport Drive). Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-38...

  • Page 122: Rep 4.4 Bm-M22 Stop Gate Stapler Motor

    Mount motor and connectors (x2). Ensure there is 1 mm spacing between crank and sensor. Reverse Removal procedure from Step 4. Check adjustment (BQ 9 Staple and Fold Position). Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-39...

  • Page 123: Rep 4.5 Bm-Q41 Stop Gate (M22) Motor Sensor

    Make also sure that the crank is 1 mm from the bottom of the sensor. Mount sensor and connectors (x2). Reverse Removal procedure from Step 4. [ I, J ] Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-40...

  • Page 124: Rep 4.6 Bm-Q42 Home Position Stop Gate Stapler (M22) Sensor

    Follow REP 4.5 BM-Q41 Stop Gate (M22) Motor Sensor,, step 1-8. Loosen screw (x1) [A]. Disconnect connector (x1] [B]. Remove sensor BM-Q42 [C]. Replacement Reverse Removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-41...

  • Page 125: Rep 5.0 Bm-Q4 Start Sensor Saddle Stapling Sensor

    Disconnect connector [C] (x1) and remove sensor [D]. Replacement Reverse Removal procedure. NOTE: Make sure that the sleeve of the wire, do not interfere with the paper path. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-42...

  • Page 126: Rep 5.1 Bm-M9 Staple Fold Positioning Motor & Bm-Q10 Stapler Fold Positioning Motor Sensor

    Remove screws from the motor bracket (x3) [B]. NOTE: The sensor BM-Q10 is located on the motor. Remove motor [C] with bracket. Replacement Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-43...

  • Page 127: Rep 6.0 Length Transmission Shaft & Bm-Q11 Staple Fold Home Positioning Sensor

    Remove Infeed Cover (REP 1.2 Lower Infeed Cover and Infeeder). Disconnect Connector (x1) [A]. Loosen screw (x1) [B]. Remove Sensor BM-Q11 [C]. Replacement BM-Q11 Sensor Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-44...

  • Page 128: Rep 6.1 Bm-M8 Stop Gate Folder Motor, Bm-Q7 Stop Gate Folder Sensor & Bm- Q48 Clinch Trigger Sensor Right

    Replacement Sensor BM-Q7 Reverse removal procedure. Check adjustment according to: (ADJ 6.1 BM-M8 Stop Gate Folder Motor, BM-Q7Stop Gate Folder sensor & BM-Q48 Clinch Trigger Sensor Right) Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-45...

  • Page 129: Rep 6.2 Fold Stop Gate

    +0.2mm. The curve should never be convex, i.e. the curvature of the gate should never be less than zero (negative). Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 130: Rep 6.3 Bm-M7 Fold Knife Motor & Bm-Q15 Fold Knife Home Position Sensor

    Do not tighten the screws. Reinstall the Crank [G]. Reinstall screw (x1) and washer (x1) [F]. Tighten screws [H] to the motor (x3). Reverse the rest of the removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-47...

  • Page 131: Rep 6.4 Fold Transmission Module, Bm-M6 Fold Roller Motor, Bm-Q9 Fold Roller Sensor & Fold Transmission Chain

    Remove transmission module w/M6 motor assembly. Removal BM-Q9 Fold roller sensor Remove screw [I] and nut [J] for the sensor bracket. Remove sensor bracket and shaft [K]. Continued on next page Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-48...
  • Page 132 Reverse the removal procedure. Adjust the chain until the tension is almost tense. NOTE: The route of the chain [A] should be mounted according to figure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-49...

  • Page 133: Rep 6.5 Spring Support

    Turn off the main power and disconnect the power cord. Remove Rear Cover (REP 1.1 Front and Rear Cover). Remove nut and the bracket [A]. Remove nuts and bushings (x5) and Spring Support [B]. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-50...

  • Page 134: Rep 6.6 Upper Fold Rollers

    11. Unhook the wires from the springs [L] and place the springs on the screws [M]. 12. Loosen the nuts (x2) [N] in order to release the tension of the fold roller springs [O]. Continued on next page Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)
  • Page 135 Ensure the springs are placed in the correct and recorded positions. Adjust the spring tension according to ADJ 6.7 Lower Fold Roller. Upper spring Lower spring Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-52...

  • Page 136: Rep 6.7 Lower Fold Rollers

    Remove the lower fold roller (2 of 2) [H]. Replacement Reverse the removal procedure. NOTE: Make sure to lubricate, with Molybdenum grease. PerformADJ 6.7 Lower Fold Roller. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-53...

  • Page 137: Rep 6.8 Bm-Q44 Home Position Stop Gate Folder Sensor

    Remove Exit Cover (REP 1.3 Upper and Lower Exit Cover). Replace the sensor [A]. Remove screw [A] (x1). Disconnect connector [B] (x1). Replacement Replacement Reverse removal procedure. Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-54...

  • Page 138: Rep 7.0 Md6Dc Pcb "H" (Upper)

    Pinch the barbs of the pins and remove PCB ”H”. H.P4 H.P5 1 2 3 4 H.P11 H.P13 H.P3 H.P2 H.P14 1 2 3 4 DIP Switch settings H.P16 Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-55...

  • Page 139: Rep 7.1 Md6Dc Pcb "B" (Middle)

    Pinch the barbs of the pins and remove PCB ”B”. B.P4 B.P5 1 2 3 4 B.P12 B.P13 B.P11 B.P3 B.P14 B.P2 1 2 3 4 DIP Switch settings B.P16 Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-56...

  • Page 140: Rep 7.2 Md6Dc Pcb "C" (Lower)

    Pinch the barbs of the pins and remove PCB ”C”. C.P4 C.P5 1 2 3 4 C.P12 C.P11 C.P13 C.P3 C.P14 1 2 3 4 C.P2 DIP Switch settings C.P16 Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-57...

  • Page 141: Rep 7.3 Pcb Controller, Pcb "A

    Replacement Reverse removal procedure. Enter recorded NVM values: BM: Index 2-7 and 11, see GP 20 NVM reset. A.P5 A.P4 A.P3 A.P2 A.P13 A.P10 A.P8 A.P1 Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-58...

  • Page 142: Rep 7.4 Addon Pcb "F

    9.5 - 10.5KΩ J4, pin 1 Not in use & 3 F.P1 F.P6 F.P2 F.P3 F.P4 F.P5 Replacement Reverse removal procedure. Perform next section, Adjustment, before connecting Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-59...

  • Page 143: Rep 7.5 Expansion Pcb "J" 4 In 4 Out

    BM3050 upgrade kit should be transferred from the old User Interface assembly to the new one. Reverse removal procedure. See installation instruction for how to install the upgrade kit. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 144: Rep 7.7 Bm-M23 Thick Sensor Motor

    [J] is between 1-1.5 mm. Adjust the lock nut [C], so that the distance [K] is 1 mm. 1-1.5 mm 1 mm Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-61...

  • Page 145: Rep 7.8 Removing Power Supply Unit

    Loosen screws [A] and remove cover [B] (x2). Disconnect connectors P45, G.P2, F.P2 [C] (x3). Loosen nuts [D] and remove PSU (x3). Positions of G.P2 and F.P2 Replacement Reverse the removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-62...

  • Page 146: Rep 7.9 Accessing Rear Side Of Connection Bracket

    Note position of ground wires and loosen nuts [A] (x2). Tilt out Connection bracket [B] for access. Replacement Reverse the removal procedure. Replacement NOTE: Reverse the removal procedure. Remember to position ground wires correctly. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-63...

  • Page 147: Rep 8.0 Stacker Module

    If the Stacker is to be re-installed on a different unit, fasten the 2 lower screws so that they do not interfere with Covers on other modules. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 148: Rep 8.1 St-M1 Stacker Motor

    Loosen nuts [A] (x3). Slide the motor bracket [B] and remove. Disconnect connector [C] (x1). Remove screws [D] (x3). Replacement Reverse removal procedure. NOTE: Stacker motor pulley is D-shaped. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-65...

  • Page 149: Rep 10.0 Front And Rear Cover

    Open the Top Cover. Remove screw [C] (x1). Remove screws [A] (x4). Remove rear cover. Remove front cover. Replacement Reverse removal procedure. Replacement Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-66...

  • Page 150: Rep 10.1 Top Cover

    Mark the position for the hinges [C]. Replacement Loosen screws (x4) [D]. Reverse removal procedure. Check the adjustment of the Top Cover according to ADJ 10.1 Top Cover. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-67...

  • Page 151: Rep 10.2 Infeed Cover

    Remove Front and Rear Cover (REP 10.0 Front and Rear Cover). In the front, remove screws (x3) [A]. In the rear, remove screws (x3) [B]. Remove Infeed Cover. Replacement Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-68...

  • Page 152: Rep 10.3 Tr-M5 / M6 Blower Motor (Blower Assembly)

    Disconnect connectors (x2) and remove the screws (x2) and the nuts (x2) [C]. Lift out Fan Assembly [D]. Replacement Replacement Reverse removal procedure. Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-69...

  • Page 153: Rep 10.5 Tr-Sw10 Interlock Switch & Tr-Q1 Interlock Sensor

    Remove Front cover ( REP 10.0 Front and Rear Cover). Note position and remove connectors [A] (x5). Remove screws [B] to remove interlock box (x4). TR-Q1 TR-SW1.2 TR-SW1.4 TR-SW1.3 TR-SW1.1 Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-70...

  • Page 154: Rep 10.6 Protection Cover

    Protection cover consists of two parts [C] and [D]. Unhook and remove [C] from [D]. [D] remains in the Trimmer. Replacement Reverse removal procedure. Make sure that [C] and [D] latches properly. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-71...

  • Page 155: Rep 10.7 Tr-Q8 Trim Bin Full Sensor

    Remove screw and sensor TR-Q8 [A]. Disconnect connector P31 and sensor [B]. Lift out the Trim waste chute. Replace sensor TR-Q13 [C]. Replacement Reverse removal procedure. Replacement Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-72...

  • Page 156: Rep 10.9 Tr-Q2 Infeed Shaft Sensor

    Remove Rear Cover (REP 10.0 Front and Rear Cover). Remove screw (x1) and sensor TR-Q2 [A]. Remove screw (x1) and sensor TR-Q3 [A] . Replacement Replacement Reverse removal procedure. Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-73...

  • Page 157: Rep 10.11 Tr-M1 Transport / Knife Motor

    Reverse removal procedure. Check adjustment according to ADJ 10.13 TR-Q4 Transport Belt Sensor. Tension the support chain so there is no slack when tightening the screws (x3) [C]. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 158: Rep 10.13 Tr-M2 Trim Knife Motor

    If it is difficult to mount sprocket remove master link [D]. Reverse the removal procedure. Tension the chain so there is no slack when tightening screws. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-75...

  • Page 159: Rep 10.14 Tr-Q5 Trim Knife Home Position Sensor

    Use a 7 mm wrench to remove the two nuts securing the encoder disc. Remove disc. Check on the LCD that sensor TR-Q5 changes state when blocked/unblocked by actuators on the encoder disc. Remove sensor TR-Q5 [B]. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-76...

  • Page 160: Rep 10.15 Knife Guard

    Loosen the screw [A] and simultaneously keep the spacer [B] in position, until the knife protection plate come loose. Lift out and remove the knife guard [C]. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 161: Rep 10.16 Upper Trim Knife

    Assemble the transport protection plate by tighten the screws (x2) [A]. Remove the upper knife by removing the screws (x6) [B]. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-78...

  • Page 162: Rep 10.17 Lower Trim Knife

    10. When the lowest position is reach by the upper knife, then loosen the two outer screws [E]. Make sure that the springs are able to move the lower knife against the upper knife. Continued on next page Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)
  • Page 163 If it begins to be heavy to hand crank it is better to run the trim knife motors in service mode. 10 (5 sheets booklet) , 26 (13 sheets booklet) , 74 (37 sheets booklet) , 100 ( 50 sheets booklet) Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-80...

  • Page 164: Rep 10.18 Tr-Q14 Paper Path & Tr-Q6 Exit Sensor

    Disconnect connector J21 [A]. Loosen screws (x2) [B]. Remove screws (x4) [C]. Pull out the Paper path bracket [D]. Remove sensor TR-Q14 and/ or TR-Q6. Replacement Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-81...

  • Page 165: Rep 10.19 Stop Gate Carriage

    Remove Front and Rear cover (REP 10.0 Front and Rear Cover). Remove Protective cover (REP 10.6 Protection Cover). Remove connectors J20 and J21 [A]. Remove connectors, labeled TR-M4 and TR-Q12 (x2) [B]. Continued on next page Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-82...

  • Page 166: Rep 10.20 Tr-M3 Stop Gate Motor

    When positioning the carriage in place, make sure the two sliding rods and the gear rack enters their holes and slots. Sensor Reverse removal procedure (BQ 21 Stop Gate Carriage). TR-Q7 Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-83...

  • Page 167: Rep 10.21 Tr-M4 Length Adjustment Motor & Tr-Q12 (M4) Motor Encoder

    If trimming is skew, then the screw [C] need to be turned until the trim result is satisfactory. Remove Motor TR-M4 [A] and Sensor TR-Q12 [B]. Sensor TR-Q12 is included in the motor TR-M4 . Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 168: Rep 10.22 Lower Exit Belts And Foam Rollers

    Removal lower foam rollers Remove lower exit belts according to previos section. Remove the pulleys and e-clips. Remove the foam rollers [A]. Continued on next page Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-85...
  • Page 169 Mount and ensure the Paper guides are placed under the belt and not above [B]. Ensure the Paper guides are placed under the belt and not above [B]. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 170: Rep 10.23 Upper Exit Belts And Foam Rollers

    Remove e-clips (x2) [D]. (One on each side of the machine), unhook the linkage arms (x2) [E] and remove needle bearing (x2). Continued on next page Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-87...
  • Page 171 The belt tension can be adjusted by tighten the tension roller and screws (x2) [A]. NOTE: Remove e-clips (x6) and sprocket [B]. Ensure correct position of the linkage arm [B]. Remove foam rollers [C]. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-88...

  • Page 172: Rep 10.24 Transmission Chain

    Unhook spring [D]. Remove transmission chain [D]. Remove transmission chain [E]. Loosen motor screws (x3) [F]. Remove support chain [G]. Replacement Continued on next page Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-89...

  • Page 173: Rep 10.26 Knife Chain

    Tension the chain so there is no slack when tightening screws. Remove the safety block by turning the camshaft in reversed direction. Use the holes in the camshaft. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 174: Rep 10.27 Infeed Belts

    (x2) towards the center of the shafts [H]. 10. Tilt the shafts out through the cut-outs in the side frames. 11. Remove the infeed belts. Continued on next page Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-91...
  • Page 175 Pull the strips, the applied forces, F and F between belts should be approximately equal [I]. If the applied forces is not equal, adjust screws (x2) [E] until equality is obtained. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-92...

  • Page 176: Rep 10.28 Md6Dc Pcb "A

    Remove all connectors from the PCB (x8). Pinch the barbs of the four pins [A] and lift out the PCB. A.P4 A.P7 A.P6 A.P11 A.P13 A.P3 A.P14 A.P2 Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-93...

  • Page 177: Rep 10.29 Latch, Docking

    Tighten screws [A] (x4) and nuts [B] (x2). Replacement Reverse removal procedure. Note! At replacing, position set screw so point is hitting hole on the flat side of the shaft. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-94...

  • Page 178: Rep 10.31 Plunger, Upper Knife Beam

    Lift up plunger and remove retaining ring and Nylon washers (2x) [A]. Drop down plunger with spring and remove [B]. For the rest of replacement reverse removal procedure. Weaker spring Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-95...

  • Page 179: Rep 11.0 Front And Rear Cover

    Remove Rear Cover by loosen screws (x2) [B]. Loosen nuts [B] (x2). Tilt machine (REP 11.4 Tilt the Machine). Loosen nuts [C] (x2). Replacement Replacement Reverse removal procedure. Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-96...

  • Page 180: Rep 11.2 Exit Cover Assembly

    Loosen screws [A] (x2). Remove screws [B] (x2). Remove upper part of exit cover (continue to remove lower cover). Replacement Replacement Reverse removal procedure. Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-97...

  • Page 181: Rep 11.3 Top Cover

    NOTE: Press plastic stud from pivot point. Mark the position for the hinges [C]. Loosen screws [D] (x4). Replacement Reverse removal procedure (ADJ 11.3 Top Cover). Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-98...

  • Page 182: Rep 11.4 Tilt The Machine

    Place the Service bracket [A] at the base [E]. Turn foot screw on the Service bracket, until the Service bracket firmly contacts the floor [F]. Continued on next page Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-99...
  • Page 183 10. If latch looks like [P], secure it with screw from removing from front and rear cover. View from Below Replacement Reverse removal procedure. WARNING: Carefully observe that latch [N] does not come out of slot [O] during repair. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-100...

  • Page 184: Rep 11.5 Antistatic Brushes

    NOTE: The Orange wire on ”+” (or 1), and the Violet wire on ”-” (or 0). Reverse the rest of the removal procedure. Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-101...

  • Page 185: Rep 11.7 Sqf-M2 Stop Gate Motor

    Remove cam by loosening allen screw [A] (x1). Remove needle bearing [B]. Disconnect connectors labeled SQF-M2 and SQF-Q10 [C]. Remove screws [D] (x3) and remove the bearing support [E] from the motor SQF-M2. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-102...

  • Page 186: Rep 11.8 Sqf-M3 Clamp Motor

    Remove nuts (x4) [D]. Pull out the motor assembly. Remove the screw, washer and the gear/bearing assembly [E]. Remove the screws (x3) [F]. [ I ] Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-103...

  • Page 187: Rep 11.9 Sqf-M4 Roll Motor

    14. Tilt the machine (REP 11.4 Tilt the Machine). 15. Remove screws (x2) [J] and the bearings with the shafts. 16. Loosen screws (x2) [K]. Continued on next page Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-104...
  • Page 188 Tighten the timing belt until no slack. Tighten screw (x1) [P] when belt tension is good. Adjust bearings according to ADJ 11.9. ≈ 2 mm Continued on next page Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-105...

  • Page 189: Rep 11.10 Sqf-Q1 (M2) Stop Gate Sensor

    Tilt the Machine (REP 11.4 Tilt the Machine). Disconnect connector [A] (x1). Remove screw [B] and sensor [C]. min. 2 mm Replacement 1. Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-106...

  • Page 190: Rep 11.11 Sqf-M4 Roll Motor, Sqf-Q2 (M4) Right Sensor & Sqf-Q3 (M4) Left Sensor

    Disconnect connector to sensor SQF-Q2 / SQF-Q3 . Remove screw [B] (x1). Remove screw [B] (x1). Sensor Q2 Sensor Q3 Replacement Replacement Reverse removal procedure. Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-107...

  • Page 191: Rep 11.13 Sqf-Q5 Infeed Sensors

    Remove Lower Exit cover (REP 11.2 Exit Cover Assembly). Remove cable ties [F]. Remove Phototransistor. White Black White Black Replacement Replacement Reverse removal procedure. Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-108...

  • Page 192: Rep 11.15 Sqf-Q6 Clamp Sensor

    Ensure that the encoder disc is not in contact with the motor connectors, minimum distance approximately 2 mm [ H ]. If not possible, bend the connectors. Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)
  • Page 193 Fig 2. Springs in lower positions Replacement Reverse removal procedure. Ensure the springs are mounted as the recorded position (fig 1 or 2). Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-110...
  • Page 194 Do not switch the position of the right and left pulleys/shaft assemblies [B] when re-assemble. SW2.2 SW2.4 SW2.3 SW2.1 Replacement Reverse removal procedure. Check adjustment according to (ADJ 11.18 SQF-SW1 Interlock Switch). Continued on next page Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-111...
  • Page 195 Fig 1: Springs in upper positions (default setting) Ensure that one end of the spring is into the upper or lower position, and the other end centered on the infeed cover. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-112...
  • Page 196 Unhhok the belts and remove the roller shaft assembly [E]. Note the direction of the roller shaft. Slide out the lower transport belt shaft [F]. Continued on next page Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-113...
  • Page 197 Movement should not be possible if turning counter clockwise. [ I ] Check that SQF-Q5 is correctly connected (white on short leg, black on long leg). Re-assemble infeed cover (REP 11.1 Infeed Cover). Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-114...
  • Page 198 Lift the upper Feed belt assembly. Lift the lower Feed belt and remove Teflon tape. Replacement Mount the new teflon tape straps between the cut-outs for the rollers. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-115...
  • Page 199 12. Remove the springs (x2) on both sides [M]. 13. Remove the pins (x2) [N] (attached to the lower set clamp), when pulling out the lower set clamp. Continued on next page Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-116...
  • Page 200 11. Mount lower Paper guides with screws (x4) [D]. 12. Un-tilt the machine. 13. Mount Exit cover (REP 11.2 Exit Cover Assembly). 14. Check REP 11.23 Stop Gate. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-117...
  • Page 201 Run 6 sheet booklets of 80 gsm (20lb bond), from the Copier. Check appearance of booklets according to pictures below. If results are not good, proceed to BQ 12 Not Good Good Not Good Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-118...
  • Page 202 Remove Cover (REP 11.0 Front and Rear Cover). Remove all connectors from PCB [A] (x8). OFF/CLOSED Remove PCB by squeezing barbs [B] on the standoffs (x4) securing PCB. DIP Switch settings Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-119...
  • Page 203 Turn off the power and disconnect the power plug. Remove Belt stacker. Remove the connector cover by removing nuts [A] ( x 4). Replacement Reverse the removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-120...
  • Page 204 Open Slide Door slightly and remove Front Cover by lifting [D]. Turn off the main power and disconnect the power cord. Remove screws (x2) [A]. Remove Rear Cover by lifting [B]. Replacement Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-121...
  • Page 205 Remove Exit Cover [D]. Turn off the main power and disconnect the power cord. Remove screws (x4) [A]. Remove Infeed Cover [B]. Replacement Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-122...
  • Page 206 Removal Turn off the main power and disconnect the power cord. Open Top Cover. Loosen nuts (x6) [A] Remove Top Cover [B]. Replacement Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-123...
  • Page 207 Remove Interlock actuator [B]. Loosen screws (x2) [C] and relieve spring tension. Remove lock nuts and screws (x4) [D]. Remove counter balance springs (x3) [E]. Remove screws (x4) [F]. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-124...
  • Page 208 10. Remove screw [G] and fold out the mounting plate [H]. 11. Remove screws (x2) [I] on rear side. 12. Remove Top Cover Assembly. Replacement 1. Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-125...
  • Page 209 Disconnect connectors (x4) [E]. (Note position of leads) Pinch locking tabs and remove Interlock Switch [F]. Replacement Reverse removal procedure (ADJ 12.6 Interlock Switch Slide Door). Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-126...
  • Page 210 Note position of leads and disconnect connectors [B] (x4). Remove Interlock Switch, Slide Door. Replacement Replacement Reverse removal procedure (ADJ 12.6 Interlock Switch Slide Door). Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-127...
  • Page 211 Turn off the main power and disconnect the power cord. Open Top Cover. Remove the screw [A]. Disconnect the connector [B] . Remove the Exit Sensor (CT-Q7) [C]. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-128...
  • Page 212 Pull the slide out to get better access to the motor. Remove screws (x4), nuts (x4) and washers (x4) [B]. Remove Drive Motor [C]. Replacement Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-129...
  • Page 213 Loosen screw, relieve tension and tighten screw [A]. Remove Drive Motor (CT-M1) Primary Timing Belt [B]. Note Routing. [ A] Replacement Reverse removal procedure (ADJ 12.10 Drive Motor (M1) Primary Timing Belt). Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-130...
  • Page 214 Remove the Rear Cover (REP 12.0 Front and rear cover). Relieve Timing Belt tension by loosening screw [A]. Tighten screw [A]. Remove Drive Motor (M1) Secondary Timing Belt [B]. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)
  • Page 215 Remove E-clips and bearings [B] . Remove screw [A]. Remove Infeed Idler Roller [C]. Remove Infeed Drive Shaft [B]. Replacement Replacement Reverse removal procedure. Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-132...
  • Page 216 Loosen set screw [B] and remove O-ring pulley [C]. Remove retaining screw [D] Remove Exit Drive Shaft [E]. Replacement Replacement Reverse removal procedure. Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-133...
  • Page 217 Parts List on PL 12.46 Removal Turn off the main power and disconnect the power cord. Open the Top Cover. Remove Exit Idler Roller [A]. Replacement Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-134...
  • Page 218 Remove the Front and Rear Cover (REP 12.0 Front and rear cover). Remove screws (x2), washers (x2), and spacers (x2) on front and rear side [A]. Remove Exit Baffle [B]. Replacement Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-135...
  • Page 219 Remove screws and bearing retainers [A] (x2) on both front and rear side. Remove springs [B] on front and rear side (x2). rear side Replacement Reverse removal procedure. front side Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-136...
  • Page 220 14. Remove screws [L] (x2), screw and front side bearing retainer [M] and Guide Plate [N]. 15. Remove Post Trimmer Fixing Roller [K]. Replacement Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-137...
  • Page 221 Remove Primary Timing Belt (REP 12.9 Drive Motor (CT-M1) Primary Timing Belt). Remove Secondary Timing Belt (REP 12.10 Drive Motor (M1) Secondary Timing Belt). Remove screw [A]. Remove Transmission Shaft. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-138...

  • Page 222: Rep 12.20 Lower Drive Shaft

    Unlatch and pull out the Slide to disengage the Drive Dog. Loosen allen screw [D]. Remove Drive Dog [E] Replacement Reverse removal procedure (ADJ 12.23 Lower Drive Shaft). Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-139...

  • Page 223: Rep 12.21 Chassis Counter

    Removing screw [A] and folding out mounting plate [B] facilitates access. Disconnect connector [C]. Pinch locking tabs and remove Chassis Counter [D]. Replacement Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-140...

  • Page 224: Rep 12.22 Waste Transport Belt

    Remove the Drive Shaft [B] by pulling out and up. On the rear side, remove the indler Shaft [C]. Remove the Waste Transport Belt [D]. Replacement 1. Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-141...

  • Page 225: Rep 12.23 Waste Bin Full Sensor (Ct-Q11)

    Turn off the main power and disconnect the power cord. Remove screw [A]. Remove Sensor Cover [B]. Disconnect connector [C]. Remove screw [D]. Remove the Waste Transport Sensor (CT-Q11) [E]. Replacement Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-142...

  • Page 226: Rep 12.24 Waste Transport Sensor (Ct-Q14)

    Undock the Booklet Maker (REP 1.0 Undocking BM / TR / SQF). Remove the Exit Cover (REP 12.1 Infeed and Exit cover). Disconnect connector [A]. Remove screw [B]. Remove screw [C]. Remove the Waste Transport Sensor (Q14). Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-143...

