Morgana BM 2000 Operator's Manual
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Morgana BM 2000 Operator's Manual

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Booklet Maker BM 2000
Operator Manual
Doc No. T10178
Morgana Systems Limited ▪ United Kingdom ▪ www.morgana.co.uk ▪ Telephone: ( 01908 ) 608888 ▪ Facsimile: ( 01908 ) 692399

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  • Page 1 Booklet Maker BM 2000 Operator Manual Doc No. T10178 Morgana Systems Limited ▪ United Kingdom ▪ www.morgana.co.uk ▪ Telephone: ( 01908 ) 608888 ▪ Facsimile: ( 01908 ) 692399...
  • Page 2 BOOKLET MAKER BM 2000 Operating Instruction Booklet Maker Reference Part no: 81248 Doc no: T10178 Rev. date: 14 January 2010...
  • Page 3 WARNING: • Electromagnetic compliance: • 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 recievers may be expected within a distance of 10 m of the apparatus concerned.
  • Page 4 Introduction This manual contains instructions on the operation and maitenance 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 5 Safety Information When using this machine, following safety precautions should always be followed. Safety during operation WARNING: • To avoid hazardous situations like for instance 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 6 General safety, continued CAUTION: • The machine and its peripherals must be installed and maintained by a customer service repre- sentative who has completed the training course on those models. • Allways follow all warnings marked on, or supplied with, the equipment. •...
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  • Page 8: Table Of Contents

    TABLE Of CONTENTS What You Can Do With This Machine .................... 5 Guide To Components ........................7 Booklet Maker ..........................7 Options ............................10 Trimmer ............................10 SquareFolder ..........................12 1. Basics Booklet Maker ..........................13 Turning On / Off the Power ......................1 Control Panel ..........................
  • Page 9 Lubricating Staplers and Clinchers......................48 SquareFolder ..........................49 Cleaning Feed Belts ..........................49 Cleaning Square Folding Clamps......................0 8. Specifications Machine Specifications ......................... 51 Booklet Maker BM 2000 ......................1 Trimmer FTR 2000 (option) ......................2 SquareFolder SQF 2000 (option) ....................2...

  • Page 10: What You Can Do With This Machine

    The sheets from the Feeder/Collator are transported into the BM 2000 Booklet Maker and collected in the stapler area of the BM 2000 Booklet Maker. The Booklet Maker now jogs and then staples the set. The set is then transported further to the folding area where the set is folded into a booklet and then fed out to the belt stacker.
  • Page 11 The entire BM 2000 Booklet making system is controlled from a single control panel on the Booklet Maker. The control panel has only six buttons which will allow you to easily set up, adjust and operate the complete system. Buttons...

  • Page 12: Guide To Components

    Guide To Components Booklet Maker Control panel Hand feed tray (optional) Top cover Belt Stacker Power switch Belt Stacker Cover Infeed assembly Hand feed slot (for on-line mode)
  • Page 13 Booklet Maker, continued DFA. Not in use. Power receptacle Not in use. Power out to SQF 2000 CAN In: Termination socket / Interlock jumper Communication with Interlock jumper / Power out to FTR Feeder/Collator 2000 CAN Out: Termination socket / Communication with FTR 2000...
  • Page 14 Booklet Maker, continued Booklet maker, top view Tool box Stapler heads Ball cage Side guides Fold adjust lever, right side Guide Left side not shown in picture Screws for Stapler assy. Alignment tool, stapler assy. Staple detection leads, one on each Cartridge locking levers stapler head Stapler lift brackets...

  • Page 15: Options

    Options Trimmer Top cover Trim bin...
  • Page 16 Trimmer, continued Trimmer, top view Trimmer fan Docking bracket Outfeed latch Infeed roller shaft Transport belt Knives (not visible in picture) Exit compression brackets Infeed latch Trimmer stop...

