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Morgana BM500 Operating Instructions Manual

Booklet maker system
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Doc no: T10200G
Date: 27 June 2017
BM350/BM500
Booklet Maker System
Read this manual carefully before you use this product and keep it handy for future
reference.
For safety, please follow the instructions in this manual.
Operating Instruction

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  • Page 1 BM350/BM500 Booklet Maker System Operating Instruction Read this manual carefully before you use this product and keep it handy for future reference. For safety, please follow the instructions in this manual. Doc no: T10200G Date: 27 June 2017...
  • 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 10m of the apparatus concerned.
  • Page 3 Introduction This manual contains instructions on the operation and maintenance of this machine. To get maximum versatility from this machine all operators should carefully read and follow the instructions in this manual. Keep this manual in a handy place near the machine. 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 e.g. 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 CAUTION: • The machine and its peripherels must be installed and maintained by a customer service representative who has completed the training course on those models. • Always follow all warnings marked on, or supplied with, the equipment. • When you disconnect the power plug from the wall outlet, always pull the plug (not the cable). •...
  • Page 6 PAGE INTENTIONALLY BLANK.

  • Page 7: Table Of Contents

    Booklet Maker ..........................13 User interface ..........................16 Control panel ........................16 Options ..........................18 BM350/500 Booklet Maker ......................18 Live logo ..........................18 SQF500 Square Fold Module ..................... 19 FTR500 Trimmer Module ......................21 CST500 Crease Trim Module ..................... 23 CR500 Creaser Module ......................
  • Page 8 Staple position ..........................49 Adjusting staple position ....................49 Fold position ..........................49 Adjusting fold position ......................49 Fine tuning booklet appearance ....................50 Face Trimming ..........................51 Select Face Trimming Auto or Manual ................51 Square Fold Module ........................52 General ..........................
  • Page 9 Booklet Maker ........................76 Clearing misfeed(s) ........................76 Inside the Booklet Maker ....................76 Clearing misfeed in folder area ..................77 AF602/VF602 Feeder module................... 78 Clearing misfeeds ........................78 Misfeed/Jam in feeder bin ....................78 Misfeed/Jam in paper transport area ................. 78 Square Fold Module ......................
  • Page 10 Cleaning AF602 ....................... 110 VF602 Feeder Maintenance ..................... 112 Cleaning VF602 ....................... 112 Limitations in the BM350/BM500 system ..............114 Best practice for the BM350/BM500 system ..............116 8. Specification Machine Specifications ....................117 BM350/BM500 Booklet Maker ....................117 Performance diagrams ......................118 Square Fold Module ........................

  • Page 11: What You Can Do With This Machine

    To enable full bleed booklets, an FTR Trim Module have to be installed after the Booklet Maker, se below. From the CST the print-outs are transported into the BM500 or BM350 Booklet Maker where they are compiled in the stapler area.
  • Page 12 continued from previous page When a larger number of sheets are folded, an effect called creeping occurs. In order to rectify creep, a Trimmer Module can be attached after the Booklet Maker. If so, the booklets are transported from the Booklet Maker into the Trimmer where the trail edge will be cut off.

  • Page 13: Guide To Components

    Guide To Components Booklet Maker Top cover Cover for Secondary Hand Feed Latch handle Live logo, only on BM500 (optional) Belt Stacker Belt Stacker Cover Slot for optional Cover Feeder Hand Feed Tray...
  • Page 14 Booklet Maker, continued Belt Stacker Connector Upstreams Communication Downstreams Communication Power Connection Hand feeding paper guides NOTE: How to connect cables, plugs and jumpers is described at the end of this manual.
  • Page 15 Booklet Maker, continued Hand feeding paper guides Compiler area Staple cartridges (incl. stapler heads) Main power switch Set thickness sensor Control panel Fold roller guide Staple cartridge ejection lever...

  • Page 16: User Interface

    User interface The BM350/BM500 system is controlled from a panel located on the Booklet Maker. The control panel will allow you to easily set up, adjust and operate the complete system. An optional “Live logo” makes state of system visible from a distance.
  • Page 17 The Jobs Screen Pressing the [Open Jobs] button in the Start screen opens the Jobs screen. From here you can open a saved job. You can also open a saved job, custom- ize it and store the new settings. Either and save job settings.

  • Page 18: Options

    Please wait screen will be shown. The machine will automatically return to the Start screen after changes have been implemented. Options BM350/500 Booklet Maker Live logo Live logo With a BM500 upgrade kit installed, the three stripes below the user interface will signal status as follows:...