  • Page 227: Rep 12.25 Upper Drive Shaft

    10. Slide the Flex Coupling off the Fixing Roller shaft [I] Loosen set screw, remove pulley and spacer [C]. Replacement 1. Reverse removal procedure (ADJ 12.28). Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-144...

  • Page 228: Rep 12.26 Rotator Sensor (Ct-Q2)

    Remove Rotator Sensor (CT-Q2). Loosen Timing Belt tension by loosening the idler pulley screw [A]. Remove Rotator Timing Belt. Replacement Replacement Reverse removal procedure. Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-145...

  • Page 229: Rep 12.28 Rotator Disengage Solenoid (Ct-Sol1)

    Solenoid and PCB to fail. orange connector Ensure the orange connector is mounted on the indicated side. Same side as line on the Diode. Indicated side Line on Diode Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-146...

  • Page 230: Rep 12.29 Rotator Disengage Solenoid (Ct-Sol1) Idler Shaft

    Note the position of the shims between ball bearing and press nuts. Remove Rotator Disengage Solenoid (SOL1) Mechanism [C]. Replacement Replacement Reverse removal procedure. Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-147...

  • Page 231: Rep 12.31 Rotator Disengage Solenoid (Ct-Sol2)

    Solenoid and PCB to fail. orange connector Ensure the orange connector is mounted on the indicated side. Same side as line on the Diode. Indicated side Line on Diode Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-148...

  • Page 232: Rep 12.33 Rotator Disengage Solenoid (Ct-Sol2) Mechanism

    Remove screws (x2) [B]. Note position of shims between ball bearing and press nuts. Remove Rotator Disengage Solenoid (CT-SOL2) Mechanism [C]. Replacement Replacement Reverse removal procedure. Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-149...

  • Page 233: Rep 12.34 Rotator Upper Drive Shaft

    Remove screw and retainer [D]. 10. Remove Lower Drive Shaft from bracket [E]. 11. Remove Lower Drive Shaft. Replacement Replacement Reverse removal procedure. Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-150...
  • Page 234 Disconnect motor plug J.P2 on Stepper motor driver PCB “J” [A]. Free harness from cable ties [B]. Remove nuts (x2) [C] and remove bracket with motor. Remove screws (x4) [D]. Remove Motor (CT-M3) from bracket [E]. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-151...
  • Page 235 Remove Rotator Motor (CT-M3) Drive Shaft [B]. Unlatch and pull out the Slide. Remove screw [A]. Remove the lead screw by turning [B]. Replacement Replacement Reverse removal procedure. Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-152...
  • Page 236 Disconnect motor plug D.P2 on Stepper motor driver PCB “D” [B]. Free harness from tie wraps [C]. Remove motor screws (x4) [D] . Remove Registration Width Adjustment Motor (CT-M4) [E]. Replacement Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-153...

  • Page 237: Rep 12.40 Registration M4 Home Sensor (Ct-Q3)

    Remove the Rear Cover (REP 12.0 Front and rear cover). Unlatch and pull out the Slide. Disconnect connector [A]. Remove screws and lock nuts (x2) [B]. Remove Registration M4 Home Sensor (CT-Q3). Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-154...

  • Page 238: Rep 12.41 Registration Cross Rolls Drive Shaft

    [E]. rear side of slide Replacement Reverse removal procedure. Timing Belt Tension is set according to ADJ 12.44 For routing Timing Belt, see REP 12.45. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-155...

  • Page 239: Rep 12.42 Registration Cross Rollers Timing Belt

    Remove the Registration Cross Rollers Drive Shaft (REP 12.41 Registration Cross Rolls Drive Shaft). Remove the Registration Cross Rollers Timing Belt pulley [A] Remove the Registration Cross Rollers Timing Belt [B]. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-156...

  • Page 240: Rep 12.43 Registration Cross Rollers

    Push the Slide in and latch it. Secondary Alignment Rail (REP 12.48 and REP 12.49). Remove screws (x4) [A]. Remove Flexible Shaft Assemblys with Cross Rollers [B]. Replacement Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-157...

  • Page 241: Rep 12.44 Registration Cross Rollers Idler Rollers

    1. Reverse removal procedure. Adjustments according to (ADJ 12.47 Registration Cross Rollers 1. Reverse removal procedure. Adjustments according to (ADJ 12.47 Registration Cross Rollers Idler Roller). Idler Roller). Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-158...

  • Page 242: Rep 12.45 Registration Primary Alignment Rail

    Replacement Replacement Reverse removal procedure. Adjustments according to Reverse removal procedure. Adjustments according to ADJ 12.48 Registration Primary Alignment Rail. ADJ 12.49 Registration Secondary Alignment Rail. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-159...

  • Page 243: Rep 12.47 Registration Disengage Solenoid (Ct-Sol5)

    Remove locknut, Washers (x2), Spacers (x4) to detach the Solenoid plunger from the mechanism linkage [B]. Remove nuts (x2) [C] and the Bracket. Remove screws (x4) [D] and the Disengage Solenoid (CT-SOL5) from the Bracket. Continued on next page. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-160...

  • Page 244: Rep 12.48 Registration Disengage Solenoid (Sol5) Linkage

    Ensure the orange connector is mounted on the indicated side. Same side as line on the Diode. Indicated side Line on Diode Replacement Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-161...

  • Page 245: Rep 12.49 Creaser Assembly

    Disconnect Creaser Trigger Sensor (CT-Q4) Photo Transistor [C]. Open cable holders (x3) and free harness [D]. Disconnect sensor [E]. 10. Open cable holders (x3) and free harness [F]. Continued on next page. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-162...
  • Page 246 Replacement Reverse removal procedure ADJ 12.52 Creaser Assembly. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-163...

  • Page 247: Rep 12.50 Creaser Trigger Sensor (Ct-Q4) Led

    Remove Creaser Trigger Sensor (CT-Q4) Phototransistor. Replacement Replacement Reverse removal procedure Reverse removal procedure ADJ 12.54 Creaser Trigger Sensor (CT-Q4) Phototransistor. ADJ 12.54 Creaser Trigger Sensor (CT-Q4) Phototransistor. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-164...

  • Page 248: Rep 12.52 Creaser Tools Home Sensor (Ct-Q5)

    Remove Creaser Tools Home Sensor (CT-Q5). Replacement Replacement Perform ADJ 12.56 Creaser Timing Belt. Reverse removal procedure ADJ 12.55 Creaser Tools M6 Home Sensor (CT-Q5). Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-165...

  • Page 249: Rep 12.54 Creaser Tools

    11. Remove plunger mechanism [F]. 12. Remove screws (x8) and remove guide brackets (x2) [G]. 13. Remove Creaser Tools [H]. Replacement Reverse removal procedureADJ 12.57 Creaser Tools. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-166...

  • Page 250: Rep 12.55 Creaser Motor (Ct-M6)

    Unlatch and pull out the Slide. Remove Creaser Assembly (REP 12.49). Remove Creaser Timing Belt (REP 12.53). Loosen screw and remove Pulley [A]. Remove screws (x4) [B]. Remove Creaser Motor (CT-M6). Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-167...

  • Page 251: Rep 12.56 Creaser Baffle

    Open cable holders (x3) and free harness [B]. Remove springs (x2) [C]. Remove stand offs [D]. Remove screws (x2) [E]. Remove Creaser Baffle [F]. Replacement Reverse removal procedure ADJ 12.59 Creaser Baffle. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-168...

  • Page 252: Rep 13.0 Bleed Trimmer Drive Shaft

    Remove the Rear Cover (REP 12.0 Front and rear cover). Remove Timing Belt [A]. Remove screw and Bearing Retainer [B]. Pull out the Bleed Trimmer Drive Shaft [C]. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-169...

  • Page 253: Rep 13.1 Bleed Trimmer Upper Knives

    Ensure that the mating surfaces between the knife and knife shaft are thoroughly wiped clean before reassembly. Any wobble of the blades cutting edge will have impact on cutting accuracy. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)
  • Page 254 - The curved part ot the Waste Guide is inside the circumference of the lower knife [N]. rear side (non operator side) knives viewed from rear side paper travelling direction Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-171...

  • Page 255: Rep 13.2 Bleed Trimmer Lower Knives

    5mm (13/64”) waste strips to pass in-between the lower knife and the Waste Guide. Also check that there is some clearance between the arc of the Waste Guide and the Gills Guide Shaft. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-172...

  • Page 256: Rep 13.3 Bleed Trimmer Ct-M7 Home Sensor (Ct-Q6)

    Remove the Rear Cover (REP 12.0 Front and rear cover). Disconnect connector [A]. Remove screws and lock nuts (x2) [B]. Remove Bleed Trimmer CT-M7 Home Sensor (CT-Q6). Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-173...

  • Page 257: Rep 13.4 Bleed Trimmer Width Adjustment Motor (Ct-M7)

    Free harness from cable holders [C]. Remove screws fastening motor (x4) [D]. Remove Timing Belt [E]. Remove Bleed Trimmer Width Adjustment Motor (CT-M7) [F]. Replacement Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-174...

  • Page 258: Rep 13.5 Bleed Trimmer Disengage Solenoid (Ct-Sol3)

    Refer to Step 1 in the Replacement process. Failure to re-connect properly might cause Solenoid and PCB to fail. Remove screw (linkage from lever) [C]. Continued on next page. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-175...

  • Page 259: Rep 13.6 Bleed Trimmer Disengage Shaft

    Replacement Same side as line on the Diode. Reverse removal procedure ADJ 13.7 Bleed Trimmer Disengage Shaft. Indicated side Line on Diode Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-176...

  • Page 260: Rep 13.7 Bleed Trimmer Gratings Upper

    Remove Bleed Trimmer Gratings Upper. Remove screws (x2), compress gratings and remove guide shaft [B]. Remove Bleed Trimmer Gratings Lower. Replacement Replacement Reverse removal procedure. Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-177...

  • Page 261: Rep 13.9 Slide Guide

    Unlatch and pull out the Slide. Remove screws (x4) [B], pull out the slide. Remove the Slide Guide. Intentionally blank PCB mounting plate folded down for clarity Replacement Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-178...

  • Page 262: Rep 13.10 Slide Drive Shaft Transportation

    If necessary, tension the belt so that there is no slack. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 263: Rep 13.11 Transportation Disengage Solenoid (Ct-Sol4)

    Remove Transportation Disengage Solenoid (CT-SOL4). Ensure the ORN connector is mounted on the indicated side. orange connector Same side as line on the Diode. Indicated side Line on Diode Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-180...

  • Page 264: Rep 13.12 Transportation Disengage Solenoid (Ct-Sol4) Idler Shaft

    Remove screws (x2) [B]. Note position of shims between ball bearing and press nuts. Remove Idler Shaft [C]. Remove Transportation Disengage Solenoid (SOL4) Mechanism [C]. Replacement Replacement Reverse removal procedure. Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-181...

  • Page 265: Rep 13.14 Slide Latch Mechanism

    Loosen set screw and remove stop collar and washer [C]. Remove Slide Latch Mechanism. Pull out the shaft towards the rear. Intentionally blank Replacement Reverse removal procedure (ADJ 13.15 Slide Latch Mechanism). Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-182...

  • Page 266: Rep 13.15 Slide Fixing Roller

    Remove the Drive Dog (REP 12.25). Remove screw and bearing retainer [D] on the front side. Move the Fixing Roller [E] slightly to the front side. Replacement 1. Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-183...

  • Page 267: Rep 13.16 Slide "B" Baffle

    Remove nuts (x2) [B]. From rear side, remove screws (x2) [A]. Remove Slide ”B” Paper [B]. Remove Slide ”B” Baffle. Replacement Replacement Reverse removal procedure. Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-184...

  • Page 268: Rep 13.18 Slide "C" Baffle

    Remove E-clip [A]. Remove screws (x2) [A]. Remove nuts (x2) and Baffle [B]. Remove Slide ”C” Paper Path [B]. Replacement Replacement Reverse removal procedure. Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-185...

  • Page 269: Rep 13.20 Slide L/H Lower (Ct-Sol4) Baffle

    On the front and rear side, remove screws (x2), washer (x2) and spacer (x2) [E]. Remove Slide L/H Lower (CT-SOL4) Baffle assembly [F]. Replacement Reverse removal procedure Connecting SOL4 connectors (REP 13.12 Transportation Disengage Solenoid (CT-SOL4) Idler Shaft ). Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-186...

  • Page 270: Rep 13.21 Slide R/H Lower Baffle

    Remove Registration Solenoid SOL5 Trigger Sensor (CT-Q10). Remove Slide R/H Lower Baffle [D]. Replacement Replacement Reverse removal procedure Connecting SOL4 connectors Reverse removal procedure. (ADJ 13.21 Slide R/H Lower Baffle). Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-187...

  • Page 271: Rep 13.23 Cpu / Controller Pcb "A

    Release PCB from plastic studs (x4) [C]. Remove CPU Controller PCB ”A”. Replacement Reverse removal procedure. A new CPU / Controller PCB ”A” must be loaded with S/W. Refer to section 5. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-188...

  • Page 272: Rep 13.24 Solenoid Driver Pcb "B

    Ensure DIP switches are set according to below schematic figure. Reverse removal procedure. A new Solenoid Driver PCB ”B” must be loaded with S/W. Refer to section 5. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 273: Rep 13.25 Stepper Motor Driver (M7) Pcb "C

    Ensure DIP switches are set according to below schematic figure. Reverse removal procedure. A new “C” Stepper Motor Driver PCB must be loaded with S/W. Refer to section 5. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-190...

  • Page 274: Rep 13.26 Stepper Motor Driver (M4) Pcb "D

    Ensure DIP switches are set according to below schematic figure. Reverse removal procedure. A new “D” Stepper Motor Driver PCB must be loaded with S/W. Refer to section 5. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 275: Rep 13.27 Stepper Motor Driver (M1) Pcb "E

    Ensure DIP switches are set according to below schematic figure. Reverse removal procedure. A new “E” Stepper Motor Driver PCB must be loaded with S/W. Refer to section 5. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-192...

  • Page 276: Rep 13.28 Pcb Printer Interface Pcb "F

    2 Ensure that all eight positions of SW1 are set to OFF (pointing away from J1) before install. 3. Perform a NVM reset (GP 20) to download S/W into the PCB Printer Interface PCB ”F”. Plockmatic BM3050 system 27 August 2019 3.

  • Page 277: Rep 13.29 I/O Extension Pcb "G

    Remove screw and fold out PCB [A] Disconnect connectors (x3) [B]. Release PCB from plastic studs (x4) [C]. Remove I/O Extension PCB ”G”. Replacement Reverse Removal Procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-194...

  • Page 278: Rep 13.30 Stepper Motor Driver (M6) Pcb "H

    Ensure DIP switches are set according to below schematic figure. Reverse removal procedure. A new “H” Stepper Motor Driver PCB must be loaded with S/W. Refer to section 5. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 279: Rep 13.31 Stepper Motor Driver (M3) Pcb "J

    A new “J” Stepper Motor Driver PCB must be loaded with S/W. Refer to section 5. Ensure that the CAN End Termination plug is transferred to the new PCB J.J6. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 280: Rep 13.32 Scp (Short Circuit Protection) Pcb "K

    Release PCB from plastic studs (x2) [B]. Remove SCP (Short Circuit Protection) PCB ”L”. Remove SCP (Short Circuit Protection) PCB ”K”. Replacement Replacement Reverse removal procedure. Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-197...

  • Page 281: Rep 13.34 Scp (Short Circuit Protection) Pcb "M

    Remove the Exit Cover (REP 12.1 Infeed and Exit cover). Remove the Front Cover (REP 12.0 Front and rear cover). Remove screws [A] [x4) and remove cover [B]. Replacement Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-198...

  • Page 282: Rep 13.35 Scp (Short Circuit Protection) Pcb "N

    Remove the Exit Cover (REP 12.1 Infeed and Exit cover). Disconnect connectors (x2) [A]. Release PCB from plastic studs (x4) [B]. Remove SCP (Short Circuit Protection) PCB ”N”. Intentionally blank Replacement Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-199...

  • Page 283: Rep 13.36 12V Power Supply Unit

    Loosen screws (x2) [B] and tilt PSU package [C]. Disconnect leads from 24 V PSU terminal [D]. 10. Remove the 12V PSU Power Supply Unit. Replacement Reverse removal procedure (ADJ 13.36). Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-200...

  • Page 284: Rep 13.37 24V Power Supply Unit (1)

    10. Disconnect leads from 24 V PSU terminal [D]. 11. Remove the 24V PSU 1 (Power Supply Unit 1) from Support bracket. Replacement Reverse removal procedure (ADJ 13.37 24V Power Supply Unit (1). Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-201...

  • Page 285: Rep 13.38 24V (48V) Power Supply Unit (2)

    10. Remove the 24V (48 V) PSU 2 (Power Supply Unit 2) from Support bracket. Replacement Reverse removal procedure (ADJ 13.38 24V (48V) Power Supply Unit (2)). Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 286: Rep 13.39 High Voltage Power Supply Unit (Optional, For Antistatic Bars)

    - Remove Antistatic Bars Waste Transport (Figure 3). - Remove component(s) from the High Voltage Power Supply Unit (Figure 4). Figure 1: Removal High Voltage Power Supply Unit Continued on next page. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-203...
  • Page 287 BAR 1B: BAR 2B: Remove nuts (x2). Open tie wraps and free harness. Open tie wraps and free harness. Remove nuts (x2). Continued on next page. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-204...
  • Page 288 Remove screws (x2). Disconnect connector. REL2 Remove screws (x4). Figure 4: Removing component(s) from the High Voltage Power Supply Unit TR2: Disconnect connector. Remove screws (x4). Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-205...

  • Page 289: Rep 13.40 Interlock Relay (Ct-Rel1)

    Loosen screws (x2) [E], tilt the PSU unit and remove it from frame. 10. Disconnect connectors (x6) [F]. 11. Remove the Interlock Relay (CT-REL1) [G]. Replacement Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-206...

  • Page 290: Rep 13.41 Temp Sensor (Ct-Q13)

    Remove ”E” Stepper Motor Driver PCB (REP 13.27). Disconnect connector [A]. Remove nuts (x2) [B]. Remove Temp Sensor (CT-Q13). Replacement Reverse removal procedure. Replacement Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-207...

  • Page 291: Rep 14.0 Cover, Rear

    3. Tilt out top [C] 2. Open the front door [E] 4. Remove cover 3. Lift and remove front cover Replacement Replacement Reverse removal procedure Reverse removal procedure Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-208...

  • Page 292: Rep 14.2 Cover, Bin

    Reverse removal procedure. When tightening nuts for door, push door in the direction shown. Ensure that the door closes properly and has even gaps around the edges. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 293: Rep 14.4 Cover, Upper Exit

    1. Remove Cover, Upper Exit (REP 14.4) 2. Slide cover [B] upwards 2. Press Cover, Top in arrow direction and remove Replacement Replacement Reverse removal procedure Reverse removal procedure Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-210...

  • Page 294: Rep 14.6 Cover, Side

    (REP 14.8 Replacement Section). Make sure that the Reverse removal procedure belt tensioner is tensioning the belt correctly and then torque the screw [B]. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-211...

  • Page 295: Rep 14.8 Tray Table

    [D] until the bin tray is flush against the rulers. When the tray table is level, tension the timing belt. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 296: Rep 14.9 Solenoid Sol101/201

    6. Replace solenoid in reverse order 7. Adjust position of solenoid so that the tray locking latch engagement distance is 1-2mm when the solenoid is activated Replacement Reverse removal procedure Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-213...

  • Page 297: Rep 14.11 Torsion Spring, Paper Stop Upper, Side Guides

    5. Loosen set screw [A] and remove timing wheel and spacer 6. Remove screws [B] Replacement Reverse removal procedure Apply pre-tension of 70° - 120° to spring before mounting Continued on next page..Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-214...
  • Page 298 7. Remove screws [C] and screw cover [D] (on relevant screw assy) 8. Remove Lead Screw Assembly [E] Replacement Reverse removal procedure. Adjust/reinstall timing belt using REP 14.7 Level Tray Table using REP 14.8 (Replacement Section) Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-215...
  • Page 299 Replacement Reverse removal procedure Make sure to mount timing pulley using measured position [E] Note! Torque the set screw against flat surface [I] on motor shaft. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-216...

  • Page 300: Rep 14.14 Side Guide Adjustment Cable

    Replacement Replacement Reverse removal procedure Reverse removal procedure Note! Before torquing screws [B], move the sleds [D] as far inwards as possible Continued on next page..Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-217...
  • Page 301 5. Check that the mechanism moves easily up and down on both ends of the shaft 6. Repeat this at the other end of the shaft if necessary (REP 14.16) Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 302: Rep 14.16 Pivot Bracket Ib (Af602 V1)

    6. Remove screws [F], unhook belt [G] and remove timing pulley [H] Replacement 1. Reverse removal procedure 2. Mount plate [K] in upper position Adjustment See Adjustment Instructions, Section 14.15 - Same procedure but mirrored Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-219...

  • Page 303: Rep 14.17 Timing Belt Long, Feed Roller

    5. Tilt shaft and remove belt [D] Replacement Replacement Reverse removal procedure 1. Reverse removal procedure 2. Perform Calibration Optical DSD according to BM3050 Operator Manual, AF602 Feeder Settings Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-220...

  • Page 304: Rep 14.19 Pcb Sensor (Q101Pht, Q201Pht) (Optical Dsd)

    2. Perform Calibration Optical DSD according to BM3050 Operator Manual, AF602 Feeder Settings Replacement 1. Reverse removal procedure 2. Perform Calibration US DSD BM3050 Operator Manual, AF602 Feeder Settings Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-221...

  • Page 305: Rep 14.21 Pcb White Led Lamp (Lamp101, Lamp201)

    1. Remove Cover tray (3.3.3) 2. Remove screw [A] 3. Unhook LED cover [B] 4. Unscrew screw and nuts [C] 5. Disconnect connector Replacement Reverse removal procedure Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-222...
  • Page 306 4. Remove screw [E] 5. Remove gear shaft Replacement 1. Reverse removal procedure 2. Make sure that belt tension is as before and fasten screws [A, B] Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-223...

  • Page 307: Rep 14.24 Chain

    14.6). At a minimum, remove Cover, Rear (REP 14.0) 3. Remove screws and washers [A]; remove chain frame [B] 4. Move out the upper bin Replacement Reverse removal procedure Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-224...

  • Page 308: Rep 14.25 Structural Shaft/Associated Parts (Af602 V2)

    7. The structural shaft and associated brackets/parts may now be lifted out of the tray Replacement Replace parts as necessary on structural shaft. Reverse removal procedure to re-mount. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-225...

  • Page 309: Rep 14.26 Feeder Shaft Assembly / Separator Arm Assembly

    [B] to obtain a play of 0.2-0.7mm (using a hammer to knock out the pin as shown) 2. Reinstall separator arm assembly 3. Verify that the feed roller shaft falls down easily Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-226...

  • Page 310: Rep 14.27 Exit Sensor

    5. Loosen screw [D] on belt tensioner 6. Loosen tension on belt and unhook belt from motor Replacement Reverse removal procedure Continued on next page..Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-227...

  • Page 311: Rep 14.29 Drive Shaft, Paper Path

    [D] loosen screw [E] and gently push down the beam (same on back side) Measure Replacement Replacement Reverse removal procedure Reverse removal procedure Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-228...

  • Page 312: Rep 14.30 Drive Shaft, Exit Feed

    2. Remove Cover, Front (REP 14.1) 3. Remove spring [B] 4. Remove retaining rings [C] 5. Remove bearing blocks [D] and idler shaft Replacement Replacement Reverse removal procedure Reverse removal procedure Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-229...

  • Page 313: Rep 14.32 Coupling Shaft

    6. Remove screws [E] and remove the coupling shaft Replacement Reverse removal procedure. Check voltage levels by performing applicable part of RAP018 12/24/48V Low or High (section 4) Replacement Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-230...

  • Page 314: Rep 14.34 Power Supply Sp-240-24 (Psu2) 24 Vdc

    Check voltage levels by performing applicable part of RAP018 12/24/48V Low or High (section 4) Replacement Reverse removal procedure. Check voltage levels by performing applicable part of RAP018 12/24/48V Low or High (section 4) Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-231...

  • Page 315: Rep 14.36 Relay Dpno 16A/250V

    3. Calibrate Optical DSD sensor (Q201) according to BM3050 Operators Connect according to marking on connectors and relay Manual, AF602 Sensor Calibration Section Continued on next page..Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-232...

  • Page 316: Rep 14.38 Support Pcbs

    5. Make sure the DIP switches are in the correct position (see either sec- PCB CPU APP 32 tion 4 or section 8 of the Service Manual) fig. PCB M21H Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-233...

  • Page 317: Rep 14.39 Bin Interlock Switch

    4. Disconnect connectors from interlock switch 5. Pinch locking tabs on switch and remove the interlock switch [B] Replacement Reverse removal procedure Replacement Reverse removal procedure Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-234...

  • Page 318: Rep 15.0 Cover, Rear

    2. Open the front door [E] 3. Tilt out top [C] 3. Lift and remove front cover 4. Remove cover Replacement Replacement Reverse removal procedure Reverse removal procedure Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-235...

  • Page 319: Rep 15.2 Cover, Bin

    Reverse removal procedure. When tightening nuts for door, push door in the direction shown. Ensure that the door closes properly and has even gaps around the edges. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 320: Rep 15.4 Cover, Upper Exit

    1. Remove Cover, Upper Exit (REP 15.4) 2. Slide cover [B] upwards 2. Press Cover, Top in arrow direction and remove Replacement Replacement Reverse removal procedure Reverse removal procedure Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-237...

  • Page 321: Rep 15.6 Cover, Side

    1. Loosen screws [A] (x2) 1. Remove screws [A] (x4) 2. Lift cover up and out 2. Remove cover Replacement Replacement Reverse removal procedure Reverse removal procedure Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-238...

  • Page 322: Rep 15.8 Timing Belt

    Reverse removal procedure. After replacing the belt, ensure that the tray table is level (REP 15.9 Replacement Section). Make sure that the belt tensioner is tensioning the belt correctly and then torque the screw [B]. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 323: Rep 15.9 Tray Table

    5. Put a piece of duct tape on the paper stop of each fan to keep it down when lifting tray table up, see picture [C] 6. Lift out the tray table *Feeder Assembly hidden for clarity *Feeder Assembly hidden for clarity Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-240...

  • Page 324: Rep 15.10 Solenoid Sol 102/202 (Bin Lock Solenoid)

    Hold the solenoid in place and push down the link arm [D] orange connector Ensure the orange connector is mounted on the indicated side. Same side as line on the Diode. Indicated side Line on Diode Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-241...
  • Page 325 • Remove vacuum fan assembly to access screws [A], torque screws [A] to secure the solenoid in noted location 3. Re-attach vacuum fan assembly to tray Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-242...