  • Page 17: Squarefolder

    Squarefolder Top cover Upper feed belts (lifted position) Docking bracket (not visible in picture Lower feed belts Latches SquareFolder, top view...

  • Page 18: Basics

    1. Basics Booklet Maker Turning On / Off the Power Plug the Booklet Maker power cord into the wall outlet. Trimmer (optional) and SquareFolder (optional) are powered from the Booklet Maker. Open the Top cover (A). Set power switch (B) on Booklet Maker to ON position. Note The Power switch also controls Trimmer (optional) and SquareFolder (optional).

  • Page 19: Control Panel

    From this screen you can also access other screens, that will help you operate the complete BM 2000 Booklet making system. At the top, throughout the screens you can see the current state of the machine and the current job.

  • Page 20: Staples, Staple Cartridge, Stapler Head & Clinchers

    Staples, Staple Cartridge, Stapler Head & Clinchers Removing / replacing Staple Cartridge You may remove and replace the staple cartridge while the stapler head assembly is in place. Open the top cover. Raise the staple cartridge locking lever (A) as indicated in the drawing.

  • Page 21: Removing / Replacing Staple Cartridge, Continued

    Removing / replacing Staple Cartridge, continued After staple jam or empty staple cartridge has been detected, the BM 2000 will automatically advance and feed staples. This feature is called staple recovery. Follow procedure below after a staple jam or empty staple cartridge indication.

  • Page 22: Removing/Replacing Stapler Head, Continued

    Whenever you remove a stapler head, be sure to manually eject some staples before replacing it in the BM 2000. To do this, rest the stapler head on a firm surface (for example, the top of a table) and actu- ate the staple driver post up/down through full travel.

  • Page 23: Changing Staple Position And Narrow Width Paper Sizes

    Changing Staple position and Narrow width Paper Sizes Note Some situations require that the stapler assemblies are repositioned and/or that the side guide extensions are removed. This to avoid that the side guide extensions collide with the stapler assembly. If such collision should occur, the message “Side jogger collision.

  • Page 24: Setting Up Narrow Width Paper Sizes

    The anvil positioning scale (F) indicates the distance, in millimetres, from centre to centre (cc) of the staples. Type of finishing Paper format Setting (cc) booklet making .”, CD booklet making booklet making 8.”, A4 120 (default position) booklet making 11”, A 120 or 200 edge stapling...

  • Page 25: Trimmer

    Trimmer Emptying the Trim Bin Remove the trim bin by pulling handle (1). Lift out the Trim Bin by grasping the rod (2) and handle (1).

  • Page 26: Making Booklets

    2. Making Booklets Changing Settings General Procedure Changing settings can be performed 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. Procedure for temporary changes: From the Main screen, select the option you wish to change and press the [Enter] button.

  • Page 27: Custom Paper Size

    Custom Paper Size From the Main screen, select [Size] and press the [Enter] button. Select [Length] or [Width] and press the [+] or [-] button to correct paper size. The paper size can be changed in increments of 0.1 mm or approx.. 0.01 inches.

  • Page 28: Edge Staple

    Edge staple Select [Edge staple] when you want to make edge stapled sets. Press the [Enter] button to confirm. Note Finished sets will be delivered to the Trim Bin in the Trimmer. Saddle staple Select [Saddle staple] when you want make saddle stapled booklets.

  • Page 29: Corner Staple

    Corner staple Select [Corner staple] when you want to make corner stapled sets. Press the [Enter] button to confirm. Remove either stapler head and position the other stapler head and clincher as needed. See section 1. Basics. Note Finished sets will be delivered to the Trim Bin in the Trimmer.

  • Page 30: Squarefolding

    Squarefolding General The SquareFolder has seven different settings; [Off], [Mode 1], [Mode 2], [Mode ] [Mode 4], [Mode ] or [Auto]. In [Auto] mode, the Booklet Maker detects how many sheets there are in the booklet, and automatically set the SquareFold to the correct mode. Note When the SquareFold is set to [Auto] and the booklet has less than approximately 6 sheets/ booklet, the SquareFold will bypass the Square folding action, transporting the booklet out...