  • Page 19: Sqf500 Square Fold Module

    SQF500 Square Fold Module Top cover Base Connections Cable protector NOTE: How to connect cables, plugs and jumpers is described at the end of this manual.
  • Page 20 SQF500 Square Fold Module, continued The Square Fold interior has parts that you will come in contact with if a misfeed occur. Left hand side upper feed belt can not be lifted fully Square Fold, top view, right hand upper feed belts is lifted up Lower feed belts Upper feed belt release latch Upper feed belts...

  • Page 21: Ftr500 Trimmer Module

    FTR500 Trimmer Module Top cover Trim bin Base Connections Cable protector NOTE: How to connect cables, plugs and jumpers is described at the end of this manual.
  • Page 22 FTR500 Trimmer Module, continued The Trimmer interior has parts that you will come in contact with if a misfeed occurs. Trimmer, top view Set counter Trimmer stop Exit drive release Pre-cut compressing brackets Upper knife Transport belt Trimmer fan Infeed roller shaft...

  • Page 23: Cst500 Crease Trim Module

    CST500 Crease Trim Module Top cover Infeed slot Upstream docking assembly Slide door...
  • Page 24 CST500 Crease Trim Module, continued Exit slot Trim waste transport Waste container Connections...
  • Page 25 CST500 Crease Trim Module, continued Connections bracket NOTE How to connect cables, plugs and jumpers is described at the end of this manual.
  • Page 26 CST500 Crease Trim Module, continued Exit section “D” Bleed trimmer circular knives Infeed Section “A” Main switch Counter...
  • Page 27 CST500 Crease Trim Module, continued Waste chute(s) Creaser registration adjustment Bleed trimmer registration adjustment Latch handle, slide...
  • Page 28 CST500 Crease Trim Module, continued Creaser tools Jam clearance baffle, fine registra- tion, section “C” Jam clearance baffle, coarse regis- tration, section “B” Rotator...

  • Page 29: Cr500 Creaser Module

    CR500 Creaser Module 1. Top cover 5. Connector to downstream device e.g. 2. Exit slot booklet maker 3. Infeed area 6. Main power connector 4. Connector, upstream device e.g. 7. Docking bracket, ACF510 AF602/VF602/ACF510 8. Docking bracket, AF602/VF602...
  • Page 30 CR500 Creaser Module, continued 1. Creaser tool 2. Jam clearance baffels, green dot 3. Infeed roller 4. Exit roller 5. Main power switch...

  • Page 31: Bst4000-1 Belt Stacker Module

    BST4000-1 Belt Stacker Module The BST4000-1 High Capacity Belt Stacker Module is available for the Booklet Maker System. The stacker can be configured straight after the booklet maker system or in a 90 degree angle. The Belt Stacker Module has parts that you will come in contact with if a misfeed occur. Control panel Conveyor belt Stacking tray...

  • Page 32: Bst4000-1 Principle Of Operation

    BST4000-1 Belt Stacker Module, continued Power switch (on/off) Belt speed selector Run-out button (full speed) BST4000-1 Principle of Operation The belt is triggered by a signal from the Booklet Maker and will run for a set time. The belt speed can be adjusted in order to optimize the stacking function for various materials. The Run-out button is used to gather the material after a job is finished.

  • Page 33: Air Assist Feeder Af602

    Air Assist Feeder AF602 Exit area Feed rollers Docking studs Optical double sheet de- Docking bracket tection sensor Door Ultrasonic double sheet Upper bin / Bin A detection sensor Jam clearance baffles (green) Rear paper guides with Power switch blower fans Lower bin / Bin B Rear paper guide Front and Rear Paper guide...

  • Page 34: Vacuum Feeder Vf602

    Vacuum Feeder VF602 Exit area Vacuum feed belts Docking studs Optical double sheet de- Docking bracket tection sensor Door Ultrasonic double sheet Upper bin / Bin A detection sensor Jam clearance baffles (green) Rear paper guides with Power switch blower fans Lower bin / Bin B Rear paper guide Front and Rear Paper guide...

  • Page 35: Basics

    1. Basics Turning On / Off Main Power Locating power switches Make sure that all power cords are plugged into the wall outlet. (AF/VF, CR/CST, BM and BST.) NOTE: Square Fold (optional) and/or Trimmer (optional) Modules are both powered from the Booklet Maker. Open Booklet Maker top cover [A].
  • Page 36 Locating power switches, continued The CST power switch [D] is located under top cover [C]. Close top cover after operating switch. The CR power switch [E]is located under its top cover. Close top cover after operating switch. The BST power switch [F] is located on its control panel.

  • Page 37: Loading Feeder Af602/Vf602

    Loading Feeder AF602/VF602 From the Ready screen, select [AF]/ [VF]. Press Load A, Load B or Load AB depending on which bin you intend to open and load. Bin A is the upper bin. NOTE If you open both bins: both bins cannot be pulled out fully at the same time, for stability reasons.