  • Page 326: Rep 15.12 Blower Fans And Fan Exhaust Plastic Inserts

    4. Remove Insert 4. Unhook harness from cable holders [B] 5. Loosen nuts [C] (2x) 6. Slide fan out Replacement Replacement Reverse removal procedure Reverse removal procedure Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-243...

  • Page 327: Rep 15.13 Separation Fan Replacement (Fan105, Fan 205)

    The nominal position of the bracket (and hence separation fan) is when holes [D] are perfectly aligned with the holes in the separation frame. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 328: Rep 15.15 Torsion Spring, Paper Stop Upper (Side Guides)

    5. Loosen set screw [A] and remove timing wheel and spacer 6. Remove screws [B] Replacement Reverse removal procedure Apply pre-tension of 70° - 120° to spring before mounting Continued on next page..Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-245...
  • Page 329 7. Remove screws [C] and screw cover [D] (on relevant screw assy) 8. Remove Lead Screw Assembly [E] Replacement Reverse removal procedure. Adjust/reinstall timing belt using REP 15.8. Level Tray Table using REP 15.9 (Replacement Section). Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-246...
  • Page 330 Replacement Reverse removal procedure Make sure to mount timing pulley using measured position [E] Note! Torque the set screw against flat surface [I] on motor shaft. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-247...

  • Page 331: Rep 15.18 Side Guide Adjustment Cable

    2. Perform Calibration Optical DSD according to BM3050 Operator Before torquing screws [B], move the sleds [D] as far in as possible Manual, VF602 Sensor Calibration Section Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 332: Rep 15.20 Pcb Sensor (Q101Pht, Q201Pht) (Optical Dsd)

    2. Perform Calibration Optical DSD according to BM3050 Operator Manual, VF602 Sensor Calibration Settings Replacement 1. Reverse removal procedure 2. Perform Calibration US DSD BM3050 Operator Manual, VF602 Sen- sor Calibration Settings Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-249...

  • Page 333: Rep 15.22 Pcb White Led Lamp (Lamp101, Lamp201)

    2. Remove screw [A] and make sure to hold spacer [B] not to drop it into the machine. 3. Unhook LED cover [C] 4. Unscrew screws and nuts [D] (2x) 5. Disconnect connector and remove PCB Replacement Reverse removal procedure Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-250...

  • Page 334: Rep 15.24 Gear Shaft Timing Wheel

    [A] and sliding the separator pad [B] up/down (from outside the tray) Replacement 1. Reverse removal procedure 2. Make sure that belt tension is as before and fasten screws [A, B] Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-251...

  • Page 335: Rep 15.26 Chain

    15.6). At a minimum, remove Cover, Rear (REP 15.0) 3. Remove screws and washers [A]; remove chain frame [B] 4. Move out the upper bin Replacement Reverse removal procedure Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-252...

  • Page 336: Rep 15.27 Vacuum Belt

    9. With the [G] shafts loose, remove/replace vacuum belts by pulling them over the support bracket in the direction shown. After belts are in place, re-mount [G] shafts. Replacement Reverse removal procedure Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-253...

  • Page 337: Rep 15.28 Upper Support Assy

    REP 15.28 Upper Support Assy (VF602 Spare Parts Manual, PL5.0 Item 1) Plockmatic recommends replacing the entire upper support assembly when any of the components in the assembly malfunctions. For advanced technicians, Individual Paper Stops (Spare PL5.0 Item 2) are available.
  • Page 338 US Distance Sensor Top Upper Support Assy Front View Bottom Upper Support Assy (bin covers hidden for clarity) Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-255...

  • Page 339: Rep 15.29 Exit Sensor (Q303)

    5. Loosen screw [D] on belt tensioner 6. Loosen tension on belt and unhook belt from motor Replacement Reverse removal procedure Continued on next page..Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-256...

  • Page 340: Rep 15.31 Drive Shaft, Paper Path

    For the bottom shaft you need to move away two beams on front and back [D] loosen screw [E] and gently push down the beam (same on back side) Measure Replacement Replacement Reverse removal procedure Reverse removal procedure Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-257...

  • Page 341: Rep 15.32 Drive Shaft, Exit Feed

    2. Remove Cover, Front (REP 15.1) 3. Remove spring [B] 4. Remove retaining rings [C] 5. Remove bearing blocks [D] and idler shaft. Replacement Replacement Reverse removal procedure Reverse removal procedure Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-258...

  • Page 342: Rep 15.34 Baffle Hardware

    -Other Baffle Tension Springs [B] require 70-120 degrees pre-tension -Leave a 1-2mm gap between locking nut [C] and standoff [D] to allow for middle baffle to rotate freely Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 343: Rep 15.35 Sp Sensor

    3. Remove Fan and Fan Bracket (REP 15.12) 4. Disconnect SP sensor connector 5. Remove screws [A] (2x) 6. Remove the SP sensor Replacement Reverse removal procedure Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-260...

  • Page 344: Rep 15.36 Vacuum Fan Assembly

    4. Disconnect connectors from vacuum solenoid and vacuum fan 5. Note position of screws [A] (2x) in slotted holes and remove them 6. Remove entire vacuum fan assembly Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 345: Rep 15.37 Coupling Shaft

    6. Remove screws [E] and remove the coupling shaft Replacement Reverse removal procedure. Check voltage levels by performing applicable part of RAP018 12/24/48V Low or High (section 4) Replacement Reverse removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-262...

  • Page 346: Rep 15.39 Power Supply Sp-240-24 (Psu2) 24Vdc

    Check voltage levels by performing applicable part of RAP018 12/24/48V Low or High (section 4) Replacement Reverse removal procedure. Check voltage levels by performing applicable part of RAP018 12/24/48V Low or High (section 4) Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-263...

  • Page 347: Rep 15.41 Relay Dpno 16A/250V

    3. Calibrate Optical DSD sensor (Q201) according to BM3050 Operators Reverse removal procedure. Manual, VF602 Sensor Calibration Section Connect according to marking on connectors and relay Continued on next page..Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-264...

  • Page 348: Rep 15.43 Support Pcbs

    5. Make sure the DIP switches are in the correct position (see either sec- fig. tion 4 or section 8 of the Service Manual) PCB CPU APP 32 fig. PCB M21H Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-265...

  • Page 349: Rep 15.44 Bin Interlock Switch

    4. Disconnect connectors from interlock switch 5. Pinch locking tabs on switch and remove the interlock switch [B] Replacement Reverse removal procedure Replacement Reverse removal procedure Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-266...

  • Page 350: Rep 15.46 Transformer (Tr1)

    3. Disconnect harness [B], remove screws [C] (x2) and slide out the high voltage PSU 4. Disconnect connector between TR1 and REL303 5. Remove screws/nuts [D] (x4) and remove TR1 Replacement Reverse removal procedure Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-267...

  • Page 351: Rep 16.1 Docking/Undocking Twc

    Open the Schackle [E] to remove the Safety Wire [F] from the Conveyor support [G] and move the TWC away from the RCT. continued on next page Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 352: Rep 16.2 Docking/Undocking Twc, Continues

    Attach the other end of the Safety Wire around the Conveyour Support with a shackle [E] Tighten the schackle firmly with a pair of pliers or an adjustable spanner. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 353: Rep 16.3 Cable Protection

    Loosen nuts (x3) [A]. Remove screw [A]. Remove the Belt Protection [B]. Remove the Cable Protection [B]. Replacement Replacement Reverse the removal procedure. Reverse the removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-270...

  • Page 354: Rep 16.6 Antistatic Brush

    Remove the Belt Protection (REP 15.2). Remove screws (x4) [A]. Remove the Antistatic Brush [A]. Remove the Tray assembly [B]. Replacement Replacement Reverse the removal procedure. Reverse the removal procedure. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-271...

  • Page 355: Rep 16.7 Support Rollers

    With the Idler Roller, Drive Shaft and Conveyor Belt in place, adjust the Corrugator Roller so that the Belt is as close to the Plastic Waste Guides (see REP 15.7) as possible without touching them. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 356: Rep 16.9 Plastic Waste Guides

    Remove the Caster Bracket [B]. Reverse the removal procedure. The Waste Guides should snap into position. Replacement Reverse the removal procedure. Adjustment Check adjustment of the Corrugator Roller (REP 15.6). Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-273...

  • Page 357: Rep 16.11 Idler Roller

    Ensure that the clips [B] on the bearings are on the outside of the Lower Frame. NOTE Ensure that the clips [C] on the bearings are on the outside of the Upper Frame. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 358: Rep 16.13 Conveyor Belt

    Hook up the O-ring [A] on the Pulleys [B] and [C] as shown in order to to make the Conveyor NOTE Belt go in the desired transport direction. Install all parts before attempting to adjust the Corrugator Roller. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-275...

  • Page 359: Adj 1.6 Interlock Switch Assembly

    Loosen screws [G] (two on each side) to to move the rollers [B] in/out ( x4 ) Tighten screws after adjustment. figure 2 figure 3 Continued on next page. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-276...
  • Page 360 In wiring diagram, the switch as a unit is named BM-SW1. It actually consists of two switches. One software (BM-SW17) and one hardware safety interlock switch BM-SW16. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 361: Adj 4.1 Staple Quality

    Y= The distance between the paper and the right clincher If difference not within range proceed to next step, otherwise proceed to step 19. Continued on next page. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)
  • Page 362 19. Check staple position along the traveling position, see next two sections : “Adjustment staple position cross process direction” “Adjustment staple position in process direction”. [H]. Continued on next page. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-279...
  • Page 363 Move sheets a couple of cm’s (an inch) up towards the infeed and press [Cycle both staplers]. Verify function by repeating a couple of times. Continued on next page. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-280...
  • Page 364 Measure the distances x and y from lead edge to staple. Distances must not differ more than 0.2mm. If they do, repeat step 2. A certain variation in staple forming must be accepted. Exit service mode. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-281...

  • Page 365: Adj 4.2 Set Transport Calibration

    6 digits (steps). The adjustment is now completed. 13. Re-assemble the staple bracket assembly [D]. 14. Check that staple position along paper travelling direction is proper (ADJ 4.1 Staple Quality). Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 366: Adj 4.3 Set Transport Drive

    To adjust the tension, loosen screws (x2) [A]. Adjust the tension by moving the motor [B] and tighten the screws [A]. Too much tension will affect the speed negatively. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 367: Adj 6.1 Bm-M8 Stop Gate Folder Motor, Bm-Q7Stop Gate Folder Sensor & Bm-Q48 Clinch Trigger Sensor Right

    Check that the distance between the paper guide fold stop [A] and the lower paper guide of the exit cover [D] is within 1.5 ± 1 mm ( 0.6 ± 0.04”). If not within range, adjust the lower paper guides of the exit cover by reforming. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 368: Adj 6.4 Fold Transmission Chain

    After tightening nuts [B], re-check the distance between the Upper folder rollers [A]. Lubricate with Molybdenum grease, on the upper side [D] of the Cams to the upper folder rollers and the plastic wire guides. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 369: Adj 6.7 Lower Fold Roller

    The fold rollers [C] should then have been moved symmetric from each other (with a max. tolerance of 3 mm difference). If not, adjust the nuts [A] and repeat step 2. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 370: Adj 10.1 Top Cover

    Adjustment Loosen screws [A] (x4). Adjust Top cover so frame edge [B] is aligned with top of the hinge [C]. Tighten screws(x4) and nuts [A] (x4). Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-287...

  • Page 371: Adj 10.5 Tr-Sw10 Interlock Switch & Tr-Q1 Interlock Sensor

    Tighten screws after adjustment. Loosen screws [B] (two on each side) to to move the rollers [G] in/out (x4) Tighten screws after adjustment. figure 1 Continued on next page. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-288...
  • Page 372 In wiring diagram, the switch as a unit is named TR-SW1. It actually consists of two switches. One software (TR-SW10) and one hardware safety interlock switch TR-SW9. On the Trimmer there is also an interlock sensor TR-Q1. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 373: Adj 10.13 Tr-Q4 Transport Belt Sensor

    / unblocked. Re-position sensor to obtain the correct speed registration. Tighten screw [A]. TR-Q11 ADJ 10.19 Lower Trim Knife Adjustment See REP 10.17 Lower Trim Knife. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-290...

  • Page 374: Adj 11.3 Top Cover

    Adjustment Loosen screws [A] (x4). Adjust Top cover so frame edge [B] is aligned with top of the hinge [C]. Tighten screws(x4) and nuts [A] (x4). Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-291...

  • Page 375: Adj 11.9 Sqf-M4 Roll Motor Assembly

    If clearance outside range, proceed to next step. Adjust the position of the bearings by moving the screw with bearing in the slot [F]. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-292...

  • Page 376: Adj 11.18 Sqf-Sw1 Interlock Switch

    Tighten screws after adjustment. Loosen screws [B] (two on each side) to to move the rollers [G] in/out (x4) Tighten screws after adjustment. figure 1 Continued on next page. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-293...
  • Page 377 In wiring diagram, the switch as a unit is named SQF-SW1. It actually consists of two switch- es. One software (SQF-SW2) and one hardware safety interlock switch SQF-SW3. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 378: Adj 12.6 Interlock Switch Slide Door

    Slide Door is closed (Figure 1). Figure 1 Adjusting Slide Door and Interlock Switch Slide Door Actuator Loosen counter nuts and adjust magnet. Loosen screws (x2) and adjust Actuator. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-295...

  • Page 379: Adj 12.10 Drive Motor (M1) Primary Timing Belt

    Push the tensioner in the direction of the spring [B], let relax and re-tighten the screw [A]. Turn the Drive Motor (CT-M1) Primary Timing Belt Pulley clockwise 2 revolutions [C]. Repeat step 1-2. Intentionally blank Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-296...

  • Page 380: Adj 12.11 Drive Motor (Ct-M1) Secondary Timing Belt

    Push the tensioner in the direction of the spring [B], let relax and tighten the screw [B]. Turn the Drive Motor (CT-M1) Secondary Timing Belt Pulley clockwise 2 revolutions [C]. Repeat step 1-2. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-297...

  • Page 381: Adj 12.12 Docking Bracket, Infeed

    The sheets OB (outboard) edges [A] should enter the CST at the corresponding mark on the label [B] ± 3mm (0.12”). If not, the infeed docking bracket on the CST must be adjusted. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 382: Adj 12.13 Docking Bracket, Exit

    Adjust Exit Docking Bracket [D] to achieve tolerance. Tighten screws and dock Booklet Maker to the CST. Repeat until alignment is correct. sheet (non-operator side) edge sheet (operator side) edge Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-299...

  • Page 383: Adj 12.23 Lower Drive Shaft

    NOTE: Exessive axial compression or tension will reduce life of the Flex Coupling. Figure 1 : Position of Flex Coupling Figure 1: Position of Flex Coupling Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-300...
  • Page 384 Figure 1 when activated. Figure 1 : Rotator Disengage Solenoid (CT-SOL1) position, activated Figure 1: Rotator Disengage Solenoid (SOL2) position, activated Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-301...

  • Page 385: Adj 12.43 Registration M4 Home Sensor (Ct-Q3)

    Measure Operator side waste strip and calculate the difference in 0.1 mm units. (Difference = Operator side measured width - Operator side theoretical width). Adjust NVM value if the difference is bigger than ± 0.5 mm. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 386: Adj 12.44 Registration Cross Rollers Drive Shaft

    [B] in order to help distribute tension evenly over the entire belt. Let relax and tighten the screw [A]. Turn the CT-M1 pulley counter clockwise 2 revolutions [C]. Repeat step 1 and 2 once more. rear side of slide Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-303...

  • Page 387: Adj 12.47 Registration Cross Rollers Idler Roller

    Tighten lock nut [D]. Turn these screws counterclock- Turn these screws counterclock- wise 2 turns when adjusting wise 3 turns when adjusting Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-304...

  • Page 388: Adj 12.48 Registration Primary Alignment Rail

    [G] Measure 5±1mm (13/64±3/64) viewed from secondary alignment rail side viewed from secondary alignment rail side to be able to point at nuts [B] Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-305...

  • Page 389: Adj 12.49 Registration Secondary Alignment Rail

    [D] viewed from secondary alignment rail side Process direction Turn the adjustment screw counter clock- wise to remedy this misalignment. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-306...

  • Page 390: Adj 12.50 Registration Disengage Solenoid (Ct-Sol5)

    Loosen screws (x2) and position solenoid linkage in contact with ball bearings (Figure1). Tighten screws. Position the Home Position Bracket so that there is 1±0.5 mm play (Figure 1). Figure 1 : Adjusting Registration Disengage Solenoid (CT-SOL5) Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-307...

  • Page 391: Adj 12.52 Creaser Assembly

    (non operator side) edge. Hold the Creaser Space Unit [C] and loosen screws [D] (x2). Position the Creaser As- sembly so that the Crease is perpendicular within ±0.5 mm. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 392: Adj 12.54 Creaser Trigger Sensor (Ct-Q4) Phototransistor

    Calculate the difference in 0.1mm units. Difference = Measured distance from Lead Edge - Theoretical distance from Lead Edge. Adjust NVM value if the difference is bigger than ±0.5mm. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 393: Adj 12.56 Creaser Timing Belt

    If not, relax belt tension and repositon pulleys [C] and [D]. Tighten screw [G]. Loosen the screws [E] and [F]. Groove is leading Process direction Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-310...

  • Page 394: Adj 12.57 Creaser Tools

    Perform Creaser Timing Belt adjustment (ADJ 12.56) Check that tools not interfere on any side by turning them in process direction with CT- M6 pulley. NOTE: Viewed from front side of module. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-311...

  • Page 395: Adj 12.59 Creaser Baffle

    Calculate the difference in 0.1 mm units. Difference = Measured Width - Theoretical Width . Adjust NVM value if the difference is bigger than ± 0.5 mm. 4±0,5mm 0.1575±0.0197” Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-312...

  • Page 396: Adj 13.6 Bleed Trimmer Disengage Solenoid (Ct-Sol3)

    Ensure that Solenoid lever is in contact with the stop when screws (x4) are tightened [A]. Loosen screw and position solenoid linkage to achieve 2±0.5mm (5/64±1/64”) when solenoid is closed [B]. Tighten screw. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 397: Adj 13.12 Transportation Disengage Solenoid (Sol4)

    Loosen screws (x2). Position solenoid CT-SOL4 and tighten the screws to achieve the play according to below figure (when activated). Transportation Disengage Solenoid (CT-SOL4) position, activated. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-314...

  • Page 398: Adj 13.15 Slide Latch Mechanism

    Attach the handle [B] and set the anvil (Allen screw) [C] so that the handle is vertical ±0.5° in closed position. Set the anvil (Allen screw) [D] so that the handle [B] is horizontal ±0.5° in open position. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ)

  • Page 399: Adj 13.21 Slide R/H Lower Baffle

    To set the output voltage of the PSU correctly. Adjustment Measure Voltage between V - (Ground) and V+ (24 VDC). Set the voltage to 24±0.1 VDC by adjusting the potentiometer at +V ADJ. Plockmatic BM3050 system 27 August 2019 3. Repairs and adjustments (REP and ADJ) 3-316...
  • Page 400 CT-119 PCB Printer Interface PCB “F” No Internal communication ......4-24 Rotator Disengage Solenoid CT-SOL2 RAP ..............4-51 CT-120 Solenoid Driver PCB “B” No CAN communication ......... 4-25 Bleed Trimmer Disengage Solenoid CT-SOL3 RAP ............. 4-52 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP)
  • Page 401 Antistatic Bars Exit (optional) RAP ................4-87 BM-023 Stop Gate Folder Motor BM-M8 Short Circuit ..........4-116 Cooling Fan (FAN1) RAP ....................4-88 BM-024 Stop Gate Folder Motor BM-M8 Open Circuit ..........4-116 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP)
  • Page 402 BM-409 Unfinished set in compiler ................4-173 BM-150 30VDC low at Lower MD6DC PCB “C” ............4-144 BM-501 Staples, Low Stapler Right BM-Q46 ............... 4-174 BM-151 30VDC very low at Lower MD6DC PCB “C” ..........4-145 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP)
  • Page 403 RS232 Program Loading Chassis 9-P D-sub RAP ............4-235 Square Folder does not square form a 4 sheet booklet RAP ........4-235 SQF-001 Transport Belt Motor SQF-M1 Short circuit ..........4-209 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP)
  • Page 404 Perform RAP 002 Ultrasonic DSD (Double Sheet Detection) ........4-281 TR-152 TR-SW1 Software signal TR-SW10 RAP ............4-264 RAP 107/207 Bin Empty, Bin A/B .................. 4-283 TR-153 Interlock Sensor Faulty TR-Q1 ................ 4-266 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP)
  • Page 405 RAP 107/207 Bin Empty, Bin A/B .................. 4-347 RAP 025 BIN Switch Software Signal ................4-314 RAP 108/208 Too Thin, Bin A/B ..................4-348 RAP 026 CPU PCB ”A” ....................4-315 RAP 027 CPU PCB ”H” ....................4-317 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP)
  • Page 406 CR-112 Stepper motor driver CR-M1 PCB “G” No CAN communication ....4-409 RAP 028 CPU PCB ”L” ....................4-383 CR-113 Stepper motor driver CR-M1 PCB “H” No CAN communication ....4-409 RAP 029 Door Switch Interlock Circuit ................ 4-385 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP)
  • Page 407 RAP 018 Top Cover Switch Interlock circuit ............... 4-429 RAP 019 Top Cover Switch software signal ..............4-430 RAP 020 SCP PCB ”K” ....................4-431 RAP 021 SCP PCB ”L” ....................4-432 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP)
  • Page 408 • Verify that paper delivery from the upstream device is delivered to the booklet maker per that device specification. Go to the RAP for the fault code displayed. • Go to the Blank UI (no backlight) RAP. Continued on next page. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP)
  • Page 409 Continued on next page. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-10...
  • Page 410 Booklet Maker is powered on with broken F1 fuse. If F1 fuse blows while Booklet maker is powered on CR-150 will be indicated (Communication lost). Note: Always use original fuses. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-11...
  • Page 411 • Check communication cable. • Go to the RAP for the fault code displayed. Go to the RAP for the fault code displayed. Go to the UI Blank (no backlight) RAP. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-12...
  • Page 412 Registration Width Adjustment Motor (M4) works OK. Registration Width Adjustment Motor (M4) works OK. Go to Registration Width Adjustment Motor (M4) RAP. Go to Registration Width Adjustment Motor (M4) RAP. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-13...
  • Page 413 Bleed Trimmer Width Adjustment Motor (M7) works OK. Bleed Trimmer Width Adjustment Motor (M7) works OK. Go to Bleed Trimmer Width Adjustment Motor (M7) RAP. Go to Bleed Trimmer Width Adjustment Motor (M7) RAP. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-14...
  • Page 414 Ensure that the creaser tool critical parameters are correctly adjusted (ADJ 12.57 Creaser Tools). Parameters are correctly adjusted. Go to (REP 12.54 Creaser Tools ) and (ADJ 12.57 Creaser Tools). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-15...
  • Page 415 Registration Width Adjustment Motor (M4) works OK. Bleed Trimmer Width Adjustment Motor (M7) works OK. Go to Registration Width Adjustment Motor (M4) RAP. Go to Bleed Trimmer Width Adjustment Motor (M7) RAP. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-16...
  • Page 416 Go to Creaser Motor (M6) RAP. Ensure that the creaser tool critical parameters are correctly adjusted (ADJ 12.56 & 12.57). Parameters are correctly adjusted. Go to (REP 12.55) and (ADJ 12.57). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-17...
  • Page 417 • Ensure that the Entrance Sensor CT-Q1 (PL 12.19) is clean. • Check that there are no obstructions in the paper path. Procedure • If fault persists after the initial actions. Go to the Communication RAP. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-18...
  • Page 418 Measure also that there is no short circuit between E.J6-1 to E.J6-2. There is continuity and no short circuit. Repair or replace harness (PL 12.6). Go to Stepper Motor Driver (M1) PCB “E” RAP. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-19...
  • Page 419 • Measure also that there is no short circuit between E.J6-1 to E.J6-2. There is continuity and no short circuit. Repair or replace harness (PL 12.6). Go to Stepper Motor Driver (M3) PCB “J” RAP. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-20...
  • Page 420 • Measure also that there is no short circuit between E.J6-1 to E.J6-2. There is continuity and no short circuit. Repair or replace harness (PL 12.6). Go to Stepper Motor Driver (M4) PCB “D” RAP Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-21...
  • Page 421 • Measure also that there is no short circuit between E.J6-1 to E.J6-2. There is continuity and no short circuit. Repair or replace harness (PL 12.6). Go to Stepper Motor Driver (M6) PCB “H” RAP Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-22...
  • Page 422 • Measure also that there is no short circuit between E.J6-1 to E.J6-2. There is continuity and no short circuit. Repair or replace harness. Go to Stepper Motor Driver (M7) PCB “C” RAP Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-23...
  • Page 423 “F). The communication fault remains. Exit. Replace Ribbon Cable between A.P8 and F.P2. The communication fault remains. Exit. Replace CPU/ Controller, PCB “A” (REP 13.24 CPU / Controller PCB “A”). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-24...
  • Page 424 • Measure also that there is no short circuit between E.J6-1 to E.J6-2. There is continuity and no short circuit. Repair or replace harness (PL 12.6). Go to Solenoid Driver PCB “B” RAP Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-25...

  • Page 425: Stepper Motor Driver Pcb "E" Voltage Too Low

    • Ensure that connectors G.P1, G.P2 and G.P3 are properly connected. (REP 13.29 I/O Extension PCB “G”). Procedure Procedure Go to Stepper Motor Driver (M3) PCB “J” RAP Go to Stepper Motor Driver (M1) PCB “E” RAP Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-26...

  • Page 426: Stepper Motor Driver Pcb "D" Voltage Too Low

    I/O Extension PCB “G”)) (REP 13.29 I/O Extension PCB “G”). Procedure Procedure Go to Stepper Motor Driver (M6) PCB “H” RAP Go to Stepper Motor Driver (M4) PCB “D” RAP Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-27...
  • Page 427 (REP 13.29 I/O Extension PCB “G”) (REP 13.29 I/O Extension PCB “G”) Procedure Procedure Go to Solenoid Driver PCB “B” RAP Go to Stepper Motor Driver (M7) PCB “C” RAP Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-28...
  • Page 428 Open top cover and keep the slide door closed (or use cheater), wait 30 Seconds, Measure voltage between A.P1-8 and A.P-12 (Signal and Ground). measure voltage between N.P2-1 and M.P2-8 (48V and Ground). The voltage is below 0.5VDC Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-29...
  • Page 429 Repair harness Measure resistance between SW3-4 and A.P1-9 There is continuity. Repair harness Replace PCB “A” Controller (REP 13.23 CPU / Controller PCB “A”) Close the top cover (or use cheater). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-30...