  • Page 31: On-Line / Off-Line

    On-line / Off-line The Booklet Maker can be operated in two modes. On-line mode, when used together with the Feeder/Collator, or off line mode, when used for hand feeding. On-line Mode Make necessary settings according to “Changing settings” earlier in this section. The Booklet Maker is now in stand-by and will start automatically when a set is fed from the Feeder/Collator.
  • Page 32 On-line Mode, continues Close the Booklet Maker top cover. The message “Finish set?” will be shown in the control panel. There are now two choices: • Press the “Yes” button on the Booklet Maker. The set will be finished and fed to the belt stacker.

  • Page 33: Off-Line Mode

    Off-line Mode Make sure Booklet Maker is in stand-by mode, i.e. that a job is not in progress. Make necessary settings according to “Changing settings” earlier in this section. The Booklet Maker is now in stand-by mode and will start automatically when a set is manually fed into the Booklet Maker.

  • Page 34: Admin

    3. Admin The Admin Screen From the Main screen, press the [Admin] button to get to the Admin screen. Here you will find additional features and settings. Paper size check Use [Paper size check] to verify that the Booklet Maker paper size setup corresponds to the actual hand fed sheets.

  • Page 35: Mode, Safe / Fast

    Paper size check, continues Close the Booklet Maker top cover. The message “Finish set?” will be displayed. There are now two choices: • Press the [Yes] button on the Booklet Maker. The set will be finished and fed to the belt stacker. •...

  • Page 36: System Setup

    System Setup [System Setup] allows you to change how the booklet making system setup will appear in the control panel. Select System Setup and press the [Enter] button. Scroll to the right system configuration and press the [Enter] button. Standard Paper Size By changing the paper size standard, the preset paper sizes are altered to best fit your regional standard.

  • Page 37: Service

    Reset Trim Knife From this screen you can reset the position of the trimknife. This is useful when the knife is stuck in the active/down position. You will get fault codes TR 201- 202 or BM 210-211. Select [Reset trim knife] and press the [Enter] button. Service This screen to access service is for authorized service personnel only and is password protected.

  • Page 38: Jobs

    4. Jobs Storing and Deleting Jobs The Booklet Maker has a maximum storage capacity of 10 different jobs. Also see section 2 Making Booklets. Storing a Job Change all settings according to section 2 for a particular job. Now the changes are just temporary. You can run the system with these changes but as soon as you change something again the previous settings will be lost.

  • Page 39: Recalling A Job

    Recalling a Job To recall a stored job press the [Jobs] button from the Main screen. Then press the [Jobs] button from the Jobs screen. Select one of the previously stored jobs from the list. Press the [Enter] button to recall the job. This Job is now uploaded and becomes the current job.

  • Page 40: Clearing A Paper Jam

    5. Clearing a Paper Jam Clearing a Paper Jam General If an error such as a paper jam condition should occur, it is indicated in the control panel on the Booklet Maker. The nature of the fault is generally displayed in clear text at the top. In the centre of the display the diagram shows in which module and where the error has occurred.

  • Page 41: Booklet Maker

    Booklet Maker Clearing a Paper Jam Inside the Booklet Maker To clear a paper jam in the infeed or staple area Open the top cover. Remove jammed sheets. Close the top cover. To clear a jam indicated in the folding area Open the top cover.
  • Page 42 Inside the Booklet Maker, continues If the jam still remains: Switch off the Power Set the fold adjust levers (A) on both sides to “8” to separate the fold rollers. Lift up the guide (B) from below the upper fold roller (C). Use the key (D) from the tool box and crank the upper fold roller to remove jammed sheets.