  • Page 38: Change Staple Cartridges And Check Stapler

    Change staple cartridges and Check stapler The staple cartridges contains approximately 5000 staples each. Each cartridge includes all wear-out and service parts (i.e. the stapler head). The cartridges may be removed either for renewal or for jam clearance. Change left/right staple cartridge(s) The Booklet Maker will indicate “Change left/ right/left and right staple cartridges”...

  • Page 39: Check Left/Right Stapler

    Check left/right stapler If the Booklet Maker indicates “Check left/right/ left and right stapler”, it means that there is a jam in the indicated stapler. Remove the stapler cartridge as described above. Open the Booklet Maker top cover. Press the staple cartridge ejector lever. Pull out the staple cartridge as described above.

  • Page 40: Emptying The Trim Bin

    Emptying the trim bin Remove the trim bin by lifting it and pulling it out. Remove the trim bin by lifting it and pulling it out. Trim bin Undocking the Booklet Maker Turn off the system and disconnect the main power cord. Push the docking latch [A].

  • Page 41: Belt Stacker

    Belt Stacker Setting up Belt Stacker for right-angled mode Move the inner Side Guide [A] as far as possible towards the Booklet Maker. Adjust the outer Side Guide [B] to give at least 5mm (1/4”) play. Tighten the Side Guides at both ends.

  • Page 42: Setting Up Belt Stacker For Straight Mode

    Setting up Belt Stacker for Straight Mode Adjust Side Guides to their outermost position by loosening knobs [A]. Adjust the stacking with belt speed selector.

  • Page 43: Job Preparation

    Job Preparation Paper stack preparation Hold the paper stack on a flat surface as shown Bend the paper stack Use your fingers and thumbs to pinch the paper stack With the paper pinched between your fingers, straighten out the paper stack Continued on next page...
  • Page 44 Paper stack preparation, continued Flex the paper back and forth a couple of times to break surface tension and preseparate the sheets Realign the sheets into a stack before putting them into the tray...
  • Page 45 Measuring the paper curl Take a sample of the stack (about 15 mm / 0.59” high) and place it on a flat surface Take the midpoint as reference and do all the measurements within the marked area of the picture (from the center to the leading edge in paper Measure within this area feed direction)
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  • Page 47: Making Booklets

    2. Making Booklets Changing settings General procedure Changed settings can be saved in two ways. Temporary, which means that the changes will remain until a new job is loaded or permanent, which means that the changes will be stored as a job. This job can later be recalled.

  • Page 48: Custom Sheet Size

    Custom sheet size From the Input Sheet Size screen, select Preset size No.1, Preset size No.2 or Custom sheet size and press the [Edit] button. Select Length and/or Width and key in the desired value. Save the custom size format by pressing the [OK] button.

  • Page 49: Staple Position

    Staple position Adjusting staple position From the Settings for Booklet Production screen, press the [Staple] button. Set to Manual, the staple position can be altered up to 3 mm (0.12”) on either side of the fold. Press the [+] button move position closer to the lead edge and press the [-] button move position closer to the trail edge.

  • Page 50: Fine Tuning Booklet Appearance

    Fine tuning booklet appearance You can fine tune the booklet quality by adjusting the joggers in the booklet maker. Press Finished Booklet Size Press Set Registration Fine Adjustment Press minus [-] to achieve a tighter registration. NOTE A too tight setting may worsen the result.

  • Page 51: Face Trimming

    Face Trimming Select Face Trimming Auto or Manual From the Settings for Booklet Production screen, press [Finished Booklet Size]. Trimming can now be set to No Trim, Auto Trim or Custom Booklet size. When trimming is set to Auto Trim booklet, a minimum trim, based on the information from Set Thickness Sensor, is calculated.

  • Page 52: Square Fold Module

    Square Fold Module General The Square Fold module has ten different settings - Auto, Off and Mode 1 up to Mode 8. Set to Auto, information from the set thickness sensor in the Booklet Maker is used to calculate the most appropriate mode between 1 to 7.

  • Page 53: Selecting Square Folding Mode

    NOTE When square forming thick booklets with a thin cover, the cover sheet may be spaced away from the body of the book and/or it may be crushed in the square forming process. This phenomenon is eliminated/reduced by using a heavier media as the cover. If using a heavier cover is not an option, using a lower MODE in the square forming process might help.

  • Page 54: Crease Trim Module (Option)

    Crease Trim Module (Option) Crease - Selecting Crease Mode From the Booklet Production screen, press [Crease]. The Creaser gives you the option to crease the cover sheet of the booklet in order to avoid image cracking or toner flaking at the fold. NOTE: Only for cover sheet, and less than 5 sheets.