  • Page 430: Bad Eeprom

    CT-141 Bad EEPROM An NVM value is bad. Procedure • Perform GP 20 Reset. • Re-load S/W (GP 19). • Replace PCB “A” Controller (REP 13.23 CPU / Controller PCB “A”). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-31...

  • Page 431: Can Communication With Booklet Maker Interrupted

    Check the harness between Controller PCB A, P4 and J23 for continuity and short circuit. There is continuity and no short circuit. Repair harness Check the harness between Controller PCB A, P5 and P24 for continuity and short circuit. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-32...

  • Page 432: Temp Sensor Ct-Q13 Failed Rap

    Measure resistance between Q13-3 and D.P7-10 (black wire). There is continuity. Repair harness Measure resistance between Q13-1 (red wire) and chassis. There is continuity. Measure resistance between Q13-2 (white wire) and chassis. There is continuity. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-33...

  • Page 433: Temp Sensor Ct-Q13 Overheated Rap

    Measure resistance between Q13-3 and D.P7-10 (black wire). There is continuity. Repair harness Replace CT-Q13 (REP 13.42) Replace PCB “D” (PL 12.13) (REP 13.26 Stepper Motor Driver (M4) PCB “D”). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-34...

  • Page 434: Entrance Sensor Ct-Q1 Activated Too Long

    Ensure that the CST is correctly installed. Installation is OK. Check first for paper path misalignment and Interface Cable. Installation is OK. Re-install CST. Go to AF602/VF602 RAP006 ICAN Communication Entry Re-install CST. Go to AF602/VF602 RAP006 ICAN Communication Entry Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-35...
  • Page 435 Rotator Disengage Solenoid (SOL2) and mechanism works OK. Go to Rotator Disengage Solenoid (SOL2) RAP. Check rotator disengage solenoid SOL2 according to GP4. Rotator Disengage Solenoid (SOL2) and mechanism works OK. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-36...
  • Page 436 Check rotator disengage solenoid SOL1 according to GP4. Rotator Disengage Solenoid (SOL1) and mechanism works OK. Go to Rotator Disengage Solenoid (SOL1) RAP. Check rotator disengage solenoid SOL2 according to GP4. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-37...

  • Page 437: Registration Solenoid Sol5 Trigger Sensor

    Check rotator disengage solenoid SOL2 according to GP4. Rotator Disengage Solenoid (SOL2) and mechanism works OK. Go to Rotator Disengage Solenoid (SOL2) RAP Check rotator disengage solenoid SOL2 according to GP4. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-38...

  • Page 438: Registration Solenoid Sol5 Trigger Sensor Ct-Q10 Activated Too Long

    RAP, and check that transportation drive and idler rollers are in good working order. Drive and Idler Rollers are OK. Fix problem Check rotator disengage solenoid SOL2 according to GP4. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-39...

  • Page 439: Creaser Trigger Sensor Ct-Q4 Not Activated In Time

    Check rotator disengage solenoid SOL1 according to GP4. Rotator Disengage Solenoid (SOL1) and mechanism works OK. Go to Rotator Disengage Solenoid (SOL1) RAP. Check rotator disengage solenoid SOL2 according to GP4. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-40...

  • Page 440: Creaser Trigger Sensor Q4 Activated Too Long

    Check rotator disengage solenoid SOL2 according to GP4. Rotator Disengage Solenoid (SOL2) and mechanism works OK. Go to Rotator Disengage Solenoid (SOL2) RAP Check rotator disengage solenoid SOL2 according to GP4. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-41...

  • Page 441: Exit Sensor Ct-Q7 Not Activated In Time

    Creaser Motor (M6) works OK. Go to Creaser Motor (M6) RAP. Go to Creaser Motor (M6) RAP. Ensure that the CST is correctly installed. Check first for paper path misalignment and Interface Cable. Installation is OK. Re-install CST Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-42...

  • Page 442: Creaser Tools M6 Home Sensor Ct-Q5 Not Activated In Time

    Creaser Motor (M6) RAP. Ensure that the Creaser Tool Critical parameters are correctly adjusted (ADJ 12.57 Creaser Tools). Parameters are correctly adjusted. Go to (REP 12.57) and (ADJ 12.57 Creaser Tools). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-43...

  • Page 443: Waste Bin Full Sensor Ct-Q11 Activated

    Connect plug A.P1 to CPU/Controller PCB A and plug G.P1 to I/O extension PCB “G”. Check for voltage at the P/J Q11 connector between pins 1 (red wire, 5 V) and 3 (black wire, Ground) Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP)

  • Page 444: Drive Motor Ct-M1 Rap

    Repair harness. Check for voltage at E.P3 between pins E.P3-1 and E.P3-2. The Voltage is 48VDC±10% Go to Stepper Motor Driver (M1) PCB “E” RAP Replace Drive Motor CT-M1 (REP 12.8). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-45...

  • Page 445: Rotator Motor Ct-M3 Rap

    Repair harness. Check for voltage at J.P3 between pins J.P3-1 and J.P3-2. The Voltage is 48VDC±10% Go to Stepper Motor Driver (M3) PCB “J” RAP. Replace Rotator Motor (M3) REP 12.36). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-46...

  • Page 446: Registration Width Adjustment Motor Ct-M4 Rap

    Check for voltage at C.P3 between pins D.P3-1 and D.P3-2. The Voltage is 48VDC±10% Go to Stepper Motor Driver (M4) PCB “D” RAP Replace Registration Width Adjustment Motor (M4) (REP 12.39). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-47...

  • Page 447: Creaser Motor Ct-M6 Rap

    Check for continuity between pins H.P2-3 and H.P2-4. There is continuity between pins H.P2-3 and H.P2-4. There is continuity and no short circuit. Repair harness. Check for voltage at H.P3 between pins H.P3-1 and H.P3-2. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-48...

  • Page 448: Bleed Trimmer Width Adjustment Motor Ct-M7 Rap

    The M4 system works OK? Replace the Stepper Motor Driver (M4) PCB “D” (PL 12.13) Check for continuity between pins C.P2-1 and C.P2-2. Check for continuity between pins C.P2-3 and C.P2-4. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-49...

  • Page 449: Rotator Disengage Solenoid Ct-Sol1 Rap

    Measure between the orange connector on the solenoid and B.P2-5. There is continuity. Repair Wire Harness. Go to Solenoid Driver PCB “B” RAP Replace Solenoid SOL1 (REP 12.28 Rotator Disengage Solenoid (CT-SOL1)). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-50...

  • Page 450: Rotator Disengage Solenoid Ct-Sol2 Rap

    Measure between the orange connector on the solenoid and B.P2-6. There is continuity. Repair Wire Harness. Go to Solenoid Driver PCB “B” RAP Replace Solenoid SOL2 (REP 12.31 Rotator Disengage Solenoid (CT-SOL2)). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-51...

  • Page 451: Bleed Trimmer Disengage Solenoid Ct-Sol3 Rap

    Measure between the orange connector on the solenoid and B.P2-7. There is continuity. Repair Wire Harness. Go to Solenoid Driver PCB “B” RAP Replace Solenoid SOL3 (REP 13.5 Bleed Trimmer Disengage Solenoid (CT-SOL3)). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-52...

  • Page 452: Transportation Disengage Solenoid Ct-Sol4 Rap

    Measure between the orange connector on the solenoid and B.P2-5. There is continuity. Repair Wire Harness. Go to Solenoid Driver PCB “B” RAP Replace Solenoid SOL4 (REP 13.11 Transportation Disengage Solenoid (CT-SOL4)). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-53...
  • Page 453 Measure between the orange connector on the solenoid and B.P2-6. There is continuity. Repair Wire Harness. Go to Solenoid Driver PCB “B” RAP Replace Solenoid SOL5 (REP 12.47 Registration Disengage Solenoid (CT-SOL5)) Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-54...
  • Page 454 The voltage is 5 VDC ±10%? Repair wire harness Replace Entrance Sensor (CT-Q1)REP 12.6 The Paper Entrance Sensor (Q1) works OK? Replace CPU / Controller PCB “A” (REP 13.23 CPU / Controller PCB “A”) Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-55...
  • Page 455 Replace Paper Rotator Sensor Q2 (REP 12.26 Rotator Sensor (CT-Q2)) The paper Rotator Sensor (Q2) works OK? Replace CPU / ControllerPCB “A” (REP 13.23 CPU / Controller PCB “A”) Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-56...
  • Page 456 The voltage is 5 VDC ±10%? Repair wire harness Replace the Registration M4 Home Sensor (Q3) (REP 12.40 Registration M4 Home Sensor (CT-Q3)) The paper Rotator Sensor (Q3) works OK? Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-57...
  • Page 457 Check for continuity / short circuit between the black wire at plug Q4 LED and H.P1-6. Check for continuity / short circuit between the red wire at plug Q4 and H.P1-8. There is continuity and no short circuit? Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP)
  • Page 458 Creaser Tools M6 Home Sensor (Q5) (REP 12.52) The Creaser Tools M6 Home Sensor (Q5) works OK? Replace Stepper Motor Driver (M6) PCB “H” (REP 13.30 Stepper Motor Driver (M6) PCB “H”) Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-59...
  • Page 459 Bleed Trimmer M7 Home Sensor (Q6) (REP 13.3) The Bleed Trimmer M7 Home Sensor (Q6) works OK? Replace Stepper Motor Driver (M7) PCB “C” (REP 13.25 Stepper Motor Driver (M7) PCB “C”) Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-60...
  • Page 460 Repair wire harness Replace Paper Exit Sensor Q7 (REP 12.7) The Paper Exit Sensor (Q7) works OK? Replace CPU / Controller PCB “A” (REP 13.23 CPU / Controller PCB “A”) Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-61...
  • Page 461 • Go to corresponding cover(s) REP’s: • Top Cover Assembly REP 12.3 • Interlock Switch Assembly Top Cover (REP 12.4) • Interlock Switch Slide Door (REP 12.5) • ADJ 12.6 Interlock Switch Slide Door Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-62...
  • Page 462 • Measure between the white wire Q8 and the black wire Q8 (5 V and Ground). The voltage is 5 VDC ±10%? Repair wire harness Replace CPU/ Controller PCB “A” (REP 13.23 CPU / Controller PCB “A”). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-63...
  • Page 463 • Measure between the white wire Q9 and the black wire Q9 (5 V and Ground). The voltage is 5 VDC ±10%? Repair wire harness Replace CPU/Controller PCB “A” (REP 13.23 CPU / Controller PCB “A”). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-64...
  • Page 464 Registration Solenoid SOL5 Trigger Sensor (CT-Q10) (REP 13.22) The Registration Solenoid SOL 5 Trigger Sensor (Q10) works OK? Replace CPU / ControllerPCB “A” (REP 13.23 CPU / Controller PCB “A”) Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-65...
  • Page 465 Replace the Waste Transport Sensor (Q14) (REP 12.24) The Waste Transport Sensor (Q14) works OK? Replace Stepper Motor Driver (M4) PCB “D” (REP 13.26 Stepper Motor Driver (M4) PCB “D”) Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-66...
  • Page 466 The voltage is 12 VDC ±10%. Go to 12V Power Supply Unit RAP Repair harness Go to Solenoid Driver PCB “B” RAP Replace PCB “A” Controller (REP 13.23 CPU / Controller PCB “A”) Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-67...
  • Page 467 Measure voltage between B.P11-1 and B.P11-2 (24V and Ground). The voltage is 24 VDC ±10%. Disconnect plug B.P11. Measure voltage between B.P11-1 and B.P11-2 (24V and Ground). The voltage is 24 VDC ±10%. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-68...
  • Page 468 Disconnect plug C.P4. Measure voltage between C.P3-1 and C.P3-2 (48V and Ground). The voltage is 48 VDC ±10%. Disconnect plug C.P3. Measure voltage between C.P3-1 and C.P3-2 (48V and Ground). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-69...
  • Page 469 Measure voltage between D.P3-1 and D.P3-2 (48V and Ground). The voltage is 48 VDC ±10%. Disconnect plug D.P3. Measure voltage between D.P3-1 and D.P3-2 (48V and Ground). The voltage is 48 VDC ±10%. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-70...
  • Page 470 Replace Stepper Motor Driver (M1) PCB “E” (REP 13.27 Stepper Motor Driver (M1) PCB “E”) Replace Stepper Motor Driver (M1) PCB “E” (REP 13.27 Stepper Motor Driver (M1) PCB “E”) Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-71...
  • Page 471 • Check Solenoid CT-REL3 (PL 12.20) (Optional Antistatic Kit) according to GP4. • Check Solenoid CT-COUNTER (PL 12.5) according to GP4. All listed components operate OK. Replace Controller PCB “A” PL 12.12 (REP 13.23 CPU / Controller PCB “A”). Exit Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-72...
  • Page 472 Disconnect plug H.P4. Measure voltage between H.P3-1 and H.P3-2 (48V and Ground). The voltage is 48 VDC ±10%. Disconnect plug H.P3. Measure voltage between H.P3-1 and H.P3-2 (48V and Ground). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-73...
  • Page 473 Replace Stepper Motor Driver (M3) PCB “J” (REP 13.31 Stepper Motor Driver (M3) PCB “J”) Replace Stepper Motor Driver (M3) PCB “J” (REP 13.31 Stepper Motor Driver (M3) PCB “J”) Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-74...
  • Page 474 • Activate Slide Door Interlock Switch (SW2) (PL 12.3) and Top Cover Interlock Switch (SW3) (PL 12.3). • Disconnect K.P2 and measure resistance between K.P2-1 and chassis. Resistance <=500kohm. Measure resistance between K.P2-2 and chassis. Resistance <=100kohm. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-75...
  • Page 475 Repair harness between 12V PSU and “L” SCP (Short Circuit Protection) PCB. Power off the machine. Disconnect L.P2 and measure resistance between L.P2-1 and chassis. Resistance <=500kohm. Measure resistance between L.P2-2 and chassis. Resistance <=100kohm. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-76...
  • Page 476 Repair harness and / or check / replace AC Power Switch (SW1). Measure the resistance between N (blue wire) on the 12V PSU and outgoing black,2 wire from the Power Entry. There is continuity. Repair harness Replace F1 (PL 12.5). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-77...
  • Page 477 Measure the resistance between L (brown wire) on the 24V PSU and REL 1-34(brown wire). There is continuity. Repair harness and / or check / replace AC Power Switch (SW1). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-78...
  • Page 478 Measure resistance between M.P2-2 and chassis. Resistance <=100kohm. Replace SCP (Short Circuit Protection) PCB “M” (REP 13.34). Locate the short circuit in the harness related to M.P2-2 and repair it. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-79...
  • Page 479 L (brown wire) on the 24V(48V) Power Supply Unit (2) and REL1-34 (brown wire). There is continuity. Measure resistance between N.P2-2 and chassis. Resistance <=100kohm. Repair harness and / or check / replace AC Power Switch (SW1). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-80...
  • Page 480 Top Cover Interlock Switch (SW3) (REP 12.4) Measure resistance between the white wire on the solenoid and G.P3- There is continuity. Repair Wire Harness. Measure resistance between SW2-3 and SW2-4 There is continuity. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-81...
  • Page 481 Activate alsoTop Cover Interlock Switch CT-SW3 (PL 12.6). There is 12VDC±10%. Go to I/O Extension PCB “G” RAP. Replace Interlock Relay (REL1) (REP 13.41). Replace Interlock Relay (REL1) (REP 13.40) Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-82...
  • Page 482 Repair harness and replace F1 (PL 12.5). Perform following three resistance measurements for the disconnected wires: 1. Brown wire to blue wire. 2. Brown wire to chassis. 3. Blue wire to chassis. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-83...
  • Page 483 F1 Blown Fuse RAP, continued Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-84...
  • Page 484 (Slide Door Interlock Switch (SW2)(PL 12.3) Ensure Top Cover Interlock Switch (SW3) (PL 12.3) is also activated. Listen closely to the BAR2. If there is a 50Hz sound when REL3 is activated, the BAR2 is working. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP)
  • Page 485 P27,1 and REL3,31. There is continuity. Repair harness Measure resistance between P27,2 and REL3,11. There is continuity. Repair harness Measure resistance between REL3,34 and TR2,1 (transformer connector). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-86...
  • Page 486 The voltage is 12 VDC ±15%? There is continuity. Measure VDC between REL2, A1 and GND(chassis). Repair harness The voltage is 12 VDC±15%? Measure resistance between REL2,34 and TR1,1 (transformer connector). There is continuity. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-87...
  • Page 487 Measure voltage between J.2-8 and J.2-7 on the “B” PCB. The voltage is 24 VDC ±10%. Replace Solenoid Driver PCB ”B” (REP 13.24 Solenoid Driver PCB “B”). Repair harness. Replace FAN1 (REP 13.42). Replace FAN1 (REP 13.42). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-88...

  • Page 488: Counter Rap, Ct

    Connect plug B.P12 to Solenoid Driver PCB “B” and connect the plug to the Chassis Counter. Measure between G.P3-1 and Ground. The voltage is 24VDC±10%. Replace the Solenoid Driver PCB “B” (REP 13.24 Solenoid Driver PCB “B”) Replace the Chassis Counter. The Counter functions OK. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-89...

  • Page 489: Bleed Trimmer Knives Noisy Rap

    • Ensure that the upper and lower knife shafts on operator and non-operator side are not binding or having excessive play Procedure Change knives according to: REP 13.2 Bleed Trimmer Lower Knives and REP 13.1 Bleed Trimmer Upper Knives. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-90...

  • Page 490: Drive Motor (M1) Transmission Rap

    All Components are moving as indicated? Fix problem. Return to the RAP that directed you here. Figure 1 Drive Motor (M1) Transmission Components Figure 2 Drive Motor (M1) Transmission Components Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-91...
  • Page 491 Figure 3 Drive Motor (M1) Transmission Components Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-92...

  • Page 492: Rotator Motor (M3) Transmission Rap

    • Check that all Rotator Motor (M3) Transmission Components are moving as indicated in Figure (1). All Components are moving as indicated? Fix problem. Return to the RAP that directed you here. Figure 1 Rotator Motor (M3) Transmission Components Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-93...

  • Page 493: Registration Width Adjustment Motor (M4) Transmission Rap

    All Components are moving as indicated? Fix problem. Return to the RAP that directed you here. Figure 2 Registration Width Adjustment Motor (M4) Transmission Components Figure 1 Registration Width Adjustment Motor (M4) Transmission Components Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-94...

  • Page 494: Creaser Motor (M6) Transmission Rap

    • Check that all Creaser Motor (M6) Transmission Components are moving as indicated in Figure (1). All Components are moving as indicated? Fix problem. Return to the RAP that directed you here. Figure 1 Creasser Motor (M6) Transmission Components Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-95...

  • Page 495: Bleed Trimmer Width Adjustment Motor (M7) Transmission Rap

    Fix problem. Return to the RAP that directed you here. Figure 2 Bleed Trimmer Width Adjustment Motor (M7) Transmission Components Figure 1 Bleed Trimmer Width Adjustment Motor (M7) Transmission Components Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-96...

  • Page 496: Booklet Maker (Bm)

    • Check wires for continuity for the red wire Q2 to B.P14-1. • Check for short circuit between red/white/black wires • Check for short circuit between red/white/black wires to chassis/GND There is continuity for all wires and no short circuit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-97...

  • Page 497: Infeed Motor M1 Short Circuit

    The voltage is 30 VDC ± 10%. Replace MD6DC PCB ”B” (PL 4.0). Repair/Replace wire harness. Replace MD6DC PCB ”B” (PL 4.0). Replace/Repair wire Harness. Replace motor BM-M1 (PL 5.3). Replace motor BM-M1 (PL 5.3). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-98...

  • Page 498: Back Jogger Motor Sensor Bm-Q45 No Displacement Pulses

    • Check continuity for the black wire at plug Q45 to C.P14-13 • Check for short circuit between red/white/black wires • Check for short circuit between red/white/black wires to chassis/GND There is continuity for all wires and no short circuit. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-99...

  • Page 499: Back Jogger Motor (M2) Cycle Timeout

    • Measure between the red wire Q3 and the black wire Q3 (5V and GND). • Measure between the white wire Q3 and the black wire Q3 (Signal and GND). The voltage is 5 VDC ± 10%. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP)

  • Page 500: Back Jogger Motor Bm-M2 Short Circuit

    Start Back jogger motor (BM-M2) in check motors again. Measure VDC between J.2-1 and J.2-8 The voltage is 30 VDC ± 10%. Replace “C”(PL 4.0). Replace/Repair wire Harness. Replace motor BM-M2 (PL 5.2). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-101...

  • Page 501: Side Jogger Motor Bm-M3 No Displacement Pulses

    There is continuity for all wires and no short circuit. Replace/Repair Wire Harness. • Replace motor BM-M3 (PL 5.3). • Replace MD6DC PCB “C(PL 4.0). Go to Compiler RAP Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-102...

  • Page 502: Side Jogger Motor Bm-M3 Cycle Timeout

    • Measure between the red wire Q13 and the black wire Q13 (5V and GND). • Measure between the white wire Q13 and the black wire Q13 (Signal and GND). The voltage is 5 VDC ± 10%. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP)

  • Page 503: Side Jogger Motor Bm-M3 Short Circuit

    • Check wires for Short circuit across the violet wire M3 to C.P2-2 (orange). • Check for short circuit between wires to chassis. Is there a short circuit Replace MD6DC PCB ”C” (PL 3.0). Replace/Repair wire Harness. Replace motor BM-M3 (PL 5.3) Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-104...

  • Page 504: Side Jogger Motor Bm-M3 Open Circuit

    • Disconnect plug C.P2 from MD6DC PCB “C”. • Measure VDC between J.2-2 and J2-9 The voltage is 30 VDC ± 10%. Replace MD6DC PCB ”C”. (PL 4.0) Replace/Repair wire Harness. Replace motor BM-M3 (PL 5.3) Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-105...

  • Page 505: Set Transport Motor Bm-M5 Motor Sensor Bm-Q40 No Displacement

    • Check continuity for the black wire at plug Q40 to B.P14-10 • Check for short circuit between red/white/black wires • Check for short circuit between red/white/black wires to chassis/GND There is continuity for all wires and no short circuit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-106...

  • Page 506: Set Transport Motor Bm-M5 Short Circuit

    • Check wires for short circuit across leads, the violet wire M5 to B.P2-2 (orange). • Check for short circuit between wires to chassis. Is there a short circuit Replace MD6DC PCB “B” (PL 4.0). Replace/Repair wire Harness. Replace motor BM-M5 (PL 5.0). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-107...

  • Page 507: Set Transport Motor M5 Open Circuit

    • Disconnect plug B.P2 from MD6DC PCB “B”. • Measure VDC between J.2-2 and J2-9 The voltage is 30 VDC ± 10%. Replace MD6DC PCB “B”. (PL 4.0) Replace/Repair wire Harness. Replace motor BM-M5.(PL 5.0) Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-108...

  • Page 508: Fold Roller Motor Bm-M6 No Displacement Pulses

    • Check for short circuit between red/white/black wires • Check for short circuit between red/white/black wires to chassis/GND There is continuity for all wires and no short circuit Replace/Repair wire Harness. Connect plug C.P14 to PCB “C”. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-109...

  • Page 509: Fold Roller Motor Bm-M6 Short Circuit

    Measure VDC between J.3-2 and J.3-3 The voltage is > 10 VDC. Should be approx. 18 VDC. Replace MD6DC PCB “C(PL 4.0). Replace/Repair wire Harness. Replace motor BM-M6 (PL 3.0). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-110...

  • Page 510: Fold Knife Motor Bm-M7 Cycle Timeout

    • Measure between the red wire Q15 and the black wire Q15 (5V and GND). • Measure between the white wire Q15 and the black wire Q15 (Signal and GND). The voltage is 5 VDC ± 10%. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP)

  • Page 511: Fold Knife Motor Bm-M7 Short Circuit

    • Check wires for Short circuit across the violet wire M7 to B.P3-6 (orange). Is there a short circuit Replace MD6DC PCB “B” (PL 4.0). Replace/Repair wire Harness. Replace motor BM-M7 (PL 6.2). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-112...

  • Page 512: Fold Knife Motor Bm-M7 Open Circuit

    Disconnect plug B.P3. Measure VDC between J.3-6 and J.3-7. The voltage is > 10 VDC. Should be approx. 28 VDC. Replace MD6DC PCB “B” (PL 4.0). Replace/Repair wire Harness. Replace motor BM-M7 (PL 6.2). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-113...

  • Page 513: Stop Gate Folder Motor Bm-M8 Sensor Bm-Q43 No Displacement Pulses

    • Check continuity for the black wire at plug Q43 to H.P14-10 • .Check for short circuit between red/white/black wires • Check for short circuit between red/white/black wires to chassis/GND There is continuity for all wires and no short circuit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-114...

  • Page 514: Stop Gate Folder Motor Bm-M8 Sensor Bm-Q44 Cycle Timeout

    • Check continuity for the black wire at plug Q44 to H.P13-6 • Check for short circuit between red/white/black wires • Check for short circuit between red/white/black wires to chassis/GND There is continuity for all wires and no short circuit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-115...

  • Page 515: Stop Gate Folder Motor Bm-M8 Short Circuit

    Replace/Repair wire Harness. • Replace Motor BM-M8 (PL 6.2). • Inside Booklet Maker: Check Q7, Q43, Q44 and M8 (GP4). • Check for mechanical bindings, broken, missing or loose parts. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-116...