  • Page 43: Trimmer

    Trimmer Clearing a Paper Jam The upper trimmer blade on the trimmer is protected by a knife protection plate that moves away during the cutting stroke. Jams can occur in the input area or the exit area. WARNING: Never put fingers or other parts of the body between the upper and lower trimmer knives. Clearing Jam in Input Area Lift up the infeed roller shaft (A).

  • Page 44: Clearing Jam In Exit Area

    Clearing a Paper Jam, continued Clearing Jam in Exit Area Lift the exit compression brackets (A). Secure them under the latch (B). Remove the jammed sheets from the exit area. After the jammed sheets are removed, lift up the latch (B) and place the compression brackets in the operating position.

  • Page 45: Squarefolder

    Squarefolder Clearing a Paper Jam Inside the Squarefolder Open the top cover. Lift up both upper feed belts (A). Note Press the green-labelled latches (B) to release. Remove the jams. Place the upper feed belts in normal position. Close the top cover. Exit Area Open the top cover (A).

  • Page 46: Troubleshooting

    6. Troubleshooting fault codes General When there is a jam or fault condition in the Booklet Maker system, a fault code and a short description will be displayed in the control panel on the Booklet Maker. Some faults can be rectified by the operator and some faults only by an authorized technician.

  • Page 47: Booklet Maker Fault Codes

    Booklet Maker fault Codes Remove stacked sheets This message will be displayed if there is a miss-feed or double-feed in the Feeder/Collator when the set is delivered to the Booklet Maker. Either: • Open the top cover, remove the set and close the top cover. •...

  • Page 48: Booklet Quality

    The default configuration for BM 2000 is with glass balls closest to the outfeed and plastic balls closest to the infeed. Additional replacement steel, glass and plastic balls are located in the tool box above the fold section.

  • Page 49: Squarefolding Quality

    fold Quality, continues Under extreme circumstances, when the cover sheet tends to be torn from the rest of the set, this can be rectified by adjusting the Fold Adjust Levers located above the pre-fold transport. There are eight positions for each lever. The topmost notch is the default position.

  • Page 50: General Remarks

    7. General 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 51: Placing Your Machine

    Placing Your Machine Machine Environment • Always locate the equipment on a solid support surface with adequate strength for the weight of the machine. • Always keep magnets and all devices with strong magnetic fields away from the machine. If the place of installation is air-conditioned or heated, do not place the machine where it will be: •...

  • Page 52: Access To Machine

    Access to Machine Place the machine near the power source, providing clearance as shown. 1. Left: more than 400 mm / 1 /4” 2. Front: more than  mm / 21 7/8” (). Right: more than 400 mm / 1 /4” (for stand alone installation only)

  • Page 53: Maintaining Your Machines

    Maintaining Your Machines Caution Never attempt any maintenance function that is not specifically described in this documentation. Booklet Maker Lubricating Staplers and Clinchers The parts that need lubrication are shown in the table below. Drive post Stapler drive bar Stapler lift bracket Clincher Staple driver PART...

  • Page 54: Squarefolder

    Squarefolder 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 jams is one indication of the need to clean the feed belts.

  • Page 55: Cleaning Square Folding Clamps

    Cleaning Square folding Clamps Remove any residue from upper and lower clamps (A), which is the area clamping the booklet. Pay special attention to the right angled corners of the clamp profiles.

  • Page 56: Specifications

    100 / 110 / 11 / 127 / 220 / 20 VAC + - 10% 0-60 Hz Power consumption 2 W (1 W BM 2000, 10 W SQF 2000) Stand by 0.1 - 1 kW Continuous Operation for BM Maximum 1 kW...

  • Page 57: Trimmer Ftr 2000 (Option)

    120 mm / 4.72” booklet Maximum length, 220 mm / 8.66” trimmed booklet Paper Weight (Minimum) Same as BM 2000 Paper Weight (Maximum) Same as BM 2000 Input / Output Sheets Same as BM 2000 Input / Output Sheets Same as BM 2000...
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