  • Page 55: Bleed Trim Settings - General

    Bleed Trim Settings - General The bleed trim is automatically calculated. The example shows that an SRA3 input and an A4 booklet output will lead to a bleed trim of 11.5 mm on each side of the sheets. Sheet fed to the booklet maker will be 297x450mm.

  • Page 56: Setting Up A Feeder Job In Af602/Vf602

    Setting up a feeder job in AF602/VF602 Press the Feeder button. Press Add Layer. Select bin A, B or A & B Set desired Quantity, by pressing + or -. Press OK. NOTE: Linked Bins Bin AB can be selected when you have the same sheet size in both bins.

  • Page 57: Af602 Advanced Settings

    Setting up a feeder job in AF602/VF602, continued Example: Cover sheets are placed in bin A. Body sheets are placed in bin B. The job consists of 3 body sheets and one cover sheet. AF602 Advanced Settings To reach Advanced Settings, press the Adv button.
  • Page 58 AF602 Advanced Settings, continued Load while run When Linked Bins is running, Turning on Load While Run will make it so a bin that becomes empty will automatically open to allow for reloading of paper. DSD Settings Selecting DSD Settings will allow the user to view and control which DSD Sensors are active.

  • Page 59: Operation With Af602

    Operation with AF602 Proof After loading sheets, set up a job as described earlier in this section. Press Proof: the AF602 will feed one set into the booklet maker. This allows the user to check the first booklet before starting production.

  • Page 60: Vf602 Advanced Settings

    VF602 Advanced Settings To reach Advanced Settings, press the Adv. button. Here you can modify bin settings, modify paper loading settings, modify double sheet detection (DSD) settings, calibrate sensors and test the settings. Settings Bin A / Bin B The two trays of the VF602 can be set independently.
  • Page 61 VF602 Advanced Settings, continued Separation Air (S. Air) F.F. R.F. The Separation Air Fan blows air underneath the transportation belts at the leading edge of the paper stack to maintain paper separation during feeding. Front/Rear Float Air (F.F. Air/R.F. Air) V.
  • Page 62 VF602 Advanced Settings, continued Vacuum Pickup Time The Vacuum Pickup Time is the amount of time the vacuum is activated to feed each sheet. This value can be adjusted between 75 ms and 500 ms. Press [Vacuum Pickup Time] and adjust its value using the +/-.
  • Page 63 VF602 Advanced Settings, continued Load while run When Linked Bins is running, turning on Load While Run will make it so a bin that becomes empty will automatically open to allow for reloading of paper. Vacuum Size Valve The Vacuum Size Valve controls the size of the vacuum suction area on the bottom of the vacuum chamber.
  • Page 64 VF602 Advanced Settings, continued Test Settings The [Test Settings] button is used to check the manual settings. Press this button once and then [ON] to activate all the fans and move the elevator to process position according to your settings. Stack of unseparated paper The sheets will continue to float until you push [OFF] to stop the test mode: the fans will switch off and the...

  • Page 65: Operation With Vf602

    Operation with VF602 Proof After loading sheets, set up a job as described earlier in this section. Press Proof: if bins are set to “Manual”, the VF602 will feed one set into the booklet maker. This allows the user to check the first booklet before starting production.

  • Page 66: Hand-Feeding

    Hand-feeding The Booklet maker can also be operated in hand-feed mode, as a stand-alone unit. Hand feed mode Setup the Booklet Maker to the correct paper size. Open the Hand Feed Cover [A]. Adjust the hand feeding paper guides [B] to the correct paper size. Start hand feeding sets [C] when the text [Ready to feed!] is shown in the user interface.

  • Page 67: Hand Feed Mode Using The Tray

    Hand feed mode using the tray Undock the Booklet Maker from the upstream device (see section 1). Install the Hand Feed Tray [A]. Adjust the paper guides [B] to the correct paper size. Switch the Booklet Maker on and set it to the correct paper size. The Booklet Maker will enter in Hand Feed mode automatically as soon as the first set is fed.
  • Page 68 PAGE INTENTIONALLY BLANK.

  • Page 69: Tools

    3. Tools The Tools screen From the Start screen, press the [Tools] button to get to the Settings screen. Select the setting you want to change. Press the correspond- ing button. Press to save your chang- Stacker full detection Set Stacker Full Detection ON if you want the system to stop and cycle down when the stacker is full.

  • Page 70: Software Version

    Software version Select machine by pressing the corre- sponding button to display the software version. Press [Exit] button to go back to the Set- tings screen. Square Fold stop gate offset If you increase (+) the Square Fold offset the square forming will be stronger. Please note that this setting will change all jobs.

  • Page 71: Jobs

    4. Jobs Handling jobs The Booklet Maker has a maximum storage capacity of 20 different jobs. To make temporary changes in the actual job settings or temporary changes of a stored job, see section 2. Making Booklets. From the Start screen, press the [Jobs] button to be able to store, change or delete jobs. Saving a Job To store a new job, press from...