  • Page 516: Stop Gate Folder Motor Bm-M8 Max Voltage Exceeded

    • Check for mechanical obstructions and loose screw. If all above is OK, replace motor. WARNING! Turn off the Main Power Switch and disconnect the Main Power Cord before disconnecting, removing or replacing any electrical components. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-117...
  • Page 517 • Check continuity for the black wire at plug Q10 to B.P14-6 • Check for short circuit between red/white/grey/black wires. • Check for short circuit between red/white/grey/black wires to chassis/GND Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-118...
  • Page 518 2. Measure between the red wire Q11 and the black wire Q11 (5V and GND). 3. Measure between the white wire Q11 and the black wire Q11 (Signal and GND). The voltage is 5 VDC ± 10%. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-119...
  • Page 519 • Measure VDC between J.2-3 and J.2-10 (PWM 30V and GND). The voltage is 30 VDC ± 10%. Replace MD6DC PCB “B”(PL 4.0). Replace/Repair wire Harness. Replace motor BM-M9 (PL 6.2). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-120...
  • Page 520 2. Measure between the white wire Q34 and the black wire Q34 (Signal and GND). The voltage is 5 VDC ± 10%. Repair Wire Harness. 1. Replace Motor BM-M19 (PL 4.0). 2. Replace MD6DC PCB “H”(PL 4.0) Go to rap BM-044 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-121...
  • Page 521 Start Primary Infeed motor (BM-M19) in check motors again. Measure between J.2-1 and J.2-8. The voltage is approximately 30 VDC? Replace MD6PCB “H” (PL4.0) Replace wire Harness. Replace motor M19. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-122...
  • Page 522 There is continuity for all wires and no short circuit Replace/Repair Wire Harness. • Connect plug B.P13 and B.P16 to MD6DC PCB “B”. • Go to BM-048 RAP Go to BM-018 RAP Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-123...
  • Page 523 There is continuity for all wires and no short circuit Replace/Repair Wire Harness. • Connect plug B.P13 and B.P16 to MD6DC PCB “B”. • Go to BM-048 RAP Go to BM-018 RAP Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-124...
  • Page 524 • Check wires for short between the violet wire J43-11 to B.P3-2 (orange). • Check short circuit between wires to chassis. Is there short a circuit • Replace Stapler Assembly Left.(PL 4.1) • Replace MD6DC PCB “B” (PL 4.0) Replace/Repair wire Harness. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-125...
  • Page 525 • Disconnect plug B.P3 from PCB “B”. Stapler Motor (M20) in check motors again. • Measure VDC between J.3-2 and J.3-3. Is the voltage pulse 2030 VDC? (This Pulse is short. Maybe not possible to see at Multimeter) Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-126...
  • Page 526 There is continuity for all wires and no short circuit Replace/Repair Wire Harness. • Connect plug C.P13 and C.P16 to MD6DC PCB “C”. • Go to theBM-052 RAP Go to theBM-052 RAP Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-127...
  • Page 527 There is continuity for all wires and no short circuit Replace/Repair Wire Harness. • Connect plug C.P13 and C.P16 to MD6DC PCB “C”. • Go to the BM-052 RAP Go to theBM-052 RAP Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-128...
  • Page 528 • Check short circuit between wires to chassis. Is there a short circuit • Replace Stapler Right BM-M21 (PL 7.0) • Replace MD6DC PCB “C”. (PL 4.0) Replace/Repair wire Harness. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-129...
  • Page 529 The voltage pulse is 2030 VDC? (This Pulse is short, maybe not possible to see with Multimeter) Replace MD6DC PCB “C”. (PL 4.0) Replace/Repair wire Harness. Replace Stapler Right BM-M21 (PL 7.0) Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-130...
  • Page 530 • Check continuity for the black wire at plug Q41 to H.P14-6 • Check for short circuit between red/white/black/grey wires • Check for short circuit between red/white/grey/black wires and chassis/GND. There is continuity for all wires and no short circuit. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-131...
  • Page 531 • Measure between the red wire Q42 and the black wire Q42 (5V and GND). • Measure between the white wire Q42 and the black wire Q42 (Signal and GND). The voltage is 5 VDC ± 10%. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP)
  • Page 532 Stop Gate Stapler Motor (BM-M22) in GP4. • Measure VDC between J.2-2 and J2-9. The voltage is approximately 30 VDC? Replace MD6DC PCB “H””.(PL 4.0) Replace/Repair wire Harness. Replace motor BM-M22 (PL 7.0). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-133...
  • Page 533 • Check continuity for the black wire at plug Q37-3 to F.P3-4 • Check for Short circuit between red/white/black wires • Check for short circuit between red/white/black wires to chassis/GND There is continuity for all wires and no short circuit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-134...
  • Page 534 • Measure between the red wire Q36 and the black wire Q36 (5V and GND). • Measure between the white wire Q36 and the black wire Q36 (Signal and GND). The voltage is 5 VDC ± 10%. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP)
  • Page 535 • Start Thick Set Motor (M23) in • Measure VDC between J.2-3 and J.2-10 The voltage is approximately 30 VDC? Replace MD6DC PCB “C”. Repair wire Harness. Replace motor BM-M23 (PL 7.1). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-136...
  • Page 536 • Measure between the red wire Q1 and the black wire Q1 (5V and GND). The voltage is 5 VDC ± 10%. Replace/Repair Wire Harness. Replace Sensor BM-Q1 (PL 5.3) Replace CPU/Controller PCB “A” (PL 3.1). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-137...
  • Page 537 Measure between the red wire Q4 and the black wire Q4 (5V and GND). The voltage is 5 VDC ± 10%. Replace/Repair Wire Harness. Replace Sensor BM-Q4 (PL 5.1) Replace CPU/Controller PCB “A” (PL 3.1). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-138...
  • Page 538 • Measure form Q7 Pin 1 to 3 and Q7 and Pin 2 to 3. The voltage is 5 VDC ± 10%. Replace/Repair Wire Harness. Replace BM-Q7 Sensor (PL 6.2) Replace CPU/Controller PCB “A” (PL 3.1). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-139...
  • Page 539 • Measure between the red wire Q8 and the black wire Q8 (5V and GND). The voltage is 5 VDC ± 10%. Replace/Repair Wire Harness. Replace BM-Q8 (REP 6.9) (PL 2.1) Replace CPU/Controller PCB “A” (PL 3.1). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-140...
  • Page 540 Check J4 at Left Clinch to frame for short circuit. Is there a short circuit Replace CPU/Controller PCB “A”. Replace Clinch Left (PL 7.0) Replace/Repair Wire Harness. Replace/Repair wire harness. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-141...
  • Page 541 Check J4 at Right Clinch to frame for short circuit. Is there a short circuit? Replace CPU/Controller PCB “A” (PL 3.1). • Replace Clinch Right (PL 7.0) • Replace/Repair Wire Harness. Replace/Repair wire harness. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-142...
  • Page 542 Measure between the red wire Q35 and the black wire Q35 (5V and GND). The voltage is 5 VDC ± 10%. Replace/Repair Wire Harness. Replace Q35 Replace Addon PCB “F” Replace CPU/Controller PCB “A” (PL 3.1). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-143...
  • Page 543 30VDC PSU (PL 3.1) until you reached a value between 29.8-30.2VDC. • If you have no success adjusting the voltage, go to BM-154 30VDC low at Upper MD6DC PCB “H”. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-144...
  • Page 544 • If a Square Folder/Trimmer is not installed, ensure the Terminator is connected to Booklet maker J12. • If any of the 30VDC checks are between 22.0VDC and 28.9VDC go to BM-150 30VDC Low at Lower MD6DC “C” RAP. continued on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-145...
  • Page 545 Power Flow Chart Booklet Maker Overview over the power distribution in the Booklet Maker system continued on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-146...
  • Page 546 • Power off the machine, remove the main power Cord, leave D.P2 and C.P11 disconnected. • Measure resistance between D.P2-1 and chassis, and between D.P2-2 and chassis. There is a short circuit continued on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-147...
  • Page 547 D.P2-1 and chassis, D.P2-2 and chassis. There is still a short circuit Go to Square Folder/Trimmer Service Manual, 30VDC Low RAP Repair/replace harness Repair/replace harness Replace Lower MD6DC PCB “C” Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-148...

  • Page 548: 30Vdc High At Lower Md6Dc Pcb "C

    If you have no success adjusting the voltage, perform following in order: • Load latest software version to ARM PCB “A” (PL 3.1). • Replace ARM PCB “A” • Replace 30VDC PSU (REP 7.8) (PL 3.0). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-149...
  • Page 549 Close the top cover, if there is a Square Folder/Trimmer connected close top covers. Replace Middle MD6DC PCB “B” The voltage is 29.0-31.0VDC Exit Repair/replace harness continued on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-150...
  • Page 550 BM-153 30VDC low at Middle MD6DC PCB “B”, continued Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-151...

  • Page 551: 30Vdc Low At Upper Md6Dc Pcb "H

    There might be only a short period when the voltage is present so pay attention. Close the top cover, if there is a Square Folder/Trimmer connected close top covers. The voltage is 29.0-31.0VDC continued on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-152...
  • Page 552 BM-154 30VDC low at Upper MD6DC PCB “H”, continued Replace Upper MD6DC PCB “H” (PL 4.0). Locate the short circuit related to H.P2 and H.P3 and repair/replace. Success Replace Upper MD6DC PCB “H” (PL 4.0). Exit Repair/replace harness Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-153...

  • Page 553: Relay Off Timeout Rap (Bm)

    • If a Square Folder/Trimmer is not installed, ensure the short link connector is connected to booklet maker J12 Procedure Replace REL-1 Success Go to SW1 Software signal (SW17) RAP Exit. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-154...

  • Page 554: Trimmer Communication Lost

    Leave CAN terminations disconnected, at both CAN terminations measure resistance between pin 2 and pin 7. The resistance is 120R ± 10% Replace the failed CAN termination connector(s) There is a Square Folder installed continued on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-155...
  • Page 555 • Check for short circuit between all wires from D.P6 to chassis and between different pins at J23. There is connectivity and no short circuit Repair/replace harness Replace the MD6DC PCB “A” in the Trimmer Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-156...

  • Page 556: Square Folder Communication Lost

    There is connectivity and no short circuit Replace the failed communication cable(s) (PL 10.7). Leave CAN terminations disconnected, at both CAN terminations measure resistance between pin 2 and pin 7. The resistance is 120R ± 10% Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-157...

  • Page 557: Pcb Md6Dc "B" Not Connected

    Replace/Repair Wire Harness. Measure for continuity between P4-2 on MD6DC PCB “B” and P5-2 on MD6DC PCB “C”. There is continuity. Replace/Repair Wire Harness. Replace MD6DC PCB “B” (PL 4.0). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-158...

  • Page 558: Pcb Md6Dc "C" Not Connected

    Replace/Repair Wire Harness. Measure for continuity between P4-2 on MD6DC C and P2-2 on CPU/Controller PCB “A” (PL 3.0). There is continuity. Replace/Repair Wire Harness. Replace MD6DC PCB “C(PL 4.0). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-159...

  • Page 559: Pcb Md6Dc "H" Not Connected

    Replace/Repair Wire Harness. Measure for continuity between P4-2 on MD6DC PCB “H” and P5-2 on MD6DC PCB “B”. There is continuity. Replace/Repair Wire Harness. Replace MD6DC PCB “H”” (PL 4.0). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-160...

  • Page 560: Pcb Md3Dc "O" Not Connected (Option)

    There is continuity. Replace/Repair Wire Harness. Measure for continuity between P4-2 on MD3DC PCB “O” and P3-2 on ARM PCB A. There is continuity. Replace/Repair Wire Harness. Replace MD3DC PCB “O” . Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-161...

  • Page 561: Addon Pcb "F"Not Connected

    The communication fault remains. Procedure Replace interlock switch SW 1 or Harness Exit. Replace Ribbon Cable between A.P10 and F.P5. The communication fault remains. Exit. Replace PCB “A” Controller (PL 3.1). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-162...

  • Page 562: Stacker Motor St-M1 Short Circuit

    (PL 4.0). The voltage is 24 VDC ± 10%. Replace/Repair wire Harness. Replace MD6DC PCB “B” (PL 4.0). Replace motor BM-M1 (PL 5.3). Replace/Repair Wire Harness. Replace motor BM-M1 (PL 5.3). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-163...

  • Page 563: Incompatible Cst Software

    Initial Actions Procedure Follow instructions in below GP’s to check and update software in the CST. • GP 18 Checking Versions of Installed Software • GP 19 Update Software Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-164...

  • Page 564: Sensor Bm-Q1 Not Activated In Time

    • Ensure that the Booklet maker is correctly installed (see Installation). • Go to Length Adjustment Unit RAP. • Go to Compiler RAP. • Got to Stapler RAP. • Go to Length Adjustment Unit RAP. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-165...

  • Page 565: Sensor Bm-Q4 Not Activated In Time

    • Go to Length Adjustment Unit RAP. • Go to Length Adjustment Unit RAP. • Go to Prefold Transport RAP. • Got to Stapler RAP. • Go to Stapler RAP. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-166...

  • Page 566: Sensor Bm-Q7 Not Activated In Time

    • If cover feeder is used in the job that caused the problem Go to Cover Feeder RAP. • Go to Compiler RAP. • Go to Length Adjustment Unit RAP. • Go to Length Adjustment Unit RAP. • Go to Stapler RAP. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-167...
  • Page 567 Belt Stacker RAP. • Check for obstructions in the paper path. • Go to SQF Transport RAP. • Go to Folding Unit RAP. • Go to Length Adjustment Unit RAP. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-168...
  • Page 568 - Ensure that BM-Q53 Upper bypass unit infeed sensor is clean. Procedure 1. Check for obstructions in the paper path. 2. Ensure that the Booklet maker is correctly installed (see Installation). 3. Go to Compiler RAP. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-169...
  • Page 569 PTC will become hot and break the circiut. Allowed to cool off, the circuit will be closed again. WARNING! The PTC can become very hot! PTC resistors continued on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-170...
  • Page 570 MD6DC PCB “H”” (PL 4.0). • Replace Stapler cartridge (PL 4.1). • Replace CPU/Controller PCB “A” (PL 3.1). • Replace MD6DC PCB “H”” (PL 4.0). • Replace Right Clincher. (PL 4.1). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-171...
  • Page 571 MD6DC PCB “H”” (PL 4.0). • Replace Stapler cartridge (PL 4.1). • Replace CPU/Controller PCB “A” (PL 3.1). • Replace MD6DC PCB “H”” (PL 4.0). • Replace Left Clincher (PL 4.1). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-172...

  • Page 572: Too Many Sheets

    Booklet Maker is not purged before new job is submitted to the Booklet Maker. BM-409 Unfinished set in compiler This Fault code indicates that an unfinished set must be removed from BM compiler Procedure • Remove set and try again • Check type of job • Check type of paper Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-173...

  • Page 573: Staples, Low Stapler Right Bm-Q46

    The voltage is 5 VDC ± 10%. Replace/Repair Wire Harness. • Replace Stapler Right. • Replace MD6DC PCB “C(PL 4.0). • Replace Stapler Right. • Replace MD6DC PCB “C(PL 4.0). • Replace/Repair Wire Harness. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-174...

  • Page 574: Staples, Low Stapler Left, Bm-Q49

    The voltage is 5 VDC ± 10%. Replace/Repair Wire Harness. • Replace Stapler Left. • Replace MD6DC PCB “B” (PL 4.0). • Replace Stapler Left. • Replace MD6DC PCB “C(PL 4.0). • Replace/Repair Wire Harness. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-175...

  • Page 575: Staples, Low Both Stapler (Bm-Q46, Bm-Q49)

    BM-502 ”Staples Low Stapler Left (Q49) Empty Belt Stacker and press done on the UI. Note: This function can also be turned off under the Tools menu on the UI. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-176...
  • Page 576 • Ensure that the communication cable between the Square Folder and the Trimmer is properly connected (see Installation). Make sure the microSD memory is installed. • Ensure the power to Booklet Maker and Square Folder is connected (see Installation). continued on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-177...
  • Page 577 A.P4 to J23. • Check for short circuit between all wires from A.P4 to chassis and between different pins at J23. There is connectivity and no short circuit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-178...
  • Page 578 • Check that cable from A .P2 on CPU/Controller PCB “A” to C P5 on MD6DC PCB “C” is connected (PL 3.0). • Move CAN termination to Booklet Maker. Power on. The UI starts up. continued on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-179...
  • Page 579 TR No 12VDC (Trimmer) Do following, check functionallity between the steps: • Load new software to UI-module. • Replace microSD memory, and load new UI software. • Replace module. continued on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-180...
  • Page 580 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-181...

  • Page 581: Compiler Rap

    Check for mechanical bindings, broken, missing or loose parts. Check Motor M3 (PL 3.2) according to GP4. Are the side joggers working correctly? Check for mechanical bindings, broken, missing or loose parts. Return to the previous RAP. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-182...
  • Page 582 • Check for mechanical bindings, broken, missing or loose parts. • Check adjustment of set transport drive (ADJ 4.3). • Check Set Transport Calibration (ADJ 4.2) Return to the previous RAP. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-183...
  • Page 583 Check for mechanical bindings, broken, missing or loose parts. Check Motor BM-M8 (PL 6.2) according to GP4. Is the fold stop gate working correctly? Check for mechanical bindings, broken, missing or loose parts. Return to the previous RAP. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-184...
  • Page 584 Power machine off and re-connect P11 on MD6DC “B” (PL 4.0). Disconnect P11 on MD6DC “H” (PL 4.0). Power on machine and close covers. A different fault code than BM-154 is displayed. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP)
  • Page 585 • Measure VDC at the counter connector between the orange and C.P11-2 (GND) The voltage is 30 VDC ± 10%. • Repair Wire Harness. • Replace MD6DC PCB “C(PL 4.0) • Replace Counter. • Replace MD6DC PCB “C(PL 4.0). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-186...
  • Page 586 • Leave SW1 interlock switch inactivated. Power on the machine. • Measure voltage between L (brown wire) and N (blue wire) on the 12V PSU (PL 3.1). The voltage is 90-264VAC. continued on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-187...
  • Page 587 • brown wire to blue wire. • brown wire to chassis. • blue wire to chassis. There is continuity. Replace the 30VDC PSU and replace F1. Repair harness and replace F1. Exit (bad fuse) Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-188...
  • Page 588 There might be only a short period when the voltage is present so pay attention. • Close the top cover, if there is a Square Folder/Trimmer connected, close the top covers. The voltage is 29.0-31.0VDC continued on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-189...
  • Page 589 Interlock Relay REL-1. Replace 30VDC PSU (REP 7.8) (PL 3.0). Repair/replace harness between 30VDC PSU and SCP PCB “D”. Replace SCP PCB “D” (PL 3.1). Replace SCP PCB “D” (PL 3.1). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-190...
  • Page 590 Disconnect the main power Cord. • Set SW3 to 0 • Measure resistance between N on the 12VDC PSU and 31 on REL-1. There is continuity. continued on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-191...
  • Page 591 • Measure resistance between SW3-5 and L on the mains power inlet. • Set SW3 to 0, There is continuity • Measure resistance between P45-2 and SW3-1. There is continuity Repair/replace harness Replace Mains Power Inlet Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-192...
  • Page 592 • Disconnect the Square Folder/Trimmer and connect the short link connector to Booklet maker J12, if the problem disappears when the Square Folder/Trimmer is disconnected, go to Square Folder/Trimmer Service Manual. continued on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-193...
  • Page 593 F.P2 related to the SCP PCB “F” and J.P3 related to 4IN / 4OUT PCB “J” disconnected • Close the top cover, measure resistance between J12-4 and P46-1. There is continuity Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP)
  • Page 594 A.P11, A.P12, B.P2 and connectors related to SW1 in the Trimmer are properly connected. • If a Square Folder/Trimmer is not installed, ensure the short link connector is connected to Booklet maker J12. continued on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-195...
  • Page 595 • Replace components in following order: Ribbon cable between 4IN / 4OUT PCB “J” and ARM PCB “A”. 4IN / 4OUT PCB “J” ARM PCB “A” Repair/replace harness Replace SW1 (PL 1.0). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-196...
  • Page 596 AC Power is present in the Line Module whenever the Power Cord is plugged into the Wall Outlet. go to Square Folder/Trimmer Service Manual. Success Replace REL-1 (PL 3.1) Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-197...
  • Page 597 • Ensure that connectors: H.P5, H.P4, B.P5, B.P4, C.P5, C.P4, A.P2 and A.P3 are properly connected. • Ensure all connectors related to LED LAMP PCBs “L” and “M” are properly installed. continued on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-198...
  • Page 598 • Measure resistance between F,P.1-1 and chassis, G.P.1-1 and chassis. There is a short circuit Replace 12V PSU Success Replace SCP PCB “F” and SCP PCB “G” (PL 3.0). continued on next page Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-199...
  • Page 599 Is there an OPTION 500 installed. Power off, disconnect O.P4, power on. Measure VDC between F.P2-1 and F.P2-3 related to the SCP PCB. The voltage is 12VDC±10% continued on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-200...
  • Page 600 Repair/replace harness Reconnect connectors from previous step, disconnect H.P5 Wait 120 seconds. Power on the machine, measure VDC between F.P2-1 and F.P2-3 related to the SCP PCB. The voltage is 12VDC±10% Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-201...
  • Page 601 • Ensure that connectors: H.P5, H.P4, B.P5, B.P4, C.P5, C.P4, A.P2 and A.P3 are connected. Procedure There is a No Com message displayed. Go to Booklet Maker Communication Lost (UI: “No Com”) RAP Go to UI Blank RAP Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-202...
  • Page 602 • Enter Service Mode and activate LED Lamp. Measure VDC at the LED Lamp L.P1 and M.P1 connector, between the red and white (12VDC and GND) The voltage is 12 VDC ± 10%. continued on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-203...
  • Page 603 XCAN and ICAN OVERVIEW Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-204...
  • Page 604 If it is hard to make selections, power off then on. • Go to SW1 Interlock circuit (TR-SW9,TR-SW10) RAP (if TR is installed). • Go to TR-153 RAP Interlock sensor faulty TR-Q1. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-205...
  • Page 605 Also check short circuit between wires to chassis. There is a Short circuit. Replace MD6DC PCB “D” Replace/repair harness Replace motor ST-M1 (PL 8.0). Wiring diagram for Stacker attached to Booklet Maker Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-206...
  • Page 606 There is a short circuit. The voltage is 24 VDC ± 10%. Replace MD6DC PCB “A”. Replace MD6DC PCB “D” Replace/Repair Wire Harness. Replace/repair harness Replace motor ST-M1 (PL 8.0). Replace Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-207...
  • Page 607 • Check for short circuit between A.P2-10 and chassis/GND There is continuity for all wires and no short circuit • Replace/Repair Wire Harness. • Replace MD6DC PCB “A”. Replace motor ST-M1 (PL 8.0). Replace motor ST-M1 (PL 8.0). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-208...
  • Page 608 The voltage is 18 VDC ± 10%. Replace MD6DC PCB ”D”. Replace/Repair wire Harness. Replace MD6DC PCB ”D”. Replace motor SQF-M1 (PL 10.7). Replace/Repair wire Harness. Replace motor SQF-M1 (PL 10.7). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-209...
  • Page 609 • Disconnect plug D.P14 from PCB “D”. • Measure between the J.14-9 and J14-3 (5V and Signal GND). The voltage is 5 VDC ± 10%. Replace MD6DC PCB “D” Replace/Repair wire Harness. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-210...
  • Page 610 Replace sensor Q1(REP11.10) Replace MD6DC PCB “D” Inside Square Folder: Check Q5, Q6, Q7, M1 and SOL1-4. Check for mechanical bindings, broken, missing or loose parts. Clean the Transport belts. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-211...
  • Page 611 Replace/Repair wire Harness. Is there a short circuit. • Replace motor SQF-M2 (PL 10.7). • Replace MD6DC PCB ”D”. Replace MD6DC PCB ”D”. Replace/Repair wire Harness. Replace motor SQF-M2 (PL 10.7). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-212...
  • Page 612 • Check for mechanical bindings or worn/broken parts. Is there a short circuit • Replace motor SQF-M3 (PL 10.5). • Replace MD6DC PCB ”D”. Replace MD6DC PCB ”D”. Replace/Repair wire Harness. Replace motor (PL 10.5). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-213...
  • Page 613 • Connect plug D.P16 and D.P14 to MD6DC PCB ”D”. • Measure between the red wire Q4 and the black wire Q4 (5V and GND). The voltage is 5 VDC ± 10%. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP)
  • Page 614 • Check short circuit between wires to chassis. Is there a short circuit Replace/Repair wire Harness. • Replace motor SQF-M4. Replace MD6DC PCB ”D”. • Replace MD6DC PCB ”D”. Replace/Repair wire Harness Replace motor SQF-M4. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-215...
  • Page 615 Connect plug D.P13 and D.P14 to MD6DC PCB ”D”. Measure between the red wire Q2 and the black wire Q2 (5V and GND). The voltage is 5 VDC ± 10%. continued on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-216...
  • Page 616 Measure between the red wire Q3 and the black wire Q3 (5V and GND). The voltage is 5 VDC ± 10%. Replace/Repair wire Harness Replace sensor SQF-Q2 Replace MD6DC PCB ”D”. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-217...

  • Page 617: Roll Motor Sqf-M4 Pulse Timeout

    • Replace MD6DC PCB ”D” Inside Square Folder: Check Q5, Q6, Q7, M1, M2, M3 and SOL1-4. Check for mechanical bindings, broken, missing or loose parts. Clean the Transport belts. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-218...

  • Page 618: Infeed Sensor Sqf-Q5 Faulty

    The voltage is 5 VDC ± 10%. Replace MD6DC PCB ”D”. Replace/Repair wire Harness Repair wire Harness to Infeed photo transistor sensor SQF-Q5 (PL 10.4). Replace Infeed LED sensor SQF-Q5. Replace Infeed LED sensor SQF-Q5. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-219...

  • Page 619: Clamp Sensor Sqf-Q6 Faulty

    • Measure between the red wire Q6 and the black wire Q6 (5V and GND). The voltage is 5 VDC ± 10%. Replace/Repair Wire Harness. Replace SQF-Q6 Clamp Sensor. Replace MD6DC PCB ”D” Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-220...

  • Page 620: Exit Sensor Sqf-Q7 Faulty

    The voltage is 5 VDC ± 10%. Replace MD6DC PCB ”D”. Replace/Repair Wire Harness. • Replace Exit LED sensor (REP 11.14 SQF-Q7 Exit Sensors) • Replace Exit photo transistor sensor Q7 (REP 11.14 SQF-Q7 Exit Sensors). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-221...

  • Page 621: Sol1 / 3 Open Circuit

    Repair wire Harness. Repair wire Harness. • Replace SOL 2 / 4 (PL 10.4). • Replace SOL 1 / 3 (PL 10.3). • Replace MD6DC PCB ”D”. • Replace MD6DC PCB ”D”. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-222...

  • Page 622: Input Low

    • Measure VDC between A.P11-1 and A.P11-2. There might be only a short period when the voltage is present so pay attention. Close all top covers. continued on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-223...
  • Page 623 Locate short circuit related to D.P2 and D.P3 and repair/replace. Success Replace MD6DC PCB “D” Exit Replace MD6DC PCB “D” Success Go to No 30VDC from SCP PCB “D” in Booklet Maker service manual Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-224...

  • Page 624: Input High

    Procedure Perform BM-152 30VDC High at Lower MD6DC PCB “C” in Booklet Maker RAP Success • Replace MD6DC “D” in Square Folder • Replace MD6DC “A” in Trimmer Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-225...