  • Page 72: Opening And Handling Stored Jobs

    Opening and handling stored Jobs To access already stored jobs, press from the Start Screen Rename, open (load) or delete any stored job by pressing the job button and choose action.

  • Page 73: Clearing Misfeed(S)

    5. Clearing Misfeed(s) Clearing misfeed(s) General If a misfeed condition should occur, it is indicated on the Booklet Maker display. The message “Clear Misfeed(s)”, an error code and the location of the misfeed is displayed. See examples below. Misfeeds in the Booklet Maker are indicated by the error code BM-XXX and visually where in the Booklet Maker the misfeed occured.

  • Page 74: Cst Module

    CST module Clearing misfeed(s) in the paper path Infeed “A” area and exit “D” area Open the top cover. Lift up “A” [A] and “D” [B] baffles if needed. Remove any misfeed(s). Lower “A” and “D” baffles to normal position Misfeed(s) in the trimmer area are rolled out by rotating the rubber surfaced pinch roller [C].

  • Page 75: Cst, Registration And Creaser Area

    CST, registration and creaser area Open the slide door [A]. Unlatch and pull out the slide [B]. Open “B” and “C” baffles if needed. Remove any misfeed(s). Push in and latch the slide. Always remove any residual waste from waste channel and waste [C] belt before closing the slide door.

  • Page 76: Booklet Maker

    Booklet Maker Clearing misfeed(s) Inside the Booklet Maker To remedy a misfeed condition inside the Booklet Maker, either discard the set by purging or, when it is possible, remove and save the set. NOTE The Attention Sign is located in various posi- tions, indicating Area A, B or C, counting from the inlet of the Booklet Maker.

  • Page 77: Clearing Misfeed In Folder Area

    Clearing misfeed(s), continued Clearing misfeed in folder area Open Top Cover. Open the fold roller paper guide [A] by lifting (arrow 1) and pivoting (arrow 2) to access any misfed or jammed sheets/booklets between the lower and upper pair of fold rollers.

  • Page 78: Af602/Vf602 Feeder Module

    AF602/VF602 Feeder module Clearing misfeeds Misfeed/Jam in feeder bin The affected bin will unlock. Pull out the bin. If the sheet has been misfed and isn’t damaged, re-position and re-start. If sheet(s) are damaged, remove the complete set and the next booklet will be correct. Misfeed/Jam in paper transport area 1.

  • Page 79: Square Fold Module

    Square Fold Module Clearing misfeed(s) Inside the Square Fold Module Open the top cover. Lift up upper feed belts (A) to access jammed/misfed booklets. NOTE: Press the green dots (B) (only one visible in picture) on the latches to release. Remove the jammed/misfed booklets.

  • Page 80: Trimmer Module

    Trimmer module Clearing misfeed(s) The upper trimmer blade on the trimmer is protected by a knife protection plate that moves away during the cutting stroke. WARNING: Never put fingers or other parts of the body between the upper and lower trimmer knives. Clearing misfeed in input area Raise the rightmost side of the infeed roller shaft assembly (A).

  • Page 81: Clearing Misfeed In Exit Area

    Clearing misfeed(s), continued Clearing misfeed in exit area Lift the exit compressing brackets and transport belts [B]. Secure using the latch [C]. Not clearly visible in picture Remove the misfed sheets from the exit area. After the misfed sheets are removed, release the latch [C] and place the exit compressing brackets in operating position.

  • Page 82: Belt Stacker

    Belt stacker Clearing misfeed(s) Clearing misfeed on belt stacker Lift the belt stacker exit cover (A). Remove jammed/misfed booklets. Place belt stacker exit cover back in operating position.

  • Page 83: Troubleshooting

    6. Troubleshooting Fault codes General When there is a misfeed or fault condition in the Booklet Maker system, a code and/or a message will be displayed on the UI. In case there is a problem that can be rectified by the operator, a fault code and an explanation will be displayed.
  • Page 84 BM-407 Too many Indicating there are too many sheets in the Booklet Maker. Remove set. sheets BM-xxx Fault in area, Indicates that there might be an internal communication error. power off and on Power off and on the system. If problem persists, contact customer support. Check right stapler Indicates jam in either or both staplers.

  • Page 85: General Fault Codes

    Set too thick, remove Indicates that the set is too thick to be folded. Remove set. SQF-201 - SQF-206 SQF A misfeed has occurred in the Square Fold module. Clear misfeed SQF-xxx SQF Indicates that there might be an internal communication error. Fault in area, power off Power off and on the system.

  • Page 86: Close Cover(S)

    Close cover(s) When the message “Close Cover(s)” is displayed any of the interlock switches are actuated. Check that the top cover is in down position. Make sure that the cover of the Belt Stacker is in normal position, see section 5, Clearing Misfeeds, Exit area.

  • Page 87: Cst Fault Codes

    CST fault codes Waste bin full Empty Waste Box and check Waste Transport Channel and Waste Transport Belt for build-up of waste strips. It is highly recommended to empty the waste box whenever the system stops to keep up productiv- ity.

  • Page 88: Af602/Vf602 Fault Codes

    AF602/VF602 fault codes Misfeed Bin A/B Misfeed is a paper flow error detection. Misfeed checks if a sheet is moved correctly from paper pile to optical DSD sensor. Time is measured from the start of the drive roller (used to feed and separate a sheet from the paper pile) until the optical DSD sensor can see the leading paper edge.
  • Page 89 AF602/VF602 fault codes (continued) Too Thick US DSD, Bin A/B Too thick US DSD is a paper thickness error detection. Too thick US DSD checks if a sheet is too thick when it passes the ultrasonic DSD sensor Q102/202. When the ul- trasonic DSD sensor sees the leading paper edge, thickness is measured.

  • Page 90: Jam Recovery Manual Setting Vf602

    Jam recovery manual setting VF602 Below is the procedure for jam recovery using manual settings. Before starting the adjust- ments make sure that all the parameters are set to “auto” mode. Refer to “VF602 Advanced settings” in section 2 for how to adjust FAN power and Process Position.

  • Page 91: Jam, Too Long, Too Thick Errors

    Jam recovery manual setting VF602 (continued) Jam, Too long, Too thick errors When one of these messages is displayed, there might be jam or a double sheet detection in the trays. Procedure Does paper have cross process direction curl? Measure paper curl: if paper curl is negative, decrease process position by that amount, if paper curl is positive, increase process position by that amount.

  • Page 92: Trimmer Fault Codes

    Trimmer fault codes NOTE: During poor environmental conditions waste from the trimming operation may be transported through the system. To ensure that the waste is transported into the waste bin, the trim margin may be increased. Empty trim bin This message will be displayed when the trim bin is full or when a trim strip, due to static electric- ity, is prevented from falling down into the trim bin.

  • Page 93: Sensor Calibration

    Sensor Calibration AF602 Sensor Calibration Advanced Settings From the AF602 Feeder Settings Menu, Select Adv. to reach advanced settings. Calibrate Sensor Selecting Calibrate DSD / USDS will allow the user to calibrate DSD and USDS sensors. These procedures are only needed after repair/replacement or indications of misadjustment.
  • Page 94 AF602 Sensor Calibration, continued Procedure: Calibrate Ultrasonic DSD -Press Calibrate DSD -Press US. DSD A or US. DSD B -The selected bin opens -Open the AF602 front door and fetch the Ultrasonic DSD Calibration Strip. -Place the Calibration Strip as shown in the picture below: it shall be centered relative to the US DSD Sensor US DSD Calibration Strip...

  • Page 95: Vf602 Sensor Calibration

    VF602 Sensor Calibration Advanced Settings From the VF602 Feeder Settings Menu, Select Adv. to reach advanced settings. Calibrate Sensor Selecting Calibrate DSD will allow the user to calibrate DSD sensors. These procedures are only needed after repair/replacement or indications of misadjustment. Procedure: Calibrate Optical DSD -Press Calibrate DSD -Press Opt.
  • Page 96 VF602 Sensor Calibration, continued Procedure: Calibrate Ultrasonic DSD -Press Calibrate DSD -Press US. DSD A or US. DSD B -The selected bin opens -Open the VF602 front door and fetch the Ultrasonic DSD Calibration Strip. -Place the Calibration Strip as shown in the picture below: it shall be centered relative to the US DSD Sensor US DSD Calibration Strip...

  • Page 97: Remarks

    7. REMARKS Do’s And Don’ts • Always follow all warnings marked on, or supplied with, the equipment. • Always exercise care in moving or relocating the equipment. • CAUTION: Unplug the power cord from the wall outlet and machine before you move or relocate the equipment.

  • Page 98: Where To Put Your Machine

    Where to put Your Machine Machine environment • Always locate the equipment on a solid support surface, with adequate strength for the weight of the machine. • Always keep magnets and devices with strong magnetic fields away from the machine. •...

  • Page 99: Access To Machine

    Access to machine For reasonable accessibility, keep 40 cm clearance behind the machine and 60 cm on the operator side.

  • Page 100: Maintaining Your Machines

    Maintaining Your Machines Never attempt any maintenance function that is not specifically described in this documentation.