  • Page 625: Infeed Sensor Sqf-Q5 Not Activated In Time

    • Ensure that nothing interferes with the paper path direction between the Booklet Maker, and the Square Folder. • Ensure that the Square Folder is correctly installed (see chapter 1, Installation). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP)

  • Page 626: Clamp Sensor Sqf-Q6 Not Activated In Time

    • Inside Booklet Maker and Square Folder: • Check for mechanical bindings, broken, missing or loose parts, clean the Transport belts. • Ensure that nothing interferes with the paper path BM-062 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP)

  • Page 627: Exit Sensor Sqf-Q7 Not Activated In Time

    Check for mechanical bindings, broken, missing or loose parts, clean the Transport belts. • Ensure that nothing interferes with the paper path. • Ensure that nothing interferes with the paper path. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP)

  • Page 628: Stacker Full

    Check Motor SQF-M2 (PL 10.7) according to GP4. Clean the transport belts. The Stop Gate is working correctly Return to the previous RAP. Check for mechanical bindings, broken, missing or loose parts. Return to the previous RAP. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-229...
  • Page 629 SW1-1 and SW1-2 (PL 11.0) There is connectivity Go to SW1 Software signal (SW2) RAP Replace SQF-SW1 (PL 10.0) continued on next page See block schematic diagram on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-230...
  • Page 630 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-231...

  • Page 631: Sqf-Sw1 Software Signal Sqf-Sw2 Rap

    Keep the machine powered off. Keep the mains power cord, D.P15, D.P13, D.P16 and B.P2 disconnected. Close the top cover, measure resistance between SW1.3 and SW1.4. There is connectivity Continued on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-232...
  • Page 632 There is a short circuit Replace components in following order. 1. LED PCB “B” (PL 11.2). 2. MD6DC PCB “D” (PL 11.2). Repair/replace harness Replace SW1 (PL 11.0). Continued on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-233...
  • Page 633 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-234...

  • Page 634: Square Folder Does Not Square Form A 4 Sheet Booklet Rap

    • Check for Short circuit between wires (J.47-7 and J.47-8 are supposed to be shorted) • Check for short circuit between all wires and chassis/GND There is continuity for all wires and no short circuit Replace/Repair Wire Harness. Replace MD6DC PCB “D” (PL 11.2). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-235...

  • Page 635: Square Folder, Led Lamp Pcb "L"Faulty

    The voltage is 12 VDC ± 10%. • Replace/Repair Wire Harness. • Replace LED Lamp PCB “L” (PL 10.0) • Replace MD6DC PCB “D” Replace LED Lamp PCB “L” (PL 10.0). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-236...
  • Page 636 Reconnect the Power connection cable to the Trimmer and G.P2, leave Square Folder disconnected. Power on, inside Trimmer measure VDC between A.P4-4 to A.P4-5 (12V and GND). The voltage is 12VDC±10% Continued on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-237...
  • Page 637 No 12VDC RAP, continued Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-238...
  • Page 638 • Measure VDC at the counter connector between the orange and D.P10-2 (GND) The voltage is 30 VDC ± 10%. • Repair/replace harness. • Replace MD6DC PCB “D” • Replace Counter (PL 10.8). • Replace MD6DC PCB “D” Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-239...
  • Page 639 • Measure between the white wire Q4 and the black wire Q4 (Signal and GND). The voltage is 5 VDC ± 10%. Repair/replace harness. • Replace sensor TR-Q4. • Replace MD6DC PCB “A”. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-240...
  • Page 640 • Select Transport motor (M1) and Trim Knife motor (M2) and check motors. • Ensure that nothing interferes with the mechanical movement. Both motors energizes. • Lubricate where needed. Continued on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-241...
  • Page 641 TR-002 Transport Knife Motor TR-M1 timeout TR-Q5, continued Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-242...
  • Page 642 Is there a short circuit. The voltage is 22 VDC ± 10%. Replace MD6DC PCB “A”. Replace MD6DC PCB “A”. Repair/replace harness. Repair/replace harness. Replace motor TR-M1. Replace motor TR-M1. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-243...
  • Page 643 Is there a short circuit The voltage is 28 VDC ± 10%. Replace MD6DC PCB “A”. Replace MD6DC PCB “A”. Replace/Repair Wire Harness. Replace/Repair Wire Harness. Replace motor TR-M2 Replace motor TR-M2 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-244...
  • Page 644 • Measure between the red wire Q5 and the black wire Q5 (5V and GND). • Measure between the white wire Q5 and the black wire Q5 (Signal and GND). The voltage is 5 VDC ± 10%. Continued on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-245...
  • Page 645 The voltage is 28 VDC ± 10%. Replace MD6DC PCB “A”. Replace/Repair Wire Harness. • Ensure that nothing interferes with the mechanical movement. • Ensure chain is tensioned correctly. • Lubricate where needed. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-246...
  • Page 646 • Measure between the red wire Q7 and the black wire Q7 (5V and GND). • Measure between the white wire Q7 and the black wire Q7 (Signal and GND). The voltage is 5 VDC ± 10%. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP)
  • Page 647 The voltage is 28 VDC ± 10%. Is there a short circuit Replace MD6DC PCB “A”. Replace MD6DC PCB “A”. Replace/Repair Wire Harness Replace/Repair Wire Harness. Replace motor TR-M3. Replace motor TR-M3. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-248...
  • Page 648 The voltage is 5 VDC ± 10%. Replace/Repair Wire Harness. • Replace motor TR-M4 (PL 11.9). • Replace MD6DC PCB “A”. . Go to TR-012 Length Adjustment Motor (TR-M4) cycle timeout Q12 RAP Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-249...
  • Page 649 Enter Service mode and select length adjustment motor (M4) in check motors. The motor energizes. Replace motor TR-M4 (PL 11.9) • Check allen screws on TR-M4 drive gears (PL 11.9) • Lubricate where needed. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-250...
  • Page 650 The voltage is 30 VDC ± 10%. Is there a short circuit Replace MD6DC PCB “A”. Replace/Repair Wire Harness. Replace MD6DC PCB “A”. Replace motor TR-M4 (PL 11.9). Replace/Repair Wire Harness. Replace motor TR-M4 (PL 11.9). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-251...
  • Page 651 • Disconnect C.P1 to PWM To DC PCB “C” and C.P2, • Start blowers M5/M6 in check motors. • Measure VDC between C.P1-1 and C.P1-2 The voltage is 24 VDC ± 10%. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-252...
  • Page 652 • Check continuity for the black wire at plug Q15 to D.P2-6 • Check for short circuit between red/white/black wires • Check for short circuit between red/white/black wires to chassis/GND There is continuity for all wires and no short circuit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-253...
  • Page 653 The voltage is 28 VDC ± 10%. Is there a short circuit Replace MD6DC PCB “A”. Replace MD6DC PCB “A”. Replace/Repair Wire Harness. Replace/Repair Wire Harness. Replace motor TR-M8 (PL 11.6). Replace motor TR-M8 (PL 11.6). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-254...
  • Page 654 • Check for short circuit between red/white/black wires to chassis/GND Is there continuity and no short circuit between cables Replace/Repair Wire Harness. Replace sensor TR-Q2 (PL 11.4). Replace sensor TR-Q2. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-255...
  • Page 655 • Check for short circuit between red/white/black wires to chassis/GND There is continuity for all wires and no short circuit Replace/Repair Wire Harness. Replace sensor TR-Q13 (PL 11.5). Replace sensor TR-Q13 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-256...
  • Page 656 • Check for short circuit between red/white/black wires • Check for short circuit between red/white/black wires to chassis/GND There is continuity for all wires and no short circuit Replace/Repair Wire Harness. Replace sensor TR-Q3 Replace sensor TR-Q3 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-257...
  • Page 657 • Check for short circuit between red/white/black wires to chassis/GND There is continuity for all wires and no short circuit Replace/Repair Wire Harness. Replace sensor TR-Q8 (PL 11.1). Replace/Repair Wire Harness. Replace sensor TR-Q6 (PL 11.11). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-258...
  • Page 658 There is continuity for all wires and no short circuit There is continuity for all wires and no short circuit Repair wire Harness. Repair wire Harness. Replace sensor TR-Q14 (PL 11.11). Replace sensor TR-Q15 (PL 11.6). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-259...
  • Page 659 • Check for short circuit between red/black wires and between red wires to chassis/GND There is Continuity on all wires and no short circuit between red/black wires and red wires to chassis. Continued on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-260...
  • Page 660 Replace MD6DC PCB “D” (PL 11.2) Exit Replace MD6DC PCB “D” (PL 11.2) Success Go to No 30VDC from SCP PCB “D” in Booklet Maker service manual Continued on next page Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-261...
  • Page 661 TR-150, continued Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-262...
  • Page 662 Go to BM-152 30VDC High at Lower MD6DC PCB “C” in Booklet Maker service manual. Success • Replace MD6DC “A” in Trimmer • Replace MD6DC “D” in Square Folder Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-263...
  • Page 663 • Keep the machine powered off • Keep the mains power cord, A.P13, A.P16 and B.P2 disconnected, • Close the top cover, measure resistance between B.P-2 and B.P2-3. There is 10kohm±10% Continued on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-264...
  • Page 664 • Keep the mains power cord, A.P13, A.P16 and B.P2 disconnected • Open the top cover, disconnect white wire from SW1-3, measure resistance between white wire and chassis. There is a short circuit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-265...
  • Page 665 • Check for short circuit between red/white/black wires • Check for short circuit between red/white/black wires to chassis/GND There is continuity for all wires and no short circuit Replace/Repair Wire Harness. Replace sensor TR-Q1 (PL 11.2). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-266...

  • Page 666: Infeed Sensor Tr-Q13 Not Activated In Time

    • Go to Trimmer Transport RAP. • Go to Trimmer Transport RAP. • Go to Folding Unit RAP. • Go to Trim Knife RAP. • Go to Folding Unit RAP. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-267...

  • Page 667: Paper Path Sensor Tr-Q14 Not Activated In Time

    • Go to Trimmer Blower RAP. • Go to Trimmer Transport RAP. • Go to Trim Knife RAP. • Go to Trimmer Blower RAP. • Go to Trim Knife RAP. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-268...

  • Page 668: Exit Sensor Tr-Q6 Not Activated In Time

    • Go to Trimmer Blower RAP. • Go to Trimmer Transport RAP. • Go to Trim Knife RAP. • Go to Trimmer Blower RAP. • Go to Trim Knife RAP. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-269...

  • Page 669: Waste Bin Full

    • Check that both Trimmer Belt Assemblies are in their lower position Replace MD6DC PCB “A”. (REP 10.23, REP 10.24). Procedure • Perform ADJ 10.23 and 10.24. • Go to TR-021 TR-022 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-270...

  • Page 670: Trim Knife Rap

    Check Lift motor M8 and TR-Q15 (PL 11.6) according to GP4. The sensor and motor are working correctly Check for mechanical bindings, broken, missing or loose parts. Return to the previous RAP. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-271...

  • Page 671: No 12Vdc Rap

    • Reconnect the Power connection cable to the Trimmer and G.P2, leave Square Folder disconnected. • Power on, inside Trimmer measure VDC between A.P4-4 to A.P4-5 (12V and GND). The voltage is 12VDC±10% Continued on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-272...
  • Page 672 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-273...
  • Page 673 • Measure VDC at the counter connector between the orange and A.P11-2 (GND). The voltage is 30 VDC ± 10%. • Replace/Repair Wire Harness. • Replace MD6DC PCB “A”. • Replace Counter. • Replace MD6DC PCB “A”. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-274...

  • Page 674: Tr-Sw1 Interlock Circuit (Tr-Sw9,Tr-Sw10) Rap

    There is continuity Repair/replace harness • Keep the machine powered off and the mains power cord disconnected • Keep covers opened • Measure resistance between J25-4 and SW1-1 There is continuity Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-275...

  • Page 675: Trimmer, Led Lamp Faulty Rap

    The voltage is 12 VDC ± 10%. • Replace/Repair Wire Harness. • Replace LED Lamp PCB “L” (PL 11.2) • Replace MD6DC PCB “A” Replace LED Lamp PCB “L” (PL 11.2). Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-276...

  • Page 676: Af602 Fault Code Descriptions

    Stepper Motor M201 PCB (O) 48 Voltage Very High 1008 Fan204 Bin B Pulse Timeout Goto RAP 018 12/24/48V low or high Goto RAP 011 Fan x pulse time out Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-277...

  • Page 677: Fault Codes Only Presented At Performed Diagnostics

    Q201 Optical DSD Sensor Bin B Paper Present Goto RAP 009 M101/M201 Bin elevator upper home position sensor not activated in time/activated too long Check if paper is present at sensor. If not goto RAP 001 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-278...
  • Page 678 Stepper Motor M101 PCB (K) Current Malfunction Goto RAP 037 1078 Stepper Motor M201 PCB (O) Current Malfunction Goto RAP 038 1079 Stepper Motor M301 PCB (G) Current Malfunction Goto RAP 039 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-279...

  • Page 679: Af602 Raps

    Perform RAP 013 M301 Drive Motor Check M2/M3 Elevator Motor according to (REP 14.13) M2/M3 Elevator motor works Perform RAP 014 M101/M201 Elevator Motor If misfeed Perform RAP 107/207 Empty sensor. Else Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-280...

  • Page 680: Rap 101/201 Jam, Too Long, Bin A/B

    Enter the Service Mode (GP 1) Check optical DSD sensor Q101/201 according to GP 4 DSD Sensor Q101/201 works OK Perform RAP 001 Optical DSD sensor BSD on next page Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-281...
  • Page 681 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-282...

  • Page 682: Rap 107/207 Bin Empty, Bin A/B

    Swap PCB (that the faulty Empty sensor is connected to) with the PCB in the other bin. After swapping the PCB, set the address DIP switches to the settings shown in the circuit diagram. Empty sensor works at new PCB location Replace the PCB Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-283...
  • Page 683 Enter the Service Mode (GP 1) Check optical DSD sensor Q101/201 according to GP 4 DSD Sensor Q101/201 works OK Perform RAP 001 Optical DSD sensor Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-284...
  • Page 684 At the faulty location, disconnect sensor wire both from PCB and sensor. Check all wires (red, white, black) for short circuit and continuity. There is continuity and no short circuit Repair/replace harness Replace PCB “A” Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-285...
  • Page 685 Perform RAP 039 Stepper Motor Driver M301 PCB ”G” Check that transportation drive and idler rollers are in good working order Drive and idler rollers are OK Fix problem Ensure that AF602 is correctly installed. Check first for paper path misalignment and inter- face cables Installation is OK Re-install AF602 Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-286...
  • Page 686 When the Feeder wants to start feeding it asks for status from the downstream device (BM or RCT). If no response is received within a specified time, fault 401 is displayed. Initial Actions • Make sure that the communication cable is properly connected • See Service Manual BM3050-3 Section 4 BM-158 or Service Manual CST3050 Section 4 CST-150 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-287...
  • Page 687 After swapping the PCB, set the address DIP switches to the settings shown in the circuit diagram. Check sensor functionality. The optical DSD sensor at new PCB location works Replace the original CPU PCB (The one that causes the failure) Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-288...
  • Page 688 Power off, swap the US DSD sensor transmitter between the two BINs. After both transmit- ter and receiver have changed BIN location; power on, recalibrate the sensor and check functionality. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-289...
  • Page 689 There is continuity and no short circuit? Repair Harness Reconnect all connectors and Power on, measure VDC on sensor between pin 1 (red) and pin 4 (black) The voltage is 5VDC±10% Replace PCB “A” Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-290...
  • Page 690 PCB RAP “x” solved the problem Perform RAP 006 ICAN Circuit ICAN Circuit RAP solved the problem Replace the PCB “x” Exit Exit Perform RAP 006 ICAN Circuit BSD on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-291...
  • Page 691 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-292...
  • Page 692 F1 is blown Go to RAP 031 F1 Blown Fuse Go to RAP 034 PSU (12V) Go to RAP 026 CPU PCB “A” BSDs on next to next pages Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-293...
  • Page 693 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-294...
  • Page 694 Dip switch settings are OK Set correctly and exit Locate the open circuit by performing following steps: Check open circuit between [J5-4] to [J5-6] on PCBs “G” and “K”. Re- place the failed PCB Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-295...
  • Page 695 Check Home Position Sensor according to GP 4 Sensor works OK Go to RAP 010 Bin Elevator Upper and Lower Home Position Sensor Go to RAP 014 M101/M201 Elevator Motor Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-296...
  • Page 696 Swap PCB, that the faulty sensor is connected to, with the PCB in the other bin. After swap- ping the PCB, set the address dip switches to settings in the circuit diagram. Check sensor functionality Does home/outer sensor at new PCB location work Replace PCB Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-297...
  • Page 697 There is continuity and no short circuit Repair/replace harness Measure 24 volts at Fan location There are 24 volts at Fan location Replace the PCB Perform RAP 020 24/48 voltage very low entry RAP Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-298...
  • Page 698 Swap the faulty clutch with the one in the other bin. Check clutch functionality. Does clutch at new location work Replace clutch Go to RAP 020 24/48 voltage very low entry RAP Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-299...
  • Page 699 Swap the faulty stepper motor with one of the two bin stepper motors. Check motor func- tionality. Motor works at new location Replace motor Goto RAP 020 24/48 voltage very low entry RAP BSD on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-300...
  • Page 700 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-301...
  • Page 701 PCB, set the address DIP switches to settings in the circuit diagram. Check solenoid functionality. Does solenoid at new PCB location work Replace PCB Go to RAP 022 / RAP 023 Bin A / B 24V very low Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-302...
  • Page 702 Swap PCB that the faulty lamp is connected to with the one in the other bin. After swap- ping the PCB, set the address DIP switches to settings in the circuit diagram. Check lamp functionality. Does lamp at new PCB location work Replace PCB Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-303...
  • Page 703 Disconnect Counter and PCB connectors. Check all wires (red, white, black) for short cir- cuits and continuity. Also check for short circuits between all wires and chassis. There is continuity and no short circuit Repair/replace harness Replace Counter Replace PCB Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-304...
  • Page 704 V- to V+ at PSU(12V) (24V) 20.0-22.9V 25.1-27.8V 23.8-24.3 V V- to V+ at PSU(24V) V- at PSU(24V) to V+ (24/48V) 43.6-46.9 V 49.1-66.0 V 47.8-48.3 V at PSU(24/48V) 24/48V 24/48V TRIM Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-305...
  • Page 705 [C, P2-5] to [C, P2-12]. Also check for short circuit between BSD on next page all Orange wires at [C, P2] to all Black wires at [D, P2]. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP)
  • Page 706 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-307...
  • Page 707 Power off the machine. Keep V+ and V- disconnected, wait 5 seconds, Power on the ma- Exit chine and close the door. Measure voltage (VDC) between V+ and V- on the PSU (24/48V) Exit BSD on previous page output Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-308...
  • Page 708 [E, P2] and [I, P1], check continuity for all wires between Still “BIN A 24V very low” [I, P3] and [H, P1]. Replace the original CPU PCB “H” BSD on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-309...
  • Page 709 Power on Still “BIN A 24V very low” Replace the original 24V Distribution PCB “I” Go to RAP 020 24V/48V very low entry RAP Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-310...
  • Page 710 There is no short circuit Disconnect SOL201 and SOL202 connectors. Measure resistance be- tween connectors on the solenoid for both SOL201 and SOL202 The resistance is lower than 10 ohms BSD on previous page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-311...
  • Page 711 There is continuity Repair/replace harness Keep machine Powered off and the Power Cord disconnected. Measure continuity between connector [TR1-1] to [REL303, 14] and between [TR1-2] to [REL303, 34]. BSD on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-312...
  • Page 712 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-313...
  • Page 713 BIN Switch pos. 3 to [P4-20] and BIN Switch pos. 4 to [P4-21]. Check for short circuits between Black and White wire, and between Black/White wires and chassis. There is continuity and no short circuit Repair/replace harness Replace CPU PCB H/L Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-314...
  • Page 714 The voltage is 12VDC±10% Exit Replace PCB “B” Replace PCB “A” Measure VDC between GND and VCC (see image on following page). The voltage is 5VDC±10% Replace PCB “A” BSD’s on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-315...
  • Page 715 Deactivated=no plated holes are voltage present. connected to Activated= volt- age present, not +3,3VDC necessary the measuring point correct voltage level. VCC (+5VDC) measuring point LED D5 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-316...
  • Page 716 Power off, disconnect [H, P3], keep [H, P1] disconnected, power on. D5 Blue LED at PCB “H” is activated Go to RAP 016 LAMP (pay attention to short circuit measurements). BSD’s on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-317...
  • Page 717 Sensors. ing point, all four Deactivated=no plated holes are voltage present. connected to Activated= volt- age present, not necessary the +3,3VDC correct voltage measuring point level. VCC (+5VDC) measuring point Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-318...
  • Page 718 Power off, disconnect [L, P3], keep [L, P1] disconnected, power on. D5 Blue LED at PCB “L” is activated Go to RAP 016 LAMP (pay attention to short circuit measurements). BSD’s on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-319...
  • Page 719 Sensors. ing point, all four Deactivated=no plated holes are voltage present. connected to Activated= volt- age present, not +3,3VDC necessary the measuring point correct voltage level. VCC (+5VDC) measuring point Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-320...
  • Page 720 Leave connectors disconnected, Check for short circuits between the following positions: [A, P4-23,24], [A, P5-1,2,3,4] and [B, P2] to chassis. All Relay wires (six total) marked A1 and A2 to chassis Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP)
  • Page 721 Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before Repair/replace harness disconnecting, removing or replacing any electrical components or measuring Replace PCB “A” resistance inside the machine. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-322...
  • Page 722 PSU (12V) input. Check for short circuits from L to N, and L/N to chassis at the Repair/replace harness PSU (12V) input. Replace TR1 There are no short circuits Replace PSU (12V) (REP 14.33) BSD on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-323...
  • Page 723 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-324...
  • Page 724 The voltage is 90-264VAC. Replace REL301 (REP 14.36) Perform RAP 030 Door Switch software signal Success Perform RAP 029 Door Switch Interlock circuit Succes Replace Door switch Exit Exit BSD on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-325...
  • Page 725 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-326...
  • Page 726 Resistance > 200 ohms Repair/replace the Harness Leave connectors disconnected, Measure resistance between RELAY connectors (not har- ness connectors) A1 to A2. Resistance is 30-60 ohms BSD on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-327...
  • Page 727 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-328...
  • Page 728 Replace SW1 Keep the machine off and Power Cord disconnected. Measure continuity between SW1,5 Black1 wire to POW,1 and SW1,2 Black2 wire to POW,4. There is continuity BSD on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-329...
  • Page 729 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-330...
  • Page 730 The voltage is 90-264VAC for at least a short period of time. sent in the Line Module whenever the Power Cord is plugged into the Wall Outlet. Replace REL301 (REP 14.36) Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-331...
  • Page 731 The voltage is 90-264VAC for at least a short period of time. sent in the Line Module whenever the Power Cord is plugged into the Wall Outlet. Replace REL302 (REP 14.36) Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-332...
  • Page 732 The voltage is 5VDC±10% Power off, disconnect [K, P3], measure VDC between GND and VCC. The voltage is 5VDC±10% Replace PCB “K” (REP 14.37) Image, measuring points on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-333...
  • Page 733 VCC (+5VDC) measuring point +3,3VDC measuring point LED D30, motor Power in. Deactivated=no voltage present. Activated= voltage present, not necessary the correct voltage level. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-334...
  • Page 734 D5 Blue LED at PCB “L” is activated Replace PCB “O” (REP 14.37) Go to RAP 028 CPU PCB “L” Go to RAP 004 No ICAN Communication entry RAP Image measuring points on previous page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-335...
  • Page 735 [G, P5] to [B, P2], check short circuits between all wires connected to [G, P5], and between all wires from [H, P5] to chassis. Image, measuring points on page 4-324 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-336...
  • Page 736 Replace the original Stepper Motor M101 PCB “K” Exit Exit Image measuring points on page 4-328 BSD’s on next page Image measuring points on page 4-328 BSD’s on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-337...
  • Page 737 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-338...
  • Page 738 Power on the machine. Still “Stepper Motor M301 PCB 48V very low” Replace the original Stepper Motor M301 PCB “G” Exit BSD’s on next page Image measuring points on page 4-328 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-339...
  • Page 739 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-340...
  • Page 740 Goto RAP 028 CPU PCB ”L” Goto RAP 106/206 1019 Stepper Motor M101 PCB (K) 48 Voltage Very Low 107/207 Bin Empty, Bin A/B Goto RAP 020 24V/48V very low entry RAP Goto RAP 107/207 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-341...
  • Page 741 Q101 Optical DSD Sensor Bin A Open Circuit 1041 Stepper Motor M301 PCB (G) 12 Voltage Low Goto RAP 001 Goto RAP 018 12/24/48V low or high 1042 Bin A CPU PCB (H) 12 Voltage Low Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-342...
  • Page 742 Q104, M101 Upper Home Position Sensor Not Activated in Time/Activated Too Long Goto RAP 045 SP Sensor 1087 Q204 M201 Upper Home Position Sensor Not Activated in Time/Activated Too Long Goto RAP 045 SP Sensor Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-343...
  • Page 743 M2/M3 Elevator motor works Perform RAP 014 M101/M201 Elevator Motor Check Empty Sensor according to GP 4 Empty Sensor works Perform RAP 107/207 Empty Sensor Perform RAP 044 Vacuum Solenoid and Brake Clutch Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-344...
  • Page 744 Enter the Service Mode (Service tables) Check optical DSD sensor Q101/201 according to GP 4 DSD Sensor Q101/201 works OK Perform RAP 001 Optical DSD sensor BSD on next page Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-345...
  • Page 745 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-346...
  • Page 746 Swap PCB (that the faulty Empty sensor is connected to) with the PCB in the other bin. After swapping the PCB, set the address DIP switches to the settings shown in the circuit diagram. Empty sensor works at new PCB location Replace the PCB Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-347...
  • Page 747 Enter the Service Mode (GP 1) Check optical DSD sensor Q101/201 according to GP 4 DSD Sensor Q101/201 works OK Perform RAP 001 Optical DSD sensor Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-348...