  • Page 101: Square Fold Module Maintenance

    Square Fold module maintenance Cleaning feed belts The Feed belts need to be cleaned regularly when in use, and if the unit has not been used for a period of time. How often this should be done, depends on the paper type and print quality. An increasing number of misfeeds is one indication of the need to clean the feed belts.

  • Page 102: Cst Module Maintenance

    CST Module maintenance The feed rollers and paper path need to be cleaned regularly (even if the unit has not been used for a period of time). How often this should be done depends on the paper type and print quality. An increasing number of misfeeds is one indication of the need to clean the feed roller, paper path and/or the sensors.

  • Page 103: Cleaning The Fixing Rollers (3X)

    Cleaning the paper path transportation nip rollers (12x) continued Nip rollers Nip rollers (2x) Nip rollers Cleaning the fixing rollers (3x) ALSO CLEAN THE IDLING ROLLERS WARNING: Do not put your fingers within knife guards. Doing so may result in injury. Knife guards Fixing rollers continued on next page...

  • Page 104: Cleaning The Registration Cross Roller (4X) & Friction Tires (4X)

    Cleaning the fixing rollers (3x) continued Fixing rollers Cleaning the registration cross roller (4x) & friction tires (4x) Cleaning friction tires Registration cross rollers...

  • Page 105: Cleaning The Rotator Rollers (2X)

    Cleaning the rotator rollers (2x) Also clean the idler rollers Rotator rollers Cleaning the paper path sensors (5x) WARNING: Do not put your fingers within knife protections. Doing so may result in injury. Infeed sensor Exit sensor Knife protections continued on next page...
  • Page 106 Cleaning the paper path sensors (5x) continued Rotator sensor Registration sensor...

  • Page 107: Cleaning Of Creaser Tools (2X)

    Cleaning the paper path sensors (5x) continued Creaser sensor Cleaning of creaser tools (2x) After a period of time toner and paper dust may leave residuals in the grooves of the tool. These grooves need to be cleaned periodically to restore creasing performance. Grooves on both sides of the tool...

  • Page 108: Adjustment Of Bleed Trimmer Registration Angle (Parallell Cut)

    Adjustment of Bleed Trimmer registration angle (parallell cut) ADJUSTMENT OF BLEED TRIMMER REGISTRATION ANGLE (TRIMMER CUT PAR- ALLEL TO REGISTRATION EDGE AT OPERATOR SIDE) Turn adjustment screw [A] in desired direction. Change in adjustment is reflected on the reference scale [B]. Process direction Turn the adjustment screw clockwise to...

  • Page 109: Adjustment Of Creaser Registration Angle

    Adjustment of Creaser registration angle ADJUSTMENT OF CREASER REGISTRATION ANGLE Loosen the star shaped knob [A]. Turn the knurled excenter [B] to move reference mark in the desired direction. Tighten the star shaped knob [A] again. Process direc- Lower the Op- tion erator side of the creaser to remedy...

  • Page 110: Af602 Feeder Maintenance

    AF602 Feeder Maintenance Cleaning AF602 An increasing number of misfeeds is one indication of the need to clean the feed rollers. Clean every 50 000 cycles or when the number of misfeeds increases. 1. Open the bin drawer. 2. Push the feed roller shaft towards the compression spring and unhook the shaft from the coupling.
  • Page 111 Cleaning AF602, continued 6. Open the door. 7. Lift the green handles to the baffles and clean surfaces from toner smearings. 8. Clean, if needed, the feed rollers inside the baffles with rubber reactivator alcohol. 9. Replace the feed roller shaft(s) by reversing procedure in step 2.

  • Page 112: Vf602 Feeder Maintenance

    VF602 Feeder Maintenance Cleaning VF602 An increasing number of misfeeds may indicate a need to clean the VF602. Clean every 50 000 cycles or when the number of misfeeds increases. Use a vacuum cleaner, towels and brushes for general purpose cleaning of the paper path, bins, etc. In addition, follow the detailed cleaning instructions below: 1.
  • Page 113 Cleaning VF602, continued 4. Open the door. 5. Lift the green handles to the baffles and clean surfaces from toner smearings. 6. Clean, if needed, the feed rollers inside the baffles with rubber reactivator alcohol.

  • Page 114: Limitations In The Bm350/Bm500 System

    The BM350/500 Production Booklet Maker system is suited for customers whose production needs in average is less than 30,000 booklets per month. • If sheets entering the BM350/BM500 is not uniform and square the booklet quality will vary accordingly. •...
  • Page 115 Limitations in the BM350/BM500 system, continues • The optical double feed sensor in the AF/VF602 should not be turned on when feeding 200gsm / 74lb. Cover or higher density paper. You may also have to avoid using this function when processing pages with heavy dark areas.