  • Page 748: Rap 300 Exit Miss

    At the faulty location, disconnect sensor wire both from PCB and sensor. Check all wires (red, white, black) for short circuit and continuity. There is continuity and no short circuit Repair/replace harness Replace PCB “A” Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-349...
  • Page 749 Perform RAP 039 Stepper Motor Driver M301 PCB ”G” Check that transportation drive and idler rollers are in good working order Drive and idler rollers are OK Fix problem Ensure that VF602 is correctly installed. Check first for paper path misalignment and inter- face cables Installation is OK Re-install VF602 Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-350...
  • Page 750 When the Feeder wants to start feeding it asks for status from the downstream device (BM or RCT). If no response is received within a specified time, fault 401 is displayed. Initial Actions • Make sure that the communication cable is properly connected • See Service Manual BM3050-3 Section 4 BM-158 or Service Manual CST3050 Section 4 CST-150 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-351...
  • Page 751 After swapping the PCB, set the address DIP switches to the settings shown in the circuit diagram. Check sensor functionality. The optical DSD sensor at new PCB location works Replace the original CPU PCB (The one that causes the failure) Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-352...
  • Page 752 Power off and swap the US DSD sensor transmitter between the two BINs. After both the transmitter and receiver have been moved to the other bin: power on, recalibrate the sensor and check functionality. DIP settings on previous page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-353...
  • Page 753 There is continuity and no short circuit? Repair Harness Reconnect all connectors and Power on, measure VDC on sensor between pin 1 (red) and pin 4 (black) The voltage is 5VDC±10% Replace PCB “A” Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-354...
  • Page 754 PCB ‘x’ RAP solved the problem Perform RAP 006 ICAN Circuit ICAN Circuit RAP solved the problem Replace the PCB “x” Exit Exit Perform RAP 006 ICAN Circuit BSD on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-355...
  • Page 755 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-356...
  • Page 756 F1 is blown Go to RAP 031 F1 Blown Fuse Go to RAP 034 PSU (12V) Go to RAP 026 CPU PCB “A” BSDs on next to next pages Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-357...
  • Page 757 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-358...
  • Page 758 The resistance is lower than 50 ohms (short circuit) Disconnect [P5] and [P6] on PCB “G” and “K”. Check DIP switch settings for PCB “G” and “K” (See GP’s) DIP switch settings are OK Set correctly and exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-359...
  • Page 759 Check Home Position Sensor according to GP 4 Sensor works OK Go to RAP 010 Bin Elevator Upper and Lower Home Position Sensor Go to RAP 014 M101/M201 Elevator Motor Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-360...
  • Page 760 Swap PCB, that the faulty sensor is connected to, with the PCB in the other bin. After swap- ping the PCB, set the address DIP switches to settings in the circuit diagram. Check sensor functionality Does home/outer sensor at new PCB location work Replace PCB Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-361...
  • Page 761 There is continuity and no short circuit Repair/replace harness Measure 24 volts at Fan location There are 24 volts at Fan location Replace the PCB Perform RAP 020 24/48 voltage very low entry RAP Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-362...
  • Page 762 Swap the faulty clutch with the one in the other bin. Check clutch functionality. Does clutch at new location work Replace clutch Go to RAP 020 24/48 voltage very low entry RAP Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-363...
  • Page 763 Go to RAP 020 24/48 voltage very low entry RAP tionality. Motor works at new location Replace motor Goto RAP 020 24/48 voltage very low entry RAP BSD on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-364...
  • Page 764 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-365...
  • Page 765 PCB, set the address DIP switches to settings in the circuit diagram. Check solenoid functionality. Does solenoid at new PCB location work Replace PCB Go to RAP 022 / RAP 023 Bin A / B 24V very low Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-366...
  • Page 766 Swap PCB that the faulty lamp is connected to with the one in the other bin. After swap- ping the PCB, set the address DIP switches to settings in the circuit diagram. Check lamp functionality. Does lamp at new PCB location work Replace PCB Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-367...
  • Page 767 Disconnect Counter and PCB connectors. Check all wires (red, white, black) for short cir- cuits and continuity. Also check for short circuits between all wires and chassis. There is continuity and no short circuit Repair/replace harness Replace Counter Replace PCB Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-368...
  • Page 768 V- to V+ at PSU(12V) (24V) 20.0-22.9V 25.1-27.8V 23.8-24.3 V V- to V+ at PSU(24V) V- at PSU(24V) to V+ (24/48V) 43.6-46.9 V 49.1-66.0 V 47.8-48.3 V at PSU(24/48V) 24/48V 24/48V TRIM Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-369...
  • Page 769 [C, P2-5] to [C, P2-12]. Also check for short circuit between BSD on next page all Orange wires at [C, P2] to all Black wires at [D, P2]. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP)
  • Page 770 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-371...
  • Page 771 Power off the machine. Keep V+ and V- disconnected, wait 5 seconds, Power on the ma- Exit chine and close the door. Measure voltage (VDC) between V+ and V- on the PSU (24/48V) Exit BSD on previous page output Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-372...
  • Page 772 Measure continuity for all wires between [E, P2] and [I, P1], check continuity for all wires between [I, P3] and [H, P1]. Replace PCB “K” There is continuity Replace PCB “I” Replace the failed FAN/Q102 Repair/replace harness BSD on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-373...
  • Page 773 Power on machine. Still “BIN A 24V very low” Replace the original 24V Distribution PCB “I” Go to RAP 020 24V/48V very low entry RAP Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-374...
  • Page 774 Still “BIN B 24V very low” There is no short circuit Replace the original 24V Distribution PCB “M” Go to RAP 020 24V/48V very low entry RAP BSD on previous page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-375...
  • Page 775 There is continuity Repair/replace harness Keep machine Powered off and the Power Cord disconnected. Measure continuity between connector [TR1-1] to [REL303, 14] and between [TR1-2] to [REL303, 34]. BSD on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-376...
  • Page 776 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-377...
  • Page 777 BIN Switch pos. 3 to [P4-20] and BIN Switch pos. 4 to [P4-21]. Check for short circuits between Black and White wire, and between Black/White wires and chassis. There is continuity and no short circuit Repair/replace harness Replace CPU PCB H/L Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-378...
  • Page 778 The voltage is 12VDC±10% Exit Replace PCB “B” Replace PCB “A” Measure VDC between GND and VCC (see image on following page). The voltage is 5VDC±10% Replace PCB “A” BSD’s on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-379...
  • Page 779 Deactivated=no plated holes are voltage present. connected to Activated= volt- age present, not necessary the +3,3VDC correct voltage measuring point level. VCC (+5VDC) measuring point LED D5 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-380...
  • Page 780 Measure VDC between GND and 3,3VDC (see image on next page). The voltage is 3,3VDC±5% Go to RAP 016 LAMP (pay attention to short circuit measurements). Replace PCB “H” Exit BSD’s on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-381...
  • Page 781 Deactivated=no plated holes are voltage present. connected to Activated= volt- age present, not necessary the +3,3VDC correct voltage measuring point level. VCC (+5VDC) measuring point LED D5 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-382...
  • Page 782 Measure VDC between GND and 3,3VDC (see image on following page). The voltage is 3,3VDC±5% Go to RAP 016 LAMP (pay attention to short circuit measurements). Replace PCB “L” Exit BSD’s on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-383...
  • Page 783 Deactivated=no plated holes are voltage present. connected to Activated= volt- age present, not necessary the +3,3VDC correct voltage measuring point level. VCC (+5VDC) measuring point LED D5 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-384...
  • Page 784 Leave connectors disconnected, Check for short circuits between the following positions: [A, P4-23,24], [A, P5-1,2,3,4] and [B, P2] to chassis. All Relay wires (six total) marked A1 and A2 to chassis Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP)

  • Page 785: Rap 030 Door Switch Software Signal

    Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before Repair/replace harness disconnecting, removing or replacing any electrical components or measuring Replace PCB “A” resistance inside the machine. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-386...

  • Page 786: Rap 031 F1 Blown Fuse

    PSU (12V) input. Check for short circuits from L to N, and L/N to chassis at the Repair/replace harness PSU (12V) input. Replace TR1 (REP 15.44) There are no short circuits Replace PSU (12V) (REP 15.36) BSD on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-387...
  • Page 787 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-388...

  • Page 788: Rap 032 Interlock Mismatch

    The voltage is 90-264VAC. Replace REL301 (REP 15.39) Perform RAP 030 Door Switch software signal Success Perform RAP 029 Door Switch Interlock circuit Succes Replace Door switch Exit BSD on next page Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-389...
  • Page 789 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-390...

  • Page 790: Rap 033 Motor Relay

    Resistance > 200 ohms Repair/replace the Harness Leave connectors disconnected, Measure resistance between RELAY connectors (not har- ness connectors) A1 to A2. Resistance is 30-60 ohms BSD on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-391...
  • Page 791 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-392...

  • Page 792: Rap 034 Psu (12V)

    Replace SW1 Keep the machine off and Power Cord disconnected. Measure continuity between SW1,5 Black1 wire to POW,1 and SW1,2 Black2 wire to POW,4. There is continuity BSD on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-393...
  • Page 793 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-394...
  • Page 794 The voltage is 90-264VAC for at least a short period of time. sent in the Line Module whenever the Power Cord is plugged into the Wall Outlet. Replace REL301 (REP 15.39) Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-395...
  • Page 795 The voltage is 90-264VAC for at least a short period of time. sent in the Line Module whenever the Power Cord is plugged into the Wall Outlet. Replace REL302 (REP 15.39) Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-396...
  • Page 796 The voltage is 5VDC±10% Power off, disconnect [K, P3], measure VDC between GND and VCC. The voltage is 5VDC±10% Replace PCB “K” (REP 15.40) Image, measuring points on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-397...
  • Page 797 VCC (+5VDC) measuring point +3,3VDC measuring point LED D30, motor Power in. Deactivated=no voltage present. Activated= voltage present, not necessary the correct voltage level. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-398...

  • Page 798: Rap 038 Stepper Motor Driver M201 Pcb "O

    D5 Blue LED at PCB “L” is activated Replace PCB “O” (REP 15.40) Go to RAP 004 No ICAN Communication entry RAP Go to RAP 028 CPU PCB “L” Image measuring points on previous page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-399...

  • Page 799: Rap 039 Stepper Motor Driver M301 Pcb "G

    [G, P5] to [B, P2]. Check for short circuits between all wires connected to [H, P5], and between all wires from [H, P5] to chassis. Image, measuring points on page 4-59 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP)

  • Page 800: Rap 041 Stepper Motor M201 Pcb 48V Very Low

    Replace the original Stepper Motor M101 PCB “K” Exit Exit Image measuring points on page 4-328 BSD’s on next page Image measuring points on page 4-328 BSD’s on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-401...
  • Page 801 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-402...

  • Page 802: Rap 042 Stepper Motor M301 Pcb 48V Very Low

    Power on the machine. Still “Stepper Motor M301 PCB 48V very low” Replace the original Stepper Motor M301 PCB “G” Exit BSD’s on next page Image measuring points on page 4-328 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-403...
  • Page 803 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-404...

  • Page 804: Rap 043 Sp Sensor

    Perform RAP 006 ICAN Circuit Success Exit Perform RAPs for both related CPU PCBs (skip the part that guides you back to RAP SP Sensor) Success Replace the SP Sensor (REP 15.35) Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-405...

  • Page 805: Rap 044 Vacuum Solenoid And Brake Clutch

    Replace the faulty 24V Distribution PCB Power off, swap the sol/clutch with the one from the other bin. Check solenoid functionality Does the sol/clutch work at the new location Replace the faulty sol/clutch Harness check: Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-406...
  • Page 806 Check upper position sensor according to GP 4 Sensor works OK Go to RAP 045 Bin Elevator Upper and Lower Home Position Sensor Go to RAP 014 M101/M201 Elevator Motor Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-407...

  • Page 807: Dip Switch Settings

    DIP Switch Settings Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-408...

  • Page 808: Cr3050 Fault Code Descriptions

    CR-113 Stepper motor driver CR-M1 PCB “H” No CAN communica- tion Goto RAP 010 No ICAN Communication RAP CR-114 Stepper motor driver CR-M1 PCB “E” too high / too low Goto RAP 025 12/24/48V low or high Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-409...
  • Page 809 Check all wires to sensor PhT and to sensor LED for short circuit and continuity. Also check for short circuits between all wires and chassis. There is continuity and no short circuit Repair/replace harness (PL1.9) Replace CPU PCB “A” (PL1.8) Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-410...
  • Page 810 Replace Exit sensor Cover the sensor with a piece of paper, measure VDC between [A,P4-2] and [A,P4-3] The voltage is lower than 0,8VDC Replace Q5 sensor Replace CPU PCB “A” (PL 1.8) Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-411...
  • Page 811 Swap positions for PCB “G” and PCB “H” . After swapping the PCBs, set the address dip switches to settings in the circuit diagram. Check sensor functionality. The sensor works Replace sensor Q7 (PL 1.5) Replace original PCB “G” (PL1.8) Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-412...
  • Page 812 Swap positions for PCB “H” and PCB “G” . After swapping the PCBs, set the address dip switches to settings in the circuit diagram. Check sensor functionality. The sensor works Replace sensor Q6 (PL1.6) Replace original PCB “H” (PL 1.8) Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-413...
  • Page 813 There is continuity and no short circuit Repair/replace harness Replace Counter, test Counter functionallity The Counter works Replace PCB “A” (PL 1.8) Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-414...
  • Page 814 Swap positions for PCB “E” and PCB “G” After swapping the PCBs, set the address dip switches to settings in the circuit diagram. Check motor functionality. The motor works Replace motor M1 (PL 1.2) Replace original PCB “E” (PL 1.8) Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-415...
  • Page 815 Swap positions for PCB “G” and PCB “H” After swapping the PCBs, set the address dip switches to settings in the circuit diagram. Check motor functionality. The motor works Replace motor M2 (PL1.5) Replace original PCB “G” (1.8) Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-416...
  • Page 816 Swap positions for PCB “H” and PCB “G” After swapping the PCBs, set the address dip switches to settings in the circuit diagram. Check motor functionality. The motor works Replace motor M3 (PL1.6) Replace original PCB “H” (PL1.8) Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-417...
  • Page 817 ICAN Circuit RAP solved the problem Deactivated=no voltage present. Acti- vated= voltage present, not necessary Replace the PCB “x” (PL 1.8) the correct voltage level. Exit Exit Perform RAP 011 ICAN Circuit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-418...
  • Page 818 The resistance lower than 50 ohm (short circuit) Disconnect [H,P5], [H,P6] and [A,P10]. Check dip switch settings for PCB “A” and “H”. Dip switch settings are OK Set correctly and exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-419...
  • Page 819 CR3050 The voltage is 12VDC±10% Success Go to RAP 020 SCP PCB ”K” Replace PCB “A” (PL 1.8) Replace PCB “A” (PL 1.8) BSDs on next to next pages Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-420...
  • Page 820 LED +3,3VDC measuring point VCC (+5VDC) measuring point LED D5, 12V logic Power in. Deactivated=no voltage present. Acti- vated= voltage present, not necessary the correct voltage level. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-421...
  • Page 821 Power off and disconnect the Power Cord, check status of F1 located in the power inlet. F1 is blown Go to RAP 023 F1 Blown Fuse Go to RAP 012 CPU PCB “A” Go to RAP 012 CPU PCB “A” Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-422...
  • Page 822 Replace PCB “E” (PL 1.8) Measure VDC between GND and 3,3VDC (see image). The voltage is 3,3VDC±5% Replace PCB “E” (PL 1.8) Goto RAP 010 No ICAN Communication entry RAP Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-423...
  • Page 823 VCC (+5VDC) measuring point +3,3VDC measuring point LED D30, motor Power in. Deactivated=no voltage present. Activated= voltage present, not necessary the correct voltage level. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-424...
  • Page 824 Measure VDC between [L, J2-1] to [L, J2-4] at PCB “L”.(PCB Connector) The voltage is 12VDC±10% Go to RAP 021 SCP PCB ”L” Perform RAP 018 Top Cover Switch Interlock circuit Succes Replace PCB “G” (PL 1.8) Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-425...
  • Page 825 Replace PCB “H” (PL 1.8) Measure VDC between GND and 3,3VDC (see image). The voltage is 3,3VDC±5% Replace PCB “H” (PL 1.8) Goto RAP 010 No ICAN Communication entry RAP Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-426...
  • Page 826 Replace the Stepper Motor Driver PCB mentioned in the failure code Perform RAP 018 Top Cover Switch Interlock circuit Success Perform RAP 019 Top Cover Switch software signal Success Replace REL1 (PL 1.7) Exit Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-427...
  • Page 827 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-428...
  • Page 828 [A,P4-23] and [A, P4-24] [A,P4-23] and [A,P4-24] to chassis, [L,P2-1] and chassis, [REL1-A1] and [REL1-A2] to chassis [REL1-A1] and [REL1-A2] [A,P5-1,2] and chassis, There are no short circuits Repair/replace harness (PL 1.9) Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-429...
  • Page 829 Switch pos. 3 to [A, P4-23] and Top Cover Switch pos. 4 to [A, P4-24]. Check short circuit between Black to White wire and between Black and White wires to chassis. There is continuity and no short circuit Repair/replace harness (PL 1.9) Replace PCB “A” (PL 1.8) Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-430...
  • Page 830 Power off, disconnect [K,P1], measure continuity between all wires from PSU (12V) to [K,P1] also measure for short circuit between all red wires Exit from PSU (12V) to chassis and from all red wires to black wires. Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-431...
  • Page 831 Replace PCB “L” (PL 1.8) PSU (12V) to [L,P1] also measure for short circuit between all red wires from PSU (12V) to chassis and from all red wires to black wires. Exit Exit Exit Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-432...
  • Page 832 Entry to input at PSU (12V) ([L] and [N]). Set SW1 (Main switch) on. Important: The Power Cord must be disconnected! There is continuity Replace PSU (12V) (PL 1.8) Repair/replace harness between Power Entry to PSU (12V). (PL 1.9) Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-433...
  • Page 833 PSU (12V) input. Check short circuit between L to N, L and N to chassis at the PSU (12V) input. There are no short circuits Replace PSU (12V) (REPx) (PL 1.8) Locate and Repair/replace harness between SW1 and REL1/PSU (12V) BSD on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-434...
  • Page 834 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-435...
  • Page 835 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-436...
  • Page 836 V- to V+ at PSU(24V) Run diagnostics and check service codes V- at PSU(24V) to V+ Code is a single code (24/48V) <40 V >55V 47.8-48.3 V at PSU(24/48V) BSD on previous page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-437...
  • Page 837 Replace the original Stepper Motor M2 PCB “G” (PL 1.8) Exit Image measuring points on page 4-17 BSD’s on next page Image measuring points on page 4-17 BSD’s on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-438...
  • Page 838 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-439...
  • Page 839 PCBs before power on the machine. Power on. Still “Stepper Motor M1 PCB 48V to high/low” Replace the original Stepper Motor M3 PCB “H” (PL 1.8) Exit Image measuring points on page 4-17 BSD’s on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-440...
  • Page 840 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-441...
  • Page 841 The voltage is 24VDC±10% for at least a short period of time (measure during a period of at least 10 seconds after Power ON). “N” means no reaction at all on the output Replace PSU (24/48) (PL 1.8) Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-442...
  • Page 842 [N, P2-5] to [N, P2-12]. Also check for short circuit between all Orange wires at [N, P2] to all Black wires at [M, P2] BSD on next page Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP)
  • Page 843 Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-444...
  • Page 844 Power Cord when it is necessary to work inside the Power Module. AC Power is pre- sent in the Line Module whenever the Power Cord is plugged into the Wall Outlet. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP)
  • Page 845 Perform NVM reset according to GP20 Re-load S/W according to GP4 Replace PCB controller according to REP 16.25. Plockmatic BM3050 system 27 August 2019 4. Troubleshooting (RAP) 4-446...
  • Page 846 PCB Printer Interface PCB ”E” LEDs ............5-35 GP 58 PCB M21 “K” (Upper Bin M101) AF602/VF602 .........5-53 GP 29 MD6DC PCB LEDs ..................5-35 GP 59 PCB M21 “O” (Lower Bin) AF602/VF602 ..........5-54 Plockmatic BM3050 system 27 August 2019 5. Service tables (GP)
  • Page 847 PCB CPU APP 32 “A” CR3050 ..............5-56 GP 64 PCB M21 “E” (Motor M1) CR3050 .............5-56 GP 65 PCB M21 “G” (Motor M2) CR3050 .............5-57 GP 66 PCB M21 “H” (Motor M3) CR3050 .............5-57 Plockmatic BM3050 system 27 August 2019 5. Service tables (GP)

  • Page 848: Service Tables (Gp)

    NOTE: When entering SP mode, password is reset to the default value 107. Turn on the main power. When the text “Loading...” appears, press and hold a finger on the screen. Plockmatic BM3050 system 27 August 2019 5. Service tables (GP)

  • Page 849: Gp 2 Resetting / Changing The Service Mode Password

    Exit the Service mode by switching off the main power or press the [Exit] button once to go back to the “Service menu, select target” screen. Press the [Exit] button once more to leave Service menu and enter the operator mode. Plockmatic BM3050 system 27 August 2019 5. Service tables (GP)

  • Page 850: Gp 3 Diagnostics

    0 errors found” is displayed. If the two stapler cartridges were removed, reinstall them (REP 4.0 Stapler Heads, Stapler Assy and Clincher). Dock the Booklet Maker to the upstream device. Plockmatic BM3050 system 27 August 2019 5. Service tables (GP)

  • Page 851: Gp 4 Check Motors / Solenoids / Sensors

    WARNING! For safety reasons you have to press the [Unlock knife] button to be able to start TR-M2. Also you have to press the [Unlock knife] button between every cycle. Plockmatic BM3050 system 27 August 2019 5. Service tables (GP)
  • Page 852 BM-M9 ≈269mm - Staple/Fold Position Motor adjusts the position of the staple ≈460mm stop, fold stop and back jogger for different paper sizes. Continued on next page Plockmatic BM3050 system 27 August 2019 5. Service tables (GP)
  • Page 853 TR-M8 Lifter motor ST-M1 15V ±2V or Stacker Motor transports the set on the Belt Stacker. 24V ±2V or 29V ±2V Continued on next page Plockmatic BM3050 system 27 August 2019 5. Service tables (GP)
  • Page 854 Elevator motors. Moves the bin trays up and down. M301 Transport motor. Run all the belt transports in the machine. FAN101-104 Bin blowers. Air separates the sheets. FAN201-204 Continued on next page Plockmatic BM3050 system 27 August 2019 5. Service tables (GP)
  • Page 855 Vacuum release solenoid. Actuates the vacuum gasket plate open and SOL203 closed. SOL104, Brake Clutch. Stops the vacuum belts when engaged. This must be test- SOL204 ed manually, by rolling the vacuum belts and turning on the clutch. Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-10...
  • Page 856 0 = Unblocked Infeeder, paper path sensor BM-Q19 0 = No staple Staple detection clinch left BM-Q20 0 = No staple Staple detection clinch right Continued on next page Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-11...
  • Page 857 Sensor activated at end point. Length Adjustment Home Position Switch TR-Q14 0 = Unblocked Paper path sensor TR-Q15 1 = Motor home Lift motor home position sensor Continued on next page Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-12...
  • Page 858 Lower bin Ultrasonic distance meter Q303 0=Unblocked Paper exit sensor S301/S302 0 = Closed Interlock Door Switch S101/S102 0 = Closed Interlock Upper Bin (A) S201/S202 0 = Closed Interlock Lower Bin (B) Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-13...

  • Page 859: Gp 6 Voltmeter

    BM-M2 Back jogger motor LOWER BM-M3 Side jogger motor BM-M6 Fold roller motor BM-M21 Right stapler CF-M16 Drive Motor Ground only to: BM Set counter Continued on next page Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-14...
  • Page 860 Regulated 48VDC distributed through PCB “M” from 24V Power Supply Unit (1) MD1SM PCB “J” 24V (48V) Power Supply Unit (2), 48V is only present when the interlock relay (REL 1) is activated. Voltage supplies: M3 Cycle motor Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-15...
  • Page 861 Regulated 12V on PCB (L) M301 Motor PCB(G) 11.8V-12.3V Regulated 12V on PCB (G) M101 Motor PCB(K) 11.8V-12.3V Regulated 12V on PCB (K) M201 Motor PCB(O) 11.8V-12.3V Regulated 12V on PCB (O) Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-16...

  • Page 862: Gp 7 Dead Cycle

    Select Module: Remove the two stapler heads. Go to Dead Cycle. Press START to start the dead cycling. Press STOP to stop the dead cycling. GP 8 Not in use Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-17...

  • Page 863: Gp 10 Nvm Values

    Press [Go back] to reach XX Service Components menu. Press [Home] to reach Target selection menu. Press [Exit Service] when ready to exit service mode. continued on next page Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-18...
  • Page 864 Power save timeout Default 20 BM M6(Speed2) Default 2400 TR M1(Speed2) Default 1850 BM M8 up fast speed Default 1200 continued on next page BM M8 up slow speed Default 500 Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-19...
  • Page 865 1=On at the lead screw. Default value: 0 Counter Counter for Creased sheets CT Antistatic On/Off switch for Antistatic device in Waste channel. Waste 0=Off 1=On Default value: 0 Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-20...
  • Page 866 US Dist meter compensation B 100%) detection Fan malfunction PWM 10 (%) (max Limit for function detection US Distance Process Position 100%) Vacuum A US Distance Process Position Vacuum B Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-21...

  • Page 867: Gp 11 Bm Fold Delay

    If booklet quality is not acceptable, go to section Booklet Quality to adjust mechanical parameters. CST Module Procedure Perform BQ2 , BQ3, BQ4, BQ5, BQ6, BQ7 and BQ8. Continued on next page. Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-22...
  • Page 868 Continued on next page. Correctly positioned tool Not correctly positioned tool Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-23...
  • Page 869 BQ 7 Crease position in Process Direction (Mismatch) and BQ 8 Crease Insufficient Quality (Spine Cracking despite Crease) Incorrect, play between tool and Back Jogger Fingers. Correct, no play/no tension between tool and Back Jogger Fingers. Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-24...

  • Page 870: Gp 13 Trimmer Service (Trimmer Module)

    Ensure Blow Type is set to Fans. To change, press the OK button. With the Arrow button, select Fans. Press the OK button. Press Cancel to exit Trimmer Service. Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-25...

  • Page 871: Gp 15 Sqf Service Adjust Stop Gate (Square Folder Module)

    It counts up to 1000 and then resets to 0. To get the actual hardware count, check the hardware counter in the CST. Multiply by 1000 and add the number shown according to the procedure described above. Plockmatic BM3050 system 27 August 2019 5. Service tables (GP)
  • Page 872 Timing items, etc. Paper Jams Operator messages (low staples, Trimmer basket full) User Interface Example: CF-202 indicates a jam at the CF-Q3 (M4) Front Sensor in the Cover Feeder. Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-27...

  • Page 873: Gp 19 Update Software

    M21H Bin CPU Main CPU failure. Latest software can be downloaded from Plockmatic Customer center NOTE: https://plockmaticgroup.com/customer-login/ Single point download will only work for upgrades of system where all PCB’s already have valid software of minimum launch version. New PCB’s come without any software so if any Tools PCB is replaced, you must first load it individually with a valid software.
  • Page 874 1. Double-click file “BM3050_3035 Book Fold MD6DC v1.0.0 Win05.exe” and follow instruc- Procedure (AF602 M21H v.x.xx Win01, Main motor PCB “G”): 1. Double-click file and follow instructions in the loading window tions in the loading window continued on next page Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-29...
  • Page 875 1. Double-click file and follow instructions in the loading window Procedure (AF602 M21H v.x.xx Win01, Main motor PCB “G”): 1. Double-click file and follow instructions in the loading window Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-30...

  • Page 876: Gp 20 Nvm Reset

    Components menu. chine for future reference 18. Select item [NVM]. 19. Re-enter NVM values BM: Index 2-7 and 11 recorded in step 4. continued on next page Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-31...
  • Page 877 Record critical reset GP 20. NVM values (see GP 12 & 20) on a piece of paper and store in ma- chine for future reference continued on next page Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-32...

  • Page 878: Gp 21 Bm Calibrate Transport Pressure

    GP 22 Cheat Trimmer cover 15min Purpose This procedure will explain how to bypass the Trimmer Safety feature. Procedure Go to GP 4, section How to use the software cheater. Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-33...

  • Page 879: Gp 24 Sqf Adjust Mode

    Select [NVM] Scroll down to NVM 23 and/or 24. Enter a new value by pressing the [+] or [-] buttons and confirm by pressing the [OK] button. Press [Exit] Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-34...

  • Page 880: Gp 26 30Vdc Psu (Power Supply Sp-750-27) Led

    - System has an in-complete Interlock circuit (such as Cover/s open). - System has a missing / disconnected Power and / or Communication Cable/s. - System is in Power Saver Mode. Plockmatic BM3050 system 27 August 2019 5. Service tables (GP)

  • Page 881: Gp 28 Pcb Printer Interface Pcb "E" Leds

    NOTE: The description above applies to all MD6DC PCB’s in the system: • MD6DC “H” - BM • MD6DC “B” - BM • MD6DC “C” - BM • MD6DC “A” - TR • MD6DC “D” - SQF Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-36...

  • Page 882: Gp 30 Controller Pcb "A" Leds And Test Points

    The voltage will be shown on the voltmeter. Range 4.9-5.1V. GND / PGND: Ground /Power Ground is the negative reference when measuring either 30V or 5V LED (Flashes) (VCC). GND/PGND GND/ PGND Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-37...

  • Page 883: Gp 32 4In 4Out Pcb "J" Leds

    GP 32 4IN 4OUT PCB ”J” LEDs Purpose Provides an explanation of the LED indications on the PCB. D1 = Yellow LED Lit when Interlockswitch SW1(SW17 Soft Signal) activated. Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-38...

  • Page 884: Gp 33 Addon Pcb "F" Testpoints

    GP 33 Addon PCB ”F” Testpoints Purpose Provides testpoints on the PCB. GND / PGND: Ground /Power Ground is the minus Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-39...

  • Page 885: Gp 34 Set Size Guide

    A4 or 8.5x11" A3 or 11 x 17" A4 or 8,5 x 11" Paper weight Area Coverage Area Coverage Area Coverage Area Coverage Bond Offset Cover Index Full Full Full Full Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-40...

  • Page 886: Gp 35 Tag Matrix And Serial Plate Location Bm

    GP 35 Tag Matrix and Serial Plate Location BM The Tag Matrix for the BM is located on the inside of the exit cover [A]. The Serial Plate is located at the Rear Plockmatic BM3050 system 27 August 2019 5. Service tables (GP)

  • Page 887: Gp 36 Tag Matrix And Serial Plate Location Trimmer

    The tag matrix is located on on the inside of the infeed frame [A]. The serial plate is located at the Rear [B]. The serial plate is located at the Rear [B]. Plockmatic BM3050 system 27 August 2019 5. Service tables (GP)

  • Page 888: Gp 38 Tag Matrix And Serial Plate Location Ct

    The Tag Matrix is located on the inside of the rear frame [A]. located inside the Rear Cover of the Booklet Maker The Serial Plate is located at the rear [B]. Plockmatic BM3050 system 27 August 2019 5. Service tables (GP)

  • Page 889: Gp 40 Interlock Cheater Location

    The interlock cheaters for BM, TR and SQF are located inside the Booklet Maker [A]. WARNING! Always use extreme caution when operating the machine with any interlock switch cheated. Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-44...

  • Page 890: Gp 41 Cst Cpu / Controller Pcb "A" Leds

    5V is missin, Yellow LED would be OFF. Red LED is ON when the software activates 5V to J6 pins 1-6 and J13 pins 1, 4, 7, 10, 14, 17, 20, 23 Plockmatic BM3050 system 27 August 2019 5. Service tables (GP)

  • Page 891: Gp 43 Cst Stepper Motor Driver

    Stepper Motor Driver (M1) PCB “E”, “H” and Stepper Motor Driver (M3) PCB “J”, before the first system initiation the Red LED is flashing. Red LED is ON when hold current is active. Plockmatic BM3050 system 27 August 2019 5. Service tables (GP)

  • Page 892: Gp 45 Cst I/O 4In4Out Pcb "G

    +5VDC measured from GND/PGND Q11 activated GND/ Ground / Power Ground is the minus when measuring voltage PGND in the machine such as, VCC (+5VDC), +24VDC and +48VDC Q12 activated, optional Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-47...

  • Page 893: Gp 47 Cst Md3Dc Solenoid Driver Pcb "B" Test Points

    VCC (+5VDC), +24VDC and +48VDC +UNREG +24VDC measured from GND/PGND. The +24VDC is not present when interlock relay is inactivated; the voltage will be 0VDC in this state. Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-48...

  • Page 894: Gp 49 Cst Controller Pcb Cpu "A

    1 2 3 4 Remove Rear Cover. Remove Rear Cover. Remove screw ( Remove screw ( x 1) and fold out PCB [A]. x 1) and fold out PCB [A]. Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-49...

  • Page 895: Gp 50 Cst Pcb Md3Dc "B

    (* v1.00 is an example - use latest version) and follow the instruction in the program, or according to the latest bulletin. according to the latest bulletin. 1 2 3 4 1 2 3 4 Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-50...

  • Page 896: Gp 52 Cst Pcb Md1Sm "D

    (* v1.00 is an example - use latest version) and follow the instruction in the program, or according to the latest bulletin. according to the latest bulletin. 1 2 3 4 1 2 3 4 Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-51...

  • Page 897: Gp 54 Cst Pcb Md1Sm "J

    DIP-switches 3 and 4 is set to OFF (down) position Run the CST MD1SM v1.00.exe* file (* v1.00 is an example - use latest version) and follow the instruction in the program, or according to the latest bulletin. Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-52...

  • Page 898: Gp 55 Pcb Cpu App 32 "A" Af602/Vf602

    (* v1.00 is an example - use latest version according to the latest bulletin) and follow the instruction in the program. and follow the instruction in the program. 1 2 3 4 5 6 Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-53...

  • Page 899: Gp 57 Pcb Cpu App 32 "L" Af602/Vf602

    (* v1.00 is an example - use latest version according to the latest bulletin) (* v1.00 is an example - use latest version according to the latest bulletin) and follow the instruction in the program. and follow the instruction in the program. Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-54...

  • Page 900: Gp 59 Pcb M21 "O" (Lower Bin) Af602/Vf602

    (* v1.00 is an example - use latest version according to the latest bulletin) and follow the instruction in the program. and follow the instruction in the program. 1 2 3 4 5 6 Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-55...

  • Page 901: Service Tables (Gp)

    (* v1.00 is an example - use latest version according to the latest bulletin) (* v1.00 is an example - use latest version according to the latest bulletin) and follow the instruction in the program. and follow the instruction in the program. Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-56...
  • Page 902 (* v1.00 is an example - use latest version according to the latest bulletin) and follow (* v1.00 is an example - use latest version according to the latest bulletin) and follow the instruction in the program. the instruction in the program. Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-57...
  • Page 903 (* v1.00 is an example - use latest version according to the latest bulletin) and follow (* v1.00 is an example - use latest version according to the latest bulletin) and follow the instruction in the program. the instruction in the program. Plockmatic BM3050 system 27 August 2019 5. Service tables (GP) 5-58...
  • Page 904 Belt Stacker Module ..................... 6-6 6.2.8 Square Folder (Squareforming Module) ............. 6-7 6.2.9 Trimmer (Face Trimmer Module) ................ 6-8 6.2.10 AF602 ........................6-9 6.2.11 VF602 ........................6-10 6.2.12 CR3050 ......................... 6-11 6.2.13 CST ........................6-11 Plockmatic BM500 system 27 August 2019 6. Detailed Description...

  • Page 905: Detailed Description

    Back Joggers (x4) Sensor Q13 Motor M3 (in- (driven by Motor M2 (M3 home) cluding Q12) After final sheet has been tamped, staple cycle will start. and Sensor Q44) Plockmatic BM500 system 27 August 2019 6. Detailed Description...

  • Page 906: Stapler And Staple Stop Gate Modules

    This is done by motor M23 and sensor Q36 that senses thickness of set. This sensor also provides info to adjust staple-line, trim length as well as square fold mode. BK-clinch right BK-clinch left solenoid solenoid (including Q20) (including Q19) Plockmatic BM500 system 27 August 2019 6. Detailed Description...

  • Page 907: Pre-Fold Transport Module

    When the set is folded and leaves the Start Sensor Saddle Stapling Q4, (M22 home) the staple stop gate moves up, preparing to receive new sheets. By stopping in variable positions, different staple positions can be obtained. Plockmatic BM500 system 27 August 2019 6. Detailed Description...

  • Page 908: Folding Module

    15 seconds. If the sheet length is more than 400mm, fold delay is not used. Motor M7 and Plockmatic BM500 system 27 August 2019 6. Detailed Description...

  • Page 909: Belt Stacker Module

    ST-M1 for a short while to separate the booklets on the stacker period. Principle of Operation is same if it is mounted to the TR or the SQF, Exit sensor activates ST-M1. ST-M1 Plockmatic BM500 system 27 August 2019 6. Detailed Description...
  • Page 910 Trimmer Module. For some modes, multiple cycles are used. Motor M3 Motor M3 Motor M4 (including Q8) Sensor Q7 (2 pieces, 1 pcs underneath paperpath Sensor Q5 (2 pieces) Plockmatic BM500 system 27 August 2019 6. Detailed Description...
  • Page 911 When Exit sensor Q6 activates, stop gate motor M3 moves the stop gate to up position and is stopped when the stop gate home position sensor Q7 activates. Sensor Q4 Motor M4 (including Q12) Motor M3 Sensor Q7 Plockmatic BM500 system 27 August 2019 6. Detailed Description...

  • Page 912: Af602

    Exit sensor verifies that sheet exits in time • Machine continues running until programmed job ends or bin is empty • Machine stops after last sheet in set and waits for “go” signal Plockmatic BM500 system 27 August 2019 6. Detailed Description...

  • Page 913: Vf602

    Exit sensor verifies that sheet exits in time • Machine continues running until programmed job ends or bin is empty • Machine stops after last sheet in set and waits for “go” signal Plockmatic BM500 system 27 August 2019 6. Detailed Description 6-10...

  • Page 914: Cr3050

    When the sheets exit the unit, they pass an exit sensor (Q5) to ensure set integrity. • The crease unit is controlled from the Booklet Makers user interface. CST-M1 CST-M4 Plockmatic BM500 system 27 August 2019 6. Detailed Description 6-11...
  • Page 915 PCB Voltage levels PCB voltages are measured upon power on. If measeured values are not within voltage range, one or more of folllowing faultcodes will be trig- gered and displayed. Plockmatic BM500 system 27 August 2019 6. Detailed Description 6-12...
  • Page 916 The Creaser tool home sensor (Q5) is used for positioning purposes at initiation. If the home sensor signal dont change state, after a reasonable amount of time after initiation of M6 during run, following faultcode will be triggered: Plockmatic BM500 system 27 August 2019 6. Detailed Description...
  • Page 917 44-2004 Sensor Q6 Not deactivated in time after start of M7. To avoid mechanical binding, the M1 system must be running and SOL3 deactivated when M7 initiation is done. CST-Q5 CST-SOL3 Plockmatic BM500 system 27 August 2019 6. Detailed Description 6-14...
  • Page 918 (609 [mm]) / (transport speed [m/s]) ± 20% + t r (Rotation) And only if Creasing is selected. The last sheet will also trigger the Stapling action in the Booklet Maker. t r = sheets rotation time. Plockmatic BM500 system 27 August 2019 6. Detailed Description 6-15...
  • Page 919 If straight transport is selected, M3 will run at 100% of the Transport Speed. Faultcode CST-010 (Q7 activated too long) is triggered: If Rotation is selected, M3 will run at about 50% of the Transport Speed. Plockmatic BM500 system 27 August 2019 6. Detailed Description...
  • Page 920 SOL2 is deactivated (nip is actived) when sheets are rotating. SOL3, Bleed Trimmer Disengage Solenoid The purpose of this solenoid is to enable the Upper and Lower Bleed Trimmer Blades to disengage Plockmatic BM500 system 27 August 2019 6. Detailed Description...
  • Page 921 Booklet Maker ........................7-2 Trimmer ..........................7-3 Square Folder ........................7-3 CST ............................7-4 CR ............................7-4 AF602 Air Feeder / VF602 Vacuum Feeder ............... 7-5 Booklet quality specification .................... 7-6 Set Size Guide........................7-7 Plockmatic BM3050 system 27 August 2019 7. Specifications...

  • Page 922: Specifications

    2 – 50 sheets or 2 – 35 sheets Stapled Sheets (80 gsm / 20 lb. Bond or equivalent) (Stapled) Plockmatic uses QT open source license (LGPL) to develop the software used in this Input / Output 1 – 2 sheets Non stapled folding machine (https://www.qt.io/qt-licensing-terms).

  • Page 923: Trimmer

    14”x 35.5” x 24.5” Power Source Powered from Booklet Maker * When trimming SRA3 (450mm): Booklets minimum trimming is 5mm. When trimming 18” : Booklets minimum trimming is 9mm. Continued on next page. Plockmatic BM3050 system 27 August 2019 7. Specifications...

  • Page 924: Cst

    Input / Output Sheets Same as Booklet Maker Power Source 100- 230V / 50-60Hz ±10% Input / Output Sheets Same as Booklet Maker Power Consumption 400W or less Continuous operation Off-line Use Not possible Plockmatic BM3050 system 27 August 2019 7. Specifications...

  • Page 925: Af602 Air Feeder / Vf602 Vacuum Feeder

    1050 x 1250 x 705 mm 42” x 50” x 28” Power Source 100-240 V / 50-60 Hz +6%, -10% Power Consumption 4A @ 230V, 8A @ 100V Continuous operation Operating temperature 10-30°C Plockmatic BM3050 system 27 August 2019 7. Specifications...

  • Page 926: Booklet Quality Specification

    * Last 15 mm of side trim is allowed to deviate ± 1 mm. Booklet outside specification are less than 0.5 %. Measurements on folded sets are taken from the inside of the booklet. Transport direction Fig 1 Fig 2. Plockmatic BM3050 system 27 August 2019 7. Specifications...

  • Page 927: Set Size Guide

    A3 or 11x17" A4 or 8.5x11" A3 or 11 x 17" A4 or 8,5 x 11" Paper weight Area Coverage Area Coverage Area Coverage Area Coverage Bond Offset Cover Index Full Full Full Full Plockmatic BM3050 system 27 August 2019 7. Specifications...
  • Page 928 8.3 BM-TR Trimmer ......................8-4 8.4 BM-CST Rotator Creaser Trimmer ................8-5 8.4 BM-CR ........................8-6 8.5 BST4000-1 High Capacity Stacker ................8-7 8.6 AF602 Feeder ......................8-8 8.7 VF602 Feeder ......................8-9 Plockmatic BM3050 system 27 August 2019 8. Wiring...

  • Page 929: Wiring

    BM3050 Booklet Maker including Cover Feeder Plockmatic BM3050 system 27 August 2019 8. Wiring...

  • Page 930: Bm-Sqf Square Folder

    BM-SQF Square Folder Plockmatic BM3050 system 27 August 2019 8. Wiring...

  • Page 931: Bm-Tr Trimmer

    BM-TR Trimmer Plockmatic BM3050 system 27 August 2019 8. Wiring...

  • Page 932: Bm-Cst Rotator Creaser Trimmer

    BM-CST Rotator Creaser Trimmer Plockmatic BM3050 system 27 August 2019 8. Wiring...

  • Page 933: Bm-Cr

    BM-CR Plockmatic BM3050 system 27 August 2019 8. Wiring...

  • Page 934: Bst4000-1 High Capacity Stacker

    BST4000-1 High Capacity Stacker Plockmatic BM3050 system 27 August 2019 8. Wiring...

  • Page 935: Af602 Feeder

    AF602 Feeder Plockmatic BM3050 system 27 August 2019 8. Wiring...

  • Page 936: Vf602 Feeder

    VF602 Feeder Plockmatic BM3050 system 27 August 2019 8. Wiring...
  • Page 937 VF602 Feeder (continued) Plockmatic BM3050 system 27 August 2019 8. Wiring 8-10...
  • Page 938 BQ 17 Back Jogger Parallel and Aligned to Sheet ............9-28 BQ 18 BookFold Module, Square form quality ............. 9-29 BQ 19 Face Trim skew ....................9-30 BQ 20 Face Trim length ....................9-30 Plockmatic BM3050 system 27 August 2019 9. Booklet Quality (BQ)

  • Page 939: Booklet Quality (Bq)

    1 mm 0.2mm Fold Position ±0.3 mm ±0.3 mm 0.2mm Face Trim skew 1.0 mm 1.0 mm 0.2mm Face Trim position ±0.5 mm ±0.5 mm ±0.2mm Continued on next page Plockmatic BM3050 system 27 August 2019 9. Booklet Quality (BQ)
  • Page 940 Side guides too tight Set is prevented from reaching fold stop by side guides too tight Select larger paper width and test Adjust NVM 2 Continued on next page Plockmatic BM3050 system 27 August 2019 9. Booklet Quality (BQ)
  • Page 941 BQ7 alignment rail Side trim not parallel Sheet is skew side trimmed and appear as skew crease Check per BQ2 Perform per BQ2 Continued on next page Plockmatic BM3050 system 27 August 2019 9. Booklet Quality (BQ)
  • Page 942 Skew paper will always be folded skew Measure paper or compare two Replace paper trim sheets after flipping one over on long edge Side trim, skew Same as skew paper Check per BQ2 Perform per BQ2 Plockmatic BM3050 system 27 August 2019 9. Booklet Quality (BQ)
  • Page 943 Crease quality is good (No cracks in spine) out divided by two. Wi-Wo = Strip width Crease Insufficient Quality Perform BQ8 Bleed trim Image Offset Perform BQ4 Continued on next page Plockmatic BM3050 system 27 August 2019 9. Booklet Quality (BQ)
  • Page 944 Back joggers are parallel and aligned to paper Adjust staple form Perform BQ12 Adjust back jogger position Perform BQ17 The staples have the same distance to lead edge Continued on next page Plockmatic BM3050 system 27 August 2019 9. Booklet Quality (BQ)
  • Page 945 Check trim quality. Sheet edges are clean cut, free from fraying and burrs Check that upper knife is correctly tight- ened REP 10.18 Check adjustment of lower knife REP 10.19 Plockmatic BM3050 system 27 August 2019 9. Booklet Quality (BQ)

  • Page 946: Bq 2 Bleed Trimmer Not Parallel To Registration Edge (Skew Cut)

    Do not over adjust. That can cause jam on thicker stock and wrinkles on thinner stock. Continued on next page. Plockmatic BM3050 system 27 August 2019 9. Booklet Quality (BQ)
  • Page 947 7. Tighten lock nuts. play Perform BQ 6 Bleed Trimmer Cutting Quality (Dull or damaged Knives) Turn these screws coun- terclockwise 2 turns when adjusting Continued on next page. Plockmatic BM3050 system 27 August 2019 9. Booklet Quality (BQ) 9-10...
  • Page 948 Loosen screws [A] (x2). Position solenoid CT-SOL4 and tighten the screws to achieve the play according to below figure (when activated). Transportation Disengage Solenoid (CT-SOL4) position, activated Continued on next page. Plockmatic BM3050 system 27 August 2019 9. Booklet Quality (BQ) 9-11...
  • Page 949 Ensure that Solenoid lever is in contact with the stop when screws (x4) are tightened [A]. Loosen screw and position solenoid linkage to achieve 2±0.5mm (5/64±1/64”) when solenoid is closed [B]. Tighten screw. Plockmatic BM3050 system 27 August 2019 9. Booklet Quality (BQ)

  • Page 950: Bq 3 Bleed Trimmer Sheet Width (Mismatch)

    ±0.2mm from the Sheet Width entered on the UI. within ±0.2mm to the actual measured offset. • Adjust RCT [NVM 4 RCT M7 Offset] • Adjust RCT [NVM 3 RCT M4 Offset] Plockmatic BM3050 system 27 August 2019 9. Booklet Quality (BQ) 9-13...
  • Page 951 - Loosen screws [J] to adjust Waste guide position. 4. Replace the Bleed Trimmer Knives per REP 13.1 and REP 13.2 Rear side (non operator side) knives viewed from rear side Paper travelling direction Plockmatic BM3050 system 27 August 2019 9. Booklet Quality (BQ) 9-14...
  • Page 952 4. Lock the tap screw with the nut and tighten the four screws [B]. 5. Run sheets through and check the trim quality. 6. If not good enough, repeat procedure. Plockmatic BM3050 system 27 August 2019 9. Booklet Quality (BQ)
  • Page 953 Registration Edge (operator side) within ±0.2mm. • Hold the Creaser Space Unit [C] and loosen screws [D] (x2). Position the Creaser Assembly so that the Crease is perpendicular within 0.2 mm. Plockmatic BM3050 system 27 August 2019 9. Booklet Quality (BQ)

  • Page 954: Bq 7 Crease Position In Process Direction (Mismatch)

    • Adjust NVM value if the difference is bigger than ±0.2mm. • Add the Difference calculated to the current value in NVM2 CT Creasing Offset. Continued on next page Plockmatic BM3050 system 27 August 2019 9. Booklet Quality (BQ) 9-17...
  • Page 955 • Loosen the locknuts [E] and turn the set screw (x2) [F] so that the Limiting plunger gets in contact with the ball bearing and then back out 1/8 turn • Tighten the locknuts [E] (x2) NOTE: Viewed from front side of module. Continued on next page Plockmatic BM3050 system 27 August 2019 9. Booklet Quality (BQ) 9-18...
  • Page 956 • Check that tools not interfere on any side by turning them in process direction with CT-M6 • Loosen the screws [E] and [F]. pulley. [ I ] Groove is leading Process direction Plockmatic BM3050 system 27 August 2019 9. Booklet Quality (BQ) 9-19...

  • Page 957: Bq 9 Transport Feed Force

    The adjustment is now completed. 10. Re-assemble the staple bracket assembly [D]. 11. Run some books and check booklet quality 12. Enter new NVM value to NVM tag in BM top cover Plockmatic BM3050 system 27 August 2019 9. Booklet Quality (BQ) 9-20...

  • Page 958: Bq 10 Side Guide Parallelism

    Adjust the paper / side guide [A] per step 2 ( x2 ). • Tighten screws [C] and [D], recheck alignment. 4. Perform the same check on the rear side guide, adjust if needed. Plockmatic BM3050 system 27 August 2019 9. Booklet Quality (BQ)

  • Page 959: Bq 11 Side Guide Position (Side Registration Quality)

    If system is equipped with CT and TR, • Adjust staple position if needed, as described in next section make sure to turn off trimming before testing booklet quality. Continued on next page Plockmatic BM3050 system 27 August 2019 9. Booklet Quality (BQ) 9-22...
  • Page 960 • If above adjustment isn’t enough, loosen screw [F] (red painted) • Move stapler bracket in desired direction. • Tighten screws [F] Staple legs with marks from surrounding slot Plockmatic BM3050 system 27 August 2019 9. Booklet Quality (BQ) 9-23...

  • Page 961: Bq 13 Staples Parallel To Lead Edge

    11. Disconnect connectors P43, P44 and P47(x3) [C] for the stapler. 12. Remove stapler bracket assembly. 13. Remove nuts (x4) [D] and bracket [E]. 14. Enter service mode, select [Motors]. Continued on next page. Plockmatic BM3050 system 27 August 2019 9. Booklet Quality (BQ) 9-24...
  • Page 962 24. Loosen screws (x3) [H] until the stop gate can rotate around the middle screw. 25. Adjust position of stop gate. 26. Tighten screws (x3) [H] 27. Remount removed parts. Plockmatic BM3050 system 27 August 2019 9. Booklet Quality (BQ) 9-25...

  • Page 963: Bq 14 Fold Skew

    Right adjustment screw counterclockwise. If booklet is skewed as in figure rotate to adjust the fold pocket (x2) in following way : Left adjustment screw counterclockwise, Right adjustment screw clockwise. Plockmatic BM3050 system 27 August 2019 9. Booklet Quality (BQ) 9-26...

  • Page 964: Bq 15 Fold Position On Staples

    Note: One full turn of the adjustment screws [B] will move the fold stop 0.7 will move the fold stop 0.7 mm 5. Repeat from item 1. Sets presented as exiting system Clockwise counter-clockwise Plockmatic BM3050 system 27 August 2019 9. Booklet Quality (BQ) 9-27...

  • Page 965: Bq 16 Staple And Fold Position

    Decrease value (-) to make lead edge side of booklet longer, (move foldstop and staple stop up) Sets presented as exiting system Lead edge too short Lead edge too long Decrease value Increase value Press (-) to lengthen Press (+) to shorten Plockmatic BM3050 system 27 August 2019 9. Booklet Quality (BQ) 9-28...

  • Page 966: Bq 17 Back Jogger Parallel And Aligned To Sheet

    If not: Adjust the jogger position with screw [A] until they reach the edge. 7. Check that all four fingers simultaneously reach the paper edges. If not: Loosen screws (x2) [B] and adjust the angle. Plockmatic BM3050 system 27 August 2019 9. Booklet Quality (BQ)

  • Page 967: Bq 18 Bookfold Module, Square Form Quality

    Case 3 Turn adjustment nuts (2) CW No adjustment needed. Turn adjustment nuts (2) equally in operator and non- CCW equally in operator operator side. side and non-operator side. Plockmatic BM3050 system 27 August 2019 9. Booklet Quality (BQ) 9-30...

  • Page 968: Bq 19 Face Trim Skew

    5. Enter Service Mode and change NVM Value #11 so that the Booklet Width corresponds with the selected finished size. 6. Enter new trim zero value on sticker inside Trimmer module. Fig 1. Fig 2. Plockmatic BM3050 system 27 August 2019 9. Booklet Quality (BQ) 9-31...

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