  • Page 116: Best Practice For The Bm350/Bm500 System

    Best practice for the BM350/BM500 system • If the set is not properly registered (side jogged and back jogged) changing to a smaller custom size of paper in the Booklet Maker may improve the situation, only if CST is not connected.

  • Page 117: Specification

    8. Specification Machine Specifications BM350/BM500 Booklet Maker MAJOR SPECIFICATIONS Specifications Remarks Speed See performance diagrams Standard Paper Sizes A4, SRA4, B4, A3, SRA3, Custom sizes are avail- 8.5x11”, 8.5x14”, 9x12”, 11x17”, 12x18” able Paper Size (Minimum) Width 206mm / 8.1”...

  • Page 118: Performance Diagrams

    Performance diagrams Approximate performance for a system consisting of AF602-BM500-SQF500-FTR500. Software version 3.00 in BM. Speed AF-BM-SQF-FTR 1600 1400 1200 1000 Manual Feed 1500 1000 Square Fold Module Specifications Remarks Maximum Speed Same as Booklet Maker Appr. 6 - 30 sheet booklet (80gsm / 20lb Bond) Standard Paper Sizes Same as Booklet Maker...

  • Page 119: Ftr Trimmer Module

    FTR Trimmer Module Specifications Remarks Maximum Speed 1800 sets per hour Standard Paper Sizes Same as Booklet Maker Custom sizes are available Default trim length 4.5mm / (11/64”) Adjustable in 0.5mm steps Minimum trimming 1mm / (0.0394”) Recommended minimum trim is 2.5mm. Maximum trimming 16mm (per cut) Adjustable in 0.5mm steps.

  • Page 120: Cst Crease Trim Module (Option)

    CST Crease Trim Module (option) Specifications Remarks Maximum Speed Same as Booklet Maker Standard Paper Sizes Same as Booklet Maker Paper Size Minimum (Out) Same as Booklet Maker Paper Size Maximum (Out) Same as Booklet Maker Paper Width Maximum (In) 330mm Paper Weight (Minimum) Same as Booklet Maker...

  • Page 121: Creaser Cr500 (Option)

    Creaser CR500 (option) Specifications Remarks Speed Same as BM350/500 Standard Paper Sizes Same as BM350/500 Paper Size Minimum (Out) Same as BM350/500 Paper Size Maximum (Out) Same as BM350/500 Paper Width Maximum (In) Same as BM350/500 Paper Weight (Minimum) Same as BM350/500...

  • Page 122: Air Feeder Af602 / Vacuum Feeder Vf602 (Options)

    Air Feeder AF602 / Vacuum Feeder VF602 (options) Specifications Remarks Minimum paper size, W&L 120 x 210 mm Maximum paper size 356 x 660 mm Minimum paper weight 64 gsm Maximum paper weight Same as Booklet Maker Maximum loading capacity, 270 mm 10.6”...

  • Page 123: System Set Size Guide

    The following media are examples of this: Futura Laser Gloss 80c Hammermil Laser Print OPUS Gloss Exact number of sheets is depending on media type and image. BM500 BM350 Paper Size Paper Size A3 or 11x17" A4 or 8.5x11" A3 or 11 x 17"...
  • Page 124 ..Plockmatic International AB, Telefonvägen 30, S-126 26 Hägersten, Sweden This Declaration of Conformity is issued under the sole responsibility of the manufacturer Object of the Declaration Type/Model F102-012 F103-012 F105-012 BM350 Name FTR500 SQF500 BM500 Description Booklet Maker Trimmer...
  • Page 125 EU DECLARATION OF CONFORMITY ......D0001499 (E.2) Manufacturer ..Plockmatic International AB, Telefonvägen 30, S-126 26 Hägersten, Sweden This Declaration of Conformity is issued under the sole responsibility of the manufacturer Object of the Declaration F136-001, Type/Model F122-001 F122-002 F134-001 F135-001 F136-002 CT5010, CT5030, CST500,...
  • Page 126 DECLARATION OF CONFORMITY according to ISO/IEC & EN 17050-1 ......D0003152 (C.2) Issuer’s name ..Plockmatic International AB Issuer’s address ... Telefonvägen 30, S-126 26 Hägersten, Sweden Object of the Declaration Type/Model F125-001 F125-002 F125-011 F125-012 Name AF602 AF602LR VF602 VF602LR Description Air Assisted Friction Feeder...
  • Page 127 EU DECLARATION OF CONFORMITY ......D0000356 (I.3) Manufacturer ..Plockmatic International AB, Telefonvägen 30, S-126 26 Hägersten, Sweden This declaration of conformity is issued under the sole responsibility of the manufacturer Object of the Declaration Type/Model PL4700, F680 Name BST4000, BST4000-1, F680, Y980, BST6200, F656, PLBS Description Belt Conveyor Stacker object...

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